New Holland E135B Crawler Excavator Service Manual

Copyright © New Holland
SERVICE
MANUAL
SERVICE MANUAL
E135B
Crawler Excavator
E135B
Crawler Excavator
Print No.84136002 Print No.84136002

E135B
WORKSHOP MANUAL
All the information and data contained in this manual are based upon most recent information available at the
time of its publication.
NEW HOLLAND KOBELCO has the right to implement, at any time, any modification without providing any
communication.
NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

Print No. 84136002
Edition - November 2008
INTRODUCTION E135B
TO THE READER
• This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information found any errors regarding the contents of this
needed to maintain and repair this machine. manual, please contact:
- Be sure to thoroughly read this manual for NEW HOLLAND KOBELCO

correct information concerning the service CONSTRUCTION MACHINERY S.p.A.
procedures. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCES
• Please refer to the materials listed below in

addition to this service manual:
- Operation and Maintenance Instruction

Manual
- Parts Catalog
WORKSHOP MANUAL COMPOSITION
• The Workshop Manual consists of five parts: - The “Operational Performance Test” part includes
- “Safety Precautions” the information needed to carry out the machine
operational performance test.
- “Operational Principle”
- “Operational Performance Test”
- The “Troubleshooting” part includes the technical
- “Troubleshouting”
information needed for troubleshooting and
- “Repair Instructions” malfunction detection.
- The “Safety Precaution” part includes the - The “Repair Instruction” part includes information
recommended procedures that, if followed, can needed for maintenance and repair of the
avoid the risk of accident for operator and for staff machine, tools and devices needed for
related to the work and maintenance machine maintenance and repair, maintenance standards,
operations. removal/installation and assembly/disassembly
procedures.
- The “Operational Principle” part includes the
technical information concerning the operation of
main devices and systems.
IN - 1
E135B INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist))
Section number
T: Technical Manual
W: Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential
for personal injury or machine damage.
This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.
UNITS USED
SI Units (International System of Units) are used in this manual.

MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 MPa (250 kgf/cm2)
A table for conversion from SI units to other system units is shown below for reference purposes.
Quantity To convert from Into Multiply by Quantity To convert from Into Multiply by
(SI) (Others) (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW CV-PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
IN - 2
INDEX E135B
MANUAL INDEX
SAFETY PRECAUTIONS Page
Section 1 GENERALITIES ..................................................................... S1

Section 2 SAFETY PRECAUTIONS ...................................................... S2
Section 3 SAFETY PLATES .................................................................. S3
OPERATIONAL PRINCIPLE
Section 1 GENERAL
Group 1 Specifications................................................................................. T1-1
Section 2 SYSTEM
Group 1 Mechatro control system................................................................ T2-1
Group 2 Hydraulic System........................................................................... T2-2
Group 3 Electrical System ........................................................................... T2-3
Section 3 COMPONENT OPERATION

Group 1 Hydraulic Pump Assy..................................................................... T3-1
Group 2 Pilot Valve ...................................................................................... T3-2
Group 3 Control Valve ................................................................................. T3-3
Group 4 Swing Device ................................................................................. T3-4
Group 5 Travel Device ................................................................................. T3-5
Group 6 Swivel Joint.................................................................................... T3-6
Group 7 Cylinders........................................................................................ T3-7
Group 8 Air Conditioner system................................................................... T3-8
Group 9 Blade control.................................................................................. T3-9
OPERATIONAL PERFORMANCE TEST

Section 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction ................................................................................... T4-1
Group 2 Standard Performances ................................................................. T4-2
Group 3 Test Procedures ............................................................................ T4-3
Group 4 Mechatro Controller ....................................................................... T4-4
TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 Troubleshooting (by error codes)................................................... T5-1
Group 2 Troubleshooting (by trouble) .......................................................... T5-2
Group 3 Troubleshooting (trouble diagnosis mode)..................................... T5-3
E135B INDEX
REPAIR INSTRUCTIONS
Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly.................................W1-1
Group 2 Tightening Torque ........................................................................W1-2
Section 2 UPPERSTRUCTURE
Group 1 Upperstructure ..............................................................................W2-1
Group 2 Pump Device.................................................................................W2-2
Group 3 Control Valve ................................................................................W2-3
Group 4 Swing Device ...............................................................................W2-4
Group 5 Pilot Valve .....................................................................................W2-5
Section 3 UNDERCARRIAGE
Group 1 Swing Bearing ..............................................................................W3-1
Group 2 Travel Device ...............................................................................W3-2
Group 3 Swivel Joint ..................................................................................W3-3
Group 4 Track Adjuster ..............................................................................W3-4
Group 5 Front Idler .....................................................................................W3-5
Group 6 Upper and Lower Roller ...............................................................W3-6
Group 7 Tracks ...........................................................................................W3-7
Section 4 FRONT ATTACHMENT

Group 1 Front attachment...........................................................................W4-1
Section 5 ENGINE
Group 1 General ........................................................................................W5-1
Group 2 Service data .................................................................................W5-2
Group 3 Service tools ................................................................................W5-3
Group 4 Determination of overhaul ............................................................W5-4
Group 5 Disassembly of basic engine .......................................................W5-5
Group 6 Inspection and repair of basic engine ..........................................W5-6
Group 7 Reassembly of basic engine .........................................................W5-7
Group 8 Fuel System ..................................................................................W5-8
Group 9 Lubrification system .....................................................................W5-9
Group 10 Cooling system ..........................................................................W5-10
Group 11 Inlet and exhaust system ........................................................... W5-11
Group 12 Electrical system ........................................................................W5-12
Group 13 Adjustment and operation ..........................................................W5-13
Group 14 Troubleshooting .........................................................................W5-14
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS E135B
INDEX
Section 1 GENERALITIES
Section 2 SAFETY PRECAUTIONS
Section 3 SAFETY PLATES

GENERALITIES E135B
SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction Do not leave the machine until it has come to a
Manual carefully before starting, operating, complete stop.
maintaining, fuelling or servicing the machine. Always check height, width and weight limitations
Carefully read the explanation to each and all safety which may be encountered in the working site and
signs in the special section of this Manual before ensure the machine does not exceed them.
starting, operating, maintaining, fuelling or servicing Assess exact paths of gas ducts, water mains,
the machine. telephone lines, sewers, overhead and underground
Machine-mounted safety plates are colour coded electric lines and all other possible obstacles.
yellow with black borders when they refer to points Such paths should be opportunely defined by
where special ATTENTION must be paid and failure competent Authorities. If necessary, require that the
to observe them may cause a serious DANGER to service is interrupted or said installations are moved
the integrity of machine operators. They are white prior to starting the work.
with red borders and black lettering when they refer
You must know the working capacity of the machine.
to a FORBIDDEN practice.
Define the rear upperstructure swing area and
It is fundamental that all machine operators know
provide for opportune barriers to prevent access into
very well the meaning of each safety plate as this
it.
considerably decreases operating hazards and
accidents. Never exceed machine lifting capacity.
Do not allow unauthorised personnel to operate or Remain within the limits shown in the loading
service this machine. capacity chart which located on the machine.
Do not wear rings, wrist watches, jewellery, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get STARTING
caught in moving parts. Wear certified safety clothes Never start or operate a failed machine. Walk all
such as: hard hat, no-slip footwear, heavy gloves, ear around the machine before mounting.
protection, safety glasses, reflector vests, respirators Before operating the machine, make sure that any
every time the job requires it. Ask your employer possible dangerous condition has been properly
about safety regulations in force and protective removed. Before starting machine, check that
equipment. steering and attachment controls are in the neutral
Always keep the operator’s compartment, step position and the safety lever is in the LOCK position.
plates, grab-rails and handles clean and clear of Immediately report any malfunction of parts or
foreign objects, oil, grease, mud or snow to minimise systems to the maintenance managers for proper
the danger of slipping or stumbling. Remove mud or action.
grease from your shoes before operating the Prior to starting the engine, check, adjust and lock the
machine. driver’s seat for maximum riding comfort and control
Do not jump on or off the machine. Always keep both accessibility. Prior to operating the machine and/or
hands and one foot, or both feet and one hand in its attachments, check that bystanders are outside
contact with steps and/or grab rails. the machine operating range. Sound the horn.
Do not use controls or hoses as hand holds. Hoses Obey all hand signals, safety indications and signs.
and controls are movable parts and do not provide Due to the presence of flammable fluids, never
solid support. Besides, controls may be inadvertently check fuel level, refuel, charge the batteries in the
moved and cause unexpected movement of the presence of smoking materials, open flames or
machine or its attachments. sparks.
Never operate the machine or its attachments from Ensure that nobody is within the excavator operating
any position other than sitting in the driver’s seat. area before starting the machine, swinging the upper
Keep head, body, limbs, hands and feet inside the structure or moving in any direction.
operator’s compartment at all times to reduce Adjust all rear-view mirrors for maximum visibility of
exposure to external hazards. the area behind the machine.
Be careful of possible slippery conditions of the steps Ensure that engine speed is appropriate to the job to
and hand rails as well as of the ground around the be carried out.
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber
S1 - 1
E135B GENERALITIES
If any hydraulic control or system exhibits erratic properly protected against possible backlash in
performance or responds abnormally, have the case of cable or chain failure or detachment.
machine checked for air in the system. Be alert of soft ground conditions close to newly
Air in these circuits may cause incorrect movements constructed walls. The fill material and machine
with consequent accident hazard. Refer to the weight may cause the wall to collapse under the
Operation and Maintenance Instruction Manual machine.
about corrective action to be taken. In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
OPERATING If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
Do not run the engine of this machine in closed proper action.
buildings without proper ventilation capable to
Do not operate the machine until this condition is
remove harmful exhaust gases which concentrate in
corrected. Regularly check all exhaust system
the air.
components, as exhaust fumes are toxic for the
Keep the operator’s compartment free of foreign operator.
objects, especially if not firmly secured. Never use
Operators must know the performance of the
the machine to transport objects, unless proper
machine they are driving. When working on slopes or
securing points are provided.
near sudden level drops in the terrain, pay attention
Do not carry riders on the machine. Study and not to lose adherence and avoid loose soft ground
familiarise with escape routes alternative to normal since overturn or loss of machine control could result.
exit routes. For your personal safety, do not climb on
If noise level is high and exceeds 90 dB (A) over 8
or off the machine while it is in motion.
hours at the operator’s ear, wear approved ear
Make sure that bystanders are clear of the machine protection in compliance with local regulations.
operating range before starting the engine and
Do not operate the machine if you are extremely tired
operating the attachment. Sound the horn.
or feel ill. Be especially careful towards the end of the
Obey all hand signals, safety indications and signs. working shift.
When backing, always look to where the machine is Where removable counterweights are provided, do
to be moved. not operate the machine if they have been removed.
Be alert of the position of bystanders. Should When operating the machine, keep in mind height
someone enter the work area, stop the machine. limits of overhead doors, arches, overhead cables
Maintain a safe distance from other machines or and lines as well as width limits of corridors, roads
obstacles to ensure required visibility conditions. and narrow passages.
Always give way to loaded machines. Also, get to know load limits of the ground and
Maintain a clear vision of the surroundings of the paving type of the ramps you are to work on.
travel or work area at all times. Keep cab windows Beware of fog, smoke or dust that obscure visibility.
clean and repaired.
Always inspect the working area to identify potential
When pulling loads or towing through a cable or risks such as: inclines, overhangs, trees, demolition
chain, do not start suddenly at full throttle. Take-up rubble, fires, ravines, steep slopes, rough terrain,
slack carefully. Avoid kinking or twisting chains or ditches, crowns, ridge trenches,diggings in traffic
cables. areas, crowded parking lots, crowded service areas,
Carefully inspect the towing items for flaws or fenced zones. In such conditions, proceed with
problems before proceeding. Do not pull through a extreme care.
kinked chain or cable as the high anomalous stresses Whenever possible, avoid crossing over obstacles
existing in this condition may induce failures in the such as very rough terrain, rocks, logs, steps,
kinked portion. ditches, railroad tracks.
Always wear heavy gloves when handling chains or When obstructions must be crossed, do so with
cables. extreme care and at a square angle, if possible. Slow
Chains and cables should be securely anchored down.
using suitable hooks. Anchor points should be strong Ease up to the break-over point, pass the balance
enough to withstand the expected load. point slowly and ease down the other side also using
Keep anyone clear of anchor points and cables or the attachment, if necessary.
chains. To overcome deep trenches or sinking ground, place
Do not pull or tow unless the operator’s the machine perpendicular to the obstacle, drastically
compartments of the machines involved are reduce ground speed and start crossing using also
S1 - 2
GENERALITIES E135B
the attachment if necessary, only after assessing that The load must always be properly arranged in the
ground conditions allow the traverse safely and bucket; move with extreme care when transporting
without risks. oversize loads.
The gradient you may attempt to overcome is limited Do not lift and move the bucket overhead where
by factors such as ground conditions, load being persons are standing or working, nor downhill when
handled, machine type and speed, and visibility. working on a slope as this would decrease machine
There is no substitute for good judgement and stability. Load the bucket from the uphill side.
experience when working on slopes. Loads to be raised using the machine should be
Avoid operating the attachment too close to an exclusively hooked to the hitch specially provided.
overhang or high wall, either above or below the The excavator is no lifting and transportation means,
machine. Beware of caving edges, falling objects therefore it should not be used to position loads
and landslides. Remember that such hazards are accurately. Should it be exceptionally used to lift and
likely to be concealed by bushes, undergrowth and lay building components, special caution must be
such. taken as follows:
Avoid bushes, logs and rocks. Never drive over them,
nor over any other surface irregularities that
- The machine must be equipped compulsorily with
discontinue adherence or traction with the ground,
the appropriate variant provided upon request.
especially near slopes or drop-offs.
- Secure the loads to be raised using cables or
Be alert to avoid changes in adherence conditions
chains fastened with appropriate hooking
that could cause loss of control. Work with extreme
mechanisms.
care on ice or frozen ground and on stepped slopes
or near drop-offs. - Nobody should be allowed to remain under the
raised load or within the excavator operating range
The word “bulldozing” generally refers to work in
for any reason whatever.
virgin rough terrain, characterised by the presence of
all the perils and risks listed above. We emphasise
the danger represented in these conditions by large Never exceed specified loading capacity. Incorrect
tree limbs (possibly falling on the machine) and large fastening of slings or chains may cause boom/arm
roots (which may act as a leverage under the failure or failure of the lifting means with consequent
machine when up-rooted and cause the unit to bodily injuries and even death.
overturn). Always ensure that slings and chains used for lifting
Position the machine dependent upon the loading are adequate to the load and in good condition.
and unloading areas in order to swing leftwards to All loading capacities are referred to the machine
load to obtain best visibility. on a level surface and should be disregarded
Never use the bucket or attachment as a man lift when working on a slope.
or carry riders. Never use the machine as a work Avoid travelling across slopes. Proceed from uphill
platform or scaffolding. The machine must not be downhill and vice-versa. If machine starts slipping
improperly used for works not consistent with its sideways when on a slope, lower the bucket and
features (such as pushing railway cars, trucks or thrust bucket teeth into the ground.
other machines).
Working on slopes is dangerous. Grade the working
Always pay attention to people within the machine area if possible. Reduce work cycle time if it is not
operating range. possible to grade the working area.
Never move or stop the bucket, other loads or the Do not move full bucket or a load from uphill downhill
attachment above ground personnel or truck cabs. as this would reduce machine stability. Do not work
Ensure the truck driver is in a safe place before with the bucket turned to the uphill side.
loading the truck. Do not work with the bucket turned uphill as
Load trucks from side or rear. counterweights protruding downhill would reduce
Use only the type of bucket recommended machine stability on the slope and increase risk of
considering machine type, materials to be handled, overturning.
material piling up and loading characteristics, ground We recommend to work on slopes with the bucket
type and other typical conditions of the work to be downhill, after checking machine stability with the
performed. bucket empty and attachment retracted, by slowly
When transporting a loaded bucket, keep it as swinging the upper structure by 360°.
rolled-back as possible. Keep boom and arm as low Position the carriage at a right angle relative to
as possible. slopes, hanging walls, etc. to exit the working area
Ground speed should be adequate to the load and easily.
ground conditions. Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel
S1 - 3
E135B GENERALITIES
motors be positioned at the front with regard to the - Look up the in the telephone directory.
actual travel direction. Remind relative to travel - Define together with the Company representative
direction that controls are reversed. which precautions should be taken to guarantee
Always check travel motor position before moving off. work safety.
Properly judge ground conditions with particular - All electric lines should be considered as operative
attention to consistency of the area you are going to live lines even though it might be well known that
work on. the line in question is out of work and visibly
Keep the machine sufficiently far from the ditch connected to the ground.
edge. - The Electric Power Company, if previously advised
Never dig under the machine. and involved in the work, as well as machine
Operator, Owner and/or any natural person or legal
Should it be necessary to dig under the machine,
entity having rent orleased the machine or being
always ensure that digging walls are opportunely
responsible at the time by contract or by law, are
propped up against landslide to prevent the machine
liable for the adoption of the necessary
from falling into the trench.
precautions.
Do not swing the upperstructure, raise the load or
- Decrease work speed. Reaction time could be too
brake abruptly if not required. This may cause
slow and distance evaluation wrong.
accidents.
- Warn all ground personnel to keep clear of the
Prior to beginning the work near gas distribution
machine and/or load at all times. If the load has to
mains or other public utilities:
be guided down for laying, consult the Electric
- Contact the company owner of the gas mains or its Power Company to know which precautions should
nearest branch before starting the work. Look up be taken.
the number in the telephone directory.
- Appoint a person in charge of signalling duties.
- Define together which precautions should be taken This person will have the responsibility of observing
to guarantee work safety. the machine, any part of it and/or the load
- Decrease work speed. Reaction time could be too approaching the electric lines from a standpoint
slow and distance evaluation wrong. more favourable than the Operator’s. This signal
- When working near gas mains or other public man (flag-man) must be in direct communication
utilities installations, appoint a person in charge of with the Operator and the Operator must pay
signalling duties. This person will have the undivided attention to the signals supplied.
responsibility of observing the machine, any part of When working in or near pits, in ditches or very high
it and/or the load approaching the gas mains from walls, check that the walls are sufficiently propped up
a standpoint more favourable than the Operator’s. to avoid cave-in hazards.
This signal man (flag-man) must be in direct Pay the utmost attention when working near
communication with the Operator and the Operator overhang walls or where landslides may take place.
must pay undivided attention to the signals Make sure that the support surface is strong enough
supplied. to prevent landslides.
- The gas distributing Company, if previously When digging, there is the risk of cave-ins and
advised and involved in the work, as well as landslides.
machine Operator, Owner and/or any natural
Always check ground conditions and conditions of
person or legal entity having rent or leased the
the material to be removed. Support everywhere it is
machine or being responsible at the time by
required to prevent possible cave-ins or landslides
contract or by law, are liable for the adoption of the
when:
necessary precautions.
- Digging near previous trenches filled with material.
Working near electric lines can be very dangerous,
therefore some special precautions must be - Digging in bad ground conditions.
observed. - Digging trenches subject to vibration from
Within this Manual, “work near electric lines” means railroads, working machines or highway traffic.
when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
STOPPING
Regulations.
To work without risks, keep maximum possible
distance from electric lines and never trespass When the machine is to be stopped for whatever
minimum safety distance. reason, always check that all controls are in the
neutral position and that the safety lever is on the lock
- Contact the Company owner of the electric lines or
position to guarantee risk-free start-up.
its nearest branch before starting the work.
S1 - 4
GENERALITIES E135B
Never leave the machine unattended with the engine Read all safety plates mounted on the machine and
running. observe instructions they contain before starting,
Prior to leaving the driver’s seat, and after making operating, repairing, fuelling or servicing the
sure that all people are clear of the machine, slowly machine.
lower the attachment until resting it safely to the Do not allow unauthorised personnel to repair or
ground. Retract possible auxiliary tools to the closed service the machine.
safety position. Follow all recommended maintenance and service
Check that all controls are in the neutral position. procedures.
Move engine controls to the shut-down position. Do not wear rings, wrist watches, jewellery, loose or
Switch off the key-start switch. Consult the Operation hanging garments, such as ties, torn clothing,
and Maintenance Instruction Manual. scarves, unbuttoned or unzipped jackets that can get
Park the machine in a non-operating and no-traffic caught in moving parts. Wear certified safety clothes
area. Park on firm level ground. If this is not possible, such as: hard hat, no-slip footwear, heavy gloves, ear
position the machine at a right angle to the slope, protection, safety glasses, reflector vests, respirators
making sure there is no danger of uncontrolled when required. Ask your employer about safety
sliding. regulations in force and protective equipment.
If parking in traffic lanes cannot be avoided, provide Do not use controls or hoses as hand holds. Hoses
appropriate flags, barriers, flares and other signals as and controls are movable parts and do not provide
required to adequately warn the oncoming drivers. solid support. Besides, controls may be inadvertently
Always switch off the key-start switch before moved and cause unexpected movement of the
cleaning, repairing, or parking the machine to prevent machine or its attachments.
accidental unauthorised start-up. Do not jump on or off the machine. Always keep both
Never lower the attachment or auxiliary tools other hands and one foot, or both feet and one hand in
than from sitting in the operator’s seat. Sound the contact with steps and/or grab rails.
horn. Make sure that nobody is within the machine Never service the machine with someone sitting in
operating range. Lower the attachment slowly. the driver’s seat, unless this person is an authorised
Securely block and lock the machine every time you operator assisting in the maintenance being carried
leave it unattended. Return keys to the safe place out.
previously agreed upon. Perform all necessary Keep the operator’s compartment, step plates, grab
operations for stopping as detailed in the Operation rails and handles clear of foreign objects, oil, grease,
and Maintenance Instruction Manual. mud orsnow to minimise the danger of slipping or
Drive the machine far from pits, trenches, rocky stumbling.
hanging walls, areas with overhead electric lines, and Clean mud or grease from your shoes before
slopes before stopping it at the end of the working climbing on the machine or driving it.
day. Never attempt to operate the machine or its
Align the upperstructure to the tracks in order to allow attachments from any position other than sitting in the
to easily get on and off the driver’s compartment. operator’s seat.
Move all controls to the position specified for machine Keep the driver’s seat free from foreign objects,
stopping. Refer the Operation and Maintenance especially if these are not secured.
Instruction Manual. Should it be necessary to move the attachment for
Never park on an incline without accurately blocking maintenance purposes, do not raise or lower the
the machine to prevent unexpected movement. attachment from any other position than sitting in the
Follow stopping instructions contained in the operator’s seat. Before starting the machine or
Operation and Maintenance Instruction Manual. moving its attachment, sound the horn and require
that nobody remains near the machine.
Raise the attachment slowly.
Always lock all moving components or parts of the
machine that must be lifted for maintenance
MAINTENANCE purposes using adequate external means as
required by local and national regulations. Do not
allow anyone to pass or stay near or below a raised
GENERALITIES
attachment. If you are not absolutely sure about your
safety, do not stay or walk under a raised attachment.
Carefully read the Operation and Maintenance Do not place head, body, limbs, hands, feet or fingers
Instruction Manual before starting, operating, near articulated cutting edges deprived of the
maintaining, fuelling or servicing the machine in any necessary guards, unless they are suitably and
manner. safely locked.
S1 - 5
E135B GENERALITIES
Never lubricate, repair or adjust the machine with the flammable fluids to clean parts. Use proprietary
engine running, except when this is specifically certified non-flammable, non-toxic solvents only.
required by the Operation and Maintenance When using compressed air to clean parts, wear
Instruction Manual. safety glasses with side shields. Limit pressure to
Do not wear loose clothing, jewellery near rotating max. 2 bars, in accordance with local and national
parts. safety regulations in force.
When service or maintenance require access to Do not run the engine of this machine in closed
areas that cannot be reached from the ground, use a buildings without proper forced ventilation capable to
ladder or step platform conforming to local or national remove toxic exhaust gases concentrating in the air.
regulations to reach the working area. If such means Do not smoke, nor allow open flames or sparks
are not available, use machine grab rails and steps. nearby while refuelling the unit or handling highly
Always perform all service or maintenance work with flammable materials.
the greatest care and attention.
Do not use open flames as light sources to look for
Shop and/or field service platforms or ladders should leaks or inspect anywhere on the machine.
be manufactured and maintained in accordance with
Make sure that all mechanical tools provided are in
local or national safety regulations in force.
good condition at all times. Never use tools with
Disconnect batteries and label all controls to warn mushroomed or damaged heads. Always wear eye
that service work is in progress, according to local protections with side shields.
and national safety regulation requirements.
Move with extreme care when working under, on or
Block the machine and all attachments to be raised near the machine or its attachments.
according to local and national safety regulation
In case of attachment tests during which the engine
requirements.
should be kept running, a qualified operator must sit
Do not check or fill fuel tanks or install batteries near in the driver’s seat at all times while the mechanic is
burning or smoking materials and open flames due to at work.
the presence of flammable vapours.
Keep hands and clothes far off moving parts.
The fuel filler pipe nozzle must be constantly kept in
Stop the engine and move the safey lever to the lock
contact with the filler neck and this even before fuel
position before starting adjusting or repairing an
starts flowing in. Keep this contact from the beginning
assembly.
to the end of the fuelling operation to avoid possible
generation of sparks due to static electricity. Do not carry out any work on the attachment without
prior authorisation. Observe maintenance and repair
Use a truck or trailer to haul a failed machine. Should
procedures.
it be necessary to tow it, provide for suitable danger
signals as required by the local norms and In case of field service, move the machine to level
regulations and observe recommendations given in ground and block it. If work on an incline cannot be
the Operation and Maintenance Instruction Manual. avoided, securely block the machine and its
Load/unload the machine on firm level ground attachments. Move the machine to level ground as
providing safe support to the wheels of the truck or soon as possible.
trailer. Use strong access ramps, with adequate Do not twist chains and cables. Never use a twisted
height and angle. Keep the trailer flatbed free of mud, chain or cable for lifting or pulling. Always wear safety
oil or slippery materials. Tie the machine securely to gloves to handle chains or cables.
the trailer and block carriages and upperstructure. Be sure chains and cables are firmly fastened and
Never align holes or slots using your fingers; that the anchor point is strong enough to withstand
alwaysuse appropriate aligning tools. the expected load.
Remove all sharp edges and burrs from re-worked Keep all bystanders clear of the anchor point, cables
parts. or chains. Do not pull or tow unless the operator’s
Use only approved and effectively grounded auxiliary compartments of the machines involved are
power sources for heaters, battery chargers, pumps fitted with proper guards against cable or chain
and similar equipment to reduce electrical shock backlash.
hazard. Keep the maintenance area clean and dry at all
Lift and handle heavy components using hoisting times.
devices of appropriate capacity. Ensure the parts are Clean immediately all water and oil spillage.
supported by appropriate straps and hooks. Do not pile up oily or greasy rags as they represent a
Use lifting eyes provided to this aim. major fire hazard. Always store them in closed metal
Pay attention to bystanders near the lifting area. containers.
Never pour gasoline or diesel fuel into open Before starting the machine or its attachment, check,
containers. Never use gasoline, solvents or other adjust and lock the operator’s seat. Also ensure that
nobody is within the machine or attachment
S1 - 6
GENERALITIES E135B
operating range before starting or operating the injuries are most likely to occur. Pay attention to
machine and/or its attachments. prevent possible part movements by means of
Sound the horn. blocks or by keeping clear of such zones when
motion may take place during maintenance or repair.
Rust inhibitors are volatile and flammable.
Move the hydraulic system lock safety lever to the
Prepare parts in well ventilated areas. Keep open
lock position when stopping the machine for
flames away.
whatever reason.
Do not smoke.
Always install the safety stays for the hood and other
Store containers in a cool well ventilated place where hinged covers before performing any maintenance or
they could not be reached by unauthorised people. repair work in the engine compartment.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
TRANSFERS AND TRANSPORTATION
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate welder’s equipment such as Before moving or transporting the machine, block
dark safety glasses or mask, hard hat, protective upperstructure swing to prevent accidental
clothing, safety gloves and footwear always while movement.
welding or arc-cutting. Wear dark safety glasses Pay particular attention during transfer on inclines,
when you are near a welding in progress. both uphill and downhill. Keep the bucket in a position
Do not look the welding arc without proper eye to provide a possible anchor point into the ground in
protection. case of slipping.
Become acquainted with all your jacking equipment During transfers on inclines, both uphill and downhill,
and their capacity. keep the upperstructure aligned with the carriages.
Do not travel across the slope.
Ensure that the jacking point on the machine is
appropriate for the load applied. Also, be sure the Never transfer the machine in the working site, in a
supports under the jack and between the jack and the crowded area, or near people without having at least
machine are appropriate and stable. one person charged with hand-signals who could
guide the Operator.
Any equipment supported by a jack represents a
possible hazard. Always support the load onto Sound the horn to inform that you are about to move
appropriate blocking means as a safety measure off.
before proceeding with service or maintenance work, It is necessary to know load limits of bridges and
in compliance with local or national safety dimensional limits of tunnels. Such limits must never
regulations. be exceeded. You should also know machine height,
Metal cables produce steel splinters. Always wear width, and weight. Have a signal-man help you when
certified protection clothes such as safety gloves and clearances are limited.
glasses while handling them. Check distance between boom/arm and dimensional
Do not use makeshift jacks to adjust track sag. Follow limits during transfer or transportation.
instructions given in the Repair Manual. Rough terrain may cause the machine to sway and
Handle all parts carefully. Keep hands and fingers roll to such an extent that boom/arm could get to
away from gaps, gears, and similar. Always use and contact electric lines or other obstacles. Cross
wear certified safety clothes such as safety glasses, obstacles at a right angle at low speed. Pay attention
gloves and footwear. to machine shaking when the centre of gravity
overcomes the obstacle.
The attachment is kept constantly in position by an oil
column trapped into the high pressure circuit. Lower Keep the bucket down at all times during transfers.
the attachment to the ground and relieve pressure Drive with the lights on and use appropriate signals
from all circuits prior to carrying out any type of and flags.
maintenance or repair work. Get to know and respect local and national
Do not service or repair the machine if it is parked regulations.
downhill. If this is unavoidable, in case of emergency, Consider boom/arm and upperstructure dimensions
block the carriages to prevent unexpected while turning.
movement, particularly if the work is to be carried out
Use a ramp to load the machine on a trailer. If a ramp
on the final reduction units or travel motors.
is not available, fabricate one using blocks. The ramp
Consult the Operation and Maintenance Instruction should be sufficiently strong to support machine
Manual for correct maintenance procedure. weight. Always load and unload on level surface.
Areas near articulated cutting edges where
mechanical parts are in motion are where personal
S1 - 7
E135B GENERALITIES
Tow the machine following the instructions contained Before any maintenance or repair, make sure that
in the Operation and Maintenance Instruction there are no fuel or electrolyte leaks from the
Manual. batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of
ENGINE explosive gas released during charging.
Disconnect batteries before working on the electrical
Do not run the engine in closed buildings without system or carrying out any other type of work.
proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or fingers
HYDRAULIC SYSTEM
near rotating fans or belts. Be especially careful near
blower fans.
Loosen the radiator cap very slowly to relieve system Pressure fluid escaping from a very small hole can be
pressure before removing it. Always top-up coolant almost invisible and still have sufficient force to
level with the engine off or idling if hot. See the penetrate the skin. Always check any suspected
Operation and Maintenance Instruction Manual. pressure leaks using a piece of cardboard or wood.
Keep the exhaust manifold and tube free from Do not use hands. If injured by escaping fluid, obtain
combustible matters. Fit the machine with shields medical attention immediately or serious infection or
and guards when working in the presence of reaction may develop.
combustible matter free in the air. Stop the engine and ensure pressure is relieved from
Do not refuel with the engine running, especially if all systems before removing side panels, housings,
hot, as this increases fire hazard in case of fuel guards and covers. See the Operation and
spillage. Maintenance Instruction Manual.
Never attempt to check or adjust fan belt tensions Always use gauges of adequate capacity for
when the engine is running. pressure testing. Refer to the Operation and
Maintenance Instruction Manual or Repair Manual.
Do not adjust the fuel injection pump when the
machine is operating.
Do not lubricate the machine with the engine running.
Do not run the engine with the air intakes open and
not protected. If this cannot be avoided for service
reasons, place protection meshes on all intakes TOOLS
before servicing the engine.
Always keep head, body, limbs, feet, hands, and

ELECTRICAL SYSTEM fingers away from the bucket and attachments, when
in the raised position.
Pay attention to connect connecting cables to correct Prior to any maintenance or repair work, install all
poles (+ to +) and (- to -) at both ends. Do not short- supports necessary to this aim according to local and
circuit terminals. Thoroughly follow instructions given national safety regulations.
in Operation and Maintenance Instruction Manual. In case the attachment is to be operated for
Always move the key-start switch in the lock position maintenance or repair purposes, do so exclusively
before servicing or repairing the machine. while sitting in the driver’s seat. Sound the horn
Batteries contain SULPHURIC ACID. Protect the before starting the machine or moving the
eyes when working near the batteries against attachment. Require that nobody remain near the
possible sprays of the acid solution. Should acid machine. Raise the attachment slowly.
contact skin, eyes, or clothes, RINSE IMMEDIATELY Do not use the machine to transport loose objects,
IN WATER FOR AT LEAST 15 MINUTES. unless proper securing devices are provided.
Immediately seek medical attention. Never use gases other than nitrogen to charge the
Battery released gas is highly flammable. Leave accumulators.
the battery compartment cover open during
recharging to improve ventilation. Never check
battery charge by placing metal objects across the
posts. Keep sparks or open flames away from
batteries. Do not smoke near the battery to prevent
explosion hazard.
S1 - 8
RECOGNISE SAFETY INFORMATION
• This is your SAFETY ALERT SYMBOL
- When you see this symbol on your machine or

in this Manual, be alert of the potential for
personal injury.
- Follow recommended precautions and safe
operating practices.
UNDERSTAND SIGNAL WORDS
• In this Manual you will find the following words

referring to different hazard risks:
- DANGER;
- WARNING;
- CAUTION.
These words are always accompanied by the safety DANGER
alert symbol.
DANGER: indicates an imminent hazardous

situation which, if not avoided, will result in death or
WARNING
serious injury.
WARNING: indicated a potential hazardous

situation which, if not avoided, could result in death
CAUTION
or serious injury.
CAUTION: indicates a potential hazardous situation IMPORTANT

which, if not avoided, may result in minor or
moderate injury.
NOTE
IMPORTANT: indicates a situation which, if not
avoided, may cause damage to the machine.
NOTE: indicates an additional explanation for

information purposes.
ENVIRONMENTAL PROTECTION
• This Manual also contains this symbol

accompanying instructions for correct behaviour
as regards environmental protection.
S2 - 1
E135B SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS
• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.
• Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your Dealer
in the same way you order a spare part (be sure
to detail machine model and serial number upon
ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorised personnel
to operate the machine.
• Keep the machine in proper working conditions.
- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
• Safety messages in this Chapter “SAFETY
PRECAUTIONS”, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct
supervisor prior to operating or servicing the
machine.
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on
hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it
properly.
- Establish emergency priority procedures to
cope with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire
department posted near the telephone.
S2 - 2
WEAR PROTECTIVE CLOTHING
• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask;
Be sure to correctly wear equipment and clothing
for the job.
- Do not take any chances.
- Avoid wearing loose clothing, jewellery, or other
items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.
INSPECT THE MACHINE
• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.
S2 - 3
USE HAND HOLDS AND STEPS
• Falling is one of the major causes of personal

injury.
- When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.
- Prior to climbing or leaving the machine, check
that the fasteners of stepping points and the
handrails are tightened and are undamaged.
Repair them as required.
- Keep the access to the machine clear of foreign
objects and clean. Remove grease or mud from
stepping points and rails to minimise the danger
of slipping or stumbling.
- Do not use the controls or the safety lever as
hand holds when climbing on or off the machine.
- Do not climb or leave the machine running. Do
not jump on or off the machine.
- Do not climb or leave the machine while holding
tools or other objects in your hands.
- Do not climb or leave the machine while it is
moving.
ADJUST THE OPERATOR'S SEAT
• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.
- The seat should be adjusted whenever machine

operator changes.
- The operator should be able to fully press the
pedals and correctly move the control levers
with his back resting against the seat back.
- If not, move the seat fore and aft, and check
again.
S2 - 4
FASTEN SEAT BELT
• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.
- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
- Be sure to remain seated with the seat belt
securely fastened at all times when the machine
is in operation to minimise injury hazard in case
of accident.
- After a significant accident, replace the seat
belts even though they do not look damaged.
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
- Pay the utmost attention not to run over

bystanders.
- Be sure exposed personnel in the area of
operation are clear of the machine before
moving it or its attachments. Sound horn to
inform bystanders that the machine is going to
be operated.
- When operating, swinging, or moving the
machine in a congested area use a signal man.
S2 - 5
OPERATE ONLY FROM THE DRIVER'S SEAT
• Inappropriate engine starting procedures may

cause the machine unexpected movement,
possibly resulting in serious injury and even
death.
- Start the engine only from the operator’s seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across
starter motor terminals.
- Before starting the engine, ensure that all
control levers are in the neutral position.
DO NOT CARRY PERSON ON THE MACHINE
• Riders on the machine are exposed to serious

injuries.
- DO NOT carry riders on the machine. Besides

precluding a full vision by the operator, there is
the possibility of serious bodily harm or death
due to accidental falls from the machine.
CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN
• Incorrect travel controls operation may result in

serious injury and even death.
- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front of
the cab, the machine will move reverse when
travel controls are moved towards cab front.
S2 - 6
AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
• If any person is present near the machine when

backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- ALWAYS BE ALERT FOR BYSTANDERS

MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
- USE A SIGNAL PERSON WHEN BACKING

UP IF YOUR VIEW IS OBSTRUCTED.
ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
- Use hand signals, which conform to your local

regulations, when work conditions require a
signal person.
- No machine motions shall be made unless

signals are clearly understood by both
signalman and operator.
- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.
- Always make sure that rear mirrors are clean

and correctly adjusted.
- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.
S2 - 7
DRIVE MACHINE SAFELY
• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.
- Pushing down on the front of the travel pedals or

pushing the levers forward moves the machine
towards the idlers.
• Traveling on a grade may cause the machine to

slip or to overturn, possibly resulting in serious
injury or death.
- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately
20 to 30 cm (A) above the ground.
- If machine starts to skid or becomes unstable,

lower the bucket immediately.
- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope,
be sure to point the tracks uphill/downhill.
- Turning on an incline may cause the machine to

tip over. If turning on an incline is absolutely
unavoidable, do so at a place where the slope is
gentle and the surface is firm.
- Do not travel on slopes with an angle exceeding

30°. Do not travel across hill on slopes
exceeding an angle of 15°.
S2 - 8
AVOID OVERTURNING
• When working on a slope or on unstable terrain,

the danger of tipping over is present with the
possibility of subsequent serious damages or fatal
injuries.
- Pay the utmost attention when working on a
slope. If possible, level first the work area.
- Avoid swing or steering the machine on a slope.
- Decrease the operating speed and actuate the
controls carefully, to prevent sudden
movements that could result in slipping or
tipping over.
- In case the engine is cut-off, lower the bucket to
the ground, move the controls in neutral and
restart the engine.
• Pay the utmost attention when operating the

machine on frozen ground or in snowy conditions.
- Frozen ground, when the ambient temperature
increases, tends to be less firm jeopardising the
stability of the machine.
- Operate carefully when in snowy conditions.
The snow could hide invisible dangerous spots.
- Actuate the controls slowly and carefully to
prevent the machine from making unwanted
slippery manoeuvres or movements.
- Even on minor slopes, when snow is present
and on frozen ground, unwanted slippery
manoeuvres or movements of the machine
could occur.
PARK MACHINE SAFELY
• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Pull the safety lever (pilot-control shut-off lever)
to the LOCK position.
- Turn auto-idle switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Prior to leaving the machine, close the windows,
the cab door and all panels.
S2 - 9
INVESTIGATE JOB SITE BEFORE

OPERATING THE MACHINE
• Explore the working area to identify potential risks

before starting and operating the machine. Make
sure that the structure and the conditions of the
ground are safe before starting operations.
- Make sure that the digging area is sufficiently
stable and firm to support the weight of the
machine during the work operations.
- Working near edges and ditches presents a risk
for the stability of the machine. Check first that
edges and the walls of the digging are
sufficiently strong. If necessary, prop the edges
appropriately to prevent caving-ins.
- DO NOT dig too near the machine.
- Always position the tracks perpendicular to the
edge of the digging with the travel motors on the
rear side.
- When working on a slope or near the edge of the
road, have a flagman available.
PROTECTING AGAINST THE FALL OF

ROCKS AND LANDSLIDES
• When operating in zones where the possibility of
falling rocks or landslides exists or when there is
the risk for front impacts with objects that could
penetrate the cab, make sure that protection
structures are installed: F.O.P.S. (Falling Object
Protection Structure) and FRONT GUARD.
- DO NOT install any cab lifting device to the
protection structures.
- DO NOT weld, drill or modify protective
structures. Any type of modification could
weaken the structural integrity of the safety
system, with serious consequences for the
operator, in case of collision, falling objects or
landslides.
- After an accident, DO NOT try to straighten or
repair protective structures. Contact a Dealer to
verify the functionality, to repair or to completely
or partially replace the protective structures.
S2 - 10
DIG WITH CAUTION
• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law
from cables, gas lines, and water lines. If a fiber
optic cable should be accidentally severed, do
not look into the end. Doing so may result in
serious eye injury.
- Contact local authorities and/or the utility
companies directly (electric power, gas,
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground
utility lines.
OPERATE WITH CAUTION
• If the front attachment or any other part of the

machine hits against an overhead obstacle, such
as a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury
may results as well.
- Take care to avoid hitting overhead obstacles
with the boom or arm.
AVOID ELECTRIC LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
- When operating near an electric line, NEVER
MOVE any part of the machine or load closer
than 5 m plus twice the line insulator length (L).
- Check and comply with any local regulations
that may apply.
- Wet ground will expand the area that could
cause any person on it to be affected by electric
shock.
- Keep all bystanders or co-workers away from
the site.
S2 - 11
KEEP PERSONNEL CLEAR FROM

WORKING AREA
• A person may be hit severely by the swinging front

attachment or counterweight and/or may be
crushed against an other object, resulting in
serious injury or death.
- Keep all persons clear from the area of

operation and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing
radius to prevent anyone from entering the work
area.
NEVER MOVE THE BUCKET OVER

ANY ONE
• Never lift, move, or swing bucket above anyone or

a truck cab. Serious injury or machine damage
may result due to bucket load spill or due to
collision with the bucket.
SP0030
DO NOT OPERATE IN TUNNELS
• DO NOT operate the machine in enclosed spaces

or, in any case, without appropriate ventilation.
Operations in tunnels or underground sites where
potential explosive conditions exist are not
allowed. There is a danger for explosions and
potentially deadly injuries. Please comply with the
ATEX regulation relative to devices to be used in
a potentially explosive environment.
S2 - 12
NEVER UNDERCUT A HIGH BANK
• The edges could collapse or a land slide could

occur causing serious injury or death.
SAFETY LOADS MOVING
• The excavator is a machine designed specifically

to perform digging/loading works, thus it must not
be used to handle suspended loads. In the event,
under exceptional conditions, it becomes
necessary to handle materials, the following
indications must be strictly implemented:
- The machine must be equipped compulsorily
with the appropriate variant provided upon
request. Also, totally comply with the safety
precautions for the operation of the excavator as
a lifting equipment.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking
mechanisms.
- Never hook cables or chains to the bucket teeth.
- Nobody should be allowed to remain under the
raised load or within the excavator operating
range for any reason whatever.
- Never exceed specified loading capacity.
Incorrect fastening of slings or chains may
cause boom/arm failure or failure of the lifting
means with consequent bodily injuries and
even death.
- Always ensure that slings and chains used for
lifting are adequate to the load and in good
condition.
- All loading capacities are referred to the
machine on a level surface and should be
disregarded when working on a slope.
- In any case, comply with the current national or
local regulations on this matter.
S2 - 13
AVOID EXCESSIVE DIGGING EFFORTS
• Operate the machine complying with the load

limits in accordance with the "table of lifting loads"
located inside the cab.
- Do not exceed the prescribed load limits.
- Do not use the strength of the attachment to
travel or move the machine.
- Do not try digging exploiting the mass of the
machine.
PAY ATTENTION WHEN DIGGING DEEPLY
• When digging deeply, pay special attention to

prevent contacts of the attachment and the
relevant hydraulic hoses with the ground.
• DO NOT swing the turret or the undercarriage
when the attachment boom is fully lowered. Under
these conditions there is the danger that the boom
collides with the track chains.
DO NOT USE THE TRACTION FORCE OF

THE MACHINE FOR DIGGING
• Do not travel the machine to dig. In doing this, an

excessive stress on the front attachment could
results in damages to the structure. Use the
undercarriage for travelling only.
DO NOT USE THE TURRET SWING FOR

DIGGING
• Do not use the turret swing for digging or moving

rocks. An excessive stress on the front
attachment could results in damages to the
structure reducing the operating life of the swing
system. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.
S2 - 14
DO NOT USE THE BUCKET AS A HAMMER
• The use of the bucket as a hammer or for piling

operations could cause serious damages to the
bucket itself and the components of the front
attachment. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.
AVOID OPERATING THE CYLINDERS TO

FULL STROKE
• Do not extend repeatedly the bucket and the arm

cylinders full stroke with the purpose of cleaning
the bucket from residual materials. This could
cause damages to the cylinders. To remove
residues from the bucket, use water under
pressure or remove them manually.
Tolerance A ≥ 50 mm
PROVIDE SIGNALS FOR JOBS INVOLVING

A NUMBER OF MACHINES
For jobs involving several machines, provide signals

commonly known by all personnel involved. Also,
appoint a signal person to co-ordinate the job site.
Make sure that all personnel obey the signal
person’s directions.
TRANSPORTING THE MACHINE UNDER

SAFE CONDITIONS
• During loading or unloading operations of the

machine on a truck or trailer the danger for tipping
over is always present.
- Use a truck or trailer appropriate for transporting
the machine.
- Secure safely the machine to the trailer with
appropriate chains or cables. Please refer to the
chapter "TRANSPORTATION" of this Manual
for the safe loading and unloading procedures.
- Make sure that you comply with National and
local regulations when transporting the machine
on open roads.
S2 - 15
SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Keep the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it
is in motion.
- Keep hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
4. Switch off the Auto-Idle.
5. Let the engine idle with no load for at least
five minutes until it has cooled down.
6. Move the key-start switch to the OFF
position to stop the engine.
7. Remove the ignition key from the start
switch.
8. Apply the "Maintenance in progress" tag
(see SA FETY PLATE in this C hapter).
This tag can be applied o the left-hand
control lever, safety lever or cab door.
9. Let the engine cool down.
- Do not leave the machine unattended if
servicing requires the engine running.
- If the machine is to be raised, place boom and
arm at an angle 90 to 110°. Lock machine
components which should be raised for
maintenance or repair using suitable supporting
means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary. Refer to the Chapter
MAINTENANCE in this Manual.
- Keep all components in good condition and
properly install. Immediately repair any fault.
- Immediately repair any damage.Replace worn
or failed components. Remove grease, oil,
debris build-ups.
- Disconnect the negative cable (-) from the
battery before carry out any work on he
electrical sysem or arc-welding on he machine.
S2 - 16
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause

serious injury.
- Before performing any work on the machine,

attach a maintenance in progress tag (see also
SAFETY PLATES in this Chapter) . This tag can
be applied o the left-hand control lever, safety
lever or cab door.
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
- Always lower the attachment or tool to the

ground before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported
solely by a jack.
STOP THE ENGINE PRIOR TO PERFORMING
• DO NOT perform any maintenance operation with

the engine running. Trapping by moving parts
could cause serious injuries. Stop the engine and
wait that it cools-off prior to performing
maintenance operations.
In case it is indispensable to perform maintenance
operations with the engine running, have a person
co-operating with you sitting in the operator's seat,
to cut-off the engine immediately in case of
necessity.
S2 - 17
DISPOSE OF WASTE IN THE APPROPRIATE

MANNER
• Waste improperly disposed of represents a

danger for the envinronment. Potentially
dangerous waste used on the excavators
includes lubricants, fuel, coolant, brake fluid,
filters and batteries.
- Used sealed containers when discharging

fluids. Do not use containers for food or
beverages which may induce drinking.
- Do not spill waste over the ground, into drains,

or water beds.
- Obtain information about the correct methods to

recycle or dispose of waste from local
Authorities, collection centres or your Dealer.
WORK IN A CLEAN AREA
- Before starting an operation, clean the working

area. Clear the area from all the objects that can
be dangerous for mechanics or people in the
working area.
PROPERLY LIGHT THE WORKING AREA
• Properly and safely light the working area.

- Use safe portable lamps in order to work inside
and under the machine.
- Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp,
accidentally broken, can cause fuel or oil fire.
S2 - 18
KEEP CLEAN THE MACHINE
• Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
- The engine compartment temperature can
quickly rise, after stopping the engine. IN
THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the
engine cooling process and clean the
compartment.
• Remove all the traces of grease, oil and deposits,
in order to avoid people accidents or damages to
things.
- Do not spray water or steam in the cab.
PREVENT ACID SCALDS
• The sulphuric acid, contained in the battery, is

poisonous. It is strong enough to scald the skin,
corrode clothes and cause blindness, if it is
sprayed into the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to
help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Immediately see a doctor.
S2 - 19
STARTING THE ENGINE WITH BOOSTER

BATTERIES
• If the engine is to be started using booster

batteries, ensure to comply with all procedures
detailed in the chapter OPERATING
INSTRUCTIONS.
- The operator should be sitting in the driver’s
seat to keep the machine under control when
the engine starts. Starting the engine with
booster batteries is a two man operation.
- Do not use batteries that have been stored in
the cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may
cause the batteries to explode or machine to
move unexpectedly
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
- Keep sparks, lighted matches, and flames away

from the top of battery.
- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.
• Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be
splashed into eyes, possibly resulting in
blindness.
- Be sure to wear eye protection when checking

electrolyte specific gravity.
S2 - 20
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines. Skin contact
with escaping hot water or steam can cause
severe burns.
- To prevent possible injury from hot spraying

water. Do not remove the radiator cap until the
engine is cool. When opening, turn the cap
slowly to the stop. Allow all pressure to be
released before removing the cap.
- The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation. The engine, hoses,
lines and other parts become hot as well.
- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious
injury or death.
- Securely store attachments and implements to
prevent falling.
- Keep bystanders away from storage areas.
S2 - 21
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
- Tighten all connections before applying

pressure.
- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles
for eye protection.
- In an accident occurs, see a doctor familiar with

this type of injury immediately. Any fluid injected
into the skin must be surgically removed within
a few hours or gangrene may result.
PREVENT PARTS FROM FLYING OFF
• Grease in the track adjuster is under high

pressure. Failure to follow the precautions below
may result in serious injury, blindness, or death.
- NEVER attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.
SP0047
- As pieces may fly off, be sure to keep body and
face away from air release plug to avoid injury.
Reduction gear oil is hot. Wait for gear oil to cool
down, then gradually loosen the air release plug
to release pressure.
S2 - 22
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the

body, serious injury may result.
- Guard against injury from flying pieces of metal

or debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.
HANDLE FLUIDS SAFELY - AVOID FIRES
• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injuty or death.
- Do not refuel the machine while smoking or

when near open flame or sparks.
- Always stop the engine before refuelling the

machine.
- Fill the tank outdoors.
• All fuels, most lubrificants, and some antifreeze

fluids are flammable.
- Store flammable fluids well away from fire

hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn

spontaneously.
S2 - 23
PREVENT FIRES
• Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts
which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
• Check for Shorts:
- Short circuits can cause fires.
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
• Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF
position to confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
• Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S2 - 24
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
- Stop the engine by turning the key-start switch

to the OFF position if there is time.
- Use a fire extinguisher if there is time.
- Exit the machine.
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
- If you must operate in a building, be sure there

is adequate ventilation. Either use an exhaust
pipe extension to remove the exhaust fumes or
open doors and windows to bring enough
outside air into the area.
SP0062
USE APPROPRIATE TOOLS
• Use tools appropriate for the job to be performed.
- Inappropriate tools, parts and procedures might

generate dangerous conditions.
- Use tools of correct size to tighten or loosening

securing elements, in order to avoid injuries
caused by a wrench getting out of control.
- Do not use U.S. Standard or British Standard

tools on metric fasteners and vice versa.
• Use only genuine spare parts (please refer to the

Spare Parts Catalogue).
S2 - 25
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials when welding, soldering, etc.
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
- Do not weld or flame cut pipes or tubes that

contain flammable fluids.
- Clean them thoroughly with non-flammable
solvent before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING OR

HEATING
• Hazardous fumes can be generated when paints

is heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and
dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing
the dust. Wear an approved respirator.
2. If you use solvent or paint stripper, remove
stripper with soap and water before
welding. Remove solvent or paint stripper
containers and other flammable material
from a re a. Allow fumes to disperse at
least 15 minutes before welding or
heating.
S2 - 26
WELDING REPAIR INTERVENTIONS
• Welding repair interventions must be performed

only by a certified welder with sufficient
experience. Also, appropriate safety rules must be
implemented by all the personnel involved in the
operations. The duration through time of the
welding depends upon the quality and the
accuracy with which the operation is performed.
- Identify first all the fracture points and the zones
in which welding is required.
- Clean accurately the zones involved.
- Remove all paint and inspect the parts with
penetrating liquid or a magnetic particle tester.
- Move the starter switch into position "OFF" and
wait for 4 seconds to cut-off electricity from the
system.
- Disconnect the negative terminal (-) from the
battery.
- Connect the ground cable of the welder at least
1 m from the component to be welded.
- Make sure that the ground cable is NOT
connected to a seal or bearing and that there
are noo seals or bearings between the ground
cable and the part to be welded.
- Avoid welding pieces at low temperature i. e.
below 16 °C. If necessary, warm-up the part
involved prior to welding it.
- Remove paints from all surfaces prior to
warming-up or welding. Painted surfaces, when
warmed-up or when welded, can generate toxic
fumes.
- Use appropriate masks or protective glasses.
- Wear gloves and adequate clothing to protect
the skin.
S2 - 27
NOTE:
S2 - 28
SAFETY PLATES E135B
SAFETY PLATES
2 1
SP0108
1 2
SP0109
1. Attachment operating range safety plate.

2. Track adjuster plate.
S3 - 1
E135B SAFETY PLATES
5 4 3
11 8 10
SP0110
3. Counterweight operating range safety plate. 8. Engine hood warning plate.

4. Read-your-manual plate. 9. Controls lock/unlock plate (safety lever).
5. Special equipment movement warning plate. 10. Hydraulic oil pressurised tank warning plate.
6. Open windscreen warning plate aperta 11. No-stepping warning plate.
(inside the cab).
7. Tag indicating maintenance in progress.
S3 - 2
SAFETY PLATES E135B
1 - Attachment operating range safety plate
Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
Border and icons: black
2 - Track adjuster plate
It shows that obligation is made to consult the

Operation and Maintenance Instruction Manual
prior to acting on the track adjust valve.
Danger of severe injuries.
Background: yellow
3 - Counterweight operating range safety plate
Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the
attachments. Sound the horn.
Background: yellow
S3 - 3
E135B SAFETY PLATES
4 - Read-your-manual plate
It is positioned in the cab to recommend to

carefully read the Operation and Maintenance
Instruction Manual prior to starting, operating,
servicing, refuelling or carrying out any other
work on the machine.
Background: yellow
5 - Special equipment movement warning plate
It shows the danger represented by the special

equipment hitting the cab.
Pay special attention as no stops are provided to
prevent this problem.
Background: yellow
6 - Open windscreen warning plate
It indicates the risk of injuries deriving from the

windscreen not being locked or being
improperly locked in the open position.
Background: yellow
S3 - 4
SAFETY PLATES E135B
7 - Tag indicating maintenance in progress
Maintenance staff is obliged to apply the tag that

indicates that the machine is not fully efficient
and warns about maintenance staff being
located in not visible positions. This tag should
be applied to the left-hand control lever, safety
lever or cab door.
Background: yellow
8 - Engine hood warning plate
It highlights the obligation to stop the engine

before opening engine hood.
Danger of severe injuries following the presence
of rotating parts such as fan, pulleys, and belts.
Background: yellow
9 - Controls lock/unlock plate
It shows the position that the safety lever can

assume when the engine is running.
When the operator is about to leave the cab with
the engine running, even if for a short time, he
must move the safety lever to the LOCK
position. Controls are disabled and therefore no
accidental machine or attachment movement is
possible.
Background: white
S3 - 5
E135B SAFETY PLATES
10 - Hydraulic oil pressurised tank

warning plate
It indicates that the hydraulic oil is pressurised.

Consult the Operation and Maintenance
Instruction Manual. Prior to intervening on the
hydraulic oil tank, bleed the pressure by
actuating the appropriate bleeding button
located on the cap. The hydraulic oil, at
operating temperature, can cause burns in
case of contact with the skin.
Background: yellow
11 - No-stepping warning plate
It instructs not to step on the zone where this

decal is attached.
Background: yellow
Cross: red
S3 - 6
OPERATIONAL PRINCIPLE
OPERATIONAL PRINCIPLE E135B
SECTION AND GROUP CONTENTS
Section 1 GENERAL
Group 1 Specifications
Section 2 SYSTEM
Group 1 Mechatro Control System
Group 2 Hydraulic System
Group 3 Electrical System

Group 1 Hydraulic Pump Assy
Group 2 Pilot Valve
Group 3 Control Valve
Group 4 Swing Device
Group 5 Travel Device
Group 6 Swing Joint
Group 7 Cylinders
Group 8 Air Conditioner
Group 9 Blade control
SECTION 1 E135B
GENERAL
CONTENTS
Group 1 - Specifications
Main components.................................... T1-1-1
Hydraulic components ........................... T1-1-5
Excavator performance .......................... T1-1-8
Engine data............................................. T1-1-8
Engine characteristic curve..................... T1-1-9
Digging data (Monoblock Version).......... T1-1-10
Digging data (Triple Articulation
Version) ............................................. T1-1-11
Digging data (Monoblock Version with
undercarriage equipped with blade) .. T1-1-12
Digging data (Triple Articulation
Version with undercarriage
equipped with blade).......................... T1-1-13
Transporting dimensions
(Monoblock Version) .......................... T1-1-14
(Triple Articulation Version) ............... T1-1-15
(Monoblock Version with
(Triple Articulation Version with
Bucket applications as a function
of the arms ........................................ T1-1-18
SPECIFICATIONS E135B
MAIN COMPONENTS
SM2863
1- Bucket 11 - Swing motor 21 - Track link

2- Bucket link 12 - Fuel tank 22 - Batteries
3- Idler link 13 - Hydraulic oil tank 23 - Upper roller
4- Bucket cylinder 14 - Control valve 24 - Track guide
5- Arm 15 - Engine muffler 25 - Lower roller
6- Arm cylinder 16 - Hydraulic pump 26 - Air cleaner
7- Boom 17 - Engine 27 - Crawler adjuster
8- Boom cylinder 18 - Counterweight 28 - Front idler
9- Cab 19 - Engine radiator 29 - Shoe plate
10 - Swivel joint 20 - Travel motor
T1-1-1
E135B SPECIFICATIONS
Main Components – Upper Structure
8
H C F
A E
D
G B
2
6
3 4 SM2859
1- Control Cab 5- Hydraulic Pump

2- Proportional Solenoid Valve Block 6- Control Valve
3- Radiators 7- Swing Motor Unit
4- Engine 8- Center Joint
T1-1-2
Main Components – Under Carriage
3 1
2
H I
C D
A B
E E
section A - A
SM2860
1- Right Travel Motor Unit 4- Swing Gear

2- Left Travel Motor Unit 5- Front Idler Assy
3- Center joint
T1-1-3
Main Components – Front Attachment
2 7
1
3
4 6 2 8 7
3
1
SM0014
1- Boom cylinder 5- Monoblock Boom

2- Arm cylinder 6- Boom (Triple Articulation Version)
3- Bucket Cylinder 7- Arm
4- Positioning Cylinder (Triple Articulation 8- Positioner (Triple Articulation Version)
Version)
T1-1-4
HYDRAULIC COMPONENTS
HYDRAULIC PUMP
Item Main pump Gear pump for pilot

Pump K7V63DTP175R-0E13-VC ZX10L7RZ2-07G
Variable displacement plunger Fixed displacement type gear
Type
pump: regulator attached type pump
Max. displacement capacity cm3 (in3) 65.2 (3.98) x 2 10 (0.61)
rpm
(Clockwise
Revolution Rated
seen from
2000 ←
shaft end)
Pressure Rated MPa (psi) 34.3 (4974) 5.0 (725)
L/min 130 (34) x 2 at 7.8 MPa
Max. flow 20 (5.3)
(gal/min) (1130 psi)
Max. input Power
kW (PS) 64.9 (88.3) 3.1 (4.2)
(at 2000 rpm)
Max. input torque
N•m (lbf•ft) 310 (229) 14.7 (10.8)
(at 1600 rpm)
Model KR76-0E13PV - KR76-0E13-V
Control
Electric flow control, positive flow control
Regulator function
With solenoid proportional reducing valve (KDRDE5K-31/
Others
30C50-123)
Mass kg (lb) 84 (185)
NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
CONTROL VALVE
Item STD VALVE
Model KMX13YD / B44006
Max. flow rate L/min (gal/min) 130 (34) x 2
Main relief valve set pressure MPa (psi) 34.3 (4,974) at 30 (7.9 gal/min) x 2 L/min
Over load relief valve set pressure MPa (psi)
Boom R, Bucket R, Arm H 37.8 (5,482) at 30 (7.9 gal/min) L/min
Mass kg (lb) 155 (341)
Item OPT VALVE

Model KADV22Y / 501103A03
Over load relief valve set pressure MPa (psi)
Positioner R 37.8 (5,482) at 30 (7.9 gal/min) L/min
Positioner H 37.8 (5,482) at 30 (7.9 gal/min) L/min
Mass kg (lb) 11 (24.3)
T1-1-5
PILOT VALVE
ATTACHMENT TRAVEL
Model PV48K2004 6TH6NRZ
Primary pressure 5.0 MPa (725 psi) 4.9 MPa (710 psi)
Secondary pressure 0.6 ~ 3.2 MPa (87 ~ 464 psi) 0.54 ~ 2.35 MPa (78.3 ~ 340.7 psi)
Rated flow 20 L/min (5.3 gal/min) 25 L/min (6.6 gal/min)
Mass Approx. 2 kg (4.4 lbs) Approx. 8 kg (17.6 lbs)
SWING MOTOR UNIT

Model M2X63CHB-13A-36/28E-60
Swash-plate type, fixed-displacement plunger
Type
motor
Displacement cm3 (in3) 60.0 (3.66)
Hydraylic motor
Working pressure MPa (psi) 28.0 (4,060)

L/min
Max. flow 132 (34.87)
(gal/min)
Braking torque N•m (lbf•ft) 655 (483)
Release pressure MPa (psi) 2.3 (333)
Relief set pressure MPa (psi) 29 (4,206)
Mass kg (lb) 29 (64)
Antireaction Type 2KAR6P72/240-716

valve block Mass kg (lb) 5 (11)
Hydraulic motor assy mass kg (lb) 34 (75)
Model RG06D19J2
Speed reduction type Planetary 2-stage
Reduction ratio 19.2

Reduction unit
Lubicate oil Gear oil SAE90 (API class GL–4 grade)
Lubicate oil volume L (gal) 1.65 (0.43)
Grease Extreme pressure lithium base # 2 grease

Grease volume cm3 (in3) 500 (30.51)
Mass kg (lb) 79 (174)
Total mass kg (lb) 113 (249)
T1-1-6
TRAVEL DEVICE
Type GM21VA-A-45/76-2
Gear ratio 54.0
11,100/19,200 N•m
Rating torque
(8,186/14,160 lbf•ft)
Reduction unit
Output speed 51.4/31.3 rpm
Lubricant oil Gear oil SAE#90 GL4
Lubricant oil volume 2.1 L (0.55 gal)
44.9/75.5 cm3/rev
Max. displacement
(2.74/4.61 cu.in/rev)
Max working pressure 34.32 MPa (4,976.4 psi)
Hydraulic motor Max. speed 2,777/1,688 rpm (2nd/1st)
Flow rate 130 L/min (34 gal/min)
2 speed control pressure 1.96~6,86 MPa (284~995 psi)
Auto 2 speed control pressure 28.44 MPa (4,124 psi)
Brake torque 206 N•m (152 lbf•ft)
Parking brake
Release pressure 0.76 MPa (110 psi)
Mass 145 kg (320 lbs)
CYLINDERS
Center distance
Cylinder bore / of pins
Use Rod Dia. Stroke Full extend B / Cushion Mass
Full retract A
mm (in) mm (in) mm (in) kg (lb)
Ø 100 / Ø 70 1,028 2,516 / 1,488 With cushion 100
Boom
(3.94 / 2.76) (40.47) (99.05 / 58.58) on rod side (220)
Ø 115 / Ø 80 1,120 2,835 / 1,715 With cushion 138
Arm
(4.53 / 3.15) (44.09) (111.61 / 67.52) on both sides (304)
Ø 95 / Ø 65 903 2,293 / 1,390 With cushion 82
Bucket
(3.74 / 2.56) (35.55) (90.27 / 54.72) on rod side (180)
Ø 125 / Ø 85 825 2,190 / 1,365 177
Positioning Without cushion
(4.92 / 3.35) (32.48) (86.22 / 53.74) (390)
T1-1-7
EXCAVATOR PERFORMANCE
GRADEABILITY ......................................................................................................................................... 70%
TRAVEL SPEED
Speed
First speed 3.4 km/h (2.1 mph)
Second speed 5.5 km/h (3.5 mph)
ENGINE DATA
MAIN SPECIFICATIONS
- Manufacturer .........................................................................................MITSUBISHI HEAVY INDUSTRIES
- Model ...................................................................................................................................... D04FR-74KW
- Type ..................................................................................... Diesel, 4 stroke, direct injection, turbocharged
- Number of cylinder ...........................................................................................................................4 in-line
- Bore ................................................................................................................................... 102 mm (4.02 in)
- Stroke................................................................................................................................. 130 mm (5.12 in)
- Total displacement .................................................................................................... 4,249 cm3 (259.28 in3)
- Compression ratio ............................................................................................................................... 17.8:1
- Net power at flywheel at 2,000 rpm (ISO 14396) ................................................................. 74 kW (101 PS)
- Net power at flywheel at 2,000 rpm (ECE R120) ................................................................. 74 kW (101 PS)
- Torque at 1,600 rpm....................................................................................................... 375 N•m (277 lbf•ft)
- Engine idle at no-load ............................................................................................. 1,015 min-1 (1,015 rpm)
INJECTION PUMP
- Manufacturer .................................................................................................................................... BOSCH
- Type ................................................................................................................... Common rail high pressure
- Injection order ....................................................................................................................................1-3-4-2
BATTERY
- Voltage - Capacity............................................................................................................. 2 x 12 V - 100 Ah
STARTER MOTOR
- Manufacturer ................................................................................................NIKKO ELECTRIC INDUSTRY
- Voltage - Output......................................................................................................................... 24 V - 5 kW
ALTERNATOR
- Manufacturer ................................................................................................NIKKO ELECTRIC INDUSTRY
- Type ........................................................................................................................................0-35000-4838
- Voltage - Output.......................................................................................................................... 24 V - 50 A
T1-1-8
ENGINE CHARACTERISTIC CURVE
Condition to be measured: the net value is indicated, measuring without cooling fan.
SM2862
Fuel consumption volume

= (Fuel consumption rate / 0.835 x 1000) x kW x Load factor (α)
= (233 g/kW h / 0.853 x 1000) x 74 kW x α
= 20.65 α L/h
α: standard load factor (0.70 ~ 0.80)
Fuel consumption in regular operation (load factor 0.70 ~ 0.80) 14.5 L/h ~ 16.5 L/h
T1-1-9
DIGGING DATA
(Monoblock Version)
A
A‘
B B‘
NH0701
Unit: mm (in)
Arm 2100 (82.68) 2450 (96.46) 2950 (116.14)

A 8097 (318.78) 8428 (331.81) 8914 (350.94)
A’ 7940 (312.60) 8278 (325.90) 8774 (345.43)
B 5147 (202.63) 5498 (216.46) 5998 (236.14)
B’ 4884 (192.28) 5267 (207.36) 5807 (228.62)
C 8411 (331.14) 8633 (339.88) 8977 (353.42)
D 6009 (236.57) 6232 (245.35) 6575 (258.86)
E 2600 (102.36) 2651 (104.37) 2918 (114.88)
T1-1-10
DIGGING DATA
(Triple Articulation Version)
A
A‘
E
B B‘
NH0702
Unit: mm (in)
Arm 2100 (82.68) 2450 (96.46) 2950 (116.14)

A 8195 (322.64) 8534 (335.98) 9030 (355.51)
A’ 8041 (316.57) 8386 (330.16) 8890 (349.99)
B 4919 (193.66) 5267 (207.36) 5769 (227.13)
B’ 4789 (188.54) 5142 (202.44) 5655 (222.64)
C 9386 (369.53) 9701 (381.92) 10168 (400.31)
D 6951 (273.66) 7268 (286.14) 7738 (304.64)
E 2600 (102.36) 2198 (86.53) 2628 (103.46)
T1-1-11
DIGGING DATA
(Monoblock Version with undercarriage equipped with blade)
A
A‘
B B‘
NH0703
Unit: mm (in)
Arm 2100 (82.68) 2450 (96.46) 2950 (116.14)

A 8097 (318.78) 8428 (331.81) 8914 (350.94)
A’ 7940 (312.60) 8278 (325.90) 8774 (345.43)
B 4853 (191.06) 5201 (204.76) 5701 (224.45)
B’ 4613 (181.61) 4994 (196.61) 5522 (217.40)
C 8411 (331.14) 8633 (339.88) 8977 (353.42)
D 6009 (236.57) 6232 (245.35) 6575 (258.86)
E 2600 (102.36) 2651 (104.37) 2918 (114.88)
T1-1-12
DIGGING DATA
(Triple Articulation Version with undercarriage equipped with blade)
A
A‘
E
B B‘
NH0704
Unit: mm (in)
Arm 2100 (82.68) 2450 (96.46) 2950 (116.14)

A 8195 (322.64) 8534 (335.98) 9030 (355.51)
A’ 8041 (316.57) 8386 (330.16) 8890 (349.99)
B 4919 (193.66) 5267 (207.36) 5769 (227.13)
B’ 4723 (185.94) 5086 (200.24) 5609 (220.82)
C 9386 (369.53) 9701 (381.92) 10168 (400.31)
D 6951 (273.66) 7268 (286.14) 7738 (304.64)
E 2600 (102.36) 2198 (86.53) 2628 (103.46)
T1-1-13
TRANSPORTING DIMENSIONS
(Monoblock Version)
G D
H
F
I C
L
M A
N B
NH0705
Unit: mm (in)
A B C D E F G H I L
(1) 7853 (1) 2693
(309.17) (106.02)
3044 3750 892 2130 (2) 7858 (2) 2803 2413 2880 787 456
(119.84) (147.64) (35.12) (83.86) (309.37) (110.35) (95.0) (113.39) (30.99) (17.95)
(3) 7790 (3) 3150
(306.69) (124.02)
With arm: (1) 2100 mm (82.68 in)
(2) 2450 mm (96.46 in)
(3) 2950 mm (116.14 in)
M Track shoe width mm (in) 500 (19.68) 600 (23.62) 700 (27.56) 800 (31.50)
N Gauge mm (in) 2490 (98.03) 2590 (101.97) 2690 (105.91) 2790 (109.84)
(*) Working weight kg (lb) 13175 (29045) 13400 (29541) 13625 (30037) 13850 (30533)
Spec. ground pressure bar (psi) 0.42 (6.09) 0.36 (5.22) 0.31 (4.50) 0.28 (4.05)
(*) With arm 2450 mm (96.46 in) and bucket 0.61 m3 (0.80 yd3)
T1-1-14
(Triple Articulation Version)
G D
H
F
I C
L
M A
N B
NH0706
Unit: mm (in)
A B C D E F G H I L
(1) 7852 (1) 2579
(309.13) (101.54)
3044 3750 892 2130 (2) 7823 (2) 2710 2413 2880 787 456
(119.84) (147.64) (35.12) (83.86) (307.99) (106.69) (95.0) (113.39) (30.99) (17.95)
(3) 7733 (3) 3116
(304.45) (122.68)
With arm: (1) 2100 mm (82.68 in)
(2) 2450 mm (96.46 in)
(3) 2950 mm (116.14 in)
N Gauge mm (in) 2490 (98.03) 2590 (101.97) 2690 (105.91) 2790 (109.84)
T1-1-15
(Monoblock Version with undercarriage equipped with blade)
E
O
G D
H
F
I C
L
M A
N B
NH0707
Unit: mm (in)
A B C D E F G H I L O
(1) 7853 (1) 2693
(309.17) (106.02)
3044 3750 892 2130 (2) 7858 (2) 2803 2413 2880 787 456 2434
(119.84) (147.64) (35.12) (83.86) (309.37) (110.35) (95.0) (113.39) (30.99) (17.95) (95.83)
(3) 7790 (3) 3150
(306.69) (124.02)
With arm: (1) 2100 mm (82.68 in)
(2) 2450 mm (96.46 in)
(3) 2950 mm (116.14 in)
N Gauge mm (in) 2490 (98.03) 2590 (101.97) 2690 (105.91) 2790 (109.84)
(* ) With arm 2450 mm (96.46 in) and bucket 0.61 m3 (0.80 yd3)
T1-1-16
(Triple Articulation Version with undercarriage equipped with blade)
E
O
G D
H
F
I C
L
M A
N B
NH0708
Unit: mm (in)
A B C D E F G H I L O
(1) 7852 (1) 2579
(309.13) (101.54)
3044 3750 892 2130 (2) 7823 (2) 2710 2413 2880 787 456 2434
(119.84) (147.64) (35.12) (83.86) (307.99) (106.69) (95.0) (113.39) (30.99) (17.95) (95.83)
(3) 7733 (3) 3116
(304.45) (122.68)
With arm: (1) 2100 mm (82.68 in) and blade positioned toward the equipment
(2) 2450 mm (96.46 in)
(3) 2950 mm (116.14 in)
N Gauge mm (in) 2490 (98.03) 2590 (101.97) 2690 (105.91) 2790 (109.84)
T1-1-17
BUCKET APPLICATIONS AS A FUNCTION

OF THE ARMS
Monoblock
BUCKETS
Capacity Arm mm (in)

Widthmm dm3 (yd3) Masskg
(in) SAE J296 (lb) 2100 (82.68) 2450 (96.46) 2950 (116.14)
(ISO 7451)
500 (19.68) 280 (0.37) 315 (694.45)
750 (29.53) 424 (0.55) 350 (771.62)
850 (33.46) 498 (0.65) 370 (815.71)
900 (35.43) 536 (0.70) 380 (837.76)
1000 (39.37) 610 (0.80) 415 (914.92)
1100 (43.31) 684 (0.89) 440 (970.03)
1200 (47.24) 758 (0.99) 470 (1036.17)
Triple Articulation
BUCKETS
Capacity Arm mm (in)

Widthmm dm3 (yd3) Masskg
(in) SAE J296 (lb) 2100 (82.68) 2450 (96.46) 2950 (116.14)
(ISO 7451)
500 (19.68) 280 (0.37) 315 (694.45)
750 (29.53) 424 (0.55) 350 (771.62)
850 (33.46) 498 (0.65) 370 (815.71)
900 (35.43) 536 (0.70) 380 (837.76)
1000 (39.37) 610 (0.80) 415 (914.92)
1100 (43.31) 684 (0.89) 440 (970.03)
1200 (47.24) 758 (0.99) 470 (1036.17)
General digging work (specific weight of material < 1.8 t/m3)
Slightly heavy digging work (specific weight of material < 1.5 t/m3)
Loading work (specific weight of material < 1.2 t/m3)
Bucket not applicable
T1-1-18
SECTION 2 E135B
SYSTEM
CONTENTS
Group 1 - Mechatro Control System 6 Positioning circuit (triple articulation

version) .............................................. T2-2-10
1 Preface .............................................. T2-1-1
7 Color coding standard for hydraulic
2 Summary of Mechatro control system T2-1-2 circuits................................................ T2-2-12
2.1 Mechatro control system in 8 Neutral circuit .................................... T2-2-12
general ..................................... T2-1-2
9 Travel circuit ...................................... T2-2-14
2.2 Unload valve control ................. T2-1-4
10 Bucket circuit ..................................... T2-2-16
2.3 Positive control & P-Q control... T2-1-5
11 Boom circuit ...................................... T2-2-18
2.4 Boom up conflux control ........... T2-1-7
12 Swing circuit ...................................... T2-2-22
2.5 Arm in recirculation & conflux
13 Arm circuit ......................................... T2-2-24
control....................................... T2-1-8
14 Combined circuit ............................... T2-2-30
2.6 Arm-in anti-cavitation control .... T2-1-10
15 Pressure draining (releasing) circuit . T2-2-34
2.7 Arm-out conflux control............. T2-1-11
2.8 Bucket digging (dump) control.. T2-1-12 Group 3 - Electrical system
2.9 Swing priority control ................ T2-1-13
Electrical system main components........ T2-3-1
2.10 Travel straight control ............... T2-1-14
Electrical system (Overall system) ..... T2-3-1
2.11 Pressure release control
(include extra pressure release) T2-1-16 Electrical system diagram ...................... T2-3-14
2.12 N&B switch control (option) ...... T2-1-18 Electrical system diagram (No. 1) ...... T2-3-14
2.13 Option conflux control (option).. T2-1-19 Electrical system diagram (No. 2) ...... T2-3-16
Electrical system diagram (No. 3) ...... T2-3-18
2.14 N&B solenoid relief valve control . T2-1-20
Electrical system diagram (No. 4) ...... T2-3-20
3 Mechatro controller ............................ T2-1-21
Wiring harness ........................................ T2-3-22
3.1 Summary of multi display ......... T2-1-21
Cluster gauge wiring harness
3.2 Self diagnosis display ............... T2-1-27 assembly................................... T2-3-23
3.3 Service diagnosis display Platform wiring harness assembly .... T2-3-25
function ..................................... T2-1-33
Upper frame wiring harness assembly . T2-3-27
3.4 Trouble history diagnosis.......... T2-1-43
ECU wiring harness assembly ........... T2-3-29
3.5 Trouble diagnosis mode ........... T2-1-44
3.6 Set procedure of maintenance
schedule ................................... T2-1-45
3.7 Adjusting procedure of display . T2-1-46
3.8 Mechatro control equipment ..... T2-1-54
Group 2 - Hydraulic circuits

1 Summary ........................................... T2-2-1
2 Hydraulic circuits and components .... T2-2-2
3 N&B hydraulic circuit (option) ............ T2-2-4
4 Holding valve for boom & arm (option)T2-2-6
5 Dozer hydraulic circuit ....................... T2-2-8
MECHATRO CONTROL SYSTEM E135B
1. PREFACE
This chapter explains only those related to the electro hydraulic conversion as mechatro control. This chapter
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding
the conditions before and after each conversion, refer to the hydraulic system and the electric system.
T2-1-1
E135B MECHATRO CONTROL SYSTEM
2 SUMMARY OF MECHATRO CONTROL SYSTEM

2.1 MECHATRO CONTROL SYSTEM IN GENERAL
ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC‫ޓޓ‬
PILOT SECONDARY PRESSURE VOLTAGE OUTPUT L1
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT
L2
LH RH LH RH
OPTION PILOT VALVE
PILOT VALVE
PILOT VALVE FOR TRAVEL
FOR ATT
SE-9
SE-10
SE-11
MULTI CONTROL VALVE OR SENSOR BLOCK
LOW PRESSURE SENSOR

SE-4
(4)
L3
SE-3
(3) L4
GAUGE CLUSTER
SE-2 L5
(2)
LCD DISPLAY
FOR SELECTION SE-1
(1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
LOWER SW.
SCREEN CHANGE SE-7
(7)
BUZZER STOP L6
MODE (6)
WASHER
WIPER SE-5
(5)
OUTPUT VOLTAGE
TRAVEL
DECEL
SERIAL COMMUNICATION
SERIAL COMMUNICATION
ACCEL DIAL
SE-16
SE-23
PROPORTIONAL VOLTAGE
HIGH PRESSURE SENSOR
C-1 SE-22 L7
MECHATRO CONTROLLER A1 A2
ENGINE A3
INJECTOR SPEED SENSOR
SE-13
KPSS
RELEASE SWITCH PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
: INJECTOR P2 PUMP PROPORTIONAL VALVE
: E/G SPEED SENSOR CAN COMMUNICATION L8

C-3
: LOW PRESSURE SENSOR ENGINE CONTROLLER
(ATT : 7pcs, TRAVEL : 2pcs) ENGINE SPEED L9
COMMAND CURRENT
: ACCEL DIAL POTENTIOMETER VOLTAGE 24V
PROPORTIONAL COMMAND CURRENT
E-27
EMERGENCY MODE ACCEL DIAL
SM3167
T2-1-2
MAIN CONTROL VALVE

L1
SE-29
L2
ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) PSV-E SV-13
P1 UNLOAD
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
SOL
P1 P2
(1) (3) (5) (7) PSV-I
L3 DIGGING UP REVERSE REVERSE RIGHT ARM IN
L4 SOLENOID VALVE
L5
L6
SWING MOTOR PARKING RELEASE
TRAVEL MOTOR 1,2 SPEED SELECT
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
SAFETY LOCK LEVER

TRAVEL 1,2 SPEED
TRAVEL STRAIGHT
ARM IN 2 SPEED
L7
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV
-A -D -C -B -3 -1 -4
(7)
ARM IN
L8 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L9
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
SM3168
T2-1-3
2.2 UNLOAD VALVE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0118
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in
respective low pressure sensors.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3. Each unload pressure proportional valves output pilot secondary pressure according to the command
output by mechatro controller and switches each unload spools.
4. With this operation, the bleed opening according to lever manipulated movement is obtained, consequently
the pump pressure which is used to actuate each actuators are delivered and makes each actuator start
operating.
T2-1-4
2.3 POSITIVE CONTROL & P-Q CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0119
T2-1-5
1. Positive control
1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each
low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator,
and consequently the working speed according to the lever manipulated movement will be obtained.
2. P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller
and the mechatro controller processes pilot signal and operates the command according to the input
voltage (load pressure).
2) The lower value between command values calculated by positive control and operated value found by
P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve
as command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.
POSITIVE CONTROL P-Q CONTROL
PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
PILOT PRESSURE PUMP DELIVERY PRESSURE
SM0120
T2-1-6
2.4 BOOM UP CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE SM0121
1. On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valve.
4. With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and
also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are
switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during
boom up operation.
T2-1-7
2.5 ARM IN RECIRCULATION & CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE
SM0122
T2-1-8
1. Recirculation and conflux (Low loading)

1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2
spool and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional
valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure
sensor and the output voltage is input to mechatro controller. And the mechatro controller processes
pilot signal according to the combined operation and outputs command, which is different from the arm-
in independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse
proportional valve for arm-in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure
and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool
controls recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from
mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch
P1, P2 unload valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2
unload spools and arm 2 spool are switched according to the command output by mechatro controller,
and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps
delivery oil during arm operation.
2. Recirculation cut
The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load
is raised during arm operation the mechatro controller processes pilot signal processing according to the
pressure detected by high pressure sensor and outputs command to cut recirculation into reverse
proportional valve for arm-in 2 spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the
command output by mechatro controller and switches arm 2 spool to recirculation cut position, and
consequently recirculation passage is blocked.
T2-1-9
2.6 ARM-IN ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi PILOT SIGNAL
PROCESS REVERSE PROPORTIONAL
VALVE CONTROL PROCESS
FOR ARM 2 SPOOL PSV-Bpi

pi
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi
ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0123
1. On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input
to low pressure sensor.
2. The engine speed command output by accel potentiometer is input to mechatro controller.
3. Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes
pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve
and P2 unload proportional valve.
4. And also outputs command according to input pressure output by potentiometer to reverse proportional
valve for arm 2 spool.
5. Each proportional valve outputs pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if
pump delivery rate is low due to low engine speed.
T2-1-10
2.7 ARM-OUT CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
SECONDARY PRESSURE SM0124
1. On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and
is input to low pressure sensor.
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control
valves.
4. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out
operation.
T2-1-11
2.8 BUCKET DIGGING (DUMP) CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SM3169
SECONDARY PRESSURE
1. On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches
bucket spool and is input to low pressure sensor.
processes pilot signal and outputs command according to the input voltage to P1 pump proportional valve
and P1 unload proportional valve.
controller and changes P1 pump delivery rate and switches P1 unload valve.
T2-1-12
2.9 SWING PRIORITY CONTROL
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
SE-5 SE-7
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE SM0127
1. During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low
pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing
operation pilot secondary pressure switches swing spool and is input to low pressure sensor.
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve
for arm 2 spool.
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight
spool, arm 2 spool.
4. With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are
switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently
the return oil on arm cylinder rod side is recirculated into arm cylinder head side.
5. Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery
rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with
minimum speed drop possible.
T2-1-13
2.10 TRAVEL STRAIGHT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
OPTIONAL
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
LOW
SE-10 SE-9 SE-11 PRESSURE
SENSOR
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C
‫ޓޓ‬
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
PILOT‫ޓޓޓ‬
SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
PILOT ‫ޓ‬
SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
pi : PROPORTIONAL VALVE PILOT‫ޓޓޓ‬

SECONDARY PRESSURE
SECONDARY PRESSURE
SM3170
T2-1-14
1. Judgment travel straight

1) During travel operation (right and left), pilot pressure switches each travel spool and is input to low
pressure sensor on carrying out attachment system operation.
2) Mechatro controller decides as travel straight on receiving the input according to the combination
shown in the table from the low pressure sensor and turns travel straight signal on.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
2. Operation of each proportional valve
(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in
travel straight condition.)
1) Travel straight proportional valve outputs switching pressure according to the high priority select
pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during
operation.
2) P1 unload proportional valve outputs switching pressure according to the high priority select pressure
in the attachment system operating pilot pressure during operation.
3) P2 unload proportional valve outputs switching pressure according to the high priority select in the
travel operating pilot pressure during operation.
4) P1 pump proportional valve outputs switching pressure according to the high priority select pressure in
the attachment system operating pilot pressure during operation.
5) P2 pump proportional valve outputs switching pressure according to the high priority select in the travel
operating pilot pressure during operation.
ATT operation Boom Arm Bucket Swing Option

Travel operation (P1)
Travel operation (P2)
T2-1-15
2.11 PRESSURE RELEASE CONTROL (INCLUDE EXTRA PRESSURE RELEASE)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
EXTRA
P4
SE-28 UNLOAD VALVE

PRESSURE
RELEASE
CONTROL
pi
SOLENOID
pi
ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER SECONDARY PRESSURE
SM3171
T2-1-16
1. Change mechatro controller to “PRESSURE DRAING MODE” by operating switch on gauge cluster.
For detail of changing mode method, refer to “Pressure draining (releasing) circuit” on GROUP 2 -
HYDRAULIC CIRCUIT.
2. Once mechatro controller decides it as pressure release control, regardless of each input signal (operating
pilot, accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to
minimum tilt angle.
2) Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to
pressure release control speed.
3) Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary
pressure fixes P1 and P2 unload valves to the maximum opening.
3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure)
to be released by operating each control lever and switching spool with the unload valve opened.
5. In case of EXTRA pressure release specification, switch mechatro controller to pressure release control
mode in a similar way of above mentioned (1.). And in similar way of usual pressure release control, pump
delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be
released by operating each control lever and switching spool.
T2-1-17
2.12 N&B SWITCH CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH MECHATRO

CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID SM0131
1. Nibbler circuit
1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of
main control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error
display is output to gauge cluster.
2. Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error
display is output to gauge cluster.
T2-1-18
2.13 OPTION CONFLUX CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE SM0132
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
1. Select the Conflux with the aid of Conflux/Single switch.

2. On starting option operation, option operating pilot pressure switches option spool and is input to low
pressure sensor.
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve.
4. Each proportional valves output pilot proportional valve secondary pressure according to the command
output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload
valves and travel straight valve of the control valve.
5. The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and
P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
T2-1-19
2.14 N&B SOLENOID RELIEF VALVE CONTROL
SOLENOID RELIEF
PSV-E
BOOM UP CONFLUX
VALVE
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
SOLENOID RELIEF
PILOT P2 P1
VALVE
VALVE
PSV-I
RELIEF VALVE
SOLENOID
OUTPUT
LOW
PRESSURE
SENSOR
SE-11
OPTION PILOT
SECONDARY PRESSURE
SM3172
1. Solenoid relief valve

Using solenoid relief valve, relief pressure is able to set in advance.
1) Using gauge cluster, setting pressure of A and B mode is selectable individually.
2) When optional operation is done, command value according to setting pressure which is selected with
solenoid relief valve is output from mechatro controller.
3) Each proportional valve outputs pilot proportional secondary pressure according to command value
from mechatro controller, and the pressure switches relief pressure.
T2-1-20
3. MECHATRO CONTROLLER
3.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
1. Controls
GAUGE
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
STARTER SWITCH
KPSS WORK MODE
RELEASE SWITCH
ACCEL DIAL
FUSE &
RELAY BOX
MECHATRO
CONTROLLER
EMERGENCY
ACCEL DIAL
SWING PARKING ENGINE

BRAKE RELEASE ECU
SWITCH
A
DETAIL A
SM3173
2. Gauge cluster
11
No. Name
22:00 1 Engine coolant temperature gauge
2 Fuel level gauge
H 3 Screen change switch
4 Buzzer stop switch
1 5 Work mode select switch
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 Select switch
10
6 11 Multi display (LCD)
4 9 8 5 7
SM0134
T2-1-21
3. Screen selection by work mode select switch

After starting engine, "S" mode is usually set.
The work modes "S","H","B" and "A" are selected in order every time ( ) is pressed.
Select efficient work mode according to the working condition and the purpose from the following table.
The selected mode is displayed on the left lower corner on multi display.
• S mode: For standard digging work

• H mode: For heavy duty digging work
• B mode: For works with breaker
• A mode: For works with crusher (nibbler)
10:25
CAUTION
- The initial setting (default) of work mode had been H
set to “S” mode at factory.
As for the work mode after engine starts, the mode
that was used the last time engine was stopped is
automatically set.
Check that the selected mode conforms to the work
before starting work.
- Check that the attachment in use conforms to the
work mode before starting work. If not conformed,
select proper mode with the work mode select
switch.
- The operation under improper work mode may
cause damage to machine.
SM0135
Work mode Display Contents
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
㧿
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
㧴
B mode
10:25 For the work with breaker, select "B mode" without fail.
㧮
A mode
10:25 For the work with crusher (nibbler), select "A mode".
㧭
CAUTION
For the work with breaker, select “B mode” without fail.
The work with breaker in any mode other than “B mode” may cause damage to the hydraulic equipment and
breaker
T2-1-22
1) Pump flow rate adjustment (A mode /B mode) 1 2 3 4

No. Switches
1 Screen change switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6 SM0140
Depending upon the type of breaker or crusher mounted, it is possible to select one of the nine pre-set flow
rate/pressure settings. To select one of the nine settings, follow the procedure mentioned below.
Main screen In Nibbler mode (A mode)
10:25 Flow rate L/

150 min Flow rate L/
150 min
Pressure A 50 MPa Pressure B 50 MPa
H A A
(a)
SET 1 SET 2 SET 9
L/
Flow rate 200 min
Pressure A 50 MPa
A
In Breaker mode (B mode)
L/
Flow rate 150 min
Pressure B 50 MPa
B
SET 1 SET 2 SET 9
L/
Flow rate 200 min
Pressure B 50 MPa
B SM1432
1) Turn the starter key into position “ON”. The display shows the main screen (a).
2) The display on the left lower corner of screen is changed in order of "S"→"H"→"B"→"A" each time the work
mode button (3) is pressed under the condition where main screen (a) is displayed.
3) Press work mode button (3) and select mode “A” or mode “B”. The display shows the values of the flow rate
and pressure.
4) Press “Select” button (8) to enter the selection menu of the pre-set flow rate/pressure values.
5) Select the setting using windshield washer button (4) or wiper button (5).
6) Confirm the setting by pressing “Select” button (8).
7) By pressing "Screen Change" button you return to the main screen (a).
T2-1-23
4. MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the end of recommended replacement/change interval specified
for filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 5,000 Hr
This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.
1) Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change.
492Hr
ENGINE OIL
H
2) Remaining time display to the coming fuel filter replacement

This display shows the remaining time to the coming engine fuel filter
replacement.
492Hr
FUEL FILTER
H
3) Remaining time display to the coming hydraulic oil filter replacement

This display shows the remaining time to the coming hydraulic oil filter
replacement.
992Hr
HYD. FILTER
H
4) Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil
change.
4992Hr
HYD. OIL
H
NOTE:
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the paragraph 3.6 “SET PROCEDURE OF MAINTENANCE SCHEDULE”.
T2-1-24
5. Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen.
The display functions of multi display are explained below.
CLOCK DISPLAY
SELF DIAGNOSIS / WARNING
MACHINE CONDITION
H
MULTI DISPLAY INDICATIONS
SM0146
1) Display function for operator .........................Screen usually displayed during operation

1.1 Clock display function ............................Current time is displayed.
1.2 Self-diagnosis display ............................When abnormality is detected on mechatro system like
sensor, proportional valve, etc., this displays error code.
1.3 Warning display .....................................When machine was thrown into dangerous state, or was
failed, displays warning symbol. (For warning contents, see items shown on the next page.)
1.4 Machine condition display ......................Displays machine operating condition.
2) Display function for maintenance...................Displays remaining time up to replacement/change of
following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function.......................Stores abnormality occurred on mechatro system in the past
and displays in order of recent occurrence.
4) Mechatro adjustment display .........................Displays procedure for adjustment of mechatro system like
output adjustment and unload adjustment, etc.
5) Service diagnosis display...............................Displays information like pressure sensor sensed value,
proportional valve command, etc. output by mechatro controller
6) Failure diagnosis mode display function .......Specifies failed section automatically for failures which are not
detected by self diagnosis and displays the results.
T2-1-25
• Warning table
These descriptions indicate error codes stored as “trouble history code”
W009 W005 W011
CAUTION ATTACHMENT LOW ENG OIL PRESS. PREHEAT
W006
HEAVY LIFT ON HIGH ENG WATER TEMP. CHARGE ERROR
CPU W004
DATA COMMUNICATION LOW ENG WATER LEVEL LOW FUEL LEVEL

ERROR
W001 W010
SWING BRAKE DRAIN WATER AUTO WARMING UP

DISENGAGED SEPARATOR
W008
ENG LOW PRESSURE CLOGGED AIR FILTER CHANGE ENG OIL

(ENGINE STOP)
CPU
ATTACHMENT HYDRAULIC SYSTEM

OVER LOAD BACK UP MODE
NOTE: Error codes were stored as trouble history, and displayed on the monitor by the
trouble history display function.
T2-1-26
Warning Condition
Trouble
Level Buzzer sounds
Priority Screen Condition Only Engine History
(*) Type Auto Manual Code
Key ON Run
(**) Stop Stop
Data from Mechatro controller
1 DATA COMMUCATION ERROR O O 3 x O
is not received
The swing parking brake
1 SWING BRAKE DISENGAGED O O 2 O O W001
switch is turned ON
Engine is stopped after engine
1 ENGINE STOP O 1 O x
oil pressare low warning
A
HYDRAULIC SYSTEM BACK UP KPSS release switch is switched to
1 O O 2 O O
MODE “Release” side.
Impossible to drain hyd.
2 FAIL DRAIN HYD. PRESSURE O O 1 x O
Pressure
2 DRAINING HYD. PRESS. Possible to drain hyd. Pressure O 4 x O
The selector valve (OPT) is

1 CAUTION ATTACHMENT O 2 x O W009
malfunction
After finishing warming up
2 FINISH WARM-UP O 2 O x
control
Low engine oil pressure O 2 x O W005
3 LOW ENG OIL PRESS.
Disconnection O
The engine water is more than

3 HIGH ENG. WATER TEMP. O O 3 x O W006
105 °C
Water in water separator filter
3 DRAIN WATER SEPA O O 3 x O W010
is increased
3 CLOGGED AIR FLTR The air filter is clogged O O 3 x O W008
B
According to the self diagnosis
3 (SELF DIAGNOSIS SCREENS) O O 3 x O
control
The heater relay contact is
3 PREHEAT O O 3 O W011
faulty
4 CHARGE ERROR No signal from the alternator O -
4 LOW FUEL LEVEL The fuel level is less than 10 % O O -
The warter engine coolant

4 LOW ENG WATER LEVEL O - W004
reservoir is low
The auto warming up control is
5 AUTO WARMING UP O -
activated
The remaining time is reached
5 CHANGE ENG OIL O O -
zero Huors
(*) 1: these extremely influence safety and the machine (**) 1: Continuation
performance 2: Beep ON 0.2 sec. OFF 0.3 sec.
2: these warn the machine control mode is switched 3: Beep ON 0.5 sec. OFF 0.5 sec.
3: fatal failure 4: Beep ON 0.5 sec. OFF 1.0 sec.
4: normal priority warning
5: low priority message
3.2 SELF DIAGNOSIS DISPLAY

1. Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during
machine operation through self diagnosis. The failed items are displayed on multi display of gauge
cluster. For connector No. and pin No., refer to the section "Mechatro Control Equipment" explained later.
Electric circuit diagram or harness is available to identify wire No. and wire color.
2. I/O configuration
CONTROL
Pressure sensor, Engine controller SERIAL COMMUNICATION

INPUT Proportional valve, Battery relay
Gauge cluster
Selector valve (SOL) (Buzzer sound)
SM1433
T2-1-27
3. Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure
type with the aid of error code.
Alphabet: Decide system failure occurred.
10:25 B 01 3 Last 2nd and 3rd digits: Specifies failed section.
B013
Last 1 digit: Specifies failure type.
This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE SM0148
ALPHABET
A B C D E F G H I K R
Controller Low pressure High pressure Proportional Proportional Potentiometer
valve for valve for Solenoid valve Speed sensor Communication Battery relay Relay output
memory sensor sensor etc.
nd rd
2 AND 3 DIGIT
Wiper ark
01 Boom up P1 pump P1 unload P1 pump ATT boost Throttle Battery relay prevention
Torque adjust Swing parking Wiper ark

02 data
Boom down P2 pump P2 unload P2 pump
brake
Boom angle forward
Unload Travel 1,2 Wiper ark

03 adjust data
Arm out Boom head Travel straight Relief adjust 1
speed
Arm angle reverse
Option
04 Arm in Relief adjust 2
selector
Washer motor
Bucket
05 digging
Arm 2 spool for

06 Bucket dump
arm in
07 Swing
09 Travel right Fuel sensor
10 Travel left
Selector CAN
11 position communication
13
14
15
16 P1 side option AIS relay 2
Engine stop
17 P2 side option
relay
Safety lock
18 lever relay
Adjustment
21 data sector 1
Safety relay
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust
Cluster
31 communication
LAST DIGIT
Larger than Larger than
0 normal range normal range
Transistor
1 - OFF failure/ CAN error
Transistor ON Transistor ON
2 - Wrong output Wrong output
failure failure
Over run
Transistor ON
3 - Disconnection Disconnection Disconnection Disconnection failure / Disconnection Disconnection Time is over
Power source Power source Power source Contact point Power source
4 -
short circuit short circuit short circuit is melted and short circuit
adhered
5 Wrong value
T2-1-28
ECU failure code list
[Class]/Limitation of
Failure Malfunctioned
Content of Failure output when failure
Code component occurs
20081 ECU failure [1]
20082
ADC monitoring
20084 A/D converter is abnormal in ECU. Engine is shut down
20088
00291 Analog signal input is defective. [5]
Accelerator sensor 1
00292 Defective analog input signal from controller is detected. -
Accelerator signal mutual comparison is defective. [5]
Accelerator sensor mutual
03838 When there is deflection of 20% or more between CAN
diagnosis -
signal and analog signal, sensor detects it.
01081 Atmospheric pressure sensor fails [4]
Atmospheric pressure Defective operation of atmospheric pressure sensor in ECU
01082 sensor (Disconnection, short circuit and characteristic defect) is Engine power down
detected.
01021 Boost pressure sensor failure [4]
Boost pressure sensor Defective operation of boost pressure sensor attached to

01022 engine (Disconnection, short circuit and characteristic Engine power down
defect) is detected.
01101 Coolant temperature sensor failure [5]
Coolant temperature Defective operation of coolant temperature sensor attached
01102 sensor to engine (Disconnection, short circuit and characteristic Engine power down
defect) is detected.
05181 Q tune resistance failure [8]
Q tune resistance SRC
05182 Input failure of Q tune resistance is detected. -
Crank sensor failure [3]
Cam single operation
06351 It is detected that crank sensor fails and engine is operated
warning Engine power down
with the cam sensor.
06361 Cam sensor failure [5]
Cam sensor Failure of cam sensor (Disconnection, short circuit, and
06362 -
damaged tooth) is detected.
06371 Crank sensor failure [3]
Crank sensor Failure of crank sensor (Disconnection, short circuit, and
06372 Engine power down
damaged tooth) is detected.
Misalignment between Misalignment between cam and crank [3]
02281
cam and crank Misalignment between cam and crank is detected. Engine power down
CAN communication failure [7]
00914 CAN accelerator It is detected that accelerator opening (APPREQ) received
-
with CAN is defective.
APPREQ message time-
16744 Accelerator opening (APPREQ) signal is received by CAN.
out -
But it detects that the CAN cannot receive the signal.
20284 CAN transmission time-out
The transmission of CAN message is defective. -
06771 Glow relay failure [5]
06772
Glow relay power stage
06774 Failure of glow relay or wiring harness is detected. -
06778
ECU failure [1]
12311 SPI communication error SPI (Serial peripheral interface): Serial communication
Engine is shut down
malfunction between CPU and each internal IC occurs.
T2-1-29
12354 EEPROM
Defective reading and writing to EEPROM are detected. -
12358
ECU failure [5]
16688 Recovery occurrence Recovery (partial reset) occurred by ECU internal
-
malfunction.
ECU failure [5]
16698 Recovery generation Recovery (partial reset) occurred by ECU internal
-
malfunction.
ECU failure [5]
16708 Recovery generation Recovery (partial reset) occurred by ECU internal
-
malfunction.
ECU failure [1]
15421 CJ940 excessive voltage
The supply voltage is excessive for power stage control IC. Engine is shut down
ECU failure [1]
15432 CJ940 voltage is too low
The supply voltage is too low for power stage control IC. Engine is shut down
6511 Injector failure (ECU internal circuit) [1]
6512 Injector drive bank 1
The injector drive circuit detected short circuit. Engine is shut down
6518
Injector failure (ECU internal circuit) [1]
The injector drive circuit detected disconnection. Engine is shut down
6531 Injector failure (ECU internal circuit) [1]
6532 Injector drive bank 2 The injector drive circuit detected short circuit. Engine is shut down
6538
Injector failure (ECU internal circuit) [1]
The injector drive circuit detected disconnection. Engine is shut down
6552
Injector drive IC
6554 IC which controls injector is malfunctioned. Engine is shut down
6558
6562
Injector drive IC
6564 IC which controls injector is malfunctioned. Engine is shut down
6568
6571 Injector failure [1]
6574 Injector #1
Short circuit is detected in injector or harness. Engine is shut down
6578
Injector failure [5]
6584 Injector #1
Disconnection is detected in injector or harness. -
6594 Injector #2
6598
6604 Injector #2
6614 Injector #3
6618
6624 Injector #3
T2-1-30
6634 Injector #4
6638
6644 Injector #4
20004 MPROP power stage MPROP failure [2]
Disconnection and
20008 excessive load Disconnection or short circuit of MPROP or harness. Engine power down
MPROP power stage MPROP failure [2]

20011
VB short Battery short circuit of MPROP or harness Engine power down
MPROP power stage MPROP failure [2]
20022
GND short circuit GND short circuit of MPROP or harness Engine power down
ECU failure [1]
14848 Supervision
Malfunction judgment by self-diagnosis function in ECU. Engine is shut down
16711 CAN A Pass off
Disconnection and short circuit of CAN communication line -
16731 CAN C Pass off
Disconnection and short circuit of CAN communication line -
Oil pressure switch failure [8]
198 Oil pressure switch
Engine speed is high but sensor is OFF status. LOW IDLE
Oil pressure switch failure [1]
1008 Oil pressure switch
Engine speed is high but sensor is OFF status. Engine is shut down
ECU failure [5]
20051 Engine speed
Recognized engine speed is defective. -
DBV valve opening [2]
20411 DBV valve opening
It is recognized that DBV opened. Engine power down
DBV valve is opened forcibly. [2]
20422 DBV kick off Open valve forcible command is ordered for entering into
Engine power down
Limp-home mode.
DBV valve is seized in DBV valve is seized in closed position [1]
20434
closed position If you try to open valve forcibly, valve doesn't open. Engine is shut down
Holding pressure of DBV is abnormal. [1]
Holding pressure of DBV
20441 Holding pressure of DBV 2-step is higher than standard
2-step is too high Engine is shut down
level.
Holding pressure of DBV Holding pressure of DBV is abnormal. [1]
20452
2-step is too low Holding pressure of DBV 2-step is lower than standard level. Engine is shut down
281 PTO failure for backup [2]
PTO accelerator sensor Disconnection and short circuit of PTO or harness are
detected.
20111 Rail pressure sensor failure [2]
Rail pressure sensor SRC Disconnection and short circuit of rail pressure sensor or
harness are detected.
20121 Rail pressure sensor offset Rail pressure sensor failure [2]
20122 monitoring Zero-adjustment failure of rail pressure sensor. Engine power down
Rail pressure governor has Rail pressure control failure [4]
deviation
20131
(Nonattainment of target Rail pressure doesn't achieve target value. Engine power down
value)
T2-1-31
deviation
20141 (Nonattainment of target Despite fully pressurized feed of pump, rail pressure doesn't
value & Fully pressurized achieve target value. Engine is shut down
feed of pump)
deviation
20151 (Pressure exceeds target Despite fully closed pump, rail pressure is higher than target
value & Pump doesn't Engine power down
value.
inject)
Rail pressure governor Rail pressure control failure [1]
20161
(Real pressure is too low) Rail pressure is lower than standard value. Engine is shut down
Rail pressure governor Rail pressure control failure [2]
20171
(Real pressure is too high) Rail pressure is higher than standard value. Engine power down
11104 Shut-off pass test
Emergency injection stop circuit doesn't operate. -
11108
10791 Sensor supply voltage ECU failure [5]
10792 monitor 1 Failure of 5V power line which supplies power to sensor. -
ECU failure [1]
20098 TPU monitoring Failure of TPU in ECU Failure of Arithmetic circuit of
Engine is shut down
rotational pulse.
ECU failure [1]
20108 SPI Judgment of malfunction by self-diagnosis for ECU Error of
Engine is shut down
watch dog.
NOTE: for detail of engine error code refer to section “ENGINE”
T2-1-32
3.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro
controller. This section explains the operating procedure and examples of each screen. The values in display
changes according to the conditions like engine speed, attachment position, etc.
1. Service diagnosis display screen operating procedure
1) Turn starter switch ON keeping buzzer stop switch pressed.
2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
• Mode No.1: Screen No.1~No.30
• Mode No.2: Screen No.1, Screen No.31~No.40
• Mode No.3: Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)
Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns
to No.1. (No.1→No.2→No.3→No.1→...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then
returns to No.3. (No.3→No.2→No.1→No.3→...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
T2-1-33
2. Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis “Mode No.1”
No. Displays Contents No. Displays Contents

1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YY22E00131F1 P/No. indication K-1 AIS RELAY 2 ON Indicated value
PROGRAM VERSION K-2 SAFETY RLY --- Indicated value
1-VER 1.00 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 0.00 MERIT controller program version KEY SWITCH ON Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER ON Indicated value
SWITCH OFF Switch
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 1000 No load setting rpm B-1 BOOM RAISE
MEAS1 1000 Actual rpm 1 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS2 1000 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 0.4 V 0.0 M Sensor voltage / Pressure converted value
WATER TEMP 20°C --- Coolant temperaturre sensor B-3 ARM OUT
MODE H Work mode 0.4 V 0.0 M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 0.5V Potentiometer voltage B-4 ARM IN
POS. 0% Voltage % indication 0.4 V 0.0 M Sensor voltage / Pressure converted value
ECU OUTPUT 1.0V Accel output voltage to engine B-5 BUCKET DIG
controller 0.4 V 0.0 M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
0.4 V 0.0 M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. --- Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. --- Measured value B-9 TRAVEL (R)
SWITCH --- Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL (L)
COMP. ON Set value in computer 0.5 V 0.0 M Sensor voltage / Pressure converted value
MEAS. ON Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 0.0 V 0.0 M Sensor voltage / Pressure converted value
B-19 DOZER 2
0.0 V 0.0 M Sensor voltage / Pressure converted value
SM3174
T2-1-34

7 17
NO.7 P.SENSOR PROPO-V NO.17 PRESS.SENSOR
C-1 PUMP P1 C-5
0.4 V 0.3 M Sensor voltage / Pressure converted value 0.0 V 0.0 M Sensor voltage / Pressure converted value
C-2 PUMP P2 C-6
0.5 V 0.3 M Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
0.0 V 0.0 M
C-3 BOOM-HEAD
C-7
0.7 V 3.4 M
Sensor voltage / Pressure converted value 0.0 V 0.0 M Sensor voltage / Pressure converted value
C-4 BOOM-ROD
0.0 V 0.0 M C-8
E-3 OPT RELIEF 1 Sensor voltage / Pressure converted value 0.0 V 0.0 M Sensor voltage / Pressure converted value
COMP. 0 mA 20.0 M Set value in computer / Converted value from pressure
MEAS. 0 mA 20.0 M Measured value / Converted value from pressure
E-4 OPT RELIEF 2
COMP. 0 mA 20.0 M Set value in computer / Converted value from pressure
MEAS. 0 mA 20.0 M Measured value / Converted value from pressure
8 18
NO.8 PROPO-VALVE NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 --- ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI2 ON ON/OFF indication
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI3 --- ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 --- ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
COMP. 350 mA 0.6 M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 750 mA 0.0 M Set value in computer / Converted value from pressure DI11 --- ON/OFF indication
MEAS. 750 mA 0.0 M Measured value / Converted value from pressure DI12 OFF ON/OFF indication
DI13 --- ON/OFF indication
9 19
NO.9 PROPO-VALVE NO.19 DIGITAL INPUT
E-1 P1 PUMP DI15 --- ON/OFF indication
COMP. 430 mA 1.0 M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 425 mA 1.0 M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0 mA Power shift DI18 --- ON/OFF indication
FLOW RATE 30 L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 ON ON/OFF indication
COMP. 430 mA 1.0 M Set value in computer / Converted value from pressure DI21 --- ON/OFF indication
POWER SHIFT 0 mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 30 L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
2.1 V 38% Fuel level DI30 --- ON/OFF indication
H-10 HYD.OIL TEMP DI31 --- ON/OFF indication
0.0 V 0 ͠ Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW OFF Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 --- ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 --- ON/OFF indication
ENG OIL FILTER --- Engine oil filter clogging DI36 --- ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 --- ON/OFF indication
DOUBLE FLOW OFF Conflux/Single flow select switch DI38 --- ON/OFF indication
KPSS SW OFF KPSS switch DI39 --- ON/OFF indication
HEATER --- Command from grid heater DI40 --- ON/OFF indication
ENG OIL LEVEL --- Engine oil level DI41 --- ON/OFF indication
COOLANT LEVEL OK Coolant level DI42 --- ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH --- Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. --- Set value in computer MEAS. OFF Measured value
MEAS. --- Measured value DO5 COMP. --- Set value in computer
F-6 MEAS. --- Measured value
COMP. --- Set value in computer DO6 COMP. OFF Set value in computer
MEAS. --- Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
16 22
NO.16 PRESS.SENSOR NO.22 DIGITAL OUTPUT
B-11 DO8 COMP. ON Set value in computer
0.4 V 0.0 M Sensor voltage / Pressure converted value MEAS. ON Measured value
B-12 DO9 COMP. --- Set value in computer
0.0 V 0.0 M Sensor voltage / Pressure converted value MEAS. --- Measured value
B-13 DO10 COMP. --- Set value in computer
0.0 V 0.0 M Sensor voltage / Pressure converted value MEAS. --- Measured value
B-14 DO11 COMP. OFF Set value in computer
0.0 V 0.0 M Sensor voltage / Pressure converted value MEAS. OFF Measured value
MEAS. ON Measured value
SM3175
T2-1-35
No. Displays Contents

23
NO.23 DIGITAL OUTPUT
DO16 COMP. ON Set value in computer
DO18 COMP. ON Set value in computer
DO20 COMP. --- Set value in computer
MEAS. --- Measured value
24
NO.24 DIGITAL OUTPUT
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW ON Wiper rise-up switch
REVERSE SW ON Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention relay
CW MOTOR RLY OFF Wiper normal rotation relay
CCW MOTOR RLY OFF Wiper reverse rotation relay
WASHER SW OFF Washer switch
MOTOR RELAY OFF Washer motor relay
27
NO.27 MERIT SYSTEM
COMMUNICATION OFF Status of communication in MERIT controller

0
0000000000
28
NO.28 ENG CONT.
TRANS.COUNT. 0 Counted number of transmission error
RECEIVE COUNT. 0 Counted number of reception error
DIAG STATUS 0 Diagnosis status
NUMBER OF DIAG 0 Numbers of error
BOOST PRESS. 0 Boost pressure
BOOST TEMP. 0°C Boost temperature
BAROMETRIC P. 0 Atmospheric pressure
FUEL TEMP. 0°C Fuel temperature
FUEL CONS. 0 Fuel consumption
INTAKE TEMP. 0°C Intake air temperature
ENG PRESS. 0 Engine oil pressure
GLOW --- Glow output from ECU
ENG STOP --- Engine stop command from ECU
TORQUE 500 Calculated torque of ECU
SM3176
T2-1-36

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1 PUMP 0.2 M Pump pressure sensor
YY22E00131F1 P/No. indication C-2 P2 PUMP 0.3 M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 417 mA Command current
1-VER 1.00 Program version indication E-2 P2-PSV 417 mA Command current
2-VER 0.00 MERIT controller program version D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current
SERVICE DIAG 2 Service diagnosis mode 2 D-3 S-TRAVEL 350 mA Command current
B-5 BUCKET DIG 0.0 M Bucket digging pressure sensor
B-6 BUCKET DUMP 0.0 M Bucket dump pressure sensor
G-3 ENG SPEED 1000 Engine actual speed
POWER SHIFT 0 mA Power shift current
31 34
NO.31 BOOM NO.34 TRAVEL
C-1 P1 PUMP 0.2 M Pump pressure sensor C-1 P1 PUMP 0.2 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
B-1 BOOM RAISE 0.0 M Boom up pressure sensor D-3 S-TRAVEL 350 mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0 M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0 M Travel left pressure sensor
POWER SHIFT 0 mA Power shift current Pi-P1 0.0 M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0 M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
D-3 S-TRAVEL 350 mA Command current D-3 S-TRAVEL 350 mA Command current
D-6 ARM-IN-2 750 mA Command current E-3 OPT RELIEF 0 mA Command current
B-3 ARM OUT 0.0 M Arm out pressure sensor B-16 P1 OPT 0.0 M P1 side option pressure sensor
B-4 ARM IN 0.0 M Arm in pressure sensor B-17 P2 OPT 0.0 M P2 side option pressure sensor
B-1 BOOM RAISE 0.0 M Boom up pressure sensor F-4 OPT SELECT --- Optional selector SOL (Nibbler line)
B-7 SWING 0.0 M Swing pressure sensor DOUBLE FLOW SW OFF Conflux/ Single selector switch
G-3 ENG SPEED 1000 Engine actual speed G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current POWER SHIFT 0 mA Power shift current
SM3177

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YY22E00131F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 1.00 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 0.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode 3 CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2230 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515 mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
7 mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0 M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 930 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 565 mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 565 mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 0 0 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 0 0 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 0 0 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 0 0 Angle adjustment
SM3178
T2-1-37
3. Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these
data to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 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 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM

C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 450~550 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
T2-1-38
Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 549 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 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 1970~2030
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~16.5 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~16.5 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 550~700 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 550~750 mA
T2-1-39
Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~18.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~18.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 606~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 606~750 mA
* Measure the values after a lapse of 5 minutes or * Measure the values after a lapse of 5 minutes or
after release of low temperature mode after release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 8.0~13.0 M
E-2 P2-PSV 500~610 mA E-2 P2-PSV 642 mA
T2-1-40

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 750 mA
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

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 650 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
T2-1-41

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 480~590 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 480~590 mA E-2 P2-PSV 665~750 mA
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 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value * Conflux switch is OFF. Relief set pressure is value
of shipping. of shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVEL
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
B-9 TRAVEL (R) 2.0~2.5 M B-9 TRAVEL (R) 0.0 M
B-10 TRAVEL (L) 0.0 M B-10 TRAVEL (L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
T2-1-42
3.4 TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as
one of history. And the errors are able to be indicated on the multi display.
• A part of warning contents is stored (the stored items are listed in warning table).
• The error code for self diagnosis is stored.
1. How to display
1) Turn starter switch on.
2) Press buzzer stop switch continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR
Error detected in the past
SM0154
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
• Press washer switch ( ) A, and the item moves upward.
• Press wiper switch ( ), and the item moves downward.
5) Turn starter switch off, and the display is disappeared.
2. How to delete contents of trouble history

1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.
NOTE: all the stored items are erased. It is impossible to erase data partially.
T2-1-43
3.5 TROUBLE DIAGNOSIS MODE

The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code)
like disconnection and abnormal output. This is useful to save the time for troubleshooting.
1. Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller identifies
the normal condition or failed condition of the system.
For details of how to use, refer to Chapter: “TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
T2-1-44
3.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display which allows confirmation of remaining time to the coming
replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the
remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc.
and perform the initial setting by the following order.
Screen change Buzzer stop KPSS work mode
NOTE: interval of replacement of parts is mentioned switch switch select switch
below.
Washer
• Engine oil : 500 Hr switch
• Fuel filter : 500 Hr
• Hydraulic filter : 1,000 Hr
Select Wiper
• Hydraulic oil : 5,000 Hr switch switch
Auto accel Travel speed
switch select switch
SM0155
Procedure Operating Procedure Display on Multidisplay
After several seconds,

NEW HOLLAND display is changed to 10:25
1 Turn starter key switch on. KOBELCO clock autmatically.
H
Press " " switch press once display

change switch on the switch panel once. And 10:25 Press screen change 250 Hr
2 ENGINE OIL
the clock display changes to the display of switch once more.
remaining time for coming engine oil change. H H
Press " " switch press once select

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
H
When required to adjust the interval to the coming

Replacing interval is
4
change time by 10 hours, press " " switch 250 Hr changed with each 500 Hr
and the time to the coming engine oil change is ENGINE OIL ENGINE OIL
pressing of switch.
added. Press " " switch and the time to the
coming engine oil change is reduced.
When desired to return to the initial set time,

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL
time is stored. H
SM0156
NOTE:
1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does
not sound.
T2-1-45
3.7 ADJUSTING PROCEDURE OF DISPLAY

1. For operator
1) Clock Adjustment Switches 1 2 3 4

No. Switches
1 Screen Change Switch
2 Buzzer Stop Switch
3 Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch 5
7 Auto Accel Switch 8 7 6 SM0140
8 Select Switch
Main screen (a)

SWITCH STATUS
10:25 CLOCK/CONTRAST 13:15
H H
(a) (b)
(c) (d) (e)

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15
Select Year/Month/Day/Hour/Minute Increase/Decrese

SM0157
1) Turn starter key switch on and display main screen (a) for operator, and then press select switch (8)
and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4) Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in
operations of FEED (6) and FEED (7).
5) After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting
is completed, and then the screen returns to main screen (a).
T2-1-46
2) Contrast Adjustment Switches 1 2 3 4

No. Switches
1 Screen Change Switch
2 Buzzer Stop Switch
3 Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch 5
7 Auto Accel Switch 8 7 6 SM0140
8 Select Switch
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555) SM0158
1) Turn starter key switch on and display main screen (a), and press select switch (8) and display
"SWITCH STATUS CLOCK CONTRAST" select screen (b).
2) In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3) In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and
then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4) Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5) Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
6) Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
T2-1-47
2. Function for service

Following items are provided for adjustment of service function.
• LANGUAGE/LOGO
Function Explanation Note Range Default
All language data is stored in 15
LANGUAGE To change language ISO
one gauge cluster languages
LOGO To change Company Logo 5 Logos NHK
• ADJUSTING MODE 1
Function Explanation Note Range Default
To change wiper control, when special
RISE-UP WIPER CAB is installed on demolition OFF is for special CAB ON/OFF ON
machine
P1 OPT SENSOR To activate the self-diagnosis when P1 Switch to ON when 2PB is
ON/OFF OFF (*)
ACTIVE OPT pressure sensor is failed installed
P2 OPT SENSOR To activate the self-diagnosis when P2 Switch to ON when N&B
ON/OFF OFF (*)
ACTIVE OPT pressure sensor is failed option is installed
To use P1 option pedal for P4-rotation
LEFT PEDAL
circuit, releasing auto accel. And not ON/OFF OFF
ACTIVE
activating unload valve
1:No selector valve
SELECT OPT Switch to ON when N&B
2:Selector Valve + Mechanical relief 1 or 3 1 or 3 (*)
SYSTEM option is installed
3:Selector Valve + Electrical relief
ADJ OVERLOAD To change the pressure for overload
10 - 27 18
PRESS alarm in EU
ENG SPEED To activate the engine speed
ON/OFF OFF
DISPLAY information for customer
6, 8, 10, 12,
AUTO ACCEL To change auto accel control type 18
14, 16, 18
To change the starting MODE X: return to default MODE
START MODE S, H, B, A, X X
(S,H,B,A) when key sw is ON
To cancel the low temp. mode to
CANCEL LOW OFF = Low Temp. Mode
prevent hydraulic hunching at low ON/OFF OFF
TEMP MODE ACTIVE
temp.
DRAIN HYD. To activate the drain hydraulic When switch is ON, this
ON/OFF OFF
PRESS pressure function function starts.
20 - 35
20 Mpa (at
To adjust Pressure and Flow for Pressure
ADJ OPT HAMMER Follow setting procedure 130 L/min)
Hammer (9set) 30 - 130
130 L/min
Flow rate
20 - 35
20 Mpa (at
To adjust Pressure and Flow for Pressure
ADJ OPT NIBBLER Follow setting procedure 130 L/min)
Nibbler (9set) 30 - 130
130 L/min
Flow rate
(*) Autodetect
T2-1-48
2.1 Setting the language
To modify the language, proceed as follows:

1. Keep BUZZER CUT-OFF button (1) pressed
and, at the same time, move the STARTER
SWITCH onto “ON”; the screen shows display
(A). 10:25
2. Keep BUZZER CUT-OFF button (1) pressed,
then press SELECT button (2) three times; the S
screen shows display (B).
3. Press SELECT button (2); the screen shows
display (C) indicating the symbol of the language 1
previously set, for example: ENG (English).
4. Press WIPER button (3) or WINDSHIELD 4
WASHER button (4), once or more until the
symbol of the desired language is displayed, for 5
example FRA (French); the screen shows
2 3
display (D).
5. Press SELECT button (2) to memorize the
language selected, the screen shows display SM0069
(E). At this stage, the language is selected and

after about three seconds returns automatically
to display (B).
To exit the program, move the STARTER
SWITCH onto “OFF”. NO. 1
MAIN CONT. P/N
(A) YY22E00131F1
PROGRAM VERSION
1-VER 1.00
2-VER 0.00
SERVICE DIAG 1
List of the languages available:

1 2
EU (ISO icons only)
LANGUAGE/LOGO
ITA ADJUSTING MODE 1
USA (B) PRESET BY FACTORY
CHN
IDN
THA SELECT LANGUAGE
ESP ENG
FRA (C)
FEED
DEU
VNM
4
MYS
MMR 3
TAM SELECT LANGUAGE
POR FRA
(D)
ENG
FEED
JPN
SELECT LANGUAGE
FRA
(E)
FEED
SM3179
T2-1-49
2.2 Setting Adjusting Mode 1

NO. 1
To enter the displays Adjusting Mode 1 proceed as MAIN CONT. P/N
(A)
YY22E00131F1
follows:
PROGRAM VERSION
1-VER 1.00
2-VER 0.00
1. Keep BUZZER CUT-OFF button (1) pressed

SERVICE DIAG 1
and, at the same time, move the STARTER 1

x3
2
SWITCH onto “ON”; the screen shows display
LANGUAGE/LOGO
(A) ADJUSTING MODE 1
2. Keep BUZZER CUT-OFF button (1) pressed, (B) PRESET BY FACTORY
then press SELECT button (2) three times; the

screen shows display (B).
3. Press WINDSHIELD WASHER button (3) to get 3
ADJUSTING MODE 1, the screen shows display LANGUAGE/LOGO
(C). ADJUSTING MODE 1
4. By pressing SELECT button (2) you enter the (C) PRESET BY FACTORY
Adjusting Mode 1 functions; the first function is

shown on the screen, display (D).
To enter the other functions, actuate WIPER
button (3), to move forward or WINDSHIELD 11
WASHER button (4), to return back. RISE-UP WIPER
(D) ON
FEED
2.3Adj. Overload Press (tip-over momentum 4 3

device) SM3180
To modify the value of the pressure at which the

pressure sensor goes ON to operate the tip-over
LANGUAGE/LOGO
momentum device, proceed as follows: ADJUSTING MODE 1
1. In function Adjusting Mode 1, display (C), press (C) PRESET BY FACTORY
SELECT button (2) to enter the functions and

use WIPER button (3), to select function 63 -
ADJ OVERLOAD PRESS on display (E). 2
2. Press SELECT button (2) to choose the number 3
relative to the setting pressure, display (F).
18 = 180 bar 63
ADJ OVERLOAD PRESS
3. Press WINDSHIELD WASHER button (4), to (E) 18
increase the pressure, or WIPER button (3), to FEED
decrease it.
4. Set the desired pressure value (for example: 11),
display (G), press SELECT button (2) to 63
memorise it. ADJ OVERLOAD PRESS
By pressing SCREEN CHANGE button (5) you (F) 18
return to display (C). FEED
To exit the program, move the STARTER

SWITCH onto “OFF”.
4 3
63
ADJ OVERLOAD PRESS
(G) 11
FEED
63
ADJ OVERLOAD PRESS
11
FEED
5
SM0073
T2-1-50
2.4 Drain Hyd. Press
To drain the hydraulic pressure from the system,

LANGUAGE/LOGO
proceed as follows: ADJUSTING MODE 1
1. In function Adjusting Mode 1, display (C), press (C) PRESET BY FACTORY
SELECT button (2) to enter the functions and
using WIPER button (3), select on the display
function DRAIN HYD. PRESS, display (H). 2 3
2. Press SELECT button (2) to show the writing
OFF, display (I).
(H)
DRAIN HYD PRESS
3. Press WINDSHIELD WASHER button (4) to OFF
activate function ON, display (L). FEED
4. Press SELECT button (2) and start the engine.

The screen shows display (M). At this point, with
the engine in operation, actuate the pilot valves
performing all the movements so that the (I)
DRAIN HYD PRESS
pressure is drained from all the actuators. OFF

FEED
The function is automatically deactivated by
returning the STARTER SWITCH onto “OFF”.
4
NOTE: if the monitor displays “FAIL DRAIN HYD
PRES.” this means that the pressure draining DRAIN HYD PRESS
operation has not been performed correctly. In this (L) ON
case, repeat the operation. FEED
(M)
10:25
PR
S
SM0072
T2-1-51
2.5Adj. Opt. Hammer/Nibbler

To adjust pressure and flow rate for hammer or nibbler, follow the procedure mentioned below.
The initial flow rate and pressure for hammer or nibbler are set by Manufacturer at 130 L/min and 50 MPa. The
adjustment (increase or decrease) of flow rate is changeable by 10 L/min step, the adjustment (increase or
decrease) of pressure is changeable by 1 MPa.
Nibbler (Crusher)
LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY
(C)
69 ADJ OPT
(N)
FEED
SET 1 SET 2 SET 3 SET 9
L/ L/ L/ L/
Flow rate 130 min Flow rate 130 min Flow rate 130 min Flow rate 130 min
Pressure A 50 MPa Pressure A 50 MPa Pressure A 50 MPa Pressure A 50 MPa
L/ L/ L/ L/
Pressure A 50 MPa Pressure A 50 MPa Pressure A 50 MPa Pressure A 50 MPa
L/ L/ L/ L/
Pressure B 50 MPa Pressure B 50 MPa Pressure B 50 MPa Pressure B 50 MPa
SM3181
1. In function Adjusting Mode 1, display (C), press SELECT button to enter the functions and use WIPER
button to select function 69 – ADJ OPT, on display (N).
2. Press SELECT button to enter the selection menu of the set flow rate/pressure values for adjusting.
3. Press SELECT button to choose the number relative to the flow rate. Press WINDSHIELD WASHER button
to increase the flow rate, or WIPER button to decrease it.
4. Press SELECT button to choose the number relative to the pressure (A). To select the pressure, start the
engine and actuate the breaker/crusher pedal, keeping it pressed with the heel of the foot. Press
WINDSHIELD WASHER button to increase the pressure, or WIPER button to decrease it. When desired
pressure is indicated, press SELECT button to set. (When SELECT button is pressed, be careful that 0MPa
is usually displayed at time if you do not depress the heel side of breaker/crusher pedal down.)
5. Then pressure (B) is indicated, and adjust the pressure, keeping the breaker/crusher pedal pressed with
the toe of the foot. Press WINDSHIELD WASHER button to increase the pressure, or WIPER button to
decrease it. When desired pressure is indicated, press SELECT button to set.(When SELECT button is
pressed, be careful that 0MPa is usually displayed at time if you do not depress the toe side of breaker/
crusher pedal down.)
6. Set the desired flow rate and pressure values, press SELECT button to return to display (N).
By pressing SCREEN CHANGE button you return to display (C).
To exit the program, move the STARTER SWITCH onto “OFF”.
T2-1-52
Breaker
LANGUAGE/LOGO
ADJUSTING MODE 1
PRESET BY FACTORY
(C)
69 ADJ OPT
(N)
FEED
SET 1 SET 2 SET 3 SET 9
L/ L/ L/ L/
L/ L/ L/ L/
SM3182
1. In function Adjusting Mode 1, display (C), press SELECT button to enter the functions and use WIPER
button to select function 69 – ADJ OPT, on display (N).
2. Press SELECT button to enter the selection menu of the set flow rate/pressure values for adjusting.
3. Press SELECT button to choose the number relative to the flow rate. Press WINDSHIELD WASHER button
to increase the flow rate, or WIPER button to decrease it.
4. Press SELECT button to choose the number relative to the pressure (B). To select the pressure, start the
engine and actuate the breaker/crusher pedal, keeping it pressed with the toe of the foot. Press
WINDSHIELD WASHER button to increase the pressure, or WIPER button to decrease it. When desired
pressure is indicated, press SELECT button to set. (When SELECT button is pressed, be careful that 0MPa
is usually displayed at time if you do not depress the toe side of breaker/crusher pedal down.)
5. Set the desired flow rate and pressure values, press SELECT button to return to display (N).
By pressing SCREEN CHANGE button you return to display (C).
To exit the program, move the STARTER SWITCH onto “OFF”.
T2-1-53
3.8 MECHATRO CONTROL EQUIPMENT

1. C-1 Mechatro controller
1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
SM0159
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
25 DL EARTH / OPEN(5V）
26 GP 0V
27 CANH1 CAN communication
E/G ECU
28 CANL1 CAN communication
29 DO 20 Spare Output EARTH/OPEN
32 DO 23 Extra pressure release Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
SM1437
T2-1-54
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
17 A27 Separate option Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Dozer Input 0.5~4.5V
22 D1 37 Spare Input GND / OPEN
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
11 A15 Spare Input 0.5~4.5V
12 GA 0V
13 GA 0V
16 Reserved
SM3183
T2-1-55
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
5 A18 Spare Input 0.5㨪4.5V
6 GA 0V
7 GA 0V
12 GA 0V
13 A21 0V
Spare Input
14 GA 0,5~4,5V
15 A22 0V
Fuel level Input
16 GP 0,5~4,5V
17 A23 0V
Spare Input
18 GA 0,5~4,5V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
23 A25 Extra pressure source Input 0.5~4.5V
24 GA 0V
25 GA 0V
28 DI 1 Spare Input GND / OPEN
CN105 1 +24V 20~32V
Battery relay output side
2 +24V 20~32V
3 +24V Battery relay output side 20~32V

4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Spare Output 24V/OPEN
7 DO 11 Selector opt. Output 24V/OPEN
8 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Spare Output +0~800mA
26 D7- -0~800mA
28 D8- -0~800mA
29 D9+ Spare Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
SM3184
T2-1-56
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Spare Shield GND
3 F1+ Spare Output +24V 1.5A
4 F1- Output +24V 1.5A
5 F2+ Output +24V 1.5A
6 F2- Output +24V 1.5A
7 OIL Spare 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
12 D12- -0~800mA
14 D13- -0~800mA
16 D14- -0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Spare CAN communication
24 CANL2 CAN communication
CN107 1 DI 3 Spare Input +24V/OPEN
2 DI 8 Water separator Input EARTH / OPEN
3 DI 9 Spare Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
6 DI 12 KPSS release Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Extra pressure Input EARTH / OPEN
17 Reserved
SM3185
T2-1-57
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 Boom/Dozer Input GND / OPEN
6 DI 16 Wiper rise up㩩 Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation Input GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 Drain pressure Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
24 Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Spare 0~5V
28 H2- 0V
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Spare Output GND / OPEN
6 DO 6 Boom/Dozer select Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
15 Reserved
16 GP 0V
17 TXD2 Tranmission RS232C communication
Spare
19 RTS RS232C communication
20 CTS RS232C communication
21 SHG2 Shiled GND
22 DO 10 Spare SV 24V/OPEN
SM3186
T2-1-58
2. Gauge cluster (symbol C-2)

1) General view
4. BUZZER
1. MULTI
DISPLAY LCD
2. COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
5. SCREEN
CHANGE
SWITCH ETC.
6. BUZZER STOP SWITCH 7. WORK MODE SWIHCH
SM0165
2) Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
Gauge cluster → Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller → Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 — — 7 White
ON)
GND (RS232C
4 — — 8 Black
communication)
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller,
displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
4) Summary of display and drive item
No. Item Remarks

1 Monitor display LCD dot 120×168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
5 Screen change switch
7 Work mode select switch
T2-1-59
3. Relay & fuse box (symbol E-1)

1) General view
(Overhead view of box)

LABEL INSIDE
Note) These circles indicate the parts

which are used in standard specification
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
22 1 3 1 3
11
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME
SM3187
T2-1-60
2) Circuit diagram
SM0167
T2-1-61
SM3188
T2-1-62
SM0169
T2-1-63
4) High pressure sensor : YN52S00048P1
ECONOSEAL SERIES MARK(+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft) SM0170
5) Low pressure sensor : LC52S00019P1
Tightening torgue
Vout
29.434.3N.m (21.725.3lbf.ft)
PF1/4
Vcc GND
ELECTRIC CONNECTING DIAGRAM
(Ex. Construction of internal controller)
SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
SM0171
T2-1-64
HYDRAULIC SYSTEM E135B
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass
volume handling and low fuel consumption.
Performance Device Function Features Performance Device Function Features
• Travel straight • Travel straight at combined operation • Electric flow controlled variable displacement • Pump delivery rate control by a current
pump command to the solenoid proportional valve
Pump
of the variable displacement pump
Mass handling capability

• Travel 2-speed change & Auto 1st (low) • 1-2 travel speed change and low speed / high • Positive flow rate control • Flow control by positive pilot control pressure
speed return torque at heavy duty
Travel
• Auto parking brake • Automatic braking when parking • Boom up conflux circuit • Speed up of boom up operation
Attachment
• Motor overrun protection • Prevents overrunning of travel motor on the down • Arm conflux circuit • Speed up of arm operation
hill slope.
• Travel pilot operation • Prevents hunting by the built in travel • Optimum operation by work mode select • Efficient operation in all work modes
shockless mechanism (H,S,A,B)
• Reverse rotation protective function • Easy positioning to protect it from swinging • Auto accel • Reduce fuel consumption and noise by
consumption
computer
back when stops swinging. lowering engine speed when control lever is
Low fuel
Micro
in neutral position.
• Swing priority circuit • Easy operation of stable swing speed, arm
Swing
(simultaneous operation of arm in and swing slanted leveling, swing press digging
motions)
• Automatic swing parking brake • Swing parking brake when operating at on a
slope
• Hydraulic pilot control system • Light action with operating lever

Easy operability and safety
• Pilot safety lock system • Cut out of pilot circuit by safety lock lever.
• Lock valve (boom / arm) • Protect boom and arm from unexpected drop
Attachment
(Natural fall).
• Boom/Arm safety valve (Option) • Prevention of boom and arm falling when
boom head side and arm rod side pipings
• Emergency manual valve for lowering • For safety, this valve lowers risen attachment
attachment to the ground, if the machine stops with
engine trouble, and the pressure in the
cylinder of attachment can be released.
• 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
• Return circuit oil filter • To prevent hydraulic oil from contamination
Others
• 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.
• Main control valve with optional valve • Optional piping and additional work are easy
• Switching of return line for N&B machine in • Switching of return line for N&B machine is
the cab (Option) able to change with a switch in the cab
T2-2-1
E135B HYDRAULIC SYSTEM
2. HYDRAULIC CIRCUITS AND COMPONENTS
HYDRAULIC DIAGRAM READING KEY
Item Component name
1 Hyd. pump assy
2 Control valve (main)
3 Swing motor unit
4 Travel motor unit
5 Boom cylinder (RH & LH)
6 Arm cylider
7 Bucket cylinder
8 Swivel joint
9 Pilot valve (ATT)
10 Pilot valve (travel)
11 Inline filter
12 Suction strainer
13 Solenoid valve assy
14 Return filter
15 Air breather
16 Restrictor
17 Shuttle valve
18 Low pressure sensor block
T2-2-2
HYDRAULIC CIRCUIT (MONOBLOCK VERSION)
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3189
T2-2-3
3. N&B HYDRAULIC CIRCUIT (OPTION)

N&B HYDRAULIC CIRCUIT READING KEY
Item Component name
50 Selector valve
51 Stop valve
52 Pilot valve
53 Overload relief valve
The hydraulic circuit for N&B is used to add to

standard circuit
Selection condition and proportional valve

command when any of nibbler single & conflux flow
or breaker in service.
Command signal of solenoid proportional valve

SELECTION
(W:O, W/O: -)
Electromagnetic
Conflux/single flow command signal of P1 P2 Travel P1 P2
changeover switch selector valve (50) Pump Pump Straight Unload Unload
(W:O, W/O: -)
Conflux flow of
Conflux “ON” - O O O O O
nibbler
Single flow of
Conflux “OFF” - - O - - O
nibbler
Breaker Conflux “OFF” O - O - - O
When using nibbler, according to specification of

nibbler installed, choose confluence or single flow
by confluence flow changeover switch.
Adjust overload relief valve (53) of optional port to

customize specification ordinary set pressure.
T2-2-4
N&B HYDRAULIC CIRCUIT
51
52
53
50
SM3190
T2-2-5
4. HOLDING VALVE FOR BOOM & ARM

(OPTION)
HOLDING VALVE FOR BOOM
The holding valve for boom prevents the boom
falling in case of head side cylinder piping breaks.
HOLDING VALVE FOR ARM

The holding valve for arm prevents the arm falling in
case of rod side cylinder piping breaks.
HYDRAULIC CIRCUIT READING KEY

Item Component name
54 Holding valve for boom cylinders
55 Holding valve for arm cylinder
T2-2-6
HOLDING VALVE FOR BOOM & ARM HYDRAULIC CIRCUIT
55
54
54
SM3191
T2-2-7
5. DOZER HYDRAULIC CIRCUIT

READING KEY
Item Name of component
56 Hydraulic pump
57 Gear pump
58 Solenoid valve
59 Control valve
60 Right dozer cylinder
61 Left dozer cylinder
62 Boom/dozer pilot valve
The dozer hydraulic circuit is added to the standard

hydraulic circuit.
OPERATION
When the relevant button is pressed either on the
right pilot valve or the switch panel, solenoid valve
(58) is actuated thus the spool of solenoid valve (58)
is moved.
When the blade lifting operation is performed, the
piloting secondary proportional pressure exits port 4
of the right pilot valve (62), it is monitored by low
pressure sensor (SE-3) and is sent to port P1 of
solenoid valve (58). The piloting secondary
proportional pressure exits port B1 of solenoid valve
(58), enters port Pa1 of control valve (59) and
moves the spool of control valve (59). The oil
delivered by gear pump (57) enters port P and exists
port A1 of control valve (59) and flows to the blade
cylinder rod sides (60, 61). From the opposite side,
the oil returning from the blade cylinder head side
(60, 61) flows to port B1 of control valve (59) and
through the spools returns to the tank.
When the blade lowering operation is performed,
the piloting secondary proportional pressure exits
port 2 of the right pilot valve (62), it is monitored by
low pressure sensor (SE-4) and is sent to port P2 of
solenoid valve (58). The piloting secondary
proportional pressure exits port B2 of solenoid valve
(58), enters port Pb1 of control valve (59) and
moves the spool of control valve (59). The oil
delivered by gear pump (57) enters port P and exists
port B1 of control valve (59) and flows to the blade
cylinder head side (60, 61). From the opposite side,
the oil returning from the blade cylinder rod side (60,
61) flows to port A1 of control valve (59) and through
the spools returns to the tank.
T2-2-8
DOZER HYDRAULIC CIRCUIT
60
56
61
57
62
58
59
SM3192
T2-2-9
6. POSITIONING CIRCUIT
(TRIPLE ARTICULATION VERSION)
HYDRAULIC POSITIONING CIRCUIT READING

KEY
Item Component name
63 P1 OPT valve
64 Holding valve for positioner cylinder
65 Positioner cylinder
66 Positioning pilot valve
OPERATION
When the operation for positioning is performed, the

pilot proportional secondary pressure is delivered
through port A of the positioning pilot valve (66) and
flows to PAo1 port of the P1 OPT valve (63) then,
the spool of P1 OPT valve (63) is switched. The
pressure oil by P1 pump is supplied to (R) side of
positioner cylinder (65) through Ao1 port of P1 OPT
valve (63). On the other hand, the return oil from (H)
side of positioner cylinder (65) returns to the tank
circuit thorough Bo1 port of P1 OPT valve (63).
The holding valve (64) prevents the positioning
falling in case of rod side cylinder piping breaks.
T2-2-10
POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)
64
F
65
66
63
SM3193
T2-2-11
7. COLOR CODING STANDARD FOR 8. NEUTRAL CIRCUIT 8.3 PUMP POSITIVE FLOW CONTROL
HYDRAULIC CIRCUITS This section describes the following. (1) Type: The operation is maintained until the
Blue 8.1 Bypass cut valve and unload valve control Electric flow controlled variable displacement opening of spool sleeve is closed.
Feed, drain circuit pump.
8.2 Safety lock lever and pilot circuit
less than 0.44 MPa (64 psi) 8.3 Pump positive flow control (2) Principle:
Green The current command I to the pump’s solenoid 8.4 PUMP P-Q CURVE CONTROL OPERATION
8.4 Pump P-Q (Pressure-Quantity) curve
Return, make up circuit, proportional valve controls the delivery rate of (1) Type:
control
0.44~0.59 MPa (64~86 psi) the pump. Electrical flow control type variable pump
Purple (3) Operation: (2) Principle:
Secondary pilot pressure, 8.1 OPERATION OF BY-PASS CUT VALVE AND 1) Flow rate rise operation (Eg. P1 pump) Perform an operation of the value from pump
(including proportional vlave) UNLOADING VALVE HOUSED IN CONTROL By operating any of control levers, the high pressure sensor to P-Q curve control value,
0.59~5 MPa (86~725 psi) VALVE operating secondary pressure of pilot valve and send a command to the pump solenoid
Red (1) By-pass cut valve rises, and the rising pressure is transformed proportional valve.
Primary pilot pressure, On starting engine, P1 and P2 unloading to the rise of output voltage corresponding (3) Operation:
(including proportional vlave) proportional valves (PSV-D, PSV-B) output to the pressure input by the low pressure The pump high pressure sensor converts the
5 MPa (725 psi) secondary pressure according to the command sensor. Mechatro controller signal- pressure to the output voltage corresponding to
Orange output by mechatro controller, and this pressure processes this change of voltage, resulting the pump delivery pressure.
Main pump drive pressure, exerts on PBp1 and PBp2 ports, and in rise of command current value I to the The mechatro controller converts the voltage
5~34.3 MPa (725~4970 psi) consequently the by-pass cut spool is switched pump proportional solenoid valve and output by the high pressure sensor to the P-Q
to CLOSE side. consequently the pump flow rate rises. This curve control value. On the other hand, select
Blue tone
The by-pass cut spool is usually held on CLOSE is called "Positive Control System". the pump positive control command current
At valve operation
side after the engine started. And it is switched As the pump command current value rises, value from the low pressure sensor in lower
Red valve the secondary pressure of proportional
to OPEN side only when failure occurred on order, and the values are output to respective
When solenoid proportional valve (reducing) is solenoid valve also rises. On the regulator
pump proportional valve and mechatro pump proportional valve as a command current.
operating attached on the pump, the spool (652)
controller. With this operation, the pump power is
Red solenoid through piston (643) is pushed leftward, and controlled so as not to be exceed the engine
In active and exciting (2) Unloading valve stops at the position where being in
On starting engine, like by-pass cut valve, the power, therefore engine dose not stall.
proportion to the force of pilot spring (646).
Displaying the flow circuit and standby circuit when secondary pressures output by P1 and P2 The tank port connected to the large bore of
operating. unloading proportional valves (PSV-D, PSV-B) servo piston (532) opens, and the piston
Regarding the electrical symbols in this manual, exert on PCb and PCa ports, consequently the moves leftward by delivery pressure P1 of
refer to the electric circuit diagram. P1 and P2 unloading valves are switched to the small bore resulting in the increase of tilt
OPEN side. angle ( ).
The servo piston (532) and spool (652) are
8.2 SAFETY LOCK LEVER AND PILOT CIRCUIT connected to feedback lever (611).
(1) Purpose: Therefore when servo piston moves
To protect attachment from unexpected leftward, the spool (652) also moves
movement for safety. rightward by means of feedback lever. With
this movement, the opening of spool sleeve
(2) Principle:
closes gradually, and the servo piston stops
Cut pressure source of pilot valve for operation.
at the position the opening closed
(3) Operation: completely.
If the safety lock lever (red) is pushed forward 2) Flow rate reduction operation
after the engine starts, the limit switch (SW-11) As the current value I of mechtro controller
is turned on. The timer relay is actuated one reduces, the secondary pressure of
second later which causes the solenoid (SV-4) solenoid proportional valve reduces, and
of the solenoid valve block (13) to be energized spool (652) is moved rightward by the force
and makes the pilot operating circuit to stand by. of pilot spring (646). With the movement of
spool, the delivery pressure P1 usually flows
into the large bore of piston through the
spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of
area, resulting in the reduction of tilt angle.
Similarly, when the servo piston moves
rightward, the spool (652) is moved leftward
by the feedback lever.
T2-2-12
NEUTRAL CIRCUIT: Positive control function at safety lock lever down (unloked position)
562
4 3
646
1 8
532
643
611
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3207
T2-2-13
9. TRAVEL CIRCUIT 9.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
9.1 Travel forward pilot simultaneous operation
1) Purpose:
circuit
Change travel motor speed with switch.
9.2 2 speed travel solenoid command circuit
and auto 1-speed return function (2) Principle:
If the switch is turned, an electric signal is
9.3 Travel main circuit
issued. It excites the 2-speed travel solenoid
9.4 Travel motor function which in turn converts the primary pilot pressure
and the self pressure to a tilting angle of the
9.1 TRAVEL FORWARD PILOT variable displacement motor.
SIMULTANEOUS OPERATION CIRCUIT (3) Operation:
(1) Purpose: If the rabbit marked switch on the gauge cluster
Light operating force and shockless operation is pressed, the solenoid (SV-3) of the
(2) Mechatronics : proportional valve block (13) is excited and
changes the proportional valve. Then the
1) If the travel lever with damping mechanism
solenoid command pressure is issued from port
is operated for travel right, left and forward
A3, enters the P port of the travel motor (4),
motions, the secondary pilot proportional
opens the oil passage to the 2nd speed select
pressure comes out of the 3, 1 ports of P/V
piston, and causes the motor to run in the 2nd
(10). The higher of the pressures is
speed tilting mode by its self pressure.
selected, comes out of the 6, 5 ports and
However, when the main circuit pressure rises
acts upon the low pressure sensors (SE-9)
above 27.3 MPa (3960 psi), the motor’s self
(SE-10).
pressure pushes the 2nd speed select piston
2) The pilot secondary pressure flows to PBr back to the 1st speed.
and PBL ports of the control valve (2),
moves the travel spool, and switches the
main circuit. 9.3 TRAVEL MAIN CIRCUIT
3) The low pressure sensor output voltage is (1) Operation:
input into mechatro controller. The mechatro The delivery oil from Pump A1 and A2 ports by
controller performs signal processing and changing the travel spool with the operation of
outputs current corresponding to the travel pilot flows into A port on the left side motor
increase of flow rate to P1 pump (4) and B port on the right side motor (4)
proportional valve (PSV-P1) and P2 pump through C,D ports of swivel joint (8) from Br, BL
proportional valve (PSV-P2), and at the ports of C/V, and rotates the travel motor.
same time the command current is output to
P1 unloading valve (PSV-D) and P2
unloading valve (PSV-B). 9.4 TRAVEL MOTOR FUNCTION
4) The secondary pressures output by P1 (1) Function:
pump proportional valve (PSV-P1) and P2 1) Prevents the motor from over running on a
pump proportional valve (PSV-P2) exert on slope.
pump regulator, actuating the pump on the 2) Check valve that prevents cavitation of the
delivery flow rate increase side. hydraulic motor.
5) The secondary pressure delivered in P1 3) Shockless relief valve and anti cavitation
unloading valve (PSV-D) and P2 unloading valve when inertia force stops.
valve (PSV-B) is fed to PBp1, PCb, PBp2
4) High/Low 2 step speed change mechanism
and PCa ports provided in control valve (2).
and auto 1st speed return at high load.
The secondary pressure from proportional
valve which has exerted on PBp1 and PBp2 5) Travel parking brake.
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral
position.
valve which has exerted on PCb and PCa
ports switches the unloading spool in
CLOSE side.
T2-2-14
TRAVEL CIRCUIT: Travel 2nd speed, RH & LH simultaneous operation.
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3208
T2-2-15
10. BUCKET CIRCUIT <When lever is operated>

When the pressure 0.6MPa (87psi) is input to
This section describes the following.
low pressure sensor in STD specification (travel,
10.1 Bucket digging pilot circuit bucket, swing, arm), proportional voltage from
10.2 Auto accel operation low pressure sensor inputs in mechatro
10.3 Flow control in the work mode controller, and then the engine speed returns to
the dial set position corresponding to the lever
operation.
10.1 PILOT CIRCUIT FOR BUCKET DIGGING

(1) Mechatronics :
10.3 FLOW CONTROL IN THE WORK MODE
1) When the operation for bucket digging is
performed, the pilot proportional secondary (1) Principle:
pressure is delivered through port 1 of the When the engine speed is intermediate speed
right pilot V (9), flows to PAc port, and acts or lower, command current value to have the
on the low pressure sensor (SE-1), and at pump delivery rate constant is output.
the same time the bucket spool is switched. (2) Operation:
2) The voltage output by low pressure sensor Even if the engine speed specified by
(SE-1) inputs in mechatro controller. The acceleration potentiometer is low speed, as the
Mechatro controller performs signal delivery rate corresponds to the intermediate
processing and outputs current speed, the actuator moves earlier than the
corresponding to the increase of pump flow movement equivalent to the control lever angle
rate to pump proportional valve (PSV-P1) on rate in light load operation.
the P1 pump side, and at the same time the
command current is output to P1 unloading
valve (PSV-D).
In the following pages, the relation of
operation of low pressure sensor to both the
increase of pump flow rate and unloading
proportional valve is the same. Therefore
the explanation is omitted.
3) The secondary pressure output by P1 pump
proportional valve (PSV-P1) exerts on pump
regulator, actuating the pump onto the
delivery flow increase side.
4) The secondary pressure delivered in P1
unloading valve (PSV-D) is led to PBp1 and
PCb ports provided in control valve (2).
valve which has exerted on PBp1 port holds
the by-pass cut spool on CLOSE side, like
the operation in the lever neutral position.
valve which has exerted on PCb port
switches the unloading spool in CLOSE
side.
10.2 AUTO ACCELERATION OPERATION

(1) Principle:
Auto acceleration actuates according to signals
from low pressure sensor.
(2) Operation:
<When lever is set to neutral position>
In the event where the sensor does not receive
signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the
engine speed should be raised to 1000 rpm.
T2-2-16
BUCKET CIRCUIT: Bucket digging, Auto-accelation and Standby flow rate constant control
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3209
T2-2-17
11. BOOM CIRCUIT

This section describes the boom raise conflux
operation.
11.1 Boom up pilot circuit
11.2 Boom up 2 pumps conflux main circuit in
C/V
11.1 BOOM RAISE PILOT CIRCUIT

(1) Operation:
1) If boom up operation is performed, the
secondary pilot proportional pressure from
the right pilot valve (9) gets out of port 4 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.
11.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) 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
LCb through parallel circuit and flows into
boom spool.
2) Then the oil passes through boom spool,
opens lock valve of boom lock valve CRb,
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 CCb 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.
T2-2-18
BOOM CIRCUIT : Boom up operation, Confluence function.
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3194
T2-2-19
This section describes boom lower operation. 11.5 CONSTANT RECIRCULATION FUNCTION
11.3 Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
11.4 Prevention of natural fall by lock valve and (1) Purpose:
actuation at lowering Prevention of cavitation during boom lowering
11.5 Constant recirculation function of boom motion.
down main circuit (2) Principle:
The oil returning from the boom cylinder head
(H) is recirculated to the rod (R).
11.3 BOOM DOWN PILOT CIRCUIT
(1) Operation: (3) Operation:
When the oil is supplied to the boom cylinder rod
1) If the boom down operation is performed, (R) side during boom down operation, the boom
the secondary pilot proportional pressure moves faster than it should do in some cases by
comes out of port 2 of the right pilot valve (9) the self weight of the attachment.
and acts upon the low pressure sensor (SE- On that occasion, the circuit pressure on the rod
4). (R) side is on the negative side.
At the same time, the pressure acts upon The oil supplied to the boom cylinder rod (R)
the PBb port of C/V (2). flows into the A1 port of the P1 pump and the P1
2) The voltage output of the low pressure port of C/V. The oil then passes through the
sensor (SE-4) enters the mechatro boom spool and goes out of the Bb port.
controller and processed in it. On that occasion, the oil returning from the head
3) Then, the proportionl secondary pressure (H) goes through the recirculation path in the
fed into C/V (2) PBb port and branches off in boom spool, pushes the check valve in the spool
two lines and switches boom spool and open, is recirculated to the Bb port and is
releases boom lock valve. supplied to the rod (R). When the (R) pressure
is larger than the head (H) pressure, the check
valve in spool closes.
11.4 PREVENTION OF NATURAL FALL BY LOCK
Thereupon, the recirculation is stopped.
VALVE AND ACTUATION AT LOWERING
(1) Purpose:
Prevention of natural fall when the lever is
neutral
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) 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 CRb 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 CRb 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.
T2-2-20
BOOM CIRCUIT: Boom down operation & Prevention of natural boom falling.
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3195
T2-2-21
12. SWING CIRCUIT as the swing spool is shifted, the oil pushes the
load check valve LCs open through the parallel
This section describes the following operations.
circuit, enters the B port of the swing motor via
12.1 Swing left pilot circuit the As port of C/V (2), and rotates the swing
12.2 Swing auto parking brake motor counterclockwise.
12.3 Swing main circuit
12.4 Swing motor circuit
12.4 SWING MOTOR CIRCUIT
(1) Anti cavitation circuit at swing deceleration
12.1 PILOT CIRCUIT FOR LEFT SWING
(2) Shockless relief valve that prevents the swing
(1) Operation: motor from being reversed.
1) When the left swing operation is performed,
the pilot proportional secondary pressure is
delivered through port (1) of left pilot V (9),
and the secondary pressure acts on PAs
port of C/V (2), and simultaneously flows out
from Pss port of C/V and acts on low
pressure sensor (SE-5).
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 PAs
port of C/V (2) switches the swing spool.
12.2 SWING AUTO PARKING BRAKE

(1) Purpose:
Swing lock in neutral position and parking
(2) Principle:
Release mechanical brake only when required
to operate swing and arm in.
(3) 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-5, 7).
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing
low pressure sensors (SE-5) is reduced to
zero.
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.
12.3 SWING MAIN CIRCUIT

(1) Operation:
The oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and is
branched off into the bypass line and the parallel
circuit. However, since the bypass line is closed
T2-2-22
SWING CIRCUIT: Swing operation (LH)
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3196
T2-2-23
13. ARM CIRCUIT flowed into arm cylinder head (H) side
through Aa port of C/V (2).
3) The return oil from arm cylinder (R) side
13.1 Arm in, light-load operating pilot circuit
flows in Ba port of C/V (2) and passes
13.2 Arm in, light-load variable normal through the Ba port because the arm lock
recirculation main circuit / internal conflux valve CRa is open, and is flowed into arm 2
main circuit spool through arm 1 spool.
4) Because arm 2 spool is switched to normal
13.1 ARM IN, LIGHT-LOAD OPERATING PILOT recirculation position, causing restriction of
CIRCUIT passage to tank, the return oil from arm
(1) Purpose: cylinder (R) side flows into arm cylinder (H)
Speed-up and Anticavitation when the arm is at side.
light loaded. • Because, at light load, the pressure in
cylinder rod (R) side is higher than that in
(2) Principle:
the head (H) side, it opens the check valve
The oil returning from the arm cylinder rod (R) is
housed-in arm 2 spool and is recirculated
recirculated variably to the head (H) at arm 2
in the head (H) side, resulting in the speed
spool in C/V.
up of arm-in operation at light load.
(3) Operation: 5) Cavitations prevention control in arm-in
1) When the arm in operation is performed, the operation.
secondary pilot proportional pressure gets Command current is output to arm 2
out of port 4 of the left pilot valve (9) and acts solenoid proportional valve by signal
upon the low pressure sensor (SE-7). processing of E/G speed and arm-in pilot
At the same time, the pressure is branched pressure, accordingly the arm 2 spool is
off in two flows, acts upon the PAa1 port and switched to neutral (cavitations prevention)
the PLc2 port, changes over the arm spool position, resulting in cavitations prevention.
and the arm lock valve CRa releases.
2) The output voltage by the low pressure Position of arm 2 spool
sensor is input into mechatro controller, and
is pilot signal-processed, and is output to Neutral position
P1, P2 pump proportional valve (PSV-P1), (Anticavitation position)
Normal recirculation position
(PSV-P2) and arm 2 inverse proportional
valve (PSV-A). Recirculation
3) The secondary pressure from pilot
proportional valve, which is reduced by arm
2 inverse proportional valve (PSV-A) From arm out
switches arm 2 spool. P/V
From arm 2 inverse
proportional valve SM3197
13.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL
RECIRCULATION, INTERNAL CONFLUX Reference:
MAIN CIRCUIT In light-load arm-in operation (normal
(1) Operation: recirculation, conflux), when the attachment
1) The P2 pump delivery oil flows in travel left to which the circuit in P1 pump side is
section through P2 port of C/V (2) and is applied is operated, the meter-in path of arm
branched off in by-pass circuit and parallel 2 spool is closed, resulting in single flow
circuit, but because arm 1 spool is switched, operation.
the delivery oil which goes through parallel
circuit opens load check valve LCa and is Spool position at arm in,
light load and combined operation
flowed into arm 1 spool. (This position is not shown in hydraulic diagram)
2) On the other hand, P1 pump delivery oil Meter-in passage (Close)
flows in P1 port of C/V (2), and the flows in Neutral position
travel straight section and travel right
tandem path. Then because arm 2 spool
was switched, the delivery oil opens load
check valve LCAT2, goes through arm 2 Arm 2 spool
Normal recirculation position
spool, and confluences with P2 pump SM3198
delivery oil in the valve section, and then is
T2-2-24
ARM CIRCUIT: Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3199
T2-2-25
This section describes the following operations. 4) The return oil returns directly into tank circuit
13.3 Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
13.4 Arm in, heavy load operating sequence
confluxed main circuit Position of arm 2 spool
Recirculation cut position Neutral position

13.3 ARM IN, HEAVY LOAD OPERATING PILOT
CIRCUIT
From arm out
(1) Operation:
P/V
1) 1)In arm-in operation, when the heavy From arm 2 inverse
loading is applied to arm and the P2 pump proportional valve
SM3200
pressure increases to the set pressure, the
voltage output by P2 pump pressure sensor
(SE-23) is converted to signal (signal
processing) by mechatro controller,
consequently the current of arm 2 solenoid
proportional valve is controlled according to
the load pressure and the arm variable
recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light
load operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
13.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose:
Speed up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) 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 circuit and parallel
circuit. Consequently the arm spool is
switched and pushes and opens load check
valve LCa through parallel circuit, and flows
in the arm spool.
2) On the other hand, P1 pump delivery oil
flows in P1 port of C/V (2), and flow in travel
right tandem passage through travel straight
section. Then because arm 2 spool was
switched, the delivery oil opens load check
valve LCAT2, and confluences with P2
pump delivery 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.
T2-2-26
ARM CIRCUIT: Arm in (Heavy load) operation, Arm confluence & recirculation cut function
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3211
T2-2-27
This section describes the following operations. 13.7 NATURAL FALL PROTECTION WITH ARM
13.5 Arm out pilot circuit LOCK VALVE
13.6 Arm out 2 pumps conflux main circuit (1) Purpose:
13.7 Natural fall protection with arm lock valve To prevent the arm from falling naturally by the
weight of the arm and bucket.
(2) Principle:
13.5 ARM OUT PILOT CIRCUIT
Complete seat of the return circuit against the
(1) Operation: arm spool of the arm cylinder (R) side circuit.
1) When the arm out operation is performed, (3) Operation:
the secondary pilot proportional pressure
gets out of port 2 of the left pilot valve (9), 1) When the secondary pressure for arm
and acts upon the low pressure sensor (SE- operation disappears and the arm cylinder
8). At the same time, the oil is branched off stops, the pressure on the rod (R) side
in two flows and act upon the PBa1 and passes through the selector of the lock valve
PBa2 ports of C/V (2). from the Ba port of C/V, acts the back
pressure on the lock valve CRa and seats
2) The operating proportional secondary
the lock valve.
pressure flowed in PBa1 port of C/V (2)
switches the arm 1 spool. 2) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall
3) Then, the operating secondary pressure
of the arm due to oil leaks through the arm
flowed in PBa2 port of C/V (2) switches the
spool is prevented.
arm 2 spool valve.
13.6 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
(3) 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.
T2-2-28
ARM CIRCUIT: Arm out operation, Confluence function
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3212
T2-2-29
14. COMBINED CIRCUIT 4) However, a portion of the flow is led to the

travel straight spool notch restriction. The
This section describes only the difference in
speed of attachments like, boom, travel,
combined operation.
etc. is adjusted by the circuit of restriction.
14.1 Boom up / travel, pilot circuit
14.2 Boom up / travel, main circit
14.1 BOOM UP / TRAVEL, PILOT CIRCUIT

(1) Operation:
<different point of pilot circuit from independent
operation>
1) The mechatro controller outputs command
current to travel straight solenoid valve
(PSV-C) after signal processing, and the
solenoid proportional valve outputs
secondary pressure and acts on PTb port of
C/V (2).
2) Then the pressure of PTb port switches the
travel straight valve one step.
14.2 BOOM UP / TRAVEL, MAIN CIRCUIT

(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:
1) P1 pump delivery oil flows through P1 port of
C/ V(2) and branches off in P1 parallel circuit
and travel straight spool.
P2 pump delivery oil flows through P2 port of
C/ V(2) and branches off in P2 tandem
circuit and travel straight spool.
2) The delivery oil flowed into P1 parallel circuit
of P1 pump opens check valve CT1 and
LCb 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 CT2
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 independent operation, P1 pump
delivery oil exerts on swing and attachment
operations.)
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 independent operation, P2 pump
delivery oil exerts on travel operations.)
T2-2-30
COMBINED CIRCUIT: Boom up & Travel forward 1st speed operation, Travel straight function.
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3210
T2-2-31
In this section, the independent operation is omitted Position of arm 2 spool

and describes difference in combined operation.
14.3 Swing / Arm in light load, pilot circuit Position of forced recirculation
14.4 Swing / Arm in, swing priority main circuit Meter-in passage (Close)
Neutral position
14.3 SWING / ARM IN LIGHT LOAD, PILOT From arm 2 From

inverse arm out
CIRCUIT proportional valve P/V
(1) Operation:
Normal recirculation position Arm 2 spool
1) On operating swing (left) and arm in motions
simultaneously, mechatro controller outputs SM3214
command current to travel straight solenoid

proportional valve (PSV-C) and arm 2
solenoid inverse proportional valve (PSV-A)
according to signal processing, and this
proportional valve outputs secondary
pressure, which acts on PTb port and PAa2
port of C/V(2).
2) PTb port pressure switches the travel
straight spool, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
14.4 SWING / ARM IN, SWING PRIORITY MAIN

CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
(3) Operation:
1) The swing main circuit operates with P2
pump flow. But on P2 pump circuit side, the
flow goes to the swing circuit and arm circuit
simultaneously because the swing circuit
and arm circuit are parallel. Then since the
return oil from arm cylinder rod (R) side is
restricted in the arm 2 spool because the
arm 2 spool is switched to forced
recirculation position, the pressure of return
oil is raised, causing the rise of circuit
pressure on the arm cylinder head (H) side.
2) At the same time meter-in of arm 2 spool
closes and 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".
T2-2-32
COMBINED CIRCUIT: Swing / Arm in operation, swing priority function
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3215
T2-2-33
15. PRESSURE DRAINING (RELEASING) 15.2 PRESSURE RELEASING MAIN CIRCUIT

CIRCUIT (1) Operation:
15.1 Pressure releasing pilot circuit CAUTION:
15.2 Pressure releasing main circuit before to perform the hydraulic pressure releasing,
make sure to place bucket on the ground.
15.1 PRESSURE RELEASING PILOT CIRCUIT
When the operating lever is shifted to neutral
(1) Purpose:
during engine running, "DRAINING HYD.
To release the pressure in main circuit for piping
PRESS." is displayed on the gauge cluster
repair works.
while the mode switch is changed to pressure
(2) Principle: relieving mode.
After the mode is switched to "Pressure Relief In this time the intermittent buzzer sounds
Mode" with switch on gauge cluster, mechatro continuously. When right and left operating
controller outputs the following commands. levers are operated 4 or 5 times to their full
1) Minimum tilting command value to pump stroke, pressure is relieved.
proportional valve (PSV-P1, PSV-P2). After draining pressure is completed, turn off the
2) Output “pressure relief control speed starter key and buzzer sound stops. If the pump
command value” at ECU. (Electric system). pressure is determined to be more than 1 MPa
3) Stand-by command value to P1, P2 (145 psi) by the output value of the high
unloading proportional valves. pressure sensor (SE 22, SE 23) (or the high
How to switch to "Pressure release pressure sensors are broken) "FAIL DRAIN
mode" HYD. PRESS" is displayed and the buzzer
1) Select the service diagnosis mode 1. sounds continuously. In that case, also the
(Keeping pressing of the "BUZZER STOP buzzer is not stopped unless the engine key is
SWITCH" [ ] on gauge cluster, turn turned to OFF. Repeat the pressure releasing
the starter key ON.) procedure once again.
2) Select the service Adjustment Mode 1.
(Under the condition that "Screen No.1" (2) Hydraulics:
of "Service diagnosis mode 1" is If the Unloading valves are turned to the
indicated, keeping pressing of the pressure release position, the oil delivered by
"BUZZER STOP SWITCH", press the each pump is unloaded to the tank passage. If
SELECT switch [ ] 3 times. the spools are switched by pilot operation, the
When "LANGUAGE/LOGO", remaining pressure from the actuators may be
"ADJUSTING MODE 1" and "PRESET relieved to the tank circuit, i.e. the main circuit
BY FACTORY" are displayed, press [ ] pressure may be released.
or [ ] switch, and highlight "ADJUSTING
MODE 1", and then press "SELECT
Switch" again.)
3) When "ADJUSTING MODE 1" screen is
displayed, press [ ] or [ ] switch,
several times and "DRAIN HYD. PRESS.
OFF " screen appears.
4) Press "SELECT Switch" and highlight
"OFF", and press [ ] switch to change
to "DRAIN HYD. PRESS. ON", and then
press " SELECT Switch" again.
(3) 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.
T2-2-34
PRESSURE DRAINING (RELEASING) CIRCUIT: at pressure release mode
4 3
1 8
11
15 12
14
18
17
9
9
7
10
5
16
13
16
SM3213
T2-2-35
T2-2-36
ELECTRICAL SYSTEM E135B
ELECTRICAL SYSTEM MAIN COMPONENTS

ELECTRICAL SYSTEM (Overall system)
'
'
&
( 60
A - Cab Control D - Hydraulic System Electrical Components

B - Mechatro Controller and Fuse&Relay box E - Engine Electrical Components
C - Batteries, Batteries Relay, Fuse link F - Light, Horn, ect
T2-3-1
E135B ELECTRICAL SYSTEM
A - CAB CONTROL
Electrical components

60
1 - Cluster gauge (C2) 11 - Climate controls panel (C-4)

2 - Blade selection button (SW-81) 12 - Quick coupling switch (opt.) (SW-59)
3 - Starter switch (SW-1) 13 - Tuner (E-7)
4 - Engine speed throttle (SE-16) 14 - Cab work lights switch (opt.) (SW-26)
5 - Work lights switch (SW-55) 15 - Parking brake release switch (SW-4)
6 - Single/Double flow switch (SW-15) 16 - Horn switch (SW-10)
7 - “Heavy Lift” switch (opt.) (SW-35) 17 - "KPSS" switch (SW-5)
8 - Load momentum switch (opt.) (SW-12) 18 - Drain pressure switch (SW-96)
9 - Cigarette lighter (E-14) 19 - Blade selection switch (SW-80)
10 - Hour meter (E-3) 20 - "Emergency Mode" Potentiometer (E-27)
T2-3-2
Cluster Gauge
SM0003
1 - Coolant temperature indicator 7 - Windshield washer button

2 - Fuel level indicator 8 - Wiper button
3 - Screen change button 9 - Buzzer cut-off button
4 - Select button 10 - Travel speed button
5 - Auto-Idle button 11 - Display
6 - Work Mode button
T2-3-3
Cluster gauge wiring harness

9,(:,

,
(

: %U

9,(:(
60
1 - Starter switch (SW-1) 11 - Wiper motor (M-3)

2 - Engine speed throttle (SE-16) 12 - 12 V socket (E-23)
3 - Work light switch (SW-55) 13 - Speaker right (E-9)
4 - Single/Double flow switch (SW-15) 14 - Connector for cab work light (SW-26)
5 - “Heavy Lift” switch (SW-35) (opt.) 15 - Connector for room light (L-5)
6 - Over load alarm select switch (SW-12) (opt.) 16 - Connector for wiper interlock switch (SW-19)
7 - (opt.) 17 - Speaker left (E-8)
8 - Cigarette lighter (E-14) 18 - Hour meter (E-3)
9 - Cluster gauge (C-2) 19 - Connector with “A” label (CN-5F)
10 - Starter switch (GND) (SW-1) 20 - Connector with “B” label (CN-6F)
T2-3-4
Control levers, safety lever

60
1 - Horn switch (SW-10) 7 - Cab work lights switch (opt.) (SW-26)

2 - Horn switch (Equipment rotation - opt.) (SW-5) 8 - Quick coupling switch (opt.) (SW-59)
3 - Equipment rotation left switch (Equipment rotation 9 - Tuner (E-7)
- opt.) (SW-34) 10 - Platform wiring harness
4 - Blade selection button (SW-81) 11 - Blade selection switch (SW-80)
5 - Equipment rotation right switch (Equipment 12 - Drain pressure switch (SW-96)
rotation - opt.) (SW-33) 13 - Opt.
6 - Safety lever switch (SW-11)
T2-3-5
B - MECHATRO CONTROLLER, ENGINE CONTROLLER UNIT, FUSES & RELAY BOX, DC – DC

CONVERTER

60
1 - Mechatro Controller Unit (C-1)
2 - Fuse & Relay box (E-1)
3 - DC-DC Converter (E-22)
4 - Engine Controller Unit ECU (C-6)
5 - ECU wiring harness
6 - Platform wiring harness
7 - "KPSS" switch (SW-5)
T2-3-6
Fuse & Relay box

FUSES
60
FUSES BOX FUSES BOX
FUSE No. PROTECTED CIRCUIT Rating FUSE No. PROTECTED CIRCUIT Rating
(A) (A)
FUSE 1 Cab Work Light 20 FUSE 19 Air Conditioner 5
FUSE 2 Cab Work Light 20 FUSE 20 Work Light 20
FUSE 3 Monitor 5 FUSE 21 DC-DC Converter 10
FUSE 4 Wiper , Washer 20 FUSE 22 Option 8 5
FUSE 5 Option 1 20 FUSE 23 Option 7 15
FUSE 6 Option 3 20 FUSE 24 Option 20
FUSE 7 Air Conditioner 15 FUSE 25 Safety Look Lever 10
FUSE 8 Air Conditioner 5 FUSE 26 Mechatro Controller 5
FUSE 9 Opt. (Bucket rotation) 5 FUSE 27 Mechatro Controller 20
FUSE 10 Relay, Hour Meter 5 FUSE 28 Engine Controller (ECU) 15
FUSE 11 Cigarette Lighter 10 FUSE 29 Engine Controller (ECU) 15
FUSE 12 Horn, Horn Relay 10 FUSE 30 Monitor (Back Up) 5
FUSE 13 Radio 10 FUSE 31 Fuel Supply Pump 15
FUSE 14 Starter Key Switch 20 FUSE 32 Mechatro Contr. (Back Up) 5
FUSE 15 Room Lamp, Tuner 5 FUSE 33 Spare 5
FUSE 16 Option 2 10 FUSE 34 Spare 10
FUSE 17 Option 4 10 FUSE 35 Spare 15
FUSE 18 Solenoid Valve 10 FUSE 36 Spare 20
T2-3-7
RELAYS
60
1 - Window washer motor relay (R-32) 10 - Engine emergency stop relay (R-25)
2 - Wiper motor reversing relay (R-30) 11 - Horn relay (R-5)
3 - Cab working light relay (R-9) 12 - Glow relay (R-53)
4 - Cab working light relay (R-11) 13 - Blade selector relay (R-40)
5 - Working light relay (R-6) 14 - Wiper motor relay (R-31)
6 - Alternator relay (R-28) 15 - Wiper motor relay (R-29)
7 - Auto-Idle stop relay 2 (R-24) 16 - Extra dis-press sensor relay (R-17)
8 - Lever look relay (R-26) 17 - Revolution right relay (R-12)
9 - Auto-Idle stop relay 1 (R-23) 21 - Revolution left relay (R-13)
T2-3-8
C - BATTERIES, BATTERIES RELAY, FUSES LINK

60
1 - Batterie relay (R-1) 4 - Pre-Heater relay (R-3)

2 - Fuse Link 1, 2, 3, 4 (E-25) 5 - Fuse Link 5 (E-27)
3 - Batteries (E-12)
Fuses located into radiators compartment

Fuse No. Protected circuit Value (A)
FUSE 1 Fuses powering (1 – 6) 60
FUSE 2 Fuses powering (17 - 32) 60
FUSE 3 Alternator 80
FUSE 4 Glow plug relay (R-3) 60
FUSE 5 Fuses powering (10 - 15) 60
T2-3-9
D – HYDRAULIC SYSTEM ELECTRICAL COMPONENTS (1)

60
1 - Pomp P2 proportional solenoid valve (PSV-P2) 10 - Swing parking brake solenoid valve (SV-1)
2 - Pump P1 proportional solenoid valve (PSV-P1) 11 - Pump P2 sensor (SE-23)
3 - Lever lock solenoid valve (SV-4) 12 - Bucket digging sensor (SE-1)
4 - Swing pressure sensor (SE-5) 13 - Bucket dump sensor (SE-2)
5 - P2 Unload proportional solenoid valve (PSV-B) 14 - Boom raising sensor (SE-3)
6 - Travel priority prop. solenoid valve (PSV-C) 15 - Boom lowering sensor (SE-4)
7 - P1 Unload proportional solenoid valve (PSV-D) 16 - Arm in sensor (SE-7)
8 - Arm 2 inverse prop. solenoid valve (PSV-A) 17 - Arm out sensor (SE-8)
9 - Two speed select solenoid valve (SV-3) 18 - Pump P1 sensor (SE-22)
T2-3-10
D – HYDRAULIC SYSTEM ELECTRICAL COMPONENTS (2)

' 4

"
! 0 !
0
4

60
21 - Extra valve selector press sensor (SE-29) (opt.) 27 - P2 Opt. sensor valve (SE-11)
22 - Extra dis-press solenoid valve (opt.) (SV-11) 28 - Selector B&N solenoid valve (SV-13)
23 - Extra dis-press sensor (opt.) (SE-28) 29 - Quick coupler solenoid valve (SV-14) (opt.)
24 - P1 opt. sensor valve (SE-20) 30 - Blade selection solenoid valve (SV-17)
25 - Travel right sensor (SE-9) 31 - Bucket rotation solenoid valve (opt.) (SV-6)
26 - Travel left sensor (SE-10) 32 - Bucket rotation solenoid valve (opt.) (SV-7)
T2-3-11
E – ENGINE ELECTRICAL COMPONENTS

60
1 - Air filter restriction switch (SW-8) 5 - Alternator assembly (E-2)

2 - Water separator switch (SW-36) 6 - Engine revolution sensor (SE-13)
3 - Receiver dryer (E-10) 7 - Air compressor (E-11)
4 - Starter motor assembly (M-1) 8 - Fuel sensor (SE-15)
T2-3-12
F – ELECTRICAL COMPONENTS (Lights, Horns)

60
1 - Frame Working light (L-2) 5 - Horn low (E6)

2 - Boom Working light left (L-1) 6 - Engine room light (L-11)
3 - Boom Working light right (L-6) 7 - Engine room light switch (SW-16)
4 - Horn high (E5)
T2-3-13
ELECTRICAL SYSTEM DIAGRAM
ELECTRICAL SYSTEM DIAGRAM READING KEY (No. 1)
Item Description Code

1 Fuse box E-1
2 Key starter switch SW - 1
3 Fuse link box E - 25
4 Auto-Idle stop relay 1 R - 23
5 Starter motor M-1
6 Starter relay R-2
7 Safety relay R-4
8 Alternator relay R - 28
9 Battery relay R-1
10 Fuse link (60 A) E - 27
11 Auto-Idle stop relay 2 R - 24
12 Alternator E-2
13 Engine controller check connector -
14 Battery E - 12
15 Engine emergency stop relay R - 25
16 Resistor -
17 Glow relay (ECU) R - 53
18 Glow plug relay R-3
20 Emergency Mode Potentiometer E - 27
21 Glow plug -
23 Engine harness -
25 Diode D-4
26 Diode D - 13
27 Diode D - 14
28 Diode D-9
29 Diode D - 12
31 Hour meter E-3
32 Engine controller unit (ECU) C-6
33 Mechatro Controller C-1
T2-3-14
ELECTRICAL SYSTEM DIAGRAM (No. 1)

60
T2-3-15

34 Cluster gauge C-2
35 "KPSS" switch SW - 5
36 Accel potentio pressure sensor SE -16
37 Bucket digging sensor SE - 1
38 Bucket dump sensor SE - 2
39 Boom raising sensor SE - 3
40 Boom lowering sensor SE - 4
41 Arm in sensor SE - 7
42 Arm out sensor SE - 8
43 Swing sensor SE - 5
44 Travel right sensor SE - 9
45 Travel left sensor SE - 10
46 Pump P1 sensor SE - 22
47 Pump P2 sensor SE - 23
48 P1 option sensor (2PB) SE - 20
49 P2 option sensor (Hammer) SE - 11
50 Fuel level sensor SE - 15
51 Engine speed sensor SE - 13
52 Resistor E - 15
53 Blade selection relay R - 40
54 Swing parking release switch SW - 4
55 Swing parking brake solenoid valve SV - 1
56 Two-speed select solenoid valve SV - 3
57 Blade selection solenoid valve SV - 17
58 P2 Unload proportional solenoid valve PSV - B
59 Travel priority proportional solenoid valve PSV - C
60 P1 Unload proportional solenoid valve PSV - D
61 Arm two-speed inverse proportional solenoid valve PSV - A
62 Pump P1 proportional solenoid valve PSV - P1
63 Pump P2 proportional solenoid valve PSV - P2
64 OPT. Relief adjustment proportional solenoid valve 1 PSV - E
65 OPT. Relief adjustment proportional solenoid valve 2 PSV - I
66 Boom/blade selection switch SW - 80
67 Blade selection button SW - 81
T2-3-16

60
T2-3-17

68 Air filter restriction switch SW - 8
69 Water separator switch SW - 36
70 Conflux/single select switch SW - 15
71 Lever lock switch SW - 11
72 Lever lock relay R- 26
73 Operating lever lock solenoid valve SV - 4
74 Heavy lift switch SW - 35
76 Extra dis-press solenoid valve (opt.) SV - 11
77 Extra dis-press sensor relay (opt.) R - 17
78 Prevent spark relay R - 31
79 Wiper motor relay R - 29
80 Wiper motor reversing relay R - 30
81 Window washer motor relay R - 32
82 Wiper motor M-3
83 Washer motor M-4
84 Wiper interlock switch SW - 19
85 Selector detect sensor (opt.) SE - 29
86 Selector solenoid (opt.) SV - 13
87 Air conditioner ampl. C-4
88 Receiver drier E - 10
89 Air compressor clutch E - 11
90 Cigarette lighter E - 14
91 Room light L-5
92 Horn relay R-5
93 Horn high E-5
94 Horn low E-6
95 Horn switch right (opt.) SW - 5
96 Horn switch left SW - 10
97 Extra pressure switch (opt.) SW - 44
98 Extra dis-press sensor (opt.) SE - 28
T2-3-18

60
T2-3-19

99 Revolution left nibbler relay - Extra (A) relay R - 13 / R - 43
100 Revolution right nibbler relay - Extra (B) relay R - 12 / R - 42
101 Diode D - 16
102 Diode D - 17
103 Diode D - 10
104 Revolution right nibbler switch - Extra (B) switch SW - 33
105 Revolution left nibbler switch - Extra (A) switch SW - 34
106 Revolution right nibbler solenoid valve - Extra (B) solenoid SV - 6
107 Revolution left nibbler solenoid valve - Extra (A) solenoid SV - 7
108 Engine room light switch SW - 16
109 Engine room light L - 11
110 Fuel supply pump (automatic fuel stop) M - 11
111 Auto grease motor opt. M-8
112 Fleet link opt. -
113 Antenna GPS -
114 Antenna GSM -
115 6P Connector -
116 Cab working light relay 1 (opt.) R-9
117 Cab working light relay 2 (opt.) R - 11
118 Cab working light switch (opt.) SW - 26
119 Cab working light front 1 (opt.) L-7
120 Cab working light front 2 (opt.) L-8
121 Cab working light front 3 (opt.) L - 15
122 Cab working light front 4 (opt.) L - 16
123 Cab working light back 1 (opt.) L - 18
124 Cab working light back 2 (opt.) L - 17
125 12 V Socket E - 23
126 DC – DC Converter E - 22
127 Radio E-7
128 Antenna -
129 Speaker left E-8
130 Speaker right E-9
131 Seat heater (opt.) SW - 36
132 Over load alarm select switch (opt.) SW - 12
133 Pressure sensor: boom head cylinder (for over load alarm) (opt.) SE - 26
134 Drain pressure switch SW - 96
135 Work light relay R-6
136 Work light switch SW - 55
137 Boom working light right L-6
138 Boom working light left L-1
139 Frame working light L-2
140 Qiuck Coupler solenoid valve (opt.) SV - 14
141 Qiuck Coupler switch (opt.) SW - 64
142 Diode D - 22
143 Diode D - 23
T2-3-20

60
T2-3-21
WIRING HARNESS
CLUSTER GAUGE WIRING HARNESS ASSEMBLY READING KEY
ASSEMBLY CABLES ON THE CONNECTORS
- The connector view on the cable

are from “X” side
SM0199
SM0251
T2-3-22
CLUSTER GAUGE WIRING HARNESS ASSEMBLY
SM0099
T2-3-23
PLATFORM WIRING HARNESS ASSEMBLY READING KEY
60

SM0199
T2-3-24
PLATFORM WIRING HARNESS ASSEMBLY
60
T2-3-25
UPPER FRAME WIRING HARNESS ASSEMBLY READING KEY
60

SM0199
T2-3-26
UPPER FRAME WIRING HARNESS ASSEMBLY
60
T2-3-27
ECU WIRING HARNESS ASSEMBLY READING KEY
60
SM0199
T2-3-28
ECU WIRING HARNESS ASSEMBLY
60
T2-3-29
NOTES:
T2-3-30
COMPONENT OPERATION
COMPONENT OPERATION E135B

Group 1 Hydraulic Pump Assy
Group 2 Pilot Valve
Group 3 Control Valve
Group 4 Swing Device
Group 6 Swivel Joint
Group 7 Cylinders
Group 8 Air Conditioner system
Group 9 Blade control
SECTION 3 E135B
COMPONENT OPERATION
CONTENTS
Group 1 - Hydraylic pump assy Cartridge type solenoid proportional relief

valve for N&B ..................................... T3-3-41
Outline .................................................... T3-1-1
Installation.......................................... T3-3-41
General view and hydraulic ports ...... T3-1-1
Air breathing....................................... T3-3-42
Hydraulic circuit diagram .................. T3-1-2
Outside view ...................................... T3-3-43
Specifications .................................... T3-1-3
Specifications..................................... T3-3-43
Hydraulic pump ...................................... T3-1-4
Construction....................................... T3-3-44
Operation .......................................... T3-1-7
Regulator ............................................... T3-1-9 Group 4 - Swing device
Construction....................................... T3-1-9 Outline .................................................... T3-4-1
Operation .......................................... T3-1-11 General view ...................................... T3-4-1
Adjusting the regulator ....................... T3-1-14 Specifications..................................... T3-4-3
Causes of fault resulting from Construction ........................................... T3-4-4
regulator ........................................ T3-1-15
Swing motor ....................................... T3-4-4
Control curve of pump............................. T3-1-16
Anti-reaction valve ............................. T3-4-6
Group 2 - Pilot valve Swing reduction unit........................... T3-4-7
Pilot valve (ATT) ..................................... T3-2-1 Hydraulic motor ....................................... T3-4-8
Outline ............................................... T3-2-1 Valve casing section ............................... T3-4-9
Construction....................................... T3-2-2 Operation of anti-cavitation check
plunger ........................................... T3-4-9
Operation ........................................... T3-2-3
Operation of relief valve ..................... T3-4-9
Pilot valve (travel) ................................... T3-2-5
Brake section .......................................... T3-4-12
Outline ............................................... T3-2-5
Swing reduction unit................................ T3-4-13
Construction and operation................ T3-2-6
Group 5 - Travel device
Group 3 - Control valve
Outline .................................................... T3-5-1
Control valve ........................................... T3-3-1
Characteristics ................................... T3-5-1
Control valve ports ............................. T3-3-3
General view ...................................... T3-5-2
Specifications .................................... T3-3-4
Rotation direction ............................... T3-5-2
Construction and operation................ T3-3-5
Hydraulic circuit.................................. T3-5-3
Main relief valve (601) ....................... T3-3-12
Construction ............................................ T3-5-4
Over load relief valve (602, 606)........ T3-3-13
Travel motor....................................... T3-5-4
Arm 2 spool (308) .............................. T3-3-14
Reduction unit .................................... T3-5-6
Boom spool (301) .............................. T3-3-14
Operating description .............................. T3-5-7
Lock valve selector (211) ................... T3-3-15
Reduction gear................................... T3-5-7
Bypass cut valve (605) ...................... T3-3-16
Hydraulic drives....................................... T3-5-8
Swing shuttle valve cover (204) ......... T3-3-17
Function ............................................. T3-5-8
Hydraulic circuit diagram......................... T3-3-18
Operation ................................................ T3-3-19
Group 6 - Swivel joint Boom/Blade selection button ............. T3-9-9

Outline..................................................... T3-6-1 Boom/Blade selection switch ............. T3-9-9
Construction (Standard Version .............. T3-6-2 Boom/Blade selection relay................ T3-9-10
Construction (Version with blade) ........... T3-6-4
Operation ................................................ T3-6-5
Group 7 - Cylinders
Outline..................................................... T3-7-1
Construction ............................................ T3-7-2
Boom cylinder ................................... T3-7-2
Arm cylinder ...................................... T3-7-3
Bucket cylinder .................................. T3-7-4
Positioning ........................................ T3-7-5
Blade cylinder .................................... T3-7-6
Operation ................................................ T3-7-7
Group 8 - Air conditioner system

Basic system of air conditioner
(HVAC air conditioner) ....................... T3-8-1
Air cycle ............................................. T3-8-1
Auto air conditioner system outline .... T3-8-2
Component and construction .................. T3-8-3
Function ............................................. T3-8-11
Disassembly and assembly..................... T3-8-17
Precautions to be exercised in
operation ........................................ T3-8-17
Disassembly and assembly of unit..... T3-8-18
Charging refrigerant ................................ T3-8-22
Precautions to be exercised in
operation ........................................ T3-8-22
Operating procedure .......................... T3-8-23
Electric circuit .......................................... T3-8-27
Wiring diagram and connectors ......... T3-8-27
Structure and operation of each
functional parts and the inspection .... T3-8-29
Troubleshooting ...................................... T3-8-32
Self diagnosis function on display of
panel .................................................. T3-8-39
Explanation of indication for failure .... T3-8-39
Explanation of monitor mode ............. T3-8-41
Group 9 - Blade control

Outline..................................................... T3-9-1
Blade.................................................. T3-9-3
Blade control cylinders....................... T3-9-4
Swivel joint ......................................... T3-9-4
Blade control valve............................. T3-9-5
Blade switching hydraulic valve ......... T3-9-6
Gear pump for blade .......................... T3-9-7
HYDRAULIC PUMP ASSY E135B
OUTLINE
General view and hydraulic ports
PSV1
a5
Dr1
A3
A2
A1
B3
B1
a4 PSV2
3 4 4 2 a5
a4 PSV1 PSV2 a5
PSV2 PSV1
5 Dr1
B3 6
Dr1
B3
B1
A3 Dr2
Dr3
a1 a2 Dr1 B1 a3
B3
a3
(Dr1) (PH1) (PH2) Dr1 PH2

Dr3
1
SM2801
1- Main pump assy PSV2 - Servo assist port G 1/4-13

2- Regulator assy PH1 - Pressure sensor port G 3/8-17
3- Regulator assy PH2 - Pressure sensor port G 3/8-17
4- Solenoid proportional reducing valve (Q.ty 2) a1 - Gauge port G 1/4-15
5- Gear pump assy (for pilot) a2 - Gauge port G 1/4-15
6- PTO gear case a3 - Gauge port G 1/4-14
A1 - Delivery port SAE 6000 psi 3/4'' a4 - Gauge port G 1/4-13
A2 - Delivery port SAE 6000 psi 3/4'' a5 - Gauge port G 1/4-13
B1 - Suction port SAE 2500 psi 2 1/2'' A3 - Delivery port of gear pump G 1/2-19
Dr1 - Drain port G 1/2-19 B3 - Suction port of gear pump G 3/4-20.5
Dr2 - Drain port G 3/4-20 Dr3 - Drain port of gear pump G 3/8-15
PSV1 - Servo assist port G 1/4-13
T3-1-1
E135B HYDRAULIC PUMP ASSY
Hydraulic circuit diagram
4 PSV1 PH1 A1 a1 a2 A2 PH2 PSV2 4
a4 a5
3 2
B1
Dr1 A3
5
1
B3 Dr3 a3
Dr2
SM2802
1- Main pump assy

2- Regulator assy
3- Regulator assy
4- Solenoid proportional reducing valve (Q.ty 2)
5- Gear pump assy (for pilot)
6- PTO gear case
T3-1-2
Specifications
Item Main pump Gear pump for pilot

Pump K7V63DTP175R-OE13-VC ZX10L7RZ2-07G
Variable displacement plunger Fixed displacement type gear
Type
pump: regulator attached type pump
Max. displacement capacity cm3 65.2 x 2 10
rpm
(Clockwise
Revolution Rated
seen from
2000 ←
shaft end)
Rated 34.3 (4974)
Pressure MPa (psi) 5.0 (725)
ATT boost -
L/min 130 (34) x 2 at 7.8 MPa
Max. flow 20 (5.3)
(gal/min) (1131 psi)
Max. input Power
kW (PS) 64.9 (88.3) 3.1 (4.2)
(at 2000 rpm)
Max. input torque
Nm (lbf•ft) 310 (229) 14.7 (10.8)
(at 1600 rpm)
Model KR76-OE13PV - KR76-OE13-V
Control
Electric flow control, positive flow control
Regulator function
With solenoid proportional reducing valve
Others
(KDRDE5K-31/30C50-123)
Mass kg (lbs) 84 (185)
NOTE: the max. input power and the max. input torque of the main pump include those of the gear pump.
T3-1-3
HYDRAULIC PUMP
MAIN PUMP
(Three Bond No.1305N)

533 789 733 732 532 214 548 531 702 792 901 954 724 717 723 402 151 981 983
535 534
806 808 152
953 211
490 899
255 04
261
111 774
A A
127
710
406
123
824
251
212 271 153 468 156 466 157 313 124 711 116 312 886 314 401 467 141 272 113
727 723 732
05
Nm (lbf ft)
401, 402 M16 240 (177)
406 M6 12 (8.9)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 1/2 110 (81)
490 NPTF1/16 11 (6.5)
531, 532 M20X1.5 240 (177)
533 M30 220 (162)
806 M12 60 (44)
808 M16 130 (96)
section A-A SM2803
111 Drive shaft (F) 312 Valve block 723 O-ring; 1B P11 (Q.ty 6)
113 Drive shaft (G) 313 Valve plate (R) 724 O-ring; 1B P8 (Q.ty 12)
116 Gear #1 314 Valve plate (L) 727 O-ring; 1B P18 (Q.ty 4)
123 Roller bearing (Q.ty 2) 401 Socket bolt; M16X150 (Q.ty 2) 732 O-ring; 1B P14 (Q.ty 4)
124 Needle bearing (Q.ty 2) 402 Socket bolt; M16x190 (Q.ty 2) 733 O-ring; 1B P28 (Q.ty 2)
127 Bearing spacer (Q.ty 2) 406 Socket bolt; M6X16 (Q.ty 4) 774 Oil seal
141 Cylinder block (Q.ty 2) 466 VP plug; PF1/4 (Q.ty 2) 789 Back up ring; P14 (Q.ty 2)
151 Piston (Q.ty 18) 467 VP plug; PF3/8 (Q.ty 2) 792 Back up ring; G30 (Q.ty 2)
152 Shoe (Q.ty 18) 468 VP plug; PF1/2 (Q.ty 4) 806 Nut; M12 (Q.ty 2)
153 Retainer plate (Q.ty 2) 490 VP plug; NPTF1/16 (Q.ty 9) 808 Nut; M16 (Q.ty 2)
156 Spherical bushing (Q.ty 2) 531 Tilting pin; M20X1.5 (Q.ty 2) 824 Snap ring (Q.ty 2)
157 Cylinder spring (Q.ty 12) 532 Servo piston M20×1.5 (Q.ty 2) 886 Spring pin (Q.ty 4)
211 Shoe plate (Q.ty 2) 533 Plug; M30 (Q.ty 2) 899 C-ring (Q.ty 2)
212 Swash plate (Q.ty 2) 534 Stopper (L) (Q.ty 2) 901 Eye bolt M10 (Q.ty 2)
214 Tilting bushing (Q.ty 2) 535 Stopper (S) (Q.ty 2) 953 Socket screw; M12X23 (Q.ty 2)
251 Swash plate support (Q.ty 2) 548 Feed back pin (Q.ty 2) 954 Set screw; M16 (Q.ty 2)
255 Lock pin (Q.ty 2) 702 O-ring; 1B G30 (Q.ty 2) 04 Gear pump
261 Seal cover (F) 710 O-ring; 1B G95 05 PTO unit
271 Pump casing (F) 711 O-ring; 1B G80
272 Pump casing (R) 717 O-ring; 1B G125 (Q.ty 2)
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
T3-1-4
GEAR PUMP (FOR PILOT)
887
Section X-X
710 700 354 351 887 433
Z
X
B3
X
434
X
311 A3
312 X
732 Dr3
a3 850
Dr3 Z
307 308 355
435 361 353 310 309 434 466

725
Section Z-Z
Nm (lbf ft)
312 M14x1,5 29 (21)
433, 434
M8 17 (13)
435
466 G 1/4 16 (11)
SM2804
307 - Poppet 435 - Flange socket; M8×20 (Q.ty 4)

308 - Seat 466 - Vp plug; G1/4
309 - Ring 700 - Ring
310 - Spring 710 - O-Ring
311 - Adjust screw 725 - O-Ring
312 - Lock nut; M14×1.5 732 - O-Ring
351 - Gear case 850 - Locking ring
353 - Drive gear 887 - Pin; (Q.ty 2)
354 - Driven gear a3 - Gauge port; G1/2 53 Nm (39.1 lbf•ft)
355 - Filter A3 - Delivery port; G1/2 53 Nm (39.1 lbf•ft)
361 - Front case B3 - Suction port; G3/4 74 Nm (54.6 lbf•ft)
433 - Flange socket; M8×40 (Q.ty 2) Dr3 - Drain port; G3/8 34 Nm (25.1 lbf•ft)
434 - Flange socket; M8×55 (Q.ty 2)
T3-1-5
PTO GEAR CASE
125 468
711
118
11 262
728
117
414
126 825
128
710
10 435
12 886
826
SM0749
10 - Idle shaft 414 - Socket bolt; M10x20 (Q.ty 4)

11 - Gear case 435 - Flange socket; M10×20 (Q.ty 4)
12 - Pin 468 - Vp plug: G3/4
117 - 2nd gear 710 - O-Ring; 1B G80
118 - 3rd gear 711 - O-Ring; 1B G85
125 - Ball bearing (Q.ty 2) 728 - O-Ring; 1B P24
126 - Roller bearing 825 - Snap ring
128 - Bearing spacer (Q.ty 2) 826 - Snap ring
262 - Cover 886 - Pin (Q.ty 2)
T3-1-6
Operation
The pump assy is equipped with two pumps

arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives 111
the two pumps and, at the same time, drives the
pilot gear pump arranged on another shaft.
The pump assy consists largely of: 116
- the rotary group, the main part of the pump that
makes rotary on;
- the swash plate group that changes the delivery
rate;
- the valve block group that selects between oil
suction and delivery;
- the PTO group that transmits the drive power to
the gear pump.
SM0750
ROTARY GROUP
The rotary group consists of shaft (111) (113),
cylinder block (141), piston (151), shoe (152), plate
(153), spherical bushing (156), bearing space (127)
and cylinder spring (157). The sub group of the piston-shoe is pressed against
The shaft is supported by bearings (123) and (124) the shoe plate by the cylinder spring, via the retainer
at its both ends. The shoe, which is caulked to the plate and the spherical bushing, so that it moves
piston, forms a spherical joint and relieves it of thrust smoothly over the shoe plate. The cylinder blocks
force that is generated by load pressure. (141) are also pressed against valve plates (314) by
Further, the piston is provided with a pocket so it the action of cylinder spring (157).
moves lightly on shoe plate (211), taking hydraulic
balance.
111
312 313
124
116
124
314
141
157
156
153
151
211
152
SM0245
T3-1-7
SWASH PLATE GROUP

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
lock pin (256), C-ring (899), tilting bushing (214), 532
tilting pin (531) and servo piston (532). The swash
plate is the cylindrical part that is formed on the
opposite side of the shoe sliding surface and is 531
supported by the swash plate support. 214
The hydraulic force controlled by the regulator flows
into the hydraulic chamber that is provided on both
sides of the servo piston. This moves the servo
piston to the right and left. The result is that the
211
swash plate swings on the swash plate support via 212
the spherical part of the tilting pin and changes the
tilting angle (a).
251
SM0246
VALVE BLOCK GROUP

The valve block group consists of valve block (312),
valve plates (313) (314) and spring pin (886). The
valve plates having two crescent-shaped ports are
313
installed to valve block (312) to feed oil and recycle
it from cylinder block (141). The oil switched over by
312
the valve plate is connected with the external pipe
by way of the valve block.
111
886
116
314
141
PTO GROUP
SM2805
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd
gear are supported by bearings (125) and (126)
117
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 126
cylinder block. If we keep an eye on a single piston,
it makes a motion away from the valve plate (oil
suction process) in the first 180° and a motion
toward the valve plate (oil delivery process) in the
remaining 180°. If the swash plate is not inclined 118
125
(zero tilting angle), the piston does not stroke i.e.
delivers no oil.
The shaft rotation is taken up by the 1st gear (116) 125
and transmitted to the 2nd gear (117) and the 3rd
gear (118), in that order, to drive the gear pump that
is linked to the 3rd gear. SM0248
T3-1-8
REGULATOR
Construction
496 O-RING
325 079
624 627
631 A
643
B B
731
924
407
801
724
402
656
A 733
651 646
652 754 658 887 754
466
755
755 541 543
897 496 418 601
415 496 545
726 543 B-B
616 545
614 755 Nm (lbf ft)

402,407 M6 12 (8.9)
875 541 29 (21)
415 M8
418 M5 6.9 (5.1)
724 708 466 PF 1/4 16 (12)
496 NPTF1/16 8.8 (6.5)
611 614 M141.5 27 (20)
801 M10 29 (21)
A-A SM2806
T3-1-9
325 - Valve casing 651 - Sleeve

402 - Socket bolt; M6x16 (Q.ty 4) 652 - Spool
407 - Socket bolt; M6x30 (Q.ty 4) 656 - Block cover
415 - Socket bolt; M8x40 (Q.ty 4) 658 - Plug
418 - Socket bolt; M5x12 (Q.ty 2) 708 - O-Ring
466 - Vp plug; PF1/4 724 - O-Ring (Q.ty 5)
496 - Plug; NPTF1/16 (Q.ty 9) 726 - O-Ring
541 - Seat (Q.ty 2) 731 - O-Ring
543 - Stopper (Q.ty 2) 733 - O-Ring
545 - Ball (Q.ty 2) 754 - O-Ring (Q.tà 2)
601 - Casing 755 - O-Ring (Q.tà 3)
611 - Feedback lever 801 - Nut; M10
614 - Fulcrum plug 875 - Pin
616 - Prevention plug 887 - Pin
624 - Spring seat 897 - Pin
627 - Adjusting stem 924 - Set screw; M10x20
631 - Sleeve 079 - Solenoid proportional reducing valve
643 - Pilot piston
646 - Pilot spring
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
T3-1-10
Operation
CONTROL FUNCTION
Electric flow control
• Positive flow control
SUMMARY
The regulator KR76-OE13-V for the in-line type axial
piston pump K7V series is composed of the control
mechanism as mentioned below:
Electric flow control and positive flow control

The tilting angle of the pump (delivery rate) is
controlled by controlling the current command value
of the solenoid proportional reducing valve attached
to the regulator. The regulator makes positive flow
control (positive control) that increases the delivery
rate as the secondary pressure of the solenoid
proportional reducing valve rises. Since this function
permits the output power of the pump to be varied,
it is possible to attain optimum power according to
the operating condition. Also, since the pump
delivers only the necessary oil flow, the machine
does not consume excessive power.
POSITIVE FLOW CONTROL

As shown in the figure on the right, the regulator
regulates the delivery rate of the pump by command Q
current I.
I SM0250
T3-1-11
FLOW RATE INCREASE
As the command current I rises, the secondary

pressure of solenoid proportional reducing valve
(079) increases. This causes spool (652) to move
via pilot piston (643) and stops where the hydraulic
pressure pushing the spool rightwards balances
with the action of pilot spring (646).
If the spool (652) moves, port CL opens to the tank
port. This causes the pressure of the large diameter
part of servo piston (532) to go away. This causes
the servo piston (532) to the left by delivery pressure
P1 of the small diameter part, resulting in an
increase in the tilting angle.
Feedback lever (611) is linked with the servo piston
and sleeve (651). As the servo piston moves to the
left, the feedback lever rotates on point A which
causes the sleeve to the right. As the servo piston
moves to the right, the feedback lever rotates on
point A to move the sleeve to the left. The result is
that the opening of the spool sleeve begins to close
gradually and the servo piston settles down when
the opening of the spool sleeve closes completely.
FLOW RATE DECREASE

As the command current I decreases, the
secondary pressure of the solenoid proportional
valve decreases. This causes the spool to move to
the left. When the spool (652) has moved, delivery
pressure P1 reaches port CL via spool and is
admitted to the large diameter chamber of the servo
piston. Delivery pressure P1 is admitted to the small
diameter part of the servo piston at all times. The
servo piston moves rightward by areal difference to
decrease tilting angle. As the servo piston moves to
the right, the feedback lever rotates on point A to
move the sleeve to the left. The sleeve keeps
moving till the opening of the spool sleeve closes
and settles down when the spool sleeve closes
completely.
T3-1-12
079
651 652
627
643 DELIVERY
801
PRESSURE
P1
924
808 646
954 611
953
P1
DELIVERY
PRESSURE
806
532
TILTING MAX. TILTING MIN.
PSV
CL PORT
SM2807
T3-1-13
Adjusting the regulator

The regulator may be adjusted in terms of maximum
flow, minimum flow, horsepower (at back-up control) Q
control characteristics, flow control characteristics
using the adjust screw.
ADJUSTING THE MAXIMUM FLOW

(See HYDRAULIC PUMP-construction)
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.
Only the maximum flow varies, but other control
characteristics remain unchanged.
Adjust screw No 954 I (Pi)
No. of turns for tightening 1/4 Q
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 3.4
ADJUSTING THE MINIMUM FLOW

(See HYDRAULIC PUMP-construction)
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.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care I (Pi)
should be used of the fact that overtightening may SM0996
increase a required power at the maximum delivery

pressure (at relieving action).
Adjust screw No 953 Q
No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 2.9
ADJUSTING THE FLOW CONTROL

CHARACTERISTICS
(See REGULATOR-Construction)
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. I (Pi)
SM0998
Adjust screw No 924

No. of turns for tightening 1/4
Increase Pilot pressure Pi MPa 0.16
Decrease in delivery flow L/min 10.1
T3-1-14
Causes of fault resulting from regulator
When trouble due to this regulator occurs, disassemble

and inspect it referring to "Chapter W2-2".
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. Spool (652) and sleeve (651) are stuck
• Disassemble and clean it.
4. Pilot piston (643) are stuck
THE MAX. FLOW RATE IS NOT DELIVERED

1. Check that secondary pressure of solenoid
proportional reducing valve is normal.
2. Pilot piston (643) are stuck
3. Spool (652) and sleeve (651) are stuck
NOTE: when the damage of part is severe, replace

the part with new one.
T3-1-15
CONTROL CURVE OF PUMP
250
200
150
Q 2000min-1
Q [ L/min ]
(H mode)
1800min-1
(S mode)
100
[3] [2]
[1]
50
Q min. (2000min-1)
0 5 10 15 20 25 30 35 40
Pd [MPa]
SM2808
Two pumps loaded:

[1] 49 kW H mode at operating attachment
[2] 64 kW H mode at traveling or optional working
[3] 44 kW S mode at operating attachment
T3-1-16
PILOT VALVE E135B
PILOT VALVE (ATT)
OUTLINE
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) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A
Model PV48K2004
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)
Weight Approx. 1.9 kg (4.2 lbs)
A
PORT 1, 3 PORT 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]
Secondary pressure [MPa (psi)]

Operation torque [N.m (lbf.ft)]
Operation torque [N.m (lbf.ft)]

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
1.17 (0.86) 1.17 (0.86)
0.98 (0.72) 0.98 (0.72)
0 0 0 0
0 1.1 2 4 6 7 0 1.12 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
SM0591
T3-2-1
E135B PILOT VALVE
CONSTRUCTION
****312
302
501
***301
*212
213
151
211
214
216- 2 216- 1
241- 2 241- 1
201- 2
201- 1
**217
101 221
PORT 2,4 PORT 1,3

SM0592
Tightening Tightening
No. Parts Q.ty torque No. Parts Q.ty torque
Nm (lbf•ft) Nm (lbf•ft)
101 Casing 1 216-2 Spring seat 2
151 Plate 1 **217 Washer 2 (Shim) 4
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
*212 Push rod 4 ***301 Joint: M14 1 47.1 (34.7)
213 Seal 4 302 Circular plate 1
214 O-ring: 1B P20 4 ****312 Adjust nut: M14 1 68.6 (50.6)
216-1 Spring seat 2 501 Boots 1
Note: * apply grease on top section;

** secondary pressure adjusting shim
*** apply grease on rotating and sliding sections. Be careful the assembling drirection
**** apply Loctite #277
T3-2-2
PILOT VALVE E135B
OPERATION
1. Lever in neutral (See Fig.SM0593)

The action of spring (509) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201).
Therefore, spool (201) (for return) is pushed up
by spring (221) [spring seat (216)]. The output
ports (2, 4) connect with the T port. The result
is that the output pressure is equal to the tank
pressure. 216
509
221
201
PORT (2,4) PORT (1,3) SM0593
2. When the pilot lever is tilted (See Fig.SM0594)

When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)]
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 port 2 ,4 to produce 511
a pressure.
216
201
PORT (2,4) PORT (1,3)
SM0594
3. Lever held (See Fig.SM0595)

When the pressure at ports (2, 4) rises to a level
equivalent to the action of spring (509) 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 port open while 509
ports (2, 4) and the T port close. Thus the
secondary pressure is kept constant.
T PORT
P PORT
PORT (2,4) PORT (1,3) SM0595
T3-2-3
E135B PILOT VALVE
4. Operation in the area where the tilting angle of

the 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 the bore of the push rod.
This keeps the output pressure connected with
the P port pressure.
Furthermore, on a model in which a spring seat
and a spring are built in the push rod, 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.
T3-2-4
PILOT VALVE E135B
PILOT VALVE (TRAVEL)

OUTLINE
Outside view
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
SM0596
Specifications
P T
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
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 SM0597
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 SM0598
T3-2-5
E135B PILOT VALVE
CONSTRUCTION AND OPERATION
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 damper 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 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
SM0599
T3-2-6
CONTROL VALVE E135B
CONTROL VALVE
CONTROL VALVE OUTSIDE VIEW (1/2)
PAo
PAa2
PBa2 PBo
Arm 2 Option
PLC2
PAc PBa1
Bucket Arm 1
(P3) (P4) PAb

Boom PAs Swing
PBr
PCa
Travel right P2 unload
T3
PTb PBL
Travel straight Travel left
PBa2 PBo
VIEW A
T2
CT1
PCb PAL
PTb
Travel CMR1 CMR2 P1 unload
straight PCb
PL
PAr CP1
PBL Ar
Br Travel
PBr right PAr
XAb PBb Ab
PBs LCb
Bb (HEAD)
PAb XAb PBb
(ROD) CRb Boom
PBc PAa1 LCc
PAc Ac Bc PBc
(HEAD) (ROD) Bucket
(MU1) PAa2 PAo
PBa2 LCAT2 Arm 2 PAa2
LCAP2
PBp1 PBp2
SM2809
T3-3-1
E135B CONTROL VALVE
CONTROL VALVE OUTSIDE VIEW (2/2)
PTb PCa
PBL
(MU2)
P2
(P6) (P5)
P1
PCb PAL
T2
CT2
T1
PCb PAL
Travel left CP2
PAL PBL
AL BL
DR PCa PAr
Boom CCb P2 unload PBL
PB1 confluence
LCs XAb PBb

Swing Bs PBs
PBs As PAs
Pss CRa
Arm 1 PBc PAa1
PAa1 Aa LCa
PBa1
(HEAD)
Ba (MU1) PAa2
LCo PAo
PAo Option (ROD)
Ao PBo
Bo PBp1 PBp2
SM2810
T3-3-2
CONTROL VALVE E135B
CONTROL VALVE PORTS

Port size Tightening torque Ports Description
PF3/4 150~180 N•m (111~133 lbf•ft) (MU1), (MU2) Pluged
(T3) Pluged
Ar Right travel motor port (reverse)
Br Right travel motor port (forward)
AL Left travel motor port (reverse)
BL Left travel motor port (forward)
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)
Ao Optional pilot port
Bo Optional pilot port
PF1/2 98~120 N•m (72~89 lbf•ft) (P3) Pluged
(P4) Pluged
(P5) Pluged
(P6) Pluged
PF3/8 69~78 N•m (51~58 lbf•ft) PAa1 Arm 1 (in) pilot port
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
PAL Travel left (reverse) pilot port
PBL Travel left (forward) pilot port
PAr Travel right (reverse) pilot port
PBr Travel right (forward) pilot port
PAs Swing (left) pilot port
PBs Swing (right) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
T3-3-3
E135B CONTROL VALVE
Port size Tightening torque Ports Description

PF1/4 34~39 N•m (25~29 lbf•ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
(PL) Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
XAb Lowering boom for emergency
M10 49~65 N•m (36~48 lbf•ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
M12 83~110N•m (61~81 lbf•ft) T1 Tank port 1
T2 Tank port 2
SPECIFICATIONS
Item Specifications
Model KMX13YD/B44006
Maximum flow rate [L/min (gal/min)] 130 (34)×2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 30 ×2L/min (8×2gal/min)]
Overload relief valve set pressure
37.8 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
T3-3-4
CONTROL VALVE E135B
CONSTRUCTION AND OPERATION

Construction
Control valve (1/6)
PAa2 PAo PAo
PBp1
PBp2
275x4
213
274x4
(P4)
(P3)
212
PBa2 PBo
273x10
273x10
A
273x10
T2
J J
P1 unload PCb PAL
Travel left
(Travel straight) 273x10
C C
PAr PB1 Boom conflux
Travel right (P2 unload)
D D
XAb
XAb
PBb PBs
Boom Swing
E Pss
E
PBc PAa1
Bucket Arm 1
F F
PAa2 PAo
Arm 2 MU1 Option
G PBp1 PBp2
G
H H
B A SM2811
T3-3-5
E135B CONTROL VALVE
Control valve (2/6)
155 163 101

(P5)
P2
T1
T2 CT2
K
PAL PBL
PB1 PCa
PBs PAs
Pss
PAa1 PBa1
PAo PBc
PAp2
(P4) SECTION A-A

166 161 161155 163164
154 567 155 163

(MU2) (P6) 102
P1
973 973
CT1
PTb POb
973 973
PBr PAr
PAb PBb
973 973
PAc PBc
973 973
PBa2 PAa2
PBp1
973
(P3) SECTION B-B

161 164 163 155 161 161
SM2812
T3-3-6
CONTROL VALVE E135B
Control valve (3/6)
202 P1 unload 201

Travel left
333 PCb PAL 333
331 331
336 339
328 327
325 325
331
601 331
MR
261 261
309 306
(PL)
159
166
157
161 AL
161
511
512
521
522 CP2
CMR2 551
556 561
561
561 BL
CMR1
556
522
512
307
261 264
331 PBL
325 205
326
336 SECTION C-C
331
333 PTb
202 Travel straight
201 Travel right Boom conflux 201

333 PAr PB1 333
331 331
339 336
327 322
AbR
325 321
602
331 331
261 261
166 305
164 DR 511
162 521
Ar CCb
306
551
511 561
521
CP1
551
551 561
561
166 Br
310
164
166
161
166 T3
264 261
331
PBr
205 325
SECTION D-D 328
336
331
PCa 333
SM2813 202
P2 unload
T3-3-7
E135B CONTROL VALVE
Control valve (4/6)
203
333 Swing
331
PBs
339 Boom 204
320 PBb 333
Pss
319 331
379X3 336
211 322
331
L 216 321
L 266
261 M 331
M 266 XAb 261
166
160
303
301
561 CRb 161
Ab As
(HEAD)
556 511
524 524
LCb LCs
514
551 556
561 561
521 Bb Bs
511 (ROD)
161
264
264
602
PAb
205 PAs 206
BbR
160 266
SECTION E-E
201
201 333
333 Bucket Arm 1
PBc PAa1
331
331 336
339 322
320 321
BcR
319 AaR 602
602 331
331 261
261
161
304
Bc Aa(HEAD)
(ROD)
511 511
521 521
LCc LCa 551
561
551
561 161
Ac 561
(HEAD) CRa 556
Ba(ROD)
524
514
156
PLc2 167
264 160x2
L 302
602 L
PAc PBa1 264
205 211
AcR
205
SM2814 SECTION F-F
T3-3-8
CONTROL VALVE E135B
Control valve (5/6)
201
333
Option 201
331 Arm 2
PAa2 PAo 333
339
331
326
337
325
330
331
329
261 604
154 AoR 331
567 261
MU1
161 311
308
162
515
521 Ao
551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
511 Ba(ROD)
162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 PaR
605 605
PBp1 PBp2
Bo
BoR
166 604
153
SECTION H-H SM2815
T3-3-9
E135B CONTROL VALVE
Control valve (6/6)
T2
P1 T1
511
521
CT1
551
561
511
C P2
(MU2)
521
CT2
E 551
561
162 SECTION J-J SECTION M-M
278x5
160
266
207
267 267
528
527
T1
518
517
SECTION L-L
SECTION K-K
SM2816
T3-3-10
CONTROL VALVE E135B
Tightening torque Tightening torque

No. Parts Name Q.ty No. Parts Name Q.ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing A 1 320 Spring 2
102 Casing B 1 321 Spring 3
25~29 (18~21) 153 Plug 1 322 Spring 3
220~250 (162~184) 154 Plug PF3/4 2 325 Spring 6
110~130 (81~96) 155 Plug PF1/2 4 326 Spring 1
13~17 (9.6~13) 156 Plug PF1/8 1
20~24 (15~18) 157 Plug PF1/4 1
34~39 (25~29) 159 Plug PT1/4 1
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 5 327 Spring 2
161 O-ring 13 328 Spring 3
164 O-ring 4 331 Spring seat 24
16~18 (11.8~13.3)
166 O-ring 7 333 Spacer bolt 12
Loctite #262
167 O-ring 1 336 Stopper 6
168 O-ring 1 337 Stopper 1
201 Cover 6 339 Stopper 5
202 Cover 4 511 Poppet 11
203 Cover 1
204 Cover 1
207 Back pressure check valve
1 515 Poppet 1
cover
9.8~14 (7.2~13) 211 Lock valve selector sub 2 517 Boost check valve 1
518 Poppet 1
212 Plate 1 521 Spring 11
215 Boom lowering valve 1 524 Spring 3
216 Piston 1 527 Spring 1
261 O-ring 12
264 O-ring 8
267 O-ring 2 130~150 (96~111) 551 Plug 12
25~34 (18~25) 273 Socket bolt 40 130~150 (96~111) 556 Plug 5
98~120 (72~89) 274 Socket bolt 4 561 O-ring 17
98~120 (72~89 275 Socket bolt 4 567 O-ring 2
25~34 (18~25) 278 Socket bolt 5
9.8~14 (7.2~13) 279 Socket bolt 3
301 Boom spool sub 1 69~78 (51~58) 601 Main relief valve 1
302 Arm 1 spool 1 69~78 (51~58) 602 Over load relief valve 5
Plug assy for relief valve
303 Swing spool 1 69~78 (51~58) 604 2
hole
304 Bucket spool 1 98~120 (72~89) 605 By-pass cut valve 2
305 Boom conflux spool 1
306 Travel spool 2 69~78 (51~58) 606 Over load relief valve 1
307 Travel straight spool 1 140~180 (103~133) 973 Socket bolt 9
308 Arm 2 spool sub 1
309 P1 unload spool 1
310 P2 unload spool 1
311 Option spool 1
319 Spring 2
T3-3-11
E135B CONTROL VALVE
Main relief valve (601)
Main relief valve (Two step relief)

torque No. Parts Q’ty torque No. Parts Q’ty
69~78 (51~58) 103 Plug; M27 1 562 Back up ring 1
121 C-ring 1 611 Poppet 1
122 Spacer 1 612 Spring seat 1
123 C-ring 1 621 Spring 1
124 Filter stopper 1 651 Adjust screw 1
125 Filter 1 661 O-ring 1
163 O-ring 1 28~31 (21~23) 671 Lock nut; M14 1
512 Plunger 1
521 Spring 1
541 Seat 1
561 O-ring 1
T3-3-12
CONTROL VALVE E135B
Over load relief valve (602, 606)
564 521 124 561 611 661

301 563 123 125 562 621 612
511 522 101 102 671

161 541 162 651
SM0828
Over load relief valve

69~78 (51~58) 101 Body; M27 1 541 Seat 1
69~78 (51~58) 102 Plug; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup 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
522 Spring 1 28~31 (21~23) 671 Lock nut; M14 1
T3-3-13
E135B CONTROL VALVE
Arm 2 spool (308)
350 371 361 340 317 317 340 361 371 351
308
SM2818
Arm 2 spool
18~20 (13~15)
308 Spool 1 350 Plug 1
Loctite #638
18~20 (13~15)
317 Plunger 1 351 Plug 1
Loctite #638
371 Backup ring 2
Boom spool (301)
301 317 340 361 371 350

SM2819
Boom spool
18~20 (13~15)
301 Spool 1 350 Plug 1
Loctite #638
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Backup ring 1
T3-3-14
CONTROL VALVE E135B
Lock valve selector (211)
101
171 164
201
321
PLc A B Dr
166 541 167 511 161
SM0831
Lock valve selector

10~14
101 Casing 1 171 Socket bolt 3
(7.4~10.3)
161 O-ring 4 49~59 (36~44) 201 Plug 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
T3-3-15
E135B CONTROL VALVE
Bypass cut valve (605)
302 301 402 401
P Pi
T Dr
201 202 102 101

SM0832
Bypass cut valve

98~120 (72~89) 101 Plug 1 301 Plunger 1
201 Poppet 1 69~78 (51~58) 401 Plug 1
T3-3-16
CONTROL VALVE E135B
Swing shuttle valve cover (204)
PBs
555
A
Pss
G1/4
A SECTION B-B
166 542 541 PBs G3/8
B B
Pss
554
202
PAs
SECTION A-A
SM0833
Swing shuttle valve cover

166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
7.9~9.8
541 Steel ball 1 555 Plug 1
(5.9~7.2)
T3-3-17
E135B CONTROL VALVE
HYDRAULIC CIRCUIT DIAGRAM
2 12
3 10
11
4 9
6
7
SM2820
1- Travel straight 7- Option

2- P1 Unload 8- Arm 1
3- Travel right 9- Swing
4- Boom 10- P2 Unload
5- Bucket 11- Boom conflux
6- Arm 2 12- Travel left
T3-3-18
CONTROL VALVE E135B
OPERATION
1. In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic
tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric
control system, because the by-pass cut valve (605) located on the downstream of center by-pass
passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel straight spool
(307), and then flows though the center by-pass passage (52) which passes through travel right, boom,
bucket and arm 2 and the by-pass cut valve (605) on P1 side, and flows into low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure
circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to
the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible,
because the by-pass cut valve (605) located on the downstream of center by-pass passage (55) opens,
the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the
center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass
cut valve (605) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then
returns to the hydraulic tank through tank port T1.
52
605 (D)
517
307
T1
T1
P2
P1
309
605 (*)
(D)
55 310
SM2821
In neutral position
(*) Connected to low pressure circuit of P2 side casing
T3-3-19
E135B CONTROL VALVE
2. Actuation in travel operation

a) In travel independent operation
On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed
into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor.
The pilot pressure enters ports PBr and PBL, and the right and left travel spools (306) moves leftward
or rightward the force of springs (325) (327) and the secondary pressure of solenoid proportional valves
[X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310).
The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows
into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is
fed into B side of right travel motor through port Br. The hydraulic oil delivered by hydraulic pump P2
flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left
travel motor through port BL similarly to the stream of hydraulic oil delivered by hydraulic pump P1.
But in the meantime, the return oil from the A and B sides of left and right travel operations passes
through between the perimeter of right and left travel spools (306) and casing through ports Ar and AL
and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank
through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PAr
and PAL of control valve), the actuation is similar to that in forward travel operation.
Left travel motor
B A
AL BL
CP2
306
327 325
PBL
PAL
(D)
SM2822
In left forward travel (at PBL is pressurized)
T3-3-20
CONTROL VALVE E135B
b) In travel straight operation

When actuator other than travel operation and the travel operation are operated simultaneously in the
said item a) "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
travel sides is independent from pump line on actuator.
CMR2 P2 CMR2 P2
B B
P1 P1
CMR1 CMR1
A A
307 307
325 325
328 328
P2 P1 PTb PTb
P2 P1
PTb PTb
Dr Dr Dr Dr
A A
B B SM2823
Circuit (I) Circuit (II)
A - to each actuator
B - to travel right
Movement of travel priority spool
T3-3-21
E135B CONTROL VALVE
3. Actuation in bucket operation

a) In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves
leftward the force of springs (319) (320), 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.
53
PBc PAc
320
319
304
(D)
Bc 511 LCc Ac
(R) (H) SM2824
In bucket digging operation
T3-3-22
CONTROL VALVE E135B
b) In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (319) (320), 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 rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the
perimeter of bucket spool (304) and casing and flows through low pressure circuit (D'), boost check
valve (517) and returns to the hydraulic tank through tank port T1.
53 (D)
PBc PAc
320
319
304
Bc 511 LCc Ac
(R) (H) SM2825
In bucket dumping operation
T3-3-23
E135B CONTROL VALVE
4. Boom
a) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves
rightward against the force of springs (319) (320), and simultaneously the secondary pressure of
solenoid proportional valve [XI] acts on port Pcb and switches unloading spool (309).
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter
of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.
(R) (R)
(H) (H)
53
A
(D) Bb 511 LCb Ab CRb 514
301
319
320
PAb PBb
SM2826
(A): BH chamber
In boom up operation (Boom spool)
T3-3-24
CONTROL VALVE E135B
b) In boom up conflux operation

When boom up operation is performed, the pilot pressure also enters port PB1, and boom conflux spool
(305) is switched by pressure which counters against the force of springs (321) (322). Simultaneously,
secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unload spool
(310).
The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel
passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter
of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens
conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and
confluents the hydraulic oil from the hydraulic pump P1 side.
PB1
322
321
305
511
CCb
(B)
56
SM2827
(B): Conflux passage to Ab port of P1 casing

In boom up conflux operation (Boom conflux spool)
T3-3-25
E135B CONTROL VALVE
c) In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves
leftward against the force of springs (319) (320) and the secondary pressure of solenoid proportional
valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve
selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve
poppet CRb (514) is connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and
opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and
casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port
(Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool
(301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH
chamber and passes through between the perimeter of boom spool (301) and casing, and flows
through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank
through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through
circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight
of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and
opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then
supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)
(R) (R)
(H) (H)
511 (A)
Bb 53 514
317 LCb Ab CRb
301
319
320
PAb
PBb
(D) SM2828
(A): BH Chamber
In boom down operation
T3-3-26
CONTROL VALVE E135B
5. Arm operation
a) In arm out operation
On starting arm out operation, the pilot pressure enters port PBa1 and arm 1 spool (302) moves
rightward against the force of springs (321) (322). Simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2 and arm 2 spool (308) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and
switches unload spool (309).
load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage,
and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped
passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and
casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side
(R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of
arm 1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage
(HH) and then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308)
and casing.
The return oil in low pressure circuit (D') returns to hydraulic tank through tank port T1 passing through
boost check valve (517).
(H) (R)
CRa
Ba 514
Aa 511 LCa 302
321
322 (AR)
211
P1
56
PAa1 PBa1 (D')
(D) LCAT2 LCAP2
Arm 1
P1
(D) PAa2
HH RH RR PBa2
(D) Dr Dr
Arm 2 52
PBa2
PAa2 [XR] (F)
Aa (HEAD)
53 Ba (ROD)
53
(MU1)
(G)
326 325
308
515 LCAP2 LCAT2 511 SM2829
(F): To arm 1 spool

(G): To pilot cut valve
In arm out operation
T3-3-27
E135B CONTROL VALVE
b) In arm in operation (At light load: arm recirculation function)

On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302)
moves rightward against the force of springs (321) (322). Simultaneously the secondary pressure of
solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same
time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet
CRa (514) is connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308)
moves rightward against the force of springs (325) (326) and the secondary pressure of solenoid
proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load
operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the
position of circuit (I).
load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic
pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2
(511) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens load
check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped
passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRa (514) which is located on this side of arm 1 spool (302)
is released, the return oil pushes and opens lock valve poppet CRa (514) and enters AR chamber. The
return oil in AR chamber flows through between perimeter of arm 1 spool (302) and casing, and flows
through low pressure circuit (D) and boost check valve (517). And finally, the oil returns to hydraulic oil
tank through tank port T1. The return oil in AR chamber is led to arm 2 spool (308) through casing inside
passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit
(I), the entire flow rate flows into arm 1 spool (302).
The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and
flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than
that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool
(308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied
to arm cylinder head side (H) again. (Arm recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and
flows through boost check valve (517) through low pressure circuit (D) and returns to the hydraulic tank
through tank port T1.
T3-3-28
CONTROL VALVE E135B
(H) (R)
CRa 514
Aa 511 Ba
LCa
302
321
322 (AR) 211
56
PAa1
PBa1
Arm 1
HH (a) RH RR (D)
Arm 2 52
PAa2
[XR] PBa2
53
(MU1) (D)
325
326
308 317 515 LCAP2 LCAT2 511 319
P1
(D') LCAT2 LCAP2
(D)
P1
PBa2
Dr
(F)
Ba Aa (HEAD)
Circuit (I) (ROD)
(G) SM2830
(F): To arm 1 spool

In arm in operation (At light load: arm recirculation function)
T3-3-29
E135B CONTROL VALVE
c) In arm in operation (In heavy load operation)

The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but
in heavy load operation (work required large power); the function causes the power loss. This control
valve selects the presence of recirculation function in light and heavy load operation with solenoid
proportional valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the
same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid
proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from
arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve
poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes
and opens lock valve poppet CRa (514) and enters AR chamber. The return oil in AR chamber flows
through between perimeter of arm 1 spool (302) and casing, and flows through low pressure circuit (D)
and boost check valve (517). And finally, the oil returns to hydraulic oil tank through tank port T1. The
return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside
passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (II),
the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through
boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing
and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through
circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head
side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside
passage (HH), but flows through check valve (319) and passes through boost check valve (517)
through low pressure (D) and returns to the hydraulic tank through port T1.
(H) (R)
CRa Ba 514 Circuit (II)

Aa 511 LCa
302
321
322 (AR) 211
P1
(D') LCAT2
56 LCAP2
PAa1 (D)
PBa1
P1
Arm 1 PAa2 PBa2
HH (a) RH RR (D) Dr Dr
Arm 2 52
PAa2 (F)
PBa2 Aa (HEAD)
[XR] Ba
53 (ROD)
(MU1)
(D) (G)
326 325
308 317 515 LCAP2 LCAT2

511 319 SM2831
(F): To arm 1 spool

In arm in operation (In heavy load operation)
T3-3-30
CONTROL VALVE E135B
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).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through
shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot
pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and
then is led to port Pss.
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.
204
PAs PBs
Pss
(D)
322
303 321
Bs As
56 (D)
511
A B
Swing motor
SM2832
Swing operation
T3-3-31
E135B CONTROL VALVE
7. Spool actuation for operation in option

This spool is used to control the attachment in option like Nibbler (Crusher), etc.
When the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters
ports PAo, and option spool (311) moves against the force of springs (329) (330), 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 through parallel passage (56) and pushes and
opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and
casing through U-shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the perimeter
of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost
check valve (517), and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool
(311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of
control valve, this oil passage is used as passage to connect to N&B selector valve.
(O)
Ao 511 Bo
LCo
311
604
56
330 329
PAo
PBo
(D) SM2833
Spool actuation for operation in option
T3-3-32
CONTROL VALVE E135B
8. Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R)
and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding
pressure caused by each cylinder.
a) At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left
side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside
of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve
poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to
bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet
(514) is kept pressed the lower side as shown in the figure and restricts the leaking to the minimum.
(a) (b) 541
511
1
CRb Sb PLc Dr
Ab 321
PLc Sa Sb Dr
RH
A A SECTION A-A
514
BH Sa
319
320
PBb
(D) Dr 301 SM2834
1. Return oil from boom cylinder head

2. Lock valve selector
Lock valve operation (At boom spool neutral position)
T3-3-33
E135B CONTROL VALVE
b) In boom down operation (In arm in operation)

Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511)
moves rightward as shown in the figure. After the spool (511) was moved, orifice (a) of bushing (541)
first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving
from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).
And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR
through spring chamber (319).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of
bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet
(514) down as shown in the figure is released. And since lock valve poppet (514) receives holding
pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made
up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed
upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out
opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to
the tank open, the operation has no effect on the operability of boom down operation.
In case of arm in operation, the same operation is performed because pilot pressure PAa1 of arm in
acts on lock valve selector port PLc2.
(a) (b) 541
1
511
Sb PLc Dr
CRb
Ab 321
RH PLc Sa Sb Dr
A A SECTION A-A
514
BH Sa
319
320
PBb
(D) Dr 301 SM2835
1. Return oil from boom cylinder head

2. Lock valve selector
Lock valve selector operation (At boom down operation)
T3-3-34
CONTROL VALVE E135B
9. By-pass cut valve

This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and
center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil
from each center by-pass passage to low pressure passage (D).
a) In normal operation
On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot
ports PBp1 and PBp2 of by-pass cut valve (605). This secondary pressure is the same as that actting
on pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310).
The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side
is the same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301)
moves downward against the force of spring (302). The taper section at the top end of plunger (301) is
seated on the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber
(b) of plug (101).
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and
enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring
chamber (b) of plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure
as center by-pass passage (52) and poppet (201) is pushed the seat section of casing shutting off
center by-pass passage (52) and low pressure passage (D).
Consequently, in normal operation, center by-pass passage (52) is always disconnected from low
pressure passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center
by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309).
[X1]
PBp1
301 302
(C) (b)
Dr 101
201 (a)
(D)
52
SM0969
By-pass cut valve (In normal operation)
T3-3-35
E135B CONTROL VALVE
b) At the time when failure occurred

When the electric system is failed and consequently the secondary pressure of solenoid proportional
valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since
the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring
chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other.
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and
enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring
chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet
(201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage (Dr)
through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet
(201) receives the pressure of center by-pass passage (52) and is lifted up against the force of spring
(202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage (D)
through poppet (201) of by-pass cut valve (605). Therefore when the electric system is failed, P1
unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is
cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through
by-pass cut valve (605), the abnormal rise of the pump pressure is prevented.
PBp1
301 302
(C) (b)
Dr 101
201 (a)
(D) 202
52
SM0970
By-pass cut valve (In condition of failure)
T3-3-36
CONTROL VALVE E135B
10. Boost check valve, By-pass check valve

a) Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates
boost pressure necessary for the low pressure passage.
a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against
the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the
pressure generated by spring (527) is used as the boost pressure for the low pressure passage.
528
527
T1
518
517
T2
(D)
SM2836
Boost check valve operation
T3-3-37
E135B CONTROL VALVE
b) By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass
check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified
pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank
are protected from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve
(518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly
returns to the hydraulic tank through tank port T2.
528
527
T1
518
517
T2
(D) SM2837
By-pass check valve operation
T3-3-38
CONTROL VALVE E135B
11. Emergency manual valve for leaving attachment

Needle valve (Emergency manual valve for lowering attachment) is equipped internally between Ab port
of boom cylinder head side and boom lock valve. For safety, this valve lowers risen attachment to the
ground, if the machine stops with engine trouble. Only in case that the boom is lowering, the pressure in
the cylinder of attachment can be released by operating arm or bucket control lever.
a) Functional explanation
In normal cases, the needle valve was blocked completely to prevent pressure leak of boom circuit.
a. Lowering of boom
Loosen lock nut at first and loosen the needle valve to the end of contact.
IMPORTANT: needle valve is provided the mechanism of stopper against falling out. But the mechanism might
cause break by undue force.
The oil of boom cylinder (1) head side (H) flows into drain passage (4) through orifice, and boom
lowers slowly. The time of boom lowering to the ground takes about 4 to 8 minutes in accordance
with machine position and holding pressure
b. Function of actuator
Oil pressure of XAb port is reduced by releasing holding pressure of boom cylinder head side to
drain passage (4) through orifice.
Operation of actuator with pilot control valve is possible by leading medium pressure via orifice from
XAb port to shuttle valve (7). In this function, this leading of medium pressure ensures primary
pressure of remote control (source of pressure). This function ensures that the cylinder movement
of boom, arm, bucket and others can be actuated only downward by self weight. Consequently the
releasing of pressure becomes possible.
But after attachment is lowered to the ground by lowering boom, holding pressure disappears, and
remote control, via pilot valve, becomes impossible.
c. Boom cylinder with holding valve
If the boom cylinder has holding valve, loosen above-mentioned needle valve together with port
relief valve of holding valve, and boom cylinder starts boom lowering.
Spool of holding valve moves to open side by back pressure of port relief valve, and holding
pressure of boom cylinder is led to “Emergency manual valve for lowering attachment”, operation of
actuator by pilot valve is possibile.
T3-3-39
E135B CONTROL VALVE
Emergency manual valve for lowering attachment
(R)
1
(H)
2
Ab
XAb 5
9
SM0993
1- Boom cylinder head side 6- Lock nut

2- Control valve 7- Shuttle valve
3- Hydraulic oil tank 8- To lever lock solenoid valve
4- Drain passage 9- To control pilot valve
5- Needle valve
T3-3-40
CONTROL VALVE E135B
CARTRIDGE TYPE SOLENOID PROPORTIONAL RELIEF VALVE FOR N&B
INSTALLATION
TOOLS
TIGHTENING TORQUE
No. PARTS TOOLS
Nm (lbf•ft)
36 mm 73.5±5
101 Body
Spanner and torque wrench (54.2±3.7)
Proportional solenoid 32 mm 15.7
801
(coil fixing nut) Spanner and torque wrench (11.8)
PROCEDURE
1. When attaching cartridge to control valve, if the cartridge can not be screwed in because connector of
solenoid valve interferes with the surrounding parts, perform the procedure in the following items 2) ~ 4).
If no interference and so on is found, only procedure in item 3) should be performed.
2. Hold the hexagonal section (Opposing flats: 36mm) of body (101) and loosen coil fixing nut on the solenoid
(801) upper part for the coil section to be rotated freely.
CAUTION
Do not remove nut, but only loosen.
3. Hold the hexagonal section (Opposing flats: 36mm) of body (101) and tighten it on the control valve.
Tightening torque: 73.5 ± 5 Nm (54.2 ± 3.7 lbf•ft)
CAUTION
Do not hold the parts other than body (101) for tightening.
4. Fit connector of solenoid valve to the proper position and tighten coil fixing nut.
Tightening torque: 15.7 Nm (11.8 lbf•ft)
COIL FIXING NUT
BODY (101)
SM2838
T3-3-41
E135B CONTROL VALVE
AIR BREATHING
TOOLS
TIGHTENING TORQUE
No. PARTS TOOLS
Nm (lbf•ft)
Proportional solenoid 17 mm
801 23 (17)
(air breathing plug) Spanner and torque wrench
PROCEDURE
1. Perform the operation in items 2) and 3) under the condition where oil is flowing into control valve and
consequently back pressure (R port pressure) is produced.
2. Loosen air breathing plug of solenoid valve until the hydraulic oil starts flowing out.
Air is flown out with hydraulic oil.
CAUTION
Be careful not to mistake it for pressure adjusting screw fixing nut.
3. After hydraulic oil left flowing out for a while, tighten air breathing plug.
Tightening torque: 23 Nm (17 lbf•ft)
PRESSURE ADJUSTING
SCREW FIXING NUT
AIR BREATHING
PLUG
O-RING
OIL FLOWS
OUT SOLENOID TUBE
SM2839
T3-3-42
CONTROL VALVE E135B
OUTSIDE VIEW
M27x1.5
Air breathing plug
Width across flats 17 (1/2-20UNF-2B)
Tightening torque: 23 Nm (17.6 lbf.ft)
Manual screw seal nut

Width across flats 12 (M6x1.0)
Tightening torque: 7.35 0.5 Nm
(5.42 0.37 lbf.ft)
Nut
Width across flats 32 (M22x1.5) Width across flats 36 (M27x1.5)
Tightening torque: 15.7 Nm Tightening torque: 73.5 5 Nm
(11.6 lbf.ft) (54.2 3.7 lbf.ft)
Use this across flats for attaching
Width across flats 36 this valve to the casing
TYPE OF CONNECTOR
EQUIVALENT TO AMP ECONOSEAL J SERIES
CONNECTORS MARK (+) CAP HOUSING
CAP HOUSING 174354-2

TERMINAL 173706-1
HYDRAULIC SYMBOL
SM2840
SPECIFICATIONS
Working pressure range (Pressure in port P) MPa (psi) 15~40 (2180~5800)

Max. working pressure (Pressure in port T) MPa (psi) 1.0 (145)
Max. flow L/min (gal/min) 300 (79.3)
Rated current mA 700
Electrical specifications
Coil resistance e 19.5 (at 20° C)
T3-3-43
E135B CONTROL VALVE
CONSTRUCTION
Across flats
for tightening 402
801 solenoid tube 701 403 202 401 204 304 305 102 303 301
assy
M22 X 1.5
1/2-20
M6 X 1.0
201 208 101 203 205 206 207 501 302 601
SM2841
TIGHTENING TORQUE
No. SIZE REMARKS
Nm (lbf•ft)
M16X1 44 (32.5) SOLENOID TUBE ASSY
M22X1.5 15.7 (11.6) COIL LOCK NUT
801
1/2-20 23 (17) AIR VENT PLUG
M6X1 7.35±0.5 (5.42±0.37) MANUAL SCREW SEAL NUT
torque No. Name Q.ty torque No. Name Q.ty
73.5±5 101 Body; M27x1.5 1 302 O-ring 1
(54.2±3.7) 102 O-ring 1 303 Backup ring 1
110 (81.1) 201 Plug; M30x1.5 1 304 Spring 1
203 O-ring 1 401 Poppet 1
204 Backup ring 1 402 Spring 1
205 Filter 1 403 Spring 1
206 Filter stopper 1 501 Sheet 1
207 C-ring 1 601 Sheet 1
208 Sheet 1 701 O-ring 1
301 Plunger 1 801 Solenoid 1
T3-3-44
SWING DEVICE E135B
OUTLINE
General view
L, IP THREAD FOR
EYE BOLT 2-M10
DEPTH 18
PB DP
B
GN
RELIEF VALVE
(B PORT SIDE)
AN
DB
RELIEF VALVE
(A PORT SIDE)
A
PG
PA C
SM2841
Tightening torque
Symbol Port name Port size
Nm (lbf•ft)
A, B Main port PF 3/4 108 (123)
DB Drain port PF 3/8 74 (55)
C Make-up port PF 3/4 167 (123)
PA, PB Pressure measuring port PF 1/4 36 (27)
PG Parking brake release port PF 1/4 36 (27)
L Gear oil level gauge PT 3/4 98 (72)
IP Gear oil filling port PT 3/4 98 (72)
DP Outlet port of gear oil PT 1/2 65 (48)
DP2 Outlet port of gear oil PF 1/2 108 (80)
AN Air vent port PT 1/4 -
GN Inlet port of grease PT 1/4 -
T3-4-1
E135B SWING DEVICE
A,(B) C DB
PG
ANTI-REACTION
VALVE BLOCK
IP DP2
DP
AN
GN
SM2842
PG
DB
PA PB
A B
Hydraulic diagram SM2843
T3-4-2
SWING DEVICE E135B
Specification
Model M2X63CHB–13A–36/285–60
Swash-plate type, fixed-displacement plunger
Type
motor
Displacement cm3 (in3) 60 (3.66)
Hydraulic motor
Working pressure MPa (psi) 28.0 (4060)

L/min
Max. flow 132 (35)
(gal/min)
Braking torque Nm (lbf•ft) 314 (232)
Release pressure MPa (psi) 2.3~4.9 (334~711)
Relief set pressure MPa (psi) 28.0 (4060) at 110 L/min (29 gal/min)
Antireaction Type 2KAR6P72/240-716

valve block Mass kg (lbs) 5 (11)
Hydraulic motor assy mass kg (lbs) 34 (75)
Model RG06D19J2
Speed reduction type Planetary 2-stage
Reduction ratio 19.2

Reduction unit
Lubicate oil Gear oil SAE90 (API class GL–4 grade)
Lubicate oil volume L (gal) 1.65 (0.44)
Grease Extreme pressure lithium base # 2 grease
Grease volume cm3 (in3) 500 (30.5)
Total mass kg (lbs) 113 (249)
T3-4-3
E135B SWING DEVICE
CONSTRUCTION
Swing motor
992
303 451 131 444
351
355 A-A
051
401 488 469 051-1
468
106 487 444 433 981 390 391 438 980
303 472
451 707
712 706
A A
131 982
702 114
111 117
743 121
742 113
123
116
117 432 471 443 106 101 491 304 437 124 122 301
SM2844
T3-4-4
SWING DEVICE E135B
torque torque
No. Parts Q.ty No. Parts Q.ty
Nm Nm
(lbf•ft) (lbf•ft)
177 (131) 051 Relief valve; M33-P1.5 2 240 (177) 401 Socket bolt; M16×75 4
051-1 O-ring; 1B G30 2 432 Snap ring 2
101 Drive shaft 1 433 Ring 1
106 Spacer 3 437 Snap ring 1
438 Snap ring 1
1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
113 Retainer (spherical bushings) 1 451 Pin 2
114 Cylinder spring 1 36 (27) 468 Plug; PF1/4 2
116 Push rod 12 108 (80) 469 ROMH plug; M22-P1.5 2
117 Spacer 2 471 O-ring; 1B G80 1
121 Piston 9 472 O-ring; W1516,WG34 1
122 Shoe 9 487 O-ring; 1B P11 2
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
706 O-ring; W1516,WG31 1
707 O-ring; W1516,WG36 1
712 Brake spring 20
301 Casing 1 742 Friction plate 3
303 Valve casing 1 743 Separator plate 4
304 Front cover 1 1.7 (1.2) 980 Plug; PF3/8 1
351 Plunger 2 4.4 (3.3) 981 Plug; PF3/4 1
0.9 (0.6) 982 Plug; PF1/4 1
355 Spring 2 98 (72) 992 Plug; PT3/4 1
390 Name plate 1
391 Rivet 2
T3-4-5
E135B SWING DEVICE
Anti-reaction valve
901 902 171
B1 B B
A1 A A
C C
101
A,B
A1,B1
401 403 404
151 904 903

C-C SM2845
torque No. Parts Q.ty torque No. Parts Q.ty
101 Body 1 404 Backup ring 2
9 (6.6) 151 Plug 4 901 Name plate 1
29 (21) 171 Socket bolt; M8x60 6 902 Pin 2
69 (51) 401 Swing reactionless valve; M22 2 2.7 (2) 903 Plug; PF1/2 2
403 O-ring; 1B P20 2 904 O-ring 2
T3-4-6
SWING DEVICE E135B
Swing reduction unit
602 230 231 204 286 211 912 285 287 911 283 403 603 922
210
921
202 282
* 203
913
285
*
402
910
801
925
920
926
102
401
915
201
SM2846
torque torque
Nm Nm
102 Casing 1 402 Roller bearing 1
201 Drive shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Capscrew; M12x100 8
203 No.2 planetary gear 4 98 (72) 603 Capscrew; M12x135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Snap ring 3
230 No.2 spider 1 912 Snap ring 1
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter; PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose; PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug; PF1/2 1
287 Side plate t=2 3 22 (16) 925 Relief fitting; PT1/4 1
401 Roller bearing 1 22 (16) 926 Grease nipple; PT1/4 1
Coat the part marked * with Three Bond #1217.
T3-4-7
E135B SWING DEVICE
HYDRAULIC MOTOR
Operation
If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as
shown on the figure on the right, the hydraulic
Cylinder block (111)
pressure acts upon piston (121) and creates force F
in the axial direction.
The force F may be divided into force F1 vertical to F2
shoe plate (124) via shoe (122) and force F2 at right F1
angles with the shaft. F
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment. Drive shaft (101)
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of
high pressure oil.
If the oil supply and discharge directions are Valve
reversed, the drive shaft rotates in the opposite plate
direction. Shoe Shoe Piston (131)
Theoretical output torque T can be given by the plate (122) (121)
(124)
following equation. SM0575
PXq
T=
2X Low pressure oil High pressure oil
p: Effective differential pressure MPa

q: Displacement per revolution cc/rev
OUTLET INLET (a)
SM0576
T3-4-8
SWING DEVICE E135B
VALVE CASING SECTION
Operation of anti-cavitation check plunger

Since the system using this type of motor is not
equipped with a valve having a counterbalance
function, the motor is rotated beyond the oil feed
rate in some cases. 351
The system has check plunger (351) and sucks in
deficient oil, in order to prevent cavitation from
occurring due to oil deficiency.
M port
Operation of relief valve
(Make-up port)
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.
SM0578.
The relief valve begins to operates when the DIRECTIONAL VALVE
hydraulic pressure that is determined by the SM0577
product of the pressure-receiving area A1 of
plunger (301) and the pressure P balances the
hydraulic pressure that is determined by the
Chamber h
product of the pressure-receiving area A2 of
Orifice m Spring (321) Piston 1 (302)
the plunger (301) and the pressure Pg of
chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to P
spring (321) increases by this movement of the
piston. R
Pressure Chamber g
As the result, the relief pressure P is raised and receiving A3 A2
area A1 Plunger (301) A4
controlled in the pressure boost time t1 from P1 Orifice n
till Ps. SM0578
This process is explained in the following in the
relationships between the movements of the
components and the relief pressure:
a) Condition shown in Fig.SM0579. Chamber h
Orifice m Spring (321)
If the P port of the relief valve is pressurized, Pin (303) Piston 1 (302)
pressure is built up in chamber g via the
restrictor m of plunger (301).
The hydraulic pressure acting on plunger P
(301) increases and when it balances the
load Fsp of spring (321), the relief valve R
performs relieving action by the pressure Orifice n
Chamber g
Plunger (301)
P1.
This relationship is expressed as: SM0579
P1×A1=Fsp1+Pg1×A2
where Fsp1:
primary set load value of spring (321).
T3-4-9
E135B SWING DEVICE
b) Condition shown in Fig.SM0580.

The pressure of chamber g acts upon the
pressure-receiving area A3-A4 of piston 1 Chamber h
Orifice m Spring (321)
Pin (303) Piston 1 (302)
(302). When the hydraulic pressure rises
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to P
the left while discharging the oil of chamber
h arranged between piston 1 and adjust plug R
(401) into chamber g via orifice n provided in Plunger (301)
Orifice n
Chamber g
piston 1 (302), chamber h serves as a
dumping chamber. SM0580
The load of the spring increases slowly till
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.
Orifice m Spring (321) Pin (303) Piston 1 (302)
c) Condition shown in Fig.SM0581
The machine does not travel to the left
further when piston 1 (302) arrives at the
end of adjust plug (401). Therefore, the P
relief valve keeps its normal relieving action
whereby the relief pressure is held at P2. R
In the processes a. to c. above, the relief Plunger (301) Orifice n
Chamber g
pressure changes as shown in Fig.SM0582.
SM0581
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.SM0580.
SM0582
T3-4-10
SWING DEVICE E135B
3. Operation of anti-reaction valve

a) Neutral condition
Fig.SM0583 illustrates the relationship
between the neutral condition of the anti-
reaction valve and the hydraulic circuits.
Now, let us consider a braking condition in
which brake pressure generates on the AM
port side.
b) When brake pressure occurs:
If pressure (P) generates at the AM port, it ANTI REACTION
VALVE
passes through the passage L, the hole on
ANTI REACTION
the shaft of seat (313) and the passage m of VALVE
plunger (311) and is led to the n chamber.
SM0583
When the pressure P rises above a value
(Ps) set by spring (321), plunger (311)
compresses spring (321) and shifts it to the
left.
Seat (313) compresses weak spring (322)
as pushed by plunger (311) and moves to
the left. L
c) At anti-reaction action
When inertia load stops moving (point Y Fig.
k
SM0587), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward 322 313 321 311 SM0584
the right return side by the action of spring
(321). Seat (313) tries to move to the right by
m n
the action of spring (322), but since
chamber p provides damping action by
orifice g, the return of the seat makes a time
P=PS
delay with regard to the return of the
plunger. L
Consequently, seat t opens. This makes a
passage connecting the AM port and BM
ports or both ports of the hydraulic motor by 322 313 321 311
way of →t→r→k. The result is that the SM0585
pressures at the AM and BM ports become

equal (Pb), falling into the condition at point p t
Z in Fig.SM0587. This prevents the
hydraulic motor from swing shock by the
closing pressure of the AM port. P<PS
k
322 313 g r 321 311
SM0586
P Y
PS
PB
X
Z
T
SM0587
T3-4-11
E135B SWING DEVICE
BRAKE SECTION
Operation
The cylinder (111) is jointed by drive shaft (101) and
a spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves Oil pressure
Spring force
provided in casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against
casing (301) via separator plate (743) and brake
712
piston (702) by the action of brake spring (712), 702
frictional force is created between friction plate (742)
and casing (301) and between separator plate (743) Oil 743
chamber
and brake piston (702). The frictional force bounds 742
the drive shaft to brake the motor. 301
In the meantime, when brake release pressure 101 111
applied to the oil chamber formed between brake SM2847
piston (702) and casing (301) overcomes the spring
force, the brake is released as brake piston (702)
moves till friction plate (742) is separated from
casing (301).
T3-4-12
SWING DEVICE E135B
SWING REDUCTION UNIT
Operation
The swing reduction unit is used to reduce the
rotating speed which is transmitted by the hydraulic Ring gear (Fixed) Planetary shaft
motor and to convert it to the strong turning force
(torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism. Spider
The planetary mechanism is made up of sun gear,
planetary pinion, planetary shaft, spider and ring Sun
gear, as shown in in Fig.SM0589. gear
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (211). Sun gear
(211) is engaged with planetary pinion (210) and
rotates, but since ring gear (202) is fixed, planetary
pinion (210) revolves about sun gear (211) with the
planetary shaft and spider (231).
Planetary pinion
SM0589
The role of spider is to hold the planetary pinion and
planetary shaft and transmits the power from the
planetary pinion to the spider through the planetary
shaft.
The #1 spider (231) is linked with #2 sun gear (204) Swing motor
by the involute spline, and transmits the power to
211
the 2nd stage planetary mechanism.
For the operation of the 2nd stage planetary, the 204
power is transmitted to sun gear (204) → planetary
pinion (203) → spider (230) similarly to the 1st
231
stage.
The #2 spider (230) is linked with pinion shaft (201) 202
by the involute spline, and pinion shaft (201) is 230
engaged with the swing gear fixed on the
undercarriage (lower frame) and rotates.
A
102 chamber
402
B
801 chamber
201
401
SM2848
T3-4-13
E135B SWING DEVICE
NOTES:
T3-4-14
TRAVEL DEVICE E135B
OUTLINE
Characteristics
Type GM21VA-A-45/76-2
Gear ratio 54.0
Rating torque 11100/19200 Nm (8186/14160 lbf•ft)
Reduction gears unit Output speed 51.4/31.3 min-1
Lubricant oil Gear oil SAE#90 GL4
Lubricant oil volume 2.1 L (0.55 gal)
Max. displacement 44.9/75.5 cm3/rev (2.74/4.61 cu•in/rev)
Max. working pressure 34.32 MPa (4976.4 psi)
Max. speed 2777/1688 min-1

Hydraulic motor
Flow rate 130 L/min (34 gal/min)
2 speed control pressure 1.96~6.86 MPa (284~995 psi)
Auto 2 speed control pressure 28.44 at 4.90 MPa (4124 at 710.5 psi)
Brake torque 206 Nm (152 lbf•ft)

Parking brake
Release pressure 0.76 MPa (110 psi)
Mass 145 kg (320 lbs)
T3-5-1
E135B TRAVEL DEVICE
General view
18-M16 X P2.0
20-M16 X P2.0
1
A
D
2
Y Z
X
B
3
1
P
3
Z
SM2849
Rotation direction
Oil inlet Oil outlet Rotation direction

port port (View X)
A B Clockwise
B A Counterclockwise
Port name Port size Function

1 PF1/2 Oil filling port
2 PF1/2 Oil level check port
3 PF1/2 Oil drain port
P PF1/4 Pilot (2 speed changeover) port
D PF1/2 Drain port
A, B PF3/4 Motor drive port
T3-5-2
TRAVEL DEVICE E135B
Hydraulic circuit
D P
SM2850
T3-5-3
E135B TRAVEL DEVICE
CONSTRUCTION
Travel motor
116
115
135
324 112
336 139
328 109
325
326 341
331 377
354
327 301
330
380 383358
352 113
353 150
329
398 376
396 358 352 343 323

327
353
358 352
381 383
380 379
366 330
398 378 331
363 399 398 326
359 208 201
384 210 325
357 208 207 328
210
209 336
324
212
203
103
204 202 106
105
213 206
211 107
205
108
151
104
110
114
110
145 132
149
102
171
167
185
161
162
SM3051
T3-5-4
TRAVEL DEVICE E135B
No. Name Q.ty No. Name Q.ty No. Name Q.ty

102 Shaft 1 185 Spring 1 341 Parallel pin 1
103 Swash plate 1 201 Valve seat 1 343 Socket bolt 10
104 Cylinder block 1 202 Valve 1 352 Plug 3
105 Piston 1 203 Sleeve 1 353 Ball 2
106 Shoe 1 204 Collar 1 354 Plug 5
107 Retainer plate 1 205 Plug 1 357 Plug 1
108 Thrust ball 1 206 Spring 1 358 O-ring 3
109 Timing plate 1 207 O-ring 1 359 O-ring 1
110 Washer 2 208 Back-up ring 2 363 Spool 1
112 Piston 1 209 O-ring 1 366 Spring 1
113 Spring 10 210 Back-up ring 2 376 Orifice 1
114 Spring 1 211 O-ring 1 377 Filter 1
115 Friction plate 3 212 O-ring 1 378 Ball 1
116 Separator plate 4 213 Shim 1 379 Plug 1
132 Oil seal 1 301 Rear flange 1 380 Plug 2
135 O-ring 1 323 Spool 1 381 Piston 1
139 O-ring 1 324 Plug 2 383 O-ring 2
145 Snap ring 1 325 Washer 2 384 Orifice 2
149 Bearing 1 326 Plug 2 396 Plug 2
150 Bearing 1 327 Valve 2 398 Plug 8
151 Needle roller 3 328 Spring 2 399 Name plate 1
161 Piston 1 329 Orifice 2 - - -
162 Shoe 1 330 Spring 2 - - -
167 Pin 2 331 O-ring 2 - - -
171 Parallel pin 2 336 O-ring 2 - - -
T3-5-5
E135B TRAVEL DEVICE
Reduction unit
24
22
29
24
29
23
2
33
32
34 35
14
13
4
36
15
6
16
3
8
10
17
7
30
31
11
27
5
11
12
28
9
12
SM3052
No. Name Q.ty No. Name Q.ty

1 Hub 1 16 Parallel pin 1 3
2 Spindle 1 17 Parallel pin 2 3
3 Spider 1 1 22 Lock washer 2
4 Sun gear 1 1 23 Shim 1
5 Planetary gear 1 3 24 Bearing 2
6 Pin 1 3 27 Needle bearing 3
7 Spider 2 1 28 Needle bearing 3
8 Sun gear 2 1 29 Floating seal 2
9 Planetary gear 2 3 30 Plug 3
10 Pin 2 3 31 O-ring 3
11 Thrust washer 1 6 32 O-ring 1
12 Thrust washer 2 6 33 O-ring 2
13 Thrust plate 1 34 Parallel pin 2
14 Cover 1 35 Socket bolt 12
15 Coupling 1 36 Snap ring 1
T3-5-6
TRAVEL DEVICE E135B
OPERATING DESCRIPTION
REDUCTION GEAR
1. Function
This reduction gear unit is composed of two
stage planetary gear mechanism. The
reduction gear reduces the high speed of
hydraulic motor and converts it low-speed,
high-torque rotation.
2. Operating description
The rotation of hydraulic motor shaft is 7 5
transmitted to sun gear (4) of the first stage
which is linked with shaft (102) in spline. 4
At that time, the hub (1) is rotated by the 102
rotation of the planetary gears (5). The hub (1)
rotation is transmitted to carrier (3) which
connected to planetary gears (5), and that input output
causes sun gear (6) rotation of the second
stage.
2
The rotation of sun gear (6) is transmitted to the
hub via three planetary gears (7) of the second
stage. 6
The generated rotation of reduction gear is 3
output rotation. 1 SM3053
T3-5-7
E135B TRAVEL DEVICE
HYDRAULIC DRIVES
FUNCTION
Hydraulic motor
This hydraulic motor is a swash plate type axial
piston motor, converting the hydraulic force from the
pump to rotary motion.
Brake valve
a) Controls inertia when stopping the hydraulic
motor, in order to provide smooth stopping.
b) Prevents runaway rotation when the hydraulic
motor is rotated by external force.
This is done by preventing hydraulic cavitation.
c) Prevents the generation of abnormally high
pressure when the hydraulic motor is stopped
suddenly.
Parking brake
The parking brake prevents the hydraulic motor
from being rotated by external force while stopped.
A friction plate type mechanism is used, constructed
so as to form one unit with the hydraulic motor.
High-Low 2-Speed Switching Mechanism

Switches the hydraulic motor between high speed
rotation with low torque, and low speed rotation with
high torque.
OPERATING PRINCIPLES AND DESCRIPTION

109 104 102
Hydraulic motor
Hydraulic fluid fed from the hydraulic pump enters
the GM motor through the rear flange (301), passes
through the brake valve and timing plate (109) and
enters the cylinder block (104). This hydraulic fluid
is fed only into one side of a line connecting the
upper and lower dead points (Y1-Y2) of the piston
stroke (105). The hydraulic fluid pushes each of the
pistons (105), creating force F(=P×A). This force
operates on the oblique surface of the swash plate 105 103
(103). Force F is separated into components F2 and
Y1
F3 according to the angle of the oblique surface. Of
the two components, the radial component force F3 θ
generates torque (=F3×ri). The sum of the torque F3
F2
T(=S(F3×ri) of each of the pistons (105) is the rotary P A
F3
F3
force of the hydraulic motor. This rotary force F1 ri
passes through the pistons (105) and rotates the F3
cylinder block (104) and the shaft (102).
F3
Y2
SM3054
T3-5-8
TRAVEL DEVICE E135B
Brake valve
a) Operation (Brake released)
The pressure oil is led to through port (A), opens
valve (327), and led to port (C) on the section 328 B 323 327 A 329
side of hydraulic motor to rotate hydraulic motor.
At the same time, the pressure oil enters
chamber (a) through orifice (329), and exerts on
the end of spool (323) to generate the force.
Then the force of spring (328) slides the spool
(323) placed on the neutral position leftward.
The sliding of spool (323) forms the space
(passage) between spool (323) and rear flange E a
D C
(301) with spool groove.
This passage is connected to port (D) and port
(B) of the return circuit of the hydraulic motor,
and the returns oil returns to tank side, enabling
hydraulic motor to rotate.
Then, the sliding of spool (323) leads pressure oil
to port (E). The pressure oil led to port (E) moves
piston (112) of parking brake, and releases
parking braking force. (For details, refer to item
"Parking brake".)
If pressurized oil is supplied from port (B), the
movements of spool (323) and valve (327) are SM3055
reversed so that the hydraulic motor is rotated
reversely.
b) Self-traveling
While machine is being operated, as the travel
speed is increased due to steep slope, the oil B A
328 323 327 329
flow rate of the hydraulic motor is higher than the
supply flow rate of the hydraulic oil pump.
The rotation of the hydraulic motor in this case is
called a self-traveling. (Overrun) While self-
traveling, the pressure is lowered similar to the
stopping condition. Then brake valve is moved
similar to the stopping condition, throttles
passage in the return side of hydraulic motor,
and generate backing pressure. E a
D C
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution having
a balance with the supply flow rate of pump.
SM3056
T3-5-9
E135B TRAVEL DEVICE
c) Stop / Stall (Braking Operation)

If pressurized oil supply through the port (A) is
suspended while traveling, the hydraulic force to
push up the spool (323) is lost, and the spool 328 B A 329
323 327
(323) which is slid to left side, tries to return to the
neutral position due to the spring (328) force. At
that time, through the oil in the chamber (a) tries
to flow out to the port (A) side through the orifice
(329), its flow is restricted and some back
pressure is generated by the throttle effect in the
orifice (329) controlling the return speed of the
spool (323). At the same time, the hydraulic
E a
motor tries to rotate with its inertia force even 325 D C
though the pressurized oil is suspended, and the
return oil from the hydraulic motor tries to return
to the port (B) side from the port (D) through the
passages on spool groove and rear flange (301).
When the spool (323) entirely return to neutral
position, the passage on the hydraulic motor of
the oil return side is completely closed by the
spool (323), and the hydraulic motor ceases its
rotation. While machine working, the brake valve
smoothly stops rotation of-the hydraulic motor
which tries to rotate with its inertia force, by
SM3057
means of throttling the return side passage of the
hydraulic motor, generating back pressure due
to shape of the spool groove and controlling the
return speed of the spool.
On the other hand, when braking is operated, the
hydraulic motor tries to rotate with its inertia force
and to intake oil with its pumping function.
However, because the intake side is closed its
passage with the spool (323), the oil supply is
suspended. This causes cavitation in the
hydraulic motor. To prevent the cavitation, the
valve (327) is operated by very slight negative
pressure to open the passages of port (A) side
and intake port (C) of the hydraulic motor.
And when pressurized oil is supplied through the
port (B), each motion of the mentioned parts
above becomes symmetrical right and left to stop
the hydraulic motor.
T3-5-10
TRAVEL DEVICE E135B
High-Low 2-Speed Switching Mechanism

a) Low Speed
When the pilot pressure is not supplied through
the port (P), the valve (363) is pushed up to the
upper position due to the spring (366) force and B A
pressurized oil through the port (A) or (B), the 366
pressurized oil is cut off at port (C), and oil in the 363 P θ1
chamber (W) is released into the drain (motor B 103 Y
case) through the valve (363). A W
C
Accordingly, the tilt angle of the swash plate 161
(103) becomes the maximum θ1 resulting the
maximum stroke volume and low speed rotation
of the hydraulic motor.
SM3058
b) High Speed
When the pilot pressure is supplied through the
port (D), it defeats the spring (366) force and
pressurized oil through the port (A) or (B) to push
down the valve (363) to lower position, the
pressurized oil at the port (C) is led to the B A
chamber (P) through the valve (363), and the 366 X

piston (161) pushes the swash plate (103) up to 363 P θ2
the plane X and maintain it at its position. B 103

A W
At that time, the tilt angle of the swash plate C
becomes the minimum θ2 resulting the minimum 161
stroke volume and high speed rotation of the
hydraulic motor.
SM3059
c) Automatic shifting to low speed during high

speed operation
If the load is increased while high speed
operation, the oil pressure at the port (A) or (B)
B A
is also increased. And when the oil pressure
reaches to specified pressure, it excesses the 366
pilot pressure, and the valve (363) is pushed up 363 P θ1
to upper position, and oil in the chamber (W) is

B 103 Y
A W
released into the drain (motor case) through the C
valve (363). 161
At that time, the swash plate (103) gets touch
with the plane Y of spindle, and the tilt angle of
swash plate (103) becomes the maximum 1 and
is maintained at its position resulting low speed
SM3060
rotation.
T3-5-11
E135B TRAVEL DEVICE
NOTE:
T3-5-12
SWIVEL JOINT E135B
OUTLINE
General view (Standard Version)
E
A
F B
D
VIEW Y
VIEW Z
Z
SM0568
Specifications
Working pressure 34.3 MPa (4973.5 psi)
High pressure ports A,B,C,D Max. impact pressure 51.5 MPa (7467.5 psi)
Working pressure 0.49 MPa (71 psi)
Low pressure ports E
Working pressure 5 MPa (725 psi)
Low pressure ports F
Rated flow 30 L/min (8 gal/min)
Revolution 15 min-1
A,B,C,D (body) PF 1
A,B,C,D (stem) PF 3/4
Ports size
E PF 1/2
F PF 1/4
Length (height) 368 mm (14.5")
Weight 24.5 kg (54 lbs)
T3-6-1
E135B SWIVEL JOINT
Construction (Standard Version)
G
5
Section G - G
SM2649
1- Body 7- O-Ring
2- Stem 8- Capscrew; M8x20 (Q.ty 2) 30.4 Nm (22.4 lbf•ft)
3- Thrust plate 9- Capscrew; M8x30 (Q.ty 3) 30.4 Nm (22.4 lbf•ft)
4- Cover 12- Plug
5- Seal 13- O-Ring (Q.ty 2)
6- Seal (Q.ty 5)
T3-6-2
SWIVEL JOINT E135B
General view (Version with Blade)
H H C F
G
B
A E
D
G B
C B
A
G
E
SM2857
Specifications
High pressure ports A,B,C,D Max. impact pressure 51.5 MPa (7467.5 psi)
High pressure ports F, G
Low pressure ports H, I
Rated flow 15 L/min (4 gal/min)
Working pressure 0.49 MPa (71 psi)
Low pressure ports E
Revolution 15 min-1
A,B,C,D (body) PF 1
A,B,C,D (stem) PF 3/4
Ports size
E, F, G PF 1/2
H, I PF 1/4
Length (height) 490.5 mm (19.3")
Weight 64.5 kg (142.2 lbs)
T3-6-3
E135B SWIVEL JOINT
Construction (Version with Blade)
H H C F
2
A E
6 D
G B
D
C
A H
G 11
F
7
E E
8 9
3 10 4
SM2858
1- Body 7- O-Ring
2- Stem 8- Capscrew; M8x20 (Q.ty 2) 30.4 Nm (22.4 lbf•ft)
3- Thrust plate 9- Capscrew; M8x30 (Q.ty 4) 30.4 Nm (22.4 lbf•ft)
4- Cover 10- Plug (Q.ty 2)
5- Seal (Q.ty 8) 11- Plug
6- O-Ring (Q.ty 2)
T3-6-4
SWIVEL JOINT E135B
OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (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.
T3-6-5
E135B SWIVEL JOINT
NOTE:
T3-6-6
CYLINDERS E135B
OUTLINE
General view
B
gth
en
e dl A
te nd gth
ex en
lly te dl
Fu ac
r etr
F ully
Part No. and Manufacturing No.

Stamp position
SM0560
Specifications
Center
distance of
Cylinder bore Dry
Stroke pins
Use Rod Dia. Cushion weight
Full extend B /
Full retract A
mm (in) mm (in) mm (in) kg (lbs)
Ø 100 / Ø 70 1028 2516 / 1488 With cushion 100

Boom
(3.94 / 2.76) (40.47) (99.05 / 58.58) on rod side (220)
Ø 115 / Ø 80 1120 2835 / 1715 With cushion 138
Arm
(4.53 / 3.15) (44.09) (111.61 / 67.52) on both sides (304)
Ø 95 / Ø 65 903 2293 / 1390 With cushion 82
Bucket
(3.74 / 2.56) (35.55) (90.28 / 54.72) on rod side (181)
Ø 125 / Ø 85 825 2190 / 1365 177
Positioning Without cushion
(4.92 / 3.35) (32.48) (86.22 / 53.74) (390)
Ø 110 / Ø 65 220 880 / 660 61
Blade Without cushion
(4.33 / 2.56) (8.66) (34.65 / 25.98) (135)
T3-7-1
E135B CYLINDERS
CONSTRUCTION
Boom cylinder
25 3 23
26 24
9 8 7 6 12 4 5 11 10 2 1 13 14 20 17 16 18 19 15 21 22
SM2851
1- Cylinder tube 14- Cushion seal

2- Piston rod 15- Piston; M48 x 3 3851 Nm (2840 lbf•ft)
3- Rod cover 16- Seal ring
4- Bushing 17- Backup ring (Q.ty 2)
5- Snap ring 18- Slide ring (Q.ty 2)
6- Buffer ring 19- Slide ring (Q.ty 2)
7- U-Ring 20- Shim
8- Backup ring 21- Stop dowel; M10 x 1.5 31.5±5.9 Nm
9- Wiper ring (23.2 ± 4.4 lbf•ft)
10- O-Ring 22- Steel ball
11- Backup ring 23- Pin bushing
12- Socket bolt; M14 x 2 x 65 (Q.ty 12) 171 Nm 24- Wiper ring (Q.ty 2)
(126 lbf•ft) 25- Pin bushing
13- Cushion bearing 26- Wiper ring (Q.ty 2)
T3-7-2
CYLINDERS E135B
Arm cylinder
30 31 30 31
9 8 3 7 6 13 4 5 10 11 12 2 1 14 15 17 18 16 20 21 22 19 23 24
27
25
26
29
28
SM2852
1- Cylinder tube 17- Slide ring (Q.ty 2)

2- Piston rod 18- Slide ring (Q.ty 2)
3- Rod cover 19- Stop dowel; M8x16 14.7 Nm (10.8 lbf•ft)
4- Bushing 20- O-Ring
5- Snap ring 21- Back-up ring
6- Buffer ring 22- Piston nut; 1860 Nm (1372 lbf•ft)
7- U-Ring 23- Stop ring
8- Backup ring 24- Cushion plunger
9- Wiper ring 25- Spring
10- O-Ring 26- Spring support
11- Backup ring 27- Check valve
12- O-Ring 28- O-Ring
13- Socket bolt; M16 (Q.ty 10) 353 ± 10 Nm 29- Plug
(260 ± 7.4 lbf•ft) 30- Wiper ring
14- Cushion bearing 31- Pin bushing
15- Piston; 981 Nm (723.5 lbf•ft)
16- Seal ring
T3-7-3
E135B CYLINDERS
Bucket cylinder
24 23 9 8 7 6 12 4 5 3 14 10 11 2 1 13 15 17 18 16 19 20 21 22 23 24
SM2853
1- Cylinder tube 13- Cushion bearing

2- Piston rod 14- O-Ring
3- Rod cover 15- Piston; 981 Nm (723.5 lbf•ft)
4- Bushing 16- Seal ring
5- Snap ring 17- Backup ring (Q.ty 2)
6- Buffer ring 18- Slide ring (Q.ty 2)
7- U-Ring 19- O-Ring
8- Backup ring 20- Backup ring
9- Wiper ring 21- Piston nut; 1860 Nm (1372 lbf•ft)
10- O-Ring 22- Stop dowel; M8x16 14.7 Nm (10.8 lbf•ft)
11- Backup ring 23- Pin bushing
12- Socket bolt; M14 (Q.ty 8) 211 ± 5 Nm 24- Wiper ring
(155 ± 3.7 lbf•ft)
T3-7-4
CYLINDERS E135B
Positioning
22 21 21 22
9 8 7 6 4 12 5 3 10 11 2 1 13 17 16 15 14 18 19 20
SM2854
1- Cylinder tube 13- Piston

2- Piston rod 14- Seal ring
3- Rod cover 15- Backup ring (Q.ty 2)
4- Bushing 16- Slide ring (Q.ty 2)
5- Snap ring 17- Slide ring (Q.ty 2)
6- Buffer ring 18- Piston nut; M65 x 3 5470 Nm (4034 lbf•ft)
7- U-Ring 19- Stop dowel; M12x1.75 57±10.7 Nm (42±7.9 lbf•ft)
8- Backup ring 20- Steel ball
9- Wiper ring 21- Pin bushing
10- O-Ring 22- Wiper ring
11- Backup ring
12- Socket bolt; M16 x 2 (Q.ty 12) 267 Nm
(197 lbf•ft)
T3-7-5
E135B CYLINDERS
Blade cylinder
22 21 20 22
9 3 8 7 6 4 10 11 5 1 2 12 14 13 15 16 17 18 19
SM2861
1- Cylinder tube 12- Piston

2- Piston rod 13- Seal ring
3- Rod cover 14- Backup ring
4- Bushing 15- Slide ring
5- Snap ring 16- O-Ring
6- Buffer ring 17- Backup ring
7- U-Ring 18- Piston nut
8- O-Ring 19- Stop dowel
9- Wiper ring 20- Pin bushing
10- O-Ring 21- Pin bushing
11- Backup ring 22- Wiper ring
T3-7-6
CYLINDERS E135B
Hydraulic cylinder construction

(for boom, arm and bucket cylinders)
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); the O-Ring (10) and the back-up
ring (11) are located between cylinder tube assy (1)
and cylinder head (3).
Operation
If pressurized oil is fed alternatively to the oil inlet

and outlet provided in the cylinder, force acts on the 13 “A” “B”
piston which in turn causes the piston rod (2) to
extend and retract. 15
2
Operation of cylinder with cushion HEAD ROD

SIDE SIDE
CUSHION ON ROD SIDE
The cushion mechanism is provided to prevent the
generation of shock when the moving speed of CUSHION 3
piston (15) is not reduced and strikes cylinder head STROKE
(3). SM2855
An oil in chamber "A" returns to the tank by passing

through paths "B" and "C" at a fixed flow rate in a
intermediate stroke state of pressing bottom side.
Next, in a state of just before stroke end, cushion “D” “B”

ring (13) plunges into path "B".
At this time, an oil in chamber "A" passes clearance
"D" and mouth gap "C", an oil flow volume returning
to tank suddenly drops and the piston part “C”
movement slows down.
SM2043
T3-7-7
E135B CYLINDERS
CUSHION ON HEAD SIDE

This construction is similar to the one of cushion on
rod side. In a state of intermediate stroke pressing F
rod side, an oil in chamber "A" returns to tank by
"A"
passing through path "B" and "C" at a fixed flow rate. E
Next, in a state of just before stroke end, plunger (F)
plunges into path "B". At this time, an oil in chamber
"A" paths clearance "D" and restricted path "C", an
oil flow volume returning to tank (E) suddenly drops
and the piston part movement slows down.
"B" "D"
"C"
"C"
SM2856
T3-7-8
AIR CONDITIONER SYSTEM E135B
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.
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.
T3-8-1
E135B AIR CONDITIONER SYSTEM
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
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
SM0024
T3-8-2
COMPONENT AND CONSTRUCTION
COMPONENT
27
33 30
27-1
40
32
39
27-3 27-4
27-2
35
35-6
35-7
35-1 35-11
35-2 35-5
35-8
34
35-10
35-9
SM2864
Air conditioner group
No. Parts Q.ty No. Parts Q.ty No. Parts Q.ty

27 Air conditioner assy 1 33 Pulley 1 35-7 L hose 1
27-1 Air conditioner unit 1 34 Condenser 1 35-8 L hose: Ø 15 1
27-2 Hose 2 35 Air dryer assy 1 35-9 S tube: Ø 16 1
27-3 Clamp 2 35-1 Receiver dryer 1 35-10 L tube: Ø 8.5 1
27-4 Filter 1 35-2 Bracket 1 35-11 D tube: Ø 12 1
30 Panel assy 1 35-5 S hose: Ø 24 1 39 Filter 1
32 Compressor 1 35-6 D hose 1 40 Solar radiation sensor 1
T3-8-3
CONSTRUCTION
(1) Air conditioner unit
48
49
46 44 47
31
42 31
41
50
3 1
45 1
32 43
1 A
39
37
38
36
40
B
2
33
SM2865
Air conditioner unit (1/2)
T3-8-4
1 1 31 14 16
6
1
5
15
1 31
62
1 3
1 1
D
E 4
7
1
A
28 1 1 1
27
1
20 13
C 26
60
11
29
24 23
22
21
23
24
82
51 83
54 79
63
9
78 C 84 61
17 E
18
D
31
B
10
19
12
25
1
3
31
77
SM2866
Air conditioner unit (2/2)
T3-8-5
No. Parts Q.ty No. Parts Q.ty No. Parts Q.ty

1 Screw M5×16 23 19 Relay 2 40 KK-box lower packing 1
2 Main harness 1 20 Evaporator 1 41 Vent lever 1
3 MA air mix 3 21 Expansion valve 1 42 Face lever 1
4 Blower controller 1 22 O-ring 1 43 Foot joint lever 1
5 Upper casing 1 23 O-ring 1 44 MA mode lever 1
6 Air mix door 1 24 Screw M5×40 2 45 Foot lever 1
7 Air mix lever 1 25 Thermistor 1 46 Face lever cam 1
8 Lower casing 1 26 Thermistor holder 1 47 Vent lever cam 1
9 Air mix door sub 1 27 Heater core 1 48 Face rod 1
10 Air mix lever sub 1 28 Pipe holder 1 49 Vent rod 1
11 Blower 1 29 Thermistor 1 50 Foot rod 1
12 Lever MA air mix 1 31 Screw M4×30 9 52 Inner air filter 1
13 Intake door 1 32 Upper casing 1 55 Screw M6×25 10
14 MA intake lever 1 33 Lower casing 1 56 Screw M8×25 10
15 Intake lever 1 36 Foot door 1 59 Evaporator packing 1
16 Intake rod 1 37 Vent door 1 60 Casing packing A 1
17 Air mix rod 1 38 Face door 1 61 Casing packing B 1
18 Air mix rod sub 1 39 KK box upper packing 1
Receiver dryer
1 - Pressure switch
2 - Sight glass
A 2 B
3 - Desiccant
4 - Suction pipe
5 - Filter
6 - Receiver tank
A - Refrigerant INLET
B - Refrigerant OUTLET
2 -M6
1
3
4
SM0037
T3-8-6
PIPING
Air conditioner
JAM NUT FOR
40 TENSION PULLEY T=46.1 (33)
30
D
27
A
L
B
25
C
25 E
26
53
4
INITIAL BELT TENSION
When the belt is pushed by the
force of 23N, adjust the
l part
deflection of L partto
tobe
be3mm.
3mm.
26
53
58 69 61
62
NOTE 66
1. Apply oil for refrigerant R134a to the
33
O-rings of all air-conditioner hose fittings. 16
2. Refrigerant volume : 900r50g
3. T : Tightening torque Nm (lbf.ft) 33
6
60 33
22 9
10
32
A B
SM2867
Air conditioner piping (1/2)
T3-8-7
53
12
8 26
8 65 13
25
63 2
1 1
2 5
54 X
5
53 51
52 50
55 5 64 53
8 67
24
53
X
15
39
C D
3
23
35
8 59
23
17
25
14
19
68
34
56
57
E
SM2868
Air conditioner piping (2/2)
T3-8-8
Air conditioner
Nm (lbf·ft) Nm (lbf·ft)
1 Hose: L = 2700 1 46.1 (34.0) 33 Pulley assy 1
2 Hose: L = 2800 1 34 Condenser 1
3 Bracket 1 35 Air dryer assy 1
4 V-belt 1 39 Filter 1
3.92 ~ 4.9
5 Clip 4 40 Solar radiation sensor 1
(2.9 ~ 3.6)
6 Sems bolt: M10x25 4 50 Connector 1
7 Sems bolt: M6x20 2 51 Connector 1
8 Sems bolt: M8x20 7 52 Clip 1
9 Capscrew: M8x100 4 46.1 (34.0) 53 Sems bolt: M10x20 5
10 Washer 4 54 Grommet 1
12 Tube for heater: L = 2400 1 55 Grommet 1
13 Tube for heater: L = 2400 1 4.4 (3.2) 56 Capscrew: M6x50 4
14 Tube for D hose: L = 2600 1 57 Washer 4
15 Tube for S hose: L = 2950 1 59 Bracket 1
16 Bracket 1 60 Pulley 1
17 Tube for L hose: L = 900 1 46.1 (34.0) 61 Capscrew: M10x25 1
19 Tube for L hose: L = 300 1 62 Washer 1
46.1 (34.0) 22 Sems bolt: M10x45 4 63 Bracket 1
23.5 (17.3) 23 Sems bolt: M8x25 6 64 Pulley 1
24 Clip 1 46.1 (34.0) 65 Capscrew: M10x25 1
25 Clip 10 66 Nut 2
26 Clip 3 67 Bracket 1
27 Air conditioner assy 1 68 Bracket 1
30 Panel 1 70 Clip 1
32 Compressor assy 1
1 - Air conditioner assy

2 3 4 5 2 - Unit connection bolt
1 3 - Unit connection tube assy
S
6 4 - Compressor connection bolt
D
5 - S Tube
7 6 - D Hose
7 - Compressor assy
8 8 - Receiver connection bolt
15 9 - Condenser
14 10 - L Hose
11 - Receiver dryer mounting bracket
12 - Receiver dryer
13 - L Hose
14 - L Tube
13 12 11 10 9 15 - S Hose
SM2869
T3-8-9
AIR DRYER ASSY
B
A
C
8 5
A
4 6 5
10 6
4 11
3
8
2
1 7
B C
SM2870
Air dryer assy

Tightening torque Tightening torque
No. Parts Q’ty No. Parts Q’ty
Nm (lbf·ft) Nm (lbf·ft)
1 Receiver dryer 1 7 L hose 1
2 Bracket 8 L hose 1
20 ~ 25 (14.8 ~ 18.4) 3 Capscrew 2 9 S tube 1
8 ~ 12 (5.9 ~ 8.9) 4 Capscrew 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1
T3-8-10
FUNCTION
Mechanism of cooling circuit
MECHANISM OF COOLING
In the cooling process, the refrigerant that flows HFC-134a (R134a)
through the cooling circuit changes its phases from CH2FCF3
Chemical formula
liquid to gas and vice versa during which process
heat is transferred from the low temperature part Molecular weight 102.03
(compartment) to the high temperature part (outside Boiling point –26.19 °C
of the vehicle). Critical temperature 101.14 °C
Critical pressure 4.065 MPa
Kind of Refrigerant Critical density 511 kg/m3
Many kinds of refrigerants that change in that way Density of saturated liquid (25 °C) 1206 kg/m3
are available, but the following requirements are
Specific volume of saturated
needed for use in such applications: vapor (25 °C) 0.0310 m3/kg
• Latent heat of vaporization (heat of vaporization)
Latent heat of vaporization (0 °C) 197.5 kJ/kg
is large.
Flammability Non flammable
• It is easy to liquefy (condense). (It does not
require very high pressure for condensation.) Ozone destruction coefficient 0
• 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.)
• 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.
Table shows the principal characteristics of the P (MPa)
R134a refrigerant that is used in this machine. 4
R134a
CHARACTERISTICS OF REFRIGERANT 3
In general, the fluid (general term of gas and liquid)
has the following qualities: LIQUID
2
1. As a gas under certain pressure is cooled down,
it begins to condensate at a certain temperature GAS
to take a liquid state. The temperature at which 1
condensation begins is unique to each
substance (fluid) at a given pressure. The
temperature determined by a given pressure is 0 15 18 35 50 T (°C)
called saturation temperature. SM0038
T3-8-11
2. Inversely to 1. above, the pressure at which a

gas condenses for a temperature is
determined. This pressure is called saturation
1
pressure.
Figure beside illustrates the relationships 2
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 3 9
righthand side of the curve in figure, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper 6
lefthand side of the curve, the refrigerant takes
a liquid state.
Let us think of a case where an air-conditioner 4 5
is operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
7 8
heat from the air of the compartment. In order
to cool the inside of the compartment down to
25 °C, the refrigerant must transform
(evaporate) from a liquid to a gaseous state at
SM0039
a lower temperature. It can be seen from the
figure that R134a under a pressure above the
1 - Inside of the compartment (cab)
atmospheric pressure is capable of cooling the
2 - Evaporator
inside of the compartment sufficiently. (If a
3 - Blower
refrigerant that requires a pressure below the 4 - Compressor
atmospheric pressure to cool it to a required 5 - Cooling fan
temperature is used, air is mixed into the 6 - Inside of engine room
circuits, thereby deteriorating the performance 7 - Condenser
of the cooling unit.) In the process in which 8 - Receiver dryer
gaseous refrigerant is brought back to a liquid 9 - Expansion valve
state, the refrigerant is cooled and condensed
by the outer air exceeding 35 °C.
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 Mpa, as
seen from the figure.
Cooling circuit
The figure illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air
of the compartment is the evaporator. The object air
is cooled off by utilizing the fact that the refrigerant
takes heat off the surrounding area as evaporation
heat as it evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant takes
place is the evaporator, cooled air is constantly
delivered to the circumference of the evaporator by
the blower fan. In the meantime, liquid refrigerant
(slightly wet vaporized refrigerant) is fed into the
evaporator, when "cooling" effect is attained. For
instance, in order to cool the air to 15 °C, the
refrigerant can not absorb evaporation heat from the
air unless it evaporates at a temperature lower that Furthermore, the cooling effect deteriorates unless
15 °C. For that purpose, it can be seen from the the feed rate of the refrigerant is controlled so that
figure that the pressure of the refrigerant in the all of the refrigerant supplied to the evaporator
evaporator must be less than 0.51 MPa. vaporizes and turns into dry vapor.
T3-8-12
Consequently, the cooling circuit is so constructed

that the evaporator can cool down an object (air in
this case) sufficiently (i.e. so as to decrease the
pressure in the evaporator) and that an adequate
amount of refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator
is held low by the throttling action of the expansion
valve and the suction action of the compressor. The
compressor acts as a pump that allows the
refrigerant to circulate. The compressive action of
the compressor and the heat exchange (heat
radiation) action of the condenser transform the
refrigerant in a dry vapor state back to a liquid state.
Component parts
EVAPORATOR
The evaporator is an important heat exchanger that
absorbs the heat of the compartment air (object) by 1
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air. 2
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if the
water drops freeze. Therefore, how to discharge
water is an important point. 3
The amount of refrigerant supplied to the evaporator
is controlled by the expansion valve which is
described in the following. In order to attain proper
control, it is necessary to reduce the pressure drop 4
of the refrigerant of the evaporator. Accordingly, SM0026
reducing the pressure drop is one element that 1 - Evaporator
makes the evaporator attain its full performances. 2 - O-ring
3 - Expansion valve
EXPANSION VALVE 4 - Socket bolt M5 x 40
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.
T3-8-13
The expansion valve feeds the flowing high-

pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid 1
refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the
refrigerant at the same time.
The figure beside shows how the block type
2
expansion valve is constructed. The temperature
sensing part is provided in the shaft of the
3
expansion valve to directly detect the refrigerant
temperature at the outlet of the evaporator. 4
The diaphragm contains R134a in saturated state.
The pressure in the diaphragm changes according
to the temperature detected by the sensor. The
change in the pressure causes the force acting upon
the diaphragm to vary accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side reduces 5
the pressure abruptly as it passes through the valve
(throttling action). On that occasion, part of the 6
refrigerant evaporates by the very heat of the
refrigerant and cooled off. The result is that low- 7
pressure low-temperature damp refrigerant vapor is
fed to the evaporator. SM0040
The opening of the valve is determined by the 1 - Diaphragm

equilibrium between the pressure (low) of the 2 - Evaporator side
evaporator side, the action of the adjust spring and 3 - Refrigerant outlet
the pressing force of the diaphragm (the 4 - Shaft
5 - Refrigerant inlet
temperature of the refrigerant at the outlet of the
6 - Ball valve
evaporator to be sensed by the thermowell). The
7 - Spring
feed rate is controlled automatically so that under
the pressure in the evaporator, the refrigerant is
properly overheated (3 ~ 8 degrees) and goes out of
the evaporator. This action is carried out by sensing
the refrigerant temperature at the outlet of the
evaporator as against the inlet pressure of the
evaporator and consequently controlling the feed
rate of the refrigerant.
This means that if the refrigerant pressure drop in
the evaporator is excessive, it is difficult to control
the overheating or the feed rate of the refrigerant.
For this reason, the smaller the pressure drop of the
evaporator, the better.
The expansion valve senses the pressure and the
temperature at the outlet of the evaporator and
controls the overheating of the refrigerant and the SM0041
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block
type expansion valve.
T3-8-14
COMPRESSOR
The compressor performs the following three
functions in the cooling circuit: 1
1. Suction action
2. Pumping action
3. Compressive action
2
1. The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2. The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling. 3
3. The compressive action, as combined with the
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the SM0042
pressure increases. For instance, it becomes 1 - D Hose

possible to cool down the refrigerant by the use 2 - S Hose
of an outer air of 35 °C and liquefy it. The 3 - Compressor
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only
for a short period, the refrigerant hardly
exchanges heat with outer air. That is to say, it
takes a near form of thermally insulated
compression, so that the refrigerant discharged
by the compressor turns into high-temperature
high-pressure vapor and is delivered to the
condenser.
CONDENSER
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by
the use of outer air and condenses the refrigerant.
The direction in which heat moves is from the
refrigerant to air, the opposite to the case of the
evaporator. Fins are equipped on the outer air side
to improve thermal transfer. If the refrigerant is not
cooled well by the condenser, the air in the
compartment can not be cooled sufficiently by the
evaporator. For that purpose, it is necessary to
secure ventilation required for the cooling of the
refrigerant.
SM2871
T3-8-15
RECEIVER DRYER
1. Receiver Tank
On the air-conditioner, the revolution of the 1 2
compressor varies greatly which causes the
proper flow of refrigerant in the cooling circuit to 3
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it
when the cooling circuit needs much
refrigerant. The receiver tank also stores an
4
extra amount of refrigerant to be used for filling
balance and supplement small amounts of
leakage of the refrigerant through penetration
into rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or clogs 5
the circuit as the water freezes in the expansion
valve. It is desirable that the amount of water 6
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for
7
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the 8
only means of confirming the inside of the
circuit visually.
4. Filter
5. Pressure Switch
This machine employs pressure switches of
high/low pressure type. SM0043
The pressure switch protects the circuit by 1 - Refrigerant inlet
cutting off the power supply to the compressor 2 - Sight glass
when high pressure increases abnormally high 3 - Refrigerant outlet
(more than 3.14 MPa). 4 - Pressure switch
The pressure switch also detects the leakage of 5 - Desiccant
refrigerant by cutting the power supply to the 6 - Suction pipe
7 - Filter
compressor when the pressure of the circuit
8 - Receiver tank
falls below 0.196 MPa.
T3-8-16
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS TO BE EXERCISED IN
OPERATION
1. Special Refrigerator Oil
Unit: N·m (lbf·ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils TIGHTENING
PIPE FASTENING PART
TORQUE
other than SP20 may not be used. Since SP20
tends to absorb moisture and may corrode D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
paint and resin, the following points must be D hose and condenser 19.6~24.5 (14~18)
noted:
L hose and condenser 11.8~14.7 (8.7~11)
1) Do not keep open all pipe connections on a
new compressor and the component parts L hose and receiver dyer (M6 bolt) 7.8~11.8 (5.8~8.7)
of the installed refrigeration circuit L hose and air-conditioner unit 11.8~14.7 (8.7~11)
(Remove valves and caps at the pipe
openings of the compressor, just before S hose and air-conditioner unit 29.4~34.3 (22~25)
connecting pipes. If you have removed a Expansion valve 1.96~2.45 (1.4~1.8)
pipe joint for repair, put a cap to both ports
immediately.)
2) Use care so SP20 does not adhere to the
painted surface and resin parts. In case Unit: N·m (lbf·ft)
SP20 has adhered to such surfaces, wipe it TIGHTENING
off immediately. SCREW SIZE
TORQUE
2. The receiver dryer is filled with desiccant to N4, T4 machine screw, M4 0.78~1.18 (0.58~0.87
absorb moisture in the circuit. Therefore,
remove the valve at the pipe port immediately N5, T5 machine screw, M5 1.96~2.45 (1.4~1.8)
before connecting pipes. M6 (mounting part of L hose
7.85~11.8 (5.8~8.7)
joint)
3. Tightening Torque
M6 (except mounting part of L
1) Pipe Joints 9.8~11.8 (7.2~8.7)
hose joint)
When connecting pipe joints, coat the O-ring
M8 (mounting part of S,D hose
with special oil (SP20) and fasten to the 19.6~24.5 (14~18)
joints)
tightening torque indicated in the table,
using a double spanner. M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
2) Screws and Bolts M8 (other than those mentioned
11.8~15.7 (8.7~12)
Fasten to the tightening torque indicated in above)
the table M10 39.2~53.9 (29~40)
4. 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 REPLACED PARTS AMOUNT TO BE FILLED IN
service life will occur. If the oil volume is large, EVAPORATOR 40 cc (2.4cu·in)
the cooling ability will be deteriorated.
Once the air-conditioner is operated, part of the CONDENSER 40 cc (2.4cu·in)
oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right Drain out the volume of oil left in
Table, adjust the oil level to that of table. COMPRESSOR the compressor to be replaced,
from the new compressor.
5. Before performing operation, stop the engine
and turn off all power supplies to the equipment
related to the air-conditioner. RECEIVER DRYER 20 cc (1.2cu·in)
6. After the operation is over, confirm that all faults HOSES 20 cc (1.2cu·in)
have been repaired completely, by operating
the air-conditioner.
T3-8-17
DISASSEMBLY AND ASSEMBLY OF UNIT

1. Removing inner air filter
Slide the inner air filter (1) leftward and remove 7 2
it from the unit (2).
SM0027
2. Removing selector box

5 3
Remove 6 plus screws (3), remove connector 8
(4) connected to the mode actuator (5) on mode
selector box (6), and separate the mode
selector box from the unit (2).
3. Removing main harness

4
Pull out 3 harness clamps (7) from the unit (2),
and disconnect all connected connectors and 6 2
remove harness (8) on the body from the unit
(2).
SM0028
4. Removing upper unit case

1) Remove air MIX rod (9) and air MIX rod sub
(10) from air MIX lever (11).
2) Remove 12 plus screws (12) which are used
to install the upper and lower unit casings
(2a).
Pull out the upper unit casing (2b) upward 11 12
giving attention to the thermistor harness so
as not to be caught by the casing.
2b
10
2a
SM0029
T3-8-18
5. Replacing blower controller

1) Remove 2 plus screws (14) and remove the 2b
blower controller (15) from the upper unit
casing (2b).
2) Install new blower controller by the reverse
procedure of removal.
* Do not disassemble the blower controller.
14 15
SM0030
6. Removing heater core

16 17
1) After draining the coolant, remove heater
hos e from the heater core (16). 18
2) Remove 1 plus screw (17), and remove pipe 20
clam (18) which is used to secure the heater 19
core and then remove the heater core (16)
from the lower unit casing (2a).
3) Install it by the reverse procedure of
removal.
7. Replacing blower motor

1) Disconnect connector which is connected to
the blower motor and remove the blower
motor (19) from the lower unit casing (2a).
* Do not remove the fan from the blower

motor.
2a SM0031
2) Install it by the reverse procedure of

removal.
8. Replacing evaporator and expansion valve

1) Take the evaporator (20) with expansion
valve off from the lower casing. 20
2) Remove evaporator sensor (21) with sensor
holder (22) from the removed evaporator
(20).
22
3) Insert the sensor holder into the new
evaporator at the position shown in Fig. 105mm
(4.1 inch)
SM0032 and install the evaporator sensor
(21) again.
A - 11th rows of fin 21
SM0032
T3-8-19
4) Remove 2 socket bolts M5×40 (23) with

Allen wrench (4 mm) and remove the
expansion valve from the evaporator (20). 20
5) Fit O-ring (24) (NF O-ring 5/8 and 1/2 one
each) to new evaporator.
A
* When assembling again, fit O-ring paying
attention so as not to be caught with others.
(Socket bolt M5×40 (2 pcs.) Tightening torque:
24
6.9N•m (5.1lbf•ft)
* Do not apply undue force to pipe of evaporator

outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator.
Moreover, when tube assembly (27-6) (see
Pag. T3-8-3 Fig. SM0025) connected with 25
expansion valve (25) is disconnected from
expansion valve, similar careful work is
necessary.
23
9. Replacing motor actuator SM0033
1) Replacing mode actuator

a) Remove connector (26) connected to the 29
motor actuator (27).
28
b) Remove FACE rod (28) and VENT rod
(29) which is used to connect MA mode 30 26
lever (30) and mode cam from the
holder. 31
c) Remove 3 plus screws (31) and remove
the motor actuator (27) with lever MA 27
mode from the unit.
d) Remove the lever MA mode from the
removed motor actuator, and install it on
new motor actuator by the reverse
2) Replacing air mixing actuator SM0034
a) Remove connector (32) connected to the

motor actuator.
b) Remove rod air MIX (33) which is used to 33
connect the motor actuator (27) and the 36
lever MA air MIX.
c) Remove 3 plus screws (34) and remove
the motor actuator (35) with MA lever air 32
MIX (36) from the unit.
d) Remove the MA lever air MIX from the
removed motor actuator, and install it on
new motor actuator by the reverse
34
35 SM0035
T3-8-20
3) Replacing inner and outer air switching 40

actuator
a) Disconnect connector (37) connected to
the motor actuator (38).
b) Remove intake rod (39) from MA intake 39
41
lever (40).
c) Remove 3 plus screws and remove the
motor actuator (38) with MA intake lever
(40) from the unit. 37
d) Remove the MA intake lever (40) from
the removed motor actuator, and install it
on new motor actuator by the reverse
38
SM0036
T3-8-21
CHARGING REFRIGERANT
PRECAUTIONS TO BE EXERCISED IN OPERATION

1. Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person
familiar with how work is done for handling refrigerant.
WARNING
• 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. -26°C (-15°F)]. Therefore, handle
it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
2. Storage and Transportation

1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a
is filled in the can in a saturated liguefied state, the pressure in the can increases sharply as
temperature rises. The can may blast as the result.
It is for this reason why the can temperature must be kept below 40°C (104°F).
2) For storage, choose a cold dark place not exposed to direct sunlight.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside
pressure to rise and may cause the can to blow out. 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. Also, the inside of the trunk
room may rise to a dangerous temperature level even in the summer time. Use sufficient care,
therefore, taking the above into account.
5) Note that if the can has scratches, 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) Store cans beyond the reach of children.
3. Charging
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the
low pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to
an extent that you do not feel hot when you put your hand in the water.) If the can is put in hot water or
heated by a direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the
gauge manifold in any case.
4. Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the
air-conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components
of the air-conditioner correctly and speedily. Pay full attention to the entry of water and dust.
CAUTION
• Be careful about overcharge of gas.
• Fasten pipes to a specified torque.
T3-8-22
OPERATING PROCEDURE
The change of refrigerant in the air conditioner - The "gas charging procedure" consists in the filing
requires a "vacuum generation procedure" and a the circuit with refrigerant, after applying a
"gas charging procedure". vacuum. the filling of the gas is not only depending
upon the cooling performance of the air
- The "vacuum generation procedure" consists in conditioner, but it influences also the useful
removing moisture from the air conditioner circuit. working life of the circuit components. An
In the event even a small quantity of moisture excessive overloading increases considerably the
remains in the system, it would freeze in the small pressure of the system and damages the cooling
orifices of the expansion valve when in operation. performance. On the contrary, a too low charging,
This causes a clogging of the circuit or the results in an insufficient circulation of lubricant oil
formation of rust, with a series of operational in the compressor, causing the wear of the moving
troubles. prior to filling the circuit with refrigerant, parts of the compressor.
apply the vacuum and cause the boiling and
vaporisation of the moisture. In this manner, WARNING
moisture is eliminated from the system. The gas filling operation involves the handling of
highly compressed gases; it is dangerous to handle
the gas without complying strictly with the relevant
procedures. The procedures and the protections
described in this manual for the filling of refrigerant
gas must be strictly adhered to.
Vacuum making operatio Refrigerant filling operation
More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in

making making air-tightness refrigerant gas leak refrigerant
Lower than
-750m mHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1 MPa
SM0194
T3-8-23
PROCEDURE FOR THE GENERATION

OF VACUUM
1. Close high pressure valve (3) and low pressure
valve (1) on gauge manifold (2).
2. Connect the red charging pipe (5) and the blue
one (6) to compressor service valves (8) "D" 2
and "S" as described in the figure. 1 3
WARNING 6 5
Never exchange by mistake the high pressure pipe
with the low pressure pipe when connecting them.
4
Install the pipe firmly until a click noise is heard.
Connect the quick release joint of the charging pipe D
with the service valve of the compressor. If the
charging pipe is connected in the opposite direction,
mini-valve (9) of the compressor fails to open. S
3. Connect the central valve of the gauge manifold

with charging pipe (4) of the vacuum pump (7). 8 7
SM0016
IMPORTANT: some types of manifold are not
equipped with an open/close valve in the central
part.
4. Open high pressure valve (3) and low pressure

valve (1) of gauge manifold (2).
5. Start the vacuum pump and let it operate 30
minutes to generate the vacuum.
6. At the end of the vacuum phase for the
prescribed time (vacuum value: lower than 750
mm Hg) close the high pressure valve (3) and
the low pressure valve (1) of the gauge D S
manifold (2).
7. Cut-off the vacuum pump.
8. With the high pressure valve (3) and the low
pressure valve (1) closed, check, after five 8 9
minutes, that the pressure gauge dial does not
return to zero. SM0017
NOTE: in the event the pressure gauge moves

toward zero, this indicates the presence of a
leakage. Tighten again the connecting joints and
apply the vacuum again, verifying that there are no
further leakages.
T3-8-24
PROCEDURE FOR THE CHARGING OF THE GAS

1. After applying the vacuum repeatedly,
exchange charging pipe (4) of the gauge 2
manifold (2), from the vacuum pump to the
service can (9). 11
2. Open the valve of service can (10). Close the

high and low pressure valves of the gauge
manifold. Press central bleeding valve (11) of 4
the side service opening on the low pressure
side of the gauge manifold using a screwdriver
in order to let out the air in the charging pipe by 10
the pressure of the refrigerant. Proceed with
this operation until a whistle is heard coming 9
from the bleeder.
SM0018
3. Open high pressure valve (3) of the gauge

manifold and charge the refrigerant to a
pressure of 0.1 MPa.
Once the charge is completed, close high
pressure valve (3) of the gauge manifold and 1 3
service valve (10).
WARNING
Never start operating the compressor during this D
work. The starting of the compressor causes the
blowing of the service can.
10
4. Check that there are no leakages of gas in the S

cycle, using a gas leakage tester. Retighten
and eliminate all points of leakage.
SM0019
IMPORTANT: to check for gas leakages, always

use a tester for R134a. Do not use one for flon gas
service as it provides poor sensitivity.
5. Make sure that high pressure valve (3) and low

pressure valve (1) of the manifold and service
valve can (10) are closed.
6. Start the engine running it at 1500 ± 100 rpm
and open fully the door and windows of the cab.
7. Activate the air conditioner, setting it at
maximum ventilation speed and at lowest
temperature.
8. During the charging of the gas, set the discharge
pressure of the compressor to 1.4 ~ 1.6 MPa.
T3-8-25
9. Open low pressure valve (1) of the gauge

manifold and service valve can (10) and fill with 12
refrigerant until all air bubbles in sight window
(12) of the dryer disappear.
Total quantity of gas to be charged: 900 ± 50 g.
10. Once the refrigerant change operation is
terminated, close low pressure valve (1) of the
gauge manifold and the service valve can (10).
CAUTION
Do not open the high pressure valve of the manifold
under any circumstance nor place the service can
upside down.
SM2872
11. The level of refrigerant is correct only once the

air conditioner is activated and through the
inspection sight window, just a few air bubbles
are seen and, afterward, a white colour slightly
milky is seen.
IMPORTANT: when the air conditioner operates

with an insufficient quantity of refrigerant, this has a
negative effect on the compressor; on the contrary,
when the refrigerant is charged with an excessive
quantity, the cooling performance is lost. Also, the
pressure of the system increases abnormally.
12. Disassemble the manifold disconnecting the

charging pipes from the compressor, as
indicated here below.
a. Press the quick release coupling of the
charging pipe on the low pressure side
against the service valve of the compressor
so that the refrigerant doers not escape
leaking when loosening the connection. As
soon as the nut has been removed,
disconnect the charging pipe from the
service valve.
b. Wait for the pressure in the high pressure
site to decrease, indicated on the pressure
gauge, to a value of 1.0 MPa.
A: Appropriate quantity of refrigerant
c. Disconnect the red charging pipe from the B: The system is overloaded
high pressure side, in the same manner as C: Insufficient quantity of refrigerant
described for the low pressure.
T3-8-26
ELECTRIC CIRCUIT
WIRING DIAGRAM AND CONNECTORS

Wiring Diagram
(A)(B)
2
(C)
12 3
(N)
(R) (D)
155(BR) 150(BP)
4
FUSE 20A 15 85E(WB)
18(RG) (E)
25(WG)
FUSE 5A
13 26(RL)
FUSE 15A
E24(B) 5
FUSE 5A
(Q) (M)
FUSE BOX
(L) (F)
6
(P) 11
(K)
10 (G)
14
7
9
(J) (H)
8
SM0044
(I)
1 - CCU(Operation Panel + Controller) 9 - Blower AMP

2 - Evaporator Sensor 10 - Blower Motor
3 - Air Inlet Sensor 11 - Blower Off Relay
4 - Solar radiation Sensor 12 - Pressure Switch
5 - Motor Actuator (for air mix) 13 - Main Key Switch
6 - Motor Actuator (for Mode) 14 - Compressor
7 - Motor Actuator (Rec/Fresh) 15 - Light Switch
8 - Compressor Relay
T3-8-27
Connectors
(A) JAE (B) JAE

HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000
(C) MAKER : YAZAKI CORP.

HOUSING No. : 7123-2228
(D) MAKER : YAZAKI CORP. (E) NIPPON AMP KK 174056-2
HOUSING No. : 7123-2228 TERMINAL : 175062-1
TERMINAL : 17111 TERMINAL : 17111
(F) JAE IL-AG5-7S-S3C1 (G) JAE IL-AG5-7S-S3C1 (H) JAE IL-AG5-7S-S3C1

TERMINAL : AG5-C1-5000 TERMINAL : AG5-C1-5000 TERMINAL : AG5-C1-5000
(I) MAKER : YAZAKI CORP. (J) MAKER : YAZAKI CORP. (K) MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249 HOUSING No. : 7123-2237 HOUSING No. : 7123-6020
TERMINAL : 17111 TERMINAL : 17111 TERMINAL : 7116-2871
(M) MAKER : YAZAKI CORP. (N) MAKER : YAZAKI CORP.

(L) MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40
HOUSING No. : 7123-2249 REAR HOLDER : 7157-6260-30
TERMINAL : 17111 TERMINAL : 7114-2871 TERMINAL : 7116-2871
26 25 85E
150 E24 18
(P) (R) MAKER : SUMITOMO

MAKER : YAZAKI CORP. (Q) NIPPON AMP KK HOUSING No. : 6189-0094
7120-8019 170889-1 HARNESS SEAL : 7160-8234
CP3.96MA 170003-5 TERMINAL : 1500-0110
150 155
SM0045
JAE : JAPAN AVIATION ELECTRONICS

INDUSTRY, LTD.
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
T3-8-28
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION

1. Control panel and control unit
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 (Inner and outer air flow select,
air mix), fan motor and compressor on the
output side. And the self-diagnosis
performance is provided to facilitate the trouble
shooting.
2. Blower controller (TKS-B215A1)
The power transistor shifts the fan motor into
variable speed with base current from the SM0047
control unit.
TERMINAL
NO. CONTINUITY
1 2 3 B
CONTINUED
+ -
(4.7 k ±5%)
- + NOT CONTINUED
TESTER CONTINUED (DIODE
PARALLEL AND
+ -
FORWARD DIRECTION Lg
FLOW) L
In normal operation
1) Disconnect the connector of blower
amplifier.
2) Check continuity between terminals on the 㨫㨫
blower amplifier side.
* The installing position is provided on the

left side of air-con unit.
SM0048
T3-8-29
3. 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. A
When the blower OFF relay turns on, the A
source voltage is supplied to the blower
motor and the blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control.
SM0049
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay
because this relay has polarity.
5. Inspection: Inspect the continuity
between 3 and 4 according to the
conditions mentioned below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-
2:
Not continued
4. Air mix actuator
Air mix actuator is installed at the center of air-
con unit, and opens and closes air mix damper
through the link.
The air mix actuator contains potentiometer
which is switched by being coupled to the shaft
of actuator.
When the target air mix door position is

determined through the temperature control
switch, the control unit reads the level of
CONTROL AMPLIFIER MOTOR ACTUATOR
potentiometer of the actuator, and determines
the rotating direction of motor in either normal LIMITER
COOL
rotation or reverse rotation. Then as the motor POTENTIO 5V
POTENTIO
rotates, the contact point is moved, and when POTENTIO GND
the contact point is detached or the output

signal of control unit turns OFF, the motor stops HOT
rotating.
SM0050
T3-8-30
5. The actuator for inner and outer

The actuator for inner and outer air flow select
is installed on the blower intake unit, and opens
and closes inner and outer air damper through
the link. The actuator for inner and outer air flow
select contains position detection switch which
is switched with the movement of shaft of the
actuator.
When the inner and outer damper position is
set by the inner and outer switch on the control
panel, the control unit reads the signal of the AMPLIFIER MOTOR ACTUATOR
position detection switch in the actuator and

determines the rotation direction of motor in
either normal rotation or reverse rotation. Then
as the motor rotates, the position detection
INNER AIR SIDE
switch also rotates and makes it stop at the set
position of the inner and outer air damper. OUTER AIR SIDE
LIMITER
6. Evaporator sensor
This sensor is used to control the evaporator SM0051
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 inspecting items
(Specification)
Terminal resistance:
at 0 degree C: 7.2 k
at 25 degree C: 2.2k
7. Dual pressure switch SM0052
This dual pressure switch is attached on L-hose

and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from
possible failure at the time when abnormal
pressure was generated on the high pressure
side.
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)
SM0053
ON
OFF
0.20MPa 3.14MPa
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
8. Solar radiation sensor

This solar radiation sensor, which is used to
correct the solar radiation to the auto air
conditioner detects the strength and solar
orientation of sunbeam after transforming them
into current by means of photo diode.
Inspection: Check for the continuity between
terminals.
SM0054
T3-8-31
TROUBLESHOOTING
Note : M/A is motor
Air temperature does not fall. actuator
* is any of the
numbers 0 ~ 9
If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set
temp. display of the panel.
NO YES
"HL.*" is shown on the set temp. display • Connector for air mix M/A is disconnected or in
of the panel poor contact.
• Air mix M/A is failed.
NO YES • Main harness shows poor continuity.
A snow mark ( ) on the A snow mark ( ) on

panel is flashing. panel is flashing. Inspect and correct or replace parts.
NO YES
• Inner air sensor or harness is disconnected or shorted • Both inner air sensor and evaporation
• Inner air sensor connector is disconnected or in poor sensor are disconnected or shorted.
contact. • Controller failed.
See section monitor mode. See section monitor mode.
Inspect and correct or replace parts.

A
NO YES
Blowout temp. falls if temp. is set at 18.0 °C • Evaporation sensor connector is

(64.4 °F) (COOLMAX) and the blowout mode is disconnected or in poor contact.
changed to vent mode. • Evaporation sensor is disconnected or
shorted.
NO YES Inspect and correct or replace parts.
Air mix damper is in Cool air flowing into inner

COOLMAX. air sensor Inspect and correct or replace parts.
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch on
eliminate cause, correct and and off. Inspect and correct Controller is faulty Inspect duct or
measure operating force. electric circuits. or inner air sensor eliminate cause for
(less than 14.7N: OK) is faulty. cool air intrusion.
Refer to Troubleshooting for
refrigeration cycle.
Inspect and replace.
NO YES
• Inspect, correct or replace M/A lever M/A failed or controller

link. is out of order.
• After cleaning lever link, apply grease.
Replace.
T3-8-32
Air temperature does not rise.

Note : * is any of the
numbers 0 ~ 9
HL.E is shown on the set temp. display of

the panel.
NO YES
"HL.*" is shown on the set temp. display • Connector for air mix M/A is disconnected or in
of the panel. poor contact.
• Air mix M/A is failed.
NO YES • Main harness shows poor continuity.
• Inner air sensor or harness is disconnected or

shorted Inspect and correct or replace parts.
• Inner air sensor connector is disconnected or in
poor contact.
See section monitor mode.
NO YES
NO YES
Blowout temp. rises at blowout
mode if temp. is set at HOT MAX
32.0 °C (64.4 °F)
NO YES
Air mix damper is in Warm air is flowing into

HOT MAX inner air sensor.
NO YES
NO YES
If M/A action is at stop, Inspect warm water piping.
eliminate cause, correct and Controller or inner Inspect duct or
measure operating force. air sensor is out of eliminate causes
(less than 14.7N: OK) order. for warm air entry.
Inspect and replace.
NO YES
• Inspect, correct or replace M/A lever M/A failed or controller

link. is out of order.
• Clean lever link and apply grease.
Replace.
T3-8-33
Blower motor does not run.
Note 1) At air flow HI, battery voltage acts across

both terminals (+) and (-) of blower motor.
NO YES
Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.
Note 2) Inspect blower motor relay. Blower Approx. 10V acts across light green wire
motor rotates if white / red wire and and grounding of blower amplifier.
red wire of blower motor relay are
direct connected.
NO YES
NO YES
Controller is out of order. Remove blower amplifier and check
Replace. for continuity across light green wire
Wire harness is faulty. and black wires; you get continuity.
Inspect and correct or
replace. NO YES
Eliminate cause Inspect and

Battery voltage acts across white / red and replace blower repair harness.
wire and body of blower motor relay. amplifier.
NO YES
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
Replace relay. Inspect and correct harness or

replace controller.
Note 1) Measure with connector set.

Note 2) Always turn off air-conditioner, starter key switch and light switch before work.
T3-8-34
Blower motor speed does not change.
CASE (1)
"HL.*" is shown on the set temp. display of Note) * is any of the
the panel. numbers 0 ~ 9.
NO YES
Replace blower amplifier • Inner air sensor or harness is disconnected or

controller. shorted.
• Inner air sensor connector is disconnected or in
poor contact.
See section monitor mode.
CASE (2)
Does not blower motor speed change
because the setting mode is other face
mode?
NO YES
Is door or front window open? See CASE (1).
NO YES
The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch
T3-8-35
Magnet clutch does not engage.
Snow mark ( ) lights if A/C

switch is pressed.
NO YES
Snow mark ( ) flickers and Voltage acts upon clutch.

E is shown on panel display. NO YES
To A On page T8-3-28. Voltage is applied to pressure switch Clutch faulty.

harness.
NO YES
Voltage acts across white / green wire Pressure switch is faulty or refrigerant
and Ground (Black) connector gas is under charged or overcharged.
connected to excavator.
Refer to troubleshooting for

NO YES
refrigeration cycle.
Inspect clutch fuses. Inspect air-conditioner
harness. No fault.
NO YES
Replace harness. Replace controller.
Inner air and outer air do not change
Inner / outer air mode display on

operation panel is flickering.
NO YES
M/A lever includes foreign Connector of inner/outer air M/A is

matter or is broken. disconnected or in poor contact. Or
M/A failed or main harness failed.
NO YES
Inspect or replace.
M/A failed Remove foreign matter
and replace parts.
Replace
T3-8-36
Trouble with refrigeration cycle.
Both high and low pressures are lower.
Air bubbles are seen in sight glass.
NO YES
Cooling does not work if run at high speed. Oil comes out from piping and parts.
NO YES NO YES
Expansion valve is Expansion valve is frozen Natural leak from hose. Gas leaks from pipe
clogged or maladjusted. or intruded by water. joints and parts.
Adjust or replace After making vacuum, Charge gas. Retighten or replace

expansion valve. refill refrigerant and parts.
replace receiver.
Low pressure is higher.
NO YES
Air bubbles are seen in sight glass. High pressure is lower.
Compressor cylinder does not get hot. Compressor cylinder gets very hot.
Expansion valve is maladjusted. (too much open) Compressor does not discharge well.
Replace expansion valve. Replace compressor
High pressure is lower.
Air bubbles are seen in sight glass.
NO YES
High pressure gets lower slowly. Condenser is fouled or clogged.
YES NO
High pressure circuit before receiver is Clean condenser. Air bubbles are hard to go out even if
clogged up. water is poured on condenser.
Remove clogging or Air is mixed. Make vacuum

replace parts. and refill refrigerant.
T3-8-37
Modes do not change.
Mode display (Mark of person) on

operating panel is flickering.
NO YES
M/A rod does not disengage. Mode M/A connector is disconnected

or in poor contact or M/A failed or
NO YES main harness is faulty.
Repair. Each damper lever does not
disengage. Inspect or replace.
NO YES
Repair. When rod is removed and cam is operated

by hand, it is heavy. (more than 19.6N.).
NO YES
M/A or controller is out of order. • Cam or damper shaft includes foreign

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

• Clean cam and apply new grease.
T3-8-38
SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL
The failure of motor actuator and each sensor can be identified on the display of panel.
POSITION OF INDICATION FOR FAILURE.
SM0055
The error is indicated on 3 digits segment.

EXPLANATION OF INDICATION FOR FAILURE.
Failure of Motor Actuator
1. HL.E is indicated on 3 digits segment.
Check harness or connector to motor actuator for the air

mix damper for disconnection.
SM0056
2. MODE is flickering.
Check harness or connector to motor actuator for the air

outlet damper for disconnection.
SM0057
3. R/F is flickering.
Check harness or connector to motor actuator for the
inner and outer air damper for disconnection.
Note: The above indication and flickering does not
function if the harness and connector were
disconnected under the condition the panel ON/
OFF switch is ON.
After the failure was occured, if the panel ON/
OFF switch is turned ON, it functions.
After correction of failure, if the starter switch is
SM0058 not switched from OFF to ON the error indication
and flickering are not released.
T3-8-39
Failures of sensors
1. HL.* is indicated on 3 digits segment.
Check the inner air sensor or the harness for

disconnection and short circuit, and also connectors for
disconnection.
SM0059
(* is any of the numbers 0 to 9.)
2. **E and mark are flickering.
(** is displayed leaving the present set temperature value.)
Check evaporator sensor or the harness for

disconnection and short circuit, and also connectors for
disconnection.
SM0060
Note: The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition
the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
Communication error of control amplifier and panel

1. E is indicated on the only use segment of display.
Check the harness of control amplifier and panel for

disconnection, and connectors for poor connection.
SM0061
T3-8-40
EXPLANATION OF MONITOR MODE

When error “failure of sensors” is displayed, the monitor mode is available to identify the sensor condition
(disconnection, short circuit).
1. Position of monitor mode indication
SM0062
3 DIGITS SEGMENT SEGMENT FOR ONLY

MONITOR INDICATION
2. Operation of monitor mode
A B E
SM0063
C D
1. Press inner and outer air flow select switch (A) and ON/OFF switch (D) simultaneously for 1 second.
2. Press AUTO switch (E).
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3. Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit
and 2nd digit of segment in three digits. The 1st digit is indicated by "H".
4. Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by
pressing UP or DOWN of blower switch (B) or (C), and the required sensor is selected from the list
below.
SEGMENT ASSIGNMENT LIST
0 INNER AIR SENSOR

1 EVAPORATOR SENSOR
2 SOLAR RADIATION SENSOR
SM0064
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5. The monitor display is terminated by pressing the inner and outer air flow select switch (A) and ON/OFF
switch (D) for 1 second again, or turning off the main switch of excavator.
Notes:
- The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
- Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch (D) again, and the error display is disappeared.
T3-8-41
3. Contents of monitor mode display

Refer to the list of segment display exclusively used for monitor and the list of segments in three digits.
1. Example 1
When the segment exclusively used for monitor

indicates 0 (displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.
SM0065
2. Example 2

indicates 1 (displays the evaporator sensor condition),
since the segment indicates 00, the sensor is in
disconnection condition according to the list of 3
segments.
--> The evaporator sensor is in disconnection condition.
SM0066
3. Example 3
indicates 2 (displays the solar radiation sensor
condition), since the segment indicates FF,the sensor is
in short-circuiting condition according to the list of 3
segments.
-->The solar radiation sensor is in short-circuiting
SM0067 condition.
4. List of 3 segments
SECOND SEGMENT
INNER AIR SENSOR DISCONNECTION

EVAPORATOR SENSOR DISCONNECTION
SOLAR RADIATION SENSOR SHORT-CIRCUITING
THIRD SEGMENT
EACH SENSOR IS NORMAL
SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING
INNER AIR SENSOR SHORT-CIRCUITING

EVAPORATOR SENSOR SHORT-CIRCUITING
SM0068
T3-8-42
BLADE CONTROL E135B
OUTLINE
General view of the blade control components
3
2 5
1
SM3154
1 - Blade 4 - Blade control valve

2 - Blade control cylinders 5 - Blade switching hydraulic valve
3 - Swivel joint 6 - Gear pump
T3-9-1
E135B BLADE CONTROL
SM3155
7 - Boom/blade selection button

8 - Boom/blade selection switch
9 - Boom/blade selection relay
T3-9-2
BLADE CONTROL E135B
BLADE
The blade is composed of a welded frame on which a plate is attached and on this a cutting edge is welded.
The frame is pivoting on the lower frame of the undercarriage through two pins. The blade is controlled by the
action of two cylinders hinged to the blade frame and the lower frame through four pins.
The cylinders control the blade moving upward 500 mm (19.7 in) and downward 587 mm (23.1 in) with respect
to the ground. Two guards are installed on the cylinders.
Unit: mm (in)
110 (4.3)
2490 (98.0)
2590 (101.9)
2690 (105.9)
690 (27.2)
L 2790 (109.8)
110 (4.3)
Ø60 (2.3)
3
1
4 769 (30.3)
2
R8
(34 81
.7)
56
°
.4
572 (22.5)
29.8
°
480 (18.9)
500 (19.7)
587 (23.1)
6
71
R1 7.5)
9.1°
( 6
1664 (65.5)
2433 (95.8)
SM3156
1 - Blade frame 3 - Cutting edge

2 - Blade 4 - Pivot pins
T3-9-3
E135B BLADE CONTROL
BLADE CONTROL CYLINDERS

The blade control cylinders are installed between the lower frame and the blade.
For the features of the blade control cylinders, please refer to Group 7 "Cylinders”.
SM3157
SWIVEL JOINT
The swivel joint in blade version differs from the swivel joint of standard version only because it has two
additional connections (F, G) for the blade control.
For the features of swivel joint in blade version, please refer to group 6 "Swivel joint”.
C B
G A
SM3158
T3-9-4
BLADE CONTROL E135B
BLADE CONTROL VALVE

The blade control valve is installed on the main control valve and it is made of a spool with a pressure relief
valve and two safety valves.
Pressure relief valve (V1) is set at 20.6 MPa (at 50 L/min) (2987 psi at 13.2 gal/min) whereas the safety valves
(overload) (V2) are set at 27.5 MPa (at 30 L/min) (3987.5 psi at 8 gal/min).
Pa1 Pa1
V2
(G)
(G)
A A
P P
B B
V2
V1
Pb1 Pb1
SM3159
Hydraulic diagram
B1
A1
Pa1
V2
Pb1
V1
(G)
P
SM3160
V1 - Pressure relief valve

V2 - Safety valve (overload)
T3-9-5
E135B BLADE CONTROL
BLADE SWITCHING HYDRAULIC VALVE

The blade switching valve is installed on the upper frame near the solenoid valve block and the sensor block.
It is composed of blade selection solenoid valve (SV-17) directly installed on a one-spool two-way switching
hydraulic valve. The boom/blade selection solenoid valve switches the secondary piloting pressure flowing
from the right pilot valve to the main control valve controlling the boom lifting spool (under rest conditions; i.e.
with solenoid valve SV-17 not energised) or the blade control valve (under work conditions; i.e. with solenoid
valve SV-17 energised).
A2 A1
Ev
A
Z B2 B1 VIEW A
PP
T
P2 P1
B2 B1
T
PP
SECTION Z-Z
Ev
T A2 B2 A1 B1
PP
P2 P1
Vc
SM3161
VC - Blade switching hydraulic valve

EV - Blade selection solenoid valve (SV-17)
T3-9-6
BLADE CONTROL E135B
GEAR PUMP FOR BLADE

The gear pump for the blade control circuit is installed on the PTO group.
General view and hydraulic ports

2
B4, A4
SM3162
1 - Main pump assy

2 - Gear pump assy for blade
A4 - Delivery port G35
B4 - Suction port G40
Specifications
Pump SGP2A27F1H1-R533
Fixed displacement type
Type
gear pump
Max. displacement capacity cm3 27.4
rpm
(clockwise
Rated revolution 2000
seen from shaft
end)
MPa 20.6
Working pressure
(psi) (2987)
L/min 55
Max. flow
(gal/min) (14.5)
kg 5.4
Mass
(lb) (11.9)
T3-9-7
E135B BLADE CONTROL
Construction
70 65 1 2 5 6
57 52 50-51 4 56 55
SM3163
1 - Front cover 52 - Gasket (Q.ty 2)

2 - Body 51 - Gasket (Q.ty 2)
3 - Drive gear 55 - Socket bolt M12 (Q.ty 4)
4 - Driven gear 56 - Washer (Q.ty 4)
5 - Side plate (Q.ty 2) 57 - Bushing (Q.ty 4)
6 - Rear cover 65 - Oil seal
50 - Back-up strip (Q.ty 2) 70 - Retainer ring
T3-9-8
BLADE CONTROL E135B
BOOM/BLADE SELECTION BUTTON

The boom/blade selection button (1) located on the back of the right level, selects momentarily, as long as it is
kept pressed, the blade controls.
When the button is pressed (position ON) the Mechatro Controller energises relay R-40 activating solenoid
valve SV-17.
SM3164
BOOM/BLADE SELECTION SWITCH

The boom/blade selection switch located on the right side switch panel, selects the blade controls, when
switched into position ON (side with symbol pressed).
When the switch is pressed (position ON) the Mechatro Controller energises relay R-40 activating solenoid
valve SV-17.
SM3165
T3-9-9
E135B BLADE CONTROL
BOOM/BLADE SELECTION RELAY

Boom/blade selection relay R-40 (2) is located on the fuse-relay box in the cab behind the operator's seat and
has the purpose of activating boom/blade selection solenoid valve SV-17.
When the Mechatro Controller receives the activation signal from the boom/blade selection switch or the button,
it provides a ground signal to the relay that is energised, thus, boom/blade selection solenoid valve SV-17 is
energised.
SM3166
T3-9-10
OPERATIONAL PERFORMANCE TEST

OPERATIONAL PERFORMANCE TEST E135B
Section 4 OPERATIONAL PERFORMANCE TEST

Group 1 Introduction
Group 2 Standard Performances
Group 3 Test Procedures
Group 4 Mechatro Controller
SECTION 4 E135B
OPERATIONAL PERFORMANCE
TEST
CONTENTS
Group 1 - Introduction
How to Use the Maintenance Standard
and Cautions to Be Exercised ........... T4-1-1
Preparation for Performance Tests......... T4-1-2
Group 2 - Standard Performances

Performance Inspection Standard
Table.................................................. T4-2-1
Group 3 - Test Procedures

Measurement of engine speed ............... T4-3-1
Measurement of hydraulic pressure........ T4-3-2
Measuring travel performances .............. T4-3-7
Measuring swing performances .............. T4-3-11
Measuring attachment operating
performances ..................................... T4-3-15
Measuring performances of swing
bearing............................................... T4-3-17
Group 4 - Mechatro Controller

Engine control input/output ..................... T4-4-1
Adjustment of Mechatro controller output
(A-B-C adjustment) ............................ T4-4-2
INTRODUCTION E135B
HOW TO USE THE MAINTENANCE

STANDARD AND CAUTIONS TO BE
EXERCISED
Application Cautions to be Exercised at Judgment
WHEN THE MACHINE IS NEW EVALUATION OF MEASURED DATA

Confirm that the performances are in accordance Disagreement of measuring conditions, variations of
with standard specifications as compared to the data peculiar to a new machine, and measuring
performance standards. errors are to be evaluated. Determine generally at
what levels measured values are located, instead of
AT SPECIFIC SELF INSPECTION (RULE BY determining whether or not values fall within or run
COUNTRY) out of the reference values.
Use the data for the criterion, for the purpose of DETERMINING CORRECTION, ADJUSTMENT
correction, adjustment and replacement. OR REPLACEMENT
WHEN PERFORMANCES ARE DETERIORATED Machine performances deteriorate with time as
parts wear and some deteriorated performances
Determine whether it is caused by a fault or end of may be restored to new levels. Therefore, determine
service life after long hours of operation, to be used correction, adjustment or replacement, depending
for safety and economical considerations. upon the operating hours, kind of work and
circumstances in which the machine is placed, and
WHEN MAIN COMPONENTS ARE REPLACED
condition the machine performances to its most
For example, use data to restore performances of desirable levels.
pumps and others.
Other Cautions to be Exercised
Terminology
PARTS LIABLE TO DEGRADE
STANDARD VALUES
Rubber products, such as, hydraulic hoses, O-
Values to be used to condition or assemble a new Rings, and oil seals deteriorate with time; replace
machine. Where special notes are not given, these them at regular intervals or at overhauls.
values represent standard specifications (machine
with standard attachments and standard shoes). PARTS REQUIRING REGULAR REPLACEMENT
Out of critical hoses that are necessary to secure
REFERENCE VALUES FOR REMEDY
safety, we designate Very Important Parts (V.I.P)
Values at which readjustment is required. In order to and recommend that they should be replaced
ensure performance and safety it is strictly regularly.
prohibited to use the machine over the specified
values. INSPECTION AND REPLACEMENT OF OILS AND
GREASES
SERVICE LIMIT
In performing maintenance, it is necessary for the
This is the limit value at which reconditioning is user to familiarize himself with how to handle the
impossible without replacement of parts. If the value machine safely, cautions to be exercised and
is expected to exceed the service limit before next inspection/lubrication procedures. Refer to the
inspection and correction are performed, replace operators manuals as well.
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.
T4-1-1
E135B INTRODUCTION
PREPARATION FOR PERFORMANCE

TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
The machine
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
Test area
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m, and to make a full
swing with the front attachment extended. SM1231
3. If required, rope off the test area and provide

signboards to keep unauthorized personnel
away.
Precautions
1. Before starting to test, agree upon the signals
to be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these
signals, and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid
accidents due to landslides or contact with SM1232
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch escaping
oil. Pay special attention to this when removing
hydraulic pipings.
Make precise measurement

1. Accurately calibrate test instruments in
advance to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
STANDARD PERFORMANCES E135B
PERFORMANCE INSPECTION STANDARD TABLE
NOTE: unless otherwise specified, measure it on "H" mode.
Measuring Position Standard Adjusting Measuring

Inspection Item Unit
Position Size Port Value Point Condition
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank Class - Sampling
or less
Hydraulic oil temperature Tank surface 50 ± 5 - Atmospheric
Std. Measuring condition
°C temp
Water temperature Radiator surface 75 ± 15 - 50 °C ~ -10 °C
H mode Lo idle 1000 ± 50 Low throttle
H mode Hi idle 2000 ± 50 Full throttle (Hi Idle)

Engine speed
Measure the engine speed at

Auto-Idle 1050 ± 50 Adjustment
multi display on the gauge
cluster, or measure with diesel min-1 not
B mode Hi idle 2000 ± 50 required Perform all
speed meter measurement with the
A mode Hi idle 2000 ± 50 air-conditioner “OFF”
S mode Hi idle 1900 ± 50
Pilot primary pressure circuit G pump a3 5.0 +0.5 PR1 HI idle

-0
P1 a1
valve pressure
ATT Travel 34.3 +0.7 MR1 Boom up

Main relief
P2 a2 -0,5
Power - -
- - -
boost - -
H 37.8 +0
-4.0
OR3 Boom up
Boom a1
R 37.8 +0 OR4 Boom down
-4.0
H 37.8 +0 OR1 Bucket digging
-4.0
Bucket a1
High pressure circuit
R 37.8 +0 OR2 Bucket dump

-4.5
Over load relief valve pressure
Main pump
H PF 1/4 +0 MPa OR7 Arm in

37.8
-4.0
Arm a2
R 37.8 +0 OR8 Arm out
-4.0
LH OR5 Swing LH
Swing a2 +3.4
28.0 +0.5
RH OR6 Swing RH
Forward -
RH a1 34.3 +1,7
Reverse -0,5 - Simultaneous
Travel
Operation of travel RH
Forward - and LH
LH a2 34.3 +1,7
Reverse -0,5 -
H +0.5 - -
24.5 -0
Blade G
R 24.5 +0.5
-0
- -
T4-2-1
E135B STANDARD PERFORMANCES
Measuring
Inspection Item Standard value Unit
condition
st 23.3~25.7
Track link revolution 1 speed
s/3 rev
(RH, LH)
2nd speed 13.8~15.2
In 2.8~3.4
Arm
Out 2.4~3.0
Operating speeds
Digging 2.8~3.4
Bucket
Operating time Dumping 2.1~2.7
s (At no load)
of cylinder In 2.8~3.4
Positioner
Out 4.8~5.4
Up 1.5~2.1
Blade
Down 1.9~2.5
Swing speed RH - LH 13.8~17.4 s/3 rev

Amount of travel
deviation 2nd speed 0~240 mm / 20 m
Parking brake drift 15° Gradient 0 mm / 5 min

Performance of Swing Neutral position after
55~75 degree
brake 180° full speed swing
Performance
Swing parking brake

15° Gradient 0 mm
drift
Tip of the bucket tooth 90
Boom cylinder 3
ATT amount of drift mm / 5 min (At no load)
Arm cylinder 4
- -
Amount of horizontal play at the bucket tooth 30~50 mm
NOTE: over load relief valves OR1~OR8 described in advance (8) (4)
correspond to the following operations.
(5) (6) (1) (2)
1. Bucket digging 5. Swing left
2. Bucket dump 6. Swing right (7) (3)
3. Boom up 7. Arm in
4. Boom down 8. Arm out
T4-2-2
TEST PROCEDURES E135B
MEASUREMENT OF ENGINE SPEED
Warming up of engine
Start engine to raise the coolant temperature of

engine to 60 to 90°C (140 to 194°F) at surface of
radiator upper tank. RED WHITE
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 (149 to 221°F), so confirm that
the pointer indicates the temperature within the BLUE
white range.
SM3143
Engine speed measured value through service

diagnosis
1. Turn "ON" the starter switch with the buzzer

GAUGE CLUSTER
stop switch 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 the "Wiper switch" on the gauge cluster is
pushed.
BUZZER STOP
4. The screen returns like No.45, No.44....each SWITCH
time the "Washer switch" is pushed.
WASHER
5. The display does not disappear unless the
SWITCH
starter switch is turned to"OFF".
WIPER
SWITCH
SCREEN CHANGE SWITCH SM0851
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V SM1555
T4-3-1
E135B TEST PROCEDURES
MEASUREMENT OF HYDRAULIC
PRESSURE
Preparing to measure hydraulic pressure
HYDRAULIC EQUIPMENT
6.9 MPa (1000psi) pressure gauge: 1unit a4 PSV1 PSV2 a5
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for
analysis: 1 set
MEASURING CLEANLINESS OF HYDRAULIC OIL Dr1

(Dr1) B3
IMPORTANT : after releasing air in the hydraulic oil

tank, open the cover and sample oil in the hydraulic
(Dr1) Dr1
tank, and measure with the instrument for analysis.
If the measured value is higher than the standard a3
a1 a2
value, replace the return filter or change the
hydraulic oil.
SM3144
Place to install pressure gauge

MAIN CIRCUIT
After releasing the pressure in hydraulic oil tank and
system, replace plugs PF1/4 of main pump gauge
ports (a1) (a2) with fittings for pressure
measurement, and attach pressure gauge 49 MPa
(7100 psi).
PILOT CIRCUIT
Replace pilot gauge plug (a3) with fitting PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).
BLADE CIRCUIT
Replace plug (G) of blade command valve with G
fitting PF3/8 for pressure measurement, and attach
pressure gauge 49 MPa (7100 psi).
EXTRA CIRCUIT
Replace plug (G) of command valve with fitting PF3/
8 for pressure measurement, and attach pressure
gauge 49 MPa (7100 psi).
SM3153
T4-3-2
Pressure adjustment position

MAIN CONTROL VALVE
Relief valve position on main control valve.
PLUG FOR
OR7 : ARM (H) OPTIONAL RELIEF
MACHINE
TOP
MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R)

(ATT & TRAVEL)
View from right front of machine SM3145
OR4 : BOOM (R) OR1 : BUCKET (H)
MACHINE
TOP
OR8 : ARM (R) PLUG FOR OPTIONAL RELIEF
View from left bottom of machine SM3146
T4-3-3
PILOT RELIEF VALVE

The pilot relief valve PR1 is located on the gear
pump that is attached to the main pump. A3
a3
Dr3
PR1
B3
SM3147
SWING OVER LOAD RELIEF

The swing motor is equipped with plugs PA, PB for
pressure measurement, but the measurement is
PA PB
carried out using gauge ports (a1) and (a2).
SWING RIGHT SWING LEFT

OVERLOAD RELIEF OVERLOAD RELIEF
OR6 OR5
SM3148
a4 PSV1 PSV2 a5
Dr1
(Dr1) B3
(Dr1) Dr1
a3
a1 a2
SM3144
T4-3-4
Procedure for adjusting relief valve
PILOT RELIEF VALVE

Adjust it with adjust screw (311).
: 24 mm
: 29.4 N•m (22 lbf•ft)
: 6 mm
No. of turns of adjust Pressure change MPa

screw (psi)
1 turn Approx. 2.1 (305)
LOCK NUT HEX24

MAIN RELIEF VALVE
(Commom for travel and ATT sections) 311 SM1287
Loosen lock nut (7) and adjust the pressure with the
adjust screw (6).
: 27~31 N•m (20~23 lbf•ft)
7
: 19 mm Adjust screw
: 4 mm 6

screw (psi)
1 turn Approx. 17.7 (2560) SM3149
OVER LOAD RELIEF VALVE

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw

(2).
: 22 mm
: 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm
2 1
screw (psi)
SM0860
1 turn Approx. 17.7 (2560)
T4-3-5
OVER LOAD RELIEF VALVE (SWING)

When the adjustment of pressure is required,
loosen lock nut (1) and adjust the pressure with cap 1 2
(2).
: 30, 38 mm
: 118 N•m (87 lbf•ft)
: 12 mm
3
R
No. of turns of adjust Pressure change MPa SM0861

screw (psi)
1 turn Approx. 10 (1450)
OVER LOAD RELIEF VALVE (TRAVEL)

This valve was adjusted by manufacturer and
shipped. Do not replace the parts except O-ring. 205
Loosen cap (205) and adjust the pressure with shim
(213).
: 10 mm
213
SM3150
T4-3-6
MEASURING TRAVEL PERFORMANCES
Travel speed
PURPOSES
Measure the track link revolution and confirm the
performances between the hydraulic pump and the
travel motor of the travel drive system.
CONDITIONS
Hydraulic oil temperature ;45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
PREPARATION
Attach the reflection panel with a magnet to the
travel motor cover. SM0863
Swing the swing frame through 90° as shown in
Figure and make the crawler on one side take off the
ground, using the attachment.
MEASUREMENT REFLECTION
PANEL
Engine revolution: Hi idle
2-speed travel switch: 1st speed and 2 nd
speed
Measuring points: Right and left
Method, example:
Measure the revolutions visually.
Track link revolution Unit: s/3 rev

SM0864
Reference
Measurement Standard Service
value for
item value limit
remedy
H mode 1st 23.3~25.7 29.8~32.8 37.0~
RH& speed
LH H mode
13.8~15.2 17.6~19.4 21.9~
2nd speed
T4-3-7
Deviation of travel
PURPOSE
Measure the amount of deviation at 20m (66ft) travel
and confirm the horizontal balance between the
hydraulic pump and the travel motor of the travel
drive system.
CONDITION
Hydraulic oil temperature: 45~55 °C
(113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Approx. 30~40 cm
Engine revolution: Hi idle. (1~1.3 ft)
PREPARATION SM0865
1. Straight course more than 30m (108ft).

2. Travel position in which the bottom of the
bucket is lifted by about 30cm (1ft).
MEASUREMENT
1. Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding A
the preliminary run of 3~5m (10~16ft).
20m
2. Operate the travel lever at the same time.
Travel deviation Unit: mm (in)/20m (66ft)

Measuring Standard Reference value Service
SM0866
position value for remedy limit
240 (9.45)
A 480 (18.9) 720 (28.4)
or less
T4-3-8
Performances 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.
CONDITION
BOOM FOOT PIN
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position.
ARM TOP PIN
PREPARATION
Place an angle meter on the shoe plate and confirm 15 degree slope
that it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide SM0867
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.
MEASUREMENT
Five minutes after the engine stops, measure the
movement distance of the matching mark.
Parking brake Units: mm (in)/5 min

Measuring Standard Reference value Service
position value for remedy limit
C 0 1 (0.04) 2 (0.08) ANGLE METER
GUIDE FRAME C
SM0868
T4-3-9
Drain rate of travel motor
PURPOSE
To measure the drain rate of the travel motor and to
confirm the performances of the travel motor.
CONDITIONS
Hydraulic oil temperature: 45~55°C
(113~131°F)
PREPARATION
1. Place a stopper under the RH and LH travel FORWARD 90 o 10
sprockets. (3.54") (0.394")
o 22 PIPE
2. Stop the engine and release pressure from the (0.866")
40
(1.57")
hydraulic circuit.
RIB "A" 150
3. Connect a hose with the drain port of the travel STOPPER (5.91")
"B"
motor and take drain in a container.
o 80
(3.15")
MEASUREMENT AT TRAVEL LOCK ROTARY DIRECTION
SM0869
WARNING
Unless you observe the rotary force direction at
travel lock, rib "A" may be broken by stopper "B" in
some cases.
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.
Drain rate of travel motor
Drain rate of travel motor Unit: L (gal)/30 s

Measuring Standard Reference value
Service limit
position value for remedy SM0870
Drain rate 5 (1.3) 13 (3.4) 15 (4.0)
T4-3-10
MEASURING SWING PERFORMANCES
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
(113~131°F)
Firm, level ground
PREPARATION
Put the bucket empty and extend the boom, arm and
bucket cylinder fully.
And the machine becomes a position of minimum
reach.
MEASUREMENT
Swing the machine by bringing the swing level to its
full stroke. After a preliminary run of one turn,
measure the time required to make three complete
turns.
Swing speed Unit : s/3 rev SM0871

Service limit
position value for remedy
Swing speed
13.8~17.4 17.7~22.3 25.2~
at min. reach
T4-3-11
Performance of swing brake
PURPOSE
Confirm the braking torque performances by the
swing relief valve.
ARM TOP BOOM FOOT
PIN PIN
CONDITIONS
(113~131°F)
Firm, level ground
SM0872
PREPARATION
1. Put the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
2. 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.
MEASUREMENT
1. When operating in regular swing speed, by
shifting lever to neutral position at pole position
MEASURING THE LENGTH OF THE ARC OVER
the swing operation stops. THE OUTER CIRCUMFERENCE OF OUTER RACE
2. Calculate the swing drift angle by the following MATCHING MARKS ON
equation, after the upper swing body stops, OUTER RACE
using the amount of deflection (m) of the
matching marks on the swing race and the
length (m) of the circumference of the swing
race:
Amount of deflection of
MATCHING MARKS
matching marks [m (ft-in)] ON INNER RACE
Swing drift
= x 360°
angle (°) Circumferenzial lenght of
SM0873
swing race [m (ft-in)]
Swing brake performance Unit : degree

Service limit
Swing 180° 75° 83° 90°
T4-3-12
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. Put
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.
PREPARATION SM0874
Put the angle meter on the shoe plate and make

sure that the angle is more than 15 degree.
Put a matching mark on the outer race side and on
MEASUREING THE LENGTH OF THE ARC OVER
the inner race side. THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
OUTER RACE
MEASUREMENT
When five minutes has passed after the engine
stops, measure the length of the movement of the
matching marks.
MATCHING MARKS
Performance of swing ON INNER RACE
Unit : mm(in)/5min
parking brake
Measuring Standard Reference value SM0875
Service limit
C 0 1 (0.04) 2 (0.08)
T4-3-13
Drain rate of swing motor
PURPOSE
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
CONDITIONS
(113~131°F)
Firm, level ground
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. SM0876
4. Put a plug to the tank side.
MEASUREMENT AT SWING LOCK

1. Start the engine and put the side faces of
bucket against the inside of the right or left shoe
plates.
2. Relieve the swing motor at full stroke of the
swing motion.
3. Collect the amount of drained oil in a container
for 30 seconds.
Drain rate of swing motor Unit : L(gal)/30sec

Service limit
Drain rate 5.0 (1.3) 8.0 (2.1) 11.0 (2.9)
T4-3-14
MEASURING ATTACHMENT OPERATING

PERFORMANCES
Operating time of cylinders
PURPOSE
Measure the operating time of the arm, positioning
and bucket and confirm the performances between
the hydraulic pump and the cylinder of the
attachment drive system.
CONDITIONS
(113~131°F)
Operating time excluding the cushion stroke.
PREPARATION
Firm level ground with the bucket empty.
30 cm (1 ft)
MEASUREMENT
Arm in and out, positioning in and out, bucket
digging and dump
In a position in which the tooth of the bucket rises to
a level of about 30cm (1ft) above ground, measure
the full stroke operating time required with the arm,
the positioning and bucket operating levers at full
30 cm (1 ft)
stroke.
Cylinder Operating time Unit : sec

9
Service limit
1 2.8~3.4 3.6~4.4 4.7~
2 2.1~2.7 2.7~3.5 3.6~ 10
7 2.8~3.4 3.6~4.4 4.7~
8 2.4~3.0 3.1~3.8 4.1~ 30 cm (1 ft)
9 2.8~3.4 3.6~4.4 4.7~
SM0877
10 4.8~5.4 6.1~6.9 7.5~
T4-3-15
Oil tightness of cylinders
PURPOSE
Confirm that the cylinder oil tight by checking the
moving length of the cylinder rods. B
BOOM FOOT PIN
C
CONDITIONS
A
(113~131°F) D
Firm, level ground
After cylinders are replaced, bleed off air from the ARM TOP PIN
SM0878
cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range
of the cushioning mechanism.
PREPARATION
Put the bucket empty. Extend the arm cylinder rod
50mm (2in) from the most retracted position. And
extend the bucket cylinders fully. Then hold the
boom so that the arm top pin is positioned at same
height with boom foot pin.
MEASUREMENT
Measure the items five minutes after the engine is
turned off.
Oil tightness of cylinder Unit: mm(in)/5min

Service limit
A 3 (0.12) 6 (0.24) 9 (0.35)
B 4 (0.16) 8 (0.32) 12 (0.47)
C - - -
D 90 (3.54) 115 (4.53) 150 (5.91)
T4-3-16
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.
CONDITIONS
Firm, level ground
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making
abnormal sound during turning.
PREPARATION
1. Install a dial indicator to the magnetic base and LOCATION OF BEARING
MOUNTING BOLTS
fix it to the lower frame.
2. Direct the upper swing body and the lower
frame toward the travel direction, bring the SWING BEARING
probe of the dial indicator in contact with the A
bottom surface of the outer race on the swing
body side and set the reading at zero.
DIAL INDICATOR
LOWER FLAME
MEASUREMENT
Measuring position 1 and 2
Measure the displacement of the outer race in the SM0879
axial direction in position 1 [The arm at 90°~110°
and the crawler front is lifted by attachment about
30cm (1ft)] and in position 2, using a dial indicator.
Axial play of swing bearing Unit: mm (in)

Service limit
0.5~1.5 1.9~2.9 3.0~
A
(0.02~0.06) (0.08~0.11) (0.12~)
90 ~100
30cm
SM0880
Position 1
ARM TOP BOOM FOOT

PIN PIN
SM0872
Position 2
T4-3-17
Measuring position 3
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 ARM TOP BOOM FOOT
pin. Then swing the bucket right and left by man PIN PIN
power.
But in this case, the gap of the attachment is
included.
Right and left movement of

Unit: mm (in) SM0872
the tip of bucket
Service limit
Position 3
30~50
Benna 80 (3.15) 120 (4.72)
(1.18~1.97)
T4-3-18
MECHATRO CONTROLLER E135B
ENGINE CONTROL INPUT/OUTPUT
C-3:
ENGINE CONTROLLER INJECTOR
C-2: E-1:
GAUGE CLUSTER FUSE&RELAY BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
VALVE
STARTER ACCEL C-1:
SWITCH POTENTIO METER MECHATRO CONTROLLER
SM1560
ENGINE CONTROL EQUIPMENT
Speed sensor
Installing place: engine flywheel housing.
Sensor attaching procedure: screw the speed

sensor into engine flywheel housing. CN-136F
: 19 mm
SM3151
Work mode select switch

If the work mode select switch is pressed, a signal
istransmitted to the C–1 controller and changes the
work modes in the order of H→B→A→S and back
to H again.
WORK MODE
SELECT SWITCH
SM0885
T4-4-1
E135B MECHATRO CONTROLLER
ADJUSTMENT OF MECHATRO
CONTROLLER OUTPUT (B-C
ADJUSTMENT)
Purpose of the adjustment
There are 2 kinds of adjustment of mechatro

controller as shown below; every adjustment is an
essential function to ensure performance of
machine.
1. Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the
output variation by coordinating the output
hydraulic pressure with engine rated output.
2. 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:
1. Mechatro controller
2. Engine or engine controller
3. Hydraulic pump or hydraulic pump proportional
valve
4. Unloading proportional valve, spool of
unloading valve.
Preparation
1. Raise the oil temperature to about 50°C

(122°F) to warm up the engine.
2. Turn the air-con OFF.
3. 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, 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.
T4-4-2
Adjusting procedure
MULTI DISPLAY
BUZZER STOP SWITCH WORK MODE SELECT SWITCH
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
SM0886
ADJUSTMENT OF PUMP ("B" ADJUSTMENT)

PROCEDURE
1. Turn starter key switch ON keeping the work
mode selector switch on the gauge cluster
pressed, and hold it for 5~10 seconds, and then
release it. (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 selecting adjustment is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If
the adjustment operation is once performed,
"FIN" is indicated.And the lever lock solenoid is
automatically released, disabling all operations.
3. Press selector switch on gauge cluster to
display "START ENG"."Engine SPEED", P1, SM0887
P2 "PUMP PRESSURE" and "STEP"
(acceleration command voltage) are indicated.
T4-4-3
4. The adjustment automatically shifts from

engine to pump, the speed shifts from LOW
idling to HIGH idling. And "MEMORY PUMP" is
displayed.
And the unloading proportional valve and pump
proportional valve actuate, accordingly the
loading of pump is increased.The "ENGINE
SPEED", P1, P2 "PUMP PRESSURE" and P1,
FINISH PUMP
P2 pump "PROPO-VALVE" current (command ENGINE SPEED
value) are indicated. 2000rpm
PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
E-1 300mA E-2 300mA
5. After detection of the engine rated speed, the

adjustment of pump is automatically
SM0889
completed. And "FINISH PUMP" is displayed.
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the
adjustment is completed. The unloading
adjustment required later is not performed, and
default value is written.).
T4-4-4
ADJUSTMENT OF UNLOADING VALVE (“C”

ADJUSTMENT)
PROCEDURE
1. The adjustment shifts from pump to unloading,
and the unloading valve actuates, accordingly MEMORY UNLOAD
the pump pressure is detected. ENGINE SPEED
2000rpm
And "MEMORY UNLOAD" is displayed.The PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
"ENGINE SPEED", P1, P2 "PUMP D-1 300mA D-2 300mA
PRESSURE" and P1, P2 "PROPO-VALVE"

voltage (command value) are indicated".
2. When the unloading valve operates to the
specified value, the adjustment of unloading
proportional valve is automatically terminated.
And "FINISH UNLOAD" is displayed.
The speed is shifted to the speed
corresponding to acceleration
SM3152
potentiometer.The adjusting current value is
indicated on the display of current of P1, P2
unloading proportional valves. The adjusting
range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically

stored.).
CORRECTIVE ACTION TAKEN WHEN THE

ADJUSTMENT CAN BE NOT PERFORMED
1. In cases where the adjustment of pump can not
be performed; And "ERROR PUMP" is
displayed.
Judging condition 1:
P1 and P2 average pump pressure at the time
when the adjustment is completed is 25MPa or
less. SM0891
the adjustment does not complete although the
pump proportional valve current reaches to the
specified value.
The P1 and P2 pump pressures usually
increase to 33~38MPa. When the pressure
does not increase:
a. 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.
b. 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
T4-4-5
2. In cases where unloading valve can not be

performed; And "ERROR UNLOAD" is
displayed.
the pump pressure does not increase up to the
pressure in the range of the specified
adjustment. Or the increased pressure is held SM0892
as it is.
pressure sensor of either P1 pump or P2 pump
is failed.
Normally the pump pressures of P1 and p2
pumps gradually increase to 10~25MPa.
(It may be affected by operating oil
temperature.)
When the pump pressure does not increase:
a. 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
T4-4-6
OTHER PRECAUTIONS
1. In the event of a failure, there is case where the
adjustment may not be performed normally.
First serve the machine, and perform the
adjustment work.
2. In the condition where large load is constantly
applied to engine, the adjustment could not be
performed normally.
WHEN THE ADJUSTMENT OF UNLOADING

VALVE ONLY IS PERFORMED (“C”
ADJUSTMENT)
In the event where only unloading valve and
unloading proportional valve are replaced, perform
the adjustment of unloading valve only.
PROCEDURE
1. Turn starter switch ON keeping the work mode
selector switch on the gauge cluster pressed,
MULTI DISPLAY
and hold it for 5~10 seconds, and then release (EXAMPLE)
it.
(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.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If
the adjustment operation is once performed,
"FIN" is indicated.And the lever lock solenoid is
automatically released, disabling all operations.
3. Change the adjusting items with washer switch
( ) and wiper switch ( ), and select "ADJUST
UNLOAD".
Like the output adjustment, when adjustment
data is not entered in mechatro controller,
"READY" is indicated. If the adjustment
operation is once performed, "FIN" is indicated.
4. Press selector switch on gauge cluster to
display "START ENG". SM0893
"ENGINE SPEED", P1, P2 "PUMP

PRESSURE" and "STEP" (acceleration
command voltage) are indicated.
T4-4-7
5. After starting engine, press selector switch on

gauge cluster and "MEMORY UNLOAD" is MEMORY UNLOAD
indicated, the engine speed is automatically ENGINE SPEED
2000rpm
increased and the adjustment of unloading PUMP PRESSURE
C-1 2.0M C-2 2.0M
valve is performed. PROPO-VALVE
D-1 300mA D-2 300mA
"ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and "PROPO-VALVE" are
indicated.
6. When the unloading proportional valve
operates to the specified value, the adjustment
of unloading proportional valve automatically
completes. "FINISH UNLOAD" is indicated.
The speed is shifted to the speed
corresponding to acceleration potentiometer. SM0894
The value of adjusting current is indicated on

the display of current of P1 and P2 unloading
proportional valves. The adjusting range is
usually 520~635mA.
Stop the engine. (The adjusted data is automatically

stored.)
T4-4-8
TROUBLESHOOTING
TROUBLESHOOTING E135B
Section 5 TROUBLESHOOTING
Group 1 Troubleshooting (by Error Codes)
Group 2 Troubleshooting (by trouble)
Group 3 Troubleshooting (Trouble diagnosis mode)
SECTION 5 E135B
TROUBLESHOOTING
CONTENTS
Group 1 - Troubleshooting (by Error

Codes)
1. Judgment of actual thing at site ......... T5-1-1
2. Classification on failure and
troubleshooting .................................. T5-1-2
3. The blown fuse of Mechatro
Controller ........................................... T5-1-2
4. Troubleshooting by Error Codes ........ T5-1-2
Group 2 - Troubleshooting (by trouble)

1. Hydraulic system ............................... T5-2-1
2. Electric systems ................................. T5-2-28
2.1 Wiring checking procedure ......... T5-2-28
2.2 Trouble ....................................... T5-2-31
3. Engine................................................ T5-2-35
Group 3 - Troubleshooting (Trouble

diagnosis mode)
1. Trouble diagnosis mode .................... T5-3-1
TROUBLESHOOTING (BY ERROR CODES) E135B
OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred.
This manual describes how to solve the specific
phenomenon systematically as early as possible.
For troubleshooting concerning the inside of
equipment, refer to troubleshooting for each manual
of equipment.
1. JUDGMENT OF ACTUAL THING AT SITE SM0100
GET TO THE SITE AS QUICKLY AS POSSIBLE Attending the field to verify actual thing
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
VERIFY BACKGROUND
OF TROUBLE OCCURRED
1. Model name and serial number
2. Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3. Operating time by hour-meter
4. History of trouble occurred and additional works.
5. Recurrence of past trouble, or problems on the SM0101
additional works.
Verifying background of trouble occurred
HOW TO DIAGNOSE TROUBLE

1. Verify defective part
2. Make the condition of trouble again
3. Where defective parts can not be verified,
surmise causes systematically.
4. Verify reasons for surmise
5. Report methods, procedure, and period for
repairing to user.
SM0102
EXPLANATION OF THE CAUSE OF TROUBLE
Confirm the symptoms of the trouble
1. Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2. Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those
surfaces. SM0103
Diagnosing fail by means troubleshooting
T5-1-1
E135B TROUBLESHOOTING (BY ERROR CODES)
2. CLASSIFICATION OF FAILURE AND TROUBLESHOOTING
Classify failures into the following 3 types and carry out the troubleshooting.
No. Classes of failure Troubleshooting
A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster code.
B When no failure is detected currently but error When it is hard to recreate the failure situation,
code after self diagnosis is remained in trouble cancel the data in the history and reproduce the
history failed situation or suppose the cause according to
the troubleshooting by error code, and then repair
it.
C When error code after self diagnosis is not • Carry out troubleshooting according to
displayed or is not remained in the history instructions in Chapter T5-2
"TROUBLESHOOTING BY TROUBLE".
• Carry out troubleshooting according to
instructions in Chapter T5-3 "TROUBLE
DIAGNOSIS MODE".
3. THE BLOWN FUSE OF MECHATRO CONTROLLER
If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. 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.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021
4. 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 Trouble Described

Code page
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed. T5-1-5
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. T5-1-6
A215 Written data of ROM adjustment data is incorrect. T5-1-6
A225 Writing of ROM adjustment data is incorrect. T5-1-7
A235 Written data of ROM hour meter data is incorrect. T5-1-7
A245 Writing of ROM hour meter data is incorrect. T5-1-8
A255 Writing of proportional valve adjustment data is incorrect. T5-1-8
B012 Incorrect output of boom up pressure sensor T5-1-9
B013 Disconnection of boom up pressure sensor T5-1-9
B014 Short-circuit of boom up pressure sensor T5-1-10
B022 Incorrect output of boom down pressure sensor T5-1-10
B023 Disconnection of boom down pressure sensor T5-1-11
T5-1-2

Code page
B024 Short-circuit of boom down pressure sensor T5-1-11
B032 Incorrect output of arm out pressure sensor T5-1-12
B033 Disconnection of arm out pressure sensor T5-1-12
B034 Short-circuit of arm out pressure sensor T5-1-13
B042 Incorrect output of arm in pressure sensor T5-1-13
B043 Disconnection of arm in pressure sensor T5-1-14
B044 Short-circuit of arm in pressure sensor T5-1-15
B052 Incorrect output of bucket digging pressure sensor T5-1-16
B053 Disconnection of bucket digging pressure sensor T5-1-16
B054 Short-circuit of bucket digging pressure sensor T5-1-17
B062 Incorrect output of bucket dump pressure sensor T5-1-17
B063 Disconnection of bucket dump pressure sensor T5-1-18
B064 Short-circuit of bucket dump pressure sensor T5-1-18
B072 Incorrect output of swing pressure sensor T5-1-19
B073 Disconnection of swing pressure sensor T5-1-19
B074 Short-circuit of swing pressure sensor T5-1-20
B092 Incorrect output of travel right pressure sensor T5-1-20
B093 Disconnection of travel right pressure sensor T5-1-21
B094 Short-circuit of travel right pressure sensor T5-1-22
B102 Incorrect output of travel left pressure sensor T5-1-23
B103 Disconnection of travel left pressure sensor T5-1-23
B104 Short-circuit of travel left pressure sensor T5-1-24
B113 Disconnection of pressure sensor of optional selector positioning T5-1-25
B114 Short-circuit of pressure sensor of optional selector positioning T5-1-26
B162 Incorrect output of P1 optional side pressure sensor T5-1-26
B163 Disconnection of P1 side optional pressure sensor T5-1-27
B164 Short-circuit of P1 side optional pressure sensor T5-1-28
B172 Incorrect output of P2 optional side pressure sensor T5-1-28
B173 Disconnection of P2 side optional pressure sensor T5-1-29
B174 Short-circuit of P2 side optional pressure sensor T5-1-29
C012 Incorrect output of P1 pump pressure sensor T5-1-30
C013 Disconnection of P1 pump pressure sensor T5-1-30
C014 Short-circuit of P1 pump pressure sensor T5-1-31
C022 Incorrect output of P2 pump pressure sensor T5-1-31
C023 Disconnection of P2 pump pressure sensor T5-1-32
C024 Short-circuit of P2 pump pressure sensor T5-1-32
C033 Disconnection of boom head pressure sensor T5-1-33
C034 Short-circuit of boom head pressure sensor T5-1-33
D012 Failure of output transistor ON at P1 unload proportional valve T5-1-34
D013 Disconnection of P1 unload proportional valve T5-1-34
D022 Failure of output transistor ON at P2 unload proportional valve T5-1-35
D023 Disconnection of P2 unload proportional valve T5-1-36
D032 Failure of output transistor ON at travel straight proportional valve T5-1-36
D033 Disconnection of travel straight proportional valve T5-1-37
D062 Failure of output transistor ON at arm in high speed proportional valve T5-1-38
D063 Disconnection of arm in high speed proportional valve T5-1-39
T5-1-3

Code page
E012 Failure of output transistor ON at P1 pump proportional valve T5-1-39
E013 Disconnection of P1pump proportional valve T5-1-40
E022 Failure of output transistor ON at P2 pump proportional valve T5-1-41
E023 Disconnection of P2 pump proportional valve T5-1-41
E032 Failure of output transistor ON at OPT relief 1 proportional valve T5-1-42
E033 Disconnection of OPT relief 1 proportional valve T5-1-42
E042 Failure of output transistor ON at OPT relief 2 proportional valve T5-1-43
E043 Disconnection of OPT relief 2 proportional valve T5-1-43
F021 Failure of output transistor OFF and GND short of swing parking SOL valve T5-1-44
F023 Failure of output transistor ON and disconnection of swing parking SOL valve T5-1-44
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve T5-1-45
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve T5-1-46
F041 Failure of output transistor OFF and GND short of optional selector SOL valve T5-1-46
F043 Failure of output transistor ON and disconnection of optional selector SOL valve T5-1-47
G032 Overrun of speed sensor of direct input Mechatro-controller T5-1-48
G033 Disconnection of speed sensor of direct input Mechatro-controller T5-1-48
Mechatro controller direct input speed sensor and received data from engine controller
G042 T5-1-49
are overrun
Mechatro controller direct input speed sensor and received data from engine controller
G043 T5-1-49
are disconnected
H013 Disconnection of acceleration potentio T5-1-50
H014 Power short-circuit of acceleration potentio T5-1-50
H091 Failure of GND short-circuit of fuel sensor T5-1-51
H093 Disconnection of fuel sensor T5-1-51
I111 Received error of CAN1 communication (passive error) T5-1-52
I113 Received error of CAN1 communication (time-out) T5-1-52
I313 Received error of cluster communication (time-out error) T5-1-53
K014 Adhesion of battery relay terminal T5-1-54
R014 Failure of arc prevention relay of wiper motor T5-1-55
R024 Failure of normal rotation relay of wiper motor T5-1-56
R034 Failure of reverse rotation relay of wiper motor T5-1-57
R044 Failure of washer motor relay T5-1-58
R134 Failure of swing flasher relay T5-1-59
R144 Failure of swing flasher relay T5-1-60
R154 Failure of travel alarm relay T5-1-61
R164 Failure of auto idling stop relay 2 T5-1-62
R174 Failure of engine forcible stop relay T5-1-63
R184 Failure of lever lock relay T5-1-64
T5-1-4
Table 1
Error code
Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 •
2 •
3
Table 2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the
Judging condition
adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation.
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Screen No. 9 E-1 P1 PUMP
Service diagnosis
Screen No. 9 E-2 P2 PUMP
checking screen
Screen No.
1 • Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
T5-1-5
Table 3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
Judging condition
range.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Screen
8 D-1 P1 UN-LOAD (BP-CUT)
No.
Service diagnosis Screen
checking screen No.
Screen
No.
1 • Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
3
Table 4
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging condition Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen
No.
checking screen No.
Screen
No.
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
T5-1-6
Table 5
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging condition Check adjustment data, and judge the data is correct or not.
Control in the
Control can be done by default value.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
2
3
Table 6
Error code A235
Trouble The data of ROM houmeter is written incorrectly.
Judging condition Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
2
3
T5-1-7
Table 7
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging condition Check hourmeter memory, and judge the data is incorrect.
Symptom The hourmeter data which was judged as error is taken as 0 Hr. No problem in normal operation.
Control in the
Normal control is available.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
2
3
Table 8
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging condition Check proportional valve adjustment data, and judge the data is incorrect.
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
2
3
T5-1-8
Table 9
Error code B012
Trouble Boom up pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the sensor after
Judging condition
starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The boom up operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen
5 B-1 BOOM RAISE
No.
checking screen No.
Screen
No.
1 • Boom up pressure sensor SE-3 When B012 is cancelled and other error occurs by turning starter switch on after
exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
Table 10
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging condition The input voltage from boom up pressure sensor is less than 0.1 V.
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current. (Current value in all
event of failure operation is neutral). Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen
5 B-1 BOOM RAISE
No.
checking screen No.
Screen
No.
1 • Boom up pressure sensor SE-3 When B013 is cancelled and other error occurs after exchanging the connector
with other sensor.
2 • Wiring between boom up
When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
Check wiring for possible failure according to the wiring checking procedure
CN-126F
and repair it if necessary.
CN-101F
T5-1-9
Table 11
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging condition The input voltage from boom up pressure sensor is 4.7 V or more.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral).
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
normal condition
Screen
5 B-1 BOOM RAISE
No.
checking screen No.
Screen
No.
1 • Boom up pressure sensor SE-3 When B014 is cancelled and other error occurs after exchanging the connector
with other sensor.
2 • Wiring between boom up
CN-126F
CN-101F
Table 12
Error code B022
Trouble Boom down pressure sensor outputs error.
Judging condition
Symptom The boom down operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-2 BOOM LOWER
No.
checking screen No.
Screen
No.
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on after
SE-4 exchanging the connector with other sensor.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
T5-1-10
Table 13
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging condition The input voltage from boom down pressure sensor is 0.1 V or less.
Control in the
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
normal condition
Screen
5 B-2 BOOM LOWER
No.
checking screen No.
Screen
No.
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the connector
SE-4 with other sensor.
2 • Wiring between boom down
CN-127F
CN-101F
Table 14
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging condition The input voltage from boom down pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-2 BOOM LOWER
No.
checking screen No.
Screen
No.
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
T5-1-11
Table 15
Error code B032
Trouble Arm-in pressure sensor outputs error.
Judging condition
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-3 ARM OUT
No.
checking screen No.
Screen
No.
1 • Arm-out pressure sensor SE-8 When B032 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between arm-out pressure When B032 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
Table 16
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging condition The input voltage from arm-out pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-3 ARM OUT
No.
checking screen No.
Screen
No.
1 • Arm-out pressure sensor SE-8 When B033 is cancelled and other error occurs after exchanging the connector
with other sensor.
2 • Wiring between arm-out pressure
sensor and controller
CN-131F
CN-101F
T5-1-12
Table 17
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging condition The input voltage from arm-out pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-3 ARM OUT
No.
checking screen No.
Screen
No.
1 • Arm-out pressure sensor SE-8 When B034 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
Table 18
Error code B042
Trouble Arm-in pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure
Judging condition
sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-4 ARM IN
No.
checking screen No.
Screen
No.
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between arm-in pressure When B042 is displayed after turning the starter switch on after the connector
T5-1-13
Table 19
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging condition The input voltage from arm-in pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-4 ARM IN
No.
checking screen No.
Screen
No.
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the connector
SE-7 with other sensor.
2 • Wiring between arm-in pressure
CN-130F
and repair it if necessary..
CN-101F
T5-1-14
Table 20
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging condition The input voltage from arm-in pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen No. 5 B-4 ARM IN
Service diagnosis
Screen No.
checking screen
Screen No.
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
2 • Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector
CN-101F and repair it if necessary..
T5-1-15
Table 21
Error code B052
Trouble Bucket digging pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the bucket digging
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-5 BUCKET DIG
No.
checking screen No.
Screen
No.
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
Table 22
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging condition The input voltage from bucket digging pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-5 BUCKET DIG
No.
checking screen No.
Screen
No.
T5-1-16
Table 23
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging condition The input voltage from bucket digging pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-5 BUCKET DIG
No.
checking screen No.
Screen
No.
Table 24
Error code B062
Trouble Bucket dump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
Judging condition
Symptom The bucket dump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
5 B-6 BUCKET DUMP
No.
checking screen No.
Screen
No.
T5-1-17
Table 25
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging condition The input voltage from bucket dump pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-6 BUCKET DUMP
No.
checking screen No.
Screen
No.
Table 26
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging condition The input voltage from bucket dump pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
5 B-6 BUCKET DUMP
No.
checking screen No.
Screen
No.
T5-1-18
Table 27
Error code B072
Trouble Swing pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the swing pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The swing operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-7 SWING
No.
checking screen No.
Screen
No.
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector
Table 28
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging condition The input voltage from swing pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-7 SWING
No.
checking screen No.
Screen
No.
T5-1-19
Table 29
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging condition The input voltage from swing pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-7 SWING
No.
checking screen No.
Screen
No.
Table 30
Error code B092
Trouble Travel right pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the travel right
Judging condition
Symptom The travel right operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-9 TRAVEL (R)
No.
checking screen No.
Screen
No.
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
T5-1-20
Table 31
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging condition The input voltage from Travel right pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-9 TRAVEL (R)
No.
checking screen No.
Screen
No.
T5-1-21
Table 32
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging condition The input voltage from Travel right pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-9 TRAVEL (R)
No.
checking screen No.
Screen
No.
T5-1-22
Table 33
Error code B102
Trouble Travel left pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the travel left
Judging condition
Symptom The travel left operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-10 TRAVEL (L)
No.
checking screen No.
Screen
No.
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
Table 34
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging condition The input voltage from Travel left pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-10 TRAVEL (L)
No.
checking screen No.
Screen
No.
T5-1-23
Table 35
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging condition The input voltage from Travel left pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-10 TRAVEL (L)
No.
checking screen No.
Screen
No.
T5-1-24
Table 36
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition The input voltage from option selector position detect pressure sensor is 0.1 V or less.
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
16 B-11
No.
checking screen No.
Screen
No.
1 • Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on after
pressure sensor exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option selector
When B113 is displayed after turning the starter switch on after the connector
position detect pressure sensor
is exchanged with other sensor.
and controller
CN-162F
CN-104F
T5-1-25
Table 37
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition The input voltage from selector position detect pressure sensor is 4.7 V or more.
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
16 B-11
No.
checking screen No.
Screen
No.
1 • Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on after
pressure sensor exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
When B114 is displayed after turning the starter switch on after the connector
position detect pressure sensor
is exchanged with other sensor.
and controller
CN-162F
CN-104F
Table 38
Error code B162
Trouble P1 side option pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P1 side option
Judging condition
Symptom The P1 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-16 P1 OPT.
No.
checking screen No.
Screen
No.
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
T5-1-26
Table 39
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P1 side option pressure sensor is 0.1 V or less.
Symptom The P1 side option does not work. All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
Screen
6 B-16 P1 OPT.
No.
checking screen No.
Screen
No.
T5-1-27
Table 40
Error code B164
Judging condition The input voltage from P1 side option pressure sensor is 4.7 or more.
Symptom The P1 side option does not work. All operation speed slows down.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
Screen
6 B-16 P1 OPT.
No.
checking screen No.
Screen
No.
Table 41
Error code B172
Trouble P2 side option pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P2 side option
Judging condition
Symptom The P2 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
6 B-17 P2 OPT.
No.
checking screen No.
Screen
No.
T5-1-28
Table 42
Error code B173
Judging condition The input voltage from P2 side option pressure sensor is 0.1 V or less.
Symptom The selection of conflux does not work. All operation speed slows down.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-17 P2 OPT.
No.
checking screen No.
Screen
No.
Table 43
Error code B174
Judging condition The input voltage from P2 side option pressure sensor is 4.7 V or more.
Symptom The selection of conflux does not work. All operation speed slows down.
Control in the
event of failure
Returned in
normal condition
Screen
6 B-17 P2 OPT.
No.
checking screen No.
Screen
No.
T5-1-29
Table 44
Error code C012
Trouble P1 pump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
Judging condition
Symptom The P1 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 C-1 PUMP P1
No.
checking screen No.
Screen
No.
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
Table 45
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P1 pump pressure sensor is 0.1 V or less.
Control in the
P1 pump pressure is controlled to 25 MPa.
event of failure
Returned in
normal condition
Screen
7 C-1 PUMP P1
No.
checking screen No.
Screen
No.
T5-1-30
Table 46
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging condition The input voltage from P1 pump pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
7 C-1 PUMP P1
No.
checking screen No.
Screen
No.
Table 47
Error code C022
Trouble P2 pump pressure sensor outputs error.
After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
Judging condition
Symptom The P2 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 C-2 PUMP P2
No.
checking screen No.
Screen
No.
T5-1-31
Table 48
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging condition The input voltage from P2 pump pressure sensor is 0.1 V or less.
Control in the
event of failure
Returned in
normal condition
Screen
7 C-2 PUMP P2
No.
checking screen No.
Screen
No.
Table 49
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging condition The input voltage from P2 pump pressure sensor is 4.7 V or more.
Control in the
event of failure
Returned in
normal condition
Screen
7 C-2 PUMP P2
No.
checking screen No.
Screen
No.
T5-1-32
Table 50
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging condition The input voltage from boom head pressure sensor is 0.1 V or less.
Symptom Overload alarm is not actuated.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 C-3 BOOM-HEAD
No.
checking screen No.
Screen
No.
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
Table 51
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging condition The input voltage from boom head pressure sensor is 4.7 V or more.
Symptom Overload alarm is not actuated.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 C-3 BOOM-HEAD
No.
checking screen No.
Screen
No.
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
T5-1-33
Table 52
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more.
Symptom Option conflux can not be done.
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on after
PSV-D exchanging the connector with other sensor.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
Table 53
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
The feed-back value from proportional valve is 100 mA or less.
Judging condition
(If output is 150 mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode).
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
PSV-D exchanging the connector with other sensor.
T5-1-34
Table 54
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
PSV-B exchanging the connector with other sensor.
T5-1-35
Table 55
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Judging condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
PSV-B exchanging the connector with other sensor.
Table 56
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0 mA
event of failure
Returned in
normal condition
Screen
8 D-3 S-TRAVEL
No.
checking screen No.
Screen
No.
1 • Travel straight proportional When D032 is cancelled and other error occurs by turning starter switch on after
valve exchanging the connector with other sensor.
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
T5-1-36
Table 57
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Judging condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0 mA.
event of failure
Returned in
normal condition
Screen
8 D-3 S-TRAVEL
No.
checking screen No.
Screen
No.
1 • Travel straight proportional When D033 is cancelled and other error occurs by turning starter switch on after
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
T5-1-37
Table 58
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000 mA or more
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned in
normal condition
Screen
8 D-6 ARM IN-2-SPEED
No.
checking screen No.
Screen
No.
1 • Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch on after
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
T5-1-38
Table 59
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned in
normal condition
Screen
8 D-6 ARM IN-2-SPEED
No.
checking screen No.
Screen
No.
1 • Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch on after
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
Table 60
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Control in the
event of failure
Returned in
normal condition
Screen
9 E-1 PUMP P1
No.
checking screen No.
Screen
No.
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on after
PSV-P1 exchanging the connector with other sensor.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
T5-1-39
Table 61
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Judging condition
Control in the
event of failure
Returned in
normal condition
Screen
9 E-1 PUMP P1
No.
checking screen No.
Screen
No.
T5-1-40
Table 62
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Control in the
event of failure
Returned in
normal condition
Screen
9 E-2 PUMP P2
No.
checking screen No.
Screen
No.
Table 63
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Judging condition
Control in the
event of failure
Returned in
normal condition
Screen
9 E-2 PUMP P2
No.
checking screen No.
Screen
No.
T5-1-41
Table 64
Error code E032
Trouble OPT relief 1 proportional valve and output transistor ON are failure.
Symptom Electromagnetic relief valve is disabled.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 E-3 OPT RELIEF 1
No.
checking screen No.
Screen
No.
1 • OPT relief 1 proportional valve When E032 is cancelled and other error occurs by turning starter switch on after
2 • Wiring between OPT relief 1 When E032 is displayed after turning the starter switch on after the connector
Table 65
Error code E033
Trouble OPT relief 1 proportional valve's wiring is disconnected.
Judging condition
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 E-3 OPT RELIEF 1
No.
checking screen No.
Screen
No.
T5-1-42
Table 66
Error code E042
Trouble OPT relief 2 proportional valve and output transistor ON are failure.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 E-4 OPT RELIEF 2
No.
checking screen No.
Screen
No.
Table 67
Error code E043
Trouble OPT relief 2 proportional valve's wiring is disconnected.
Judging condition
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen
7 E-4 OPT RELIEF 2
No.
checking screen No.
Screen
No.
T5-1-43
Table 68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom Swing parking is not available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
3 F-2 SWING-BRAKE
No.
checking screen No.
Screen
No.
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure
found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
Table 69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24 V level while exciting command is not output.
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Screen
3 F-1 POWER BOOST
No.
checking screen No.
Screen
No.
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
T5-1-44
Table 70
Error code F031
Trouble Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is 24 V level while exciting command is output.
normal condition
Screen
3 F-3 1/2-TRAVEL
No.
checking screen No.
Screen
No.
1 • Travel 1, 2 speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2
speed solenoid valve and When F031 is displayed after the connector is exchanged with other solenoid
valve.
controller
CN-122F
CN-105F
T5-1-45
Table 71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen
3 F-3 1/2-TRAVEL
No.
checking screen No.
Screen
No.
1 • Travel 1, 2 speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2
speed solenoid valve and When F033 is displayed after the connector is exchanged with other solenoid
valve.
controller
CN-122F
and repair it if necessary..
CN-105F
Table 72
Error code F041
Trouble Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Screen
11 F-4 OPT SELECT
No.
checking screen No.
Screen
No.
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
T5-1-46
Table 73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Symptom Option selector valve does not change to breaker side or it does not change from breaker to nibbler.
Control in the
Normal control.
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Screen
11 F-4 OPT SELECT
No.
checking screen No.
Screen
No.
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
T5-1-47
Table 74
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging condition Engine rpm input is 3000 rpm or more. (Only trouble history).
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
Screen
2 G-3 MEAS 1 (for mechatro controller)
No.
2 G-3 MEAS 2 (receive from engine controller)
checking screen No.
Screen
No.
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SV-13 Normal value: 1.6~2.0k .
Check wiring for possible failure according to the wiring checking
solenoid valve and controller
procedure and repair it if necessary.
CN-136F
Especially check wiring for false disconnection and noise included.
CN-106F
(Controller is broken by only applying power to grounding of signal).
Table 75
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection.
Judging condition Voltage of alternator is 12 V or more, and speed sensor indicates excess low engine rpm.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
Screen
2 G-3 MEAS 1 (for mechatro controller)
No.
2 G-3 MEAS 2 (receive from engine controller)
checking screen No.
Screen
No.
SE-13 Normal value: 1.6~2.0k .
2 • Wiring between engine speed
sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-106F
(Controller is broken by only applying power to grounding of signal.).
T5-1-48
Table 76
Error code G042
Trouble Mechatro controller direct input speed sensor and received data from engine controller are overrun.
Judging condition Engine rpm input is 3000 rpm or more. (Only trouble history).
Control in the
Normal control
event of failure
Returned in
normal condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service diagnosis
Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen
Screen No.
CN-136F
Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
5 • Engine controller Check that the error is corrected after replacement of controller.
Table 77
Error code G043
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Voltage of alternator is 24V or more, and speed sensor and receipt data from engine controller
Judging condition
indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command
event of failure
Returned in
normal condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service diagnosis
Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen
Screen No.
CN-136F CN-106F
3 • Wiring between ECU engine
speed sensor and controller
5 • Engine controller Check that the error is corrected after replacement of controller.
T5-1-49
Table 78
Error code H013
Trouble Accel potentiometer is disconnected.
Judging condition The input voltage from accel potentiometer is 0.1 V or less.
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Screen
2 H-1 ACCEL VOLT.
No.
checking screen No.
Screen
No.
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-102F
Table 79
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging condition The input voltage from accel potentiometer is 4.7 V or more.
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Screen
2 H-1 ACCEL VOLT.
No.
checking screen No.
Screen
No.
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.0k .
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
CN-102F
T5-1-50
Table 80
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging condition The input voltage from fuel sensor is 0.1 V or less.
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Screen
10 H-9 FUEL LEVEL
No.
checking screen No.
Screen
No.
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 .~ FULL 5
2 • Wiring between fuel sensor and
controller Check wiring for possible failure according to the wiring checking procedure
CN-104F
Table 81
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging condition The input voltage from fuel sensor is 4.7 V or more.
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Screen
10 H-9 FUEL LEVEL
No.
checking screen No.
Screen
No.
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 .~ FULL 5
2 • Wiring between fuel sensor and
CN-104F
T5-1-51
Table 82
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging condition Reception from engine controller can not receive correctly.
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1 • Wiring between ECU and
controller
CN-3F
(There is a possibility of false disconnection).
CN-101F
Table 83
Error code I113
Trouble Reception of cluster communication is abnormal. (time-out error)
Judging condition Reception from gauge cluster can not receive correctly. It has been affected little.
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20 °C.
event of failure
Returned in
normal condition
Screen
2 G-5 WATER TEMP
No.
checking screen No.
Screen
No.
1 • Wiring between ECU and
CN-101F
T5-1-52
Table 84
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging condition Reception from gauge cluster can not receive correctly.
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
normal condition
Screen
No.
checking screen No.
Screen
No.
1 • Wiring between gauge cluster
and controller Check wiring for possible failure according to the wiring checking procedure
CN-101F
T5-1-53
Table 85
Error code K014
Trouble Battery relay contact welded.
The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON
Judging 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
Returned in Turn key switch ON.
normal condition Or when the power supply 24 V to mechatro controller is stopped.
Screen
4 K-1 AIS RELAY 2
No.
4 K-3 KEY SWITCH OFF
checking screen No.
Screen
No.
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24 V power lives on battery relay secondary side, check on battery
CN-256F relay for 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
R-24 relay coil side. If power of battery relay on secondary side falls, remove either
• Alternator relay auto idling stop relay 2 or 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
relay/alternator relay and When K014 is left displayed with the relay removed.
controller Check that no power 24 V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
CN-109F, CN2-1
When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box
Replace fuse/relay box.
E-1
T5-1-54
Table 86
Error code R014
Trouble Wiper motor arc prevention relay error.
The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen
25 PREVENT ARC
No.
checking screen No.
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 failed.
R-31 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed.
prevention relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse& relay box When no failure found after checking on wiring and R014 is left displayed.
E-1 Replace fuse/relay box.
T5-1-55
Table 87
Error code R024
Trouble Wiper motor forward rotation relay error.
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move.
Control in the
event of failure
Returned in
normal condition
Screen
25 CW MOTOR RLY
No.
checking screen No.
Screen
No.
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
2 • Wiring between wiper motor

forward rotation relay and When R024 is left displayed with the relay removed.
CN-109F, CN2-1
When no failure found after checking on wiring and R024 is left displayed.
• Fuse& relay box
E-1
T5-1-56
Table 88
Error code R034
Trouble Wiper motor reverse rotation relay error.
The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
Judging condition
power source.
Symptom Wiper does not move after forward rotation.
Control in the
event of failure
Returned in
normal condition
Screen
25 CCW MOTOR RLY
No.
checking screen No.
Screen
No.
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
2 • Wiring between wiper motor

forward rotation relay and When R034 is left displayed with the relay removed
CN-109F, CN2-1
When no failure found after checking on wiring and R034 is left displayed
• Fuse& relay box
E-1
T5-1-57
Table 89
Error code R044
Trouble Washer motor relay error.
Judging condition The mechatro controller output line to washer motor relay is short-circuited with the power source.
Symptom Washer motor does not move.
Control in the
event of failure
Returned in
normal condition
Screen
25 MOTOR RELAY
No.
checking screen No.
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 relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
• Fuse& relay box When no failure found after checking on wiring and R044 is left displayed
T5-1-58
Table 90
Error code R134
Trouble Swing flasher relay error.
Judging condition The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom Right swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
Screen
22 D13
No.
checking screen No.
Screen
No.
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher
R-19 relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal
condition.
2 • Wiring between swing flasher

When R134 is left displayed with the relay removed
relay and controller
Check that no power 24 V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F
figure C) according to the wiring checking procedure and replace it if necessary.
T5-1-59
Table 91
Error code R144
Trouble Swing flasher relay error.
Judging condition The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom Left swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
Screen
22 D14
No.
checking screen No.
Screen
No.
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher
R-19 relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal
condition.
2 • Wiring between swing flasher

When R144 is left displayed with the relay removed
relay and controller
Check that no power 24 V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F
figure B) according to the wiring checking procedure and replace it if necessary.
T5-1-60
Table 92
Error code R154
Trouble Travel alarm relay error.
Judging condition The mechatro controller output line to travel alarm relay is short-circuited with the power source.
Symptom Travel alarm does not actuate.
Control in the
event of failure
Returned in
normal condition
Screen
23 D15
No.
checking screen No.
Screen
No.
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit for
R-8 failure, replace it with new one if failed.
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
• Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
T5-1-61
Table 93
Error code R164
Trouble Auto idle stop relay 2 relay error.
Judging condition The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
event of failure
Returned in
normal condition
Screen
4 K-1 AIS RELAY 2
No.
checking screen No.
Screen
No.
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay unit
R-24 for failure, replace it with new one if failed.
2 • Wiring between auto idle stop When R164 is left displayed with the relay removed
relay 2 and controller Check that no power 24 V is produced on relay (-) line according to the wiring
T5-1-62
Table 94
Error code R174
Trouble Engine forcibly stop relay error.
Judging condition The mechatro controller output line to engine forcibly stop is short-circuited with the power source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate..
Control in the
event of failure
Returned in
normal condition
Screen
4 K-3 ENG STOP
No.
checking screen No.
Screen
No.
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check relay
R-25 unit for failure, replace it with new one if failed.
2 • Wiring between engine forcibly When R174 is left displayed with the relay removed
stop relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
T5-1-63
Table 95
Error code R184
Trouble Safety lock lever relay error.
Judging condition The mechatro controller output line to safety lock lever relay is short-circuited with the power source.
Symptom Safety lock lever timer does not actuate.
Control in the
event of failure
Returned in
normal condition
Screen
4 K-4 LOCK LEVER
No.
checking screen No.
Screen
No.
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is , it is in abnormal condition.
2 • Wiring between safety lock lever When R184 is left displayed with the relay removed
T5-1-64
TROUBLESHOOTING (BY TROUBLE) E135B
TROUBLESHOOTING BY TROUBLE
1. 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.
1. All controls do not function/slow

2. Engine down/stalled
3. Move at lever neutral position
4. Poor fine operability
5. Slow boom up, insufficient power
6. Slow boom down, insufficient power for lifting up body
7. Slow arm in, insufficient power
8. Slow independent arm out (in the air)
9. Slow bucket digging
10. Slow bucket dumping
11. Swing operation not functioned/slow
12. Noise during swing operation
13. Swing on a slope drifts when control lever is in neutral position
14. Swing drifts at stopping
15. Travel speed is slow/poor
16. Travel deviation
17. Travel 1st/2nd speed cannot be switched
18. Machine does not stay on slope in travelling
19. Machine does not travel straight in simultaneous operation of travelling and attachment.
20. Breaker works slowly and power is poor
21. Option selector valve malfunction: not switched to breaker circuit
22. Option selector valve malfunction: not switched to nibbler circuit
T5-2-1
E135B TROUBLESHOOTING (BY TROUBLE)
1. 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

(10 A) on the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by
switch diagnosis Push down the lever and it turns on, push tester, or check that the power
up and it turns off. voltage is lowered by pushing
the lever down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for
switching solenoid is switched connector. 24 V by pushing the lever possible failure.
correctly down, 0 V by pushing it up Check harness for possible
failure.
4 Safety lever lock Carry out service No.4 K-4 lock lever: Check action of relay by tester
relay diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor • Stop engine stop and key is on Check 5 V power for controller
position.
All pilot low pressure sensors are 0
MPa to 0.1 MPa.
6 Solenoid valve for Measure pressure About 0 MPa by pushing the lever up, Replace solenoid valve
safety lock lever of solenoid A1 port and 4 MPa or more by push it down.
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 4 MPa or more in high Check gear pump and the
primary pressure at idling relief valve for possible failure
gear pump
9 Multi control valve (in Change position Since all are blocked due to poor
case that travel is switching performance, check that the
operable) lever select pattern is set to the proper
position.
10 Actual measuring Carry out service • No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/ diagnosis D-1 P2 unload valve (cut valve) largely differed from the
P2 unload • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.3 Boom up full lever & check proportional valve and
relief controller for possible failure.
11 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2 MPa in boom up full lever and high
directly at the ports idling operation
A7 and A5 of 8
sections solenoid
block
12 Actual measuring Carry out service • No.9 E-1 P1 pump In case where the reading is
current value of P1/ diagnosis. E-2 P2 pump largely differed from the
P2 pump • See Service Diagnosis Data List actually measured value,
proportional valve Operation No.18 Travel right full lever check proportional valve and
& idling controller for possible failure.
Operation No.19 Travel left full lever &
idling
T5-2-2
13 Secondary pressure Measure the pump Check that pump proportional valve Replace proportional valve
of pump proportional proportional valve secondary pressure is 2.7 MPa or more
valve secondary pressure in right (left) travel full lever and high
directly in idling idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve
14 Main relief pressure Carry out service • See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures Reset or replace
are 32 MPa in boom up full lever, high
idling and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
17 Pump Visual check When removing, inside parts (cylinder Replace

block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.
2. Engine down/stalled
current value of P1/ diagnosis E-2 P2 pump largely differed from the
proportional valve Operation No. 1 Operation is nil check proportional valve and
controller for possible failure.
2 Secondary pressure Measure the pump Check that P1/P2 pump proportional Replace proportional valve
of P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0 MPa in control lever neutral
directly (Ports a3, and high idling operation.
a4)
3 Pressure sensor of Check pressure • See Service Diagnosis Data List Check pressure sensor and
P1, P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
resistance against sliding
Free from abnormal damage, etc on outside
surface

T5-2-3
3. Move at lever neutral position
1 Pilot pressure Carry out service Check that targeted pilot pressure of Check remote control valve
sensor diagnosis sensor is 0MPa in high idling
2 Remote control Check targeted Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage
3 Main spool Check targeted Check that spool is free from abnormal Replace
spool visually damage and spring is free from
breakage
4 Over load relief Check targeted Free from dust entered in port relief Replace
valve spool visually valve. Seat is free from abnormality
5 Lock valve poppet Check targeted Seat is free from abnormality Replace
(in case of boom and poppet visually
arm)
6 Lock valve selector Exchange lock Check that the trouble is reversed Replace
(in case of boom and valve selector of
arm) boom/arm and
boom/arm
7 Holding valve spool Check that smooth Free from abnormal resistance against Replace
for boom sliding of spool in sliding Do not pull spool out of sleeve
(in case of boom) sleeve forcibly.
8 Holding valve relief Check targeted Filter free from abnormal contamination Replace
valve for boom spool visually
(in case of boom)
9 Cylinder Check targeted Make sure of no problem of seals by Replace cylinder or seals
cylinder visually disassembling and investigation
4. Poor fine operability
1 Pressure sensor Carry out service • See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
• All low pressure sensors are 0MPa to
0.1 MPa
3 Secondary pressure Measure the Check that P1/P2 unloads secondary Replace proportional valve
of unload proportional valve pressures is within the range of 2.7 MPa
proportional valve secondary pressure or more in control lever neutral and high
A7 and A8 of 8
sections solenoid
block
T5-2-4
of P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5 to 1.0 MPa in control lever neutral
directly. (Ports a3, and high idling operation
a4)
6 Slow return check Visual check Check that slow return check valve Clean and replace
valve of pilot line installed on pilot line is free from dust
(in case of boom up entered
or arm out)
5. Slow boom up, insufficient power
1 Boom up pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0 MPa or more Check remote control valve
valve remote control in boom up full lever and high idling When equipped with multi
pressure of boom operation control valve, check it while
up changing lever pattern
3 Pump pressure Carry out service • See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high
operation. pressure sensor.
proportional valve Operation No.3 Boom up full lever & check proportional valve and
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2 MPa in boom up full lever and
directly at the ports high idling operation
A7 and A5 of 8
sections solenoid
block
proportional valve Operation No.4 boom up full lever & in check proportional valve and
operation controller for possible failure.
proportional valve secondary pressure 1.8 to 3.0 MPa in boom up full lever and
directly (Ports a3, high idling operation
a4)
T5-2-5
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)
valve breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for Visual check When removing, free from abnormal Replace
boom (poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.
13 Boom spool Visual check When removing, free from abnormal Replace
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool Disassembly and Free from abnormal resistance against Replace spool assembly
and recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is
low.
15 Conflux spool Visual check When removing, free from abnormal Replace
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
16 Main relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is relief
low.
17 Over load relief Visual check (Head Pressure is 32 MPa or more in boom up When only relief pressure of
valve side) full lever and high idling. Free from dust boom up is low, replace valve
<Trouble> entered in over load relief valve. Seat is
Relief pressure is free from abnormality
low.
6. Slow boom down, insufficient power for lifting up body
1 Boom down Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
T5-2-6
2 Remote control Measure remote Check that pressure is 3.0 MPa or more Check remote control valve
valve control pressure of in boom down full lever and high idling When equipped with multi
boom down directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis • See Service Diagnosis Data List largely differed from the
unload proportional Operation No.5 boom down full lever actually measured value,
valve & in operation check proportional valve and
4 Secondary pressure Measure the Check that P1 unload secondary Replace proportional valve
of P1 unload proportional valve pressures are within the range of 0.8 to
proportional valve secondary pressure 1.2 MPa in boom down full lever and
A7 of 8 sections
solenoid block.
pump proportional Operation No.5 boom down full lever actually measured value,
valve & in operation check proportional valve and
6 Secondary pressure Measure the pump Check that P1 pump proportional valve Replace proportional valve
of P1 pump proportional valve pressures are within the range of 2.0 to
proportional valve secondary pressure 2.5 MPa in boom down full lever and
a4)
7 Actual measuring Carry out service Check that the value is not change • Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight • See Service Diagnosis Data List • In case where the reading is
proportional valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value,
& idling check proportional valve
Operation No.19 Travel left full lever & and controller for possible
idling failure.
8 Travel straight Measure directly High idling pressure is 0.8 MPa or less Replace proportional valve
proportional valve the travel straight regardless neutral/operation
secondary pressure proportional valve
secondary
pressure.
valve breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
T5-2-7
11 Holding valve Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding Free from (Check on the casing side for
<Trouble> abnormal damage, etc on outside damage)
Boom down is slow. surface
12 Boom spool Visual check When removing, free from abnormal Replace
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Check boom spool Disassembly and Free from abnormal resistance against Replace spool assembly
Machine can not be
lifted by supporting
with boom.
low.
15 Over load relief Visual check Free from dust entered in port relief Replace
valve valve.
<Trouble> Seat is free from abnormality
Machine can not be
lifted by supporting
with boom.
7. Slow arm in, insufficient power
1 Arm in pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.6 arm in full lever and sensor
valve pressure remote control in arm in full lever and high idling When equipped with multi
pressure of arm in operation control valve, check it while
changing lever pattern
sensor diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high
operation. pressure sensor
proportional valve Operation No.6 Arm in full lever & check proportional valve and
T5-2-8
proportional valve secondary pressure 1.2 MPa in arm in full lever and high
directly at the ports idling operation.
A7 and A5 of 8
sections solenoid
block.
proportional valve Operation No.7 Arm in full lever & in check proportional valve and
of P1, P2 pump proportional valve valve pressures are 2.0 MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, operation. (Secondary pressure is
a4) affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service • See Service Diagnosis Data List In case where the reading is
current value of arm diagnosis Operation No. 1 Operation is nil largely differed from the
in spool 2 Operation No.6 Arm in full lever & actually measured value,
proportional valve relief check proportional valve and
Operation No.7 Arm in full lever & in controller for possible failure.
operation
9 Secondary pressure Measure directly Check that secondary pressure of Replace proportional valve
of arm in spool 2 the proportional proportional valve secondary pressures
proportional valve valve secondary are within the range of following
pressure at the Lever neutral: 0 MPa
ports A8 (arm 2 Motion in the air: 1.7 to 2.2 MPa
spool) of 8 sections Arm in relief: 2.5 MPa or more
solenoid block.
idling failure.
11 Secondary pressure Measure directly 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight the proportional regardless of neutral/operation
proportional valve valve secondary
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
valve breakage
T5-2-9
low.
14 Over load relief Visual check (Head Pressure is 32 MPa or more in arm in When only relief pressure of
valve side) and relief. arm in is low, replace valve
<Trouble> Free from dust entered in over load relief
P1, P2 pressure is valve.
low. Seat is free from abnormality
15 Over load relief Visual check (Rod Pressure is 32 MPa or more in arm out When only relief pressure of
valve side) and relief. arm out is low, replace valve
P1, P2 pressure is valve.
low. Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
P1, P2 pressure is Free from abnormal damage, etc on damage)
P1, P2 pressure is Free from abnormal damage, etc on damage)
high or low. outside surface
18 Check arm 2 spool Disassembly and Free from abnormal resistance against Replace spool assembly
Arm in power is
poor.
19 Check lock valve Visual check Free from abnormal resistance against Replace
poppet sliding (Check on the casing side for
Both P1, P2 outside surface
pressures are high.
8. Slow independent arm out (in the air)
1 Arm out pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
valve remote control in arm out full lever and high idling When equipped with multi
pressure of arm out operation control valve, check it while
T5-2-10
sensor diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high
proportional valve Operation No.8 Arm out full lever & check proportional valve and
proportional valve secondary pressure 1.2 MPa in arm out full lever and high
A7 and A5 of 8
sections solenoid
block
proportional valve Operation No.9 Arm out full lever & in check proportional valve and
proportional valve secondary pressure 1.5 to 2.7 MPa in arm out full lever and
a4) (Secondary pressure is affected by oil
temperature and attachment weight)
idling failure.
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
valve breakage
low.
T5-2-11
12 Over load relief Visual check (Rod Pressure is 32 MPa or more in arm out When only relief pressure of
valve side) and relief. arm out is low, replace valve
P1, P2 pressure is valve. Seat is free from abnormality
low.
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
outside surface
15 Check arm 2 spool Disassembly and Free from abnormal resistance against Replace spool assembly
<Trouble> (spring side) Spring is free from breakage.
Both P1, P2
pressures are low.
16 Check lock valve Visual check Free from abnormal resistance against Replace
poppet sliding (Check on the casing side for
Both P1, P2 outside surface
pressures are high.
9. Slow bucket digging
1 Bucket digging Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
2 Remote control Measure directly Check that pressure is 3.0M Pa or more Check remote control valve
valve remote control in bucket digging full lever and high When equipped with multi
pressure of bucket idling operation control valve, check it while
digging changing lever pattern
sensor diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high
unload proportional Operation No.12 Bucket digging full actually measured value,
valve lever & relief check proportional valve and
proportional valve secondary pressure 1.2 MPa in bucket digging full lever and
A7 and A5 of 8
sections solenoid
block
T5-2-12
pump proportional Operation No.13 Bucket digging full actually measured value,
valve lever & in operation check proportional valve and
of P1 pump proportional valve pressures is 2.7 MPa or more in bucket
proportional valve secondary pressure digging full lever and high idling
directly (Ports a3) operation.
current value of diagnosis Operation No.12 Bucket digging full largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve and
9 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
valve breakage
Operation No.3 Boom up full lever and
relief
12 Travel straight spool Visual check When removing, free from abnormal Replace
outside surface
13 Bucket spool Visual check When removing, free from abnormal Replace
Both P1, P2 Free from abnormal damage, etc on damage)
pressures are high. outside surface
14 Over load relief Check targeted Free from dust entered in over load relief Replace
valve spool visually valve.
Seat is free from abnormality.
10. Slow bucket dumping
1 Bucket dump Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.14 Bucket dump full sensor
valve remote control in bucket dump full lever and high idling When equipped with multi
pressure of bucket operation control valve, check it while
dump changing lever pattern
T5-2-13
sensor diagnosis for P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high
unload proportional Operation No.14 Bucket dump full actually measured value,
valve lever & relief check proportional valve and
of P1 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2 MPa in bucket dump full lever
directly at the ports and high idling operation.
A7 and A5 of 8
sections solenoid
block
pump proportional Operation No.15 Bucket dump full actually measured value,
valve. lever & in operation check proportional valve and
of P1 pump proportional valve pressures is 2.7 MPa or more in bucket
proportional valve secondary pressure dump full lever and high idling operation.
directly (Ports a3)
current value of diagnosis Operation No.14 Bucket dump full largely differed from the
travel straight lever & relief actually measured value,
9 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7 MPa or more in bucket
proportional valve valve secondary dump full lever and high idling operation
pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
low. piston (Check it through PBP2 port.)
valve breakage
T5-2-14
<Trouble> Operation No.3 Boom up full lever and
low.
outside surface
14 Bucket spool Visual check When removing, free from abnormal Replace
Both P1, P2 Free from abnormal damage, etc on damage)
pressures are high. outside surface
valve spool visually valve.
11. Swing operation not functioned/slow
1 Swing pressure Carry out service • See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
valve remote control in boom up full lever and high idling When equipped with multi
pressure of swing operation control valve, check it while
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF
4 Swing parking brake Measurement of Lever neutral: 0 MPa Replace solenoid valve
solenoid solenoid valve A2 In operation: 4 MPa or more
port
5 Shuttle valve Visual check No contamination on spool cover (short Clean or replace
<Trouble> side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle
6 Pump pressure Carry out service • See Service Diagnosis Data List Check high pressure sensor
sensor diagnosis for P2 Operation No.11 Swing full lever and
pump pressures in in operation
operation
T5-2-15
unload proportional Operation No.11 Swing full lever & in actually measured value,
valve operation check proportional valve and
proportional valve secondary pressure 1.2 MPa in swing full lever and high
A5 of 8 sections
solenoid block
pump proportional Operation No.11 Swing full lever & in actually measured value,
valve operation check proportional valve and
of P2 pump proportional valve pressure is 2.7 MPa or more in swing full
proportional valve secondary pressure lever and high idling operation
directly (Ports a3,
a4)
(Check this trouble Operation No.18 Travel right full lever actually measured value,
by only swing & idling check proportional valve
operation) Operation No.19 Travel left full lever & and controller for possible
idling failure.
(Check this trouble pressure at the
by only swing ports A6 (travel
operation) straight) of 8
sections solenoid
block
valve breakage
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
T5-2-16
15 Swing spool Visual check When removing, free from abnormal Replace
outside surface
16 Swing relief valve Check set pressure • See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
low.
17 Swing motor Visual check Inner parts (cylinder block, piston, valve Replace
brake etc) are to be free from abnormal
resistance against sliding.
outside surface (brake plate etc)
18 Swing reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from swing metal powder. reduction gear
reduction gear drain
19 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
12. Noise during swing operation
1 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
2 Measurement of Lever neutral: 0 MPa Replace solenoid valve

solenoid valve A2 In operation: 4 MPa or more
port
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of resistance against sliding
cavitation at Spring is free from breakage.
stopping)
4 By-pass check Visual check When removing, free from abnormal Replace
valve resistance against sliding
(Sound of Spring is free from breakage.
cavitation at
stopping)
5 Swing motor Visual check Disassemble and inspect abnormal Replace

(Brake valve/ wear and scuffing
friction plate)
6 Swing motor Visual check When removing, free from abnormal Replace
piston resistance against sliding
T5-2-17
7 Swing reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from swing metal powder. reduction gear
reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally Replace

worn and chipped.
13. Swing on a slope drifts when control lever is in neutral position
1 Swing pressure Carry out service • •Engine stop & starter key ON Check and replace pressure
sensor diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1 MPa.
valve breakage
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake release
switch
4 Measurement of Lever neutral: 0 MPa Replace solenoid valve

solenoid valve A2 In operation: 4 MPa or more
port
5 Swing motor Visual check Disassemble and inspect abnormal Replace

(Brake valve/friction wear and scuffing
plate)
6 Parking brake Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage
14. Swing drifts at stopping
1 Shuttle valve Visual check No contamination on spool cover Clean or replace

<Trouble> (short side) and orifice. No damage
Pilot pressure is on spool cover (long side) and
low shuttle.
2 Swing pressure Carry out service • Engine stop & starter key ON Replace pressure sensor
sensor diagnosis All pilot low pressure sensors are
within range of 0 to 0.1 MPa.
3 Swing relief valve Check set • See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.10 Swing full lever
Relief pressure is and relief
low.
T5-2-18
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.
5 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is free
valve from breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
15. Travel speed is slow/poor
1 Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
valve remote control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left
idling
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports (reverse) full lever and high idling
A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa
idling
T5-2-19
6 Secondary pressure Measure the pump Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, (reverse) full lever and high idling
a4) operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
7 Actual measuring Carry out service Check that the value is not change • Check voltage of low
current value of diagnosis regardless of operation pressure sensor other than
travel straight • See Service Diagnosis Data List sensor for travel
proportional valve Operation No. 1 Operation is nil • In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve and
idling controller for possible failure
8 Secondary pressure Measure directly the 0.8 MPa or less in high idling operation Replace proportional valve
of travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure
valve breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
outside surface
11 Travel spool Visual check of When removing, free from abnormal Replace
<Trouble> targeted spool resistance against sliding (Check on the casing side for
Pump pressure is Free from abnormal damage, etc on damage)
12 Travel motor relief Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel
valve 32 MPa or more in right and left travel motorÅfs relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel
locked crawler belt) and high idling motorÅfs relief valve is failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, valve Replace
plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
14 Parking brake in Visual check When removing, free from abnormal Replace
travel motor resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from travel metal powder. reduction gear
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
T5-2-20
16. Travel deviation
1 Travel right and left Carry out service • See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
valve remote control in travel right (left), forward (reverse) full
pressure of travel lever and high idling operation
right and left
3 Actual measuring Carry out service Check that the value is not change • Check voltage of low
current value of diagnosis regardless of operation pressure sensor other than
travel straight • See Service Diagnosis Data List sensor for travel
proportional valve Operation No. 1 Operation is nil • In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve
idling and controller for possible
failure.
pressure
idling
directly at the ports (reverse) full lever and high idling
A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa
idling
8 Secondary pressure Measure the pump Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, (reverse) full lever and high idling
a4) operation
Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more
T5-2-21
9 Exchange P1 for P2 Exchange delivery Check the direction of deviation If the direction is changed,
pipe of P1 for P2 inspect a pump. If the
direction is not changed,
inspect a valve and travel unit.
valve breakage
Check sealing ability of shuttle valve and
entry of dust in orifice
outside surface
Spring is free from breakage
12 Travel spool Visual check of When removing, free from abnormal Replace
<Trouble> targeted spool resistance against sliding (Check on the casing side for
Pump pressure is Free from abnormal damage, etc on damage)
13 Travel motor relief Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel
valve 32 MPa or more in right and left travel motorÅfs relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel
locked crawler belt) and high idling motorÅfs relief valve is failed.
Replace as necessary
14 Travel motor Visual check Inner parts (piston, cylinder block, valve Replace
plate, brake valve spool) are to be free
from abnormal resistance against
sliding.
15 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
gear oil from travel metal powder. reduction gear
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
resistance against sliding
outside surface

T5-2-22
17. Travel 1st/2nd speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft
ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the
function of automatic speed change.)
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, MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON, MEAS ON on gauge cluster
2 Travel 1/2 speed Measure A3 port Lever neutral: 0 MPa Replace solenoid valve
switching solenoid pressure on In operation: 4 MPa or more
solenoid valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in Visual check Free from abnormal wear on piston and Replace
travel motor seal (Check on the casing side for
damage)
18. Machine does not stay on slope in travelling
1 Pilot pressure Carry out service • Engine stop & starter key switch is ON Check pressure sensor and
sensor diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1 MPa Check remote control valve
valve breakage
3 Parking brake in Visual check When removing, free from abnormal Replace
travel motor resistance against sliding
4 Orifice of passage Visual check Free from entry of dust Remove dust or replace
for parking brake in
travel motor
19. Machine does not travel straight in simultaneous operation of travelling and attachment.
1 Actual measuring Carry out service No. 8 D-3 S-TRAVEL is should be • Check voltage of low
current value of diagnosis COMP 590 mA and MEAS 560~620 mA pressure sensor other than
travel straight in both travel full lever and in boom-up travel sensor
proportional valve full lever at high idling. • In case where the reading is
largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.
T5-2-23
2 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve
of travel straight the proportional range of 1.8 to 2.2 MPa in both travel full
proportional valve valve secondary lever and in boom-up full lever at high
pressure idling.
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
20. Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)
1 Pressure sensor for Carry out service • See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full sensor
valve remote control in optional attachment full lever and high
pressure of travel idling operation
right and left
3 Actual measuring Carry out service • See Service Diagnosis Data List •In case where the reading is
current value of P1/ diagnosis Operation No.16 P2 side OPT full largely differed from the
P2 unload lever and relief actually measured value,
proportional valve secondary pressure 1.2 MPa
directly at the ports
A7 and A5 of 8
sections solenoid
block
5 Actual measuring Carry out service • See Service Diagnosis Data List • Check voltage of low
current value of diagnosis Operation No.16 P2 side OPT full pressure sensor other than
travel straight lever & relief sensor for optional
proportional valve attachment
• In case where the reading is
largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.
6 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7 MPa or more in optional
proportional valve valve secondary attachment full lever and high idling
pressure at the operation
ports A6 (travel
straight) of 8
sections solenoid
block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
T5-2-24
8 Relief pressure Check set pressure • See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is 24.5
MPa.)
9 Remote control Check targeted Check sealing ability of shuttle valve and Replace
valve remote control entry of dust in orifice.
valve
outside surface
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
P1, P2 pressures outside surface
are high. Spring is free from breakage.
valve spool visually valve
21. Option selector valve malfunction: not switched to breaker circuit.

(Indication of failure is displayed. For reference, see "Table 1 - Action of optional selector solenoid valve")
1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector Screw for Check that the error indication is Replace solenoid valve
solenoid emergency disappeared by turning emergency
screw
3 N&B selector Carry out service • No.11 F-4 Option selector is B mode Check solenoid valve
solenoid diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector Carry out service • No.16 B-11 Check pressure sensor
pressure sensor diagnosis Data List Check harness
3.0 MPa at B mode and 0.0 MPa at A
mode
T5-2-25
22. Option selector valve malfunction: not switched to nibbler circuit.

(Indication of failure is displayed. For reference, see "Table 1 - Action of optional selector solenoid valve")
1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector Carry out service • No.11 F-4 Option selector is A mode Check solenoid valve
solenoid diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB
T5-2-26
Table 1 - Action of optional selector solenoid valve

Safety Optional Selector
Safety
lock selector valve
Engine lock lever Work Spool Failure diagnosis
No. lever valve detecting Warning display
condition SW's mode position display
relay's COMP. pressure
input
output MEAS. sensor
1 Running ON OFF A OFF Nibbler Normal — —
"SELECTOR VALVE [F042] displayed
2 Running ON OFF A ON Breaker Normal
FAILURE" simultaneously
"SELECTOR VALVE —
3 Running ON OFF A OFF Breaker Normal
FAILURE"
4 Running ON OFF A ON Nibbler Normal — [F042] displayed
5 Running ON OFF B ON Breaker Normal — —
"SELECTOR VALVE [F043] displayed
6 Running ON OFF B OFF Nibbler Normal
FAILURE" simultaneously
"SELECTOR VALVE —
7 Running ON OFF B ON N&B Normal
FAILURE"
8 Running ON OFF B OFF Breaker Normal — [F043] displayed
"SELECTOR VALVE [B113] displayed
9 Running ON OFF — — — Failure
FAILURE"
10 Stopping — — — — — — — —
11 — OFF — — — — — — —
12 — — ON — — — — — —
T5-2-27
2. ELECTRIC SYSTEMS
2.1 WIRING CHECKING PROCEDURE

Check for continuity between connector terminals, CONNECTOR
presence or absences of short-circuit with other
wires, and presence or absences of short-circuit
with machine body grounding.
1. Checking for disconnection between WIRE
connectors.
(When both ends measurement is easy
because of short distance between connectors) TESTER
SM0104
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.
(When both ends measurement is difficult

because of long distance between connectors)
JUMPER
Measure the resistance using tester. WIRE
Where the resistance is zero (0), if the terminal
on one side is connected to frame body
grounding with jumper wire, it is in normal TESTER
condition. FRAME BODY GROUNDING
The resistance is 1 M or more when the SM0105
terminal on one side is not connected to frame

body grounding with jumper wire, it is in normal
condition.
2. Checking for presence or absence of short-

circuit with machine body
When the resistance is 1 M or more, it is in
normal condition. TESTER
FRAME BODY GROUNDING
SM0106
3. Checking for presence or absence of short-

circuit between wirings.
When the resistance is 1 M or more, it is in
normal condition. TESTER
SM0107
T5-2-28
4. Checking connector terminal for contact

Insert male terminal into female terminal unit, INSERT
and then check that the inserting force is
equivalent to other female terminals.
If looseness is there, replace the female MALE TERMINAL FEMALE TERMINAL
terminal with new one.
SM0108
Clean the dirt terminal.
ATTENTION
Do not insert the male terminal the thickness differs.
It may cause loose connection.
5. 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.
Since the voltage may vary between with
connector connected and with connector not
connected. Measure the voltage with each
connector connected whenever possible.
6. Checking the general view of connector

CRIMPED
a. Check the terminal crimped condition. PART
Pull one electric cable with the about 3kg

force, and make sure that the cable does RUBBER
not come out of the terminal. PLUG
RECEPTACLE.
When came out, replace the terminal and CONTACT
crimp it again. PLUG
SEALING
b. Check connector for imperfect insertion (is housed in plug)
Check that all top ends form a line on the DOUBLE LOCK
PLATE FOR PLUG
same position as seen from the connector DOUBLE LOCK
engaged side. PLATE FOR CAP
When moved along, push it in further CAP

through wire inserting hole.
TAB.CONTACT
SM0109
c. Check connector for intruding of water. RUBBER PLUG
Pull out the connector and check that the

inside is free from intruding of water.
When water intruding is found, check
rubber plug for damage and also that the
sealing is fitted properly.
T5-2-29
7. When abnormality occurs at intervals

When the abnormality situation can not be
reoccurred during checking operation, try the
following operations.
a. Check that variable of display exists or not
on the service diagnosis screen while
shaking the harness or giving shock by
operating the machine.
b. Check that variables of resistance and
voltage exist or not using tester while
shaking the harness.
c. Turn starter switch on and apply electricity
continuously, and check it again after the
temperature of wiring and equipment was
raised.
8. 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.
Block of grounding is located
under floor plate of cab.
SM0110
T5-2-30
2.2 TROUBLE
1. Engine does not stop.
2. "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
3. Auto accel does not actuate. (The engine speed does not automatically slow down.)
4. Auto accel does not actuate. (The engine speed does not automatically speed up.)
5. Wiper does not function.
T5-2-31
1. Engine does not stop.

No
Sections Contents/normal value Corrective action, others
.
1 Starter key switch Check signal of No.4 K-3 Key switch Check continuity between
starter key switch OFF at starter key switch OFF terminals of starter switch
ON by carrying position using tester
out service ON at starter key switch ON position
diagnosis.
2 Engine forcible When ON is No.4 K-3 Key switch Check on engine forcible
stop relay displayed with the OFF at starter key switch OFF stop relay
starter switch position
OFF, then pull out ON at starter key switch ON position
R-25 engine
forcible stop relay
and carry out the
service diagnosis.
3 Wiring Voltage between 0 V when starter switch is OFF Check harness
line No.62 among Check diode D-9 between
starter switch, starter switch and auto
engine forcible idling stop relay 1
stop relay,
enginestop
solenoid and the
body grounding
2. "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No
.
1 Fuse No.1 fuse (5 A) Not blown fuse Check harness
Replace fuse
2 Mechatro Accel control Engine speed varies according to Check mechatro controller
controller accel potentiometer operation. and replace as necessary
(Use remote control because the
auto accel function is working.)
3 Wiring Transmission See “WIRING CHECKING Repair wiring
circuit line No.770 PROCEDURE"
from mechatro
controller to
gauge cluster
4 Gauge cluster Gauge cluster Replace gauge cluster
T5-2-32
3. Auto accel does not actuate. (The engine speed does not automatically slow down.)
No
.
1 Engine coolant Check engine No.2 G-5 WATER TEMP Replace engine coolant
temperature coolant Auto accel does not work in the sensor
temperature by temperature -15 °C or less.
carrying out Warm up and raise the coolant
service diagnosis. temperature to – 15 °C or more
2 Gauge cluster Indication of auto Mark "Display/not display" for auto Replace gauge cluster
accel accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is in the range of 0~0.1 MPa at
control lever neutral position.
4. Auto accel does not actuate. (The engine speed does not automatically speed up.)
No
.
1 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is raised with control lever
operated.
T5-2-33
5. 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
SM0111

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.19 D125 Check wiper interlock switch
Wiper interlock Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
switch Check according to "WIRING
CHECKING PROCEDURE"
and repair it if necessary
3 Rise up limit switch Service diagnosis No.25 Wiper system Check according to "WIRING
built-in wiper motor CHECKING PROCEDURE"
Reverse limit switch Switch action in operation
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay
When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
relay Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
R-30: Check that the relay is worked as shown in the table. Check that the relay is excited.
* When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
Reverse rotation from the wiper startup, turn OFF all relay's outputs. if necessary.
relay
T5-2-34
3. ENGINE
Factors Checking
Leak,
Filters Liquid
clogging
Air leak between turbocharger and intake manifold

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 starting ability (Takes 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 rotate (With fuel injection)
Insufficient
Engine poor run-up (Low follow-up ability)

rotation
Rotation in bad condition (hunting)
Engine stalled during operation

Poor output
Output is lowered
Overheating
Exhaust smoke is black
Exhaust smoke is white
Lager 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
T5-2-35
Factors Checking Electric equipment

Shovel side Shovel side Engine side
Loose mounting bolts, damage of mounting rubber
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 key switch
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble

Faulty starting

Insufficient

rotation

Poor output
Output is lowered
Overheating

Other failures

coolant quantity
Vibration
T5-2-36
Intake and Lubrication Cooling

Factors Fuel system exhaust system
system
system
Seizing and interference of turbocharger

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged
Failure of thermostat (Do not open)

Leak and crush of hydraulic piping
Fuel leak into the head cover
Improper fuel injection time
Failure of regulation valve
Damage of water pump

Failure of supply pump
Failure of relief valve

Failure of injector
Failure oil pump

Trouble
Faulty starting

Insufficient

rotation

Poor output
Output is lowered
Overheating

Other failures

coolant quantity
Vibration
T5-2-37
Factors Engine body
Wear and damage of rear oil seal and seal surface

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
Faulty engine starting/engine rotates but no exhaust gas

(No fuel injection)
Faulty engine starting/exhaust gas is emitted but engine
does not rotate (With fuel injection)
Insufficient

rotation

Poor output
Output is lowered
Overheating

Other failures
Intruding of oil in coolant, back flow, reduction of coolant

quantity
Vibration
T5-2-38
TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) E135B
1. TROUBLE DIAGNOSIS MODE
The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not
be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal
output.
1. Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are
automatically actuated, the sensor detects the machine condition and the mechatro controller identifies
the normal condition or failed condition of the system.
2. How to use and flow chart

The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing
buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
T5-3-1
E135B TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
No.1 No.2 No.3

SELECT SWITCH
LANGUAGE/LOGO 8 FAULT DIAG MODE DIAG MODE 1
BUZZER STOP SWITCH
ADJUSTING MODE 1 DIAG MODE 2
PRESET BY FACTORY
FEED SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1
SENSOR CHECK START ENG LOWER BOOM DIAG MODE 1

ENGINE SPEED
RELEASE LOCK In diagnosis
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND LEVER START operation
PROPO-VALVE About 15 minutes
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
For
Forthe
tthediagnosing
diagnosingitems,
items,see
seeTable
Table 48-1.
1.
When
Whenrequired
requiredto
tostop
stopin indiagnosis
diagnosis
Turn engine on operation,press
operation, pressthe
thebuzzer
buzzerstop
stopswitch
switch
manually. BACK TO No.3 and
andthetheoperation
operationisisforcedly
forcedlystopped.
stopped.
The data at the time of judgment

can be confirmed with the select
RESULT OF DIAGNOSIS RESULT OF DETAIL switch.
When
DIAG MODE 1 not failed, DIAG MODE 1 1 P1 UNLOAD
ENGINE SPEED
0000 rpm
END ENGINE STOP OK O K PRESSURE
C-1 00.0M C-2 00.0M
PROPO-VALVE
E-1 005mA E-2 005mA
DATA END FEED D-1 300mA D-2 300mA
The other judgments can be

Engine stops confirmed with the feed button.
automatically. RESULT OF DIAGNOSIS
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm
P1 UN-LOAD SPOOL NG NG PRESSURE

C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
The suspected trouble sections are displayed in order of

possibility. The suspected three sections in maximum are
BACK TO No.3 displayed. When desired to see other suspected trouble sections,
press feed " " button. For diagnosis results and corrective
actions to be taken, see Table 2.
SM0114
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground.
If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or
death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail
to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select
valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually
measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis
possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as
an example. When multiple troubles are occurred at the same time, there is a case no accordance of
diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-2
No.4 CASE OF DIAG MODE 2
SENSOR CHECK START ENG

ENGINE SPEED
LOWER BOOM DIAG MODE 2
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND START
PROPO-VALVE
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
In the normal condition, OK is

displayed when the control
lever is moved to stroke end.
SM0115
SEARCHABLE OPERATION
Boom up
Boom down
Bucket digging
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P2 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground.
If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or
death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail
to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place
the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate
attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-
LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
T5-3-3
Table 1 - Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum
1 1 P1 UNLOAD
and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
2 2 P1 UNLOAD
P1 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
3 3 P1 UNLOAD
and P1 side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency
4 1 P2 UNLOAD
position, and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
5 2 P2 UNLOAD
P2 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
6 3 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the flow rate at P1 side is
7 1 P1 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
8 2 P1 PUMP
P1 side flow rate is minimum?
9 3 P1 PUMP
position, and P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is
10 1 P2 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
11 2 P2 PUMP
P2 side flow rate is minimum?
12 3 P2 PUMP
position, and P2 side flow rate is maximum?
Is normal pressure generated in the condition that P1 side flow rate is minimum,
13 1 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum,
14 2 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little
15 1 P1 ENGINE
by little when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little
16 2 P2 ENGINE
by little when P2 side flow rate is relieved?
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
SENSOR CHECK Disconnection of pressure sensor, Short
service diagnosis and replace it if
NG circuit, Abnormal output
necessary
Secondary pressure is excessive high
against the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
P1 UN-LOAD SPOOL Stuck at full-stroke side Check P1 unload spool and replace it
NG Stuck at neutral side if necessary
T5-3-4
Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
against the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
against the command
P2 UN-LOAD SPOOL Stuck at full-stroke side Check P2 unload spool and replace it
NG Stuck at neutral side if necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
against the command Check P1 pump proportional valve
P1 PUMP PSV NG
against the command
Delivery rate is excessive large against the Check P1 pump regulator and
command replace it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.
against the command Check P2 pump proportional valve
P2 PUMP PSV NG
against the command
Delivery rate is excessive large against the Check P2 pump regulator and
command replace it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.
against the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low valve and replace it if necessary
against the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
PUMP 1 PRESS. SEN- Check P1 high pressure sensor and
Pressure is recognized lower than it is
SOR NG replace it if necessary
PUMP 2 PRESS. SEN- Check P2 high pressure sensor and
Pressure is recognized lower than it is
SOR NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary
T5-3-5
[MEMO:]
T5-3-6
REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS E135B
Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly
Group 2 Tightening Tourque
Section 2 UPPERSTRUCTURE
Group 1 Upperstructure
Group 2 Pump device
Group 3 Control device
Group 4 Swing device
Group 5 Pilot valve
Section 3 UNDERCARRIAGE
Group 1 Swing bearing
Group 3 Swivel joint
Group 4 Track adjuster
Group 5 Front idier
Group 6 Upper and lower roller
Group 7 Tracks
Section 4 FRONT ATTACHMENT

Group 1 Front attachment
Section 5 ENGINE
Group 1 General
Group 2 Service data
Group 3 Service tools
Group 4 Determination of overhaul
Group 5 Disassembly of basic engine
Group 6 Inspection and repair of basic engine
Group 7 Reassembly of basic engine
Group 8 Fuel system
Group 9 Lubrification system
Group 10 Cooling system
Group 11 Inlet and exhaust system
Group 12 Electrical system
Group 13 Adjustment and operatio
Group 14 Trobleshooting
1-
SECTION 1 E135B
GENERAL INFORMATION
CONTENTS
Group 1 - Precautions for Disassembly Group 2 - Tightening Torque

and Assembly Torque Chart .......................................... W1-2-1
Precautions for Disassembly and Piping Joint............................................. W1-2-4
Assembly .......................................... W1-1-1
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY E135B
PRECAUTIONS FOR DISASSEMBLY AND

ASSEMBLY
PREPARATIONS FOR DISASSEMBLY - If it is unavoidably necessary to disassemble and

modify, it should be carried out by experts or
- Thoroughly wash the machine before bringing it
personnel qualified through service training.
into the shop. Bringing a dirty machine into the
shop may cause machine components to be - Make match mark on parts for reassembling.
contaminated during disassembling/assembling, - Before disassembling, read Disassembling
resulting in damage to machine components, as Instruction in advance, and determine if the
well as decreased efficiency in service work. disassembly and assembly are permitted or not.
- Be sure to thoroughly understand all - For parts which are required to use jig and tools,
disassembling/assembling procedures don’t fail to use the specified jig and tools.
beforehand, to help avoid incorrect disassembling - For parts which can not be removed in the
of components as well as personal injury. specified procedure, never force removal. First
- Check and record the items listed below to check for the cause.
prevent problems from occurring in the future. - Inspecting parts. Measure the wear of parts and
1. The machine model, machine serial clearance, and record the measured values.
number, and hour meter reading.
- If an abnormality is detected, repair or replace the
2. Reason for disassembly (symptoms, failed parts.
parts, and causes).
- The removed parts should be put in order and
3. Clogging of filters and oil, water or air leaks, tagged so as to install on proper places without
if any. confusion.
4. Capacities and condition of lubricants.
- For common parts, pay attention to the quantity
5. Loose or damaged parts. and places.
- Prepare the necessary tools to be used and the
area for disassembling work.
REASSEMBLING HYDRAULIC EQUIPMENT
- Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves. - During the parts cleaning, ventilate the room.
- Confirm the position of first-aid kit and fire - Remove adhering oil by compressed air, and
extinguisher, and also where to make contact for apply hydraulic oil or gear oil, and then assemble
emergency measure and ambulance to prepare them.
for accidents and fire. - Replace the removed O-ring, back-up rings and
- Attach "Don’t operate" tag to control lever, and oil seal with new ones, and apply gear oil on them
begin a meeting before starting the work. before assembling.
- Removes dirt and water on the surface on which
liquid sealant are applied, decrease them, and
DISASSEMBLING AND ASSEMBLING
apply liquid sealant on them.
HYDRAULIC EQUIPMENT
- Before assembling, remove rust preventives on
- Before removing pipes, release the pressure of new parts.
hydraulic oil tank, or open the cover on the return
- Use special tools to fit bearings, bushing and oil
side to tank, and take out the filter.
seal.
- Drain the oil in the removed pipes into pan to
prevent the oil from spilling on the ground. - Assemble parts matching to the marks.
- After completion, check that there is no omission
- Pipes with plugs or caps to prevent oil leaking,
of parts.
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.
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.
W1-1-1
E135B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
INSTALLING HYDRAULIC EQUIPMENT

- Confirm hydraulic oil and lubrication oil.
- Bleeding Air from Hydraulic System
Air release is required in the following cases:
1. Change of hydraulic oil
2. Replacement of parts on suction pipe side
3. Removing and attaching hydraulic pump
4. Removing and attaching swing motor
5. Removing and attaching travel motor
6. Removing and attaching hydraulic cylinder
IMPORTANT: if hydraulic oil and lubricating oil are

not filled and also air bleed is not performed, the
hydraulic equipment may be damaged.
- 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.
IMPORTANT: for cylinder, don’t move it to the

stroke end at beginning.
- Air in pilot circuit can be bleed out by only

operating digging, swing and travelling motions
thoroughly.
- Check hydraulic oil level.
Move attachments to hydraulic oil check position,
as indicated in the figure.
- Open the hydraulic pump compartment door, then
check the oil level on visual indicator (1) located
on the hydraulic oil reservoir. If the indicator is
within level marks, the oil quantity is acceptable.
W1-1-2
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY E135B
Floating Seal Precautions

1. In general, replace the floating seal with a new
one. If the floating is to be reused, follow these
procedures: A
1) Keep seal rings together as a matched set
with seal ring faces together. Insert a piece
of cardboard to protect surfaces.
2) Check the seal ring face (A) for scuffing,
scoring, corrosion, deformation or uneven
wear.
3) Check O-Ring (B) for tears, breaks,
deformation or hardening.
B
2. If incorrectly assembled, oil leakage or damage SM0172
will occur. Be sure to do the following, to
prevent trouble.
1) Clean the floating seal and seal mounting
bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with
compressed air.
2) Clean the floating seal and seal mounting
bores, as dust on them tends to enter the
floating seal when installing it.
3) Check that the O-Ring is not twisted, and
that it is installed correctly on the seal ring.
4) After installing the floating seal, check that RIGHT
seal ring surface (C) is parallel with mating
face (A) by measuring the distances (a) and
(b), as illustrated.
If these distances differ, correct the O-Ring WRONG
(B) seating.
SM0173
RIGHT WRONG
a
A a
b b
a=b a≠b
SM0174
W1-1-3
E135B PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
ELECTRICAL EQUIPMENT
- 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.
- 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.
- Remove battery grounding terminal before
beginning work close to battery and battery relay
with tools.
WARNING
Battery fluid is dangerous. 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 was swallowed:
drink milk or water.
W1-1-4
TIGHTENING TORQUE E135B
TORQUE CHART
WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque
specifications. Two kinds of bolts, hexagon bolts T
and socket bolt, each made of different material, are
used. Make sure to employ the correct bolts and
tighten them to specification when assembling the
machine or components.
Hexagon T Bolt Socket Bolt
SM0175
Specified Tightening Torque Chart
T Bolt,
Hexagon
Wrench Socket
Bolt Dia. Wrench
Size bolt
Size
(Nm)
M18 13 6 29.5
M10 17 8 64
M12 19 10 108
M14 22 12 175
M16 24 14 265
M18 27 14 390
M20 30 17 540
M22 32 17 740
M24 36 19 930
M27 41 19 1370
M30 46 22 1910
M33 50 24 2550
M36 55 27 3140
W1-2-1
E135B TIGHTENING TORQUE
IMPORTANT
1. Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their
friction coefficients.
2. Torque tolerance is ± 10%.
3. Be sure to use bolts of correct length. Bolts that
are too long cannot be tightened, as the bolt tip
comes into contact with the bottom of the bolt
hole. Bolts that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart are for general
use only.
Do not use these torques if a different torque is
given for a specific application.
5. Make sure that the nut and bolt threads are
clean before installing. Remove dirt or
corrosion, if any.
Bolt Tightening Order

When tightening two or more bolts, tighten them
alternately, as shown, to ensure even tightening.
Equally tighten upper

and lower alternately Tighten diagonally Tighten from center and diagonally
1.4 1 12 9 4 1 6 7 14
6 3
4 5
2.3 13 8 5 2 3 10 11
2
SM0176
W1-2-2
Service Recommendations for Split Flange
IMPORTANT
1. Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal
wear. Unevenness causes seal extrusion. If SM0177
defects cannot be polished out, replace the
component.
2. Be sure to use only specified O-rings. Inspect
WRONG
O-rings for any damage. Take care not to file O-
ring surfaces. When installing an O-ring into a
groove, use grease to hold it in place.
3. Loosely assemble split flange halves. Make
sure that the split is centrally located and
perpendicular to the port. Hand-tighten the
bolts to hold the parts in place. Take care not to
pinch the O-ring.
4. Tighten bolts alternately and diagonally, as SM0178
shown, to ensure even tightening.
5. Do not use air wrenches. Using an air wrench
often causes tightening of one bolt fully before
tighten the others, resulting in damage to O-
rings or uneven tightening of bolts.
Nut and Bolt Lockings SM0179
• Lock Plate
RIGHT WRONG
IMPORTANT: do not reuse lock plates. Do not try to
bend the same point twice.
• Cotter Pin
Do not bend it round
Bend along edge sharply
IMPORTANT: do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while
loosening.
RIGHT RIGHT WRONG
• Lock Wire
IMPORTANT: apply wire to bolts in the bolt-
tightening direction, not in the bolt-loosening
direction.
Bend along edge sharply
SM0180
RIGHT RIGHT WRONG
RIGHT WRONG
Loosen
Tighten
SM0181
W1-2-3
PIPING JOINT
Pipe Thread Connection / Union Joint
Tightening Torque Specifications 1 4 3 5 2
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines.
Joint Body SM0182
IMPORTANT
1. Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces
(4) and (5), possibly cracking adaptor (1). Be 37°
sure to tighten union nut (3) to specifications.
37°
2. Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint.
Take care not to damage them when
connecting /disconnecting. Male Union Joint Female Union Joint
SM0183
Wrench Size Tightening Torque

Type
Union Nut Joint Body (Nm)
37° Union Joint 19 17 29
22 19 39
27 22 78.5
36 30, 32 157
41 36 205
50 46 323.6
NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.
W1-2-4
O-Ring Seal Joint

O-Ring (6) seats against the end face of adaptor (7)
to seal pressure oil. 7 6 9
IMPORTANT
1. Be sure to replace O-Ring (6) with a new one
when reconnecting.
2. Before tightening union nut (9), confirm that O- 8 10 Joint body
SM0184
Ring (6) is seated correctly in O-Ring groove
(8). Tightening union nut (9) with O-Ring (6)
displaced will damage O-Ring, resulting in oil
leakage.
3. Take care not to damage O-Ring groove (8) or
sealing face (10). Damage to O-Ring (6) will
cause oil leakage.
4. If union nut (9) is found to be loose, causing oil
leakage, do not tighten it to stop the leak.
Instead, replace O-Ring (6) with a new one,
then tighten union nut (9) after confirming that
O-Ring (6) is securely seated in place.
Wrench Size Tightening Torque

Union Joint
(Nm)
Nut Body
19 17 29.4
22 19 68.6
27 22 93
30 27 137.3
36 30 175
41 36 205
50 46 320
W1-2-5
Screwed-In Connection
IMPORTANT: many types of screwed-in connec- PT PF

tions are used for hose connections.
Be sure to confirm that the thread pitch and thread 30°
type (tapered or straight) are the correct type before
using any screw-in connection.
Male Tapered Thread Male Tapered Thread Male Straight Thread
Wrench Tightening Torque SM0185
Joint Body (Nm)

17, 19 34
22 49
27 93
36, 32 157
41 205
50 320
60 410
Seal Tape Application

Seal tape is used to seal clearances between male Internal Thread
and female threads, so as to prevent any leakage
between threads.
Clearance
Be sure to apply just enough seal tape to fill up
thread clearances. Do not overwrap. External Thread SM0186
• Application Procedure
Leave one to two pitch threads uncovered
Confirm that the thread surface is clean, free of
dirt or damage.
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque

Low-pressure-hose clamp tightening torque differs
SM0187
depending on the type of clamp.
See below for correct tightening torque of each type
of low-pressure-hose clamp. T-Bolt Type Worm Gear Type
T-Bolt Type Band Clamp:

4.4 Nm (0.45 kgf m)
Worm Gear Type Band Clamp:
5.9 a 6.9 Nm (0.6 a 0.7 kgf m)
SM0188 SM0189
W1-2-6
Connecting Hose
WARNING
WRONG RIGHT
1. When replacing hoses, be sure to use only
genuine parts. Using hoses other than genuine
hoses may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in a fire
on the machine.
2. Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or SM0190
separation of fitting.
Utilize print marks on hoses when installing
hoses to prevent hose from being installed WRONG RIGHT
kinked.
Rubbing Against Each Other
3. If hoses rub against each other, wear to the
hoses will result, leading to hose rupture. Take
necessary measures to protect hoses from
rubbing against each other.
Take care that hoses do not come into contact SM0191
with moving parts or sharp objects.
WRONG RIGHT
Clamp Clamp
Rubbing
SM0192
WRONG RIGHT
Rubbing
Clamp
SM0193
W1-2-7
NOTE:
W1-2-8
SECTION 2 E135B
UPPERSTRUCTURE
CONTENTS
Group 1 - Upperstructure Group 3 - Control valve

Removal and installation of Removal and installation of control valveW2-3-1
upperstructure....................................... W2-1-1 Preparation ....................................... W2-3-1
Preparation ....................................... W2-1-1 Removal of control valve................... W2-3-1
Removal of upperstructure ............... W2-1-1 Installation of control valve................ W2-3-2
Removal and installation of the cab ....... W2-1-2 Control valve ports ................................. W2-3-3
Removal of the cab ........................... W2-1-2 Assembly and disassembly of control
Installation of the cab ........................ W2-1-3 valve...................................................... W2-3-12
Removal and installation of Preparation for disassembly ............. W2-3-12
counterweight........................................ W2-1-4 Inspection after disassembly............. W2-3-25
Removal of counterweight ............... W2-1-4 Reassembly ...................................... W2-3-25
Installation of counterweight ............ W2-1-5 Maintenance standards.......................... W2-3-31
Disconnecting hoses of swivel joint Trobleshooting ....................................... W2-3-32
lower side.............................................. W2-1-6
Removal and installation of main frame. W2-1-7 Group 4 - Swing device
Removal of main frame..................... W2-1-7 Removal and installation of swing
Installation of main frame.................. W2-1-8 device.................................................... W2-4-1
Preparation ....................................... W2-4-1
Group 2 - Pump device Removal ........................................... W2-4-2
Removal and installation of hydraulic Installation ........................................ W2-4-3
pump device.......................................... W2-2-1
Disassembly and assembly of swing
Preparation ...................................... W2-2-1 device ................................................... W2-4-4
Removing of the hydraulic pump
device .............................................. W2-2-2
motor .................................................... W2-4-6
Installing of the hydraulic pump
Preliminary operations ...................... W2-4-8
device ............................................. W2-2-5
Disassembly...................................... W2-4-8
Main pump ............................................. W2-2-9
Assembly .......................................... W2-4-14
Gear pump ............................................. W2-2-10
Power take off (PTO) ............................. W2-2-11 reduction unit ........................................ W2-4-21
Disassembly hydraulic pump device...... W2-2-12 Disassembly...................................... W2-4-22
Assembly .......................................... W2-2-16 Assembly .......................................... W2-4-27
Maintenance standard .......................... W2-2-20 Maintenance standards ......................... W2-4-33
Troubleshooting ..................................... W2-2-21 Swing motor ...................................... W2-4-33
Disassembly and assembly of regulator... W2-2-23 Reduction unit ................................... W2-4-35
Regulator disassembly ..................... W2-2-24 Special tools .......................................... W2-4-37
Regulator assembly .......................... W2-2-27 Swing motor ...................................... W2-4-37
Disassembly and assembling PTO unit.... W2-2-30 Swing reduction unit.......................... W2-4-35
Maintenance standard ...................... W2-2-32
Tool table .......................................... W2-2-33
Group 5 - Pilot valve

Removal and installation of right and
left pilot valve ........................................ W2-5-1
Preparation ....................................... W2-5-1
Removal............................................ W2-5-1
Installation......................................... W2-5-2
Removal and installation of travel pilot
valve...................................................... W2-5-3
Preparation ....................................... W2-5-3
Removal............................................ W2-5-3
Installation......................................... W2-5-4
Disassembly right and left pilot valve ..... W2-5-5
Disassembly right and left pilot valve W2-5-6
Assembly right and left pilot valve.......... W2-5-9
Assembly right and left pilot valve..... W2-5-10
Pilot valve (for travel) ............................. W2-5-13
Construction...................................... W2-5-13
Disassembly and assembly .............. W2-5-14
Drain of hydraulic pilot control unit.... W2-5-21
UPPERSTRUCTURE E135B
REMOVAL AND INSTALLATION OF UPPERSTRUCTURE
WARNING
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear
and appropriate to hold the weight of load.
Preparation Removal of upperstructure

1. Park the machine on a firm, level surface. 1. Remove the front equipment and the boom
cylinders, performing the operations described
in the procedure at pages W4-1-1 (Refer to:
2. To drain the hydraulic pressure from the Section 4 - “Front Attachment”).
Hydraulic System, refer to procedure
“Releasing the hydraulic pressure” at page T2-
1-47. 2. Remove the cab, performing the operations
described in the procedure at page W2-1-2
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual 3. Remove the counterweight, performing the
pressure present in the tank itself. operations described at page W2-1-4.
4. Disconnect the hoses of swivel joint lower side,

performing the operations described in the
procedure at page W2-1-6.
5. Remove the main frame performing the

operations described in the procedure at page
W2-1-7.
W2-1-1
E135B UPPERSTRUCTURE
REMOVAL AND INSTALLATION OF THE CAB
Removal of the cab

1. Remove floor mat.
2. Remove cover (1). 1
Lift cover (1) upwards and remove it. (Fixed
with 2 clips).
3. Remove cover assy (2).
1) Loosen 4 sems bolts (3) M6x16 and lift
cover assy (2) up.
2) Disconnect each connector for both
speakers. Then remove cover assy (2).
4. Remove the harness connector (See section 3
T2, group 3) 2
1) Disconnect connectors of cluster gauge
harness: (CN-5F), (CN-6F), (CN-61F), (CN-
62F) and earth wire (P-1) at rear right of cab.
2) Disconnect antenna cable coming from SM0259
backside of tuner at rear left of cab.

5. Remove the plastic tube for the window washer Disassembly and assembly of cover (1)
from the rear left of cab. and cover assy (2)
6. Remove the right panel of cab.

1) Remove 2 caps (4), loosen 2 sems bolts (5)
M6x25 and 1 sems bolt (6) M6x16, and right
panels (7) and (8) are freed.
: TORX driver T30 9
2) Lift cover (9) upwards and remove it. (Fixed
with 3 clows and 2 clips).
3) Unfix 3 harness clips (10) of inside on right
panel (8). And free the harnesses
connected to key switch. 3
4) With harnesses are connected condition,
10
install key switch cover (9) to bracket (11) of 5
rear cab temporally. (See Fig. SM0261).
4 7
5) Disconnect harness connectors of work light
switch on right panel (7), air conditioner 10 6
panel and cigarette lighter, and remove right 5
panel (7) and (8).
6) Loosen sems bolts (12) M6x16 and (13) 10
M6x40, one each, and remove front panel 4
(14) with air conditioner duct. 8
: Plus driver
12
14
13 SM0260
Disassembly and assembly of right panels

(8), (9) and (14)
W2-1-2
7. Remove cab attaching bolt.

9
1) 5 capscrews (15) M12x65 and 1 capscrew
(16) M12x30
2) 2 nuts (17) M16
8. Slinging cab.
1) Remove two plastic plugs at the front of the 11
ceiling of the cab. Then place a wire sling
with eye bolts (18) and a hook around the
cab, as shown in Fig. SM0263.
2) Then lift up slowly avoiding interference with
surroundings.
Eye bolts M10 (q.ty 2).
Wire with hook:
Length 1.5 m (4ft 11in), Dia. 8 mm (0.315in)
– (3 pcs).
NOTE: weight of cab: Approx. 265 kg (584 lbs) SM0261
17 15
installation of the cab

Install it in reverse order of removing according to 15
the Tightening Torque Table.
Tightening
Allen wrench
Tightening position torque
HEX
Nm (lbf•ft) 16
Nut M16 - (17) 24 191 (140)
Capscrew - (2), (9) 19 79.4 (60) 15
Sems bolt M6 - Torxdriver 15
8.5 (6.3) Smontaggio e rimontaggio dei bulloni di fissaggio
(5), (6) T30 15
cabina SM0262
Sems bolt M6 -
Plus driver 5.0 (3.7)
(12), (13)
18
18
SM0263
W2-1-3
REMOVAL AND INSTALLATION OF

COUNTERWEIGHT
Removal of counterweight
1. Remove plugs (1) from the counterweight and
attach two M36 eye bolts to the counterweight.
1
NOTE: approximate mass of counterweight:

2000 kg (4410 lbs)
2. Attach wire rope (2) to eye-bolts (3) using

shackles.
Take out slack of wire rope by applying tension
slowly with a crane or hoist. SM0264
Wire with hook:
Length 1.5 m, dia. more than 16 mm – (2 pcs.).
3. Remove 4 bolts (4) M27.

Lift counterweight using a crane or hoist.
: 41 mm 2
4. Remove shim (5), (6), (7) from the frame. 3
5
6
7
4 SM0265
5. Lower the counterweight on proper stand.
SM0266
W2-1-4
Installation of counterweight
NOTE: approx. weight of counterweight: 2000 kg

(4410 lbs)
1. Attach lifting tools (2) to eye-bolts (3) of 2

counterweight.
2. Install shim (5), (6), (7) onto the frame as it was. 3
3. Lift counterweight and install it onto the frame. 5

6
7
4. Install bolts M27 (4) and washers to
counterweight and tighten temporarily.
: 41 mm
4 SM0265
1
5. Remove wire rope.
Tighten the bolts (4) with a power wrench and
torque wrench.
: 41 mm
: 1150 ± 150 Nm (848 ± 110 lbf•ft)
6. Remove eye-bolts (3) and install plugs (1) onto

the counterweight.
4 SM0267
W2-1-5
DISCONNECTING HOSES OF SWIVEL JOINT

LOWER SIDE
Disconnect the hoses on the lower side of swivel joint.
NOTE: close all openings with plugs to keep clean.
1. Disconnect the two hoses (1). (E Port: PF1/2)

: 27 mm
2. Disconnect the hoses (2) and (3).
(A and B Port: 1 3/16-12 UN)
: 36 mm
Tightening torque: 177 ± 18 Nm (130.5 ± 13.2 lbf•ft)
3. Disconnect the hoses (4) and (5).
(C and D Port: 1 3/16-12 UN)
: 36 mm
Tightening torque: 177 ± 18 Nm (130.5 ± 13.2 lbf•ft)
4. Disconnect the two hoses (6). (H and I Port:
PF1/4)
: 19 mm
1 1
H I 5
4
C D 3
2
B
A
E E
6 6
SM2642
W2-1-6
REMOVAL AND INSTALLATION OF MAIN

FRAME
Removal of main frame
NOTE: approximate mass of main frame: 3300 kg

(7277 lbs).
1. Attach a chain block (1) to the boom foot side

and the rear of the upper frame.
2. Adjust chains lengths to level the frame.
IMPORTANT: make sure rear chains do not touch

engine.
SM2663
W2-1-7
3. Put matching marks (M) on swing bearing and

M
main frame.
4. Remove the 36 bolts (5) M16, the reamer bolt

(6) M24, from the swing bearing.
: 24 mm
5
5. Lift main frame slightly from undercarriage.
Level main frame by adjusting the chain blocks. SM0271
6. Remove main frame.

A
Installation of main frame
NOTE: approximate mass of main frame: 3300 kg

(7277 lbs).
Installing is done in the riverse order of removing.

6
1. Clean mating surfaces of upper frame and
swing bearing. SM0272
2. Apply Loctite # 515 to the inside of the

capscrews on the contact surface (A) (fig.
SM0272).
3. Slinging upper frame.

Match marks and install it with a reamer bolt (6)
and a washer temporarily.
SM0273
W2-1-8
IMPORTANT: confirm the reamer bolt position (X) S

referring to Fig SM2178. (S) points to the soft zone
of the outer ring.
X
4. Apply Loctite # 262 onto thread of bolts (5)

then, install bolts.
: 24 mm
: 270 ± 27 Nm (199 ± 19.9 lbf•ft)
5. Apply Loctite # 262 onto thread of reamer bolts

(6) then, install reamer bolt. SM2178
: 24 mm Apply Loctite # 515 to the shaded area

: 270 ± 27 Nm (199 ± 19.9 lbf•ft)
W2-1-9
NOTE:
W2-1-10
PUMP DEVICE E135B
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP DEVICE
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.Prevent these
dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Preparation
1. Park the machine on a firm, level surface.
C4
2. To drain the hydraulic pressure from the
“Releasing the hydraulic pressure” at page T2- C1
1-5.
3. Cut-off the engine. Press the valve located on Q

the hydraulic oil cap to release any residual
pressure present in the tank itself.
4. Remove six capscrews M10x25 (C4). C
: 17 mm
5. Remove cover (C1).
6. Take out suction strainer (C).
7. Install suction stopper (Q) (xxxxxxxx).
8. Remove all protection panels and doors to give SM2181
access to the Hydraulic Pump Device.
W2-2-1
E135B PUMP DEVICE
REMOVING OF THE HYDRAULIC PUMP

DEVICE
12 17
17
1. Loosen screws (17) M10x35 and remove half
clamp (12), then disconnect 2 hoses (1), (2) 12
from the delivery side.
: 8 mm 1
2
2. Remove pilot pump suction hose (A4).
: 36 mm A15
A2
3 A6
3. Remove 4 capscrews (A15) M12x30.
: 10 mm
A5
4. Disconnect elbow (A6) of suction hose (3) from

pump. SM2922
5. Remove drain hose (A5). A2 A1

: 36 mm
6. Disconnect drain hose (A2) of port Dr3. A3

: 22 mm
7. Only if necessary, disconnect pilot primary

pressure P1 side hose (A1) of port Psv1.
: 22 mm
8. Disconnect pilot pump delivery hose (A3) of A4

port Psv1.
: 22 mm
SM2923
W2-2-2
PUMP DEVICE E135B
9. Remove clips (22).

SE-22 22 SE-23
10. Remove the connector of P1 pump pressure

sensor (SE-22) and the connector of P2 pump
pressure sensor (SE-23).
11. Remove the screw (25) and the clip (26).

23 25 26
12. Remove the connector of P1 pump proportional

valve (23) and the connector of P2 pump
proportional valve (24).
25 26 24
SM2924
13. Put a wire sling on the hydraulic pump

andtension the wire sling a little. Loosen 8
capscrews (4) M10x30.
: 17 mm
W2-2-3
E135B PUMP DEVICE
14. Draw out the power take-off assy from the

flywheel housing slowly, adjusting the tension 0
3
of the wire rope.
On that occasion, the assembly is drawn out
with the insert NA (2-3) remaining on the
flywheel side.
15. Remove element (2-1) from the tip of the spline

shaft. 4
3
2-6
2-4
16. Remove 4 capscrews (2-6) M16x45 that fasten
insert R (2-4) and remove insert R (2-4). 2-7
: 14 mm
2-2
1
2-8 2-1 2-3 2-5
17. If you loosen 2 set screws (2-7) M16x18, hub SM2945
(2-2) comes off from the spline shaft of the
pump.
: 8 mm
18. Remove 4 capscrews (2-5) M16x55 that fasten

the insert NA (2-3) with the engine side
flywheel, as necessary. Then remove and
spring pin (2-8) from insert NA (2-3).
: 14 mm
19. Loosen 2 capscrews (3) M16×50, and remove

bracket (4) from pump (0).
W2-2-4
PUMP DEVICE E135B
INSTALLING OF THE HYDRAULIC PUMP

DEVICE
2-6
Installing is done in the reverse order of removing.
1. Installing bracket (1) Tighten bracket (1) with
capscrew (3) and install bracket temporarily. 2-4
Apply Loctite #262 2-1
: 14 mm
: 191 ± 19 Nm (141 ± 14 lbf•ft) 2-2
aa
2. Put hub (2-2) into the pump spline till it enters 5

mm (0.12 in) from the end face of the spline. 2-7
Then, install two set screws (2-7) and fix them
together.
3
: 8 mm 2-8
I
: 110 ± 10 Nm (81± 7 lbf•ft)
2-3 1
2-5
3. Installing insert R (2-4) into hub (2-2) by means
of capscrews (2-6). 5
: 14 mm (0.197")
: 220 ± 10 Nm (162 ± 7 lbf•ft)
4. Put element (2-1) into hub (2-2) and insert R (2-

50 (1.97")
4). VIEW I
DETAIL aa SM2946
5. Put spring pin (2-8) into insert NA (2-3) and

install it to the engine flywheel by means of
capscrews (2-5).
: 14 mm
: 220 ± 10 Nm (162 ± 7 lbf•ft)
W2-2-5
E135B PUMP DEVICE
6. Lift the pump with bracket (1). Place coupling in

the groove of element (2-1) so as to receive
insert NA (2-3).
2-1
7. Coat 8 capscrews (4) M10x30 with Loctite #262

and put them in place.
: 17 mm
: 64.7 ± 6.4 Nm (48 ± 4.8 lbf•ft)
2-3
4
SM3018
8. Fasten hoses (1), (2) on the delivery side with

half clamp (12) and sems bolt (17) M10x35.
12 17
: 8 mm 17
12
: 57 ± 5.7 Nm (42 ± 4.2 lbf•ft)
2
9. Install suction hose (3) fixing elbow (A6) to the
hydraulic pump with 4 capscrews (A15) A15
M12x30.
: 10 mm
A2
: 67 ± 6.7 Nm (49 ± 4.9 lbf•ft)
3 A6
A5
SM2922
W2-2-6
PUMP DEVICE E135B
10. Install pilot pump delivery hose (A3) of port

Psv1. A2 A1
: 22 mm
: 49 ± 4.9 Nm (36 ± 3.6 lbf•ft)
A3
11. If removed, install hose (A1) of port Psv1.
: 22 mm
: 49 ± 4.9 Nm (36 ± 3.6 lbf•ft)
12. Install drain hose (A2) of port Dr3.

: 22 mm
: 49 ± 4.9 Nm (36 ± 3.6 lbf•ft)

A4
SM2923
13. Install drain hose (A5). SE-22 22 SE-23

: 36 mm
: 118 ± 11 Nm (87 ± 8.7 lbf•ft)
14. Install the connectors of the pressure sensor

(SE-22) and (SE-23) and fasten them with clips
(22).
15. Install the connectors of the proportional valve

(23) and (24) and fasten them with clips (26) 23 25 26
and screws (25).
25 26 24
SM2924
W2-2-7
E135B PUMP DEVICE
16. Remove suction stopper (Q) (xxxxxxxx).
C4
17. Install suction strainer (C).
C1
18. Install cover (C1).

Q
19. Tighten six capscrews M10x25 (C4). C

: 17 mm
: 50 ± 5 Nm (37 ± 3.7 lbf•ft)
IMPORTANT: when the pump is replaced,

replenish more than 1l (0.26 gal) of hydraulic oil
from the drain port (D1). SM2181
20. Bleed air by loosening the drain port (Dr).
Dr
21. Check the hydraulic oil level.
22. Start engine and check it for oil leak and noise.
23. Attach drain down pipe under engine muffler.
SM2947
24. Install all protection panels in reverse order of

removing.
W2-2-8
PUMP DEVICE E135B
MAIN PUMP
(Three Bond No.1305N)

533 789 733 732 532 214 548 531 702 792 901 954 724 717 723 402 151 981 983
535 534
806 808 152
953 211
490 899
255 04
261
111 774
A A
127
710
406
123
824
251
212 271 153 468 156 466 157 313 124 711 116 312 886 314 401 467 141 272 113
727 723 732
05
Nm (lbf ft)
401, 402 M16 240 (177)
406 M6 12 (8.9)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 1/2 110 (81)
490 NPTF1/16 11 (6.5)
531, 532 M20X1.5 240 (177)
533 M30 220 (162)
806 M12 60 (44)
808 M16 130 (96)
section A-A SM2803
04 - Gear pump 271 - Pump casing (F) 711 - O-ring 1B G80

05 - PTO gear case 272 - Pump casing (R) 717 - O-ring 1B G125 (Q.ty 2)
111 - Shaft (F) 312 - Valve block 723 - O-ring 1B P11 (Q.ty 6)
113 - Shaft (R) 313 - Valve plate (R) 724 - O-ring 1B P8 (Q.ty 12)
116 - 1st gear 314 - Valve plate (F) 727 - O-ring 1B P18 (Q.ty 4)
123 - Roller bearing (Q.ty 2) 401 - Socket bolt M16x150 (Q.ty 2) 732 - O-ring 1B P14 (Q.ty 4)
124 - Needle bearing (Q.ty 2) 402 - Socket bolt M16x190 (Q.ty 2) 733 - O-ring 1B P28 (Q.ty 2)
127 - Bearing spacer (Q.ty 2) 406 - Socket bolt M6x16 (Q.ty 4) 774 - Oil seal
141 - Cylinder block (Q.ty 2) 466 - VP plug PF1/4 (Q.ty 2) 789 - Backup ring P14 (Q.ty 2)
151 - Piston (Q.ty 18) 467 - VP plug PF3/8 (Q.ty 2) 792 - Backup ring G30 (Q.ty 2)
152 - Shoe (Q.ty 18) 468 - VP plug PF1/2 (Q.ty 4) 806 - Nut M12 (Q.ty 2)
153 - Retainer (Q.ty 2) 490 - Plug NPTF1/16 (Q.ty 9) 808 - Nut M16 (Q.ty 2)
156 - Spherical bushing (Q.ty 2) 531 - Tilt pin M20x1,5 (Q.ty 2) 824 - Stop ring (Q.ty 2)
157 - Cylinder spring (Q.ty 12) 532 - Servo piston M20x1,5 (Q.ty 2) 886 - Spring pin (Q.ty 4)
211 - Shoe plate (Q.ty 2) 533 - Plug M30 (Q.ty 2) 899 - C-ring (Q.ty 2)
212 - Swash plate (Q.ty 2) 534 - Stopper (long) (Q.ty 2) 901 - Eye bolt M10 (Q.ty 2)
214 - Tilting bushing (Q.ty 2) 535 - Stopper (short) (Q.ty 2) 953 - Set screw M12x23 (Q.ty 2)
251 - Swash plate support (Q.ty 2) 548 - Feed back pin (Q.ty 2) 954 - Set screw M16 (Q.ty 2)
255 - Lock pin (Q.ty 2) 702 - O-ring 1B G30 (Q.ty 2)
261 - Seal cover (F) 710 - O-ring 1B G95
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
W2-2-9
E135B PUMP DEVICE
GEAR PUMP
887
Section X-X
710 700 354 351 887 433
Z
X
B3
X
434
X
311 A3
312 X
732 Dr3
a3 850
Dr3 Z
307 308 355
435 361 353 310 309 434 466

725
Section Z-Z
Nm (lbf ft)
312 M14x1,5 29 (21)
433, 434
M8 17 (13)
435
466 G 1/4 16 (11)
SM2804
307 - Poppet 434 - Flange socket; M8x55 (Q.ty 2)

308 - Seat 435 - Flange socket; M8x20 (Q.ty 4)
309 - Ring 466 - Vp plug PF1/4
310 - Spring 700 - Ring
311 - Adjust screw 710 - O-ring
312 - Lock nut M14x1.5 725 - O-ring; 1B
351 - Gear case 732 - O-ring; 1B P16
353 - Drive gear 850 - Locking ring
354 - Driven gear 887 - Pin (Q.ty 2)
355 - Filter A3 - Delivery port G1/2 53 Nm (39.1 lbf•ft)
361 - Front case B3 - Suction port; G3/4 74 Nm (54.5 lbf•ft)
433 - Flange socket; M8x40 (Q.ty 2) Dr3 - Drain port G3/8 34 Nm (25.1 lbf•ft)
W2-2-10
PUMP DEVICE E135B
POWER TAKE OFF (PTO)
125 468
711
118
11 262
728
117
414
126 825
128
710
10 435
12 886
826
SM0749
10 - Idle shaft 414 - Socket bolt; M10x20 (Q.ty 4)

11 - Gear case 435 - Socket bolt; M10x20 (Q.ty 4)
12 - Pin 468 - Vp plug G3/4
117 - 2nd gear 710 - O-Ring 1B G85
118 - 3rd gear 711 - O-Ring 1B P24
125 - Ball bearing (Q.ty 2) 728 - O-Ring 1B G80
126 - Roller bearing 825 - Snap ring
128 - Bearing spacer (Q.ty 2) 826 - Snap ring
262 - Cover 886 - Pin (Q.ty 2)
W2-2-11
E135B PUMP DEVICE
DISASSEMBLY HYDRAULIC PUMP DEVICE

• Proceed with disassembly operations in a clean
place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging.
• Clean the parts removing dust and rust, etc. on
pump surface with wash oil.
• Drain out the oil in the pump casing by removing
drain port plug (468).
:10 mm
NOTE: drain out oil from the plug of the front pump
and the rear pump.
1. Removing piloto pump.

Remove the socket bolts (433), (434) then
remove pilot pump (04).
: 6 mm
05
435
2. Removing PTO unit.
Remove the socket bolts (435), then remove
PTO unit (05).
: 8 mm SM0278
3. Removing regulator. 415 2

Remove the socket bolts (415), then remove
regulators (2).
: 6 mm
SM2948
W2-2-12
PUMP DEVICE E135B
4. Loosen socket bolt (401), (402) that fasten

pump casing (271), (272) and valve block 271 402 272
(312).
: 14 mm
401
SM2949
5. Place the pump level on a work bench with its

mounting surface of the regulator facing down.
312 271
Then separate pump casing (271) and valve
block (312).
NOTE: when facing the mounting surface of the

regulator down, place a rubber board on a work
bench so as not to score the mounting surface.
When the pump casing has been separated from
the valve block, draw out the 1st gear (116) at the
same time.
SM0280
6. Draw out cylinder (141) out of pump casing 271

(271), (272) in parallel to shaft (111), (113). At
141(151)(157)
the same time draw out piston (151), (152)
plate (153), spherical bushing (156) and 153
cylinder spring (157).
156
NOTE: use care so as not to score the sliding

surface of the cylinder, spherical bushing, shoe and
the swash plate.
SM0281
W2-2-13
E135B PUMP DEVICE
7. Remove socket bolt (406) and seal cover (261).

406
: 5 mm
261
NOTE: the seal cover may be drawn out with ease

if it is taken out by tightening bolts in the tapped
holes of the seal cover.
An oil seal is fitted to seal cover. Therefore, use care
so as not to score the oil seal.
SM0282
8. Tap lightly the shaft end (111), (113) by means

of a plastic hammer and draw out the shaft from
the pump casings (271), (272). 271 272
111 113
SM2925
9. Draw out shoe plate (211) and swash plate

(212) from pump casings (271), (272).
271 272
211 212
SM2926
10. Draw out C-ring (899) and lock pin (255) which
locks swash plate support (251). And free the
251
swash plate support from locking, and rotate it
counterclockwise. Then remove swash plate
support (251) from pump casing.
SM2927
W2-2-14
PUMP DEVICE E135B
11. Remove valve plate (313 and 314) from valve

block (312).
NOTE: the valve plate may come off during the 312
separation of pump casing from valve block.
314
(313)
SM0286
12. If necessary, remove Q min-plug (533),

534
stopper (L) (534), stopper (S) (535), servo 531
piston (532) and tilting pin (531) from pump 272
532 808
casing (271), (272), and remove needle bearing
(124) from valve block (312).
• When removing the tilting pin, use care so as not
to score the head of the tilting pin, using a jig. 533
535
• It is hard to separate the tilting pin from the servo 806
piston in some cases as Loctite is coated on the
mating part between them. Use care so as not to
score the servo piston by applying undue force. 124
• Do not draw out needle bearings except when
their service life has ended.
• Do not loosen Q min-plug (533) of valve block
(312). A set flow rate changes.
312
SM2928
W2-2-15
E135B PUMP DEVICE
Assembly
1. Assembly is a reverse order of disassembly,
but notice the following:
- Repair scored parts at disassembly. Get
replacements ready beforehand.
- Wash parts sufficiently in cleaning oil and dry
them with jet air.
- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as O-
Rings and oil seals.
- Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
- Do not mix up front pump parts with rear
pump parts.
251
IMPORTANT: SM2929
• When the servo piston, the tilting pin, the stopper
(L), the stopper (S) and the Q min-plug have
been removed, install them to the pump casing.
• When tightening servo piston and tilting pin, use
a jig so as not to damage the head of the tilting
pin and feedback pin. Coat the screwed part with
Loctite #262.
2. Install lock pin (255) and C-ring (889) in pump

casing (271). Then align swash plate support
(251) with spigot of pump casing, and rotate it
in clockwise. And fix swash plate support (251)
with lock pin.
3. Install shoe plate (211) on swash plate (212). SM2930

Then insert tilting bushing of swash plate into
tilting pin (531), and fix swash plate (212) and
shoe plate (211) to swash plate support (251) 251
properly. 271 (531)
IMPORTANT:
• Confirm by the fingers of your both hands that
swash plate moves smoothly.
• The shaft be installed easily if grease is applied
to the sliding parts of swash plate and swash
plate support.
• Do not damage the sliding surface of shoe plate. 212
SM0289
W2-2-16
PUMP DEVICE E135B
4. Install shaft (111), (113) fitted with bearing

(123), bearing spacer (127) and snap ring
(824), to pump casing (271), (272). 271,272
NOTE: Do not knock on the shaft with a hammer or 251

somethings.
Fix the bearing by lightly tapping the outer race of it
by means of a plastic hammer and set it exactly to 123
the end by using a steel rod and others.
127,824
111 SM2931
5. Install seal cover (261) to pump casing (271)

and fix it with socket bolts (406).
271
: 5 mm
: 12 Nm (8.8 lbf•ft) 261
NOTE: Coat the oil seal in seal cover with a thin film 406
of grease.
Handle the oil seal with sufficient care so it is not
scored.
SM0291
6. Assemble the piston cylinder sub compound to

the cylinder block (141), piston (151), shoe
(152), plate (153), spherical bushing (156) and 141(151,152,157)
cylinder spring (157).
Align the spherical bushing with the cylinder 156
spline and insert them into the pump casing.
153
SM0292
W2-2-17
E135B PUMP DEVICE
7. Install valve plate (313 and 314) to valve block

(312) by aligning pin.
NOTE: do not mistake the suction and delivery 312

sides of the valve plate.
314
(313)
SM0293
8. Install valve block (312) to pump casing (271)

and fasten them together with socket bolts 312 271
(401). 401
: 14 mm
: 240 Nm (177 lbf•ft)
NOTE: Work will be promoted if assembly is started

from the rear pump.
Exercise care so as not to mistake the direction of
the valve block (312). Install it so the regulator
comes up as seen from the front side and the
suction flange comes on the right.
SM0294
Insert the 1st gear into the valve block beforehand
and connect it with the spline of the shaft.
9. Install regulator (2) pinching feedback pin of

tilting pin in feedback lever of the regulator,
then install the regulator and fasten socket bolt 2
(412) e (413).
: 6 mm
: 17 Nm (12.5 lbf•ft)
IMPORTANT: do not mistake the front regulator for

the rear regulator.
SM2932
W2-2-18
PUMP DEVICE E135B
10. Install PTO cover (05) and fasten socket bolts

(435) and pin (889).
: 8 mm
: 33 Nm (24.3 lbf•ft)
05
435
SM0278
11. Install gear pump (04) and fasten socket bolts

(435).
: 6 mm
: 17 Nm (12.5 lbf•ft) 435
435
311
312
466 SM0276
W2-2-19
E135B PUMP DEVICE
MAINTENANCE STANDARD:
Recommended
Standard
value for
Part name and inspection item dimension Remedy
replacement
mm (in)
mm (in)
Clearance between piston and cylinder 0.032 0.056
Replace piston or cylinder.
bore (D-d) (0.00126) (0.00220)
SM0520
Gap between piston and caulked part of 0 ~ 0.1 0.3

Replace piston shoe assy.
shoe (d) (0 to 0.0039) (0.0118)
SM0521
3.9 3.7
Thickness of shoe (t) Replace piston shoe assy.
(0.154) (0.146)
t
SM0522
41.1 40.3
Free height of cylinder spring (L) Replace cylinder spring.
(1.618) (1.587)
L
SM0523
Combined height of retainer plate and 17.0 15.8 Replace a set of spherical bushing
spherical bushing (H-h) (0.669) (0.662) or retainer plate.
SM0524
Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section). Surface roughness requiring

3-Z
Swash plate (shoe plate face). correction.
Cylinder (sliding section). Standard surface roughness
Less than 0.4 Z (lapping)
Roughness of each surface. (correction value)
W2-2-20
PUMP DEVICE E135B
TROUBLESHOOTING
Locating causes of troubles

The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1. Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on it
as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements may
be damaged. In that case check the drain oil in the pump casing as well.
2. Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valve's relief valve's are of regular frequency. In case
vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3. When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines.
This will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4. Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes by
measuring pressures.
Troubleshooting
1) Overloading to engine
Cause Remedy Remarks

1. Revolution and pressure are 1) Set pressure to specified
higher than set values. value.
2. Regulator torque is set higher 2) Readjust regulator. 2) Refer to Regulator Manual.
than normal.
3. Pump's internal parts are 3) Replace damaged parts. 3) Check filter and drain oil to see
seized or broken. if abnormal wear particles are
present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.
W2-2-21
E135B PUMP DEVICE
2) Pump's oil flow rate is extremely low and delivery pressure is not available.

1. Regulator is out of order. 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pump's internal parts are 2) Replace damaged parts. 2) Check filter and drain oil.
seized or broken.
3. Attached pump is out of order. 3) Replace damaged parts. 3) Remove attached pump and
check shaft joint.
4. Attached valve is out of order. 4) Replace attached valve. 4) Refer to Manual for Attached
Valve.
5. Regulator is piped incorrectly. 5) Pipe correctly.
3) Abnormal Sound and Vibration

1. Cavitation. 1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil is not 1-2) The attached pump is in
clouded. trouble.
1-3) The suction pipe is inhaling
air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2) Replace piston shoe and shoe
plate.
3. Cylinder is cracked. 3) Replace cylinder.
4. Pump is installed improperly. 4) Correct installation.
5. Regulator is hunting. 5) Repair regulator. 5) See Regulator Manual.
6. Relief valve in attached valve 6) Repair attached valve.
ishunting.
W2-2-22
PUMP DEVICE E135B
DISASSEMBLY AND ASSEMBLY OF REGULATOR
402
656
733
041 601 496 627
543 724 646
545 624
541
415 801
755 924
418
496
079
652 875
726
496 651 614
041 616
466 496 658
755 755 754
724
407 887
643
731 754
631
897
611 708
325
SM2933
041 - Check valve sub 643 - Pilot piston

079 - Solenoid proportional reducing valve 646 - Pilot spring
325 - Valve casing 651 - Sleeve
402 - Socket bolt; M6x16 (Q.ty 4) 652 - Spool
407 - Socket bolt; M6x30 (Q.ty 4) 656 - Block cover
415 - Socket bolt; M8x40 (Q.ty 4) 658 - Plug
418 - Socket bolt; M5x12 (Q.ty 2) 708 - O-Ring
466 - Vp plug; PF1/4 724 - O-Ring (Q.ty 5)
496 - Plug; NPTF1/16 (Q.ty 9) 726 - O-Ring
541 - Seat (Q.ty 2) 731 - O-Ring
543 - Stopper (Q.ty 2) 733 - O-Ring
545 - Ball (Q.ty 2) 754 - O-Ring (Q.ty 2)
601 - Casing 755 - O-Ring (Q.ty 3)
611 - Feedback lever 801 - Nut; M10
614 - Fulcrum plug 875 - Pin
616 - Prevention plug 887 - Pin
624 - Spring seat 897 - Pin
627 - Adjusting stem 924 - Set screw; M10x20
631 - Sleeve
NOTE: the number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.
W2-2-23
E135B PUMP DEVICE
Tightening torque of bolt, plug, nut and servo piston

Tightening torque
N. Thread size
Nm (lbf.ft)
401, 402 M16 240 (177)
406 M6 12 (8.8)
414 M10 57 (42)
466 PF1/4 36 (27)
467 PF3/8 74 (55)
468 PF1/2 110 (81)
490 NTPF1/16 8.8 (6.5)
531, 532 M20x1.5 240 (177)
533 M30 220 (162)
806 M12 60 (44)
808 M16 130 (95)
Regulator disassembly
1. Selecting a place for disassembly.
466
• Choose a clean place.
• Spread rubber sheet or cloth on work bench to
protect parts from damaging.
2. Remove dust and rust, etc. on regulator surface

with wash oil.
SM2934
3. Remove socket bolts (415) and separate the
regulator from the pump body.
: 6 mm
4. Remove ROH-plug (466) for a port of valve

casing (601). And remove ROH-plug (466) for 407
psv port too.
5. Remove socket bolts (407) and remove valve

casing (325) with solenoid proportional
reducing valve (079).
: 5 mm
325 079
SM2935
W2-2-24
PUMP DEVICE E135B
6. Remove socket bolt (402) and cover (656).

: 5 mm
IMPORTANT:
the cover is assembled with set screw (924) and hex 402
nut (801), but do not loosen them. If they are
loosened, the pressure settings change.
656
SM2936
7. Draw out sleeve (631) and pilot piston (643)

from the regulator body.
631 643
SM2937
8. Removing looseness prevention plug (616).
IMPORTANT:
removing of looseness prevention plug may cause
damage of plug. (But in this case, there is no
functional problem.)
616
SM2938
W2-2-25
E135B PUMP DEVICE
9. Remove fulcrum plug (614) and feedback lever

(611).
614 611
SM2939
10. Draw out spool (652) and sleeve (651) from the
sleeve hole of the regulator casing.
11. Draw out plunger (627). Then take out pilot

spring (646) and spring (624).
652 651
SM2940
NOTE: the plunger comes off easily if an M4 bolt is
used.
627 646 624
12. The disassembly is complete when the check

valve (041) [seat (541), ball (545), and stopper
(543)] have been drawn out.
NOTE: the check valves are placed on two places;

the mating surface of the pump casing and on the
matching surface of the valve casing. SM2941
IMPORTANT: take care not to lose the parts

because they are small.
W2-2-26
PUMP DEVICE E135B
Regulator assembly
Assembly is a reverse order of disassembly, but
notice the following.
• Do not fail to correct parts damaged during
disassembly and get replacement parts ready
beforehand.
• Entry of foreign matter causes faulty functions;
clean parts thoroughly, dry them with jet air and
work in a clean place.
• Do not fail to coat the sliding parts with clean
hydraulic oil, before proceeding to assembly.
• Seals and O-rings must be replaced with new
ones.
• Using torque wrench, the bolts and plugs should
be tightened to the specified torques, with a 10%
maximum tolerance.
1. Install the check valve (041) [Seat (541), ball

601
(545) and stopper (543)] to casing (601).
NOTE: assemble the check valve into the matching

surface of the pump casing and the matching
surface of the valve casing.
2. Place sleeve (651) and spool (652) into the

sleeve hole of casing (601).
651 652
SM2942
IMPORTANT:
• Make sure the spool and the sleeve slide
smoothly in the casing without catching.
• Make sure the direction of the spool is correct.
3. Insert pin (897) of feedback lever (611) into the

pin hole of the sleeve and fix the feedback lever
with fulcrum plug (614).
IMPORTANT:
operate the feedback lever and make sure that it
does not have much looseness and that it operates
without catching. 611
SM2943
W2-2-27
E135B PUMP DEVICE
4. Place the prevention plug (616).
616
SM2938
5. Place spring seat (624), pilot spring (646) and

plunger (627) into the hole in the sleeve.
624 646 627
SM2944
6. Attach cover (656) to casing (601) and fasten

them together with socket bolts (402).
NOTE: the cover is fitted with adjusting screw (924)

and hex nut (801).
402
656
SM2936
7. Assemble sleeve (631) and pilot piston (643)

into casing (601).
631 643
SM2937
W2-2-28
PUMP DEVICE E135B
8. Attach valve casing (325) fitted with solenoid

proportional reducing valve (079) to casing 407
(601) and fasten them together with socket
bolts (407).
325 079
SM2935
9. Install ROH-plug (466) to A port of valve casing

(601). And install ROH-plug (466) to Psv port 466
too.
SM2934
W2-2-29
E135B PUMP DEVICE
DISASSEMBLING AND ASSEMBLING PTO UNIT
125 468
711
118
11 262
728
117
414
126 825
128
710
10 435
12 886
826
SM0749
10 - Shaft 414 - Socket ROH M10x20 (Q.ty 4)

11 - Case 435 - Capscrew ROH M10x20 (Q.ty 4)
12 - Pin 468 - Vp plug G3/4
117 - 2nd gear 710 - O-ring; 1B G80
118 - 3rd gear 711 - O-ring; 1B G85
125 - Ball bearing (Q.ty 2) 718 - O-ring; 1B P24
126 - Roller bearing 825 - Ring
128 - Bearing spacer (Q.ty 2) 826 - Ring
262 - Cover 886 - Pin (Q.ty 2)
W2-2-30
PUMP DEVICE E135B
Disassembly
1. Proceed with disassembly operations in a clean

place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging. 414
2. Remove dust, rust, etc, on pump surface with 262

wash oil (468).
: 27 mm
: 74 Nm (54.6 lbf•ft) 468
SM0525
3. Remove the socket bolts (414). Then remove
the cover (262).
: 8 mm
: 33.3 Nm (24.6 lbf•ft)
115
4. Remove snap ring (885) and idle shaft (115).

Then draw out 2nd gear (117), roller bearing 117
(126) and bearing spacer (128). (126, 128)
NOTE: roller bearing can not be separated from 2nd

gear (117).
SM0526
5. Remove snap ring (825) and draw out 3rd gear

(118) and ball bearing (125).
NOTE: ball bearing (125) can not be separated from

3rd gear (118).
125
Assembly
118
Assembly is a reverse order of disassembly, but
notice the following:
- Repair scored parts at disassembly. Get
replacements ready beforehand.
- Wash parts sufficiently in cleaning oil and dry SM0527
them with jet air.

- Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
- In principle, replace sealing parts such as O-Rings
and oil seals.
- Tighten socket bolts and plugs to specified
torques in this Manual.
W2-2-31
E135B PUMP DEVICE
MAINTENANCE STANDARD
In case a pitching (1 pit is more than 1mm, while the

area ratio is more than 5%) is seen on the gear tooth 1
surface of 2nd gear (117) and 3rd gear (118),
replace the gears. Replace the gears also in case
they show excessive damage.
Air pulling out point

2
1. After the relief valve installation, start the
engine.
2. Loosen the air pulling out plug (1), until O-ring
(2) comes off, to allow the air flows out.
3. Air pulling out operation is completed when, for
two seconds, only hydraulic oil flows out from
plug (1).
4. Tighten the plug (1) to specified torque.
: 17 mm
: 23 Nm (17 lbf.ft)
SM1251
W2-2-32
PUMP DEVICE E135B
TOOL TABLE
REF. CODE DESCRIPTION

Q XXXXXXXX Suction stopper assy
1 - Rod
2 - Nut M8
3 - Cover
4 - O-ring
2
3
50
(1.97")
R8
113 (4.45")
(1
.3
15 2 (0.08”)
") M8 NUT
O8 (1.315")
600 (23.6")
(0.295")
7.5
+0.5 +0.0197
100 0 (3.94" 0 )
M8
(0.787")
108
20
1 3
(4.25" )
SM2950
W2-2-33
E135B PUMP DEVICE
NOTE:
W2-2-34
CONTROL VALVE E135B
REMOVAL AND INSTALLATION OF CONTROL VALVE
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Preparation “Releasing the hydraulic pressure” at page. T2-

1-45.

2. To drain the hydraulic pressure from the the hydraulic oil cap to release any residual
Hydraulic System, refer to procedure pressure present in the tank itself.
Removal of control valve

1. Remove the panel protecting the control valve,
removing the securing screws.
: 19 mm 1
2. Disconnect all hoses, pipes and connectors

from the control valve (1).
NOTE: attach caps to hoses and pipes. Attach

labels or tags to hoses and pipes, to aid in
assembly.
3. Remove the control valve securing screws (2).

: 24 mm
NOTE: control valve assembly mass: 158 kg (348

2 SM2673
lbs).
4. Remove the control valve.
W2-3-1
E135B CONTROL VALVE
Installation of control valve
1. Install control valve (1) to frame and tighten the

bolts (2).
: 24 mm 1
: 235 ± 24 N•m (173 ± 17.5 lbf•ft)
2. Connect all hoses, pipes and connectors to the

control valve.
2 SM2673
Thread Ports Connector/Bolt Hose nut

Type Oppo- Tightening Oppo- Tightening
sing torque sing torque
flats N•m (lbf•ft) flats N•m (lbf•ft)
PB1, PBp1, PBp2, PCa, PCb, PL, PLc2, ORS 19 36.5 ± 2.5 19 29 ± 2
PF1/4 Joint (27 ± 2) (21 ± 3.6)
Pss, PTb, XAb
DR, PAa1, PAa2, PAb, PAc, PAL, PAo, 22 73.5 ± 4.5 22 49 ± 5
PF3/8 PAr, PAs, PBa1, PBa2, PBb, PBc, PBL, (54.5 ± 3.5) (36 ± 3.6)
PBo, PBr, PBs
27 109 ± 11
PF1/2 (P3), (P4), (P5), (P6)
(80.5 ± 8.5)
Aa, Ab, Ac, AL, Ao, Ar, As, Ba, Bb, Bc, 36 165 ± 15 36 118 ± 10
PF3/4 (122 ± 11) (87 ± 7.2)
BL, Bo, Br, Bs, (MU1), (MU2), T3
Sems bolt 8 57 ± 8
M10 P1, P2
(42 ± 6)
10 96.5 ± 13.5
M12 T1, T2
(71 ± 10)
3. Install the panel protecting the control valve

using the relevant securing screws.
: 19 mm
: 110 ± 11 N•m (81.1 ± 8.1 lbf•ft)
W2-3-2
CONTROL VALVE E135B
CONTROL VALVE PORTS (1/2)
Functions Ports Ports on right front sides (on machine) Ports Functions
PBp1 P1 bypass cut

P2 bypass cut PBp2 PAa2 Arm 2 in
Option PAo Mu Make-up line
㧙 Bucket (R) relief valve
Arm (H) relief valve 㧙
PBC Bucket out
Arm 1 out PBa1
XAb Emergency manual valve drain
Swing right PBs PBb Boom down
Boom conflux PB1 㧙 Boom (H) relief valve

PAr Travel right reverse
Travel left reverse PAL
㧙 Main relief valve
Tank return T2 Mounting surface PCb P1 unload
Ports on rear left sides (on machine)
Arm 2 out PBa2 LEFT RIGHT PBo Option
Bucket digging PAc 㧙 Arm (R) relief valve
Bucket (H)relief valve 㧙 PLc2 Arm in lock valve
Boom(R)relief valve 㧙 PBa1 Arm out
Boom up PAb PAs Swing left
Travel right forward PBr PCa P2 unload
Travel straight PTb PBL Travel left forward

Mounting surface
Ports on bottom sides (on machine)
LEFT RIGHT
P2 pump P2
P1 pump P1
SM2654
W2-3-3
E135B CONTROL VALVE
CONTROL VALVE PORTS (2/2)
Function Ports Ports on left side (on machine) Ports Function

FRONT REAR
Bucket dump BC SIDE SIDE
Boom up Ab AC Bucket digging
Bb Boom down
Emergency manual valve drain XAb BR Travel right forward
Travel right reverse AR

Mounting
surface
Ports on right side (on machine)

REAR FRONT
SIDE SIDE
Option Bo Ao Option
Aa Arm 1 out
Arm 1 in Ba Pss Swing low pressure sensor
Swing right Bs As Swing left
Travel left forward BL Dr Drain
AL Travel left reverse

Mounting
surface
T1 Tank return
SM2665
W2-3-4
CONTROL VALVE E135B
Control valve (1/6)
273x10
T2
J J
P1 unload 273x10
(Travel straight) PCb PAL Travel left
C C
Travel right PAr PB1 Boom conflux

(P2 unload)
D D
977
XAb
XAb
978x2
Boom PBb PBs Swing
E E
Pss
Bucket PBc PAa1 Arm 1

F F
PAa2 PAo
Arm 2 MU1 Option
G G
PBp1 PBp2
H H
B A
PAa2 PAo PAo
PBp1
PBp2
275x4
213
274x4
(P4)
(P3)
(P3)
(P4)
212
PBa2 PBo
273x10 SM2666
W2-3-5
E135B CONTROL VALVE
Control valve (2/6)
155 163 101

(P5) P2
T1
T2
CT2
K
PAL PBL
PB1
PCa
PBs PAs
Pss
PAa1 PBa1
PAo PBc
PAp2
(P4)
166 161 161 155 163 164
SECTION A-A
154 567 155 163 102
(MU2) (P6)
P1
973 973
CT1
PTb POb
973 973
PBr PAr
PAb PBb
973 973
PAc PBc
973 973
PBa2 PAa2
PBp1
973
(P3)
161 164 163 155 161 161
SECTION B-B
SM2667
W2-3-6
CONTROL VALVE E135B
Control valve (3/6)
202 201
P1 unload Travel left
333 PCb PAL
333
331 331
336 339
328 327
325
325
331
601 331
MR
261 261
309 306
(PL)
159
166
157
161 AL
161
511
512
521
522
CP2
CMR2 551
556 561
561
561 BL
CMR1
556
522
512
307
261 264
331 PBL
325 205
326 SECTION C-C
336
331
333 PTb
202 Travel straight
201 Travel right Boom conflux 201

333 PAr PB1
333
331 331
339 336
327 AbR
322
325 321
602
331 331
261 261
166 305
164 DR
511
162 521
Ar
CCb
306
551
511
561
521
CP1
551
551
561
561
166 Br
310
164
166
161
166 T3
264 261
PBr
331
205 325
SECTION D-D 328
336
331
PCa 333
P2 unload 202 SM2668
W2-3-7
E135B CONTROL VALVE
Control valve (4/6)
203
333 Swing
331
PBs
339 Boom 204
320 PBb 333
Pss
319 331
379X3 336
211 AbR 322
331
L 216 321
L 266
261 M 331
M 266 XAb 261
166
160
303
301
561 CRb 161
Ab As
(HEAD)
556 511
524 524
LCb LCs
514
551 556
561 561
521 Bb Bs
511 (ROD)
161
264
264
602
PAb
205 PAs 206
BbR
160 266
SECTION E-E
201
201 333
333 Bucket Arm 1
PBc PAa1
331
331 336
339 322
320 321
BcR
319 AaR 602
602 331
331 261
261
161
304
Bc Aa(HEAD)
(ROD)
511 511
521 521
LCc LCa 551
561
551
561 161
Ac 561
(HEAD) CRa 556
Ba(ROD)
524
514
156
PLc2 167
264 160x2
L 302
602 L
PAc PBa1 264
205 211
AcR
205
SECTION F-F
SM2669
W2-3-8
CONTROL VALVE E135B
Control valve (5/6)
201
333
331 Arm 2 Option 201
333
339 PAa2 PAo
331
326 337
325
330
331
329
261 604
154 AoR 331
567 261
MU1
161 311
308
162
515
521 Ao
551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
511 Ba(ROD)
162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 PaR
605 605
PBp1 PBp2
Bo
BoR
166 604
153
SECTION H-H
SM2670
W2-3-9
E135B CONTROL VALVE
Control valve (6/6)
T2
511 P1 T1
521
CT1
551
561
511
C P2 521
(MU2)
CT2
E 551
561
SECTION M-M
162 SECTION J-J
278x5
160
266
207
267
267
528
527
T1
518
517
SECTION L-L
SECTION K-K
SM2671
W2-3-10
CONTROL VALVE E135B
torque No. Name Q.ty torque No. Name Q.ty
101 Casing A 1 308 Arm 2 spool 1
102 Casing B 1 309 P1 unload spool 1
27 ± 2 (18.5 ± 1.5) 153 Plug 1 310 P2 unload spool 1
235 ± 15 (173 ± 11) 154 Plug PF3/4 2 311 Optino spool 1
120 ± 10 (88.5 ± 7.5) 155 Plug PF1/2 4 319 Spring 2
15 ± 2 (11.3 ± 1.5) 156 Plug PF1/8 1 320 Spring 2
22 ± 2 (16.5 ± 1.5) 157 Plug PF1/4 MEC 1 321 Spring 3
36.5 ± 2.5 (27 ± 2) 159 Plug PF1/4 1 322 Spring 3
8.8 ± 1 (6.5 ± 0.7) 160 Plug PF1/16 MEC 5 325 Spring 6
161 O-ring 1B G30 13 326 Spring 1
162 O-ring 1B G25 6 327 Spring 2
163 O-ring 1B P18 4 328 Spring 3
167 O-ring 1B P8 1 331 Spring seat 24
168 O-ring 1B P11 1 17 ± 1 (12.55 ± 0.75) 333 Spacer bolt 12
11.9 ± 2.1 (8.75 ± 1.55) 211 Valve selector 2 517 Poppet 1
212 Plate 1 518 Poppet 1
216 Boom lowering valve 1 522 Spring 2
264 O-ring 1B G35 8 527 Spring 1
267 O-ring 1B P32 2 140 ± 10 (103.5 ± 7.5) 551 Plug 12
29.5 ± 4.5 (21.5 ± 3.5) 273 Socket bolt 40 140 ± 10 (103.5 ± 7.5) 556 Plug 5
109 ± 11 (80.5 ± 8.5) 274 Socket bolt 4 561 O-ring 1B P20 17
109 ± 11 (80.5 ± 8.5) 275 Socket bolt 4 567 O-ring 1B P24 2
11.9 ± 2.1 (8.75 ± 1.55) 278 Socket bolt 5 73.5 ± 4.5 (54.5 ± 3.5) 601 Main relief valve 1
11.9 ± 2.1 (8.75 ± 1.55) 279 Socket bolt 3 73.5 ± 4.5 (54.5 ± 3.5) 602 Port relief valve 5
301 Boom spool 1 73.5 ± 4.5 (54.5 ± 3.5) 604 Relief valve plug 2
302 Arm 1 spool 1 109 ± 11 (80.5 ± 8.5) 605 Bypass cut valve 2
303 Swing spool 1 73.5 ± 4.5 (54.5 ± 3.5) 606 Port relief valve 1
304 Bucket spool 1 160 ± 20 (118 ± 15) 973 Socket bolt 9
305 Boom conflux spool 1 977 Name plate 1
306 Travel spool 2 978 Rivet 2
307 Travel straight spool 1
W2-3-11
E135B CONTROL VALVE
ASSEMBLY AND DISASSEMBLY OF CONTROL

VALVE
PREPARATION FOR DISASSEMBLY
General cautions • Do not strike or twist components by force even

• Since hydraulic components are finished for if they are tight, or the components develop burrs
precision with small clearance, it is necessary to or are broken. This makes the components
disassemble them in a clean and not dusty impossible to be assembled and results in oil
place. Use clean tools and cleaning oil and leakage and deterioration in performances.
handle components with sufficient care. Therefore, handle components with full care.
• Attach a tag to each component so it is
• If the control valve is removed from the machine, reassembled in a correct position.
clean ports thoroughly and put a plug in each • Once disassembled, do not reuse O-rings and
port so as to prevent entry of dust and water. backup rings. Remove them with the tip of a steel
When installing the control valve back to the wire shaped in a spatula. Take care so the
machine, do not remove plugs until the valve is groove is not scored.
properly piped. • If parts are left, as they are halfway during
• Study the structural drawing before beginning disassembly or after disassembly, they may rust
work and prepare necessary parts according to due to moisture and dust. When interrupting
the purpose and the scope of the operation. work for unavoidable reason, use care so as to
Some parts are not available loosely but in prevent parts from rusting, or being exposed to
assemblies. Therefore, prepare parts dust.
beforehand according to the Parts Manual Replacing the main plungers
Cautions in disassemly • Since the main plunger is selectively fitted to the
• Since components are finished to high precision, housing, it is designated as “not service part”.
handle them with sufficient care. Use care so as Therefore, note that in principle the main plunger
not to bump components against each other or cannot be replaced in the field. In case the
drop them. plunger must be replaced fore some reason,
inform us with the model and the manufacturing
number that are stamped on the nameplate.
Tools
Prepare the following tools before disassembling

the control valve.
No. Tools Q.ty Remarks

a Vise 1
1 of each
b Box and wrench 19 mm, 24 mm, 27 mm, 32 mm
size
1 of each
c Allen wrench 5 mm, 6 mm, 10 mm, 12 mm, 14 mm, 22 mm
size
d Spanner 1 32 mm
e Loctite #262 -
f Spatula 1
g Pincers 1
h Adjustable wrench 1
W2-3-12
CONTROL VALVE E135B
The figures in parentheses after part names in this

manual represent those item numbers in the
structural sectional drawing under Fig. SM2666 to
Fig. SM2671.
1. Place the control valve on a work bench so as
to locate back pressure check valve upwards.
CAUTION: Disassemble the valve in a clean place,

and be careful not to damage flange surfaces or
plate mounting surfaces.
SM2678
Disassembling P1 unload spool

1. Loosen the socket bolts (273) and remove the 202 273
spring cover (202) and the O-ring (261) for P1
unload spool.
SM2679
2. Draw out, from casing B (102), as a assy of P1

unload spool (309), spring seat (331), springs 309 331 325 328 336 333 102
(325), (328), stopper (336) and bolt (333).
SM2680
3. Fix the P1 unload spool assy with vise via a

protective plate (aluminum plate, etc.) and 309 331 325 328 336 333
remove bolt (333). Then separate spring seat
(331), springs (325), (328) and stopper (336)
from P1 unload spool (309).
SM2681
W2-3-13
E135B CONTROL VALVE
Disassembling the travel spool (left travel and

right travel) 201 273
1. Loosen the socket bolts (273) and remove the
spring cover (201) and the O-ring (261) for
travel.
SM2682
2. Draw out the assy of travel spool (306), spring

seat (331), springs (325), (327), stopper (339) 306 331 325 327 339 333 101
and bolt (333) from casing A (101).
CAUTION: When drawing out the spool assy, take

care so as not to score the casing A (101) or the
casing B (102).
SM2683
3. Loosen the socket bolts (273), remove the

spring cover (201) and the O-ring (261) for 273 201
travel.
SM2684
4. Draw out the assy of travel spool (306), spring

306 331 325 327 339 333
seat (331), springs (325), (327), stopper (339)
and bolt (333) from casing B (102).
102

care so as not to score the casing A (101) or the
casing B (102).
SM2685
W2-3-14
CONTROL VALVE E135B
5. Fix the travel spool assy with vise via a

protective plate (aluminum plate, etc.). Remove 306 331 325 327 339 333
bolt (333) and separate spring seat (331),
springs (325), (327) and stopper (339) from
travel spool (306).
SM2686
Disassembling the boom conflux spool

202 273
1. Loosen socket bolts (273) and remove spring
cover (201) for boom conflux and O-ring (261).
SM2687
2. Draw out the assy of boom conflux spool (305),

spring seat (331), springs (321), (322), stopper 305 331 321 322 339 333 101
(339) and bolt (333) from casing A (101).
CAUTION: When drawing out the spool assy, use

care so as not to score casing A (101).
SM2688
3. Fix the boom conflux spool with vise via a

protective plate (aluminum plate, etc.) and
305 331 321 322 339 333
remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (339) from boom conflux
spool (305).
SM2689
W2-3-15
E135B CONTROL VALVE
Disassembling the boom spool

1. Loosen socket bolts (273) and remove spring 203 273
cover (203) for boom spool and O-ring (261),
(266).
SM2690
2. Draw out the assy of boom spool (301), spring

seat (331), springs (319), (320), stopper (339) 301 331 319 320 339 333
CAUTION: When drawing out the spool assy, take 102

care so as not to score casing B (102).
SM2691
3. Fix the boom spool assy with vise via a

from boom spool (301). Do not disassemble
boom spool (301) further unless there is special
reason.
SM2692
Disassembling the swing spool

204 273
1. Loosen the socket bolts (273) and remove the
spring cover sub (204) and the O-ring (261),
(266) for swing. Do not disassemble spring
cover sub (204) further unless there is special
reason.
SM2693
W2-3-16
CONTROL VALVE E135B
2. Draw out the assy of swing spool (303), spring

seat (331), springs (321), (322), stopper (336) 303 331 321 322 339 333 101
and bolt (333) from casing A (101).

SM2694
3. Fix the swing spool assy with vise via a

protective plate (aluminum plate, etc.) and
303 331 321 322 339 333
remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from swing spool (303).
SM2695
Disassembling bucket spool

1. Loosen socket bolts (273) and remove bucket 201 273
spring cover (201) and O-ring (261).
SM2696
2. Draw out the assy of bucket spool (304), spring

seat (331), springs (319), (320), stopper (339) 304 331 319 320 339 333
102
SM2697
W2-3-17
E135B CONTROL VALVE
3. Fix the swing spool assy with vise via a

from swing spool (303).
SM2698
Disassembling arm 1 spool

1. Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 1 spool.
201 273
SM2699
2. Draw out the assembly which is consist of arm

1 spool (302), spring seat (331), spring (321, 302 331 321 322 339 333 101
322), stopper (336) and bolt (333) from casing
A (101).

SM2700
3. Fix the arm 1 spool assy with vise via a

302 331 321 322 339 333
protective plate (aluminum plate etc.) and
remove bolt (333).
Then remove spring seat (331), spring (321,
322) and stopper (336) from arm 1 spool (302).
SM2901
W2-3-18
CONTROL VALVE E135B
Disassembling arm 2 spool

1. Loosen socket bolts (273), and remove spring 201 273
cover (201) and O-ring (261) of arm 2 spool.
SM2902
2. Draw out the assembly which is consist of arm

2 spool (308), spring seat (331), spring (325, 308 331 325 326 339 333
326), stopper (339) and bolt (333) from casing
B (102).
102
SM2903
3. Fix the arm 2 spool assy with vise via a

protective plate (aluminum plate etc.) and 308 331 325 326 339 333
remove bolt (333).
326) and stopper (339) from arm 2 spool (308).
Do not disassemble arm 2 spool (308) further
unless there is special reason.
SM2904
Disassembling option spool

1. Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of option spool.
273 201
SM2905
W2-3-19
E135B CONTROL VALVE
2. Draw out the assembly which is consist of

option spool (311), spring seat (331), spring 311 331 329 330 337 333 101
(329, 330), stopper (337) and bolt (333) from
casing A (101).

SM2906
3. Fix the option spool assy with vise via a

protective plate (aluminum plate etc.) and
311 331 329 330 337 333
remove bolt (333).
330) and stopper (337) from option spool (311).
SM2907
Disassembling travel straight spool

1. Loosen the socket bolts (273) and remove the 307 331 325 328 336 333 102
spring cover (202) and the O-ring (261) for
travel straight.
2. Draw out the assy of travel straight spool (307),

spring seat (331), springs (325), (328), stopper
(336) and bolt (333) from casing B (102).

care so as not to score the casing B (102).
SM2908
3. Fix the travel straight spool assy with vise via a

protective plate (aluminum plate, etc.). Remove 307 331 325 328 336 333
bolt (333) and separate spring seat (331),
springs (325), (328) and stopper (336) from
travel straight spool (307).
SM2909
W2-3-20
CONTROL VALVE E135B
Disassembling P2 unload spool

1. Loosen socket bolts (273), and remove spring 202 273
cover (202) of P2 unload spool and O-ring
(261).
SM2910
2. Draw out the assembly which is consist of P2

unload spool (310), spring seat (331), spring 310 331 325 328 336 333
(325), (328), stopper (336) and bolt (333) from
casing A (101).
101
SM2911
3. Fix the P2 unload spool assy with vise via a

protective plate (aluminum plate etc.) and 310 331 325 328 336 333
remove bolt (333). Then remove spring seat
(331), spring (325), (326) and stopper (336)
from P2 unload spool (310).
SM2912
Removing spool covers

273
1. Travel, boom, bucket, arm 1, arm 2 and option.
Loosen socket bolts (273) and remove spool
cover (205) and O-ring (264).
2. Swing. Loosen socket bolts (273) and remove

spool cover (206) and O-ring (264), (266). Do 205
not disassemble spool cover (206) further
unless there is special reason.
206
205
SM2913
W2-3-21
E135B CONTROL VALVE
Removing relief valve and plug assy for relief

valve hole
601
1. Remove the main relief valve (601) and
overload relief valve (602), (606) and relief hole
plug (604) from the casing.
NOTE:
• Distinguish overload relief valve between (602)
and (606) with a tag to prevent them from being 602
confused during reassembly, as they are the 602
same in appearance and shape but differ in
pressure setting. 604
• Regarding the disassembly of the relief valves
SM2914
themselves, do not disassemble it.
Removing by-pass cut valve

1. Remove by-pass cut valve (605) from the
casing.
Remove the by-pass cut valve, giving particular
attention to the poppet and spring which may
be remained on the inside of casing
605
SM2915
W2-3-22
CONTROL VALVE E135B
Removing lock valve selector valve sub

1. Loosen socket bolt and remove lock valve
selector valve sub (211) from the casing.
Further disassembly of the lock valve selector
sub is not allowed.
When the removal of lock valve selector sub on
boom spool side is required, remove the boom
lowering emergency manual valve (216)
simultaneously.
Further disassembly of the boom lowering
emergency manual valve (216) is not allowed.
211
SM2916
Removing back pressure check valve

1. Loosen socket bolt (278) and remove back 207 278
pressure check valve (207) from the casing.
SM2917
2. Remove springs (527), (528), boost check

valve poppet sub (517) and by-pass check
valve poppet (518) from the casing. The further
517 527 518 528
disassembly of boost check valve poppet sub
(517) is not allowed.
Replace control valve so that the spool cover
face directs downward.
CAUTION: When replacing, take care so as not to

score the spool cover.
SM2918
W2-3-23
E135B CONTROL VALVE
Removing plate
1. Loosen socket bolts (274), (275) and remove 213 275
plates (212), (213). 212
2. After removing plates, remove all O-rings (161),
(164) remained on the casing side. 274
SM2919
Removing check valve

1. Remove plugs of load check valve, conflux 551 556
check valve, etc. and then remove poppet (511)
and spring (521).
2. Load check valve on the swing section.
Remove plug (556) and then remove poppet
(511) and spring (524).
CAUTION: The plug and spring in use differ from

the above. Do not mix the parts when assembling
parts again.
3. Load check valve on arm 2 section.

SM2920
(515) and spring (521).
CAUTION: The poppet in use differs from the

above. Do not mix the parts when assembling parts
again.
4. Lock valve.
(514) and spring (524).
CAUTION: The plug, poppet and spring in use differ

from the above. Do not mix the parts when
assembling parts again. 511
SM2921
5. Main relief valve.

(512) and spring (522).
CAUTION: The plug, poppet and spring in use differ

from the above. Do not mix the parts when
assembling parts again.
The plugs in which the procedure for disassembly is

not included in the above procedure are usually
used to block auxiliary holes and holes caused by
casting. Do not disassemble further if unnecessary.
W2-3-24
CONTROL VALVE E135B
INSPECTION AFTER DISASSEMBLY

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean
sheet of paper or cloth for inspection.
Control valve
1. Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2. Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3. If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.
IMPORTANT: take care not leave lapping compound behind in the casing or block.
4. Confirm that the outer circumference of the sliding part of a manual spool is free from scratches, dents,
and the like. Remove any small defects with an oil stone or lapping compound.
5. Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages
are free from foreign matter.
6. Replace any broken or deformed spring with new one.
7. Replace all O-ring with new ones.
Relief valve
1. Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact
surface is even all over.
2. Manually confirm that the main poppet slides smoothly onto and off the seat.
3. Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free
from defects such as scratches.
4. Confirm that each spring is free from breakage, deformation, and excessive wear.
5. Confirm that the orifices of the main poppet and its seat are not clogged.
6. Replace all O-rings with new ones. (Between casing and seal)
REASSEMBLY
Assembly is performed in reverse order of disassembly.
For the tightening torque of socket bolts and plugs refer to page W2-3-11.
Precautions on reassembling O-ring

1. Confirm that O-rings are free from defects caused by poor handling.
2. Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3. Do not stretch O-rings to the extent that they become permanently set.
4. When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves
after installation, and can cause oil leaks.
5. Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards.".
W2-3-25
E135B CONTROL VALVE
Installing check valve

1. Load check valve, conflux check valve, and so on.
Attach poppet (511) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the
specified torque. (8 places)
: 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)
2. Load check valve of swing section.

specified torque. (1 place)
: 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)
3. Load check valve of arm 2 section.

specified torque. (1 place)
: 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)
4. Lock valve section.

: 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)
5. Main relief valve section.

: 140 ± 10 N•m (103.5 ± 7.5 lbf•ft)
CAUTION: take care to prevent misassembling of parts and assembling position error because the parts are
similar in shape.
Assembling plate
1. Place O-rings (161), (164) in casing.
2. Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.
: 109 ± 11 N•m (80.5 ± 8.5 lbf•ft)
NOTE: Replace control valve so that this plate face directs downward.
W2-3-26
CONTROL VALVE E135B
Assembling back pressure check valve

1. Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).
2. Attach O-rings (267) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt
(278) to the specified torque.
: 11.9 ± 2.1 N•m (8.75 ± 1.55 lbf•ft)
Assembling lock valve selector sub

1. Attach lock valve selector sub (211) to the casing and tighten socket bolt to the specified torque.
: 11.9 ± 2.1 N•m (8.75 ± 1.55 lbf•ft)
Assembling by-pass cut valve

1. Attach by-pass cut valve (605) to casing and tighten it to the specified torque.
: 109 ± 11 N•m (80.5 ± 8.5 lbf·ft)
CAUTION: Take care to prevent drop of poppet and spring when attaching by-pass cut valve.
Assembling relief valve and relief valve hole plug assembly

1. Tighten main relief valve (601), port relief valves (602), (606) and relief valve hole plug assembly (604) in
respective place to the specified torque.
: 73.5 ± 4.5 N•m (54.5 ± 3.5 lbf•ft)
CAUTION: Assemble it giving attention to the label attached when disassembling to prevent mistake because
the port relief valves (602), (606) are similar in shape.
Assembling P2 unload spool

1. Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate,
etc.), fit spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified
torque.
: 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)
CAUTION:
• Apply Loctite #262 when tightening bolt (333).
• Take care not to deform P2 unload spool (310) because of careless over clamping.
2. Place P2 unload spool assembly in casing A (101).
CAUTION: Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and
tighten socket bolt (273) to the specified torque.
: 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)
W2-3-27
E135B CONTROL VALVE
Assembling spool in option

1. Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (329), (330) and stopper (337) and tighten bolt (333) to the specified torque.
: 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)
CAUTION:
• Take care not to deform option spool (311) because of careless over clamping.
2. Place spool assembly in option in casing A (101).
CAUTION: Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and
: 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)
Assembling arm 2 spool

1. Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.),
: 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)
CAUTION:
• Take care not to deform arm 2 spool (308) because of careless over clamping.
2. Place arm 2 spool assembly in option in casing B (102).
CAUTION: Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
3. Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
socket bolt (273) to the specified torque.
: 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)
W2-3-28
CONTROL VALVE E135B
Assembling arm 1 spool

1. Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.)
and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified
torque.
: 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)
CAUTION:
• Take care not to deform arm 1 spool (302) because of careless over clamping.
2. Place arm 1 spool assembly in casing A (101).
CAUTION: Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and
: 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)
Assembling bucket spool

1. Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.),
: 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)
CAUTION:
• Take care not to deform bucket spool (304) because of careless over clamping.
2. Place bucket spool assembly in casing B (102).
CAUTION: Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
3. Attach spring cover (201) with O-ring (261) attached to the spring side of bucket spool assembly and
: 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)
W2-3-29
E135B CONTROL VALVE
Assembling swing spool

1. Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.),
: 17 ± 1 N•m (12.55 ± 0.75 lbf•ft)
CAUTION:
• Take care not to deform swing spool (303) because of careless over clamping.
2. Place swing spool assembly in casing A (101).
CAUTION: Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
3. Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly
and tighten socket bolt (273) to the specified torque.
: 29.5 ± 4.5 N•m (21.5 ± 3.5 lbf•ft)
W2-3-30
CONTROL VALVE E135B
MAINTENANCE STANDARDS
Inspection of components
Part name Inspection item Criterion and remedy
1. If any of the following parts are damaged,
replace the casing.
• Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
• Area of sealing part that is in contact with
1. Look for scratches, rusting and O-ring.
Casing
corrosion. • Sealing and seating part of main or
overload relief valve.
• Area of seating part or sliding part of
poppet.
• Sealing part of plug.
• Defects of other parts that seem to prevent
normal function.
1. If a detectable defect with your fingernail is
1. Look for scratches, galling, rusting and
found on the sliding part of the outer
corrosion.
Spool circumference, replace the spool.
2. Insert the spool in the casing bore, and 2. If the spool damages the O-ring or does not
move it while turning it. move smoothly, repair or replace the spool.
1. Look for damage on the poppet and If spring is damaged, replace it.
the spring. 1. If the seat of poppet or spring are damaged,
Poppet correct or replace it.
2. Insert the poppet in the casing, and 2. If the poppet moves lightly without catching, it
move it. is normal.
1. Look for rust, corrosion, deformation,
Spring and related parts and breakage of the spring, spring 1. If damaged heavily, replace.
seat, stopper, spacer bolt and cover.
1. Look for rust and damage on outer
1. Replace.
surface.
Main relief valve,
2. Inspect the contact face of the valve
Port relief valve, 2. If damaged, replace.
seat.
By-pass cut valve
3. Inspect the O-ring, backup ring, and 3. As a general rule, replace all parts with new
seal. ones. (Between casing and seal)
W2-3-31
E135B CONTROL VALVE
TROUBLESHOOTING
1. If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the
main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump
delivery pressure, load pressure, etc. If any part of the system is to be disassembled for inspection, follow
the disassembly and reassembly procedures in this manual.
2. Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the
system is to be disassembled, take dust protection measures beforehand.
3. Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or
the like.
4. Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
Control valve
Trouble Cause Remedy

1. Travel does not occur. 1. Malfunctioning main relief valve. 1. Check travel relief valve pressure.
Slow to start up • Foreign matter between main • Disassemble and clean. If
(or poor power). poppet and seat. damaged heavily, replace the
Slow response. • Foreign matter between poppet assy as a unit.
and seat. • Same as above.
• Sticking main poppet. • Correct sticking part with oil
• Broken or deformed spring. stone.
• Clogged main poppet throttle. • Replace spring.
• Loosened adjusting screw. • Remove foreign matter.
• Readjust, and tighten lock nut to
specified torque.
2. Machine does not move straight 1. Malfunctioning travel straight valve. 1. Check pilot pressure.
during simultaneous operation of • Sticking spool. • Correct sticking part with oil
travel and attachment. • Broken or deformed spring. stone.
• Clogged small hole in spool. • Replace spring.
• Remove foreign matter.
2. Malfunctioning main relief valve. 2. Remove main relief valve.
W2-3-32
CONTROL VALVE E135B

3. Excessive natural falls of 1. Excessive clearance between 1. Replace spool.
attachment under its own weight casing and spool.
when spool is in neutral. 2. Spool is not completely in neutral 2. Check secondary pilot pressure.
position. • Disassemble, clean and smooth
• Foreign matter between casing sticking part with oil stone.
and spool, or sticking spool. • Replace spring.
• Broken or deformed spring. • Remove foreign matter.
• Clogged pilot circuit.
3. Malfunctioning overload relief 3. Check overload relief valve
valve. Refer to item 1. 1) above. pressure. (See page W2-3-25)
(See page W2-3-25) • Clean and check damage on seat
• Foreign matter between valve surface.
seat and casing.
4. Lock valve function is faulty. 4. Replace
(Arm, boom) • Disassemble, clean.
• Foreign matter between poppet • Correct stuck part with oil stone or
seat and casing. replace.
• Poppet is stuck. • Replace spring.
• Broken or deformed spring. • Replace lock valve selector assy.
• Selector spool is stuck.
4. When raising attachment, at first it 1. Malfunctioning load check valve. 1.
drops. • Foreign matter between poppet • Disassemble and clean. If heavily
and casing. damaged, replace control valve.
• Sticking poppet. • Correct sticking part with oil
• Broken or deformed spring. stone.
• Replace spring.
5. Bucket, boom, arm or swing does 1. Malfunctioning main spool. 1. Check secondary pilot pressure.
not operate. • Excessive clearance between • Replace spool.
Slow to start up (or poor power). casing and spool. • Disassemble and clean.
Slow response. Foreign matter between casing • Correct stuck part with oil stone.
and spool. • Replace spring.
• Sticking spool. • Remove foreign matter.
• Broken or deformed return
spring.
2. Malfunctioning main relief valve. 2. Check main relief valve pressure.
Refer to item 1. 1) above. Refer to item 1. 1) above.
(See page W2-3-25) (See page W2-3-25)
3. Malfunctioning overload relief 3. Check overload relief valve
valve. Refer to item 1. 1) above. pressure.
(See page W2-3-25) (See page W2-3-25)
W2-3-33
E135B CONTROL VALVE

6. Boom conflux does not operate. 1. Malfunctioning conflux valve. 1. Measure pilot pressure.
• Excessive clearance between • Replace spool.
casing and spool. • Disassemble and clean.
• Foreign matter between casing • Correct stuck part with oil stone.
and spool. • Replace spring.
• Sticking spool. • Remove foreign matter.
• Broken or deformed return
spring.
Relief valve

1. No pressure rise. Main or pilot poppet of relief valve is Check for foreign matter on each
sticking and valve is open, or there is poppet.
foreign matter on valve seat. Confirm that each component slides
smoothly.
If failure is found, replace it as an
assembly.
2. Unstable relief pressure. Main or pilot poppet of relief valve seat If failure is found, replace it as an
is damaged. assembly.
3. Incorrect relief pressure setting. 1. Wear due to foreign matter. 1. Replace damaged assembly.
2. Loosened locknut or adjusting 2. Adjust pressure.
screw.
4. Oil leak. 1. Damaged seat. Confirm that each component operates
Damaged O-ring. smoothly. Replace damaged or worn
component.
1. If failure is found, replace it as an
assembly.
2. Sticking component due to foreign 2. Confirm that there are no scratches,
matter. scores, or foreign matter present
before reassembling.
If failure is found, replace it as an
assembly.
W2-3-34
SWING DEVICE E135B

SWING DEVICE
WARNING
Possible leakages of fluids under pressure could
penetrate the skin, causing serious injuries. Prevent
these dangers, discharging the pressure before
disconnecting hydraulic pipes or other pipes. Press
the valve located on the hydraulic oil tank to release
any residual pressure present in the tank. Hydraulic
oil, at the end of a work shift, can be very hot and
can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that
the oil and components are cooled-off. Check that
the lifting devices (hooks, chains, etc.) are in perfect
conditions without any sign of excessive wear and
appropriate to hold the weight of load.
Preparation
2. To drain the hydraulic pressure from the

“Releasing the hydraulic pressure” at page. T2-
1-45.

the hydraulic oil cap to release any residual
pressure present in the tank itself.
4. Remove the bracket assy and the top cover.
W2-4-1
E135B SWING DEVICE
Removal
1. Remove hose (1) from the Tee in the makeup

port C. 1
: 36 mm 6
C
2. Remove the hoses (2 and 3) from the Tee in the 2 3
B
drain port DB. 5
: 27 mm A
DB
3. Remove the hose (4) from the elbow of the PG
port.
: 19 mm PG 4
SM3141
4. Remove the hoses (5 and 6) from the
connectors of the A, B port.
: 30.32 mm
10
5. Put in plugs into the opened ports on the swing
motor unit.
6. Remove the clip (7) from the frame by loosing

the screws (8).
: 17 mm 9
8
7. Remove the swing motor unit by loosing the 7
screws (9) (Q.ty 9).
7
: 30 mm
8 SM3142
8. Remove the plastic cap (10) M10 at the top of

the swing motor and install the lifting eye bolt.
9. Sling and remove the swing unit.
NOTE: swing unit weight: 113 kg (249.2 lbs)
W2-4-2
SWING DEVICE E135B
Installation
1. Clean mating surfaces of swing motor unit and

10
upper frame.
2. Apply Loctite #515 on entire mounting surface

of swing motor unit.
3. Place the swing unit on the upper frame.

IMPORTANT: use care so no dirt falls into the swing
grease bath. 9
8
NOTE: swing unit weight: 113 kg (249.2 lbs)
7
4. Remove the lifting eye bolts and inserts on the 7
holes, the plastic caps (10) M10, previsiously
8 SM3142
removed.
5. Fix the swing unit to the frame by tightening the
screws (9) (Q.ty 9).
: 30 mm
1
: 539 ± 54 Nm (397.5 ± 40 lbf.ft)
6
6. Fix the clip (7) to the frame by tightening the
screws (8).
C
2 3
: 17 mm B
5
: 46.1 ± 4.9 Nm (34 ± 3.6 lbf.ft)
A
7. Before piping for draining, fill casing with
hydraulic oil from drain port of motor. DB
8. Install the hoses (5 and 6) on the elbows of port

A and B. PG 4
: 30,32 mm
SM3141
: 137 ± 14 Nm (101 ± 10 lbf.ft)
9. Install the hose (4) on the elbow of port PG.
: 19 mm
: 29 ± 4.9 Nm (21.4 ± 3.6 lbf.ft)
10. Install the hoses (2 and 3) on the tee in the drain
port DB.
: 27 mm
: 78 ± 4.9 Nm (57.5 ± 3.6 lbf.ft)
11. Install the hose (1) on the make up port C.
: 36 mm
: 118 ± 9.8 Nm (87 ± 7.2 lbf.ft)
12. Before starting operation, check the gear oil
level of swing reduction unit.
Amount of oil: 1.65 L (0.436 US gal)
IMPORTANT: when starting operation, operate

motor in low idling and at low speed for several
minutes, and check it for possible oil leak and noise.
W2-4-3
E135B SWING DEVICE

OF SWING DEVICE
Before disassembly, clean the outside of the

reduction unit thoroughly and check for no damage
or scratches.
Disassembly swing motor from reduction unit

3
4
1. Place the swing device on a stable work bench
as shown in figure, remove plug (1) and drain
out oil. X
: 27 mm
2. Remove the drain hose (2) from reduction unit.

: 27 mm 2
1
SM3140
3. Remove oil filling tube (3) from reduction unit.
: 24 mm
4. Put a matching mark (X) on the matching

surface of the figure on the right side.
5. Loosen all socket bolt (4) M12. Attach eye bolts

(M10) in the lifting bolt holes in the top surface
of the swing motor and lift the assy by crane.
If it is hard to remove the swing motor assy from
the reduction unit, float it by inserting a flat-
blade screwdriver in the groove of the flange.
: 10 mm
W2-4-4
SWING DEVICE E135B
Assembly swing motor on reduction unit

1. Place the reduction unit on a stable work
bench.
Attach eye bolts (M10) in the tapped holes of
the swing motor and put a wire sling in them.
3
2. Apply sealant Loctite #515 on the matching 4
surface of reduction unit, insert the spline joint
of the swing motor and match the matching
X
marks (X).
3. Apply sealant Three-Bond #1217 on the socket

bolts (4) M12 and fasten them at the prescribed
tightening torque.
: 10 mm
2
: 98 Nm (72.2 lbf•ft) 1
SM3140
4. Fit drain hose (2) and plug (1).

: 27 mm
: 108 ± 11 Nm (80 ± 8 lbf•ft)
5. Coil sealing tape on the thread portion of oil

filling tube (3) and fit it to the reduction unit.
: 24 mm
: 108 ± 11 Nm (80 ± 8 lbf•ft)
NOTE: temporarily fit the level bar to the pipe and

check the level.
6. Fill reduction unit with gear oil SAE90 (API

Service Grade GL-4).
W2-4-5
E135B SWING DEVICE
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
992
303 451 131 444
351
355 A-A
051
401 488 469 051-1
468
106 487 444 433 981 390 391 438 980
303 472
451 707
712 706
A A
131 982
702 114
111 117
743 121
742 113
123
116
117 432 471 443 106 101 491 304 437 124 122 301
SM2844
W2-4-6
SWING DEVICE E135B
torque torque
Nm Nm
177 (131) 051 Relief valve; M33-P1.5 2 240 (177) 401 Socket bolt; M16×75 4
051-1 O-ring; 1B G30 2 432 Snap ring 2
101 Drive shaft 1 433 Ring 1
106 Spacer 3 437 Snap ring 1
438 Snap ring 1
1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
113 Retainer (spherical bushings) 1 451 Pin 2
114 Cylinder spring 1 36 (27) 468 Plug; PF1/4 2
116 Push rod 12 108 (80) 469 ROMH plug; M22-P1.5 2
117 Spacer 2 471 O-ring; 1B G80 1
121 Piston 9 472 O-ring; W1516,WG34 1
122 Shoe 9 487 O-ring; 1B P11 2
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
706 O-ring; W1516,WG31 1
707 O-ring; W1516,WG36 1
712 Brake spring 20
301 Casing 1 742 Friction plate 3
303 Valve casing 1 743 Separator plate 4
304 Front cover 1 1.7 (1.2) 980 Plug; PF3/8 1
351 Plunger 2 4.4 (3.3) 981 Plug; PF3/4 1
0.9 (0.6) 982 Plug; PF1/4 1
355 Spring 2 98 (72) 992 Plug; PT3/4 1
390 Name plate 1
391 Rivet 2
W2-4-7
E135B SWING DEVICE
Preliminary operations
1. Hydraulic components are precision products

and have small clearance. Therefore,
assemble and disassemble in a less dusty
clean place. Use clean tools and cleaning oil
and handle components with full care.
2. If a component is removed from the main body,

clean the area around the ports thoroughly and
plug them up so no dust and water do not enter.
When fitting them back to the body, do not
remove the plugs till piping is completed.
3. Study the structural drawing before the work

begins and prepare necessary parts according
to your purpose and the scope of work. Seals
and O-Rings once removed can not be used
again.
4. The piston and the cylinder block are shop fitted

when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder
block.
Disassembly
NOTE: choose a clean place, and lay with a rubber

sheet or a cloth on a work bench. Handle the valve
casing with care so parts do not have dents.
1. Fixing the motor to the work bench. Direct the

shaft end of the drive shaft (101) downand fix it
on a bench convenient for disassembly. On that 303
occasion, leave a matching mark on themating
part between casing (301) and valve casing
(303). 301
SM3061
W2-4-8
SWING DEVICE E135B
2. Remove relief valve.

Loosen relief valve (051) and separate it from
valve cover (303). 303
: 41 mm 051
SM3062
3. Remove swing shockless valve block.

Loosen socket bolt (V171) and separate swing V171 052 303
shockless valve block (052) from valve casing
(303).
: 6 mm
SM3063
4. Removing the anti-cavitation check plunger.

Separate RO plug (469) from valve casing
(303) and draw out spring (355) and plunger
(351).
: 10 mm
NOTE: exercise care so as not to score the plunger

seat.
W2-4-9
E135B SWING DEVICE
5. Remove valve casing and valve plate.

Loosen socket bolt (401) and separate valve
casing (303) from casing (301). [If the socket
bolt (401) are loosened, the valve casing floats
off casing (301) by the force of brake spring 401
(712)].Then separate valve plate (131) from
valve casing (303).
: 14 mm 303
301
NOTE: work with care so the valve seat does not
come off from the valve casing. (In some cases, the
valve plate is adhered on the cylinder side.) When
inserting a screwdriver or something between the
matching surfaces, use care so as not to score the SM3064
matching surfaces.
6. Remove brake spring.

303
Draw out brake spring (712) from brake piston
(702).
712
301
SM3065
7. Remove brake piston.

Draw out brake piston (702) from casing (301),
using the special tool (A) (380001938).
(A)
NOTE: hold it upright, utilizing the bolt holes in the 702

brake piston.
301
SM3066
W2-4-10
SWING DEVICE E135B
8. Remove cylinder.
Place the motor level and draw out the cylinder 301
(111) from the drive shaft (101). Then draw out
piston (121), retainer plate (123), spacer (117)
and shoe plate (124).
WARNING
use care when drawing out the cylinder as push rod
(116) tends to come off. Exercise care so as not to
score the sliding surfaces of the cylinder, retainer
and shoe.
In case the shoe plate does not come off, remove it 111
SM3067
after the work sequence (12).
9. Remove separator plate.

Draw out friction plate (742) and separator plate
(743) from casing (301). 437
304
301
SM3068
10. Remove front cover.

Take off snap ring (437) with pliers and
separate front cover (304) from casing (301).
304
WARNING
when drawing out the front cover, take care so as
not to score the sliding surface of the oil seal.
You may remove the front cover with the drive shaft.
301
SM3069
W2-4-11
E135B SWING DEVICE
11. Remove drive shaft.

Separate drive shaft (101) from casing (301) by
lightly tapping the end face of the valve casing
side (303) of drive shaft (101), using a plastic
mallet.

surface of the oil seal.
12. Remove shoe plate.

Draw out shoe plate (124) from the housing
side of roller bearing (443) of casing (301) by 101 301
lightly tapping it with a steel rod. SM3070
13. Remove inner race of roller bearing.

Remove snap ring (432) and spacer (106) from PRESS
drive shaft (101) and draw out the inner race of 101
roller bearing (443) by means of a press.
443
NOTE: you may knock on the inner race of the roller
bearing with a steel bar, but knock on it evenly all
around so the bearing is not damaged.
Do not use the removed bearing again.
Put the press bench
on the inner race.
SM3071
14. Remove oil seal.

Draw out oil seal (491) from front cover (304),
utilizing a round plate.
NOTE: do not reuse the removed oil seal. 304

(491)
PRESS
ROUND PLATE
491
SM3072
304
SM3073
W2-4-12
SWING DEVICE E135B
15. Remove roller bearing.

Separate roller bearing (444) from valve casing
(303), using a slide hammer bearing puller.
101
NOTE: do not reuse the removed bearing. 444
303
SM3074
W2-4-13
E135B SWING DEVICE
Assembly
1. Holding casing. 301

Place the casing (301) facing its valve casing
(303) downward.
SM3075
2. Installing inner race of roller bearing.

Fit snap ring (432) and spacer (106) to drive
shaft (101), insert the inner race of roller
bearing (443), and shrinkage fit the inner race.
Put spacer (106) in and fix snap ring (432).
444
101
WARNING
106
beware of the orientation of the inner race of the
roller bearing.
SM3076
OUT PUT SHAFT SIDE

Set the spacer to the
R (round) side of the
bearing inner race.
432
106 SM3077
SM3078
W2-4-14
SWING DEVICE E135B
3. Shrinkage fitting inner race of roller bearing.

Shrinkage-fit the inner race of roller bearing
(444) to drive shaft (101). Then fit snap ring
(433). 444
4. Installing outer race of roller bearing.

Place drive shaft (101) with roller bearing (443)
on its output shaft, and insert the drive shaft into
101
casing (301). Then lightly knock on the outer
race of roller bearing (443) via a steel bar, using
a hammer.
NOTE: knock on the outer circumference of the

SM3079
outer race evenly all round till it stops at the step of
the casing.
5. Insert oil seal.

Put oil seal (491) into front cover (304), using a
jig.
WARNING:
be careful about the direction of the oil seal.
Fix the oil seal till it stops at the step of the casing.
304 (491)
SM3080
6. Fit O-ring.
Fit O-ring (471) to casing (301).
471
NOTE: coat the lip of the oil seal with a thin film of
grease and put it in with care so as not to score the
lip of it. (Wind tape on the spline of the drive shaft so 301
the lip of it is not scored by the spline.) Tap the outer
circumference evenly round to prevent it from being
scored.
SM3081
Wind protective tape
101
SM3082
W2-4-15
E135B SWING DEVICE
7. Installing front cover.

Fit front cover (304) to casing (301) by lightly
304
tapping the cover with a plastic mallet.
8. Fitting the snap ring.

Fit snap ring (437) to casing (301), using pliers.
SM3083
9. Put shoe plate (124) into casing (301).

124
NOTE: put the larger chamfer side of the shoe plate
into the casing side.
Coat the matching surface with a thin film of grease
to prevent the shoe plate from falling off.
301
SM3084
10. Insert push rod.

Put push rod (116) in cylinder (111).

surface of the cylinder. (Put two push rods into one
hole.) 111
116
SM3085
11. Installing retainer.

Then mount retainer (113) fitted with spacer
(117) on the cylinder. 113
117
SM3086
W2-4-16
SWING DEVICE E135B
12. Installing the piston sub assy to the plate.

Set piston sub assy (121,122) to plate (123).
123
121,122
SM3087
13. Assembling the piston sub assy into the

121,122,123
cylinder.
Assemble piston sub assy (121,122) with plate 111
(123) into cylinder (111) and insert it in place,
aligning it with the spline of drive shaft (101).
NOTE: the drive shaft can be set easily if the phase

of the retainer (113) and the cylinder spline is
matched.
14. Installing separator plate and friction plate.

Replace casing (301) so front cover (304) side 101
faces down. Then Assemble separator plate SM3088
(743) and friction plate (742) into casing (301),
in that order. Fit four separate plates and three
friction plates. 743
NOTE: assemble four notches in the gear teeth of

friction plate so the same phases are aligned up and
down.
Fix notches in the four claws of separator plate.
301
SM3089
742
Selector valve mount

SM3090
301
SM3091
W2-4-17
E135B SWING DEVICE
15. Fit O-ring.

Fit O-rings (706)(707) to casing (301). 707 (706)
NOTE: in that case, coat the O-rings with grease

beforehand. This will prevent the O-rings from
breaking when inserting brake piston. 301
SM3092
16. Installing brake piston.

Fit brake piston (702) to casing (301).
702
NOTE: install the brake piston so four slits of it are

positioned as shown in the below figure. (Match the
M8 screws to the below figure.) 301
If brake piston is hard to enter because of the
resistance of the O-rings, screw in socket bolt M8
into the brake piston and knock on it evenly by
means of a plastic mallet.
SM3093
2-M8 702
SLIT
Selector valve mount
SM3094
17. Installing brake spring. 702 712

Fit brake spring (712) to brake piston (702).
NOTE: at that time, make sure that the spring is set

snugly in the spotface of the brake piston.
SM3095
W2-4-18
SWING DEVICE E135B
18. Insert outer race of roller bearing.

Insert the outer race of roller bearing (444) into
valve casing (303), knocking it lightly by means
of a steel bar.
NOTE: knock on the outer circumference of the

outer race evenly around and fix it so it stops at the 444
step of the valve casing.
303
SM3096
19. Installing valve plate.

Assemble valve plate (131) into valve casing 131
(303) and then fit O-ring (472) in place.
NOTE: coat the contact surface of the valve plate

with a thin film of grease. (To prevent it from falling
off.)
Apply grease
SM3097
20. Installing valve casing.

Attach valve casing (303) to casing (301) and
fasten it with socket bolt (401).
: 14 mm
: 240 Nm (177 lbf•ft)
303
WARNING
301
beware of the direction of the valve casing.
Be careful so the valve plate does not come off.
Use care so the brake spring does not fall down.
SM3098
Fasten the socket bolts evenly all around.
W2-4-19
E135B SWING DEVICE
21. Fitting plunger.

Place plunger (351) and spring (355) into valve
casing. Fasten RO plug (469) with O-ring (488) 401 351
into valve casing.
: 10 mm
: 108 Nm (80 lbf•ft)
NOTE: make sure that the plunger moves smoothly.
355 (488,469)
SM3099
22. Installing relief valve.

Fit backup ring (051-2) and O-ring (051-1) to
relief valve (051) and fasten the relief valve
against valve casing (303). 051 (051-1, 051-2) 303
: 41 mm
: 177 Nm (130 lbf•ft)
23. Installing plugs.

Fit O-ring (487) to plug (468) and attach it to
valve casing (303).
: 19 mm
: 36 Nm (27 lbf•ft)
SM3100
24. Installing swing shockless valve block.
Fit O-ring (V161) to the swing shockless valve
block. Then fasten the valve block against valve
casing (303) with socket bolts (V171). 052 (V161) 303
V171
: 6 mm
: 29 Nm (22 lbf•ft)
SM3101
W2-4-20
E135B SWING DEVICE
DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
602 230 231 204 286 211 912 285 287 911 283 403 603 922
210
921
202 282
* 203
913
285
*
402
910
801
925
920
926
102
401
915
201
SM2846
torque Nm No. Parts Q.ty torque Nm No. Parts Q.ty
102 Casing 1 402 Roller bearing 1
201 Drive shaft 1 403 Needle bearing 3
202 Ring gear 1 98 602 Capscrew; M12x100 8
203 No.2 planetary gear 4 98 603 Capscrew; M12x135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Snap ring 3
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 920 Adapter; PT1/2 1
285 Side plate t=1 7 108 921 Hose; PF1/2 1
286 Thrust washer t=2 1 108 922 Plug; PF1/2 1
287 Side plate t=2 3 22 925 Relief fitting; PT1/4 1
401 Roller bearing 1 22 926 Grease nipple; PT1/4 1
Coat the part marked * with Three Bond #1217.
W2-4-21
SWING DEVICE E135B
Disassembly
1. Remove snap ring (912).
2. Remove No.1 sun gear (211). 211
SM3102
3. Remove No.1 carrier assy.

Remove the No.1 carrier assy (231) with the
No.1 planetary gear (210) and others.
210
SM3103
W2-4-22
E135B SWING DEVICE
4. Disassembly No.1 carrier assy.
NOTE: put a matching mark on each of the

planetary gears and pins so combination and pairing
do not change.
a. Remove snap ring (911). Then remove side

plate (287) at the top. 911
287
SM3104
b. Remove No.1 planetary gear (210) and

needle bearing (403).
403 210
SM3105
c. Remove side plate (285) under the

planetary gear.
285
SM3106
d. After removing three No.1 planetary gears

(210), remove thrust washer (286) in the
center.
286
NOTE: do not remove No.1 pin (283) from No.1
carrier (231) unless there is anything wrong.
If the No.1 pin is removed, you need a special
caulking tool at reassembly.
However, make sure that the ø2 mm (0.079 in) oil 2 (0.079")
hole of No.1 pin (283) is directed outwards with (OIL HOLE)
respect to the center of No.1 carrier (231).
SM3107
W2-4-23
SWING DEVICE E135B
5. Remove No.2 sun gear (204).
204
SM3108
6. Remove No.2 carrier assy (230).

230
SM3109
7. Disassembly No.2 carrier assy.

282,910
NOTE: do not disassemble the No.2 carrier assy

further unless there is anything wrong. Check all
parts for possible failure. 203,285
It is recommended that the No.2 carrier assy be
replaced as a pair, but in case part of it must be
replaced for an unavoidable reason, follow the
procedure below.
a. Push spring pin (910) in further and draw out

No.2 pin (282).
SM3110
NOTE: do not reuse the removed No.2 pin.
b. Draw out No.2 planetary gear (203) and side

plate (285) sideways.
W2-4-24
E135B SWING DEVICE
8. Remove ring gear.

The bottom of the two holes is provided with 202
M12 screw threads to draw out the ring gear
(202). Utilise motor mounting socket bolts (602)
to draw it out.
: 10 mm
SM3111
9. Separate snap ring (913) from drive shaft (201).
10. Remove drive shaft. 913

Support the flanged part of the drive shaft (201)
so the shaft end faces down and place the drive
shaft on a work bench. Draw out the shaft 201
downwards, while tapping the center of it with a
plastic mallet.
NOTE: do not disassemble it further unless there is

anything wrong.
Check all parts for possible failure.
It is recommend that the drive shaft assy be
replaced as a set. In case part of it must be replaced SM3112
for an unavoidable reason, follow the procedure

below.
If nothing faulty is discovered on inspection at this
stage, no further disassembly is needed.
W2-4-25
E135B SWING DEVICE
11. Remove roller bearing.

As shown on the figure on the right, support the PRESS
drive shaft assy and draw out bearing seal
(915) and roller bearing (401), using a press
and a special tool (C) (380001942). (C)
WARNING
roller bearing (402) is left in the casing. Since the
shaft falls down, use care so as not to damage it.
The removed oil seal and the bearing seal can not
be used again.
915
401
SM3113
12. Remove oil seal (801) from casing (102).

102
801
SM3114
W2-4-26
SWING DEVICE E135B
Assembly
1. Assembly drive shaft assy.

402
a. Insert bearing seal.
801
Insert bearing seal (915) into drive shaft 102
GRASSO
(201).
401
915
201
SM3115
b. Press-fitting roller bearing.

Coat the inside of roller bearing (401) with
GRASSO
sufficient grease and press it into the drive
shaft, using a press. Set the inner race firm
into the shaft by knocking on the steel bar,
till the hammer springs back. Then apply
grease so it reaps as shown in Figure.
Grease: EP type (Shell Alvania grease
EP2).
NOTE: roller bearing (401) has a bank in the middle.

Push grease in to both sides before assembling the
bearing into the shaft.
201
SM3116
2. Place casing (102) on a level bench.
3. Installing drive shaft assy.

Lift the drive shaft assy upright, using the screw
in the end of the shaft and put it into the casing.
Thread size: M10, Depth 20 mm (0.787 in).
201
NOTE: lightly tap the outer race of the bearing so it

is completely level. If the outer race is tilted, it does 102
not enter by light tapping in some cases. On such
occasion, pull it out once, place it level and do the
job once again.
SM3117
W2-4-27
E135B SWING DEVICE
4. Place the casing by supporting the flanged part

so the shaft end faces down.
5. Installing oil seal.

Insert oil seal (801) into casing (102).
NOTE: use the special tool (B) (380001941). Place

the oil seal level and fix it so the lip is not scored.
6. Press-fitting roller bearing.

Insert roller bearing (402) by using the special
tool (D) (380001943) that holds down both the
inner race and the outer race and also using a
press. (D)
Always use the special tool (D) (380001943)
and set it properly..
402
SM3118
7. Fit snap ring (913).

913
SM3119
W2-4-28
SWING DEVICE E135B
8. Assembly No. 2 carrier assy.
a. Place side plate (285) by matching it to the

pinholes.
230 285 282 203
b. Put No.2 planetary gear (203) in.
c. Check the hole location, peeping through it
from above. Match the No.2 pin (282) with
the hole for spring pin (910) and the hole in
the No.2 carrier and set the pin, while
tapping it lightly.
910
SM3120
9. Apply liquid packing to the matching surface

between casing (102) and ring gear (202).
Three-Bond #1104B
10. Installing ring gear. 202

Install ring gear (202) to casing (102), checking
the location of the matching marks and
102
temporarily fasten them together by means of
four capscrews or socket bolts M12×100.
Always place plain washers on the bolts so the
matching surface of the motor is not scored.
: 19 mm o : 10 mm
: 78 Nm ( 58 lbf•ft) or over
SM3121
11. Installing No.2 carrier assy.

Install the No.2 carrier assy (230) into the ring
gear.
12. Installing No.2 sun gear.

230
Put in No.2 sun gear (204).
SM3122
W2-4-29
E135B SWING DEVICE
13. Assembly No.1 carrier assy.

a. Place No.1 carrier (231) on a level bench.
b. Make sure that all three ø2 mm (0.079 in) oil
holes of No.1 pin (283) are directed 204 286 211 285 287 283 403 210
outwards with respect to the center of No.1 231
carrier (231), as shown in the figure.
2 (0.079")
(OIL HOLE)
231
SM3123
SM3125
c. Installing thrust washer.

Put in thrust washer (286) in the center.
286
SM3124
W2-4-30
SWING DEVICE E135B
d. Installing side plate.

Put in side plates (285).
286
WARNING
the upper and lower side plates differ in thickness;
take care so as not to mistake one for another.
403
285
SM3126
e. Installing needle bearing and No.1 planetary

gear.
Fit needle bearing (403) and No.1 planetary
gear (210) into position as shown in Figure.
210
SM3127
f. Installing side plate.

Put side plate (287) in and fit snap ring
(911).
911
287
SM3128
14. Installing No.1 carrier assy.

Assemble the No.1 carrier assy (231). Make 231
sure that thrust washer (286) in the center sits
in the convex part of No.2 sun gear (204).
286
204
SM3129
W2-4-31
E135B SWING DEVICE
15. Installing No.1 sun gear.

Assemble No.1 sun gear (211).
211
16. Apply liquid packing.
Remove the temporarily fastened bolts and
coat the mounting surface of the hydraulic
motor of ring gear (202) with liquid packing 202
(Three-Bond #1104B).
17. Fit snap ring (912).
SM3130
W2-4-32
SWING DEVICE E135B
Swing motor
1. Replacement standards for parts.
If parts are worn out beyond the below
standards, replace or recondition them.
However if they show excessive damage on
their surface, replace them.
Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (in)
mm (in)
Clearance between piston and cylinder bore
(D-d)
Replace piston or
d D 0.016 (0.00063) 0.046 (0.00181)
cylinder
SM3131
Gap between piston and caulked part of shoe

(σ)
Replace piston and

0 0.3 (0.01181)
shoe assy
SM3132
Thickness of shoe
(t)
Replace piston and

4.0 (0.1575) 3.8 (0.1496)
shoe assy
t
SM3133
Assembled height of retainer plate and retainer

(H-h)
Replace a spherical
H 5.5 (0.2165) 5.0 (0.1968) bushing and a retainer
h plate as a pair.
SM3134
Thickness of friction plate
3.5 (0.1378) 3.1 (0.1220) Replace

t
SM3135
W2-4-33
E135B SWING DEVICE
2. Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace
the part.
Standard for correcting sliding surfaces

Surface roughness requiring
Name of part Standard surface roughness
correction
Shoe Ra = 0.2 (lapping) Ra = 0.8
Shoe plate Ra = 0.1 (lapping) Ra = 0.8
Cylinder Ra = 0.4 (lapping) Ra = 3.2
Valve plate Ra = 0.2 (lapping) Ra = 1
• Lap each sliding surface to a standard

roughness level or finer.
• If the sliding surface of the cylinder block, valve

plate, retaining plate or spherical bushing is
roughened, replace parts in pairs.
W2-4-34
SWING DEVICE E135B
Reduction Unit
1. PARTS INSPECTION AND REPLACEMENT d. Drive shaft roller bearing (Rear side).
STANDARDS. Replace the bearing if the race surface and
the rollers show pitching and flaking.
a. If pitching is seen on the tooth surface of the
sun gear, the planetary gear and the ring e. No. 2 planetary gear
gear; (Single pit is more than ø1 mm (0.039 Check for the circumferential gap between
in) and the area occupancy of all pits is more the No. 2 planetary gear and the No. 2 pin
than 5%.) without disassembling the No. 2 carrier
assy. Replace the planetary gear if the gap
b. Oil seal. is more than 0.5 mm (0.01969 in).
Replace the oil seal if the lip face of it is
scored and worn. f. Thrust plate and thrust washers.
Always replace when the reduction gear is Replace the gear if the sliding surface in
disassembled for inspection or some contact with the No. 2 sun gear is extremely
reason. scored.
c. Drive shaft roller bearing (Front side). g. If pitching and flaking are seen on the rolling
Inspect as below without drawing it out from surfaces of the needle cage and the No. 1
the drive shaft: pin that support the No. 1 planetary gear;
Inspect the race surface and the rollers Replace such faulty parts.
as far as you can see and make sure that
there is no pitching and flaking.
Inspect the following as well:
a.The gear oil does not contain large
worn particles.
b.Large worn particles are not deposited
between the roller and the retainer.
c.The bearing turns smoothly by hand.
Replace it if there is any fault on the
above inspection.
Do not reuse the bearings drawn out of
the shaft.
W2-4-35
E135B SWING DEVICE
2. TABLE OF PARTS TO BE REPLACED

TOGETHER
m marks represent such parts that must be replaced
together.
∆ marks represent such parts that should preferably
be replaced together.
NOTE: Replace the inner race and the outer race of

the roller bearing together.
Parts to be replace together

N. 201 401 402 203 230 282 285 910 210 231 283 403
No. 2 planetary gear
No. 1 planetary gear

Roller bearing
Roller bearing
No. 2 carrrier
Needle cage
No. 1 carrier
Drive shaft
Side plate
Spring pin
No. 2 pin
No. 1 pin
NAME
210 Drive shaft - m m

401 Roller bearing ∆ - ∆
402 Roller bearing ∆ ∆ -
203 No. 2 planetary gear - ∆ m ∆ m
230 No. 2 carrier ∆ - m ∆ m
282 No. 2 pin ∆ ∆ - ∆ m
Parts for replacement
285 Side plate ∆ ∆ m - m

910 Spring pin ∆ ∆ m ∆ -
210 No. 1 planetary gear - ∆ ∆ ∆
231 No. 1 carrier ∆ - m ∆
283 No. 1 pin ∆ m - ∆
403 Needle cage ∆ ∆ ∆ -
W2-4-36
SWING DEVICE E135B
SPECIAL TOOLS
Swing motor
Tool Part
Purpose Figure
Number
(A)
380001938 Brake piston drawing tool 2 X 7 (0.276")
(1.57")
40
M10 SCREW ON BOTH ENDS
(EFFECTIVE THREAD
LENGTH 20 (0.787") 40 (1.57")
100 (4")
250 (10")
BORE DIA. 11
(0.433")
10 (0.4")
2 X NUT M10
M10
123 (4.84")
200 (7.87")
SM3136
W2-4-37
E135B SWING DEVICE
Swing reduction unit
Tool Part
Purpose Figure
Number
(B)
380001941 Oil seal fitting
Ø93
9
SM3137
(C)
380001942 Roller bearing (401) removing
125
118
138
0
Ø1
28
Ø1
SM3138
W2-4-38
SWING DEVICE E135B
Tool Part
Purpose Figure
Number
(D)
380001943 Roller bearing (402) fitting
Ø140
Ø74
45
SM3139
W2-4-39
E135B SWING DEVICE
NOTE:
W2-4-40
PILOT VALVE E135B
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE
WARNING
Preparation
1. Park the machine on a firm, level surface. “Releasing the hydraulic pressure” at page. T2-
1-47.
Removal
1. Free and lift rubber cap (5) complete with plate
(4) unlocking its hooks using a screwdriver.
2. Remove side panels (2) and (3) removing

securing screws.

3. Remove the handgrip (1) removing lock-nut (6)
disconnecting the relevant electric connection.

: 22 mm
IMPORTANT: attach an identification tag on each
hose to aid in reassembly.

4. Disconnect hoses from port connector PF 3/8
60
(7) and PF 1/4 (8) of pilot valve body (9).
: 19.22 mm

NOTE: attach a cap on each of disconnectd hose
ends.
5. Remove pilot valve (9) removing securing

screws (10) M6x25 complete with washers.
: 5 mm
60
W2-5-1
E135B PILOT VALVE
Installation
1. Install pilot valve (9) on the frame tightening 7

securing screws (20) M6x25 complete with 7

washers.

: 5 mm

: 11.8 Nm (8.7 lbf•ft)

3
2. Connect hoses to pilot valve body (9).
3
: 19 mm (Port: P) 60
: 29.4 Nm (22 lbf•ft)
: 22 mm (Port: 1 to 8, T)
LEFT SIDE RIGHT SIDE
: 49 Nm (36 lbf•ft)
BUCKET
5 SWING (L) GRAY 1 RED
(H)
3. Tighten the handgrip on the pilot valve (9), BUCKET
tighten lock-nut (6) and reconnect the electric 6 SWING (R) RED 2 BLUE
(R)
connector. 7 ARM (H) BLUE 3 BOOM (H) GREEN
: 22 mm
8 ARM (R) GREEN 4 BOOM (R) GRAY
4. Install side panels (2) and (3) tightening

securing screws.
5. Arrange rubber cap (5) complete with plate (4)

locking the hooks on side panel (2).

60
W2-5-2
PILOT VALVE E135B
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE
WARNING
Preparation
1. Park the machine on a firm, level surface. “Releasing the hydraulic pressure” at page. T2-
1-47.
Removal
1. Remove the cover under the cab
2. Remove the floor mats in the cab.
3. Remove the pedal removing securing screws

(1) (Q.ty 4) then remove the levers, removing
securing screws (2) (Q.ty 4).
: 13, 17 mm
4. Disconnect pressure sensors (7) from body (8).

: 24 mm

IMPORTANT: attach an identification tag on each
hose to aid in reassembly.

5. Disconnect pipes (from 3 through 6) of body
(8).

: 19, 22 mm

NOTE: attach a cap on each of disconnected hose

ends. 60
6. Remove body (8) removing securing screws (9)

complete with washers.
: 17 mm
W2-5-3
E135B PILOT VALVE
Installation
1. Install body (8) on the frame tightening securing

screws (9) complete with washers.
: 17 mm
: 37 Nm (27.4 lbf•ft)
2. Connect pipes (from 3 through 6) to body (8).

: 19 mm
: 16.7 Nm (12.3 lbf•ft)
: 22 mm
: 30 Nm (22.0 lbf•ft)
3. Connect pressure sensors (7) to body (8).

: 24 mm
: 16.7 Nm (12.3 lbf•ft)
4. Install the levers tightening securing screws (2)

and the pedals tightening securing screws (1).
: 17 mm
: 46.1 Nm (34.1 lbf•ft)

: 13 mm

: 23.5 Nm (17.4 lbf•ft)

5. Install the cover under the cab 60
: 19 mm
: 108 Nm (80.0 lbf•ft)
W2-5-4
PILOT VALVE E135B
DISASSEMBLY RIGHT AND LEFT PILOT VALVE
60
1- Adjusting nut M14 7- Plug (Q.ty 4) 17- Spring (Q.ty 2)

2- Boots 8- O-Ring (Q.ty 4) 18- Spring (Q.ty 2)
3- Circular plate 9- Push rod (Q.ty 4) 19- Washer 2 (shim) (Q.ty 4)
4- Joint M14 12- Spring seat 1 (Q.ty 2) 20- Spool (Q.ty 2)
5- Plate 14- Spring seat 1 (Q.ty 2) 21- Spool (Q.ty 2)
6- Seal (Q.ty 4) 15- Spring (Q.ty 4) 22- Casing
W2-5-5
E135B PILOT VALVE
Disassembly right and left pilot valve
Be sure to thoroughly read "Precautions for

Disassembly and Assembly" on page W1-1-1
before starting the disassembly work.
NOTE: replace O-Ring every disassembly

operations, as a rule.
1. Plug each port of pilot valve, and clean it.

P Port : PF 1/4”
1÷4 Port and T: PF 3/8”
2. Fix pilot valve with vise, via a protective plate

(Alminum plate etc.), and remove boot (2).
60
3. Remove adjusting nut (1) applying spanners to
circular plate (3).
: 22, 32 mm
4. Remove circular plate (3).

: 32 mm

5. Turn joint (4) in counterclockwise with jig (E)
(380001055) to remove it.
: 24 mm
60
WARNING
When the force of return springs (15) is high, never
loosen joint (4). If loosened, it might result in
jumping out of plate (5) plug (7) and push rod (9).
(
Remove joint (4) pressing plate (5) downward with
two fingers.
60
W2-5-6
PILOT VALVE E135B
6. Remove plate (5).

NOTE: When the force of return spring (15) è is
high, press plate to let it come up slowly.
When the force of return spring (15) is low, plug (7)
is left in casing (22) due to sliding resistance of O-
Ring (8).
60

60
7. Pull plug (7) out with a driver.
WARNING
To prevent personal injury, plug (7) must be
removed slowly and evenly until the return spring
(15) force is completely released

60
8. Remove push rod (9), plug (7), pressure

reducing valve assy (spool) and the return
springs (15) from casing (22).

NOTE: record combination of port holes on casing

and the pulled out parts. The stroke differs
according to direction.

60
W2-5-7
E135B PILOT VALVE
9. Press springs seats (12 and 14) so that the

movement is 7 mm (max), then remove spools
(20 and 21) through the larger hole of the seat.

IMPORTANT: Never push down spring seat (12) in
7 mm or more. (For port 1 and 3).
Never push down spring seat (14) in 9.4 mm or
more. (For port 2 and 4).

60
10. Remove spool (20 and 21), spring seats (12

and 14), springs (17 and 18) and washer (19).

60
11. Pull out push rod (9) from plug (7).

12. Remove O-Ring (8) from plug (7).

60
13. Remove inside seal (6) from plug (7) with small
driver
Cleaning parts
1. Clean parts with wash oil roughly and the parts
of pilot valve completely.
2. Dry parts by swabbing clean waste cloth.
3. Apply rust preventives on parts.
60
W2-5-8
PILOT VALVE E135B
ASSEMBLY RIGHT AND LEFT PILOT VALVE

60
1- Adjusting nut M14 9- Push rod (Q.ty 4) 18- Spring (Q.ty 2)

2- Boots 10- Spring (Q.ty 4) 19- Washer 2 (shim) (Q.ty 4)
3- Circular plate 11- Spring seat 2 (Q.ty 2) 20- Spool (Q.ty 2)
4- Joint M14 12- Spring seat 1 (Q.ty 2) 21- Spool (Q.ty 2)
5- Plate 13- Spring seat 2 (Q.ty 2) 22- Casing
6- Seal (Q.ty 4) 14- Spring seat 1 (Q.ty 2) 23- 2E4 Port
7- Plug (Q.ty 4) 15- Spring (Q.ty 2) 24- 1E3 Port
8- O-Ring (Q.ty 4) 17- Spring (Q.ty 2)
W2-5-9
E135B PILOT VALVE
Assembly right and left pilot valve
1. Fit washer 2 (19), springs (17) and (18), spring

seats (12) and (14) to spools (20) and 21).

60
2. Push spring seat 1 (12) so that the movement

is 7 mm or less, and install spool (20) through
the large hole of spring seat 1.
For spring seat 1 (14), push spring seat (14) in
9.4 mm or less and install spool (21).
IMPORTANT: never push down spring seat (12) in

7 mm or more. (For port 1 and 3).
Never push down spring seat (14) in 9,4 mm or
more. (For port 2 and 4).
60
3. Place springs (15) into ports 1 of casing (22),

and then install pressure reducing valve assy in
it.
Place spring (16) into ports 2,4 and then install
pressure reducing valve assy in it.

NOTE: install the removed respective assy into

respective holes.
60
W2-5-10
PILOT VALVE E135B
4. Fit O-Ring (8) and seal (6) into plug (7).

Apply hydraulic oil on surface of push rod (9).

60
60
5. Insert push rod (9) in plug (7).

60
6. Fit plug (7) assy to casing (22).

60
NOTA: When the force of spring (15) is low, it stops

at the position where it is pushed in by the sliding
resistance of O-Ring (8).
When the force of spring (15) is high, attach plate (5)
and press 4 push rods by hand at the same time,
and tighten joint (4) temporarily.
Install spools (20) ande (21) straight and evenly into
the hole of casing (22).
Take care so that plugs (7) and plate (5) do not jump
out of casing (22)

60
W2-5-11
E135B PILOT VALVE
7. nstall joint (4) on casing (22) with special tool

(E) (380001055) securely.
: 22 mm
: 47.1±2.9 Nm (34.8±2.1 lbf•ft)

(
60
8. Install circular plate (3) to joint (4).
IMPORTANT: screw it in until it comes in contact

with 4 push rods (9) equally.
The exceeding of screw in may cause malfunction of
machine.

9. Screw adjusting nut (1), applying Loctite #277
to the thread of joint, until it touches circular
plate (3), and tighten it applying spanner to stop
circular plate returning.
60
: 22 mm
: 68.6±4.9 Nm (50±3.6 lbf•ft)
: 32 mm
10. Apply heat-resisting grease (G) to joint (4)

rotating section and the top of push rod (9).

60
11. Cover it with boots (2).
12. Spray rust preventives through each port and

attach plug respectively.
60
W2-5-12
PILOT VALVE E135B
PILOT VALVE (FOR TRAVEL)

CONSTRUCTION
R
R
K
R
\
\
[ [

I
G
/RFWLWH
J
7
J
O
T
7 U
X
W 7
L 7

N 7
K X
W 7
M W
X
U
T
7
/RFWLWH

]
U
Z
7 aa
60
NOTE: T=tightening torque Nm (lbf•ft)

5 Rubber boots 2 12-x Seal ø14×20×3 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 M8×28 4 14 Check valve kit (2)
6-g Set screw M5x8 4 14-q Plug M8 2
6-l Damping screw 4 14-r Ball M6, 35 2
7 Retaining plate kit (1) 15 Orifice (4)
7-h Plate 1 15-u Plug M6 4
7-i Capscrew M10×20 2 15-t Orifice M6, ø0.6 4
7-j Shaft 2 17 Shuttle valve kit (2)
7-k Set screw M4×10 2 17-w’ Shuttle valve & orifice 2
8 Flange kit 4 17-r Ball M6, 35 2
10 Control spool 4 17-z Orifice M5, ø0.8 2
11 Return spring 4 21 Plug 4
12 Damper flange kit (4) 22 Valve body 1
12-o Damper plunger ø14 4
W2-5-13
E135B PILOT VALVE
1. Boot replacement

NOTE: 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)
2) Replace both boots with a new one.
* Reassembly: K
• First fit the lower part of the rubber boot (5)
on the retaining plate (7-h) between the 2
switch plate (6)
• Then put the lower part in the external
groove of the retaining plate.
• Finish by fitting the upper part of the
rubber boot on the switch plate.
60
2. Switch plate removal

%
1) Remove:
• The pilot control unit from the machine
• Both rubber boots
2) Remove the screw (7-k) locking the axis
using a 2 mm socket wrench. (See Fig.
SM0757 A)
* Reassembly:
• Apply a droplet of Loctite #262 on the $
locking screw thread. N
• Torque: 1.2 Nm (0.89 lbf•ft) &
I
3) Fit a M3 screw on the switch plate axis (7-j)
in order to remove it (Using pliers if
necessary). (See Fig. SM0757 B)
* Reassembly:
• Position the axis so that the hole (f) is
aligned with the locking screw (7-k) as M
shown on the picture (See Fig. SM0757 C)
4) Mark out the position of the switch plate
before removing it.
5) Repeat the operation for the second switch
' (
plate. 60
6) Reassemble parts in reverse order.
W2-5-14
PILOT VALVE E135B
3. Switch plate adjustment

I
NOTE: if the switch plate (6) is replaced, it is

necessary to adjust the regulation screws (6-f).
1) Unscrew the 2 locking screws (6-g) using a

2.5 mm socket wrench
* Reassembly :
• Apply a droplet of Loctite #262 on the
locking screw thread.
• Torque: 3 Nm 2.2 (lbf•ft)
2) Set the switch plate (6) horizontally
3) Screw on simultaneously both regulation J
screws (6-g) using a flat screw driver
(5.5x150) until feeling some resistance.
NOTE: do not misadjust the two damping screws

(6-l).
60
4) Tighten the locking screws (6-g) to hold the

regulation screws (6-f) in position.
5) Repeat the operation for the second switch
plate making sure both switch plates are
parallel.
I O
4. Retaining plate removal (7-h)
1) Remove
• Both switch plates (6)
2) Unscrew simultaneously both screws (7-i)
holding the retaining plate using a 8 mm
socket wrench.
* Reassembly : 60
screw thread.
• Torque: 30 Nm (22 lbf•ft)
L
K
60
W2-5-15
E135B PILOT VALVE
3) Lift the retaining plate (7-h) to remove it.

K
* Reassembly:
• Use the retaining plate (7-h) to insert the 4
guides into the body simultaneously and
perpendicularly (22).
5) Drain the pilot control unit.
5. Damping plunger seals replacement 60
1) Remove:
• The pilot control unit from the machine.
• Both rubber boots.
• Both switch plates.
• The retaining plate.
2) Remove the wiper ring (12-y) Remove the
wiper ring (12-o).
* Reassembly:
\ R
• Replace with a new wiper ring (12-y).
$ %
60
CAUTION
Always place the damping plunger (12-o) prior to
the wiper ring (12-y), and make sure the wiper ring K
(12-y) is correctly positioned.
\
3) Remove the damping plunger (12-o).
4) Using a needle, remove the seal (12-x) [
placed inside the body (22)
* Reassembly: R
• Replace with a new seal and grease it.

60
[
$ %
60
W2-5-16
PILOT VALVE E135B
• A: Squeeze the seal (12-x) between your [ [

fingers to obtain a 8-shape.
• B, C: Insert the seal (12-x) ithin the groove
with your fingers (lip in bottom position).
• D: Push the seal (12-x) against the side
using the round head of a small socket
wrench.
$ %
IMPORTANT: during the reassembly, make sure
the seal (12-x) is correctly positionned, and pay
attention not to damage nor twist it. [
5) Repeat the operation for the other 3

assemblies.
6) Extract the damping springs (13) from the
body (22) (using flat nose pliers).
7) Inspect the damping springs (13). If defects & ' 60
are detected, replace the 4 springs.
6. Guide/plunger and regulation unit replacement.

1) Remove
• The pilot control unit from the machine.
• Both switch plates
• The retaining plate
2) Guide/plunger replacement:
• Insert the end of a thin screwdriver
between the guide and the body (22),
carefully lift the guide to remove it from the
body.
NOTE: hold the guides with the other hand during

the extraction operation to limit the effect of the
return spring.
3) Remove the guide / plunger assembly.

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.
60
W2-5-17
E135B PILOT VALVE
6) Guide/plunger and relulation unit

replacement.
• Extract the regulation units from the body
(22) (using flat nose pliers).
• Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.

7) Return spring replacement (11):
• Extract the return springs (11) from the
body (22) (using flat nose pliers).

60
• Inspect the return springs (11). If defects

are detected, replace the 4 springs.

60
7. Throttle kit replacement

1) Remove X
• Both switch plates
• The retaining plate
• The damping plungers and springs
2) Unscrew the screw (15-u) using a 3 mm
socket wrench
* Reassembly:
screw thread

• Screw on until it sets just above the body 60
(22).
W2-5-18
PILOT VALVE E135B
3) Unscrew the throttle (15-t) using a 3 mm

socket wrench.
* Reassembly:
4) Repeat the operation for the other 3
assemblies.
5) Replace with new screws (15-u) and new
throttles (15-t).
X
W
60
8. Shuttle valve kit removal (17)

1) Remove the pilot control unit from the
machine

disassembled to perform this operation.
2) Unscrew the shuttle valve (17-w) using a 4

mm socket wrench
* Reassembly:
• Thoroughly clean the body to remove any
trace of loctite.
shuttle valve thread (17-w).
60
IMPORTANT: wait for 8 hours before using the

machine to let the Loctite #242 dry completely.
Z
60
W2-5-19
E135B PILOT VALVE
3) Put the body up-side-down to remove the

shuttle valve (17-w) and the ball (17-r).
4) Unscrew the throttle (17-z) using a 2.5 mm
socket wrench.
* Reassembly:
• Hand tighten
5) Repeat the operation for the other
subassemblies.
6) Inspect the shuttle valves (17-w), balls (17-r)
and throttles (17-z).
If defects are detected, replace all the
assemblies.
60
W
Z ]
60
9. Check valve kit removal (14)

T
1) Remove the pilot control unit from the
machine

disassembled to perform this operation.
2) Unscrew the check valve plug (14-q) using

a 4 mm socket wrench.
* Reassembly:
• Drain the pilot control unit
• Torque: 5 Nm (3.7 lbf•ft) 60
3) Put the body (22) up-side-down to remove

the ball (14-r).
4) Repeat the operation for the second check
valve kit.
5) Inspect the check valve plugs (14-q), O-
rings and balls (14-r). If defects are
detected, replace all the assemblies.

T
U 60
W2-5-20
PILOT VALVE E135B
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. T
2. Reassemble the pilot unit control completely.

3. Install the pilot unit control in the machine.
4. Slightly unscrew the check valve plug (14-q)
using a 4 mm socket wrench
5. Switch on the machine.
6. Operate gently the pedal until the bubbles
disappear.
7. Tighten the check valve plug (14-q).
Torque: 5 Nm (3.7 lbf•ft)
60
8. Repeat the operation for the other check valve
plug.
W2-5-21
E135B PILOT VALVE
NOTE:
W2-5-22
SECTION 3 E135B
UNDERCARRIAGE
CONTENTS
Group 1 - Swing bearing Group 5 - Front idler

Removal and installation of swing Disassembly and assembly front idler
bearing .................................................. W3-1-1 assy....................................................... W3-5-1
Tool table ............................................... W3-1-2 Disassembly...................................... W3-5-1
Assembly .......................................... W3-5-3
Group 2 - Travel device Maintenance standard............................ W3-5-4
Removal and installation of travel Tool table ............................................... W3-5-5
device ................................................... W3-2-1
Removing ......................................... W3-2-2 Group 6 - Upper and lower roller
Installing............................................ W3-2-4
Removal and installation of upper
Disassembly and assembly of travel motor roller ...................................................... W3-6-1
unit ........................................................ W3-2-5 Removal............................................ W3-6-1
Construction of travel motor unit ....... W3-2-5 Installation......................................... W3-6-2
Exploded view of reduction unit ........ W3-2-7
Removal and installation of lower
Exploded view of hydraulic motor ..... W3-2-7 roller ...................................................... W3-6-4
Disassembling procedure ................. W3-2-11 Removal............................................ W3-6-4
Assembly .......................................... W3-2-25 Installation......................................... W3-6-5
Maintenance standard ........................... W3-2-41 Disassembly & assembly of the upper roller . W3-6-7
Sprocket............................................ W3-2-43 Disassembly ........................................ W3-6-8
Tool table ............................................... W3-2-44 Assembly ............................................ W3-6-10
Upper roller maintenance standard........ W3-6-13
Group 3 - Swivel joint
Tool table for upper roller ...................... W3-6-14
Removal and installation of swivel joint . W3-3-1
Disassembly & assembly of the
Swivel joint disassembly and assembly . W3-3-4
lower roller ............................................ W3-6-15
Version equipped with blade.................. W3-3-5 Disassembly ........................................ W3-6-16
Disassembly ..................................... W3-3-6 Assembly ............................................ W3-6-18
Assembly .......................................... W3-3-8
Lower roller maintenance standard........ W3-6-20
Maintenance standard ........................... W3-3-10
Tool table for lower roller........................ W3-6-21
Group 4 - Track adjuster
Group 7 - Tracks
Removal and installation of track adjuster
Removal and installation of tracks ......... W3-7-1
(with front idler) ..................................... W3-4-1
Removal............................................ W3-7-1
Disassembly and assembly track Installation......................................... W3-7-3
adjuster ................................................. W3-4-2
Maintenance standard............................ W3-7-5
Maintenance standard ........................... W3-4-7
Tool table ............................................... W3-4-8
SWING BEARING E135B
REMOVAL AND INSTALLATION OF SWING

BEARING
WARNING
Wear close-fitting clothing and safety equipment ap-
propriate to the job. Use tools appropriate for the job
to be performed. Always ensure that slings and
chains used for lifting are adequate to the load and
in good condition.
Before removing the swing bearing, the upperstruc-

ture must be removed first. For removal and instal-
lation of the upperstructure, refer to “Remove and
Install Main Frame” section. In this section, the pro-
cedure starts on the premise that the upperstructure
has already been removed.
Removal
$
1. Put alignment marks on (A) swing bearing (1)
and track frame (2).

60
2. Remove screws M16 (3) (Q.ty 36) and the rele-

vant washers (Q.ty 36).
: 24 mm

60
IMPORTANT: swing bearing weight:

150 kg (331 lbs).
3. Attach lifting tools (380001026), hoist swing

bearing (4) and remove it.

60
W3-1-1
E135B SWING BEARING
Installation
Clean the matching surfaces of swing bearing and
the frame.
1. Apply THREEBOND 1102 to the matching sur-
faces of swing bearing and track frame.
IMPORTANT: swing bearing weight:

150 kg (331 lbs).
60
IMPORTANT: the soft zone (S) of the inner race $

(left side of the lower frame) and the inserting hole
for steel balls of the outer race (B) (right side of the 6
lower frame) should be opposed by 180°.
2. Hoist the swing bearing.

Align the swing bearing with the alignment mark
on the track frame and install the swing bearing.
%
NOTE: apply Loctite #262 on the thread of the

screws (3) before assembling. 60
A: Front Side
B: Position of Plug
3. Install screws M16 (3) (Q.ty 36) with the

relevant washers (Q.ty 36) and tighten them to
the prescribed torque.
:24 mm
: 270 ± 27 Nm (199 ± 20 lbf•ft)
NOTE: fill in greasebath with 8 ± 0.82 kg (17.6 ± 1.8

lbs) AMBRA MG2 or IP BIMOL 481 or equivalent
grease.

60
TOOL TABLE
TOOL NO. DESCRIPTION

380001026 Lifting tools slewing ring
W3-1-2
TRAVEL DEVICE E135B
REMOVAL AND INSTALLATION OF TRAVEL DEVICE
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these
dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes. Hydraulic oil, at the end
of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior to beginning any
intervention, make sure that the oil and components are cooled-off. The hydraulic oil tank cap can be ejected,
if the pressure is not released from the tank. Press the valve located on the hydraulic oil tank to release any
residual pressure present in the tank itself. Check that the lifting devices (hooks, chains, etc.) are in perfect
conditions without any sign of excessive wear and appropriate to hold the weight of load.
Preparation
2. To drain the hydraulic pressure from the Hydraulic System, refer to procedure "Releasing the hydraulic
pressure" at page T2-1-47.
3. Cut-off the engine. Press the valve located on the hydraulic oil cap to release any residual pressure
present in the tank itself.
INSTALL ASSY YY53D00012F1

No. NAME Q'TY REMARKS
3 CAPSCREW 40 M16x45
4 TRAVEL MOTOR ASSY 2 YY53D00013F1
60
W3-2-1
E135B TRAVEL DEVICE
REMOVING
Preparation for removal
1. Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
Removing cover
2. Remove sems bolt (6) M12x25 and also re-
move covers (1).
: 19 mm 6
1
SM0616
3. Preparation of oil pan.
Removing hydraulic pipe

4. Release pressure from travel circuit, and bleed
air in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all
pipes and joint section to protect them from
entry of dust.
: 19 mm
: 27 mm
: 36 mm
SM0617
W3-2-2
TRAVEL DEVICE E135B
Removing sprocket
5. Removing (one side) capscrews (5) M16x45
(q.ty 18).
: 24 mm
NOTE: sprocket mass: 43 kg
SM2019
Loosening travel motor attaching bolts

6. Apply match marks on travel motor and crawler
frame, and remove (one side) capscrews (3)
M16x45 (q.ty 20).
: 24 mm
SM1812
Slinging travel motor assy

7. Sling travel motor with nylon sling applied on
the side close to sprocket installing section and
remove the motor.
NOTE: motor mass: about 144 kg (317.5 lbs)
60
W3-2-3
E135B TRAVEL DEVICE
INSTALLING
Installing of the travel motor piping is performed in
the reverse order of removal.
1. Cleaning
Check that contact surface of travel motor and
crawler frame is free from burr and stain.
2. Tightening torque
Tighten capscrew and hydraulic pipes to the
torque specified in "Tightening Torque").
3. Fill inside from motor drain port to casing with
hydraulic oil before piping for drain. When
starting operation, operate motor in low idling
and at low speed for several minutes, and
check it for possible oil leakage and noise.
NAME SIZE TOOLS No. TIGHTENING TORQUE Nm (lbf•ft) REMARKS

M12 19 6 110 ± 11 Nm (81.1 ± 8.1 lbf•ft)
Bolts M16 24 3 270 ± 27 Nm (199 ± 20 lbf•ft) Apply Loctite #262
M16 24 5 279 ± 28 Nm (206 ± 20 lbf•ft)
Flareless nut for PF1/4 17 - 29.4 ± 5 Nm (21.7 ± 3.7 lbf•ft)
pipes, sleeve PF1/2 22; 27 - 78.5 ± 5 Nm (57.9 ± 3.7 lbf•ft)
PF1/4 19 - 36.3 ± 2 Nm (26.7 ± 1.5 lbf•ft)
Connector PF1/2 27 - 108 ± 10 Nm (79.7 ± 7.3 lbf•ft)
PF3/4 36 - 162 Nm (119 lbf•ft)
W3-2-4
TRAVEL DEVICE E135B
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR UNIT
CONSTRUCTION OF TRAVEL MOTOR UNIT

Cross-sectional view of travel motor unit assembly (1/2)
324 328 336 326 325 331 330 327 323 301 396 343 34
208 207 209 210 212 205 213 211 203 206 204 202 201
SECTION A-A
354 352 358 353 381 384 383 380 358 352 380 383 381 378 379 396 398 343
SECTION D-D SECTION E-E

SM2644
W3-2-5
E135B TRAVEL DEVICE
Cross-sectional view of travel motor unit assembly (2/2)
377 104 115 116 108 103 167 171 17 12 9 28 10 16 5 35

110 27
11
113
341 6
114 15
145 36
102 8
301 14
150 4
109 13
399 132
357 149
359 3
366 7
363 30
112 31
185
354
161
32 376 33 139 135 2 29 1 23 24 105 151 107 22 106 162
384 329
398 398
354
SECTION F-F SECTION G-G
SM2645
W3-2-6
TRAVEL DEVICE E135B
EXPLODED VIEW OF REDUCTION UNIT
24
22
29
24
29
23
33
32
34 35
14
13
4
36
15
6
16
3
8
10
17
7
30
31
11
27
5
11
12
28
9
12
SM2646
W3-2-7
E135B TRAVEL DEVICE
EXPLODED VIEW OF HYDRAULIC MOTOR
116
115
135
324 112
336 139
328 109
325
326 341
331 377
354
327 301
330
380 383358
352 113
353 150
329
398 376
396 358 352 343 323

327
353
358 352
381 383
380 379
366 330
398 378 331
363 399 398 326
359 208 201
384 210 325
357 208 207 328
210
209 336
324
212
203
103
204 202 106
105
213 206
211 107
205
108
151
104
110
114
110
145 132
149
102
171
167
185
161
162
SM2647
W3-2-8
TRAVEL DEVICE E135B
TRAVEL MOTOR UNIT READING KEY
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty

1 HUB 1 105 •••CYLINDER BLOCK 1 213 •SHIM 1
2 SPINDLE 1 106 •••PISTON 1
CARRIER 1 ASSY 1 104 •SHOE 1 1 REAR FLANGE ASSY 1
3 •CARRIER 1 1 107 RETAINER PLATE 1 •REAR FLANGE KIT 1
5 •PLANETARY GEAR 1 3 108 THRUST BALL 1 •••SPOOL ASSY 1
6 •CARRIER PIN 1 3 109 TIMING PLATE 1 323 •••SPOOL 1
11 •THRUST WASHER 1 6 110 WASHER 2 326 •••PLUG 2
16 •PARALLEL PIN 1 3 112 PISTON 1 327 •••VALVE 2
27 •NEEDLE
BEARING
ROLLE 3 113 SPRING 10 330 •••SPRING 2
CARRIER 2 ASSY 1 114 SPRING 1 331 •••O-RING 2

7 •CARRIER 2 1 115 FRICTION PLATE 3 301 ••REAR FLANGE 1
9 •PLANETARY GEAR 2 3 116 MAITING PLATE 4 324 •PLUG 2
10 •CARRIER PIN 2 3 132 OIL SEAL 1 325 •WASHER 2
12 •THRUST WASHER 2 6 135 O-RING 1 328 •SPRING 2
17 •PARALLEL PIN2 3 139 O-RING 1 329 •ORIFICE 2
28 •NEEDLE
ING
ROLLE BEAR- 3 145 SNAP RING 1 336 •O-RING 2
4 SUN GEAR 1 1 149 BALL BEARING 1 352 •PLUG 3

8 SUN GEAR 2 1 150 BALL BEARING 1 353 •BALL 2
13 THRUST PLATE 1 151 NEEDLE ROLLER 3 354 •HEXAGON

PLUG
SOCKET 5
14 COVER 1 PISTON ASSY 1 357 •PLUG 1 1

15 COUPLING 1 161 •PISTON 1 358 •O-RING 3
22 LOCK WASHER 2 162 •SHOE 1 359 •O-RING 1
23 SHIM 1 167 PIVOT 2 363 •SPOOL 1
24 ANGULAR
BEARING
BALL 2 171 PARALLEL PIN 2 366 •SPRING 1
FLOATING SEAL KIT 1 185 SPRING 1 376 •ORIFICE 1
W3-2-9
E135B TRAVEL DEVICE
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty

29 •FLOATING SEAL 2 377 •FILTER 1
30 PLUG 3 RELIEF ASSY 2 378 •BALL 1
31 O-RING 3 201 •VALVE SEAT 1 379 •PLUG 1
32 O-RING 1 202 •VALVE 1 380 •PLUG 2
33 O-RING 2 203 •SLEEVE 1 381 •PISTON 1
34 PARALLEL PIN 2 204 •COLLAR 1 383 •O-RING 2
35 HEXAGON SOCKET BOLT 12 205 •PLUG 1 384 •ORIFICE 2
36 SNAP RING FOR HOLE 1 206 •SPRING 1 396 •HEXAGON

PLUG
SOCKET 2
207 •O-RING 1 398 •HEXAGON

PLUG
SOCKET 8
102 SHAFT 1 208 •BACK-UP RING 2 399 •NAME PLATE 1

103 SWASH PLATE 1 209 •O-RING 1 341 PARALLEL PIN 1
CYLINDER & PISTON KIT 1 210 •BACK-UP RING 2 343 HEXAGON

BOLT
SOCKET 10
•PISTON KIT 1 211 •O-RING 1

••PISTON ASSY 9 212 •O-RING 1
W3-2-10
TRAVEL DEVICE E135B
DISASSEMBLING PROCEDURE
1. Cleaning travel motor.

A
1) Tighten the eye bolts (A) into the tapped
holes of the spindle (2).
Eye bolt: M16 2
NOTE: fasten two eye bolts into the tapped holes for
the spindle so they are located diagonally opposite
to one another.
2) Place a wire sling in the eye bolts, lift the SM2198
travel motor by hoist, and carry in to the

cleaning bath.
NOTE: travel motor assy mass: Approx. 144kg (320

lbs)
2
3) Clean the travel motor with a car brush.
1
NOTE: since soil and sand are entered in the
clearance (where the floating seal is fixed) between
hub (1) and spindle (2), clean it with particular care. SM2199
2. Installing travel motor.

1) Placing travel motor on working bench.
NOTE: align threaded holes of hub (1) and working

bench, and place travel motor in fixing hole of
working bench slowly.
1
2) Fix travel motor with two socket bolts (B) on

working bench.
SM2200
: 14 mm
CAUTION
Tighten 2 socket bolts (B) securely. If not tightened
securely, when the travel motor is reversed, it falls
and causes injury.
SM2501
W3-2-11
E135B TRAVEL DEVICE
3. Draining lubricating oil.
NOTE: if you want to disassemble only the rear

flange, go to 6. 1).
35, 31
1) Turn over the travel motor.
30
CAUTION
Loosen plug (30) slowly to avoid spurt of lubricating
oil.
SM2502
2) Loosen and remove two socket plugs (30) to

release inner pressure.
: 10 mm
NOTE: when draining out the lubricating oil, place

container under the work bench.
3) Draw out the lube oil by reversely turning the

travel motor slowly.
4) Remove O-rings (31) from removed plugs.
NOTE: do not reuse removed O-ring (31).
4. Removing cover.
1) Turn over the travel motor.
2) Remove ten socket bolts (35). A
: 10 mm 14
3) Because sealant is applied between cover

(14) and hub (1), hit upward the corner of
cover with a hammer using soft metal to
protect the cover.
CAUTION SM2503
The cover (14) may jump and remove suddenly by

hitting. Be careful not to drop the cover to avoid
injury.
4) Place a hook and a wire sling to eye bolts

(A), lift it up and remove cover (14).
13
5. Removing thrust plate.
1) Removing thrust plate (1)
SM2504
W3-2-12
TRAVEL DEVICE E135B
6. Removing 1st stage reduction gear.

1) Remove sun gear 1 (4) by hand. 4
IMPORTANT: be careful not to drop sun gear 1 (4)

it could be slippery by lubricant.
2) Fasten 3 eyebolts to the tapped holes of

carrier 1 (3). And attach wire slings and hook
in the eye bolts. Lift the carrier (3) assembly
with hoist.
SM2505
NOTE: when carrier assembly (3) is lifted with hoist,

the edge of planetary gear 1 (5) may damage the
internal teeth of hub (1). Align center line of hub (1)
with that of carrier 1 assembly, lift carrier 1 slowly
and straightly. 3
7. Removing coupling. 1
1) Remove coupling (15) from shaft (102).
SM2506
8. 2nd stage reduction gear removal.

15
1) Fasten three eyebolts to the tapped holes of
carrier 2 (7).
Place a wire sling and hook in the eyebolts,
lift carrier 2 assembly by crane.
NOTE: when carrier 2 assy is lifted by crane, the

edge of planetary gear 2 (9) could damage the
internal teeth of hub (1). Lift up it slowly, and
carefully.
SM2507
2) Remove sun gear 2 (8) by hand.
NOTE: be careful not to drop sun gear 2 (8). If could

be slippery by lubricant. 8
7
SM2508
W3-2-13
E135B TRAVEL DEVICE
9. Removing lock washer.

1
1) Fix hub (1) and workbench with using three
holes (ø14) of hub (1).
SM2509
2) Put a flathead screwdriver into the

clearance between two lock washers (22),
and widen the clearance. Place the tip of the
screwdriver to the one end of the lock
washers (22), tap it by hammer, and remove
two lock washers (22).
22
SM2510
10. Removing hub.

1
1) Remove the hexagon socket bolts, which
fixed hub (1) and workbench.
2) Fasten two eyebolts on the tapped holes of
spindle (101). Place a wire sling and hook in
the eyebolts. Lift hub (1) by crane.
WARNING
Lift up hub (1) slowly and carefully. If hub (1) is
inclined against spindle (2), for the interference,
wire sling or eyebolts could be destroyed and hit SM2511
the worker. If hub (1) does not come out

smoothly, do not pull forcefully. Instead, use
other tools such as press machine.
11. Removing floating seal.

1) Grasp inner side of floating seal (29) and lift
it up by hand.
CAUTION
Use work gloves to prevent from cutting hands at
the edge of floating seal (29). If lifting up by hand is
difficult by mudpack or such reason, use flat head 29
screwdriver as a lever. SM2512
W3-2-14
TRAVEL DEVICE E135B
12. Removing angular ball bearing.

1) Put a steel rod on the inner race of angular
bearing (24), tap 3 or 4 points evenly. Take
24
care not to damage the bearing.
NOTE:
- do not remove the angular ball bearing (24),
except for replacing the bearing. When the
outer race of angular ball bearing (24)
separates from fitness hub (1), angular ball
bearing (24) falls from hub (1 ).
- Please place a container under the workbench
SM2513
and cover with the rubber mat on it so that
angular ball bearing (24) does not get damage.
13. Removing rear flange.

324
1) Turn over travel motor. (Rear flange (301) is
on top.)
NOTE: this work is carrying out to remove easily the

plugs (324) at the following work. Do not loosen the
plugs (324) if the inside of rear flange assembly is
not disassembled.
2) Temporarily loosen plugs (324) (2 plugs).

SM2514

not disassembled. 380

352 357
not disassembled.
5) Temporarily loosen plugs (357).

SM2515
plug (357) at the following work. Do not loosen the
plug (357) if the inside of rear flange assembly is not
disassembled.
W3-2-15
E135B TRAVEL DEVICE
6) Temporarily loosen relief valve assy (203

others) (2pcs).
7) Loosen the relief valve assemblies (203
others) (2 pcs).
203
SM2516
8) Remove the relief valve assemblies (203

others) (2 pcs).
NOTE: do not reuse O-ring (207), (209), (212) and

backup ring (208), (210) which have been removed.
203
SM2517
9) Loosen and remove hexagon socket bolts

(343) (10 pcs) from rear flange (301).
: 8 mm
10) Remove rear flange (301) from spindle (2). 343

SM2518
NOTE: hold rear flange (301) with both hands, hold

up rightly and gently, and remove it. Timing plate
(109) could fall off and get damaged during this
operation. 301
11) Removing ten springs (113).

12) Removing parallel pins (341) from spindle
(2).
109(341)
13) Removing O-ring (27), (30) from spindle 113
(2).
2
NOTE: do not reuse O-ring (27), (30) which have
been removed.
SM2519
W3-2-16
TRAVEL DEVICE E135B
14) Pull out parallel pins (34) (2 pcs) from

spindle (2).
34
SM2520
15) Remove O-ring (32), (33) (2 pcs) from

spindle (2).
NOTE: do not reuse O-ring (32), (33) which have 32 33

been removed.
SM2521
14. Removing the rear flange fittings.

1) Place rear flange (301) on a work bench,
with the mating surface for spindle (2) facing
up.
2) Remove timing plate (109) from rear flange
(301).
NOTE: if it is hard to remove the rear flange in some 301(341)

cases as its mating surface is stuck with oil, insert a
spatula into the draft groove of the mating surface
on the rear flange side and hold the timing plate up.
Then the rear flange comes off. If a sharp tool like a
150 SM2522
screwdriver is put into the mating surface, the
mating surface is scored, causing oil leakage ; do
not use sharp tools.
3) Remove parallel pins (341) from rear flange

(301).
4) Remove ball bearing (150) from rear flange
(301).
W3-2-17
E135B TRAVEL DEVICE
15. Removing the brake valve from the rear flange.

1) Remove two plugs (324) from rear flange
(301).
: 36 mm
301
2) Remove O-ring (336) from plug (324).
324(336)
SM2523
3) Remove two spring retainer (325) and two

springs (328) from rear flange (301).
4) Remove spool (323) from rear flange (301).
301
NOTE: to remove spool (323), place your hand on
one part of the plug port of rear flange (301) and tilt
it down. Then spool (323) falls down. Hold the tip
and remove it. 328
323 328 325

SM2524
16. Disassemble the 2-speed selector valve.

1) Remove plug (357) from rear flange (301).
: 10 mm
357(359)
301
SM2525
2) Remove spool (363) and spring (366) from

rear flange (301).
W3-2-18
TRAVEL DEVICE E135B
17. Removing piston.

1) Remove plugs (380) (2 pcs) from rear flange 380(383)
(301).
NOTE: do not reuse removed O-ring (383)
301
SM2527
3) Remove piston (381) from rear flange (301).
381
SM2528
18. Disassembling ball check part.

1) Remove plugs (352) (2 pcs) from rear flange
(301).
NOTE: do not reuse O-ring (358) which have been

removed.
352
SM2529
3) Remove steel balls (353) from rear flange

(301).
NOTE: when it is hard to remove steel balls (353),

remove them using the magnet etc.
353
SM2530
W3-2-19
E135B TRAVEL DEVICE
19. Disassembling parking brake.
CAUTION
C
The sudden blowing of compressed air may cause
parts to fly out incurring the danger of injury. Cover
piston (112) for protection with a rag (C).
1) Blow jet air into the passage hole for the

parking brake of the spindle (2) and remove
the piston (112) from the spindle (2).
2) Remove O-ring (135), (139) from piston 2 112 SM2531
(112).
NOTE: do not reuse removed O-ring (135), (139). 112

(135,139)
20. Disassembling the hydraulic motor section.
NOTE: when placing the travel motor on its side, oil

spills ; place a container under the travel motor.
1) Lay down the travel motor through 90

degrees.
2) Drain out the oil of the travel motor.
3) Hold cylinder block (104) by hand, turn it SM2532
both ways a few times alternately and
separate shoe (106) from swash plate (103).
104(103,106,115,116)
NOTE: if cylinder block (104) is drawn out in that
condition, shoe (106) stays with swash plate (103).
Then parts (pistons, shoes, etc.) attached to
cylinder block (104) come off from cylinder block
(104) and fall into spindle (2). Care should be used
about it.
4) Hold the cylinder block (104) and remove

the shaft (102).
SM2533
NOTE: also, friction plate (115) and separator plate
(116) are also removed with cylinder block (104).
W3-2-20
TRAVEL DEVICE E135B
5) Remove friction plate (115) and separator

plate (116), attached on the removed
cylinder block (104).
106
6) Remove piston assy [piston (105) and shoe 105
(106)] and retainer plate (107) from cylinder 107
block (104). 110
104
NOTE:
- when removing the cylinder block, hold the
retainer plate (107) by both hands and remove
it with the piston assy.
- Cylinder block (104) and piston assy [piston 108
(105) and shoe (106)] are the minimum parts
unit as cylinder & piston kits. When they have to
be replaced, replace the cylinder & piston kit as
a set. (Refer to the parts manual.)
7) Remove the piston assy (105),(106) from

retainer plate (107). [Nine pistons]
116 115
8) Remove thrust ball (108) from cylinder block
SM2534
(104).
9) Draw out washer (111) from cylinder block
(104).
10) Remove three needle rollers (151) from

151
104
SM2535
W3-2-21
E135B TRAVEL DEVICE
21. Remove spring from inside of cylinder block.

1) Place cylinder block (104) on the press
104
bench.
NOTE:
- do not remove the spring except when spring is 145(110)
replaced.
- When removing the spring, align the jig (M) with
the washer in order to prevent the cylinder
block from being damaged by contact.
- Put a plastic sheet over the sliding surface of
the cylinder block so as not to damage it.
SM2536
2) Place the retainer metal jig (M) on washer

(110) and remove snap ring (145) from the
snap ring groove of cylinder block (104) by
means of snap ring pliers, while holding
down the jig (M).
114(110)
CAUTION 104
If the press is loosened too suddenly, the spring
jumps out and causes injuries. Always loosen the
press slowly.
3) Loosen the press slowly till the spring action

is released. SM2537
4) Remove the snap ring (145), washer (110),

spring (114), and washer (110) from inside
the cylinder block (104).
22. Removing out shaft (102).

1) Removing swash plate (103) from spindle
(2).
2(103,167)
NOTE: when removing it, check that pivot (167)
149
does not adhere to swash plate.
2) Draw out shaft (102) from spindle (2). On 102

that occasion, the inner race of ball bearing SM2538
(149) comes off with the shaft.

3) Draw out two pivots (167), two parallel pins
(171) and the outer race of ball bearing
(149) from spindle (2). 162
4) Draw out the 2-speed switch piston assy
[piston 162 (161) and shoe (162)] and spring 161
(185) from spindle (2).
185
SM2539
W3-2-22
TRAVEL DEVICE E135B
23. Removing ball bearing (149).
NOTE: ball bearing (149) is removed only when

replacing. E
1) Place holder (D) on the press bench and put D

shaft (102) into the holder (D).
2) Remove ball bearing (149) from shaft (102)
by pressing on the shaft end with press (E).
NOTE: do not reuse the removed ball bearing (149).
SM2540
24. Removing spindle fittings.

1) Remove shim (23) from spindle (2).
23
SM2541
2) Remove floating seal (29) from spindle (2).
NOTE: do not reuse floating seal (29) which have

been removed.
29
SM2542
3) Remove oil seal (132) from spindle (2).
NOTE: do not reuse oil seal (132) which have been

removed.
132
SM2543
W3-2-23
E135B TRAVEL DEVICE
25. Rough washing of parts.

2
1) Distinguish the four parts; hub (1), spindle 3,7
(2), cover (14), and rear flange (301) from
other parts (hereafter called built-in parts). 301
2) Put the hub, spindle, cover and rear flange
in a cleaning bath and clean them.
NOTE:
- soil and sand adhere to the outer surface of
parts in some cases; clean them and remove
soil and sand from the parts.
- Wash oil is combustible. Be careful not to cause 1(14)
SM2544
fire and get burns.
- Before cleaning stained parts, immerse them in
wash oil until dust and stain become soft and
are floated to protect them from damaging
when cleaning.
3) Put the built-in parts in a rough cleaning

container containing wash oil and clean the
parts.
26. Finish cleaning.

1) Put parts in a finish cleaning container
containing wash oil and clean them well, 3,7
turning them slowly.
2) Blow parts with dry air to remove cleaning
oil.
NOTE:
- blow compressed air in the inner surface of hub
(1), spindle (2) and rear flange (301) to dry in
the dust free and dry conditions. After drying,
apply hydraulic oil to every part.
SM2545
- Inner surface of rear flange (301), hydraulic
motor components, and RV gear assy are to be
dried naturally in the dust free and dry
conditions. After drying every part, apply
hydraulic oil to every part.
- Use care not to damage the surface of twenty
four pins (17) nor to lose them while handling.
SM2546
W3-2-24
TRAVEL DEVICE E135B
ASSEMBLY
General precaution for assembly

1. Assembly it by reversing the procedure of disassembly.
2. Assemble it in clean air condition.
3. Do not use cloth gloves during assembly.
4. Replace or repair the damaged parts during disassembly according to the instructions in the "Maintenance
standard". Replace O-ring, oil seal, etc. with new one.
5. Clean every part sufficiently, and blow them with compressed air do not use waste cloth.
6. Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor valve.
7. Tighten bolt and plug to the specified torque using torque wrench.
8. Replace reamer bolt with new ones. If it is unavoidably reused, remove completely the adhesive agent on
reamer bolt, repair flaws on bolt seat surface with oilstone, and degrease it.
9. Prior to assembling, apply grease to lip portions of O-ring, oil seal, and floating seal to protect it from being
damaged, and to moving section and sliding section.
10. After assembly, plug every port to protect the entry of dust, etc.
Preparatory arrangement for assembly
1. After replacing parts with new ones, adjust the pre-load of bearing and thickness of snap ring without fail.
1) When the following parts are replaced, the pre-load adjustment of bearing is required.
Hub (1)
Spindle (2)
Bearing (24)
NOTE: where replacing the above parts, the previously adjusted parts should be used. If unadjusted parts are
used, the travel motor moves abnormally, causing early breakage.
W3-2-25
E135B TRAVEL DEVICE
ASSEMBLING PROCEDURE
E
1. Assembling hub.
1) Place hub (1) on the press bench (F). 1
2) Place angular ball bearing (24) on hub (1),
and press in by using the main plate and a G
press machine (E) using tool (G) and a fitting
press stand (H).
3) Turn over hub (1).
4) Insert angular ball bearing (24) into hub (1) 24
in the same way 2). H
F
NOTE: make sure that the installing direction of SM2547
angular ball bearing (24) is correct.
5) Apply grease on the O-ring of floating seal

(29), and fit the O-ring into the floating seal
groove on hub (1).
NOTE: J
- when applying grease to the O-ring, remove the
O-ring from floating seal (29), and then, apply
grease thinly to entire surface.
- Use floating seal installation tool (I) and (J). I
Make sure to keep the parallel tolerance 1mm
(0.039") to end surface of the groove. If not, it
could cause seizure on floating seals (29) or oil
29
leak.
1
2. Assembling spindle.
1) Apply grease on the O-ring of floating seal
(29), and fit the O-ring into the floating seal
groove on spindle (2)
SM2548
NOTE: when applying grease to the O-ring, remove

the O-ring from floating seal (29), and then, apply
grease thinly to entire surface. Use floating seal
installation tool (J) and (K).Make sure to keep the J
parallel tolerance 1mm (0.039") to end surface of
the groove. If not, it could cause seizure on floating
seals (29) or oil leak.
2) Install eyebolts to spindle (2) so they are T

symmetrically positioned. K
29
2
SM2549
W3-2-26
TRAVEL DEVICE E135B
3) Fix spindle (2) on workbench with two

hexagon socket bolts, which should locate
symmetrically.
CAUTION
Tighten the hexagon bolts securely. Failure to do so
could result in injury if GM motor is inverted and
falls. 2
3. Clearance adjustment procedure for angular

ball bearing.
SM2550
NOTE: if any of hub (1), angular ball bearing (24) or

spindle (2) is replaced, clearance adjustment should
be conducted. If not, angular ball bearings (24)
c
could break in short period.
1) Insert lock washers (22) for measuring the

dimensions, and measure the distance (c).
2) Measure the distance (d).
NOTE: rotate hub assembly for stabilizing the

distance (d).
3) Select one of the classified shim (23) which

makes the distance "(c) -(d)" from -0.17 to - SM2551
0.13mm (-0.0051"~0.0067").
Shim (23) thickness shall be refer to the
following table.
ITEM T : mm (in) ITEM T : mm (in)

d
A 0.9 (0.035") G 1.5 (0.059")

B 1.0 (0.040") H 1.6 (0.063")
C 1.1 (0.043") I 1.7 (0.067")
D 1.2 (0.047") J 1.8 (0.071")
E 1.3 (0.051") K 1.9 (0.075")
F 1.4 (0.055") L 2.0 (0.079")
4) Attach shim (23) to spindle (2). SM2552
23
SM2553
W3-2-27
E135B TRAVEL DEVICE
4. Assembling hub.
1) Insert hub (1) into angular ball bearing (24)
assembled in spindle (2) with keeping both
1
center axes parallel.
SM2554
2) Fix hub (1) to the workbench with three long

hexagon socket bolts.
3) Put steel rod on the inner race of angular
ball bearing (24) located on reduction gear, 1
and tap softly by hammer to stabilize
angular ball bearing (24).
SM2555
4) Place lock washers (22) to the groove of

spindle (2).
5) Fit lock washers (22) into the groove of

spindle (2) by using installation tool (N). 22
SM2556
NOTE: insert lock washers (22) fully into the groove
so as not to interfere with carrier 2 (7).
6) Remove the long hexagon socket bolts,

which fix hub (1) and the workbench.
7) Rotate hub (1) two or three times.
N
NOTE: contacting state between both sliding
surface of floating seal (29) will be improved by
rotating spindle (2), and prevent initial oil leak.
8) Turn over spindle (2).
22
SM2557
W3-2-28
TRAVEL DEVICE E135B
5. Assembling spindle fittings.

1) Drive oil seal (132) into spindle (2) by using
the tool (L) to prevent it from being inclined.
L
NOTE: apply lithium grease around the lip portion of
oil seal (132) when mounting. Be careful in the 132
inclusion direction of oil seal (132).
2
2) Install two parallel pins (171) into the pin
holes of spindle (2).
3) Apply lithium grease to hemispherical
surface of two pivots (167), and fit it into
parallel pins (171) of spindle (2). SM2558
4) Apply lithium grease to spring (185), and

install spring (185) into the piston kit [piston
(161) and shoe (162)].
5) Apply hydraulic fluid to the sliding surface of
the piston kit, install it into the piston hole of
spindle (2).
6) Install two parallel pins (34) into the pin
holes of spindle (2).
162
161
SM2559
6. Assembling shaft. E
CAUTION 102
149
CAUTION: Wear thick leather gloves in handling the
heated ball bearing (149). D
1) Put ball bearing (149) in a heating tank to

heat it at 90 to 110°C [194 to 230°F] for ten
minutes and then insert it onto shaft (102), SM2560
using holder (D) and a press (E).
2) Turn the workbench by 90 degrees.
3) Insert shaft (102) to spindle (2).
IMPORTANT: take care not to scratch or cut the lip

portion of oil seal (132) in place with the splined
foremost end of shaft (102).
102
SM2561
W3-2-29
E135B TRAVEL DEVICE
7. Install oil seal (132).

1) Turn over travel motor.
2) Coat the lip of the oil seal with lithium grease
and fix oil seal (132) into the oil seal hole in
132
spindle (2), using retainer metal and a
149
hammer.
3) Assemble the outer race (with roller) of
bearing (149) into spindle (2). 2
SM2562
4) Insert swash plate (103) into spindle (2).
NOTE: apply lithium grease on swash plate (103)

where mating surface of spindle (2).Make sure that
the locating pivots (167) of spindle (2) enter pivots'
holes of swash plate (103). 103
8. Assembling cylinder block interior
NOTE:
- the sharp edge of snap ring (145) is turned and
put into the entrance side of cylinder block
(104). SM2563
- Washer (110) which touches snap ring (145)

turns and puts its sharp edge side into snap ring
side.
110
1) Insert washer (110), spring (114), washer
(110) and snap ring (145) in that order into
114
2) Place cylinder block (104) on the press
bench.
104
WARNING
When mounting snap ring (145), if the tip of the
SM2564
pliers slips out of the hole of snap ring (145), snap
ring (145) could jump out.
NOTE: press force of spring (114) is 1128N (254

lbs) or more. Protect by covering cylinder block
(104) with a vinyl sheet so the contact surface with
timing plate (109) of cylinder block (104) does not
get damaged. 109
3) Place holder (M) on washer (110), and while

clamping with the press, fit snap ring (145) in
the snap ring groove of cylinder block (104)
with the snap ring pliers. 145
104
SM2565
W3-2-30
TRAVEL DEVICE E135B
9. Assembling hydraulic motor

1) Put three rollers (151) into the holes of
cylinder block (104) and place washers
(111) and thrust balls (108) on them.
2) Fit nine piston assy to retainer plate (107).
3) Fit retainer plate (107) and 9 piston assy to
NOTE: match retainer plate (107) with the spherical

part of thrust ball (108) and install them.
151
4) Assemble cylinder block (104) fitted with 104
swash plate (103), thrust ball (108), washer SM2566
(111),retainer plate (107), piston assy (105),

(106) and roller (151), to shaft (102) that is
placed level. (to make a hydraulic motor
assy).
105,106 107
108
111
104(151)
SM2567
5) Installing cylinder block (104) into shaft

(102).
NOTE: install cylinder bock (104) into the spline of

shaft (102) by aligning the spine hole with the spline
of shaft (102).
104
SM2568
6) After installing cylinder block (104), turn it by

hand and make sure that it fits properly. If
not, inspect it.
NOTE: cylinder block (104) is not flattered after

installing it. If cylinder block (104) is flattered, thrust
ball (108) is separated and GM motor does not
rotate normally.
104 102
SM2569
W3-2-31
E135B TRAVEL DEVICE
10. Installing parking brake.

115
NOTE: immerse friction plate (115) in hydraulic oil
104
before fitting it.
1) Assemble separator plate (116) into the

inner groove of spindle (2) that houses
2) Assemble three friction plates (115) and
separator plates (116), by turns, into the
outer groove of cylinder block (104) and into
the inner groove of spindle (2). On that
occasion, fix the friction plates first and then SM2570
the separator plates.
3) Fit O-rings (135), (139) to the O-ring
grooves of piston (112). In that case, coat O-
rings (135), (139) with a thin film of grease.
4) Fitting piston (112) into spindle (2).
NOTE:
- if it is hard to fit the piston (112) into the spindle
(2) due to the resistance of O-rings (135),(139),
lightly tap the end face of the piston (112), using
a plastic mallet. 112
(135,139)
- Take care so as not to score the O-rings when
installing the piston (112). 2
SM2571
11. Attaching two-speed spool.

1) Insert spring (366) and spool (363) into rear
flange (301).
2) Fit O-ring (359) to plug (357).
NOTE: apply grease to O-ring (359).
3) Attach plug (357) to rear flange (301).

4) Temporarily tighten plug (357) into rear 366
flange (301) by hexagon wrench. (363)
SM2572
357
301
SM2573
W3-2-32
TRAVEL DEVICE E135B
12. Attaching ball check part.
1) Fit two O-rings (358) to two plugs (352).
2) Insert steel ball (353) into rear flange (301).
353
SM2574
3) Temporarily tighten plugs (352) into rear

flange (301) by hexagon wrench. 352
301
SM2575
13. Attaching piston.

2) Insert piston (381) into rear flange (301).
381
SM2528
3) Temporarily tighten plugs (380) into rear

flange (301) by hexagon wrench. 301
380
SM2576
W3-2-33
E135B TRAVEL DEVICE
14. Assembling brake valve parts in rear flange.

1) Insert spool (323) into rear flange (301).
NOTE: apply hydraulic fluid to spool (323) and insert 301

it into rear flange (301).
To insert spool (323), align the hole of rear flange
(301) with spool shaft center so as to prevent the
inner surface of rear flange (301) and the outer
surface of spool (323) from being damaged due to
interference.
Otherwise internal leaks will occur after reassembly,
resulting in performance deterioration of GM motor. 323
SM2577
3) Attach washer (325) (2 pcs) and spring

(328) (2 pcs) to plug (324) (2 pcs).
336 324
SM2578
4) Attach plug (324) (2 pcs) to rear flange

(301).
NOTE: when attach plug (324) to rear flange (301),

insert carefully so as not to deform spring (328).
5) Temporarily tighten plug (324) (2 pcs) into

rear flange (301).
SM2579
15. Assembling rear flange mounted parts.

1) Apply hydraulic fluid to ball bearing (150),
and fit it into rear flange (301).
2) Insert two parallel pins (341) into the pin
holes of rear flange (301).
3) Apply grease to the mating face of timing
plate (109) in contact with rear flange (301)
of timing plate (109).
150
SM2580
W3-2-34
TRAVEL DEVICE E135B
4) Fit timing plate (109) on rear flange (301)

using parallel pins (341) as the guide.
NOTE: fitting of timing plate (109) is carried out until

timing plate (109) adheres to rear flange (301).
Adhesion prevents from dropping timing plate (109)
from rear flange (301) when mounting rear flange
(301) on spindle (2).
109
SM2581
5) Mount ten springs (113) on the hole of rear

flange (301). 113
NOTE: apply grease to springs (113) in order to

prevent from dropping springs (113) from rear
flange (301).
SM2582
16. Assembling rear flange.

1) Fit O-rings (32), (33) (2pcs) in the O-ring
grooves of spindle (2).
32 33
NOTE: fit O-ring (32) without applying grease. If
reassembled with grease applied, the grease may
bleed from mating face of rear flange (301) and
spindle (2) when GM motor is running.
2) Put 1.0 liters of hydraulic fluid in spindle (2).

3) Install rear flange (301) on spindle (2) so
that two parallel pins (34) on spindle (2)
SM2521
enter the pin holes in rear flange (301).
4) Temporarily tighten hexagon socket bolts
(343) (10 pcs) into spindle (2) by hexagon
wrench. 301
SM2583
W3-2-35
E135B TRAVEL DEVICE
17. Tightening bolts.

1) Tighten hexagon socket bolt (343) (10 pcs)
with the specified torque.
: 102±15.7 Nm (75±11 lbf ft)
343
SM2584
2) Tighten plugs (324) with the specified

torque.
: 441±39.2 Nm (325±29 lbf ft)
SM2585

torque.
: 58.8±9.8 Nm (43±7 lbf ft)
SM2586

torque. 352
: 12.3±2.4 Nm (9±2 lbf ft)
SM2587
W3-2-36
TRAVEL DEVICE E135B

torque.
: 98.1±19.6 Nm (72±14 lbf ft)
357
SM2588
18. Attaching relief valve assembly.

1) Attach relief valve assembly (203 others) (2
pcs) to rear flange (301).
203
SM2589
2) Tighten relief valve assembly (203 others)

(2pcs) with the specified torque.
: 98.1±19.6 Nm (72±14 lbf ft)
SM2590
19. Assembling 2nd stage planetary gears.

1) The workbench is rotated and the reduction 8
gears side is turned upward.
2) Attach sun gear 2 (8) to carrier 2 (7). 7
3) Fasten three eyebolts to the tapped holes of 9
carrier 2 (7). Place a wire sling and hook in
the eyebolts, place carrier 2 assembly 1
slowly in hub (1).
NOTE: when inserting carrier assembly 2, take care

so as not to damage internal teeth of hub (1) by the
edge of planetary gears 2 (9).
SM2508
W3-2-37
E135B TRAVEL DEVICE
NOTE: place carrier 2 (7) so that planetary gears 2

(9) should be located as the illustration on the left. *
* Piping port
** Hole of 1st-2nd speed piston
** SM2591
20. Attaching coupling.

1) Attach coupling (15) to shaft (102).
15
SM2507
21. Assembling 1st stage planetary gears.

1) Place carrier assembly 1, slowly in hub (1).
5
NOTE: when inserting carrier assembly 1, take care
so as not to damage internal teeth of hub (1) by the 1
edge of planetary gears 1 (5).
SM2592
2) Insert sun gear 1 (4) with aligning spline

portion to coupling (15) first, then gear
portion second. 4
NOTE: if the gear portion of sun gear 1 (4) does not

engage with planetary gears 1 (5), lift carrier
assembly 1 until the spline of sun gear 2 (8) is
disengaged. Insert sun gear 1 (4) first, then engage
the spline of sun gear 2 (8).
SM2505
W3-2-38
TRAVEL DEVICE E135B
3) Place thrust plate (13) on carrier 1 (3).
13
SM2504
22. Assembling cover.

1) Apply "Loctite #515" to the mating surface of
hub (1) for cover (14). 1
NOTE: "Loctite #515" should be applied around the

mating surface without discontinuation.
SM2593
2) Fasten two eyebolts (A) to the tapped holes

(PF1/2) of cover (14). Place a wire sling and
hook in the eyebolts, place cover (14) on
A
hub (1) with aligning the position of bolt
holes. 14
SM2594
3) Apply "Loctite #242" to hexagon socket bolt

(35) (12 pcs). Tighten hexagon socket bolts
(35) (12 pcs) with the specified torque.
35
: 66.7±3.9 Nm (49±3 lbf ft)
SM2595
W3-2-39
E135B TRAVEL DEVICE
23. Filling lubrication oil.

1) Fill gear oil (lubrication oil) into the filling
port.
NOTE: supply 2.1 liters of gear oil Ambra Hypoide

90 - API GL 5
SM2596
2) Attach plugs (30) to ports of cover (14),

tighten them with the specified torque.
: 98.1±19.6 Nm (72±14 lbf ft)
14
24. Removing reassembled GM motor from the
workbench.
1) Turn the workbench upside down. (The 30
motor side of GM motor is turned up.)
2) Remove the bolts securing GM motor to the
workbench. SM2597
3) Fasten two eyebolts M16 to spindle (2).

4) Place a wire sling and hook in the eyebolts,
remove GM motor from the workbench with
the crane.
W3-2-40
TRAVEL DEVICE E135B
Part maintenance standard
1. Replace all seals Seal parts (O-ring, oil seal floating seal) should be replaced once disassembled even
though no damage is observed.
2. Maintenance criteria for wearing parts.
1) Replace any parts if they have severe damage on appearance.
2) Replace any parts if they have the following abnormalities.
No. PARTS TROUBLE REFERENCE ALLOWAN-

VALUE CE VALUE
1 HUB • Severe damage on appearance.
• Pitting on ring gear teeth. - -
• Abnormal wear such as scoring.
2 SPINDLE • Severe damage on appearance.
- -
• Abnormal wear such as scoring.
3,7 • Abnormal wear such as scoring.
CARRIER ASSY - -
others
4 SUN GEAR 1 SUN • Pitting on ring gear teeth.
8 GEAR 2 PLANETARY • Flaking on the outer race for needle roller bearing.
- -
5 GEAR 1 PLANETARY
9 GEAR 2
24 ANGULAR BALL BEARING • Dent, flaking or uneven wear on contact surface. - -
301 REAR FLANGE • Many scratch on sliding surfaces between spool
- -
(323) and piston (381).
102 SHAFT • Abnormal wear on contact surface between oil
seal (132). - -
• Abnormal wear on spline.
103 SWASH PLATE • Mark of sticking. - -
104 CYLINDER BLOCK • Abnormal wear on spline.
• Abnormal wear on bore surface.
- -
• Scratch or uneven wear on sliding surface with
timing plate (109).
105 PISTON ASSY • Abnormal clearance in the axial direction between Clearance Clearance
106 PISTON SHOE piston (105) and shoe (106). 0.05 mm 0.15 mm
• Abnormal wear on shoe (106). (0.002") (0.006")
107 RETAINER PLATE • Uneven wear on sliding surface with shoe (106).
• Scratch or uneven wear on sliding surface with - -
thrust ball (108).
108 THRUST BALL • Uneven wear on sliding surface with retainer plate
- -
(107).
109 TIMING PLATE • Sticking or uneven wear on sliding surface. - -
115 FRICTION PLATE • Uneven wear on both contact surface. Braking Braking
116 MAITING PLATE • Specified torque cannot be obtained. torque torque
206Nm 206Nm
• Mark of sticking.
(152 lbf ft) (152 lbf ft)
or over or over
105 PISTON • Scratch on sliding surface. - -
W3-2-41
E135B TRAVEL DEVICE
No. PARTS TROUBLE REFERENCE ALLOWAN-

VALUE CE VALUE
149 BALL BEARING • Dent, flaking or uneven wear on contact surface.
- -
150
161 PISTON SHOE • Uneven wear on both sliding surface.
- -
162 • Abnormal wear on shoe (162).
323 SPOOL • Abnormal and uneven wear on the outer
363 circumference. - -
• Severe scratch on the circumference.
381 PISTON • Severe scratch on the circumference. - -
W3-2-42
TRAVEL DEVICE E135B
SPROCKET
86.69 mm
PITCH NUMBER OF TEETH 21
(3.413 in)
SPECIFICATION
ø53.797 mm 581.67 mm
ROLLER DIA. PITCH DIA.
(2.1180 in) (22.900 in)
Unit: mm (in)
171.45 (6.750) B
86.69
)
(3.4130 8.25(0.3248)
(0.0984)
R
2.5
R
(1 R26
R 236
)
(1
36
26 )
. 0
.02
C
(22.9 1.67
(*)
58
)
P.C.D
SM2643
(*) Induction hardening on two dotted line
IMPORTANT: consult NEW HOLLAND KOBELCO for any inquiries concerning welding procedures.
Unit: mm (in)
No. NAME STANDARD VALUE REPAIRAB SERVICE LIMIT REMEDY

LELEVEL
ø 594±2 ø 586 ø 584 Reinforcement weld, repair or
A O.D. of sprocket
(23.4±0.79) (23.1) (23.0) replace.
61+1
-3
Width of sprocket 54 52
B Replace.
teeth (2.40+0.039 ) (2.13) (2.05)
-0.118
O.D. of sprocket ø 524.7 ø 516 ø 514 Reinforcement weld, repair or

C
bottom (20.66) (20.3) (20.2) replace.
W3-2-43
E135B TRAVEL DEVICE
TOOL TABLE
Ref. Name Drawing
A Long eye bolt
SM2598
D Retainer metal
SM2599
G Press fit jig for main bearing
SM2600
I Floating seal fitting tool

SM2601
W3-2-44
TRAVEL DEVICE E135B
Ref. Name Drawing
J Floating seal fitting tool
SM2602
K Floating seal fitting tool

SM2603
L Press fit jig for oil seal
SM2604
M Retainer metal
SM2605
W3-2-45
E135B TRAVEL DEVICE
Ref. Name Drawing
N Inserting jig for lock washer
SM2606
W3-2-46
SWIVEL JOINT E135B
REMOVAL AND INSTALLATION OF SWIVEL JOINT
WARNING
Preparation
2. Cut-off the engine. Actuate the manual and pedal pilot valves to release any residual pressure from inside
the hydraulic system. Press the valve located on the hydraulic oil tank to release any residual pressure
present inside the tank itself.
3. Remove hydraulic oil tank cap.
Removal
NOTE: Attach labels or tags to hoses and adapters, 3. Remove tubes (2 and 8) (PF1).
to aid in assembly.
: 36 mm
: 177 ±18 Nm (130.5 ± 13 lbf•ft)
1. Remove tube (5 and 6) (PF1/2).
: 27 mm 4. Remove tubes (3 and 4) (PF1/4).
: 78.5 ±5 Nm (57.9 ± 3.7 lbf•ft) : 19 mm
: 29.4 ±5 Nm (21.7 ± 3.7 lbf•ft)
2. Remove tubes (1 and 7) (PF1).
: 36 mm
: 177 ±18 Nm (130.5 ± 13 lbf•ft)
60
W3-3-1
E135B SWIVEL JOINT
5. Remove drain hose (2).

: 27 mm
: 78.5 ±5 Nm (57.9 ± 3.7 lbf•ft)
6. Remove hoses (4 and 6).
: 36 mm

: 177 ±18 Nm (130.5 ± 13 lbf•ft)
7. Remove hoses (1 and 3).

: 36 mm
: 177 ±18 Nm (130.5 ± 13 lbf•ft)
8. Remove hose (5).

: 19 mm
: 29.4 ±5 Nm (21.7 ± 3.7 lbf•ft)
60
9. Loosen the stop nut (7) M20 of swivel joint and

remove the screw (8) M24x140.
: 36 mm
: 120 ±12 Nm (88 ±9 lbf•ft)
60
10. Remove drain hose (10).

: 19 mm 10
: 29 Nm (21 lbf•ft)
SM2648
W3-3-2
SWIVEL JOINT E135B
11. Remove six screws (2) M10x25.

: 19 mm
: 14.7 Nm (10.8 lbf•ft)

12. Remove clip (1).
: 6.8 Nm (5.0 lbf•ft)
13. Remove seal (4).

60
14. Attach eye bolt (5), lift it up temporarily, and re-

move three screws (6) M12x40.
: 19 mm
: 110 ±11 Nm (81.1 ±8.1 lbf•ft)

NOTE: swivel joint mass: 25 kg (55 lbs).

Swivel joint mass: 65 kg (143 lbs) (Version with
blade).
60
Installation
NOTE: refer to “Removal” section above for wrench

sizes and tightening torque.
1. Proceed with the re-installation of the centre

joint following the operation in reversed order
with respect to the removal.
NOTE: swivel joint mass: 25 kg (55 lbs).

Swivel joint mass: 65 kg (143 lbs) (Version with
blade).
W3-3-3
E135B SWIVEL JOINT
SWIVEL JOINT DISASSEMBLY AND

ASSEMBLY
G
5
Section G - G
SM2649
1 - Body 7 - O-Ring
2 - Stem 8 - Socket Bolt M8 x 20 (Q.ty 2) 30.4 Nm (22.4
3 - Thrust plate lbf ft)
4 - Cover 9 - Socket Bolt M8 x 30 (Q.ty 4) 30.4 Nm (22.4
5 - Seal assy lbf ft)
6 - Seal ring (Q.ty 5) 12 - Plug
13 - O-Ring (Q.ty 2)
W3-3-4
SWIVEL JOINT E135B
VERSION EQUIPPED WITH BLADE
12
13
7
11
3 8 9
SM2608
1 - Body 7 - O-Ring
2 - Stem 8 - Socket Bolt M8 x 20 (Q.ty 2) 30.4 Nm (22.4 lbf
3 - Thrust plate ft)
4 - Cover 9 - Socket Bolt M8 x 30 (Q.ty 4) 30.4 Nm (22.4 lbf
6 - Seal ring (Q.ty 8) ft)
11 - Plug PT 3/8 (Q.ty 2)
12 - Plug PT 1/8
13 - O-Ring (Q.ty 2)
W3-3-5
E135B SWIVEL JOINT
Disassembly
The part numbers used in this disassembly proce-
dure correspond to those of a construction drawing
in the figure on page W3-3-4.
1. Mark cover (4) and body (1) with matching
marks for convenient reassembly.
2. Place a 'V' (A) block on a work bench, place a
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and wrench.
Alternately, the swivel joint may be fixed by
holding stem (2) in a vise.
$
: 6 mm
60
3. Remove cover (4) from body (1) and draw out

O-Ring (7) from cover (4).
60
4. Loosen socket bolt (8) fastening thrust plate (3),

in the same manner as the removing of the
above-mentioned cover (4).

- When removing thrust plate (3) by fixing body
(1), support stem (2) so it may not fall down.
: 6 mm
60
W3-3-6
SWIVEL JOINT E135B
5. Place body (1) on a 'V' (A)-block. Put a wooden %

block against stem (2) via the body so about

half of the stem is covered by the wooden block
(B) and knock it out using a mallet.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand.
$ 60
6. Remove the O-rings (13).

(
NOTE: Make sure the body (1) is not scored from
the tip of the spatula (E).

7. Remove the seal rings (6) by means of a spat-
ula (E).
60
8. Disassembling of the seal assy (5) (for version

without blade only). Take off the slip rings (B) C
and (C) of the seals assy (5) by means of pin of
screwdriver (A) and remove them from the
grooves (D). The figure SM2652 on side shows
the use of only one pin of screwdriver, but by
using two screwdriver pins, these can be ex-
B
tracted with more sureness.
NOTE: Make sure the body (1) is not scored from

the screwdriver (A).
1
A
5
SM2652
W3-3-7
E135B SWIVEL JOINT
Assembly
Prior to assembly, clean each parts (excluding the %
O- Ring and slipper ring), and arrange in the se-
quence of assembly.
1. Make sure that oil and grease remains have
been completely removed.
2. Apply grease on the groove, then insert the seal
rings (6) by slightly-distorting the shape as
shown in figure SM0904. Also, after inserting
all of the seals, be certain that these are in-
stalled in the seal groove by use of the spatula.
3. Apply hydraulic oil to O-ring (13) thinly and in-
sert it into O-ring groove. Check the twist of O-
ring. 60
4. Assembling of the seals ring (5) (for version

without blade only). Slipper ring (B) is assem-
bled, after first inserting the backup ring (C), by
slightly-distorting the shape as shown in figure
SM0904.
5. Lightly coat the outer circumference of stem (2)
and the inner surface of body (1) with grease or
vaseline and slowly insert stem (2) into body
(1).
NOTE: If stem (2) is pressed in too fast, the seal 2

may be damaged. Do it slowly. The clearance be-
tween body (1) and stem (2) is about 0.1 mm. Push
stem straight along the shaft center. 13
SM2653
W3-3-8
SWIVEL JOINT E135B
6. While holding stem (2) and body (1), match the

hole of thrust plate (3) and the stem (2) hole.
7. Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite 242 and tight-
en to stem (2).
: 6 mm
: 30.4 Nm (22.4 lbf•ft)
60
8. After installing O-Ring (7) to cover (4) and align-

ing the matching marks of the cover (4) and $
body (1), coat socket bolt (9) with Loctite 242
and tighten it which will then complete assem-
bly.

: 6 mm
: 30.4 Nm (22.4 lbf•ft)
60
W3-3-9
E135B SWIVEL JOINT
Allowable Limit
Item Remedy
(basis of judgment)
Sliding surface and sealed
Scored or something hurt it. Replace
parts
Sliding surface exception 1. Scored more than 0.1 mm. Replace
sealed parts 2. Scored less than 0.1 mm. Repair with oil stone
Body, Stem
1. Wear more than 0.5 mm deep. Replace
2. Wear less than 0.5 mm deep. Repair
Sliding surface ring
3. Scored less than 0.5 mm and able to
Repair
repair.
1. Wear more than 0.5 mm. Replace
2. Wear less than 0.5 mm. Repair
Cover Sliding surface ring
3. Scored less than 0.5 mm and able to
Repair
repair.
1. Protruded excessively from seal groove.
Replace
(with back-up ring)
60
2. Slipper ring narrower than 1.5 mm of

seal groove, or narrower than back-up
ring.
Slipper ring Replace (with

back-up ring)
PPPD[
60
3. Worn unevenly more than 0.5 mm.
PPPD[
Replace (with
back-up ring)
60
W3-3-10
SWIVEL JOINT E135B
Inspection after assembly

After completion of assembly, inspection for oil le-
akage, pressure resistance, etc., using a device as
shown in the figure on right.
1. High pressure port (A, B, C, D and F port).
Install a directional valve (8) and pressure

gauge (1) to the stem side port and body side
port respectively, and while watching the pres-
sure gauge (for high pressure) installed on the
body side and also by regulating high pressure
relief valve (7), gradually increase the pressure.
When the pressure has reached 1.5 times the
maximum working pressure, close stop valve
(3) and lock in the hydraulic oil in the swivel.
At this time, keep stop valve (6) on the low pres-
sure relief valve side closed for, at least, 3 min-
utes and check for any distortions, breakages
or loosening.
During the first minute, check for oil leakages
and, in case of pressure drop, this shoul be the

10% of the pressure trapped. This check should
be performed on each circuit.
2. Low pressure port (E port).
Similar to the high pressure port, install a direc-
tional valve and pressure gauge on each port of
the stem side and body side.
Open stop valve (6) on the side of low pressure
relief valve (5) and while watching the pressure
gauge (for low pressure) connected to the body 60
side and also by regulating low pressure relief
valve (5), gradually increase the pressure and
1- Pressure Gauge
check for outside leakage with a color check at
2- Swivel Joint
a pressure of 0.49 MPa.
3- Stop Valve
4- Hydraulic source
5- Relief Valve for low pressure
6- Stop Valve
7- Relief Valve for high pressure
8- Directional Valve
9- Piping, etc.
W3-3-11
E135B SWIVEL JOINT
NOTES:
W3-3-12
TRACK ADJUSTER E135B

TRACK ADJUSTER (WITH FRONT IDLER)
Before removing the track adjuster, the tracks and
the front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to ap-
plicable removal/installation sections. In this section,
the procedure starts on the premise that the tracks
and the front idler have already been removed.
Removal
NOTE: Track adjuster assembly weight: 132.5 kg

(292 lbs).
WARNING
Be sure cables are anchored and the anchor point is
strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.
1. After swinging superstructure to 90° related to

machine longitudinal centerline for easier ac-
cess to track components, remove the front
60
idler and track adjuster assembly from track
frame by prying it out, using a pry bar shown in
figure.
Installation
WARNING
Be sure cables are anchored and the anchor point is
strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.
1. As shown in figure, install the front idler and

track adjuster into spring guide on track frame.
60
W3-4-1
E135B TRACK ADJUSTER
DISASSEMBLY AND ASSEMBLY TRACK

ADJUSTER
Disassembly Track Adjuster

Be sure to thoroughly read "Precautions for Disas-
sembly and Assembly" on page W1-1-1 before
starting the disassembly work.
$
Be sure to use special tool (A) (380001029) for as-
sembly / disassembly of the track adjuster.
WARNING
Prevent personal injury. The spring force of the track
adjuster is extremely large. Thoroughly inspect the
special tool for any damage. Carefully perform as-
sembly work referring to the procedure below. 60
1. Place a jack on the bottom of the track spring

holder assembly (380001029).
2. Loosen four nuts to remove the plate (A1).
: 46 mm
A1
SM2122
NOTE: track adjuster weight: 58.5 kg (129 lbs).
3. Draw out piston (6) from grease cylinder (3) of 1 4 5 2 3 8 7 6 9

the idler adjuster assy.
4. Removing oil seal (8), seal (7) from grease
cylinder (3).
10
SM2609
W3-4-2
5. Connect the track adjuster to a hoist using a lift-

ing strap.
Set the idler adjuster assy on the stand of the jig
(A) (380001029), with its bracket side facing
up.
Remove the lifting strap.
SM2656
6. Fit retainer plate (A1) tighten holding-down nuts

alternately.
4
: 46 mm
5 A1
SM1820
7. Press spring (2) lifting it with jack so that spring

pin (4) can be removed. Loosen nut (5) and 2
remove it.
: 85 mm
SM1821
W3-4-3
8. Allow the hydraulic jack to retract slowly till the

spring is extended to its free length. Remove
the retainer plate and take off bracket (1) and
the cover (10).
: 46 mm
10
SM2655
9. Hook lifting eye nut (W) on grease cylinder (3)

top end and hoist it. Then, remove the set of
grease cylinder (3) and spring (2) using crane. W
3
Free lenght of the spring: 427 mm (16.81 in)
SM1819
W3-4-4
Assembly
1. Insert grease cylinder (3) into spring (2) and
attach lifting eye nut (W) to screw on the top 1 4 5 2 3 8 7 6 9
end of the grease cylinder (3).
Lift the grease cylinder by crane and place it in
the center of the jig stand upright (380001029).
10
SM2609
SM1822
2. Install bracket (1) and the cover (10) on top of

spring (2).
Center the rod of grease cylinder (3) and the
hole in bracket (1). Attach the retainer plate A1
(A1) and its nuts. Fasten nuts evenly all around,
and fix the idler adjuster assy to the jig body
(380001029).
1
3. By means of a hydraulic jack compress spring 4
(2) to the set length and screw nut (5) on the
5
grease cylinder (3).
Set length of the spring: 354.8 mm (13.97 in) 10
3
4. Tighten nut (5) till the holes for spring pin (4) are
aligned. Then fit spring pin (4). 2
: 46 mm
: 85 mm SM2610
W3-4-5
5. Remove idler adjuster assy from jig (380001029).
NOTE: track adjuster weight:58.5 kg (129 lbs).
60
6. Apply grease on the oil seal (8) and seal (7),

then fit on the grease cylinder (3).
7. Fill up grease in cylinder (3), remove the grease 3 8 7 6
nipple from piston (6) in order to discharge the
inside air, and press in the piston by hand.
Direct grease nipple hole downward to make air
discharge easier.
8. Tighten grease nipple (X) to piston (6).
: 19 mm
: 58.8 ± 9.6 Nm (43.4 ± 7 lbf•ft) X
SM2612
W3-4-6
Ref. Item Standard value

A Installed length of spring 354.8 mm (14.0 in)
B Free length of spring Approx. 427 mm (16.8 in)
C Stroke 39.4 mm (1.55 in)
D Set length 686 mm (27.0 in)
E Outside view of piston Neither scoring nor rusting
F Tightening torque of grease nipple 58.8 ± 9.6 Nm (43.3 ± 7 lbf•ft)
X E
aa F
C
A,B
D
X
｡
8 35
7 1
Detail aa
Section X - X
SM2611
W3-4-7
TOOL TABLE
TOOL NO. DESCRIPTION FIGURE
380001029 Jig stand track adjuster
SM2131
W3-4-8
FRONT IDLER E135B

FRONT IDLER ASSY
Disassembly
NOTE: mass of front idler assembly with bracket:

74 kg (163 lbs).

1. Remove plug (8) on the side of collar (3) to
drain oil.

: 5 mm

60
2. To remove pin (5) apply pin push bar (A) to the

top of pin, and push out striking bar lightly by $
hammer.
60
3. Put idler on repair stand. Apply push-out jig on

shaft (B), push out shaft (6) with collar (3), then

remove collar (3).
%

60
* : Push with press
W3-5-1
E135B FRONT IDLER
4. If removal of collar (3) on the opposite side is re-

quired, turn over front idler and proceed with

the procedure described in the previous step.
%

60
* : Push with press
5. With idler (1) mounted on the stand, tap bu-

shing (C) lightly by hammer, while placing the &
bushing drawing rod against the end face of bu-
shing (2) evenly all round, till it comes out.
6. Take out floating seals (4) from idler (1), collar
(3). If you intend to re-use floating seals (4),
confirm that there is no scoring and rusting on
the contact surface and store the floating seals
in pairs by placing card board between the se-
aling faces.
7. Separate O-Ring (7) from shaft (6).
60
W3-5-2
FRONT IDLER E135B
Assembly
1. Align inner hole of idler (1) and bushing (2) and
press fit it vertically with jig (D) and press, so
'

that bushing is correctly press-fitted into the id-
ler.
60
* : Push with press
2. Fit O-Ring (7) to O-Ring groove on shaft (6).

3. Press fit the O-Ring installed side of shaft (6)
into collar (3), and drive pin (5).
4. Fit the half of floating seal (4) on each side of
collar (3) and idler (1).

60
5. Install idler (1) on the shaft (6) with the floating

seal (4) fitted into shaft (6) with the toward collar
(3).
6. Fit floating seal (4) on the other side of idler (1).

60
7. Fit the half of floating seal (4) on the other collar

(3), press fit it in shaft (6), and drive pin (5) in
with hammer.

8. Fill in 200 cm³ (12.2 cu·in) of engine oil API-CD
# 30 through the plug hole of collar (3), wind seal
tape and tighten plug (8).
: 5 mm
NOTE: after installing the idler assy to the idler adju-

ster assy, make certain that no oil leaks from floating
seal and plug (8) and that idler (1) rotates smoothly.
60
W3-5-3
E135B FRONT IDLER
Front idler

&
'
(
%
$
60
Unit: mm (in)
No. ITEM STANDARD VALUE ALLOWABLE SERVICE LIMIT REMEDY

LIMIT
A Dia. of idler Replace
ø 496 (19.5) - -
projection
B Tread dia. ø 456 (18.0) ø 450 (17.7) ø 448 (17.6)
C Flange width 68 ± 1 (2.677±0.04) 63 (2.48) 60 (2.36)
D Clearance Nominal Clearance Fit Fit Replace
between shaft and size bushing
bushing ø 60 0.03 Clearance Clearance
(2.36220) (0.00118) 1.5 (0.059) 2.0 (0.079)
0.06
(0.00236)
E Interference Nominal Interference Fit Fit
between idler and size
bushing ø 64 0.03 Interference Clearance
(2.51969) (0.00118) 0 0.01 (0.0004)
0
F Oil Engine oil: API grade CD #30; Q.ty: 200 cm3 (12.2cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
W3-5-4
FRONT IDLER E135B
TOOL TABLE
Unit: mm (in)
No. NAME DRAWING
15 (0.591)
(1.18)
30
A Pin (5) striking jig
105 (4.13) 15 (0.591)
SM2659
(2.32)
59
300 (11.8)
B Shaft (6) push out jig
SM2660
(0.630)
300 (11.8)
16
C Bushing (2) drawing rod
SM2661
(0.787)
70 (2.76)
20
75 (2.95)
55 (2.17)
D Bushing (2) press fitting jig
60 -0.030
-0.060
(2.36 -0.001
-0.002 ) SM2662
W3-5-5
E135B FRONT IDLER
NOTES:
W3-5-6
UPPER AND LOWER ROLLER E135B

UPPER ROLLER
Removal
WARNING
Do not loosen valve (1) quickly or loosen it too much
as high-pressure grease in the adjusting cylinder
may spout out. Loosen carefully, keeping body parts
and face away from valve (1).
Never loosen grease fitting (2).
IMPORTANT: when gravel or mud is packed 60

between sprockets and tracks, remove it before
loosening.
1. Loosen valve (1) to drain grease.

: 19 mm

60
WARNING

Insert a piece of non-sliding rag between track
frame (5) and hydraulic jack to prevent that the latter
slides.
2. Lift track chains (3) with the hydraulic jack to a

height sufficient to remove upper roller (4).

60
3. Insert a wooden block between tracks (3) and

track frame (5).
60
W3-6-1
E135B UPPER AND LOWER ROLLER
4. Loosen and remove the nut (3); remove the

washer (4) and the screw M20 (2). 3 4
: 30 mm
5. Remove the upper roller complete with support 1

(1) extracting the shaft from the collar of the
lower frame.
2
NOTE: upper roller mass: 9 kg (20 lbs).
SM2664
Installation
1. Prior to the installation, check that the roller

turns freely by hand and there are no leaks. 3 4 2
NOTE: upper roller mass: 9 kg (20 lbs).
2. Insert the roller (1) until the collar contacts the

support. 1
S
3. Position the support roller directing the mark of

bevel (S) on the shaft end, upward.
4. Insert the screw M20 (2), the washer (4), the

nut (3) and tighten it to the specified torque.
: 30 mm
: 570 ± 30 Nm (420 ± 22 lbf•ft) SM2672
5. Remove the wooden blocks and the hydraulic

jack.
60
W3-6-2
6. Tighten valve (1).

: 19 mm
: 58.8 ± 9.6 Nm (43.3 ± 7 lbf•ft)
7. Supply grease to valve (1) to adjust tracks
tension.
Track sag specifications (A): 320 ÷ 350 mm

(12.60 ÷ 13.78 in)
NOTE: check track sag after thoroughly removing

soil stuck on the track area by washing.
60
60
W3-6-3
REMOVAL AND INSTALLATION OF LOWER

ROLLER
Removal
1. Remove the roller guard and loosen bolts (5).

: 24 mm
60
2. Lift the one side of the track frame high enough

to remove the lower roller.
Insert wooden blocks under track frame (2).

60
WARNING
Do not loosen valve (3) quickly or loosen it too much
as high-pressure grease in the adjusting cylinder
may spout out. Loosen carefully, keeping body parts
and face away from valve (3).
60
3. Loosen valve (3) to drain grease enough to

permit the roller removal.
: 19 mm

60
W3-6-4
4. Securely hold the lower roller using a fork lift.

Remove lower roller (1).
NOTE: lower roller mass: 26 kg (57.3 lbs).

60
Installation
1. Securely hold the lower roller using a fork lift.

Put lower rollers (1) on the tracks as illustration.
60
2. Lower track frame (2) enough to allow bolts (4)

to be installed into track frame (2).
60
3. Align tapped holes in track frame (2).

Tighten bolts M16x75 (4).
: 24 mm
: 320 ± 30 Nm (236 ± 22 lbf•ft)

60
W3-6-5

: 19 mm
: 58.8 ± 9.6 Nm (43.3 ± 7 lbf•ft)
5. Supply grease to valve (3) throught nipple (4) to
adjust tracks tension.

(12.60 ÷ 13.78 in)
NOTE: check track sag after thoroughly removing

soil stuck on the track area by washing. 60
60
W3-6-6
DISASSEMBLY & ASSEMBLY OF THE UPPER ROLLER
3 1 5 10 7
12
2 11 9 8
SM2613
1- Roller 7 - Screw M8 x 20 (Q.tà 2)

2- Shaft 8 - O-ring
3- Floating seal 9 - Bushing
4- Plug 10 - Lock plate
5- Thrust washer 11 - Collar
6- Cover 12 - Snap ring
W3-6-7
Disassembly
Be sure to thoroughly read "Precautions for

Disassembly and Assembly" on page W1-1-1 4 12
before starting the disassembly work. 8
7
1. Remove plug (4) and drain out oil. 6
: 6 mm 10 5
1
2. Mount upper roller assy on the support (A) and
remove snap ring (12) using snap ring pliers.
3. Take off cover (6) upwards.
4. Separate O-Ring (8) from cover (6).
5. Unscrew the two screws (7), remove lock plate

(10) and draw out thrust washer (5), from the
roller (1).
: 12 mm
SM2614
6. Put the extrusion jig (B) against the end face of

shaft (2) and push shaft with collar (11) for
floating seal (3), using a press or hammer.
2
3
11
SM2615
W3-6-8
7. Take out floating seal (3) from roller (1).
SM2616
8. Remove from collar (11), floating seal (3) that is

located on the side from which shaft (2) was
disparted.
2
IMPORTANT: collar (11) is press fitted into shaft (2) 3

by means of press.Therefore do not disassemble it.
11
SM2617
9. Since the bushing is thin, machine it on a lathe

or scrape it off, exercise care so as not to
damage the bore of roller (1). If the bushing is
not worn much, mount upper roller (1) on jig
stand jig (A), insert jig extrusion jig (C) into the
end face of bushing (9) and push it out with a
press.
C
SM2618
W3-6-9
Assembly
1. Assembly of the upper roller is done in the

reverse order of disassembly.
2. Place upper roller (1) on the top end face of

stand jig (A), with its floating seal setting side D
facing down.
3. Confirm that the outer surface of bushing (9) is

not seized and coat the outer surface of the 9
inserting side of the bushing, with molybdenum
disulfide grease. 1
4. Put extrusion jig (D) into bushing (9) and press

it in, using the bore of the bushing and the bore
of the roller as guides.
A
IMPORTANT: if you fail in this operation by

pressing the bushing unevenly, the bushing (9) is
distorted and gets unserviceable. In that case, do
not re-use the bushing as it may develop
malfunctioning after assembly. SM2619
IMPORTANT: for handling of floating seal (3), refer

to the section "Precautions for floating seal
handling" on page W1-1-3.
2
5. Two floating seals (3) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 3
- Prior to placing floating seal (3) in, apply 11
engine oil lightly to seal surface.
SM2617
SM2616
W3-6-10
6. Coat shaft (2) with a thin film of oil and insert it

into upper roller (1).

SM2620
7. Mount roller (1) on the support (A), mount the

thrust washer (5), then install the lock plate (10)
and the screw (7). Bend both ends of lock plate
(10) by 90° to contact flats of screw heads (7).
4 12
: 12 mm
8
: 30 ± 4 Nm (22.1 ± 2.95 lbf•ft) 7
6
10 5
8. Fit O-Ring (8) to the groove of cover (6).
1
NOTE: apply grease to O-Ring.
9. Install the cover (6) into roller (1) and fix snap
ring (12) using snap ring pliers.
: 19 mm
: 132.5 ± 10.5 Nm (97.7 ± 7.7 lbf•ft)
SM2614
W3-6-11
10. Fill in 34 cm3 (1.92 cu•in) of engine oil API

grade CD #30 through the plug hole (4).
11. Wind seal tape around plug (4) and tighten it to

the specified torque.
: 6 mm
4
: 12 ± 2 Nm (8.85 ± 1.47 lbf•ft)
NOTE: after assembling the upper roller, confirm

that oil is not leaking from it and that it rotates
smoothly by.
SM2621
W3-6-12
UPPER ROLLER MAINTENANCE STANDARD
F
D
A
C B
SM2677
Unit: mm (in)

LIMIT
A Diameter ø 99 (3.90) ø 95 (3.74) ø 91.5 (3.60) Replace
B Width 140 (5.51) - -
C Installing length 60 - -
D Shaft dia. ø 40+0.025 (1.5748 +0.00098) - -
-0
E Clearance Nominal size Clearance Fit Fit Replace
between shaft and ø 40 (1.5748) 0.365 Clearance Clearance bushing
bushing (0.01437) 0.7 (0.028) 1.0 (0.039)
0.287
(0.0113)
F Interference Nominal size Interference Fit Fit
between roller and ø 47 (1.8504) 0.170 Interference Clearance
bushing (0.00669) 0 0.01 (0.0004)
0.07
(0.00275)
Oil Engine oil: API grade CD #30; Q.ty: 34 cm3 (1.92 cu•in) Refill
Roller rotation Rotates smoothly by hand Reassemble
W3-6-13
TOOL TABLE FOR UPPER ROLLER
Unit: mm (in)
Ref. Name Drawing
100 (3.94)
+ + 0.04
85 1 (3.35 )
160 (6.30)
A Support jig
SM2622
38 (1.50)
30 (1.18)
B Shaft extruding jig
SM2674
59 (2.32)
(1.77-0.001)
(1.57-0.001)
45 -0.025
40 -0.025
0
0
0
C Bushing extruding jig
60 (2.36) 30 (1.18)
130 (5.12)
SM2675
(1.57-0.001)
57 (2.24)
40 -0.025
0
D Bushing fixing jig
40 (1.57)
80 (3.15)
SM2676
W3-6-14
DISASSEMBLY & ASSEMBLY OF THE LOWER

ROLLER
5 6 5 4 3 1
2 7 8 2
SM2623
1- Plug 5- Floating Seal (Q.ty 2)

2- Collar (Q.ty 2) 6- Bushing (Q.ty 2)
3- Pin (Q.ty 2) 7- Roller
4- O-Ring (Q.ty 2) 8- Axle
W3-6-15
Disassembly
Be sure to thoroughly read “Precautions for

Disassembly and Assembly” on page W1-1-1 3
before starting the disassembly work.
1. Prepare an oil container beforehand. Remove 2

plug (1) and drain out oil [approx. 190 cm3
(11.59 cu.in)]. Remove pins (3) from collars (2). 1
: 8 mm
: 8 mm
NOTE: mass of the lower roller 26 kg (57.3 lbs). SM3002
2. Put lower roller on jig (A) for repair stand so that

the shaft (8) is perpendicularly located, apply
push-out jig (B) on shaft end on upper side, and
push shaft (8) until the O-ring (4) separate from B
collar (2) with press or mallet. 4
2
3. Take out collar (2) and remove the O-ring (4)
7
from the shaft (8).
8
4. In addition, push out and remove shaft (8)
together with the lower collar (2) from the roller A
(7).
NOTE: the shaft (8) extrusion operation may cause

the remaining lube oil to flow out. Prepare an oil
container beforehand. SM3001
5. Remove floating seal (5) from collar (2).
SM3003
W3-6-16
6. Remove floating seal (5) from roller (7).
SM3004
7. Removing bushing (6).

Since thickness of bushing (6) is thin [thickness
is 3.3 mm (0.130 in)], remove it through lathe or
strip it with care, in order not to damage inner
C
hole of roller. When the wear of bushing is not
large, place upper roller (7) on jig (A) for repair 7
stand and apply the end of push-out jig (C) on
the end face of bushing (6), and push it out
striking it with mallet.
6
IMPORTANT: hammer the inside surface of roller

lightly so as not to damage the surface. Put the A
extrusion jig (C) uniformly over the circumference of
bushing (6) and extrude it perpendicularly little by SM3005
little.
W3-6-17
Assembly
1. Grease O-ring (4) and install it to groove on

shaft (8).
NOTE: replace O-ring with new one without fail at 4 8

reassembling.
SM3006
2. Fit bushing (6) into jig (D), align inner hole of

roller (7) and bushing (6) and press fit it
D
vertically into the idler, using a press with a 5
ton (11000 lbs) load.
NOTE: apply molybdenum disulfide grease on 6

press fit section of bushing, and press fit it in
ordinary temperature.
SM3007
3. Fit O-ring (4) to the one side of shaft (8) mating

pin hole of collar (2) on which floating seal (5) is
fit with pin hole of shaft (8) in advance. Use the
press of capacity 17 ton (37500 lbs) or more.
NOTE: care should be taken not to damage O-ring

2
(4) while press-fitting collar (2) to shaft (8).
5
4
8
SM3008
4. Press-fit pin (3) to pin hole on aligning pin holes

of shaft (8) and collar (2).
2
5 4
SM3010
W3-6-18
5. Fit floating seals (5) to inner holes on both ends

of roller (1).
NOTE: check that the seal surface is free from

flaws, rusts, etc. before reusing the floating seal.
7
5
8
6. Insert roller (7) from the side where collar (2), is
not press-fitted to the shaft (8). 2
SM3011
NOTE: replace O-ring (4) with new one without fail

at reassembling.
7. Grease O-ring (4) and install it to groove on

shaft (8).
4
8. Press-fit collar (2) to shaft (8).
NOTE: press-fit collar (2) on aligning pin (3) hole.

8
9. Press-fit pin (3) to pin hole on aligning pin holes

of shaft (8) and collar (2).
10. Fill in 190 cm3 (11.59 cu.in) of oil "VEEDOL 903

S3-30" or engine oil API grade CD #30 .
SM3012
11. Installing plug (1) and tighten it to the specified

torque.
·: 6 mm
1
: 12 ± 2 Nm (8.8 ± 1 lbf ft)
SM3013
W3-6-19
LOWER ROLLER MAINTENANCE STANDARD
206 0,90 (8.110 0.035)

C C
E
A
SM3014
Unit: mm (in)

LIMIT
A Diameter of flange ø 170 (6.693) - - Replace
B Treat diameter ø 140 (5.512) ø 132 (5.20) ø 126 (4.96)
C Flange width 18 (0.708) 14 (0.551) 11 (0.433)
D Shaft dia. ø 50+0.0 (1.9685 - 0.00394) - -
-0.10
E Clearance Nominal size Clearance Fit Fit Replace
between shaft and ø 50 (1.96850) 0.350 Clearance Clearance bushing
bushing (0.01378) 0.7 (0.0276) 1.0 (0.0394)
0.450
(0.01771)
F Interference Nominal size Interference Fit Fit
between roller and ø 57 (2.24409) 0.115 Interference Clearance
bushing (0.00453) 0 0.01 (0.0004)
0.035
(0.00138)
Oil Engine oil: VEEDOL 903 S3-30 Refill
API grade CD #30; Q.ty: 190 cm3 (11.59 cu•in)
Roller rotation Rotates smoothly by hand Reassemble
W3-6-20
TOOL TABLE FOR LOWER ROLLER
Unit: mm (in)
Ref. Name Drawing
140 (5.51)
290 (11.40)
110 (4.33)
A Support jig
SM2626
270(10.6)
49 (1.93)
B Shaft extruding jig
SM3009
200 (7.87)
16 (0.630)
C Bushing extruding jig
SM3015
70 (2.76)
77 (3.03)
52 (2.05)
D Bushing fixing jig
50 +0.1
0
(1.97 +0.004
0 ) SM3016
W3-6-21
NOTES:
W3-6-22
TRACKS E135B

TRACKS
Removal
WARNING
Do not loosen valve (1) quickly on loosen too much
since high-pressure grease in the adjusting cylinder
may spout out.
Loosen carefully, keeping body parts and face away
from valve (1).
60
1. Move the tracks so that master pin (3) is

positioned over front idler (4).
Put a wooden block under track shoes (5), as
shown.

60
2. To loosen the track tension, slowly turn valve

(1) counterclockwise one turn; grease will
escape from grease outlet.
: 19 mm

60
W3-7-1
E135B TRACKS
WARNING
The front idler may jump out of position due to
strong spring force when the tracks is disconnected.
Especially, the strong spring force is always applied
to the bolt part of the rod. If the rod and/or the bolt
are damaged, metal fragments may fly off when the
tracks is disconnected.
60
3. Remove master pin (3) by using a special tool.
A: 380001008
B: 380001936 60
C: 380001935
D: 380001807
E: 380001937 ' & (
G: 380001019
3: MASTER PIN
* % $
60
4. Slowly drive the machine in reverse until the

whole length of the removing track comes on
the ground.
60
5. Rotate the upperstructure 90 degrees toward

the removing track side, perpendicular to the
tracks. Operate the boom and arm so that the
angle between them is 90 to 110 degrees.
Lower the boom with the bucket rolled-in to jack
up the machine as illustrated.
60
W3-7-2
TRACKS E135B
Installation
1. Jack up the machine and put the track under

the lower roller.
Be sure to position the track in correct direction,
as illustrated.
X: Sprocket side < ;
Y: Idler side
60
2. Lift the track, and place it on sprocket (1).
60
3. Slowly turn the sprocket in forward direction.
60
4. Turn sprocket (1) until end of track (4) comes

on front idler (3).
Lower the machine and put a wooden block as
illustrated.
60
W3-7-3
E135B TRACKS
IMPORTANT: hole surfaces, link holes and

counterbore surfaces, bushing ends, shall be free
from dust and rust.

5. Install master pin (5), using a hammer and

special tool.
60
A: 380001008
B: 380001936
C: 380001935
D: 380001807
E: 380001937 ' & (
G: 380001019
5: MASTER PIN
IMPORTANT: inject rust preventive protective (ex.

TECTYL165 G) between pin and bushing
clearance. % $
*
60
IMPORTANT: If any links have been removed from

the track, be sure to charge the grease into the
clearance between the pin and bushing when
reconnecting the links. Also, apply a coat of grease
to the ends of the bushing.
Grease Charging Method:
- Stand the bushing on a flat plate.
- Fill the bushing bore with the grease.
- Insert the pin into the bushing while pushing the
bushing onto the plate (so that the bushing end
stays on the plate).
- Wipe off excess grease.

: 19 mm 60
: 58.8 ± 9.6 Nm
7. Supply grease to the cylinder through the

grease fitting (2) to adjust the track tension.

(12.60 ÷ 13.78 in)
IMPORTANT: check track sag after thoroughly

removing soil stuck on the track area by washing.
60
W3-7-4
TRACKS E135B
Link Pin and Track Bushing

• Measure the length of four links, as illustrated,
with the tension on the track.
• Do not measure the master-pin included part of
the track.
60
Unit: mm (in)
Standard Allowable Limit Remedy
A 685.8 (27.000) 706.4 (27.811) Replace
Master Pin
%
60
Unit: mm (in)
A 184 (7.244) - Replace
B 33.1 (1.303) 31.4 (1.236) Replace
W3-7-5
E135B TRACKS
Master Bushing
% &
$
60
Unit: mm (in)
A 109.5 (4.311) -
B Ø 33.338 (Ø 1.313) Ø 35 (Ø 1.378) Replace
C Ø 53.797 (Ø 2.118) Ø 51 (Ø 2.008)
Shoe
d
C
A
SM3017
Tightening torque of shoe bolt (d) M16 x 1,5: 400 ± 30 Nm (295 ± 22 lbf•ft)
Unit: mm (in)
A 199 ± 2 (7.835 ± 0.079) -
B 9.5 ± 0.5 (0.374 ± 0.020) - Replace
C 25 ± 1 (0.984 ± 0.039) 15 (0.591)
W3-7-6
SECTION 4 E135B
FRONT ATTACHMENT
CONTENTS
Group 1 - Front attachment

Front attachment removal and Boom cylinders disassembly............. W4-1-42
installation ............................................. W4-1-1 Boom cylinders assembly ................. W4-1-43
Monoblock Version ........................... W4-1-1
Maintenance standards.......................... W4-1-45
Removal............................................ W4-1-1
Inspection after disassembly............. W4-1-45
Installation......................................... W4-1-4
Triple articulation version .................. W4-1-7 Tool table ............................................... W4-1-47
Removal............................................ W4-1-7
Installation......................................... W4-1-10
Maintenance: monoblock version ..... W4-1-13
Maintenance:
triple articulation version .................. W4-1-14
Standard dimensions for arm and bucket
connection............................................. W4-1-15
Replacement of bucket ..................... W4-1-16
Removing the bucket ........................ W4-1-16
Installing the bucket .......................... W4-1-16
Bucket play adjustment..................... W4-1-16
Bucket teeth replacement ................. W4-1-17
Cylinders removal and installation .... W4-1-18
Bucket Cylinder removal ................... W4-1-18
Bucket Cylinder installation............... W4-1-20
Arm cylinder removal ........................ W4-1-21
Arm cylinder installation .................... W4-1-22
Boom cylinders removal ................... W4-1-23
Boom cylinders installation ............... W4-1-25
Positioner cylinder removal............... W4-1-27
Positioner cylinder installation .......... W4-1-28
Cylinders assembly and disassembly . W4-1-29
Bucket cylinder ................................. W4-1-29
Bucket cylinder disassembly............. W4-1-30
Bucket cylinder assembly ................. W4-1-31
Arm cylinder ...................................... W4-1-33
Arm cylinder disassembly ................. W4-1-34
Arm cylinder assembly...................... W4-1-35
Positioner cylinder
(triple articulation version)................ W4-1-37
Positioner cylinder disassembly........ W4-1-38
Positioner cylinder assembly ............ W4-1-39
Boom cylinders ................................. W4-1-41
FRONT ATTACHMENT E135B
FRONT ATTACHMENT REMOVAL AND INSTALLATION
Monoblock Version
WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this
dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the
valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns.
Before starting any intervention, make sure that oil and components have cooled off.
Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load.
Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.
Removal
1. Park the machine on firm, level ground.
Position the front attachment as illustrated and
lower the bucket to the ground.
2. Disconnect lubrication hoses (1) from boom

cylinder rod end.
: 17 mm
3. Loosen lock nuts (2), remove bolt (3) and

stopper (4) from boom cylinder rod end.
Carry out the same procedure for the other SM0200
boom cylinder.
: 22 mm
4. Attach each boom cylinder to a crane. 1

3
NOTE: boom cylinder mass: 100 kg (220 lbs)
Remove cylinder rod end pin (5) and shims (6) 4

using a hammer and bar. 2
SM0201
5 4 2
4 3 SM0202
W4-1-1
E135B FRONT ATTACHMENT
5. Slowly lower the boom cylinder using the crane

onto the wooden block.
6. Press the valve located on the hydraulic oil tank

to bleed the residual pressure inside the tank
itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
"Procedure for the bleeding of the pressure
from the hydraulic system" at page T2-1-45.
SM0203
7. Disconnect hoses (7) and (8) of bucket cylinder
and arm cylinder.
8
NOTE: if the machine is equipped with the hammer/ 11

crusher, bucket rotation or anti-drop valves variants,
disconnect the relevant hoses (9), (10) and (11).
9
Bucket (7) and arm (8) cylinder hoses:
: 30 mm
10
Hammer/crusher hoses (9):
: 36 mm
7
: 41 mm SM2632
Bucket rotation hoses (10):

: 27 mm
Anti-drop valves hoses (11):

: 22 mm
Close all openings with plugs to keep clean. 12
8. Disconnect lubrication hoses (12).

: 17 mm
SM3019
W4-1-2
9. Disconnect electrical connection of lights (13).
13
SM1243
10. Remove screws (14) and guard (15).

: 19 mm
14
11. Sling the boom to a hoist. Slightly lift the boom.
NOTE: approximate mass of the front equipment

(bucket excluded): 1700 kg (3750 lbs).
15
SM2637
12. Remove capscrew (16) from boom foot pin

(17).
: 24 mm
13. Draw out pin (17) and recover shims (18).
NOTE: mass of boom foot pin: 23 kg (51 lbs).

SM0208
14. Lift front attachment and remove it.
18 16 17
SM2633
W4-1-3
Installation
1. Lift the front attachment.

2. When aligning the pin holes, do not put your

finger in the pin holes, but align them visually.
Check that the dust seals is not damaged and
replace as necessary.
Insert the shims (18) to both right and left sides
of the boom foot boss to take out clearance
between the boom foot boss and the main 18 16 17
frame boss.
SM2633
NOTE: clearance between boom and main frame

must be less than 0.5 mm (0.0197 in).
3. When inserting the pin (17), coat the shaft with

grease. Install boom foot pin (17) using a
hammer and bar.
Install capscrew (16) and tighten it with the
specified torque.
: 24 mm
: 147 ± 15 Nm (108 ± 11 lbf·ft)
24
SM2634
4. Loosen plug (24) and apply a 3/8” grease nipple
to the grease hole for boom foot pin. Inject
grease and fill, remove nipple and lock plug
(24).
14
: 8 mm
: 30 ± 3 Nm (22 ± 2 lbf·ft)
5. Install panel (15) by tightening securing screws

(14).
: 19 mm
: 80 Nm (59 lbf·ft)
15
SM2637
W4-1-4
6. Connect hoses (7) and (8) of bucket cylinder

8
and arm cylinder.

connect the relevant hoses (9), (10) and (11).
9
: 30 mm
: 137 ± 14 Nm (101 ± 10 lbf·ft)
10
: 36 mm
: 177 ± 18 Nm (131 ± 13 lbf·ft)
Hammer/crusher hoses (9): 7 SM2632
: 36 mm
: 177 ± 18 Nm (131 ± 13 lbf·ft)
: 41 mm
: 206 ± 21 Nm (152 ± 15 lbf·ft)
: 27 mm
: 95,5 ± 9,5 Nm (70 ± 7 lbf·ft)
: 22 mm
: 49 ± 5 Nm (36.1 ± 3.7 lbf·ft)
7. Attach the boom cylinder to a crane.

SM0211
Lift the boom cylinder and align the boom 3

cylinder rod with the pin hole on the boom.
NOTA: for easy alignment, start the engine and use

5 4 2
the boom control lever.
2
8. Install shims (6) and insert pin (5).
NOTE: after adjustment of shim, the clearance of both 6

sides should be 0.6 to 1.0 mm (0.02 to 0.04 in).
4 3 SM0202
9. Install stopper (4), tighten bolts (3) and lock

nuts (2):
: 22 mm
5
: 126 ± 13 Nm (93 ± 9.5 lbf·ft)
1
3
10. Connect lubrication hoses (1) to boom cylinder
rod.
: 17 mm
: 20 Nm (14.7 lbf·ft)
4
2
SM0201
W4-1-5
11. Connect lubrication hoses (12).

: 17 mm
: 20 Nm (14.7 lbf.ft)
NOTE: fill the hydraulic oil tank with hydraulic oil to 12

the specified level. Run the engine at idle. Check
hose connections for any oil leakage.
SM3019
12. Connect electrical connection of lights (13).
13
SM1243
W4-1-6
Triple articulation version
WARNING
Removal
2. Disconnect lubrication pipes (1) from boom

cylinder rod end.
: 17 mm

SM0215
Carry out the same procedure for the other
boom cylinder.
: 22 mm
4. Attach each boom cylinder to a crane. 3

1
5
Remove cylinder rod end pin (5) and shims (6)

using a hammer and bar.
4 2
SM0216
5 4 2
4 3 SM0217
W4-1-7
5. Slowly lower the boom cylinder using the crane


itself.
7. Loosen screw (7) and remove bracket (8).

: 19 mm SM0218
8. Disconnect hoses (9), (10) and (11) of 9

positioner cylinder, bucket cylinder and arm
cylinder.
7 8

crusher, bucket rotation or anti-drop valves variants, 14
disconnect the relevant hoses (13), (14) and (17).
13
10
Positioner cylinder hoses (9) (from the control
valve): 11
: 8 mm SM3021

: 30 mm
: 36 mm

: 36 mm
: 41 mm
12
: 27 mm

: 22 mm
Close all openings with plugs to keep clean.

: 17 mm
SM3020
W4-1-8
10. Disconnect electrical connection of lights (21).
21
11. Remove screws (15) and guard (16).
: 19 mm
SM3024
12. Sling the boom to a hoist. Slightly lift the boom.
15
16
SM2638
13. Remove capscrew (19) from boom foot pin

(20).
14. Draw out pin (20) and recover shims (18).
NOTE: mass of boom foot pin: 23 kg (51 lbs).
15. Lift front attachment and remove it.

SM0223
18 19 20
SM2635
W4-1-9
Installation
1. Lift the front attachment.

(bucket excluded): 2000 kg (4410 lbs)
2. When aligning the pin holes, do not put your

finger in the pin holes, but align them visually.
Check that the dust seals is not damaged and
replace as necessary.
Insert the shims (18) to both right and left sides
of the boom foot boss to take out clearance
between the boom foot boss and the main 18 19 20
frame boss.
SM2635
NOTE: clearance between boom and main frame

must be less than 0.5 mm (0.0197 in).
3. When inserting the pin (20), coat the shaft with

grease. Install boom foot pin (20) using a
hammer and bar. Install capscrew (19) and
tighten it with the specified torque.
: 24 mm
: 147 ± 15 Nm (108 ± 11 lbf·ft)
4. Loosen plug (24) and apply a 3/8” grease nipple 24

to the grease hole for boom foot pin. Inject
grease and fill, remove nipple and lock plug SM3022
(24).
: 8 mm
: 30 ± 3 Nm (22 ± 2 lbf·ft)
15
5. Install panel (16) by tightening securing screws

(15).
: 19 mm
: 80 Nm (59 lbf·ft)
16
SM2638
W4-1-10
6. Connect bucket cylinder hoses (10), positioner

cylinder hoses (9) and arm cylinder hoses (11). 9
NOTE: if the machine is equipped with the hammer/

connect the relevant hoses (13), (14) and (17).
17
Positioner cylinder hoses (9) (from the control 14
valve):
: 8 mm 13
: 59 ± 5 Nm (43.5 ± 3.7 lbf·ft) 10
Bucket (10) and arm (11) cylinder hoses: 11
: 30 mm SM3023
: 137 ± 14 Nm (101 ± 10 lbf·ft)
: 36 mm
: 177 ± 18 Nm (131 ± 13 lbf·ft)
: 36 mm
: 177 ± 18 Nm (131 ± 13 lbf·ft)
: 41 mm
: 206 ± 21 Nm (152 ± 15 lbf·ft)
: 27 mm
: 95 ± 9.5 Nm (70 ± 7 lbf·ft)
Anti-drop valves hoses (17): SM0218
: 22 mm
: 49 ± 5 Nm (36 ± 3.7 lbf·ft)
3
7. Attach the boom cylinder to a crane.
NOTE: boom cylinder mass: 100 kg (220 lbs). 5 4 2
Lift the boom cylinder and align the boom

cylinder rod with the pin hole on the boom.
2
NOTE: for easy alignment, start the engine and use
the boom control lever. 6
8. Install shims (6) and insert pin (5). 4 3 SM0217
NOTE: after adjustment of shim, the clearance of both

sides should be 0.6 to 1.0 mm (0.02 to 0.04 in).

nuts (2):
: 22 mm
: 126 ± 13 Nm (93 ± 9.5 lbf·ft)
W4-1-11

rod.
: 17 mm
: 20 Nm (14.7 lbf·ft) 1
21
11. Connect electrical connection of lights (21).
12. Install bracket (8), screw (7) and tighten it with

: 19 mm
SM3025
: 115 ± 12 Nm (84.8 ± 8.8 lbf·ft)
13. Connect lubrication hoses (12).
NOTE: fill the hydraulic oil tank with hydraulic oil to

the specified level. Run the engine at idle.
Check hose connections for any oil leakage.
12
SM3020
W4-1-12
Maintenance: monoblock version
F E G H
A B C J K
D I
SM0213
Unit: mm (in)
Parts name Standard Allowable limit Remedy
Pin 70 (2.756) 69 (2.717)
A
Bushing 70 (2.756) 71.5 (2.815)
Pin 70 (2.756) 69 (2.717)
B Boss (Main Frame) 70 (2.756) 71.5 (2.815)
Bushing (Boom Cylinder) 70 (2.756) 71.5 (2.815)
Pin 80 (3.150) 79 (3.110)
C Bushing (Boom Cylinder) 80 (3.150) 81.5 (3.209)
Boss (Boom) 80 (3.150) 81.5 (3.209)
Pin 70 (2.756) 69 (2.717)
D
Bushing 70 (2.756) 71.5 (2.815)
Pin 70 (2.756) 69 (2.717)
E Boss (Arm) 70 (2.756) 71.5 (2.815)
Bushing (Arm Cylinder) 70 (2.756) 71.5 (2.815)
Pin 70 (2.756) 69 (2.717)
Replace
F Boss (Boom) 70 (2.756) 71.5 (2.815)
Pin 60 (2.362) 59 (2.323)
G Boss (Arm) 60 (2.362) 61.5 (2.421)
Bushing (Bucket Cylinder) 60 (2.362) 61.5 (2.421)
Pin 65 (2.559) 64 (2.520)
H Bushing 65 (2.559) 66.5 (2.618)
Pin 60 (2.362) 59 (2.323)
I
Bushing 60 (2.362) 61.5 (2.421)
Pin 65 (2.559) 64 (2.520)
J
Bushing 65 (2.559) 66.5 (2.618)
Pin 65 (2.559) 64 (2.520)
K
Bushing 65 (2.559) 66.5 (2.618)
IMPORTANT: be sure to install front attachment bushings using a press.
W4-1-13
Maintenance: triple articulation version
F E L M G
A B C D H J K
N I
SM0238
Unit: mm (in)
Parts name Standard Allowable limit Remedy
Pin 70 (2.756) 69 (2.717)
A-D-N
Bushing 70 (2.756) 71.5 (2.815)
Pin 70 (2.756) 69 (2.717)
B Boss (Main Frame) 70 (2.756) 71.5 (2.815)
Pin 80 (3.150) 79 (3.110)
C Bushing (Boom Cylinder) 80 (3.150) 81.5 (3.209)
Boss (Boom) 80 (3.150) 81.5 (3.209)
Pin 85 (3.346) 84 (3.307)
E Boss (Positioner) 85 (3.346) 86.5 (3.405)
Bushing (Positioner Cylinder) 85 (3.346) 86.5 (3.405)
Pin 90 (3.543) 89 (3.504)
F Boss (Boom) 90 (3.543) 91.5 (3.602)
Bushing (Positioner Cylinder) 90 (3.543) 91.5 (3.602)
Pin 60 (2.362) 59 (2.323)
Replace
G Boss (Arm) 60 (2.362) 61.5 (2.421)
Pin 65 (2.559) 64 (2.520)
H Bushing 65 (2.559) 66.5 (2.618)
Pin 60 (2.362) 59 (2.323)
I
Bushing 60 (2.362) 61.5 (2.421)
Pin 65 (2.559) 64 (2.520)
J-K
Bushing 65 (2.559) 66.5 (2.618)
Pin 70 (2.756) 69 (2.717)
L Boss (Positioner) 70 (2.756) 71.5 (2.815)
Pin 70 (2.756) 69 (2.717)
M Boss (Arm) 70 (2.756) 71.5 (2.815)
IMPORTANT: be sure to install front attachment bushings using a press.
W4-1-14
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION
p q
o g
h
k
j
Section A
d
l
B
m
n
a
f
b Section B
A
SM2631
E135B E135
a 350 (13.78) 349 (13.74)
b 20 (0.79) 25 (0.98)
c 514 (20.24) 501 (19.72)
d 492 (19.37) 482 (18.98)
f 1222 (48.11) →
g 376 (14.80) 379 (14.92)
h 270 (10.63) 273 (10.75)
i Ø 65 (Ø 2.56) →
j 367 (14.45) →
k 45 (1.77) →
l 386 (15.20) 379 (14.92)
m 252 (9.92) 255 (10.04)
n Ø 65 (Ø 2.56) →
o 90° →
p 45° 0°
q 390 (15.35) 393 (15.47)
Unit: mm (in)
W4-1-15
REPLACEMENT OF BUCKET
CAUTION
Replace the bucket on firm level ground. Pay close
attention to safety.
When aligning the pin bores, DO NOT INSERT
YOUR HAND OR FINGERS into the bores. It may
cause severe injury. Align the bores visually or using
a tool.
Hold the removed bucket in the stable condition.
Removing the bucket

• Place the machine on a firm and flat surface and
rest the bucket on the ground in a stable position.
• Place O-rings (1) out of the relevant seats.
Remove the pins and the retaining rings of the
pins.
• Remove pin (E) and pin (B); then remove the
bucket.
Installing the bucket

• Using a suitable hoist, place the bucket on the
same level as the tracks.
• Position the O-Rings (1) outside their seats.
• Using the arm cylinder control and boom cylinder
control make small vertical and horizontal
movements to insert pivot pin (B) connecting the
bucket to the arm into hole (A).
• Use the bucket cylinder control to align the
connecting rod (C) to hole (D) and insert pivot pin
(E).
• Secure pivot pins using lock pins and retaining IMPORTANT: during the removal of the bucket,
rings and reposition the O rings into their seats. take care that the pin are not contaminated by dirt,
sand etc. After the reinstallation of the bucket,
provide grease to the pins through the appropriate
Bucket play adjustment
fittings.
Bucket play (g) is adjusted by opportunely changing
total shims installed.
NOTE: bucket play (g) should be 0.5 (0.020 in) to

1.5 mm (0.059 in).
If bucket play (g) exceeds the specified value,

increase adjust shims as follows:
• loosen the three bolts (2) taking care to retrieve
the washers. Slide out the ring (1);
• Add adjust shims (3) until compensating the play
(g);
• Install the ring (1), and tighten securing bolts (2).
: 30 mm
: 181 ± 20 Nm (133 ± 14.7 lbf·ft)
W4-1-16
Bucket teeth replacement
WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.
• Ensure the machine is parked on a level surface.

• Rest the bucket to the ground.
• Switch off the Auto-Idle, fully turn the engine
speed manual control anticlockwise, stop the
engine, remove the ignition key and move the
safety lever in the locked position (LOCK).
• Use a hammer and punch to push lock pin (1) out
of its seat and remove the tip of bucket tooth (2).
NOTE: to push lock pin (1) out of its seat, strike it

with a punch on its upper side.
• Install a new rubber insert (3) inside lock pin (1).

• Clean the surface of bucket tooth (4) and insert a
new tip.
• Insert lock pin (1) into its seat using a punch and
hammer, until it is fully mounted.
W4-1-17
CYLINDERS REMOVAL AND INSTALLATION
WARNING
Bucket Cylinder removal


itself.
3. Complete the bleeding of the residual pressure

SM0200
4. Insert wooden block (3) between bucket

cylinder (1) and arm (2).
1
5. Disconnect lubrication hoses.
: 17 mm
3
IMPORTANT: pin (6) end of the link will drop when
pin is removed, possibly resulting in personal injury.
Be sure to secure the link using a wire before
removing pin (6). 2
6. Loosen lock nuts (4) and remove bolt (5). SM0226

Pull-out pin (6) with the help of a mallet and a
bar so that the end of the cylinder is free, then
remove adjusting shims (7).
6
: 22 mm 7 4
SM0227
W4-1-18
7. Remove capscrews (13) and disconnect hoses

(8) from bucket cylinder (1). 9
: 8 mm 12
Put plugs on cylinder pipes and hoses. 11
10
NOTE: bucket cylinder weight: 82 kg (181 lbs).

1
8. Using a hoist, slightly lift bucket cylinder (1). 8

Loosen locking nuts (9) remove screw (10) and
pull-out pin (11) with the help of a mallet and a
bar so that the end of the cylinder is free, then
remove adjusting shims (12). 8
: 19 mm
9. Remove bucket cylinder (1).
SM0228
W4-1-19
Bucket Cylinder installation
NOTE: bucket cylinder mass: 82 kg (181 lbs).

9
12
1. Connect bucket cylinder (1) to a crane using a 11
sling belt.
Align the hole of the bucket cylinder with the pin
hole on the arm-tip bracket. 10
2. Install adjusting shims (12) and insert pin (11). 1

Install screw (10) and tighten lock-nuts (9).
: 19 mm
: 83 ± 5 Nm (61.2 ± 3.7 lbf·ft)
8
NOTE: after adjustment of shim, the clearance of

both sides should be 0.6 to 1.0 mm (0.02 to 0.04 in).
8
3. Connect two hoses (8) to bucket cylinder (1).
: 8 mm
: 65.7 ± 6.9 Nm (48.5 ± 5 lbf·ft)
4. Align the bucket cylinder rod with bucket links

(13) and (14).
Install shims (7) and pin (6).

both sides should be 0.6 to 1.0 mm (0.02 to 0.04 in). SM0228

the arm control lever.
6
7 4
5. Install bolt (5) onto pin (6) then tighten lock nuts
(4).
: 22 mm
5
: 115 ± 11 Nm (85 ± 8 lbf·ft)
14
SM0229
W4-1-20
Arm cylinder removal

itself.
Complete the bleeding of the residual pressure 1
3
2. Insert a wooden block (3) between arm cylinder
(1) and boom (2).
2
3. Disconnect lubrication hoses.
: 17 mm SM0230
4. Loosen lock nuts (4), remove bolt (5) and pull- 6

7 4
out pin (6) with the help of a mallet and a bar so
that the end of the cylinder is free, then remove
adjusting shims (7).
: 24 mm
5
5. Disconnected hoses (8) and (9) from arm

cylinder.
Put plugs on cylinder pipes and hoses.
: 8 mm
: 30 mm
SM0231
6. Disconnect lubrication hose (10).

: 17 mm
8
NOTE: arm cylinder mass: 138 kg (304 lbs)
7. Using a hoist, slightly lift arm cylinder (1). 10

Loosen locking nuts (11) remove screw (12)
and pull-out pin (13) with the help of a mallet
and a bar so that the end of the cylinder is free, 9
then remove adjusting shims (14).
: 24 mm
SM0232
8. Remove arm cylinder (1). 13

14 11
12
SM0233
W4-1-21
Arm cylinder installation
NOTE: arm cylinder mass: 138 kg (304 lbs)
1. Using a crane, align the hole of the arm cylinder

with the pin hole on the boom-tip bracket.
2. Install adjusting shims (14), pin (13), install

screw (12) onto pin (13) and tighten lock-nuts
(11). 13
14 11
: 24 mm
: 147 ± 15 Nm

both sides should be 0.6 to 1.0 mm (0.02 to 0.04 in) 12
3. Connect lubrication hoses (10) and hoses (8)

and (9) to the arm cylinder.
: 17 mm
: 20 Nm (14.7 lbf·ft) SM0233
: 8 mm
: 65.7 ± 6.9 Nm (48.5 ± 5 lbf·ft)
: 30 mm
: 137 ± 14 Nm (101 ± 10 lbf·ft) 8
4. Slightly lift arm cylinder and align the arm

cylinder rod with the pin hole on the arm.
10
9
5. Install adjusting shims (7), pin (6), install screw
(5) onto pin (6) and tighten lock-nuts (4). SM0232
: 24 mm
: 147 ± 15 Nm (108 ± 11 lbf·ft)
6
7 4

SM0231
W4-1-22
Boom cylinders removal

1. Park the machine on firm, level surface and
lower the bucket teeth and arm top to the
ground with the arm and bucket cylinders fully
5
retracted.
1
3
itself.
from the hydraulic system, making reference to 4
"Procedure for the bleeding of the pressure 2
SM0201
: 17 mm
3
Remove pin (5) and shims (6). 5 4 2
: 22 mm
NOTE: boom cylinder mass: 100 kg (221 lbs) 2
6
5. Attach boom cylinder to a crane.
6. Slowly lower the boom cylinder using the crane 4 3 SM0202

7. Disconnect hoses (7) of boom cylinder. Put 7 7

plugs on cylinder pipes and hoses.
: 30 mm 8
8
8. Disconnect anti-drop hoses (8).
: 22 mm
9. Disconnect lubrication hoses head side (9).

: 17 mm SM2639
SM2133
W4-1-23
10. Remove securing screws (10) complete with

washers, then remove pin (11) and recover
: 17 mm
11. Using a hoist, lift boom cylinder. If necessary,

11
remove the other boom cylinder following the
same procedure.
10
12
SM2640
W4-1-24
Boom cylinders installation
1. Using a crane, install the boom cylinders to the

main frame.
2. Install adjusting shims (12) and pin (11), then

tighten securing screws (10) complete with
washers. 11
: 17 mm
10
: 46.1 ± 4.9 Nm (30.4 ± 3.6 lbf·ft)
12
NOTE: after adjustment of shim, the clearance of SM2640

both sides should be 0.6 to 1.0 mm (0.02 to 0.04 in)
3. Connect lubrication hoses (7) to boom cylinder. 7 7

: 30 mm
: 85 ± 5 Nm (62 ± 4 lbf·ft)
8
4. Connect anti-drop hoses (8).

8
: 22 mm
: 49 ± 5 Nm (36.1 ± 3.7 lbf·ft)
5. Connect centralised lubrication hoses (9) SM2639

located between the boom cylinders.
: 17 mm
: 20 Nm (14.7 lbf·ft)
SM2133
W4-1-25
6. Install shims (6) and insert pin (5).

3
5 4 2
nuts (2):
: 22 mm 2
: 126 ± 13 Nm (93 ± 9.5 lbf·ft)
6
rod.
4 3 SM0202
: 17 mm
: 20 Nm (14.7 lbf·ft)
9. Install the other boom cylinder following the 5

same procedure.
1
3
4
2
SM0201
W4-1-26
Positioner cylinder removal

itself.
"Procedure for the bleeding of the pressure 1
2. Insert a wooden block (3) between positioner

cylinder (1) and boom (2).
3
3. Disconnect lubrication hose rod side.

2
: 17 mm SM0236
4. Loosen lock nuts (4), remove bolt (5) and pull- 6

7 4
out pin (6) with the help of a mallet and a bar so
that the end of the cylinder is free, then remove
: 24 mm
5
5. Disconnected hoses (8) and (9) from arm

cylinder.
Put plugs on cylinder pipes and hoses.
: 10 mm
: 36 mm
SM0237
6. Disconnect lubrication hose (10).

: 17 mm
8
NOTE: positioner cylinder mass: 177 kg (390 lbs).
7. Using a hoist, slightly lift positioner cylinder (1). 10

Loosen locking nuts (11) remove screw (12)
and pull-out pin (13) with the help of a mallet
and a bar so that the end of the cylinder is free, 9
then remove adjusting shims (14).
: 24 mm
SM0232
8. Remove positioner cylinder (1). 13

14 11
12
SM0233
W4-1-27
Positioner cylinder installation
NOTE: positioner cylinder mass: 177 kg (390 lbs)
1. Using a crane, align the hole of the positioner

cylinder with the pin hole on the boom-tip
bracket.
2. Install adjusting shims (14), pin (13), install

13
screw (12) onto pin (13) and tighten lock-nuts 14 11
(11).
: 24 mm
: 147 ± 15 Nm (108 ± 11 lbf·ft)
12
3. Connect lubrication hoses (10) and hoses (8)
and (9) to positioner cylinder.
: 17 mm
: 20 Nm (14.7 lbf·ft)
: 8 mm
: 65.7 ± 6.9 Nm (48.5 ± 5 lbf·ft)
SM0233
: 36 mm
: 177 ± 18 Nm (130 ± 13 lbf·ft)
4. Slightly lift positioner cylinder and align the

positioner cylinder rod with the pin hole on the
arm. 8

10
5. Install adjusting shims (7), pin (6), install screw
(5) onto pin (6) and tighten lock-nuts (4).
: 24 mm 9
: 147 ± 15 Nm (108 ± 11 lbf·ft)
NOTE: after adjustment of shim, the clearance of SM0232
6. Connect lubrication hose rod side.

6
: 17 mm 7 4
: 20 Nm

the specified level. Run the engine at idle. Check 5
SM0237
W4-1-28
CYLINDERS ASSEMBLY AND DISASSEMBLY

Bucket cylinder
25
13
27
17 16
27
15
28
20
19 21
20
24
22
11
12
1
2
3
8 4
27
7
27 5
6
10
9
28 26 18
SM2628
1- Wiper Ring 10 - O-Ring: 1B G90 20 - Slide Ring (q.ty 2)

2- Backup Ring 11 - Cylinder Rod 21 - Piston seal
3- Seal 12 - Cylinder Tube 22 - Set Screw
4- Seal 13 - Cushion Bearing 24 - Nut
5- Bushing 15 - Piston 25 - Bushing (q.ty 2)
6- Snap Ring 16 - Backup Ring (q.ty 2) 26 - Bushing (q.ty 2)
7- Cylinder Head 17 - O-ring 27 - Seal dust (q.ty 4)
8- Socket Bolt: M14 (q.ty 8) 18 - O-Ring: 1B G95 28 - Grease nipple
9- Backup Ring 19 - Slide Ring (q.ty 2)
W4-1-29
Bucket cylinder disassembly

Be sure to thoroughly read all the precautions for 5. Loosen the piston (15) using the tool (A) then,
disassembly/assembly work on page W1-1-1 before remove the piston from cylinder rod.
starting the disassembly procedure.
The disassembly procedure below starts on the

premise that the hydraulic lines and the line
securing bands have been removed.
A
NOTE: bucket cylinder mass 82 kg (181 lbs).
1. Lift and securely place the cylinder on a

workbench using a crane. Be sure that the
cylinder is placed horizontally. Drain hydraulic
oil from the cylinder. 15
SM1883
2. Fully extend cylinder rod (11). Secure the rod

end using a crane. Remove socket bolts (8)
6. Remove back-up ring (16), O-ring (17), slide
from cylinder head (7).
rings (19), (20), from piston (15). Cut the piston
: 12 mm seal (21) by tapping it with a screwdriver or a
chisel, take cure not to strike it too hard,
IMPORTANT: be sure to pull cylinder rod (11) otherwise the groove may be damaged.
straight so as not to damage the sliding surfaces.
20 19 21 19 20
3. Pull out cylinder head (7) from cylinder tube 17

(12) by tapping with a plastic hammer.
21
4. Remove set screw (22), loosen and remove nut 16

(24) using eye wrench (B).
: 6 mm
15 SM3029
B
7. Remove cushion bearing (13) from cylinder rod
(11).
8. Remove cylinder head (7) from cylinder rod

(11).
24
9. Remove O-Rings (10), (18) and (22), backup
SM3028
rings (9) and (2) from cylinder head (7), then
remove wiper ring (1), seal (3), seal (4), snap
ring (6), and bushing (5).
W4-1-30
Bucket cylinder assembly

1. Press fit bushing (5) into cylinder head (7) with
bushing press-fitting jig (C), then fit snap ring
C
(6) in the groove.
SM3030
2. Apply a film of hydraulic oil onto internal surface

of cylinder head (7), then Install, back-up ring 18
(2), seal (3), seal (4), O-ring (18), back-up ring
9
(9) and O-ring (10) on cylinder head (7).
10
7
3. Apply grease to dust seal (1) or the hole of 5
cylinder head (7), and fit dust seal (1) to the
bottom of the hole. Press the metal ring of dust 4
seal (1) with a jig (H).
3 6
2
4. Assembling of piston assy 1
- Fit back ring (21b) of piston seal (21) in the SM3031
groove of piston (15) then, fit seal ring (21a)

with fitting jig (21a). 21c 21b
CAUTION
21a
Since it is hard to deform seal ring (21a) in room
temperature, immerse and soften it in hydraulic oil 21
heated with electric heater about 150 to 180 °C. D
Therefore slip it in piston seal groove quickly with
fitting jig (D). Wear safety gloves to avoid burn. 21a 21c
21b
- Shrink the seal ring (21a) to the original size
using correcting jig (E). 15
- Fit back-up rings (21c) to both sides of seal SM3032
ring.
E
21a
SM3033
W4-1-31
- Fit slide ring (2 places) (19) and (20) to the

bore side.
- Fit back-up rings (2 places) (16) and O-ring
(17) inside the piston. 20
19
5. Install cylinder head (7) on cylinder rod (11) 21

with inserting guide jig (F).
Apply hydraulic oil on the inserting guide jig (F) 19
and outer surface of cylinder rod lightly to make
the insertion of cylinder head smoothly. 20
17 16
SM3034
6. Remove inserting guide jig (F) and install
cushion bearing (13) to cylinder rod (11).
7
7. Apply hydraulic oil or grease to the inside of the
piston assembly and Install it to cylinder rod F
(11).
Tighten piston to a specified torque using the
tool (A).
: 981 ± 98 Nm (724 ± 72 lbf·ft)
8. Install nut (24) to cylinder rod (11) and tighten it

to a specified torque using the tool (B). Tighten 11 SM3035
set screw (22) to a specified torque.
nut (24): 1860±186 Nm (1372±137 lbf·ft)
set screw (22): 14.7 Nm (10.8 lbf·ft)
A 11
: 6 mm
9. Secure cylinder tube (12) horizontally using a

work bench. Insert cylinder rod (11) into
cylinder tube (12).
IMPORTANT: be sure to keep cylinder rod (11)

15
aligned with the centre of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
SM1884
10. Install cylinder head (7) to cylinder tube (12).

Tighten socket bolts (8).
: 12 mm
: 211 ± 15 Nm (155 ± 11 lbf·ft)
24
SM3036
W4-1-32
Arm cylinder
28
25
27
13
27
17 16 25
15
20
19 21
20
24
11
22
29
23
1
2
3
8 4
12
7
27
5
6
27
10
9
18
26
SM2629
1 - Wiper Ring 11 - Cylinder Rod 21 - Piston seal

2 - Backup Ring 12 - Cylinder Tube 22 - Set Screw: M8
3 - Seal 13 - Cushion Bearing 23 - Cushion Bearing
4 - Seal 15 - Piston 24 - Nut
5 - Bushing 16 - Backup Ring 25 - Bushing (q.ty 2)
6 - Snap Ring (q.ty 2) 26 - Bushing (q.ty 2)
7 - Cylinder Head 17 - O-ring 27 - Seal dust (q.ty 4)
8 - Socket Bolt: M16 (q.ty 10) 18 - O-Ring: 1B G115 28 - Grease nipple
9 - Backup Ring 19 - Slide ring (q.ty 2) 29 - Stopper
10 - O-Ring: 1B G110 20 - Slide ring (q.ty 2)
W4-1-33
Arm cylinder disassembly

Be sure to thoroughly read all the precautions for 5. Loosen the piston (15) using the tool (A) then,
disassembly/assembly work on page W1-1-1 before remove the piston from cylinder rod (11).

securing bands have been removed.
A
NOTE: arm cylinder mass 138 kg (309 lbs)

cylinder is placed horizontally. Drain hydraulic
oil from the cylinder. 15
SM1883
2. Fully extend cylinder rod (11). Secure the rod

6. Remove back-up ring (16), O-ring (17), slide
rings (19), (20), from piston (15). Cut the piston
seal (21) by tapping it with a screwdriver or a
: 14 mm chisel, take cure not to strike it too hard,
otherwise the groove may be damaged.
IMPORTANT : be sure to pull cylinder rod (11)
20 19 21 19 20
17
3. Pull out cylinder head (7) from cylinder tube
(12) by tapping with a plastic hammer. 21
16
4. Remove set screw (22), loosen and remove nut
(24) using eye wrench (B).
: 6 mm
15 SM3029
B 7. Remove cushion bearing (13) from cylinder rod

(11).

(11).
9. Remove O-Rings (10), (18) and (22), backup

rings (9) and (2) from cylinder head (7), then
24 remove wiper ring (1), seal (3), seal (4), snap
ring (6), and bushing (5).
SM3028
10. If necessary, using a screw driver, remove

stopper (29) and cushion bearing (23) from
cylinder rod (11).
W4-1-34
Arm cylinder assembly

C
(6) in the groove.
SM3030

of cylinder head (7), then Install, back-up ring 18
(2), seal (3), seal (4), O-ring (18), back-up ring
9
(9) and O-ring (10) on cylinder head (7).
10
7
3. Apply grease to dust seal (1) or the hole of 5
bottom of the hole. Press the metal ring of dust 4
3 6
2
- Fit back ring (21b) of piston seal (21) in the SM3031
groove of piston (15) then, fit seal ring (21a)

with fitting jig (21a). 21c 21b
CAUTION
21a
Since it is hard to deform seal ring (21a) in room
temperature, immerse and soften it in hydraulic oil 21
heated with electric heater about 150 to 180 °C. D
Therefore slip it in piston seal groove quickly with
fitting jig (D). Wear safety gloves to avoid burn. 21a 21c
21b
using correcting jig (E). 15
- Fit back-up rings (21c) to both sides of seal SM3032
ring.
E
21a
SM3033
W4-1-35
- Fit slide ring (2 places) (19) and (20) to the

bore side.
- Fit back-up rings (2 places) (16) and O-ring
(17) inside the piston. 20
19
5. Install cylinder head (7) on cylinder rod (11) 21

with inserting guide jig (F).
the insertion of cylinder head smoothly. 20
17 16
SM3034
6. Remove inserting guide jig (F) and install
cushion bearing (13) to cylinder rod (11).
7
7. Apply hydraulic oil or grease to the inside of the
piston assembly and Install it to cylinder rod F
(11).
Tighten piston to a specified torque using the
tool (A).
: 981 ± 98 Nm (724 ± 72 lbf·ft)
8. Install nut (24) to cylinder rod (11) and tighten it

to a specified torque using the tool (B). Tighten 11 SM3035
set screw (22) to a specified torque.
nut (24): 1860±186 Nm (1372±137 lbf·ft)
set screw (22): 14.7 Nm (10.8 lbf·ft)
A 11
: 6 mm
9. Install cushion bearing (23) and stopper (29) to

cylinder rod (11).
10. Secure cylinder tube (12) horizontally using a 15

cylinder tube (12).
SM1884
IMPORTANT: be sure to keep cylinder rod (11)

aligned with the centre of cylinder tube (12) when
inserting, in order to avoid damaging the rings.

: 14 mm B
: 353 ± 20 Nm (260 ± 15 lbf·ft)
24
SM3036
W4-1-36
Positioner cylinder (triple articulation version)
27
15
20
19
25
17 16
19
20
21
24
23
22
11
12
1
2
3
8 4
7
26
5
6
10
9
27
SM2630
1- Wiper Ring 9 - Backup Ring 20 - Slide Ring (q.ty 2)

2- Backup Ring 10 - O -Ring 21 - Shim
3- Seal 11 - Cylinder Rod 22 - Set Screw
4- Seal 12 - Cylinder Tube 23 - Steel Ball
5- Bushing 15 - Piston 24 - Nut
6- Snap Ring 16 - Backup Ring (q.ty 2) 25 - Bushing
7- Cylinder Head 17 - Piston seal 26 - Bushing
8- Socket Bolt (q.ty 12) 19 - Slide Ring (q.ty 2) 27 - Seal dust (q.ty 4)
W4-1-37
Positioner cylinder disassembly

Be sure to thoroughly read all the precautions for
disassembly/assembly work on page W1-1-1 before
20 19 16 17 16 19 20

securing bands have been removed. 17
NOTE: positioner cylinder mass: 177 kg (390 lbs)

cylinder is placed horizontally. Drain hydraulic 15 SM3037
oil from the cylinder.

2. Fully extend cylinder rod (11). Secure the rod (11).
: 14 mm
8. Remove O-Ring (10), backup rings (9) and (2)
from cylinder head (7), then remove wiper ring
(1), seal (3), buffer ring (4), snap ring (6), and
IMPORTANT: be sure to pull cylinder rod (11) bushing (5).

4. Remove set screw (22) and steel ball (23) from

nut (24).
: 10 mm
NOTE: cut away its mushroomed portion using a

drill first, as set screw was mushroomed with a
punch and hammer at two places after it had been
screwed in.
5. Loosen nut (24) using tool (B).

Remove shim (21) and take off piston (15) from
cylinder rod (11).
6. Remove seal ring (17), slide rings (19) and (20),

and backup rings (16) from piston (15).
W4-1-38
Positioner cylinder assembly

C
(6) in the groove.

of cylinder head (7), then Install, back-up ring
(2), seal (3), seal (4), back-up ring (9) and O- 7
ring (10) on cylinder head (7).
SM3030
3. Apply grease to dust seal (1) or the hole of
bottom of the hole. Press the metal ring of dust
10
9
7
- Fit O-ring (17b) of piston seal (17) in the
groove of piston (15) then, fit seal ring (17a) 4
using fitting jig kit (G1). 3 6
2
NOTE: since it is hard to deform seal ring (17a) in 1 SM3038
room temperature, heat it with electric heater about
60 °C, therefore slip it in piston seal groove using
fitting jig kit (G1). Wear safety gloves.
G1 17a
17

15
using correcting jig kit (G2).
17b
17a 17b G2
- Fit back-up rings (16) and slide rings (19) and
(20).
SM3039
20
19
16
19
20
SM3040
W4-1-39
5. Install cylinder head (7) on cylinder rod (11)

using inserting guide jig (F).
the insertion of cylinder head smoothly.
F
6. Remove inserting guide jig (F), apply hydraulic

oil or grease to the inside of the piston
assembly and Install it to cylinder rod (11).
7. Install shim (21) and nut (24) onto cylinder rod 11 SM3035
(11). Tighten nut (24) to a specified torque
using the tool (B).
11 24 22
: 95 mm
: 5470 Nm (4034 lbf·ft) 23
8. Insert steel ball (23) and tighten set screw (22)

to a specified torque.
Mushroom the head of set screw (22) at two
places using a punch and hammer.
: 10 mm
: 56.9 ± 10.7 Nm (42 ± 7.9 lbf·ft)
SM3047

cylinder tube (12). 12
11
IMPORTANT: be sure to align cylinder rod (11) with
the centre of cylinder tube (12) when inserting, in
order to avoid damaging the rings.

Tighten socket bolts (8). SM3042
: 14 mm
: 267 Nm (197 lbf·ft)
12
8
SM3043
W4-1-40
Boom cylinders
27
14
13
21
23 25
15
22
20
19
17 16
20 19
11
12
1
2
3
8 4
26
5
6
10
9
27 SM2627
1- Wiper Ring 10 - O-Ring 20 - Slide Ring (q.ty 2)

2- Backup Ring 11 - Cylinder Rod 21 - Shim
3- Seal 12 - Cylinder Tube 22 - Set Screw
4- Seal 13 - Cushion Bearing 23 - Steel Ball
5- Bushing 14 - Cushion Seal 25 - Bushing
6- Snap Ring 15 - Piston 26 - Bushing
7- Cylinder Head 16 - Backup Ring (q.ty 2) 27 - Seal dust (q.ty 4)
8- Socket Bolt: M14 (q.ty 12) 17 - Piston seal
9- Backup Ring 19 - Slide Ring (q.ty 2)
W4-1-41
Boom cylinders disassembly

Be sure to thoroughly read all the precautions for
disassembly/assembly work on page W1-1-1 before
starting the disassembly procedure. 20 19 16 17 16 19 20

securing bands have been removed. 17
NOTE: boom cylinder mass: 100 kg (73.7 lbs)

workbench using a crane.
Be sure that the cylinder is placed horizontally. 15 SM3044
Drain hydraulic oil from the cylinder.

2. Fully extend cylinder rod (11). Secure the rod (11).
: 12 mm 8. Remove O-Ring (10), backup rings (9) and (2)
from cylinder head (7), then remove wiper ring
(1), seal (3), buffer ring (4), snap ring (6), and
IMPORTANT: be sure to pull cylinder rod (11) bushing (5).

4. Remove set screw (22) and steel ball (23) from

piston (15).
: 8 mm
NOTE: cut away its mushroomed portion using a

drill first, as set screw was mushroomed with a
punch and hammer at two places after it had been
screwed in.
5. Remove piston (15) using tool (B). Remove

shim (21) cushion bearing (13) and cushion
seal (14).
6. Remove seal ring (17), slide rings (19) and (20),

and backup rings (16) from piston (15).
W4-1-42
Boom cylinders assembly

C
(6) in the groove.

of cylinder head (7), then Install, back-up ring
(2), seal (3), seal (4), back-up ring (9) and O- 7
ring (10) on cylinder head (7).
SM3030
3. Apply grease to dust seal (1) or the hole of
bottom of the hole. Press the metal ring of dust
10
9
7
- Fit O-ring (17b) of piston seal (17) in the
groove of piston (15) then, fit seal ring (17a) 4
using fitting jig kit (G1). 3 6
2
NOTE: since it is hard to deform seal ring (17a) in 1 SM3038
room temperature, heat it with electric heater about
60 °C, therefore slip it in piston seal groove using
fitting jig kit (G1). Wear safety gloves.
G1 17a
17

15
using correcting jig kit (G2).
17b
17a 17b G2
- Fit back-up rings (16) and slide rings (19) and
(20).
SM3039
20
19
16
19
20
SM3045
W4-1-43
5. Install cylinder head (7) on cylinder rod (11)

using inserting guide jig (F).
the insertion of cylinder head smoothly.
F
6. Remove inserting guide jig (F) and install,

cushion seal (14), cushion Bearing (13) and
shim (21), to cylinder rod (11).
7. Apply hydraulic oil or grease to the inside of the 11 SM3035

piston assembly and Install it to cylinder rod
(11). Tighten piston assembly to a specified
torque using the tool (B). 11 13 14 21 22
: 75 mm
23
: 3851 Nm (2840 lbf·ft)
8. Insert steel ball (23) and tighten set screw (22)

to a specified torque.
Mushroom the head of set screw (22) at two
places using a punch and hammer.
: 8 mm
: 31.5 ± 5.9 Nm (23 ± 4.4 lbf·ft) SM3046

work bench. Insert cylinder rod (11) into 12
cylinder tube (12).
11
IMPORTANT: be sure to align cylinder rod (11) with

the centre of cylinder tube (12) when inserting, in
order to avoid damaging the rings.
10. Install cylinder head (7) to cylinder tube (12). SM3042

: 12 mm
: 171 Nm (126 lbf·ft) 12
8
SM3043
W4-1-44
MAINTENANCE STANDARDS
Inspection after disassembly

Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental
to use are not present.
1. Inspection Item
Part Name Inspecting Section Inspection Item Remedy

1. Neck of rod pin Presence of crack Replace
2. Weld on rod hub Presence of crack Replace
3. Stepped part to which piston
Presence of crack Replace
is attached.
4. Threads Presence of seizure Recondition or replace
Refer to table A (see on next
5. Bend Measure degree of bend
page)
Piston rod
Check that:
1) Plating is not worn off to 1) Replace or replate
base metal
6. Plated surface 2) Rust is not present on 2) Replace or replate
plating
3) Scratches are not present 3) Recondition, replate or
replace
7. Bushing at mounting part Wear of I. D. Replace
1. Weld on bottom Presence of crack Replace
2. Weld on head Presence of crack Replace
Cylinder tube
3. Tube interior Presence of damage Replace
4. Bushing at mounting part Wear on inner surface Recondition or replace
1) Wear on inner surface 1) See Limit of serviceability
on next page
Rod cover 1. Bushing
2) Flaw on inner surface 2) Replace if score is deeper
than coating
2. 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 emery paper - grade 1000. 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 emery
paper - grade 1000. If the score or the indention is excessive, replace or replate the damaged part.
3) Always regrind after replating.
NOTE: the thickness of the plating must be minimum 0.03 mm (0.00118 in).
W4-1-45
3. 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
0.25 mm (0.01 in).
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 centre between the two V-block turn the
piston rod, and read the difference between the
maximum and minimum deflection on the dial
indicator.
The Table A below shows an example of

measurement.
Table A SM3048
Deflection of the
Distance
dial indicator in
between V-
the middle of the Remedy
blocks
rod
m (ft-in)
mm (in)
1 (3’3") > 1 (0.04”) Replace
W4-1-46
TOOL TABLE
Unit: mm (in)
No. DESCRIPTION DRAWING
A
B
D
Wrench for piston
A
F
Material: SS400 (JIS)
E
G T SM3049
Common
Cylinder A B C D E F G T
use bolt
40 100 80 12 300 55 30 12 – 15
Bucket
(1.58) (3.94) (3.15) (0.47) (11.8) (2.17) (1.18) (0.47-0.59) M8 x 20
60 120 90 12 300 55 30 12 – 15 (q.ty 2)
Arm
(2.36) (4.72) (3.54) (0.47) (11.8) (2.17) (1.18) (0.47-0.59)
Unit: mm (in)
A
D
Wrench for piston nut

B
SM2641
Common
Cylinder A B C D E F G T
use bolt
76 135 65 11 300 55 30 12 – 15
Bucket
(3.00) (5.32) (2.56) (0.43) (11.8) (2.17) (1.18) (0.47-0.59)
-
91 150 80 11 300 55 30 12 – 15
Arm
(3.58) (5.91) (3.15) (0.43) (11.8) (2.17) (1.18) (0.47-0.59)
Socket box wrench (75 mm)

Boom
P/N 380001845
Socket box wrench (95 mm)

Positioner
P/N 380001007
SM1366
W4-1-47
Unit: mm (in)
s=1 (0.0039)
A1
Rod bushing pressing jig
B
A
C
C D
s=1 (0.0039) E
ØA1=ØA-20 (0.878”)
SM3050
Cylinder A B C D E
0
65 -0.1
0 64.8 ± 0.1
Bucket
(0 (2.551 ± 0.0039)
(2.559) -0.0039 30 90 120
0)
(1.14) (3.54) (4.72)
0
80 -0.1
84.8 ± 0.1
Arm
(0 (3.339 ± 0.0039)
(3.150) -0.0039)
Rod bushing pressing jig Ø70 mm

Boom (Ø 2.756 in)
P/N 380001237
Rod bushing pressing jig Ø85 mm

Positioner (Ø 3.346 in)
P/N 380001890
SM1371
Unit: mm (in)
C
D
12°
Piston (slipper) seal fixing pressing jig
F
D R10
G
(0.39")
R10
(0.39”)
E
A
B
SM3201
Cylinder A B C D E F G
94.5 ± 0.1 96 ± 0.1 85 75 23 63 90

Bucket
(3.720 ± 0.0039) (3.780 ± 0.0039) (3.35) (2.95) (0.90) (2.48) (3.54)
114.5 ± 0.1 116 ± 0.1 105 95 28 63 96
Arm
(4.508 ± 0.0039) (4.567 ± 0.0039) (4.13) (3.74) (1.10) (2.48) (3.78)
W4-1-48
Unit: mm (in)
R10
(0.39”)
F
Piston seal holding-down jig
E
E
D
G
A 5 - 10°
B
SM3202
105 113 98 ± 0.1 46 75 10 - 15 100

Bucket
(4.13) (4.45) (3.858 ± 0.0039) (1.81) (2.95) (0.39 – 0.59) (3.94)
125 133 117 ± 0.1 46 75 10 - 15 100
Arm
(4.92) (5.24) (4.606 ± 0.0039) (1.81) (2.95) (0.39 – 0.59) (3.94)
Unit: mm (in)
G
R0.5
(0.02”) E F R0.5
(0.02”)
Rod cover fixing jig
F R10
Material: SS400 (JIS) (0.39”)
D
C
A
B
SM3203
0
55.5 60 60.3 ± 0.1 65 -0.1 32 28.5 155
Bucket
(2.19) (2.36) (2.374 ± 0.0039) (0 (1.26) (1.12) (6.10)
(2.559) -0.0039)
0
80 -0.1
70.5 75 75.3 ± 0.1 32 28.5 155
Arm
(2.78) (2.95) (2.965 ± 0.0039) (0 (1.26) (1.12) (6.10)
(3.150) -0.0039)

Boom
P/N 380001764

Positioner
P/N 380001884
SM1372
W4-1-49
Unit: mm (in)
G1
G Tools kit piston seals installation
G2
SM3204
Boom cylinder P/N 380001766
Positioner cylinder P/N 380001041
Unit: mm (in)
s=1 (0.0039) E s=1 (0.0039)
G H I
Dust seal pressing jig
J
H
F
Material: SS400 (JIS) A

B
C
D SM3205
Cylinder A B C D E F G H I J
75 74 77 93 5 25
Bucket
(2.76) (2.91) (3.03) (3.66) 80 5 (0.20) 15 5 (0.98)
84 89 92 106 (3.15) (0.20) 5.5 (0.59) (0.20) 25.5
Arm
(3.31) (3.50) (3.62) (4.17) (0.21) (1.00)
Dust seal pressing jig:

Boom
P/N 380001234
Dust seal pressing jig:

Positioner
P/N 380001033
SM3206
W4-1-50
SECTION 5 E135B
ENGINE
(Mitsubishi D04FR-74KW)
CONTENTS
Group 1 - General Removing cylinder head assembly . W5-5-4

Removing valve and valve spring ... W5-5-4
General ................................................ W5-1-1
Removing valve stem seal .............. W5-5-4
External view .................................. W5-1-1
System flow diagrams..................... W5-1-3 Disassembling and inspecting flywheel.... W5-5-5
Engine serial number location ........ W5-1-7 Removing flywheel.......................... W5-5-6
Main specifications ......................... W5-1-8 Removing flywheel housing ............ W5-5-6
Tips on disassembling and Disassembling and inspecting gear

reassembling....................................... W5-1-11 case, timing gear and camshaft .......... W5-5-7
Disassembling ................................ W5-1-11 Removing crankshaft pulley............ W5-5-7
Reassembling ................................. W5-1-11 Removing timing gear case ............ W5-5-8
Measuring timing gear backlash ..... W5-5-8
Group 2 - Service Data Measuring idler gear end play......... W5-5-8
Maintenance Service Data................... W5-2-1 Removing idler gear........................ W5-5-9
Engine general................................ W5-2-1 Removing camshaft ........................ W5-5-9
Basic engine ................................... W5-2-2 Separating camshaft gear............... W5-5-9
Lubrication system .......................... W5-2-6 Installing camshaft gear and thrust
Cooling system ............................... W5-2-6 plate ............................................... W5-5-10
Inlet and exhaust system ................ W5-2-6 Removing front plate....................... W5-5-10
Electrical system ............................. W5-2-7 Disassembling and inspection crankcase,
crankshaft and piston .......................... W5-5-11
List of tightening torque........................ W5-2-8
Removing connecting rod cap ........ W5-5-12
Major bolts and nuts tightening torque W5-2-8
Removing carbon deposits from the
Standard bolt and nut tightening torqueW5-2-11
upper part of cylinder liner ............. W5-5-12
Standard eyebolt tightening torque . W5-2-12
Pulling out piston............................. W5-5-12
Standard union nut tightening torque W5-2-12
Removing piston ring ...................... W5-5-13
Group 3 - Service Tools Removing piston pin ....................... W5-5-13
Removing main bearing cap ........... W5-5-13
Special Tools ....................................... W5-3-1
Removing crankshaft ...................... W5-5-14
Group 4 - Determination of Overhaul Group 6 - Inspection and repair of basic
Determining overhaul timing ................ W5-4-1 engine
Testing compression pressure............. W5-4-2 Inspecting and repairing cylinder head
and valve mechanism ......................... W5-6-1
Group 5 - Disassembly of basic engine Measuring clearance between rocker
Disassembling and inspecting cylinder bushing and rocker shaft................ W5-6-1
head and valve mechanism ................ W5-5-1 Replacing rocker bushing ............... W5-6-1
Removing injector ........................... W5-5-2 Measuring valve stem outside
Removing rocker shaft assembly.... W5-5-3 diameter and valve guide inside
Disassembling rocker shaft assembly W5-5-3 diameter ......................................... W5-6-2
Removing cylinder head bolt .......... W5-5-3 Replacing valve guide..................... W5-6-2
Inspecting valve face ...................... W5-6-3
Refacing valve face......................... W5-6-3 Measuring crankshaft journal outside

Refacing valve seat......................... W5-6-4 diameter ......................................... W5-6-23
Replacing valve seat....................... W5-6-5 Measuring crankshaft crankpin outside
Lapping valve and valve seat.......... W5-6-6 diameter ......................................... W5-6-24
Measuring perpendicularity and free Grinding crankshaft ......................... W5-6-24
length of valve spring ..................... W5-6-6 Measuring crankshaft end play ....... W5-6-25
Measuring distortion of the bottom Measuring crankshaft runout........... W5-6-25
surface of the cylinder head ........... W5-6-7 Replacing crankshaft gear .............. W5-6-26
Measuring push rod runout ............. W5-6-7 Replacing front oil seal.................... W5-6-27
Inspecting and repairing flywheel.... W5-6-8 Replacing rear oil seal..................... W5-6-27
Inspecting and repairing timing gear Inspecting main bearing surface ..... W5-6-28
and camshaft....................................... W5-6-9 Measuring clearance between main
Measuring timing gear backlash ..... W5-6-9 bearing and crankshaft journal....... W5-6-28
Measuring cam lift........................... W5-6-9
Group 7 - Reassembly of basic engine
Measuring camshaft runout ............ W5-6-9
Measuring camshaft journal outside Reassembling piston, connecting rod,
diameter ......................................... W5-6-10 crankshaft and crankcase ................... W5-7-1
Measuring camshaft bushing inside Installing main bearing .................... W5-7-1
diameter ......................................... W5-6-10 Installing thrust plate ....................... W5-7-1
Replacing camshaft bushing ........... W5-6-10 Installing crankshaft ........................ W5-7-1
Measuring front idler bushing inside Installing main bearing caps............ W5-7-2
dia. and front idler shaft outside Inserting side seal ........................... W5-7-2
diameter ......................................... W5-6-11 Installing main bearing cap bolt....... W5-7-2
Replacing idler bushing................... W5-6-12 Measuring crankshaft end play ....... W5-7-3
Replacing idler shaft ....................... W5-6-12 Reassembling piston and connecting
Inspecting tappet............................. W5-6-12 rod .................................................. W5-7-3
Measuring clearance between tappet Installing piston ring ........................ W5-7-4
and tappet guide hole .................... W5-6-13 Preparation for installing pistons ..... W5-7-4
Inspecting and repairing piston, connecting Installing connecting rod bolt and
rod, crankshaft and crankcase ............ W5-6-14 connecting rod bearing................... W5-7-5
Measuring crankcase top surface Installing Pistons ............................. W5-7-5
distortion ........................................ W5-6-14 Installing connecting rod cap........... W5-7-6
Measuring cylinder inside diameter W5-6-15 Reassembling timing gear and
Replacing cylinder sleeve ............... W5-6-16 camshaft.............................................. W5-7-7
Measuring piston outside diameter . W5-6-17 Installing front plate ......................... W5-7-7
Measuring piston ring end gap........ W5-6-17 Installing tappet ............................... W5-7-7
Measuring clearance between piston Installing camshaft .......................... W5-7-7
ring groove and piston ring ............ W5-6-18 Installing front idler gear.................. W5-7-8
Measuring piston pin bore diameter Inspecting and adjusting timing gear
and piston pin outside diameter ..... W5-6-18 after installation .............................. W5-7-8
Measuring piston protrusion............ W5-6-19 Installing front oil seal...................... W5-7-9
Measuring clearance between Installing timing gear case............... W5-7-9
connecting rod bearing and crankpin. W5-6-20
Installing crankshaft pulley .............. W5-7-9
Measuring clearance between
connecting rod bushing and piston pin W5-6-20 Reassembling flywheel......................... W5-7-10
Replacing connecting rod bushing.. W5-6-21 Installing flywheel housing .............. W5-7-10
Removing connecting rod bushing.. W5-6-21 Installing flywheel ............................ W5-7-10
Installing connecting rod bushing.... W5-6-21 Reassembling cylinder head and
Inspecting connecting rod bend valve mechanism................................. W5-7-11
and twist......................................... W5-6-22 Cleaning cylinder head bottom surface W5-7-11
Inspecting connecting rod bearing .. W5-6-22 Installing valve stem seal ................ W5-7-11
Measuring connecting rod end play W5-6-23 Installing valve and valve spring ..... W5-7-11
Weight difference of connecting rod Installing cylinder head gasket ........ W5-7-12
assembly in one engine ................. W5-6-23
Installing cylinder head assembly ... W5-7-12 Measuring exhaust manifold distortion. W5-11-3
Tightening cylinder head bolts ........ W5-7-12 Installing inlet and exhaust system ...... W5-11-4
Inserting push rod ........................... W5-7-13 Installing inlet system ...................... W5-11-4
Reassembling rocker shaft assembly W5-7-13 Installing exhaust system ................ W5-11-5
Installing rocker shaft assembly...... W5-7-13
Installing injector ............................. W5-7-14 Group 12 - Electrical system
Adjusting valve clearance ............... W5-7-14 Removing electrical system ................. W5-12-1
Installing rocker cover ..................... W5-7-14 Removing starter............................. W5-12-1
Inspecting before removing alternator W5-12-2
Group 8 - Fuel system
Removing alternator........................ W5-12-3
Removing fuel system.......................... W5-8-1
Disassembling, inspecting and
Removing fuel system (Part 1) ....... W5-8-1
reassembling electrical system ........... W5-12-4
Removing fuel system (Part 2) ....... W5-8-2
Disassembling and inspecting starter W5-12-4
Installing fuel system ...................... W5-8-3
Inspecting and repairing starter ...... W5-12-11
Installing fuel system (Part 1) ......... W5-8-3
Reassembling starter ...................... W5-12-15
Installing fuel system (Part 2) ......... W5-8-4
Disassembling and inspecting
Replacing fuel pump ....................... W5-8-5 alternator........................................ W5-12-18
Inspecting alternator ....................... W5-12-23
Group 9 - Lubrication system
Reassembling alternator ................. W5-12-26
Removing and inspecting lubrication Performance test of alternator ........ W5-12-28
system................................................. W5-9-1
Installing electrical system .............. W5-12-29
Removing and inspecting oil filter
Installing starter............................... W5-12-29
and oil cooler ................................. W5-9-1
Installing alternator.......................... W5-12-30
Removing and inspecting oil pan
and breather .................................. W5-9-2 Replacing ECU ............................... W5-12-31
Installing sensors ............................ W5-12-32
reassembling lubrication system......... W5-9-3 Group 13 - Adjustment and operation
Disassembling and inspecting oil pumpW5-9-3
Adjusting engine................................... W5-13-1
Inspecting and adjusting oil pump .. W5-9-4
Inspecting and adjusting valve
Reassembling oil pump .................. W5-9-6
clearance ....................................... W5-13-1
Inspecting oil filter ........................... W5-9-7
Inspecting belt and adjusting belt
Inspecting relief valve ..................... W5-9-7 tension ........................................... W5-13-2
Inspecting safety valve ................... W5-9-7
Break-in operation................................ W5-13-3
Installing lubrication system ................. W5-9-8 Starting up....................................... W5-13-3
Installing oil filter and oil cooler ....... W5-9-8 Inspecting engine condition after
Installing oil pan and breather......... W5-9-9 starting up ...................................... W5-13-3
Break-in operation time ................... W5-13-3
Group 10 - Cooling system
Inspection and adjustment after
Removing cooling system .................... W5-10-1 break-in operation .......................... W5-13-3
Inspecting cooling system.................... W5-10-2 Performance test (jis standard) ............ W5-13-4
Checking water pump for smooth Engine equipment condition............ W5-13-4
rotation........................................... W5-10-2 Test items and purposes................. W5-13-4
Inspecting thermostat ..................... W5-10-2 Other inspections ............................ W5-13-4
Installing cooling system ...................... W5-10-3 Engine output adjustment ............... W5-13-4
Group 11 - Inlet and exhaust system Group 14 - Troubleshooting

Removing inlet and exhaust sysytem .. W5-11-1 Troubleshooting by diagnosis codes.... W5-14-1
Removing inlet system.................... W5-11-1 Outline of control system ................ W5-14-1
Removing exhaust system.............. W5-11-2 Diagnosis codes.............................. W5-14-1
Connecting scan tester and ECU.... W5-14-1
reassembling inlet and exhaust system.. W5-11-3 When ECU does not respond ......... W5-14-1
Scan tester ........................................... W5-14-2

Operation of scan tester.................. W5-14-2
Check engine status ....................... W5-14-3
Check diagnosis codes ................... W5-14-3
Check freeze data........................... W5-14-3
Clear diagnosis codes..................... W5-14-3
Diagnosis code cross reference........... W5-14-4
Troubleshooting reference chart .......... W5-14-6
Troubleshooting with diagnosis code.. W5-14-6
Related diagnosis code................... W5-14-20
Inspecting sensors ............................... W5-14-24
Speed/timing sensor (crank, cam) .. W5-14-24
Inlet manifold pressure sensor........ W5-14-24
Water temperature sensor .............. W5-14-24
Engine oil pressure switch .............. W5-14-25
Common rail pressure sensor ......... W5-14-25
Injector solenoid.............................. W5-14-25
High pressure pump solenoid
sensor (MPROP)............................ W5-14-25
Inspecting wiring .................................. W5-14-26
Inspecting connector and harness .. W5-14-26
Inspecting the intermittent fault ....... W5-14-26
Inspecting connectors ..................... W5-14-26
Inspecting harness.......................... W5-14-26
Inspect open circuit and short circuit... W5-14-26
Inspecting open circuit and short
circuit.............................................. W5-14-27
GENERAL E135B
GENERAL
External view
Engine left view
4
3 5
6
2
1
7
A B
12
11
8
10
9
SM2873
1- Fan 8- Starter
2- Thermostat 9- Oil pan
3- Front hanger 10 - Belt
4- Oil filler 11 - Crankshaft pulley
5- Exhaust manifold 12 - Alternator
6- Turbocharger A - Front
7- Rear hanger B - Rear
W5-1-1
E135B GENERAL
Engine right view
4
3
2
5
1 6
A B
11 9
10
SM2874
1- Oil filter 8- Fuel pump

2- Oil level gauge 9- Oil pump
3- Breather 10 - Flywheel
4- Inlet manifold 11 - Flywheel housing
5- Air heater A - Rear
6- Water pump B - Front
7- Common rail
W5-1-2
GENERAL E135B
System flow diagrams

Fuel system - flow diagram
SM2875
1- Common rail A - To fuel tank

2- Injector B - From fuel tank
3- Fuel pump
W5-1-3
E135B GENERAL
Lubrication system - flow diagram
2 3 4
5
1
15
7
14
8
13
9
12
10
11
SM2876
1- Camshaft 9- Oil pump

2- Tappet 10 - Oil strainer
3- Turbocharger 11 - Safety valve
4- Valve mechanism 12 - Crankshaft
5- Piston 13 - Relief valve
6- Piston cooling nozzle 14 - Oil cooler
7- Main gallery 15 - Oil filter
8- Timing gear
W5-1-4
GENERAL E135B
Cooling system - flow diagram
3
2
4
B 5
6
1
SM2877
1- Water jacket 5- Water pump

2- Cylinder head 6- Oil cooler
3- Thermostat A - Outlet
4- Bypass pipe B - Inlet
Inlet and exhaust system - flow diagram
A
B 2
SM2878
1- Muffler A - Inlet
2- Turbocharger B - Exhaust
3- Cylinder
W5-1-5
E135B GENERAL
Electrical system - wiring diagram
2
3
1
4
13
5
6
12
8
11
9
10
SM2879
1- Inlet manifold pressure sensor 8- High pressure pump solenoid sensor (MPROP)
2- Injector power supply 9- Connector
3- Air heater relay 10 - Electronic control unit
4- Water temperature sensor 11 - Engine oil pressure switch
5- Common rail pressure sensor 12 - Speed/timing sensor (Crankshaft side)
6- Speed/timing sensor (Camshaft side) 13 - Common rail
7- High pressure pump
W5-1-6
GENERAL E135B
Engine serial number location

The engine serial number (1) is stamped on the side
of the crankcase.
1
SM2880
Stamp location of engine serial number
W5-1-7
E135B GENERAL
Main specifications
Main specifications (1 / 3)
Engine model D04FR-74KW
Water cooled, 4 cycle diesel engine,
Type
turbocharged
No. of cylinders - arrangement 4 cylinder in-line
Combustion system Direct injection
Valve mechanism Overhead
Cylinder bore x stroke 102 x 130 mm (4.02 x 5.12 in)
Displacement 4.249 L (259 cu. in)
Compression ratio 17.8
Main specification
Fuel Diesel fuel
Firing order 1-3-4-2
Counterclockwise when viewed from
Direction of rotation
flywheel side
Dimensions Length 911 mm (35.87 in)

(varies depending on the Width 719 mm (28.3 in)
specifications) Height 940 mm (37.0 in)
Dry weight Approx. 395 kg (878.8 lbs)
Cylinder sleeve type Dry
Compression ring 2
Number of piston ring
Oil ring 1 (with expander)
Open BTDC 15°
Inlet valve
Valve timing Close ABDC 45°
Engine main parts (when engine is hot) Open BBDC 49°
Exhaust valve
Close ATDC 15°
Open ATDC 21°
Internal EGR valve timing Exhaust valve
Close BBDC 55°
Starting system Starter
Starting aid system Air heater
Type Common rail fuel injection system
Fuel system Model number CP1H
Manufacturer Bosch Corporation
W5-1-8
GENERAL E135B
Forced circulation type (oil pump
Lubricating method
pressure feed type)
Classification API classification CF-4 or above class
Engine oil Total capacity
17.5 L (4.62 gal)
(including oil filter)
Type Gear type oil pump
Lubrication system Oil pump
Delivery capacity 40 L (10.57 gal) /1800 min-1
Type Piston valve type
Relief valve
Valve opening pressure 0.35 ± 0.05 MPa (50 ± 7 psi)
Oil cooler type Water-cooled, multi-plate type
Oil filter type Cartridge type paper element
Safety valve opening pressure 1.1 MPa (157 psi)
Cooling method Water-cooled, forced circulation
Coolant capacity (Engine water jacket) 6 L (1.6 gal) approx
Type Centrifugal
Water pump
Discharge capacity 133 L (35 gal) /1800 min-1
Cooling system Water pump pulley speed ratio Varies depending on the specifications
Fan belt type Ribbed belt
Fan Type Ø 600 mm (23.62 in)
Type Wax type
Thermostat
Valve opening temperature 71 ± 2 °C (160 ± 3.6 °F)
Inlet and exhaust Model number TD04HL
Turbocharger
system Qty 1
ECU Model number EDC16UC40
Control system
(Electronic Control Unit) Manufacturer Bosch Corporation
W5-1-9
E135B GENERAL
Manufacturer Nikko Electric Industry
Type 0-24000-0188
Pinion meshing type Pinion shift
Output 24 V – 5 kW
Qty 1
Ring gear and pinion ratio 10/127
Voltage 23 V
Starter No-load Current 85A or below
characteristics
Speed 3300 min-1 or more
Voltage 9V
Load
Current 1400A or below
characteristics
Torque 88.26 N·m (65 lbf·ft) or above
Minimam operating voltage 16 V or below
Electrical system
Minimam holding voltage 8 V or below
Manufacturer Nikko Electric Industry
Model number 0-35000-4838
Output 24 V – 50 A
Rated speed 5000 min-1
Alternator Direction of rotation Clockwise when viewed from pulley side
Drive system PK type, V ribbed, 12 ribs
Ground system One conductor (-) side
Regulated voltage 28.5 V ± 1 V
Temperature range tolarance -30 to +100 °C (-22 to +212 °F)
Type Electric heater
Air heater
Capacity 2.1 kW
Heater relay Fuse capacity 127 A
W5-1-10
GENERAL E135B
Tips on disassembling and reassembling
This service manual specifies the recommended

procedures to be followed when servicing Mitsubishi
engines. The manual also specifies the special tools
that are required for the work, and the basic safety
precautions to follow when working. Note that this
manual does not exhaustively cover potential
hazards that could occur during maintenance,
inspection and service work of engine. When
working on an engine, follow the relevant directions
given in this manual and observe the following
instructions:
Disassembling
1. Use correct tools and instruments. Serious
injury or damage to the engine will result from
using the wrong tools and instruments.
2. Use an overhaul stand or work bench if
necessary, and follow the disassembling
procedures described in this manual.
3. Keep the engine parts in order of removal to
prevent losing them.
4. Pay attention to assembling marks. Put your
marks on the parts, if necessary, to ensure
correct reassembling.
5. Carefully check each part for defects during
disassembling or cleaning. Do not miss
symptoms which can not be detected after
disassembling or cleaning.
6. When lifting or carrying heavy parts, exercise
utmost caution to ensure safety. Pay attention
to balance of heavy parts when handling. (Get
help, and use jacks, chain blocks and guide
bolts as necessary.)
Reassembling
1. Wash all engine parts, except such parts as oil
seals, O-rings and rubber sheets, in cleaning oil
and dry them with compressed air.
2. Use correct tools and instruments.
3. Use only high-quality lubricating oils and
greases of appropriate types. Be sure to apply
oil, grease or adhesive to the part wherever
specified.
4. Use a torque wrench to tighten parts correctly
when their tightening torques are specified.
Refer to "List of Tightening Torque".
5. Replace all gaskets and packings with new
ones unless specified otherwise. Apply
adhesive if necessary. Use only the proper
amount of adhesive.
W5-1-11
E135B GENERAL
NOTE:
W5-1-12
SERVICE DATA E135B
MAINTENANCE SERVICE DATA
Engine general
Maintenance service data table - Engine general

Unit: mm (in)
Inspection point Nominal Standard Limit Remark
Maximum revolution speed 2240 min-1 ± 10 min-1
Minimum revolution speed 1015 min-1 ± 20 min-1
When oil and water
2.9 MPa 2.6 MPa temperatures at
Compression pressure (at 300 min-1) (427 psi) (384 psi) 20 to 30°C (68 to
86 °F)
0.2 to 0.4 MPa 0.15 MPa
Rated speed Oil temperature at
Lubricating oil (28.4 to 56.9) (21.3 psi)
70 to 90 °C (158 to
pressure 0.1 MPa 0.05 MPa
Low idling 194 °F)
(14.2 psi) (7.1 psi)
Open BTDC 15°
Inlet
Close ABDC 45° ±3°
Valve timing
Open BBDC 49° (crank angle)
Exhaust
Close ATDC 15°
Internal EGR valve Open ATDC 21°

Exhaust
timing Close BBDC 55°
Valve clearance Inlet 0.25 (0.0098)

(when cold) Exhaust 0.40 (0.0157)
Deflection when
the belt forcefully
7 to 9 pressed with a
Fan belt deflection (0.276 to thumb
0.354) New fan belt
standard value 4 to 6
(0.158 to 0.236)
W5-2-1
E135B SERVICE DATA
Basic engine
Maintenance service data table - Basic engine (1 / 4)

Unit: mm (in)
Reface minimum as
possible. Total grinding
0.05 (0.0020) or
Crankcase Flatness of top surface 0.20 (0.008) thickness of crankcase
less
top and cylinder head
bottom is 0.2 max.
102.010 to
Ø 102 102.700 If limit 102.200 (4.0236) is
Inside diameter 102.045
(4.02) (4.0433) exceeded, use oversize
(4.0161 to 4.0175)
Cylinder sleeve, and hone to +0.010
0.01 (0.0004) or
sleeve Circularity to +0.045 (0.0004 to
less
0.0018). Use oversize
0.015 (0.0006) or piston and piston ring.
Cylindricality
less
If the measured value
exceeds the standard and
is less than the limit,
Clearance between main 0.050 to 0.118 0.200
replace bearing. If the
bearing and crank journal (0.0020 to 0.0046) (0.0079)
Main limit is exceeded, grind
bearing the crank journal, and use
undersize bearing.
0.100 to 0.264 Replace thrust plate. The
Width of thrust journals 0.300
(0.0039 to limit value means a play
(Thrust clearance) (0.0118)
0.01404) in the direction of thrust.
Ø 22 22.000 to 22.021 22.100 Repair limit: 102.200
Inside diameter
(0.87) (0.8661 to 0.8670) (0.8701) (4.0236)
Tappet hole Replace tappet if
Clearance between tappet 0.035 to 0.086 0.120
diameter of tappet hole is
and tappet hole (0.0014 to 0.0034) (0.0047)
+0.10 (0.0039) or less.
Clearance Front 0.04 to 0.09 0.15
Camshaft between bushing Middle (0.0016 to 0.0035) (0.0059) Replace bushing. (Ream
bushing and cam-shaft 0.04 to 0.119 0.15 if necessary.)
journal Rear
(0.0016 to 0.0047) (0.0059)
Reface minimum as
possible. Total grinding
Distortion of bottom 0.05 (0.0020) or 0.20
thickness of crankcase
Cylinder surface less (0.008)
top and cylinder head
head bottom is 0.2 max.
Compressed thickness of 1.7 ±0.05
gasket (0.07) (0.0020)
7.940 to 7.955 7.900
Inlet
Valve stem Ø8 (0.3126 to 0.3132) (0.3110)
diameter (0.315) 7.920 to 7.940 7.850
Exhaust
(0.3118 to 0.3126) (0.3091)
Valve and 0.055 to 0.085 0.150
Inlet
valve guide Clearance (0.0022 to 0.0033) (0.0059)
between guide
and stem 0.070 to 0.105 0.200
Exhaust
(0.0028 to 0.0041) (0.0079)
17 17.2 to 17.4
Height to top of valve guide
(0.669) (0.6772 to 0.6850)
W5-2-2
SERVICE DATA E135B

Unit: mm (in)
Valve seat angle Inlet

30°
(D) Exhaust
0.4 0.3 to 0.5 1.1
Inlet
Valve sinkage (0.016) (0.0118 to 0.0197) (0.0433)
(C) 0.5 0.4 to 0.6 1.1
Exhaust
Valve seat (0.020) (0.0157 to 0.0236) (0.0433)
and valve
Inlet 1.4 1.2 to 1.6 1.8
Seat width (A)
Exhaust (0.055) (0.0472 to 0.0630) (0.071)
Refacing
2.13 2.13 permissible up
Valve margin (B)
(0.084) (0.084) to 1.2
(0.047)
56.40 55.00
Free length
(2.221) (2.165)
ș = 2.0°or less
¨ = 2.0
Perpendicularity ¨ = 2.0 (0.079) or (0.079)over
Valve less
entire length
springs Lf = 56.4 (2.221)
44.0 /222.7 to
246.1 N 44.0 /207 N
Set length/load
(164.2 to 181.5 (153.3 lbf)
lbf)
Rocker bushing inside Ø 20 20.011 to 20.094
diameter (0.79) (0.7878 to 0.7911)
Ø 20 19.966 to 19.984
Rocker arm Rocker shaft diameter
(0.79) (0.7861 to 0.7868)
Clearance between rocker 0.027 to 0.128 0.150
bushing and rocker shaft (0.0011 to 0.0050) (0.0059)
0.4
Pushrod Runout 0.4 (0.016) or less TIR
(0.016)
W5-2-3
E135B SERVICE DATA

Unit: mm (in)
Runout 0.04 (0.0016) or less 0.10 (0.0039) TIR
If the diameter is the limit or
more, replace bearing. If the
Ø 90 89.95 to 89.97 89.85 diameter is less than the
Crank journal diameter
(3.54) (3.5413 to 3.5421) (3.5374) limit, grind the journal and
use undersize bearing.
Service limit: 89.10 (3.5079)
Ø 65 64.945 to 64.965 64.800
Crankpin diameter
(2.56) (2.5569 to 2.5577) (2.5512)
Distance between centers 65 ± 0.05
of journal and crankpin (2.56) (± 0.002)
Pin maximum
Parallelism between
defection: 0.01
journal and crankpin
Crankshaft (0.0004) or less
Roundness of journals and
0.01 (0.0004) or 0.03
crankpins
less (0.0012)
(diameter difference)
Cylindericity of journals
0.01 (0.0004) or 0.03
and crankpins
less (0.0012)
(diameter difference)
Fillet radius of journals R3 ± 0.2 (± 0.008)
Fillet radius of pins R4 ± 0.2 (± 0.008)
If end play is less than the
limit, replace thrust plates. If
0.100 to 0.264 0.300
End play end play exceeds the limit,
(0.0039 to 0.0104) (0.0018)
replace with oversize thrust
plates.
101.915 to 101.945 101.730
STD
(4.0124 to 4.0136) (4.0051)
0.25
Outside 102.165 to 102.195 101.980
(0.0098)/ Ø 102
diameter (4.0222 to 4.0234) (4.0150)
OS (4.02)
(at piston skirt)
0.50
102.415 to 102.445 102.230
(0.0197)/
(4.0321 to 4.0333) (4.0248)
OS
Bearing clearance check,
0.8 Gasket compressed
Protrusion from creankcase
(0.031) (installed) thickness: 1.7 ±
0.05 (0.067 ± 0.0020)
Pistons
Crearance between piston 0.005 to 0.021 0.050
pin hole and piston pin (0.0002 to 0.0008) (0.0020)
Weight difference in one 5.0 g (0.2 oz.) or
engine less
No.1
0.08 to 0.12 0.200
compres
(0.0031 to 0.0047) (0.0079)
Clearance sion ring
between piston No.2
0.08 to 0.12 0.150
ring and ring compres
(0.0031 to 0.0047) (0.0059)
groove sion ring
0.025 to 0.065 0.150
Oil ring
(0.0010 to 0.0026) (0.0059)
Compres 0.30 to 0.45
sion rings (0.0118 to 0.0177) 1.50
Piston ring End gap
0.30 to 0.50 (0.059)
Oil ring
(0.0118 to 0.0197)
W5-2-4
SERVICE DATA E135B

Unit: mm (in)
Ø 34 33.991 to 33.997
Outside diameter
(1.34) (1.3382 to 1.3385)
Clearance between pin and 0.023 to 0.054 0.080
Piston pin
connecting rod bushing (0.0009 to 0.0021) (0.0031)
Ø 34 34.020 to 34.045
Inside diameter of bushing
(1.34) (1.3394 to 1.3404)
0.05/100 (0.0020/ 0.150
Bend and twist
3.94) or less (0.0059)
Clearance between crankpin 0.035 to 0.100 0.200
Connecting and connecting rod bearing (0.0014 to 0.0039) (0.0079)
rod 0.15 to 0.35 0.50 Replace connecting rod
End play
(0.0059 to 0.0138) (0.0197) bearings.
Weight difference in one 10 g (0.4 oz.) or
engine less
0.15 (0.0059) or 0.5
Flatness
less (0.0197)
Flywheel
0.15 (0.0059) or 0.5
Runout
less (0.0197)
0.04 (0.0016) or 0.10 TIR Repair using a press, or
Runout
less (0.0039) replace.
Major axis
Major axis - minor Major axis -
46.911 +0.1 A
Inlet -0.3 axis = 6.689 minor axis =
(1.8469 +0.004 (0.2633) 6.189 (0.2437)
-0.012)
Cam lift
Major axis
Major axis - minor Major axis - B
46.256 +0.1
Camshaft Exhaust -0.3 axis = 6.229 minor axis =
(1.8211 +0.004 (0.2452) 5.729 (0.2256)
-0.012)
Front, Ø 54 53.94 to 53.96 53.90

Journal middle (2.13) (2.1236 to 2.1244) (2.1220)
diameter Ø 53 52.94 to 52.96 52.90
Rear
(2.09) (2.0842 to 2.0850) (2.0827)
0.10 to 0.25 0.30
End play Replace thrust plate.
(0.0039 to 0.0098) (0.0118)
Clearance between idler 0.009 to 0.050 0.100
Replace bushing.
bushing and shaft (0.0004 to 0.0020) (0.0039)
0.05 to 0.20 0.35
Idler Idler gear end play Replace thrust plate.
(0.0020 to 0.0079) (0.0138)
Interference between shaft 35 -0.016 to -0.035
and crankcase hole (1.38) (-0.0006 to -0.0138)
Between crankshaft gear 0.053 to 0.154 0.25
and idler gear (0.0021 to 0.0061) (0.0098)
Between camshaft gear 0.049 to 0.160 0.25
and idler gear (0.0019 to 0.0063) (0.0098)
Timing gear
Between injection pump 0.050 to 0.228 0.25 Replace gear.
backlash
idler gear and idler gear (0.0020 to 0.0090) (0.0098)
Between injection pump
0.044 to 0.163 0.25
idler gear and injection
(0.0017 to 0.0064) (0.0098)
pump gear
W5-2-5
E135B SERVICE DATA
Lubrication system
Maintenance service data table - Lubrication system

Unit: mm (in)
Backlash between the oil pump idler 0.051 to 0.197 0.35
gear and the idler gear (0.0020 to 0.0078) (0.0138)
Replace gear.
Backlash between the oil pump idler 0.049 to 0.166 0.35
gear and the oil pump drive gear (0.0019 to 0.0065) (0.0138)
-0.01 to 0.054 0.150
End clearance of gears in case
(-0.0004 to 0.0021) (0.0059)
0.05 to 0.098 0.100
Radial clearance of gear in case
(0.0020 to 0.0039) (0.0039)
Oil pump Clearance between gear shaft and
0.04 to 0.07 0.15
pump body, and clearance between
(0.0016 to 0.0028) (0.0059)
gear shaft and pump cover.
Ø 25 24.939 to 24.960
Spindle outside diameter
(0.98) (0.9818 to 0.9827)
Oil pump idler gear bushing inside Ø 25 25.000 to 25.021
diameter (0.98) (0.9843 to 0.9851)
0.10 to 0.27
Oil pump idler gear end play
(0.0039 to 0.0106)
0.35 ± 0.05 MPa
Relief valve Valve opening pressure
(49.8 ± 7.1 psi)
1.1 MPa
Safety valve Valve opening pressure
(157 psi)
Cooling system
Maintenance service data table - Cooling system

Unit: mm (in)
71 ± 2 °C
Thermostat Valve opening temperature
(160 ± 3.6 °F)
Temperature at which valve lift 85 °C
becomes 10 mm (0.039 in.) or more (185 °F)
Inlet and exhaust system
Maintenance service data table - Inlet and exhaust system

Unit: mm (in)
Distortion of exhaust manifold 0.2 (0.008) or less
W5-2-6
SERVICE DATA E135B
Electrical system
Maintenance service data table - Electrical system

Unit: mm (in)
0.06
Armature shaft runout TIR
(0.0024)
0.10
Commutator runout
(0.0039)
0.7 to 0.9 0.2
Undercut depth
Starter (0.028 to 0.035) (0.008)
17 to 18 10
Height
(0.67 to 0.71) (0.39)
Brush Less than
Spring 21.56 to 27.44 N
21.56 N
tension (15.9 to 20.3 lbf)
(15.9 lbf)
25 °C (77 °F)
Alternator Adjusting voltage 27.5 to 29.5 V
l=2
W5-2-7
E135B SERVICE DATA
LIST OF TIGHTENING TORQUE
Major bolts and nuts tightening torque

Basic engine
Major bolts and nuts tightening torque - Basic engine

Threads Tightening torque
Description Remark
Dia x Pitch (mm) Nm lbf·ft
Cylinder head bolt 12 x 1.75 137 ± 5 101 ± 3.6
Rocker cover bolt 8 x 1.25 20 ± 2 14.5 ± 1.4
Rocker shaft bracket bolt 8 x 1.25 19 ± 2 13.7 ± 1.4
Rocker arm adjusting nut 8 x 1.25 20 ± 2 14.5 ± 1.4
Main bearing cap bolt 14 x 2 137 ± 5 101 ± 3.6
Connecting rod cap nut 12 x 1.25 103 ± 5 76 ± 3.6
Flywheel bolt 12 x 1.25 83 ± 5 62 ± 3.6
Camshaft thrust plate bolt 8 x 1.25 12 ± 2 9 ± 1.4
8 x 1.25 19 ± 2 13.7 ± 1.4
Front plate bolt
10 x 1.5 35 ± 5 25.3 ± 3.6
8 x 1.25 19 ± 2 13.7 ± 1.4
Timing gear case bolt
10 x 1.5 35 ± 5 25.3 ± 3.6
Crankshaft pulley nut 30 x 1.5 706 ± 59 521 ± 43
Idler thrust plate bolt 10 x 1.25 34 ± 5 25 ± 3.6
Piston cooling nozzle 12 x 1.25 34 ± 5 25 ± 3.6
Oil pan bolt 8 x 1.25 19 ± 2 13.7 ± 1.4
Oil pan drain cock 24 x 1.5 49 ± 5 36 ± 3.6
Oil pan drain plug 24 x 1.5 59 ± 5 43.4 ± 3.6
Lifting bolt 12 x 1.75 102 ± 10 75.2 ± 7.2
W5-2-8
SERVICE DATA E135B
Fuel system
Major bolts and nuts tightening torque - Fuel system

Description Remark
Nozzle gland 8 x 1.25 30 ± 3.0 22.4 ± 2.2
Fuel pump fuel relief joint mouting 25 +2.5 18 +1.8
12 x 1.25
eye bolt 0 0
Fuel pump gear nut 14 x 1.5 70 ± 5 51.4 ± 3.6

Fuel injection pipe nut (Injector
14 x 1.5 25 ± 3 18.1 ± 2.2
side, Rail side)
Fuel pump fuel supply high
14 x 1.5 25 ± 3 18.1 ± 2.2
pressure pipe (Rail side)
Fuel pump fuel supply high
12 x 1.5 20 ± 2.0 14.5 ± 1.4
pressure pipe (Pump side)
Fuel filter air bleed plug 14 x 1.5 21 ± 4 15.2 ± 2.9
Fuel filter fuel inlet eye bolt 14 x 1.5 21 ± 4 15.2 ± 2.9
Fuel filter fuel outlet eye bolt 14 x 1.5 21 ± 4 15.2 ± 2.9
Fuel pump mouting bolt 8 x 1.25 19 ± 2 13.7 ± 1.4
Fuel pump idler shaft wahsher
10 x 1.25 34 ± 5 25.3 ± 3.6
mouting bolt
Fuel pump idler shaft mouting bolt 12 x 1.25 112.2 ± 22 82.5 ± 15.9
Lubrication system
Major bolts and nuts tightening torque - Lubrication system

Description Remark
Relief valve 22 x 1.5 49 ± 4.9 36.2 ± 3.6
Relief valve plug 18 x 1.5 44 ± 4.9 32.5 ± 3.6
Safety valve 18 x 2.0 69 ± 4.9 50.6 ± 3.6
Oil pump cover bolt 10 x 1.5 35 ± 3.5 25.3 ± 2.4
Turbocharger oil feed eye bolt 10 x 1.25 17 ± 2 12.3 ± 1.4
Cooling system
Major bolts and nuts tightening torque - Cooling system

Description Remark
Fan and water pump pulley
10 x 1.5 49 ± 5 36.2 ± 3.6
mouting bolt
Water pump, oil pump mouting
10 x 1.5 35 ± 3.5 25.3 ± 2.4
bolt (together with gear case)
Water pump mouting bolt
8 x 1.25 19 ± 1.9 13.7 ± 1.4
(together with gear case)
W5-2-9
E135B SERVICE DATA
Inlet and exhaust system
Major bolts and nuts tightening torque - Inlet and exhaust system
Description Remark
Air heater terminal nut 6x1 9±1 6.5 ± 0.7
Air heater terminal flange nut 6x1 9±1 6.5 ± 0.7
Inlet manifold bolt 8 x 1.25 19 ± 2 13.7 ± 1.4
Exhaust manifold nut 8 x 1.25 19 ± 2 13.7 ± 1.4
Electrical system
Major bolts and nuts tightening torque - Electrical system

Description Remark
Starter mouting bolt 10 x 1.25 35.3 ± 5.9 255.4 ± 42.6
Starter B terminal 10 x 1.5 18 ± 2 13.3 ± 1.4
Starter protection cover screw 5 x 0.8 2.25 ± 0.25 1.6 ± 0.1
Starter through bolt 6x1 10.29 ± 2.45 7.2 ± 1.7
Alternator E terminal 6x1 5.9 ± 1 4.3 ± 0.7
Alternator B terminal 5 x 0.8 5.9 ± 1 4.3 ± 0.7
Alternator pulley nut 20 x 1.5 97 ± 12.7 71.6 ± 9.4
Alternator through bolt 6x1 5.9 ± 1 4.3 ± 0.7
Alternator mounting bolt 14 x 1.5 97 ± 9.7 71.6 ± 9.4
Sensors and ECM
Major bolts and nuts tightening torque - Sensors and ECM

Description Remark
Water temperature sensor 10 x 1.25 21 ± 2.1 15.2 ± 1.5
Inlet manifold pressure sensor R1/4 25 ± 2 18.1 ± 1.4
Engine oil pressure switch R1/8 10 ± 2 7.2 ± 1.4
Speed/timing sensor mouting bolt
6 x 1.0 9±1 6.5 ± 0.7
(camshaft, crankshaft)
ECU mouting bolt 6 x 1.0 8.0 ± 2 5.8 ± 1.4
Pickup mouting hexagon bolt 6 x 1.0 29.4 ± 4.9 212.8 ± 35.5
W5-2-10
SERVICE DATA E135B
Standard bolt and nut tightening torque
Standard bolt and nut tightening torque

Threads Width across Strength classification
Description Dia x Pitch flats mm
(mm) (in) 7T 10.9
Nm lbf·ft Nm lbf·ft
Metric automobile screw M8 x 1.25 12 (0.47) 17 13 30 22
thread M10 x 1.25 14 (0.55) 33 24 60 44
M12 x 1.25 17 (0.67) 60 44 108 80
M14 x 1.5 22 (0.87) 97 72 176 130
M16 x 1.5 24 (0.94) 145 107 262 193
M18 x 1.5 27 (1.06) 210 155 378 279
M20 x 1.5 30 (1.18) 291 215 524 386
M22 x 1.5 32 (1.26) 385 284 694 512
M24 x 1.5 36 (1.42) 487 359 878 648
M27 x 1.5 41 (1.61) 738 544 1328 979
Nm lbf·ft Nm lbf·ft
Metric course screw thread M10 x 1.5 14 (0.55) 32 24 58 43
M12 x 1.75 17 (0.67) 57 42 102 75
M14 x 2 22 (0.87) 93 69 167 123
M16 x 2 24 (0.94) 139 103 251 185
M18 x 2.5 27 (1.06) 194 143 350 258
M20 x 2.5 30 (1.18) 272 201 489 361
M22 x 2.5 32 (1.26) 363 268 654 482
M24 x 3 36 (1.42) 468 345 843 622
M27 x 3 41 (1.61) 686 506 1236 912
Note:
(a) This table lists the tightening torque for standard bolts and nuts.
(b) The numerical values in the table are for fasteners with spring washers.
(c) The table shows the standard values with a maximum tolerance value of ± 10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)
W5-2-11
E135B SERVICE DATA
Standard eyebolt tightening torque
Standard eyebolt tightening torque

Strength classification
Threads Width across flats
4T
Dia x Pitch (mm) mm (in)
Nm lbf·ft
M8 x 1.25 12 (0.47) 8±1 6 ± 0.7
M10 x 1.25 14 (0.55) 15 ± 2 11 ± 1.5
M12 x 1.25 17 (0.67) 25 ± 3 18 ± 2.2
M14 x 1.5 19 (0.75) 34 ± 4 25 ± 3.0
M16 x 1.5 22 (0.87) 44 ± 5 32 ± 3.7
M18 x 1.5 24 (0.94) 74 ± 5 55 ± 3.7
M20 x 1.5 27 (1.06) 98 ± 10 72 ± 7.4
M24 x 1.5 32 (1.26) 147 ± 15 108 ± 11.1
M27 x 1.5 41 (1.61) 226 ± 20 167 ± 14.8
(Dry)
Standard union nut tightening torque
Standard union nut tightening torque

Width
Nominal Cap nut size M
across flats Nm lbf·ft
diameter mm (in)
mm (in)
63 M14 × 1.5 19 (0.75) 39 29
80 M16 × 1.5 22 (0.87) 49 36
100 M20 × 1.5 27 (1.06) 78 58
120 M22 × 1.5 30 (1.18) 98 72
150 M27 × 1.5 32 (1.26) 157 116
180 M30 × 1.5 36 (1.42) 196 145
200 M30 × 1.5 36 (1.42) 196 145
220 M33 × 1.5 41 (1.61) 245 181
254 M36 × 1.5 41 (1.61) 294 217
(Maximum tolerance value: ±10%, dry condition)
W5-2-12
SERVICE TOOLS E135B
SPECIAL TOOLS
Special tool list (1 / 3)

Tool name Part number Illustration Use
Valve guide installer 32F91-00400 Valve guide installation
Valve guide remover 31391-10500 Valve guide removal
36791-00200 (Inlet)
Insert caulking tool Valve seat installation
36791-00300 (Exhaust)
Sleeve installer 34291-00200 Cylinder sleeve installation
Piston ring removal/

Piston ring pliers 30091-07100
installation
Piston guide 34291-00100 Piston installation
Injector remover 32G91-00100 Injector removal
W5-3-1
E135B SERVICE TOOLS

Idler shaft puller MH061077 Idler shaft removal
Idler bushing removal/

Idler bushing puller 30091-07300
installation
Connecting rod bushing Connecting rod bushing

32F91-03050
installer removal/installation
Oil and fuel filters removal/

Oil filter wrench 34591-00100
installation
Fuel injection pump

Universal extension 30091-01101
removal/installation
Socket 58309-73100 Engine turning
Engine compression
Gauge adapter 32G91-00500
pressure measurement
W5-3-2
SERVICE TOOLS E135B

Removal for crankshaft

Puller assembly 64309-12900 gear, camshaft gear and
crankshaft pulley
Compression pressure
Compression gauge 33391-02100
measurement
Oil seal sleeve installation

Rear oil seal installer 34291-00020
on the crankshaft rear side
Camshaft bushing installer Camshaft bushing

30691-00010
set removal/ installation
Camshaft bushing
Valve spring pusher 30691-04500 removal/ Valve removal/
installation
Scan tester 32G91-00600 Diagnosis codes display
W5-3-3
E135B SERVICE TOOLS
NOTE:
W5-3-4
DETERMINATION OF OVERHAUL E135B
DETERMINING OVERHAUL TIMING
In most cases, the engine should be overhauled when the compression pressure of the engine becomes low.
An increase in engine oil consumption and blow-by gas are also considered to evaluate the engine condition.
Besides, such symptoms as a decrease in output, increase in fuel consumption, decrease in oil pressure,
difficulty of engine starting and increase in noise are also considered for judging the overhaul timing, although
those symptoms are often affected by other causes, and are not always effective to judge the overhaul timing.
Decreased compression pressure shows a variety of symptoms and engine conditions, thus making it difficult
to accurately determine when the engine needs an overhaul. The following shows typical problems caused by
reduced compression pressure.
1. Decreased output power
2. Increased fuel consumption
3. Increased engine oil consumption
4. Increased blow-by gas through the breather due to worn cylinder liners and piston rings (Visually check
the blow-by amount)
5. Increased gas leakage due to poor seating of inlet and exhaust valves
6. Difficulty in starting
7. Increased noise from engine parts
8. Abnormal exhaust color after warm-up operation
The engine can exhibit these conditions in various combinations. Some of these problems are directly caused
by worn engine parts, while others are not. Phenomena described in items (2) and (6) will result from improper
fuel injection volume, fuel injection timing, worn plunger, faulty nozzles and also faulty conditions of electrical
devices such as battery and starter. The most valid reason to overhaul an engine is a decrease in compression
pressure due to worn cylinder liners and pistons, as described in item (4). In addition to this item, it is
reasonable to take other problems into consideration for making the total judgement.
W5-4-1
E135B DETERMINATION OF OVERHAUL
TESTING COMPRESSION PRESSURE
CAUTION
a) Measure all cylinders for compression
B
pressure.
Do not measure only one cylinder and make
assumption about the other cylinders as it will A
lead to a wrong conclusion.
b) Compression pressure varies depending on the
engine speed. When measuring the
compression pressure, be sure to measure the
engine speed as well.
c) It is important to regularly check the SM2881
compression pressure so that you can tell the Testing compression pressure
change with time.
1. Disonnect the harness connector from the

injector solenoid connector.
2. Disconnect the harness connector from the
MPROP connector on the fuel pump.
3. Select a cylinder, and remove the injector in the
cylinder. (Each cylinder is tested one at a time.)
4. Install a gauge adapter P/N: 32G91-00500 (A)
in the same location that the injector was
mounted, and install a compression gauge P/N:
33391-02100 (B) to the gauge adapter (A).
5. Start the engine using starter. With the engine
running at specified speed, read the
compression gauge (B).
6. If the measured value is at the limit or below,
overhaul the engine.
Item Standard Limit

Engine speed -1 -
300 min
2.9 MPa 2.6 MPa (384
Compression pressure
(427 psi) psi) or more
W5-4-2
DISASSEMBLY OF BASIC ENGINE E135B
DISASSEMBLING AND INSPECTING CYLINDER HEAD AND VALVE MECHANISM
Wear, damage
Wear, clogging
Wear
Fatigue, damage
Wear, damage,
bend
Wear,
clogging
Fatigue, damage
Local wear
Replace
Crack, damage,
water leak, oil leak,
carbon deposit,
Replace scale deposit
Local wear, damage,

Local wear fatigue, carbon deposit
SM2882
Disassembling and inspecting cylinder head and valve mechanism
Disassembling sequence
1- Leak off hose 13 - Rocker shaft
2- Nozzle ground 14 - Cylinder head bolt
3- Injector 15 - Cylinder head
4- Rocker cover 16 - Cylinder head gasket
5- Rocker cover gasket 17 - Valve cap
6- Adjusting screw 18 - Valve cotter
7- Bolt (short) 19 - Valve retainer
8- Bolt (long) 20 - Valve spring
9- Eye bolt, oil pipe 21 - Valve, valve seat
10 - Snap ring, spacer 22 - Valve guide, stem seal
11 - Rocker arm 23 - Push rod
12 - Rocker shaft spring
W5-5-1
E135B DISASSEMBLY OF BASIC ENGINE
Removing injector
1. Hold the injection connector (5) by using a
spanner, loosen the injection pipe (4) nut and 1
remove the injection pipe.
2
8
2. With pushing (A) the pin (3) on top of the
3
injector (8), remove the leak off hose (2).
3. Disconnect the harness connector of main
harness and injector connector (5). 7
4
4. Using the injector puller P/N: 32G91-00100 (9),
remove the injector (8) and the nozzle ground 5
(7) at the same time. 6
SM2883
5. Remove the gasket (6) from the cylinder head
Removing injector
injector insertion opening.
A
3
SM2884
Pushing pin on top of injector
8
SM2885
Pulling out injector
W5-5-2
Removing rocker shaft assembly
CAUTION 1
Always loosen shorter bolts first. Failing to do so
may cause the damage to the rocker shaft bracket.
1. Loosen the rocker arm (3) adjusting screws (1)

by rotating about one turn.
2. Loosen the shorter rocker bracket bolts (2) first.
3. Then, loosen the longer rocker bracket bolts. 3
4. Remove the rokcer bracket bolts, and remove
the rocker shaft assembly from the cylinder 2
SM2886
head.
Removing rocker shaft assembly
5. Remove push rods.
Disassembling rocker shaft assembly

1. Remove eye bolt (5), oil pipe (6), and snap ring
(4).
2. Disassemble the rocker shaft (7) assembly into
the rocker arms (3), brakets (2), rocker shaft
1
springs (1) and rocker shaft (7).
7
NOTE: 6 2
(a) Be sure to arrange the parts of rocker shaft 3
assembly in the order of disassembly. 4
Reassemble the rocker shaft assembly in the
reverse order of disassembly by making sure of 5
SM2887
the original combination of rocker arm and shaft Disassembling rocker shaft assembly
assembly so that the same clearance between
the rocker shaft and arms is restored when
reassembling.
(b) Do not remove the rocker bush when it is not
faulty, and its inside diameter is not exceed the
limit.
Removing cylinder head bolt

Loosen cylinder head bolts in the numerical order as
shown in the illustration.
SM2888
Removing cylinder head bolt
W5-5-3
Removing cylinder head assembly
CAUTION
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase
surface by tools such as a screwdriver.
1. Remove the cylinder head bolt.

2. Remove the cylinder head assembly by lifting it
up.
NOTE: if the cylinder head assembly cannot be

removed due to crimping of the cylinder head
SM2889
gasket, tap the thick area on the side of the cylinder Removing cylinder head assembly
head using a plastic hammer to give a shock.
3. Remove the gasket from the cylinder head.
NOTE: if there is a cylinder head problem, check the

bolts for tightness with a torque wrench before
removing the cylinder head bolts.
Removing valve and valve spring

Using a valve spring pusher P/N: 300691-04500 (1),
compress the valve spring evenly and remove the
valve cotters. 1
NOTE: if valves are reusable, mark each valve seat

and the mating valve guide for identifying their
original positions. Do not mix valve seats with other
valve guides.
SM2890
Removing valve and valve spring
Removing valve stem seal

Grab the stem seal (1) with pliers and remove.
NOTE: be sure to replace the stem seal with the

new one when reassembling the valve and valve
spring. 1
SM2891
Removing valve stem seal
W5-5-4
DISASSEMBLING AND INSPECTING FLYWHEEL
Replace
Replace
Wear, damage, aging
Wear, crack, damage
SM2892
Disassembling and inspecting flywheel
1- Flywheel 4- Pick up
2- Flywheel housing 5- Speed/timing sensor (crankshaft side), sensor
3- Oil seal bracket
W5-5-5
Removing flywheel
CAUTION
Be careful not to cut yourself with the ring gear when
pulling out the flywheel.
Be careful not to drop or hit the flywheel when
removing.
The personnel who holds the pulley must pay due
attention to safety. Also, personnel must stay in
close contact with each other during work.
1. One personnel must firmly hold the pulley (1) 2

with a wrench to prevent the flywheel from 1
A B
turning. SM2893
Removing flywheel
2. Remove one bolt from the flywheel. A - Front
3. Screw a guide bolt (2) into the threaded hole of B - Rear
the bolt that has been removed.
4. Remove remaining bolts from the flywheel.
5. Hold the flywheel firmly with both hands, and by
moving it back and forth, pull it out straight.
NOTE: the ring gear is shrink fitted to the flywheel.

Do not remove the ring gear unless it is defective.
Removing flywheel housing
CAUTION
Be careful not to damage the oil seal.
1. Remove bolts from the flywheel housing.

2. Remove the flywheel housing.
SM2894
Removing flywheel housing
W5-5-6
DISASSEMBLING AND INSPECTING GEAR CASE, TIMING GEAR AND CAMSHAFT
Damage, wear
Flaking, contact, damage, Oil hole clogging, wear
abnormality
Replace
10
7
6 Wear
9
Wear
4
Wear, damage,
5 8 11 aging
Crack, dowel hole defect,

oil hole clogging
Replace
Wear
2
1
SM2895
Disassembling and inspecting gear case, timing gear and camshaft
1- Crankshaft pulley 7- Camshaft
2- Timing gear case 8- Camshaft gear
3- Oil seal 9- Tappet
4- Thrust plate 10 - Fuel pump gear, Fuel pump idler gear
5- Idler gear 11 - Front plate
6- Thrust plate
Removing crankshaft pulley
CAUTION
The bar that stops the the crankshaft from turning
may come off. Pay due attention to safety.
1. Screw two guide bolts into the threaded holes

at the rear end of the crankshaft. Stick a bar
across the guide bolts (2) to prevent the
crankshaft from turning.
2. Remove the crankshaft pulley (1).
3. Take out the woodruff key of the crankshaft. 1 2
A B
SM2896
SM2896
Removing crankshaft pulley

A - Front
B - Rear
W5-5-7
Removing timing gear case
CAUTION
The front plate is bolted to the crankcase from inside 1
the gear case. Do not attempt to remove the front
plate together with the gear case by tapping.
1. Remove bolts from the timing gear case (1).

2. Remove the timing gear case.
NOTE: bolts have different lengths. Pay attention to

the positions of bolts to ensure correct 2
reassembling.
SM2897
Removing timing gear case
Measuring timing gear backlash

Measure the backlash of the timing gears by using
one of the following two methods; measure the gear
play with the dial gauge plunger applied to a tooth
flank on the pitch circle at a right angle to the tooth
axis, or measure the clearance between gears by
inserting a feeler gauge between the gears at the
tooth-to-tooth contacting area. Replace the faulty
gear pair if the limit is exceeded.
Item Standard Limit

Backlash crankshaft gear 0.053 to 0.154 mm 0.25 mm
and idler gear (0.0021 to 0.0061 in) (0.0098 in) SM2898
Backlash camshaft gear 0.049 to 0.160 mm 0.25 mm Measuring timing gear backlash
and idler gear (0.0019 to 0.0063 in) (0.0098 in)
Backlash Fuel injection
0.050 to 0.228 mm 0.25 mm
pump idler gear and idler
(0.0020 to 0.0090 in) (0.0098 in)
gear
Backlash fuel injection
0.044 to 0.163 mm 0.25 mm
pump idler gear and fuel
(0.0017 to 0.0064 in) (0.0098 in)
injection pump gear
NOTE: with the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump,
install the both gears to the front plate.
Measuring idler gear end play

Using a feeler gauge or dial gauge, measure the
end play of idler gear.
If the measured value exceeds the limit, replace the
idler gear (1) with the new gear.
Item Standard Limit

0.05 to 0.20 mm 0.35 mm
End play
(0.0020 to 0.0079 in) (0.0138 in)
SM2899
W5-5-8
Removing idler gear

1. Remove the thrust plate (2) bolt.
2. Remove the idler gear (1) while turning the
gear.
1
2 SM2900
Removing idler gear
Removing camshaft
CAUTION
Be careful not to damage the cams of camshaft and
the bushings.
1
1. Reverse the crankcase.
2. Remove the thrust plate bolt.
3. Remove the camshaft from the crankcase.
4. Remove the tappet.
SM3251
Removing camshaft
Separating camshaft gear

Using a puller P/N: 64309-12900 (2), remove the
camshaft gear (1) and thrust plate from the
camshaft 2
1
NOTE: do not remove the camshaft gear from the
camshaft unless the camshaft gear or the thrust
plate is defective.
SM3252
Separating camshaft gear
W5-5-9
Installing camshaft gear and thrust plate

1. Install the woodruff key and the thrust plate (1)
on the crankshaft.
NOTE: be sure to install the thrust plate before

installing the camshaft gear (2).
2. Heat the camshaft gear with a gear heater to a

temperature of about 250°C. 1
3. Install the camshaft gear into the crankcase by
tapping with a plastic hammer. 2
SM3253
Installing camshaft gear and thrust platet
Removing front plate

1. Remove the front plate (1) bolts.
2. Remove the front plate from the crankcase. 1
NOTE: if it is difficult to remove the front plate, lightly

tap it with a plastic hammer.
SM3254
Removing front plate
W5-5-10
DISASSEMBLING AND INSPECTION CRANKCASE, CRANKSHAFT AND PISTON
Wear, scratch, rust

4
Wear, damage
5 Top surface distortion
6 Fatigue
9
Wear Scratch, crack, damage, Scale deposit,
wear, carbon deposit corrosion, flaking
8
7
Wear, crack,
oil hole clogging
19
Wear, oil hole
clogging
Damage 10
3 17
18
Wear, seizure,
flaking, damage
Scratch, crack, dent,
2 Clogging
oil hole clogging, wear
1
16
Flaking,
local contact 14
15
Replace
12 13
Scratch, seizure,
flaking Damage
11
Crack
SM3255
Disassembling and inspection crankcase, crankshaft and piston
1- Nut 11 - Main bearing cap bolt
2- Connecting rod cap 12 - Main bearing cap
3- Connecting rod bearing 13 - Side seal
4- No.1 compression ring 14 - Thrust plate
5- No.2 compression ring 15 - Main bearing (lower)
6- Oil ring 16 - Crankshaft
7- Snap ring 17 - Main bearing (upper)
8- Piston pin 18 - Piston cooling nozzle
9- Piston 19 - Crankcase
10 - Connecting rod
W5-5-11
Removing connecting rod cap

1. Lay the engine by its side.
2. Mark the cylinder number on the connecting rod
and connecting rod cap (1) so that their
combination is not changed when
reassembling.
3. Remove the connecting rod caps.
1
NOTE: mark the cylinder No. and upper/lower on
connecting rod bearings to ensure correct
reassembling.
SM3256
Removing connecting rod cap
Removing carbon deposits from the upper part

of cylinder liner
CAUTION
Be sure to remove carbon deposits from the upper
part of the cylinder liner before removing the piston,
as they could cause damage to the piston and
piston ring.
Remove carbon deposits from the upper part of
cylinder liner using a cloth or oil paper.
NOTE: be careful not to damage the inner surface

of the cylinder liner.
SM3257
Removing carbon deposit from cylinder sleeve upper area
Pulling out piston

1. Turn the crankshaft to bring the piston to the top
dead center.
2. Using a piece of wood such a hammer handle,
push the mating surface of the connecting rod
cap, and pull the piston and connecting rod
upward from the cylinder.
SM3258
Pulling out piston
W5-5-12
Removing piston ring

1. Remove the piston rings using piston ring pliers
P/N: 30091-07100 (1).
1
SM3259
Removing piston ring
Removing piston pin

1. Using snap ring pliers (1), remove the snap
ring.
2. Remove the piston pin, and separate the piston 1
from the connecting rod.
NOTE: heat the piston with a piston heater or in hot

water if the piston pin is stubborn.
SM3260
Removing piston pin
Removing main bearing cap

1. Reverse the engine.
2. Remove the main bearing cap bolt (2). 1
3. Remove the main bearing cap together with the
lower main bearing. Use a sliding hammer (1)
to remove main bearing caps on the front and
rear ends.
2
NOTE:
(a) Be careful not to damage main bearings.
(b) Mark each main bearing for its cylinder number.
SM3261
Removing main bearing cap
W5-5-13
Removing crankshaft
CAUTION
Be careful not to damage bearings when removing
the crankshaft.
1. Slowly lift the crankshaft straight up.

2. Arrange the bearings in the order of
disassembly so that their original positions are
restored when reassembling.
NOTE:
(a) When raising the crankshaft, do not allow wire SM3262
chain to come into contact with the crankshaft. Removing crankshaft
To avoid damage to the crankshaft when
raising, use a cloth belt or pad.
(b) Mark the bearings for their cylinder numbers.
W5-5-14
INSPECTION AND REPAIR OF BASIC ENGINE E135B
INSPECTING AND REPAIRING CYLINDER

HEAD AND VALVE MECHANISM
Measuring clearance between rocker bushing

and rocker shaft
Measure the rocker bushing inside diameter and the
rocker shaft diameter. If the clearance exceeds the
limit, replace either rocker bushing or rocker shaft
with a new one.
Item Nominal Standard Limit A

Rocker
Ø 20 mm 20.011 to 20.094 mm
bushing inside -
(0.7874 in) (0.7878 to 0.7911 in)
diameter
Rocker shaft Ø 20 mm 19.966 to 19.984 mm B
-
diameter (0.7874 in) (0.7861 to 0.7868 in)
Clearance SM3263
between 0.027 to 0.128 mm 0.150 mm Measuring rocker bushing and rocker shaft
-
rocker bushing (0.0011 to 0.0050 in) (0.0059in) A - Measuring directions
and shaft
B - Measuring points
Replacing rocker bushing

To replace rocker bushings (1), use a hydraulic jack.
With the rocker bushing and the rocker arm oil holes 1
(2) mated, and the bushing joint faced upward,
press fit the rocker bushing.
2
SM3264
Replacing rocker bushing
W5-6-1
E135B INSPECTION AND REPAIR OF BASIC ENGINE
Measuring valve stem outside diameter and

valve guide inside diameter
Measure the diameter at the top and bottom ends at
right angles to the outer and inner surfaces, since
valve stems and valve guides are more likely to
wear at both ends. If the outside diameter is less A
than the limit, or the clearance exceeds the limit,
replace either the valve or the valve guide with a
new one.
B
Item Nominal Standard Limit
Valve Ø 8 mm 7.940 to 7.955 mm 7.900 mm
Inlet
stem (0.315 in) (0.3126 to 0.3132 in) (0.3110 in)
outside Ø 8 mm 7.920 to 7.940 mm 7.850 mm
SM3265
diameter Exhaust Measuring valve stem outside diameter

(0.315 in) (0.3118 to 0.3126 in) (0.3091 in)
Clearance 0.055 to 0.085 mm 0.150 mm
Inlet -
between (0.0022 to 0.0033 in) (0.0059 in)
valve stem A
and valve Exhaust 0.070 to 0.105 mm 0.200 mm
-
(0.0028 to 0.0041 in) (0.0079 in)
C
guide
Valve guide 17 mm 17.2 to 17.4 mm
-
mounting dimension (0.67 in) (0.6772 to 0.6850 in)
A - Measuring directions
C - Internal micrometer
B
SM3266
Measuring valve guide inside diameter
Replacing valve guide
CAUTION
Because valve guides must be inserted to the 1
specified amount, be sure to use a valve guide
installer.
1. To remove valve guides, use a valve guide

remover P/N: 31391-10500 (1).
SM3267
Removing valve guide
2. To press-fit (A) valve guides, use a valve guide

A
17 mm (0.67 in)
installer P/N: 34491-00400 (2).

3. Check contacts between valves and valve 2
P/N:34491-00400
seats after replacing valve guides.
A - Press
SM3268
Press-fitting valve guide
W5-6-2
Inspecting valve face

Apply a thin coat of Shinmyoutan (2) or equivalent
lead-free coloring paste on the valve face, and strike
the valve face against the valve seat using a valve
lapper (1) to check for contact condition. If the
contact is not even, or any defects are found, or if
the limit is exceeded, reface or replace the valve see 1
picture ref. (A) and (B).
NOTE:
a) Inspect the valve face after the valve guide is
repaired or replaced. 2
b) Do not rotate the valve when pressing the valve SM3269
face coated with Shinmyoutan (2) or equivalent Inspecting valve face

lead-free dye against the valve seat. Inspecting
valve face.
c) Always lap the valve and valve seat after the
valve has been refaced or replaced.
Item Standard Limit

Valve seat angle 30° -
0.4 ± 0.1 mm
Inlet
Valve (0.0157 ± 0.0039 in) 1.1 mm
Valve
sinkage (0.043 in)
A B
seat 0.5 ± 0.1 mm
Exhaust
(0.0197 ± 0.0039 in)
SM3270
1.4 ± 0.2 mm 1.8 mm
Seat width
(0.0551 ± 0.0079 in) (0.071 in)
Contact between valve seat and valve
Refacing
2.13 mm permissible
Valve margin
(0.0839 in) up to 1.2 mm
(0.047 in)
C
A- Good
B- Bad
C- Seat width
D- Valve margin
D
E- Valve sinkage F
F- Valve seat angle E
SM3271
Measuring positions of valve seat and valve
Refacing valve face

If the valve face is significantly worn out, reface the
valve face using a valve refacer (1). 1
NOTE:
a) Grind the valve face using the valve refacer at
the specified angle.
b) Secure the valve margin width equal to or
greater than the limit. If the dimensions after A
refacing does not meet the specified values,
replace the valve with a new one.
A - Set the valve face angle at the specified SM3272
angle Refacing valve face
W5-6-3
Refacing valve seat

1. Use the valve seat cutter or valve seat grinder
to reface the valve seat. After refacing, sand the
valve seat lightly using 400 grit sandpaper,
inserting it between the cutter and valve seat.
2. Lap the valve in the valve seat.
NOTE:
a) Valve seat refacing should be kept to an
absolute minimum.
b) If the valve seat width exceeds the limit due to
wear or refacing, replace the valve seat with a SM3273
new one. Refacing valve seat
c) If the valve sinkage exceeds the limit after
refacing, replace the valve seat with a new one.
W5-6-4
Replacing valve seat

1. To remove the valve seat (3), weld (1) a stud (4)
to the valve seat (3) as illustrated. Then, insert
a rod into the valve guide hole from the top of
1
the cylinder head, and press out the valve seat
2
with the rod.
3
NOTE: be careful not to allow spatters to adhere to
the machined surface of the cylinder head during
welding.
2. Before inserting a new valve seat, measure the 4

cylinder head bore diameter and valve seat SM3274
outside diameter to make sure the interference Removing valve seat

meets the specified value.
3. Cool the valve seat for four minutes or more in
liquid nitrogen (at approximately -170 °C [-274 A B Unit: mm [in.]
°F]) before fitting it into the cylinder head, while
keeping the cylinder head at room temperature.
Or heat the cylinder head to 80 to 100 °C (176
to 212 °F) and cool the valve seat sufficiently in
ether or alcohol mixed with dry ice before fitting
it into the hot cylinder head.
4. Fit the cold valve seat into the cylinder head
using a insert caulking tool (5). 9 ± 0.1
[0.3543 ± 0.0039]
9.5 ± 0.1
[0.3740 ± 0.0039]
40° 45°
ø 48 +0.025
0 [ø 1.89 +0.0010
0 ] ø 39 +0.025
0 [ø 1.54 +0.0010
0 ]
SM3275
Valve seat fitting bore

A - Inlet
B - Exhaust
(In) P/N: 36791-00200

(Ex) P/N: 36791-00300 5
SM3276
Installing valve seat
W5-6-5
Lapping valve and valve seat

Always lap the valve against the valve seat after
refacing the valve seat or after replacing the valve.
1. Apply a thin coat of lapping compound (1)
evenly to the valve face.
NOTE:
a) Do not allow the compound to adhere on the
valve stem. 1
b) Compound spreads more evenly if it is mixed
with a small amount of engine oil.
c) Use medium-grain compound (120 to 150 SM3277
mesh) for initial lapping, then use fine-grain Coating valve with lapping
compound (200 mesh or finer) for finishing.
2. Use a valve lapper for lapping. Strike the valve

against the valve seat while rotating the valve
little by little.
3. Wash off the compound using diesel fuel.
4. Coat the contact surface of the valve with
engine oil, then lap the valve again.
5. Check valve-to-seat contact.
SM3278
Lapping valve and valve seat
Measuring perpendicularity and free length of

valve spring
Measure the perpendicularity and free length (2) of
the valve spring (1). If the limit is exceeded, replace
the valve spring with a new one.
1
Item Standard Limit
56.40 mm 55.00 mm
Free length
(2.2205 in) (2.1653 in)
ș = 2.0°or less 2
Less than
Entire length =
Perpendicu- ¨ 2.0 mm
larity (0.079 in) ¨ 2.0 mm
(0.079 in)
Lf = 56.40 mm SM3279
(2.2205 in) Measuring spring perpendicularity and free length
44 mm / 207 N
Set length / set 44 mm / 222.7 to 246.1 N
(1.73 in / 153
force (1.73 in / 164.2 to 181.5 lbf)
lbf)
W5-6-6
Measuring distortion of the bottom surface

of the cylinder head
CAUTION
Refacing of cylinder head should be kept to an
absolute minimum.
Excessive grinding of the cylinder head may result
in defects such as defective combustion and
stamping (contact between piston and valve).
With a straight edge placed on the bottom face of
the cylinder head, measure the bottom face
distortion using a feeler gauge. If the measurement
exceeds the limit, grind the Measuring distortion of
cylinder head bottom surface bottom face using a SM3280
surface grinder. Measuring distortion of cylinder head bottom surface
Item Standard Limit

0.05 mm
0.20 mm
Bottom surface distortion (0.0020 in)
(0.008 in)
or less
NOTE: do not grind the surfaces more than 0.2 mm

(0.008 in) in total (cylinder head bottom surface plus
crankcase top surface).
Measuring push rod runout

Measure the runout of each push rod (1). Replace if
the limit is exceeded.
Item Standard Limit Remark

Push rod 0.4 mm (0.016 in) 0.4 mm
TIR 1
runout or less (0.016 in)
SM3281
W5-6-7
Inspecting and repairing flywheel

Measuring flatness of flywheel
Place the flywheel on a surface plate and move a
dial gauge on the friction surface of the flywheel to
measure the flatness.
Grind the friction surface of the flywheel if the limit is
exceeded.
Item Standard Limit

0.15 mm
0.50 mm
Flywheel flatness (0.0059 in)
(0.0197 in)
or less
SM3282
Measuring flywheel face and radial runouts

Measure the runouts of the flywheel in the installed
condition. If the measured value exceeds the
standard, check the bolt for looseness as well as the
accumulation of foreign matter on the mounting
face.
1
Item Standard Limit
Flywheel face runout (1) Within 0.15 mm 0.50 mm 2
and radial runout (2) (0.0059 in) (0.0197 in)
SM3283
Measuring flywheel face and radial runout
Inspecting ring gear

Inspect the ring gear for a missing tooth or worn
teeth, and if defects are found, replace the ring gear.
Replacing ring gear

Removing ring gear
1. Heat the ring gear evenly using an acetylene
torch or other appropriate heat source.
2. With a rod placed on the periphery of ring gear,
tap the rod with a hammer evenly around the 1
ring gear, and remove the ring gear.
Installing ring gear

1. Heat the ring gear evenly up to approx. 150 °C
(176 °F) with an appropriate heater.
2
2. Install the ring gear (2) onto the flywheel (1)
with the no-gear-chamfering side faced to the SM3284
flywheel. Removing ring gear
NOTE: do not heat the ring gear excessively.
W5-6-8
INSPECTING AND REPAIRING TIMING GEAR

AND CAMSHAFT
Measuring timing gear backlash

Measure the backlash of the timing gears by using
one of the following two methods; measure the gear
play with the dial gauge plunger applied to a tooth
flank on the pitch circle at a right angle to the tooth
axis, or measure the clearance between gears by
inserting a feeler gauge between the gears at the
tooth-to-tooth contacting area. Replace the faulty
gear pair if the limit is exceeded.
Item Standard Limit
Backlash crankshaft gear 0.053 to 0.154 mm 0.25 mm
and idler gear (0.0021 to 0.0061 in) (0.0098 in)
SM3285
Backlash camshaft gear 0.049 to 0.160 mm 0.25 mm
and idler gear (0.0019 to 0.0063 in) (0.0098 in) Measuring timing gear backlash
Backlash Fuel injection pump 0.050 to 0.228 mm 0.25 mm
idler gear and idler gear (0.0020 to 0.0090 in) (0.0098 in)
Backlash fuel injection
0.044 to 0.163 mm 0.25 mm
pump idler gear and fuel
(0.0017 to 0.0064 in) (0.0098 in)
injection pump gear
NOTE: with the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump,
install the both gears to the front plate.
Measuring cam lift

Measure the minor and major axes of cam to
determine lobe lift. If the lift is less than the limit, 1
replace the camshaft with a new one.
2
Item Nominal Standard Limit A B
Major axis (1) Major axis – Major axis –
Minor axis (2) Minor axis =
Inlet 46.911 -0.3 mm
+0.1
= 6.689 mm 6.189 mm
(1.8469 +0.004 in) (0.2633 in) (0.2437 in)
Cam -0.012
lift Major axis – Major axis –

Major axis
Minor axis = Minor axis =
Exhaust 46.256+0.1
-0.3 mm
+0.004
6.229 mm 5.729 mm
(1.8211 -0.012 in) (0.2452 in) (0.2256 in)
SM3286
Measuring cam lift

Measuring camshaft runout

Measure the camshaft runout using a dial gauge. If
the limit is exceeded, correct the camshaft using a
press, or replace the camshaft with a new one.
NOTE: with a dial gauge set on the camshaft, rotate

the camshaft one turn and read the gauge
indication.
Item Standard Limit Remark

0.04 mm (0.016 in) 0.10 mm
Camshaft runout TIR
or less (0.0039 in) SM3287
Measuring camshaft runout
W5-6-9
Measuring camshaft journal outside diameter

Measure the diameter of each camshaft journal in
two direction at right angles to each other. If the limit
is exceeded, replace the camshaft with a new one. B
Item Standard Limit

Camshaft Front, 53.94 to 53.96 mm 53.90 mm A
journal Middle (2.1236 to 2.1244 in) (2.1220 in)
outside 52.94 to 52.96 mm 52.90 mm
diameter Rear
(2.0842 to 2.0850 in) (2.0827 in)
SM3288
Measuring camshaft journal outside diameter
Measuring camshaft bushing inside diameter

With the camshaft bushings installed in the
crankcase, measure the inside diameters using a
cylinder gauge. If the limit is exceeded, replace the A
bushing with a new one.
Item Standard Limit

Clearance Front, 0.04 to 0.09 mm
between Middle (0.0016 to 0.0035 in)
camshaft 0.15 mm
journal and (0.0059 in)
0.04 to 0.119 mm
camshaft Rear
(0.0016 to 0.0047 in)
bushing
SM3289
Measuring camshaft bushing inside diameter
Replacing camshaft bushing

Removing camshaft bushing
1. Install a camshaft bushing installer (P/N:
30691-00010) set to the camshaft bushing. 1 2
2. Remove the camshaft bushing (1) by tapping
the end of the rod (3) of camshaft bushing
installer set (4).
3
SM3290
Removing camshaft bushing
W5-6-10
Installing camshaft bushing

1. Install the camshaft bushing to a camshaft
bushing installer set (6). 1 2
2. When driving in a bushing (2), tap the end of 3
rod (4) of camshaft bushing installer set (P/N:
30691-00010) so that the oil hole (5) in the
bushing aligns with the oil hole to the oil gallery.
4
5
SM3291
Installing camshaft bushing
Measuring front idler bushing inside dia. and

front idler shaft outside diameter
Measure the front idler bushing inside diameter and
the front idler shaft outside diameter. If the inside
diameter of front idler bushing exceeds the limit,
replace the front idler bushing with a new one. If the
outside diameter of front idler shaft is less than the
limit, replace the front front idler shaft with a new
one.
Item Standard Limit

Clearance between idler 0.009 to 0.050 mm 0.100 mm
bushing and idler shaft (0.0004 to 0.0020 in) (0.0039 in)
W5-6-11
Replacing idler bushing

1. Use the idler bushing puller P/N: 30091-07300
(1) to replace idler bushing.
2. To install the bushing (3), drive it from the boss
side so that it is flush with the gear (2) boss 1
face.
3. After installing the bushing, measure the
bushing inside diameter, and if the inside
diameter exceeds the standard, ream the
bushing.
A - Removing A B SM3292
B - Installing Replacing idler bushing
2 3
SM3293
Idler bushing press fitting dimension
Replacing idler shaft

To remove the idler shaft, use the idler shaft puller
P/N:MH061077 (1). 1
NOTE: when installing the idler shaft into the
crankcase, orient the idler shaft so that its oil hole
faces the upper crankcase.
SM3294
Removing idler shaft
Inspecting tappet
Inspect the cam contact surface of the tappets. Fit
new tappets if the surface is excessively worn or
damaged.
A - Good
B - Bad
A B B
SM3295
Tappet surface in contact with camshaft
W5-6-12
Measuring clearance between tappet and

tappet guide hole
Measure clearance between the tappet and tappet
hole. Replace the tappet with a new one if the limit A B
is exceeded.
Item Standard Limit

Tappet hole inside 22.000 to 22.021 mm 22.10 mm
diameter (0.8661 to 0.8670 in) (0.8701 in)
Clearance between 0.035 to 0.086 mm 0.12 mm
tappet and tappet hole (0.0014 to 0.0034 in) (0.0047 in)
SM3296
Measuring clearance between tappet and tappet guide

hole
A - Measuring points
B - Measuring directions
W5-6-13
INSPECTING AND REPAIRING PISTON,

CONNECTING ROD, CRANKSHAFT AND
CRANKCASE
Measuring crankcase top surface distortion
CAUTION
Refacing of cylinder head should be kept to an
absolute minimum.
Excessive grinding of the cylinder head may result
in defects such as defective combustion and
stamping (contact between piston and valve).
Apply a straight edge to the top surface of the
crankcase and measure its distortion using a feeler
gauge. If the distortion exceeds the limit, grind the
cylinder head using a surface Measuring distortion
of crankcase top surface grinder. SM3297
Measuring distortion of crankcase top surface
NOTE: do not overgrind the cylinder head, as the
piston protrusion deviates from the standard value.
Item Standard Limit

Distortion of crankase 0.05 mm (0.0020 in) 0.20 mm
top surface or less (0.008 in)
NOTE: do not grind the surfaces more than 0.2 mm

in total (cylinder head bottom surface plus
crankcase top surface).
W5-6-14
Measuring cylinder inside diameter

1. Measure the inside diameter of the cylinder at * Unit: mm [in.]
three levels, i.e., upper (with much stepped
wear), middle, and lower levels, in both A
directions parallel to and perpendicular to the
crankshaft direction.
2. If the measurement is between the repair limit
and replacement limit, re-bore the cylinder to
+0.25 mm (0.0098 in) or +0.5 mm (0.0197 in)
oversize. Hone the rebored cylinder to the
accuracy of the standard. B
3. Use an oversize piston and piston rings to fit the
re-bored cylinder. SM3298
4. If the cylinder is worn unevenly, select an Measuring cylinder sleeve inside diameter
oversize that ensures complete cylindericity A - Measuring points *
when the cylinder is rebored to the maximum. B - Measuring directions *
All cylinders must be rebored to the same
oversize if one cylinder is rebored.
5. If the cylinder has a slight wear and is reused
after replacing only the piston rings, remove the
steps in worn portion in the upper part of the
cylinder using a ridge reamer. Hone it as
necessary.
Item Standard Limit

Repair limit:
102.200 mm
Cylinder sleeve 102.010 to 102.045 mm (4.0236 in)
SM3299
inside diameter (4.0161 to 4.0175 in) Replacement limit:
102.700 mm Refacing using a ridge reamer
(4.0433 in)
0.01 mm
Roundness -
(0.0004 in) or less
0.015 mm
Cylindericity -
(0.0006 in) or less
NOTE: the roughness of cylinder sleeve inner

surface is Ra 6.3 µm (0.248 µ in).
W5-6-15
Replacing cylinder sleeve

If the inside diameter of a cylinder sleeve exceeds
the limit or a clinder is found defective, replace the
cylinder sleeve only, provided that the defective
cylinder has no effects on the other cylinders.
Removing cylinder sleeve

1. Set up a boring machine on the crankcase by
aligning it with the center of the less-worn area
of the sleeve at the bottom.
2. Bore the sleeve until its stock thickness
becomes approximately 0.5 mm (0.020 in). SM3300
3. Carefully break and remove the sleeve, taking Boring cylinder sleeve
care not to cause damage to the inside surface
of crankcase.
SM3301
Removing cylinder sleeve
Installing cylinder sleeve

1. Use a cylinder sleeve installer P/N: 34291-
P/N: 34291-00200
00200 (1) to install a sleeve.
1
2. Put the sleeve into the crankcase, leaving a
protrusion of 0.3 to 0.5 mm (0.012 to 0.020 in)
at the top. Then make it flush with the
crankcase top.
3. Bore and hone the sleeve to the specified
diameter.
SM3302
Installing cylinder sleeve
W5-6-16
Measuring piston outside diameter

1. Measure the piston outside diameter of the
piston skirt at right angles to the piston pin. If it
is less than the limit, replace the piston with a
new piston. When replacing piston, be sure to
select a piston so that the piston weight A
difference in one engine is kept within the
permissible range.
SM3303
Measuring piston outside diameter

2. The piston weight is stamped on the top of

piston head. A
B
Item Standard Limit

101.915 to 101.945 mm 101.730 mm
STD
Piston (4.0124 to 4.0136 in) (4.0051 in)
C
outside 102.165 to 102.195 mm 101.980 mm
0.25 OS
diameter (4.0222 to 4.0234 in) (4.0150)
(iskirt) 102.415 to 102.445 mm 102.230 mm
0.50 OS
(40.321 to 4.0333 in) (4.0248 in)
Weight difference per 5 g (0.2 oz)
- SM3304
piston or less
Piston weight stamp location
A - Weight stamp
B - Number stamp (the prefix letter “F” and the
last five digits of part number)
C - Front mark
Measuring piston ring end gap

Place the piston ring (1) in a gauge (2) or a new
sleeve to measure the ring end gap. If the limit is A
exceeded, replace all the rings as a set.
NOTE: use a piston to push the piston ring squarely

into the gauge or the sleeve. 1
2
Item Standard Limit

Compression 0.30 to 0.45 mm
Piston ring (0.0118 to 0.0177 in) 1.50 mm
ring end
0.30 to 0.50 mm (0.0591 in) SM3305
gap Oil ring
(0.0118 to 0.0197 in) Measuring piston ring end gap
A - Gauge inside diameter
+0.045
Ø 101.5 mm+0.010
+0.0018
(Ø 4 in)
+0.0004
W5-6-17
Measuring clearance between piston ring

groove and piston ring
CAUTION
Remove carbon deposits from pistons and check
the entire circumference of the piston. 1
A
1. Remove deposits such as carbon from each
ring groove.
B
2. Check each ring groove for wear or damage. If 2
it is worn or damaged, replace the piston (1)
with a new one.
3. Insert the piston ring into the piston ring (2)
groove. Apply a straight edge and insert SM3306
thickness gauges to measure the clearance Measuring clearance between piston ring groove and
between ring and ring groove. If the limit is piston ring
exceeded, replace the piston ring with a new A - Feeler gauge
one. B - Straight edge
4. When the piston ring has been replaced,
measure the clearance again, and if the limit is
exceeded, then replace the piston with a new
one.
Item Standard Limit

No.1 0.08 to 0.12 mm 0.200 mm
Clearance compression (0.0031 to 0.0047 in) (0.0079 in)
between
No.2 0.08 to 0.12 mm 0.150 mm
piston ring
compression (0.0031 to 0.0047 in) (0.0059 in)
and ring
groove 0.025 to 0.065 mm 0.150 mm
Oil
(0.0010 to 0.0026 in) (0.0059 in)
Measuring piston pin bore diameter and piston

pin outside diameter
Measure the piston pin bore diameter and piston pin
outside diameter. Replace if the limit is exceeded.

Piston pin
Ø 34 mm 33.991 to 33.997 mm
outside -
(1.34 in) (1.3382 to 1.3385 in)
diameter
Clearance A B
between
0.005 to 0.021 mm 0.050 mm
piston pin -
(0.0002 to 0.0008 in) (0.0020 in)
bore and
piston pin
SM3307
Measuring piston pin bore and piston pin

W5-6-18
Measuring piston protrusion
CAUTION
Piston protrusion must always meet the standard,
as the amount of protrusion not only influences on
the engine performance, but also it is important to
prevent valve interference.
Measure the protrusion of each piston following the
instructions below. If the measured value does not
meet the standard, inspect the clearances between
various parts involved.
1. Bring the piston to the top dead center. SM3308
Measuring piston protrusion

2. Apply the dial gauge plunger to the top surface
of the crankcase, and zero the dial gauge.
3. Measure the protrusion at four points on the
piston head, and calculate the mean value.
NOTE: subtract the mean value from the thickness

of the gasket compressed by tightening the cylinder
head, and the clearance between the piston top and
cylinder head will be determined.
Item Standard
0.8 mm
Piston protrusion
(0.031 in)
Compressed thickness of 1.7 ± 0.05 mm
cylinder head gasket (0.067 ± 0.0020 in)
W5-6-19
Measuring clearance between connecting rod

bearing and crankpin
CAUTION
When grinding crank pins, be sure to grind all the 1
pins to the same size. 103 ± 5 Nm
Finish the fillet radius to the specified dimension. A B [76 ± 3.6 lbf·ft]
1. Reassemble the bearing into the big end of the

connecting rod.
2. Tighten the connecting rod cap (1) bolts to the
specified torque.
3. Measure the inside diameter of the connecting
rod bearing. SM3309
4. Measure the outside diameter of the crank pin. Measuring connecting rod bearing inside diameter
5. Calculate the clearance from the difference A - Measuring points

between the inside diameter of the connecting B - Measuring directions
rod bearing and outside diameter of the crank
pin.
6. Replace the connecting rod bearing if the
clearance exceeds the limit.
7. Measure the clearance between the connecting
rod bearing and the crank pin again. Use the
undersize bearing if the limit is exceeded.
8. If an undersize bearing is used, grind the crank A B
pin to the specified undersize.

Crankpin
Ø 65 mm 64.945 to 64.965 mm 64.800 mm SM3310
outside
(0.026 in) (2.5569 to 2.5577 in) (2.5512 in) Measuring crank pin diameter
diameter
Clearance
between
0.035 to 0.100 mm 0.200 mm
crankpin and -
(0.014 to 0.0039 in) (0.0079 in)
connecting
rod bearing
Measuring clearance between connecting rod

bushing and piston pin
Measure the inside diameter of the connecting rod
bushing and the outside diameter of the piston pin.
Replace if the limit is exceeded.

Bushing
Ø 34 mm 34.020 to 34.045 mm A
inside -
(0.134 in) (1.3394 to 1.3404 in)
diameter
Clearance
B
between 0.023 to 0.054 mm 0.080 mm
-
bushing and (0.0009 to 0.0021 in) (0.0031 in)
piston pin SM3311
Measuring connecting rod bushing inside diameter
W5-6-20
Replacing connecting rod bushing

Use a connecting rod bushing installer to replace
the connecting rod bushing. 1
1. With the bushing joints (2) oriented as shown in
the illustration, align the oil hole (1) of bushing
with the oil hole of connecting rod, and press-fit
the connecting rod bushing into the connecting
rod.
2. After press-fitting, insert the piston pin, and
make sure the smooth movement of the 1
connecting rod and piston without looseness.
2
SM3312
Replacing connecting rod bushing
Removing connecting rod bushing

1. Apply engine oil to the inner surface of the
connecting rod bushing (3). 1
c 2
2. Install the collar A (2) to the connecting rod
bushing. 3
3. Install the collar A and B (5) to the mandrel (1),
and tighten the nut (6). 4
4. Align the match mark (red line) on the collar A
with the match mark on the base (7). 5
5. Using a press, apply pressure slowly on the 8 6
head of the mandrel to force out the connecting 7 SM3313
rod bushing.
Removing connecting rod bushing
C - Connecting rod bushing installer
P/N: 32F91-03050
Installing connecting rod bushing

1. With the oil hole of buing aligned with the match
mark on the collar A (2), install the new 1
connecting rod bushing (1) onto the collar A. A
2. Install the collars A and B (4) to the mandrel (3), B

and tighten the nut (6).
3. Apply engine oil to the outer periphery of the
connecting rod bushing (1). Align the oil hole in
the connecting rod bushing with the match
mark (B) (red line) on the collar, then press the
bushing into the connecting rod (5). 2
SM3314
A - Connecting rod bushing installer Installing connecting rod bushing (1)

(P/N: 32F91-03050)
B - Align match mark 3
A 4
2
B 6
7
SM3315
Installing connecting rod bushing (2)
W5-6-21
Inspecting connecting rod bend and twist

1. Measure the dimensions of C and L in the
illustration to check bend (A) and twist (B) of C C
103 ± 5 Nm
the connecting rod. Straighten the connecting [76 ± 3.6 lbf·ft]
C 0.05 0.002
rod with a press to meet the standard. If the C [ ]
L 100 3.9
standard is exceeded after correction, replace
L
the connecting rod with a new one. L
C 0.05 0.002
11 [ ] C
2. In general, a connecting rod aligner is used to L 100 3.9
check bend and twist.
B
B
NOTE: before checking bend, tighten the A
connecting rod cap to the specified torque (C). A
SM3316
3. To inspect the connecting rod with the piston Inspecting connecting rod bend and twist
(1) installed, turn the piston upside down and
place it on a surface plate. Insert a round bar
having the same diameter as the crankpin into
the big-end bore, and measure the height of the
bar using a dial gauge.
Item Standard Limit

Connecting rod 0.05/100 mm 0.15 mm
bend and twist (0.0020/3.94 in) or less (0.0059 in)
SM3317
Measuring with a dial gauge
Inspecting connecting rod bearing

Inspect the connecting rod bearings. If any defect is
found, replace it with a new one.
B
A
C
SM3318
Inspecting connecting rod bearing

A - Flaking
B - Scratches
C - Fusion
W5-6-22
Measuring connecting rod end play

1. Install the connecting rods onto the respective
crankpins and tighten the connecting rod cap
bolts to the specified torque (A). A
103 ± 5 Nm
2. Measure the clearance to the crank arm (end
[76 ± 3.6 lbf·ft]
play) at two positions (above and below the
crankpin).
3. If the limit is exceeded, replace the connecting
rod with a new one.
Item Standard Limit

SM3319
Connecting rod 0.15 to 0.35 mm 0.50 mm
Measuring connecting rod end play
end play (0.0059 to 0.0138 in) (0.0197 in)
Weight difference of connecting rod assembly

in one engine
When replacing a connecting rod, be sure to check
the weight rank (1) of the connecting rod. In one
engine, all the connecting rods must be of the same
weight rank.
Item Standard
Weight difference of connecting rod 10 g (0.35 oz) or less
assembly per engine 2
SM3320
Weight difference in connecting rod assembly
Measuring crankshaft journal outside diameter

Measure the crankshaft journal diameter using a
micrometer. Check the crankshaft journal for
roundness, cylindricality and the clearance with the
bearing. If the measurement value is below the
repair limit, grind the journal to fit the undersize
bearing. If the measurement value is below the
A B
service limit, replace the crankshaft with a new one.

Repair limit =
89.85 mm
Ø 90 mm 89.95 to 89.97 mm (3.5374 in) SM3321
Diameter
(3.54 in) (3.5413 to 3.5421 in) Service limit = Measuring crankshaft journal outside diameter
89.10 mm A - Measuring points
(3.5079 in)
0.01 mm 0.03 mm
Roundness -
(0.0004 in) or less (0.0012 in)
0.01 mm 0.03 mm
Cylindericity -
(0.0004 in) or less (0.0012 in)
Deviation of 0.01
mm (0.0004 in) or
Parallelism - -
less over entire pin
length
W5-6-23
Measuring crankshaft crankpin outside

diameter
Measure the crankpin outside diameter using a
micrometer. Check the crankpin for roundness,
cylindricality, and the clearance with the bearing. If
the measurement value is below the limit, grind the
journal to fit the undersize bearing. If the
measurement value is below the service limit,
A B
replace the crankshaft with a new one.

Service limit =
Ø 65 mm 64.945 to 64.965 mm
Diameter 64.800 mm
(2.56 in) (2.5569 to 2.5577 in)
(2.5512 in) SM3322
0.01 mm (0.0004 in) 0.03 mm Measuring crankshaft diameter

Roundness -
or less (0.0012 in) A - Measuring points
0.01 mm (0.0004 in) 0.03 mm B - Measuring directions
Cylindericity -
or less (0.0012 in)
Deviation of 0.01
mm (0.0004 in) or
Parallelism - -
less over entire pin
length
Grinding crankshaft
Grind the crankshaft journal (or pin) in the diameter
that fit the inside diameter of the next undersize
main (or connecting) bearing. By doing so, the
fitness check with an actual bearing can be omitted.
When grinding, be careful not to change the fillet
radius and width. If the surface hardness is
considered to have been reduced considerably, re-
harden the crankshaft and check for flaws by means
of magnetic particle inspection.
Ensure that the surface finish accuracy of the
crankpins and journals is kept within the standard
even after the correction by grinding.
Item Undersize Finished size

0.25 mm 89.70 to 89.72 mm
(0.0098 in) (3.5315 to 3.5323 in)
0.50 mm 89.45 to 89.47 mm
Crank journal
(0.0197 in) (3.5216 to 3.5224 in)
0.75 mm 89.20 to 89.22 mm
(0.0295 in) (3.5118 to 3.5126 in)
0.25 mm
65.695 to 65.715 mm
(0.0098 in)
0.50 mm
Crankpin 65.445 to 65.465 mm
(0.0197 in)
0.75 mm
65.195 to 65.215 mm
(0.0295 in)
W5-6-24
Measuring crankshaft end play

1. Measure the crankshaft end play (clearance
between the crank arm at the thrust force
receiving journal and the bearing cap with
thrust plate attached). If the limit is exceeded,
replace the thrust plate with a new one.
2. If the limit is still exceeded after a new thrust
plate has been installed, use an oversize thrust
plate.
NOTE: in general, the rear thrust bearing wears

faster than the front thrust bearing. Therefore, in
SM3323
most cases, the correction is achieved by replacing
Width of crankshaft thrust journal
the rear thrust plate with a next oversize one.
Item Standard Limit

Crankshaft end 0.100 to 0.246 mm 0.300 mm
play (0.0039 to 0.0104 in) (0.0118 in)
Crankshaft thrust size after grinding

OS, used Os, used
Item on one on both Tolerance
side sides
+0.15 mm
33.15 33.30
(-0.0059 in)
(1.3051 in) (1.3110 in) SM3324
OS
+0.30 mm
33.30 33.45 0 to 0.039 mm
(-0.0118 in)
(1.3110 in) (1.3169 in) (0 to 0.0015 in)
OS
+0.45 mm
33.45 33.60
(-0.0177 in)
(1.3169 in) (1.3228 in)
OS
Measuring crankshaft runout

Support the crankshaft at the front and rear journals
with Vblocks, and measure the crankshaft runout at
the center journal using a dial gauge. If the runout
deviates from the standard only slightly, grind the
crankshaft to repair. If the runout exceeds the
standard considerably, straighten the crankshaft
using a press. If the limit is exceeded, replace the
crankshaft. If the crankshaft has been repaired by
grinding or pressing, inspect the crankshaft for
cracks and other harmful damage using a magnetic
particle method.
SM3325
Item Standard Limit Remark Measuring crankshaft runout

Crankshaft 0.04 mm 0.10 mm
TIR
runout (0.0016 in) or less (0.0039 in) or less
W5-6-25
Replacing crankshaft gear

Removing crankshaft gear
Using a gear puller P/N: 64309-12900 (2), remove
the gear (1) from the crankshaft.
NOTE: do not strike the gear with a hammer. 1
SM3326
Removing crankshaft gear
Installing crankshaft gear

1. Install the key (2) on the crankshaft.
2. Press-fit the gear (3) fully in alignment (1) with
the key.
2
1
3
SM3327
Installing crankshaft gear
W5-6-26
Replacing front oil seal
CAUTION
Be careful not to damage the crankshaft pulley (2)
with a chisel when breaking the sleeve (1). Be
careful not to dent or scratch the outer surface of
sleeve. 2
When oil leaks from the oil seal, replace both sleeve
(1) and oil seal with new ones.
1. Removing sleeve
Apply a chisel at right angles to the end surface 1
of the sleeve and strike it with a hammer at SM3328
three locations to loosen the sleeve and then Removing front oil seal sleeve
remove the sleeve.
NOTE: if the sleeve cannot be removed, apply the

chisel to the sleeve in the axial direction of the
sleeve and tap it lightly to make a cut and remove
crankshaft-to-sleeve interference. 1
2. Installing sleeve Install the sleeve using a press
2
so that the end of pulley becomes flush.
SM3329
Installing front oil seal sleeve
Replacing rear oil seal
CAUTION
Be careful not to damage the crankshaft when 1
remov-ing the rear oil seal. Be careful not to dent or
scratch the outer surface of sleeve.
When oil leaks from the oil seal (3), replace the oil
seal with a new one.
1. Removing rear oil seal (3)
Remove the oil seal with a puller.
2. Installing rear side oil seal (2)
SM3330
Apply an oil on the slinger (1) inner surface of
Removing rear oil seal sleeve
oil seal. Install the oil seal with an oil seal
installer (P/N: 34291-00020).
NOTE: the oil seal is united with the slinger. 2

3
SM3331
Installing rear oil seal sleeve
W5-6-27
Inspecting main bearing surface

Check the inside surface of each main bearing shell
for abnormal contact, scratches, corrosion and
peeling from foreign material. Also check the
outside surface of each bearing shell which comes
A
into contact with the crankcase or main bearing cap
for abnormal seating.
SM3332
Inspecting main bearing surface

A - Scratch on the inner and outer
circumference, corrosion, and detachment
Measuring clearance between main bearing

and crankshaft journal
CAUTION
a) When grinding crank journals, be sure to grind A B
all the journals to the same size.
b) Finish the fillet radius to the specified
dimension.
1. Reassemble main bearings.

2. Tighten the main bearing caps to the specified
torque (C).
3. Measure the inside diameter of the main C
bearings. 137 ± 5 Nm [101 ± 3.6 lbf·ft] SM3333
4. Measure the outside diameter of the crank Measuring inside diameter of lower hole of main bearing
journal.
5. Calculate the clearance between the inside
diameter of the main bearing and outside
diameter of the crank journal.
6. Replace the main bearing if the clearance
exceeds the limit.
7. Measure the clearance between the main A B
bearing cap and the crank journal again. Use
the undersize bearing if the limit is exceeded.
8. If an undersize bearing is used, grind the crank
journal to the specified undersize.
Item Standard Limit SM3334
Clearance between Measuring crank journal outside diameter

0.050 to 0.118 mm 0.200 mm
main bearing and
(0.0020 to 0.0046 in) (0.0079 in)
crankshaft journal A - Measuring points
W5-6-28
REASSEMBLY OF BASIC ENGINE E135B
REASSEMBLING PISTON, CONNECTING

ROD, CRANKSHAFT AND CRANKCASE
Installing main bearing
CAUTION
1
Do not apply oil to the bearing outer surface, as the
oil may cause the bearing seizure.
1. Press the upper main bearing (1) into position

by aligning (A) its lug to the lug groove on the
crankcase.
A
NOTE: the oil hole of the main bearing is aligned
with the oil hole of the crankcase by installing the 2
upper main bearing in alignment with the lug groove.
SM3335
2. Apply a small amount of engine oil to each bearing. Installing main bearing upper
Installing thrust plate

Install the thrust plates (2) to the crankcase outside
face of rearmost bearing and to the main bearing 2a
cap with their grooves facing outward.
2a - Thrust plate, upper
2b - Thrust plate, lower
2c - Thrust plate, lower
2b
2c SM3336
Installing thrust plate

Installing crankshaft
1. Make sure that the main bearing upper shells
that are installed in the crankcase bores have
their inner periphery (the surface comes into
contact with the journal) lubricated with an even
coat of fresh engine oil.
2. Wash the crankshaft thoroughly with cleaning
oil and dry it completely by blowing compressed
air. Then, apply an even coat of fresh engine oil
to the crankshaft journals.
NOTE: when cleaning the crankshaft, pay special

attention to the oil holes in the crank journals and SM3337
crankpins, and make sure that they are free from Installing crankshaft
any foreign matter.
3. Sling up the crankshaft horizontally, then move

it above the crankcase and lower it slowly into
position.
NOTE: when lifting the crankshaft with a chain

block, do not attach a metal hook or similar fitting
directly onto the crankshaft. Such metal fittings can
damage the crankshaft easily. Always lift the
crankshaft using cloth belts or pads on the
supporting points.
W5-7-1
E135B REASSEMBLY OF BASIC ENGINE
Installing main bearing caps
CAUTION
The foremost and rearmost caps should be installed
so that they are flush with the crankcase surface.
Install the main bearing caps from the front side in
the order of the numbers marked on them.
1. Apply engine oil to lower main bearings and
install them to the main bearing caps.
2. Apply ThreeBond 1212 (A) to the mating
surface of the foremost and rearmost caps and A
the crankcase mating faces before installing the SM3338
main bearing caps. Installing main bearing cap
NOTE: do not apply ThreeBond 1212 to any other

surface other than the mating surfaces of the
foremost and rearmost caps and the crankcase
mating faces.
3. Install the main bearing caps and temporarily

tighten bolts.
Inserting side seal

1. Apply a sealant to the outer periphery of new
side seals (3).
1 2 3 3
Sealant THREEBOND 1212 or 1211
2. With the round section of the side seals facing
outward, press them partway into the front and
rear caps using hands.
3. When the side seals are installed partway into
caps, use a tool with flat surface such as flat-
head screwdriver to install completely, taking
A
care not to bend them. SM3339
Inserting side seal

1- Crankcase
2- Bearing cap
3- Side seal
A - R section
Installing main bearing cap bolt

1. Tighten the main bearing cap bolts (1)
alternately and progressively to the specified 1
torque (1).
2. Make sure that the crankshaft rotates smoothly.
SM3340
Installing main bearing cap bolt
W5-7-2

Attach a dial gauge to the end of the crankshaft to
measure the end play.
If the end play deviates from the standard value,
loosen the main bearing cap bolts and retighten.
Make sure that the camshaft turns freely.
Item Standard Limit

Crankshaft end 0.100 to 0.246 mm 0.300 mm
play (0.0039 to 0.0104 in) (0.0118 in)
SM3341
Reassembling piston and connecting rod

1. Apply engine oil (3) to the piston pin (1), and
reassemble the piston and the connecting rod
by inserting the piston pin, observing the
1 A
orientation of piston and connecting rod shown
in the illustration. 2
NOTE: the pistons and piston pins are assembled to
each other in clearance fit. However, the piston pins
are more easily inserted into the pistons if the 3
pistons are warmed up with a heater or in hot water.
4
2. Using ring pliers, install the snap ring (2). Check SM3342
the snap ring for its tension, and make sure the Reassembling piston and connecting rod
ring fits snugly in the groove. 4- Matching mark
A - Front
NOTE: install all the snap rings so that their end gap
faces toward the bottom of the piston.
W5-7-3
Installing piston ring
CAUTION
Every piston ring has a top mark (A) such as “R”
near the end gap. Install all piston rings with this A
1
mark facing upward.
If the rings are installed upside down, it could cause
malfunctions such as excessive oil consumption or
an engine seizing. 2
1. Install the piston rings to the piston with a ring

expander. 3
2. Install the oil ring (3) with its end gap 180° away SM3343
from the butt joint of the coil spring (4), as Reassembling piston and piston ring
shown in the illustration. 1- No.1 compression ring
2- No.2 compression ring
5
SM3344
Reassembling oil ring

5- Oil ring abutment
Preparation for installing pistons

1. Lay the engine along its side.
2. Clean the cylinder sleeve inner surface and the
crank pin with a cloth, and apply engine oil.
SM3345
Cleaning and lubricating cylinder sleeve inner surface
W5-7-4
Installing connecting rod bolt and connecting

rod bearing
1. Press fit the connecting rod bolts into the
connecting rod. 1
1
NOTE: when press fitting the bolt, make sure that

the bolt fully contacts its seating position without any
interference with the shoulder of mounting surface.
2. Install the upper connecting rod bearing with its

lug fitted in the lug groove (1) of connecting rod.
3. Install the lower connecting rod bearing with its
lug fitted in the lug groove of connecting rod
cap. SM3346
Installing connecting rod bolt and upper bearing

4. Apply engine oil to the inner surface of bearing.
SM3347
Installing lower connecting rod bearing
Installing Pistons
CAUTION
Do not forcefully insert the piston, as it may cause A
damage to the piston rings and crank pin.
180° 1
1. Apply engine oil to the circumference of the
piston and piston rings.
2. Orient the ring end gaps diagonally opposite
each other avoiding the piston pin direction and 3 2
its right angle direction. 60° 60°
3. Turn the crankshaft to bring the crank pin of the B
cylinder to the top dead center. SM3348
4. Orient the front mark on the top of piston toward Orientation of piston ring end gap
engine front.
5. Using a piston guide (4), insert the piston from
the top face of crankcase into the cylinder
sleeve.
1- No.1 compression ring end gap

2- Oil ring end gap
3- No.2 compression ring end gap
4- Piston guide (P/N: 34291-00100)
A - Camshaft side
B - Combustion chamber side 4
SM3349
Installing piston
W5-7-5
Installing connecting rod cap

1. When the big end of the connecting rod comes
into contact with the crank pin, turn the 1
crankshaft 180° while pressing the piston head. 2
2. Install the connecting rod cap with its match
mark (2) facing on the same side as the match
mark on the connecting rod.
3. Tighten the connecting rod cap nuts (3) evenly 3
and progressively to the specified torque. 103 ± 5 N·m
[76 ± 3.6 lbf·ft]
4. Inspect end play of the connecting rod. If end
play is small, loosen and retighten the cap nuts. 4
SM3350
Installing connecting rod cap

1- Camshaft
2- Matching mark
3- Connecting rod cap nut tightening torque
A - Wood block
W5-7-6
REASSEMBLING TIMING GEAR AND

CAMSHAFT
Installing front plate

1. Clean the mounting surface of the gasket.
A
2. Apply sealant to the gasket to prevent it from M10 × 1.5 35 ± 5 N·m [25.3 ± 3.6 lbf·ft]
falling. M8 × 1.25 19 ± 2 N·m [13.7 ± 1.4 lbf·ft]
3. With aligning to the dowel pin, install the gasket

1
and the front plate (1).
4. Secure the front plate with mounting bolts.
SM3351
Installing front plate
A - Front plate bolt tightening torque
Installing tappet
Coat the periphery of tappets with engine oil, insert
them into the tappet holes and place them gently on
the camshafts.
Installing camshaft
CAUTION
Be careful not to damage camshaft journals, cams
and camshaft holes during insertion.
1
1. Apply engine oil to the camshaft journals and
cams.
2. Slowly insert the camshaft assembly.
3. Tighten the thrust plate bolt to the specified A
torque (A). 12 ± 2 N·m
4. Make sure that the camshaft rotates lightly. [9 ± 1.4 lbf·ft]
Move the camshaft gear (1) back and forth, and SM3352
make sure there is end play. Installing camshaft
W5-7-7
Installing front idler gear

1. Apply engine oil to the idler gear (2) shaft.
2. Install the idler gear with all match marks on it
aligned with the marks on the other gears.
1 2
3. Install the thrust plate (3) with its hole matching 34 ± 5 N·m
the pin of the idler gear shaft. [25 ± 3.6 lbf·ft]
4. Tighten the thrust plate bolt to the specified
torque (1).
5. Move the idler gear back and forth, and make
sure there is end play.
3 SM3353
Installing idler gear
1- Injection pump idler gear

2- Idler gear
1
3- Camshaft gear 3
4- Crank gear
5- Injection pump gear
5 2
4 SM3354
Timing gear train
Inspecting and adjusting timing gear after

installation
Be sure to inspect and adjust the timing gear when
the timing gear has been reassembled.
Inspecting backlash and end play

After installing the timing gears, be sure to inspect
and adjust the backlash and end play between
gears.
SM3355
SM3356
Measuring backlash of timing gear
W5-7-8
Installing front oil seal

Using an installer, install new oil seal in the timing
gear case (3). Make sure the oil seal is flush with the
gear case.
SM3357
Installing front oil seal

Installing timing gear case
1. Install the baffle plate to the front end of
1
crankshaft. M10 × 1.5 35 ± 5 N·m [25.3 ± 3.6 lbf·ft]
M8 × 1.25 19 ± 2 N·m [13.7 ± 1.4 lbf·ft]
2. Apply sealant to the gasket (2) to prevent it from
displacing, and install the gasket on the front
plate.
3. Apply engine oil to the oil seal lip.
4. Orient the cutaway of the baffle plate (5) so that
the baffle plate does not overlap the oil pump
idler gear (4). 2
5. Install the timing gear case, and secure it with 3
SM3358
the bolts.
Installing timing gear case
1- Timing gear case tightening torque
5
SM3359
Baffle plate cutaway position
Installing crankshaft pulley
CAUTION
The bar could come off. Be very careful. 1 C
706 ± 59 N·m
[521 ± 43 lbf·ft]
1. 1. Screw two guide bolts (3) into the threaded
holes at the rear end of the crankshaft. Place a 2
bar across the two guide bolts so that the
crankshaft does not turn.
2. Install the woodruff key on the crankshaft.
3. Install the crankshaft pulley (2) and tighten the
nuts (1) to the specified torque. 3 (M12×1.25mm)
A - Front A B SM3360
B - Rear Installing crankshaft pulley

C - The bar that prevents crankshaft rotation
W5-7-9
REASSEMBLING FLYWHEEL
Installing flywheel housing

1. Clean the mounting surface of the gasket.
2. Apply sealant to the gasket to prevent it from
falling off.
3. Install the gasket.
4. Install the flywheel housing, aligning its dwel pin
holes and dowel pins, and tighten the bolts.
NOTE: when the dowel pins are worn or when the

flywheel housing is replaced, replace the dowel pins
with new ones.
SM3361
Installing flywheel housing
Installing flywheel
CAUTION
The person who holds the pulley must be very 2
careful to assure safety by communicating with the 83 ± 5 N·m
person who is installing the flywheel. 1 [62 ± 3.6 lbf·ft]
3
1. One person must firmly hold the pulley (1) with
a wrench to prevent the crankshaft from
turning.
2. Screw the guide bolt (3) into the rear end of the
crankshaft.
3. Align the bolt hole of flywheel with the guide bolt A B SM3362
and install the flywheel to the crankshaft. Installing flywheel
4. Temporarily tighten bolts. A - Front
B - Rear
5. Remove the guide bolt and temporarily tighten
the last bolt.
6. Tighten the flywheel bolts to the specified
torque (2).
W5-7-10
REASSEMBLING CYLINDER HEAD AND

VALVE MECHANISM
Cleaning cylinder head bottom surface

Taking care not to damage the cylinder head bottom
surface, remove residue of old gasket.
NOTE: first, roughly scrape off residue of old gasket

using a scraper. Then, grind off the remaining
residue using an engine-oil immersed oil stone.
SM3363
Cleaning cylinder head bottom surface

Installing valve stem seal
CAUTION
Do not apply oil or liquid gasket to the inner side of A A
stem seal (1) that comes in contact with the valve
guide (2).
1
1. Apply engine oil to the lip of new valve stem
seal (1).
2. Push the shoulder of the valve stem seal and fit 2
the valve stem steal into the valve guide (2).
3. Insert the valve stem seal into the valve guide
using the valve stem seal installer. SM3364
Installing valve stem seal

A - Push the shoulder of valve stem seal
Installing valve and valve spring
1. Install the valve spring and retainer on the valve
guide. Install the valve cotter using a valve
spring pusher P/N: 30691-04500 (1). 1
P/N:30691-04500
2. Tap the top of valve stem lightly several times

with a soft hammer to make sure that the valve
spring and valve cotter (2) are properly installed
and seated firmly.
SM3365
Installing valve and valve spring
SM3366
Installing valve cotter
W5-7-11
Installing cylinder head gasket

1. Make sure that there is no dirt or dents on the
top surfaces of the crankcase and pistons.
2. Place new gasket on the crankcase by aligning
it with dowel pins on the crankcase.
Installing cylinder head assembly

Install the cylinder head on the crankcase by
aligning it with the dowel pins.
NOTE: be careful not to displace the cylinder gasket

when installing.
SM3367
Installing cylinder head assembly
Tightening cylinder head bolts

In the numerical order as shown in the illustration,
tighten cylinder head bolts (A) progressively to the A
specified torque. 137 ± 5 N·m [101 ± 3.6 lbf·ft]
15 11 7 3 2 6 10 14
17 9 1 8 16
13 5 4 12
SM3368
Tightening order of cylinder head bolt
W5-7-12
Inserting push rod

1. Insert each push rod (1) into its hole in the
cylinder head.
2. Make sure that the ball end of each push rod is 1
placed correctly on the tappet (2) cup.
SM3369
Inserting push rod
Reassembling rocker shaft assembly

1. Apply engine oil to the rocker shaft.
2. When reassembling, install the rocker shaft
assembly in the same position as it was.
1
NOTE: if the rocker shaft assembly is not installed
as it was, the clearance becomes different, and it 7
may result in a defect such as wear increase. 6 2
3
3. After reassembling, make sure the rocker arm
4
and oil pipe move freely.
5
SM3370
Reassembling rocker shaft assembly

1- Rocker shaft spring
2- Bracket
3- Rocker arm
4- Snap ring
5- Eye bolt
6- Oil pipe
7- Rocker shaft
Installing rocker shaft assembly

1. Install the valve caps to the valve heads.
2. Tighten the long bolts (1) of the rocker bracket
to the specified torque.
3. Tighten the short bolts (1) of the rocker bracket.
1
19 ± 2 N·m [13.7 ± 1.4 lbf·ft] SM3371
Installing rocker shaft assembly
W5-7-13
Installing injector
1. Install the gasket (6) to the injector (8).
2. Install the injector with the nozzle gland (7) to 1
the cylinder head. 2
8
3. With the washer spherical side faced toward 3
nozzle gland, install the washer, and secure it
by tightening the hexagon socket head bolt to
the specified torque. 7
4
4. Apply engine oil to the O-ring of leak off hose
connector (1). 5
5. With pushing (A) the pin (3) on top of the 6
SM3372
injector, install the leak off hose connector (1) to
Installing injector
the Leak off hose (2).
6. Install the injection pipe (4) to the injector (5).
NOTE: make sure that the injector is reassembled

into the same cylinder as it was before. 8
A
3
SM3373
Pushing pin on top of injector
Adjusting valve clearance

Adjust the valve clearance.
For adjusting procedures, refer to "Adjustment and
Operation."
SM3374
Installing rocker cover

1. Make sure that the gasket is firmly installed into
1
the rocker cover.
20 ± 2 Nm
2. Tighten the rocker cover mounting bolts (1) to [14.5 ± 1.4 lbf·ft]
SM3375
Installing rocker cover
W5-7-14
FUEL SYSTEM E135B
REMOVING FUEL SYSTEM
CAUTION
a) Keep open flame or heat away from fuel system before conducting the removal work. It could cause a fire.
b) Wipe off any spilled fuel. Spilled fuel could cause a fire.
c) Cover or plug any inlet and outlet openings to prevent dust from entering the fuel system.
d) For fuel pump, common rail, and injector, have a specialized maintenance shop do the maintenance work.
Removing fuel system (Part 1)

Replace: Sealing washer, O-ring, Gasket e Leak off hose.
8
B
10
2
3
4 1
5 11
16
A
18 14
17 D
15 7 9
B
C 13
12
19
D
A 20
SM3380
Removing sequence
1- Pipe clamp 11 - Bolt
2- No.1 injection pipe 12 - Hose cramp
3- No.2 injection pipe 13 - Fuel hose
4- No.3 injection pipe 14 - Fuel return pipe
5- No.4 injection pipe 15 - Comon rail
6- Leak off hose 16 - Hexagon bolt
7- Fuel hose 17 - Nozzle ground
8- Pipe cramp 18 - Injector
9- Fuel pipe 19 - Fuel pump nut
10 - Bracket 20 - Fuel pump flange, fuel pump
W5-8-1
E135B FUEL SYSTEM
Removing fuel system (Part 2)
1
2
6
5
SM3381
Removing sequence
1- Fuel pump nut 5- Bolt
2- Fuel pump gear 6- Washer
3- Bolt 7- Fuel pump idler gear, bearing
4- Fuel pump
W5-8-2
FUEL SYSTEM E135B
Installing fuel system
Installing fuel system (Part 1)
19 ± 2 N·m
[13.7 ± 1.4 lbf·ft]
70 ± 5 N·m
[51.4 ± 3.6 lbf·ft]
112 ± 22 N·m
[82.5 ± 15.9 lbf·ft]
34 ± 5 N·m
[25.3 ± 3.6 lbf·ft]
SM3382
W5-8-3
E135B FUEL SYSTEM
Installing fuel system (Part 2)

Replace: Sealing washer, O-ring, Gasket, Leak off hose
8
B
30 ± 3.0 N·m
25 ± 3 N·m
[22.4 ± 3 lbf·ft]
[18.1 ± 2.2 lbf·ft]
A
D
25 ± 3.0 N·m B 20 ± 2.0 N·m

[18.1 ± 3 lbf·ft] C [14.5 ± 1.4 lbf·ft]
25+2.5
0 N·m
[18.1 +1.8
0 lbf·ft]
SM3383
W5-8-4
FUEL SYSTEM E135B
Replacing fuel pump

Removing fuel pump
1. Remove the inspection cover for fuel pump idler
gear (4) and idler gear (3) from the timing gear 2
case. 1
2. Put a mating mark (2) on the fuel pump idler
gear and idler gear with white paint.
3. Remove the inspection cover for fuel pump nut
(1). Loosen the fuel pump nut and tighten it by
hand temporary. 4 3
5
4. Disconnect fuel pipe and oil pipe from the fuel
pump. SM3376
Removing fuel pump
5. Remove the harness connector.
6. Remove the fuel pump together with the fuel
pump flange from timing gear case.
7. Remove the fuel pump nut, and remove the fuel
pump gear (5) from the fuel pump (6).
8. Remove the fuel pump from the fuel pump
flange.
Replacing fuel pump gear

1. Remove the fuel pump nut, and remove the fuel
pump gear.
2. Install the new fuel pump gear, aligning with the
fuel pump shaft key. 5
3. Install the fuel pump nut and tighten it by hand
temporary.
6
SM3377
Replacing fuel pump gear
Replacing fuel pump idler gear

1. Remove the bolt and the washer from the fuel
pump idler gear.
2. Remove the fuel pump idler gear from the shaft
together with the bearing and the snap ring.
3. Remove the bearing and the snap ring from the
fuel pump idler gear.
4. Install the bearing and the snap ring to the new
fuel pump idler gear. 6
5. Install the fuel pump idler gear to the shaft 4
SM3378
together with the snap ring and the bearing, and Replacing fuel pump idler gear
install the washer and the bolt.
W5-8-5
E135B FUEL SYSTEM
Installing fuel pump

1. Install the fuel pump to the fuel pump flange.
2. Install the fuel pump nut and tighten it by hand
temporary.
3. Install the O-ring to the fuel pump flange.
4. With the match marks on the fuel pump idler
gear and the idler gear aligned, install the fuel
pump flange to the timing gear case.
5. Tighten the fuel pump nut to the specified
torque.
6. Connect the harness connector. SM3379
7. Install the fuel pipe and the oil pipe, and tighten Installing fuel pump
to the specified torque.
8. Install the fuel pump idler gear and idler gear
inspection cover and the fuel pump nut
inspection cover to the timing gear case.
W5-8-6
LUBRICATION SYSTEM E135B
REMOVING AND INSPECTING LUBRICATION SYSTEM
Removing and inspecting oil filter and oil cooler
Clogging, crack
Replace: Every 500 hrs
Replace
Clogging, crack
8 Replace: Every 500 hrs
Replace
1
10
6 3
Replace 5
Replace
4
2
9
Replace
SM3384
Removing sequence
1- Oil filter 6- Rail bracket
2- Drain hose 7- Oil cooler cover
3- Filter bracket 8- Oil cooler element
4- Drain plug 9- Oil cover
5- Filter base 10 - Relief valve
W5-9-1
E135B LUBRICATION SYSTEM
Removing and inspecting oil pan and breather
3
Replace
5 2
Replace Replace
Replace 8
Replace
6
SM3385
Removing sequence
1- Breather hose 6- Drain cock
2- Breather pipe 7- Oil pan
3- Vinyl tube 8- Oil strainer
4- Breather 9- Safety valve
5- Oil level gauge
W5-9-2
DISASSEMBLING, INSPECTING AND REASSEMBLING LUBRICATION SYSTEM
Disassembling and inspecting oil pump
Gear defect, wear

Once removed, replace the gear
with a new one.
Gear defect, wear

3
Wear
2
Replace
4
Crack, damage
1 Gear defect, wear
SM3386
Removing sequence
1- Gear cover 4- Drive gear
2- Driven gear 5- Spindle
3- Oil pump gear 6- Idler gear assembly
NOTE: inspect the oil pump prior to the removal of gears.
Removing oil pump gear
CAUTION 1
Once the oil pump gear (1) is removed, the oil pump
gear and the drive gear are no longer reusable. 2
Replace them with new ones.
Remove the oil pump gear (1) with a puller P/N:
64309-12900 (2).
SM3387
Removing oil pump gear
W5-9-3
Removing spindle and idler gear

Remove the spindle (1) and the idler gear (2) as a
unit. Remove the spindle and the idler gear by
tapping the edge of idler gear with a wood rod
inserted through the oil seal mounting hole of timing
gear case.
NOTE: when tapping the idler gear with a wood rod,

turn the gear.
1 2
SM3388
Removing spindle and idler gear
Inspecting and adjusting oil pump

Measuring end clearance between gears and
case
Measure the end clearance between gear width and
case depth with a dial gauge placed as shown in the
illustration. If the limit is exceeded, replace the drive
and driven gear assemblies.
Item Standard Limit

End clearance between
-0.01 to 0.054 mm 0.150 mm
gear width and case
(0.0004 to 0.0021 in) (0.0059 in)
depth
SM3389
Measuring clearance between gear and case
Measure the side clearance between gear teeth

and case
Measure the side clearance between gear teeth and
case bore with feeler gauges. If the limit is
exceeded, replace the drive and driven gear
assemblies.
Item Standard Limit

Side clearance between
0.05 to 0.098 mm 0.100 mm
gear teeth and case
(0.0020 to 0.0039 in) (0.0039 in)
bore
SM3390
Measuring clearance between gear teeth and case
W5-9-4
Measuring clearance between outside diameter

of gear shaft and inside diameters of pump
body and pump cover
CAUTION
1 2
When replacing drive and driven gears, replace the
gear assemblies.
A
1. Check gear teeth for condition. If the teeth are
defective, replace the gear assemblies.
2. Measure the inside diameters of pump body (1)
(cover) and the diameter of gear shafts. If the
clearance is more than the limit, replace the
gear assemblies, pump body, and pump cover
B
(2) whichever is badly worn. SM3391
Measuring clearance between gear shaft outside

Item Standard Limit diameter and pump body, pump cover inside diameter
Clearance between A - Measuring locations
0.04 to 0.07 mm 0.15 mm B - Measuring points
gear shafts and pump
(0.0016 to 0.0028 in) (0.0059 in)
body (cover)
Measuring spindle outside diameter and idler

bushing inside diameter
Measure the spindle outside diameter and the idler
bushing inside diameter. If excessive wear is found,
replace the part with a new one.
Item Nominal Standard

Ø 25 mm 24.939 to 24.960 mm
Spindle outside diameter
(0.98 in) (0.9818 to 0.9827 in)
Ø 25 mm 25.000 to 25.021 mm
Bushing inside diameter
(0.98 in) (0.9843 to 0.9851 in)
SM3392
Measuring spindle outside diameter and idler gear
bushing inside diameter
W5-9-5
Reassembling oil pump
Heat to 180 to 220°C [356 to 428°F].

Oil pump gear should be flush with
the shaft. Backlash
Standard: 0.049 to 0.166 mm
[0.0019 to 0.0065 in.]
Limit: 0.35 mm [0.0138 in.]
35 ± 3.5 N·m
[25.3 ± 2.4 lbf·ft]
Make sure the oil pump

Apply ThreeBond 1215 gear rotates smoothly
(ash color) to the mating
surface with the case and
cover.
Apply engine oil to every sliding section.
SM3393
Reassembling oil pump
CAUTION 1
The oil pump gear and drive gear assembly is
nonreusable parts. Replace the assembly with a
new one.
1. Heat the oil pump gear between 180 to 220°C

(356 to 428 °F).
2. Support the shaft (2) at end and force the gear
onto the shaft until its end face (2) is flush (1)
with the end of shaft.
2 SM3394
Reassembling oil pump gear and drive gear assembly
W5-9-6
Inspecting oil filter

When replacing the oil filter, sample the oil (500 ml
- 30.5 cu.in) and check for metal and other particles.
If metal or other particles are found, cut and unfold
the element, and inspect the color and shape of
metal particles trapped in the element to identify the
cause.
SM3395
Inspecting oil filter
Inspecting relief valve

1. Check the relief valve (1) and its seat for
contact. Check the spring for fatigue and
damage. If faulty, replace the relief valve with
new one. A
49 ± 4.9 Nm
2. Measure the relief valve (1) opening pressure. [36.2 ± 3.6 lbf·ft]
If the pressure does not fall within the standard
range, replace the relief valve with new one.
A
44 ± 4.9 Nm
Item Standard [32.5 ± 3.6 lbf·ft]
0.35 ± 0.05 MPa
Relief valve opening pressure
(49.8 ± 7.1 psi)
1
SM3396
Inspecting relief valve

A - Tightening torque
Inspecting safety valve

1. Make sure that the steel ball inside safety valve
slides smoothly. If faulty, replace the safety
valve with new one.
2. Measure the safety valve opening pressure. If
the pressure does not fall within the standard
range, replace the safety valve with new one.
Item Standard A
Safety valve opening pressure 1.1 MPa (157 psi) 69 ± 4.9 N·m
[50.6 ± 3.6 lbf·ft]
SM3397
Inspecting safety valve
A - Tightening torque
W5-9-7
INSTALLING LUBRICATION SYSTEM
Installing oil filter and oil cooler
When installing, apply engine

oil to the gasket, and tighten
Replace the filter 3/4 to one turn after
the gasket contacts with the
mounting surface.
Replace Replace
Replace
49 ± 4.9 N·m
[36.2 ± 3.6 lbf·ft}
Replace
Replace
SM3398
To install the lubrication system, follow the removal procedure in reverse order, observing the followings:
1. Use new gaskets and O-rings when reinstalling.
2. Clean oil passage of each part thoroughly in wash oil, and dry it completely using compressed air.
3. Install the bracket first, then install the oil filter.
W5-9-8
Installing oil pan and breather
Replace
Replace Replace
Replace
69 ± 4.9 Nm
[50.6 ±3.6 lbf·ft}
Replace
SM3399
Installing oil pan and breather
W5-9-9
NOTE:
W5-9-10
COOLING SYSTEM E135B
REMOVING COOLING SYSTEM
Replace
5
Crack, water leakage, damage
Replace
4
2 3
Crack, wear
SM3400
Removing cooling system
Removing sequence
1- Fan 4- Water pump assembly
2- Spacer 5- Thermostat assembly
3- Belt
W5-10-1
E135B COOLING SYSTEM
INSPECTING COOLING SYSTEM
Checking water pump for smooth rotation

Check to make sure that the impeller and shaft of
water pump rotate smoothly without noise and
irregularities. If faulty, replace the water pump
assembly.
Inspecting thermostat
CAUTION
Be careful of burns or a fire when measuring
tempera-ture, as it involves a high-temperature and
open flame.
To test the thermostat operation, immerse the
thermostat in a container filled with water. Heat the
water, while measuring the water temperature.
Record the temperature at the conditions shown in
the table below. If the temperatures are not within
the standard range, replace the thermostat.
SM3401
NOTE: Inspecting thermostat
(a) Stir the water in the container with a stick to
ensure uniform temperature distribution.
(b) Before installing the thermostat, be sure to
check the valve opening temperature stamped
on the thermostat valve side face.
Item Standard
Temperature at which valve starts 71 ± 2°C
opening (160 ± 3.6 °F)
Temperature at which valve lift 85°C
becomes 10 mm (0.39 in) or more (185 °F)
NOTE: when assembling, orient the thermostat with

its air breed hole faced upward.
W5-10-2
COOLING SYSTEM E135B
INSTALLING COOLING SYSTEM
Replace
Crack, water leakage, damage
Replace
M10 × 1.5
35 ± 3.5 Nm [25.3 ± 2.2 lbf·ft]
M8 × 1.25
19 ± 1.9 Nm [13.7 ± 1.4 lbf·ft]
Crack, wear
SM3402
Installing cooling system
W5-10-3
E135B COOLING SYSTEM
NOTE:
W5-10-4
INLET AND EXHAUST SYSTEM E135B
REMOVING INLET AND EXHAUST SYSYTEM
Removing inlet system
A
B
Replace Replace
2
Replace
SM3403
Removing sequence
1- Air inlet elbow
2- Air heater
3- Inlet manifold
A - Air inlet
B - Cylinder head
W5-11-1
E135B INLET AND EXHAUST SYSTEM
Removing exhaust system
Replace 1
A
2
Replace
SM3404
Removing sequence
1- Turbocharger
2- Exhaust manifold
A - Cylinder head
W5-11-2
DISASSEMBLING, INSPECTING AND REASSEMBLING INLET AND EXHAUST SYSTEM
Measuring exhaust manifold distortion

1. Check the flange for crack.
2. Check the flange suface for distortion. If the
distortion exceeds the standard, retouch the
surface.
Item Standard
Less than 0.2 mm
Exhaust manifold distortion
(0.008 in)
SM3405
Measuring exhaust manifold distortion
W5-11-3
INSTALLING INLET AND EXHAUST SYSTEM
Installing inlet system
19 ± 2 Nm
[13.7 ± 1.4 lbf·ft]
A
B
Replace Replace
Replace
SM3406
A - Air inlet
B - Cylinder head
W5-11-4
Installing exhaust system
Replace
Replace
19 ± 2 Nm
[13.7 ± 1.4 lbf·ft]
SM3407
A - Cylinder head
W5-11-5
NOTE:
W5-11-6
REMOVING ELECTRICAL SYSTEM
Removing starter
SM3408
Removing starter
Removing sequence
1- Starter
W5-12-1
Inspecting before removing alternator

Inspecting alternator operation
Locate the cause of faulty charging from
malfunctions described below. Do not remove the
alternator for inspection and repair unless
inspection cannot be performed with the alternator
installed on the engine.
Adjusted value of voltage regulator is

Overcharge high.
Faulty battery.
Low adjusted value of voltage relay.
Faulty alternator output.
Electric power consumption is
Over discharge
extremely high.
Special load is used.
Faulty wiring.
Handling precaution
Improper handling could cause damage or failure to
the alternator.
1. Connect battery cables correctly. B terminal is
positive (+), and E terminal is negative (-).
2. Do not use any high voltage tester such as
megger.
3. Do not disconnect lead wire from B terminal of
the alternator while the engine is running.
4. Battery voltage is constantly applied to B
terminal of the alternator. Do not ground at this
terminal.
5. Do not short circuit or ground at L terminal. (For
a built-in IC regulator type)
6. When a steam cleaner is used, do not allow the
steam directly contact the alternator.
W5-12-2
Removing alternator
SM3409
Removing alternator
Removing sequence
1- Alternator
2- Adjusting plate
3- Set bolt
W5-12-3
DISASSEMBLING, INSPECTING AND REASSEMBLING ELECTRICAL SYSTEM
Disassembling and inspecting starter
11
12
4
14
Open or short circuit
25
18
15
16
17 Damage, wear
13
23 Damage, wear
24
22
Damage, wear
3 21
19 Replace
20 Function of
overrunning clutch
2
6
1 Replace
5
Wear
Damage, wear
7
Replace Brush dust accumulation,

8
local wear, rust,
Replace
deterioration, insulation
Open or short circuit

9
Open or short circuit,

10 ground, damage, wear
SM3410
1- Clip ring 14 - Ball
2- Pinion stopper, pinion, spring 15 - Packing
3- Bolt 16 - Plate
4- Magnet switch 17 - Spring
5- Screw 18 - Shift lever
6- Through bolt 19 - E ring
7- Rear bracket 20 - Over runnning clutch
8- Brush holder 21 - Internal gear
9- Yoke assembly 22 - Plate
10 - Armature 23 - Gear shaft
11 - Cover 24 - Front bracket
12 - Packing 25 - Safety relay
13 - Planetary gear
W5-12-4
Removing pinion set

1. Install the jig to hold the pinion.
SM3411
Removing pinion set (1)
2. Place an appropriate tube on the pinion

stopper. Hit the tube with a hammer to push the
pinion stopper down.
SM3412
3. Remove the clip ring using snap ring plier.
NOTE: do not reuse the clip ring for reassembly.
SM3413
4. Remove the pinion stopper, pinion, spring.
NOTE: check the pinion for wear and damage.
SM3414
W5-12-5
Removing magnet switch

1. Disconnect the terminal M leads on the
magnetic switch.
SM3415
Removing magnet switch (1)
2. Remove the through bolts, and remove the

magnetic switch.
SM3416
Removing magnet switch (2)
Removing rear bracket

1. Remove the screws from the rear bracket.
SM3417
Removing rear bracket (1)
2. Remove the through bolts, and remove the rear

bracket.
SM3418
Removing rear bracket (2)
W5-12-6
Removing brush holder and brush assembly

1. Remove the brush holder.
2. Lift the brush spring up, and remove the brush
from the brush holder
SM3419
Removing brush
Removing yoke and armature

1. Remove the yoke, and the armature.
SM3420
Removing yoke and armature (1)
2. Remove the front side O-ring (1) and the rear

side O-ring (1). Do not reuse the removed O-
ring (1). Replace it with new one.
1 1
SM3421
Removing yoke and armature (2)
W5-12-7
Removing planetary gear

1. Remove the cover.
SM3422
Removing planetaly gear (1)
2. Remove the packing.
SM3423
3. Remove the planetary gears.
SM3424
4. Remove the balls from the shaft.
NOTE: be careful not to lose the balls.
SM3425
W5-12-8
Removing overrunning clutch

1. Remove the packing, the plate and the spring.
SM3426
Removing overrunning clutch (1)
2. Remove the shift lever and overrunning clutch

from the front bracket cover.
SM3427
3. Insert the flat-blade screwdriver to the groove of

the E-ring, then remove the E-ring.
SM3428
4. Remove the overrunning clutch.
SM3429
W5-12-9
Removing internal gear

Remove the internal gear.
SM3430
Removing internal gear
W5-12-10
Inspecting and repairing starter

Inspecting magnetic switch
Inspect the pressure coil and the holding coil for
open circuit using the tester.
Inspect the electrical continuity between the
terminal M and the case, if there is no electrical
continuity between them, the magnetic switch circuit
is an open circuit.
SM3431
Inspecting magnetic switch contactor

The service limit of the contactor is decided by the
1
condition of the contact surface. Inspect the
contactor by following method. Measure the load C
current of the starter. If the voltage drop between the B
A
terminal B and the terminal M is 0.3 V per 100 A or 2
more, replace the magnetic switch. C2 C1
M V
F1
NOTE: 4
a) When measuring the voltage drop, use a digital 3
Ar
volt meter (3). Measuring by an analog volt
meter results breakage. 5 E
b) Be extremely careful when connecting an SM3432
ammeter (1) to the starter (4) because of the Inspecting magnetic switch contactor
high current flowing into the starter. 1- Ammeter
2- Battery
3- Digital voltmeter
4- Starter
Measuring armature shaft runout

Using a dial gauge, measure the shaft runout. If the
runout exceeds the standard, repair or replace the
armature (1). 1
Item Standard
Armature shaft (1) runout 0.06 mm (0.0024 in)
SM3433
W5-12-11
Measuring commutator radial runout

1. Inspect the commutator (1) surface. If the
surface is rough, polish it using a 400 to 600 grit
sandpaper.
2. Measure the commutator (1) radial runout with
a dial gauge. If the measured value exceeds
the limit, replace the armature with a new one.
Item Standard
Commutator radial runout 0.10 mm (0.0039 in)
1
SM3434
Measuring commutator radial runout
Measuring undercut depth

Measure the depth of undercutting between the
commutator segments.
If the measured value is less than the limit, repair or
replace with a new part. B
C
A
Item Standard Limit
0.7 to 0.9 mm 0.2 mm
Undercutting depth 0.7 to 0.9 mm
(0.028 to 0.035 in) (0.008 in) [0.028 to 0.035 in.]
A - Defective (need recutting)
B - Insufficient recutting
C - Good SM3435
Measuring undercut depth
Inspecting insulation between commutator and

shaft (core)
1. Inspect the armature coil using a growler (1).
Apply a iron plate (2) to the armature core.
2
Replace the armature if the iron plate vibrates. 1
SM3436
Inspecting armature coil for short circuit
2. Check the insulation between the commutator

and the shaft with a tester. If faulty, replace the
armature with a new one.
SM3437
Inspecting insulation between commutator and shaft
W5-12-12
Inspecting field coil

1. Inspect the field coil for open circuit with a
tester. It is an open circuit if there is no
conticuity between the terminal M of field coil
and the bush lead.
2. Inspect the electrical conticuity between the
field coil and the yoke with a tester.
SM3438
Inspecting field coil for open circuit
Inspecting overrunning clutch

1. Rotate the pinion by hand and check that the
pinion rotates lightly to one direction.
2. Inspect the tooth flank. If wear or damage is
found, replace it with new one.
SM3439
Inspecting over running clutch
Inspecting reduction gear

Inspect the reduction gear for wear.
SM3440
Inspecting reduction gear
Inspecting bearings
Rotate the outer race of bearing (1) by hand. Check
that the outer race rotates smoothly.
1
SM3441
Inspecting bearing
W5-12-13
Inspecting brushes for wear

Measure the length of the brushes. If the measured
value is less than the limit, replace both the brush
holder assembly
[0.67 to 0.71]
Item Standard Limit
[0.40]
17 to 18
10
17 to 18 mm 10 mm
Brush length
(0.67 to 0.71 in) (0.40 in)
A
SM3442
Inspecting brush for wear

A - Wear limit (Unit: mm [in])
Measuring brush spring load

Using a new brush, measure the spring load at
which the spring lifts from the brush. If the measured
value is less than the limit, replace the spring with a
new one.
Item Standard Limit

Brush spring load Less than
21.56 to 27.44 N
(when spring is 21.56 N
(15.9 to 20.3 lbf)
installed) (15.9 lbf)
Inspecting safety switch
CAUTION
When connecting the battery, be sure to connect the A
battery in correct polarity.
B
Connect the components as shown and check the
operation of starter and safety switch.
1. Connect the terminal R (C) to the battery
negative terminal.
2. Turn on the switch and check if the starter C
operates (rotates).
3. While operating the starter, disconnect the SM3443
terminal R from the battery negative terminal Inspecting operation of safety switch
and connect the Inspecting operation of safety A - Safety relay ground (E) terminal
switch terminal R to the battery positive B - Terminal S
terminal. Check if the starter stops. C - Terminal R
NOTE: on some specifications, starter stops

operation when the connection to the battery
negative terminal is disconnected.
W5-12-14
Reassembling starter
To reassemble the starter, follow the disassembly in
reverse order and observe bellow.
Installing E-ring
Install the washer, the center bracket and
overrunning clutch assembly to the shaft, and install
the E-ring.
NOTE: install the E-ring using a plier.
SM3444
Inspecting E-ring
Installing shaft lever

Being careful with the direction, install the shift lever.
NOTE: apply grease (Nikko grease R) to the shift

lever when reassembling.
SM3445
Installing shift lever
Installing ball
Be careful not to forget to install the ball to the shaft
before installing the planetary gears.
SM3446
Installing ball
W5-12-15
Installing cover
Be careful with the installation position when
installing the cover (2).
SM3447
Installing cover
1- Notch
2- Cover
Installing yoke
1. Install the yoke to the front bracket with aligning
the mark.
SM3448
Installing yoke (1)
2. Install the yoke to the rear bracket with aligning

the mark.
SM3449
Installing yoke (2)
W5-12-16
Installing pinion
1. Install the spring and the pinion, and install the
jig (plate) (1).
1
SM3450
Installing pinion (1)
2. Install the pinion stopper. Insert the clip ring to

the jig (holder (1)) and install the clip ring using
the jig (guide (2)).
1
2
SM3451
3. Using the jig (presser), install the clip ring to the

pinion stopper.
SM3452
W5-12-17
Disassembling and inspecting alternator
4 5
6
3
3
11 Crack, damage
Rotation
10
9
12
7
17
Coil open circuit, ground
3
14
8 13
Rotation
22 Short or open circuit
16 20
18 19
23
15
Crack, damage
21
2 1
SM3453
Disassembling and inspecting alternator
1- Screw 13 - Rear bearing
2- Cover 14 - Rotor
3- Through bolt 15 - Screw
4- Nut, spring washer, plain washer 16 - Field coil
5- Pulley 17 - Stator coil
6- Fan 18 - Holder
7- Collar 19 - Regulator
8- Screw 20 - Terminal B
9- Retainer 21 - Condensor
10 - Front bearing 22 - Rectifier
11 - Front bracket 23 - Rear bracket
12 - Collar
W5-12-18
Removing cover
Remove the screws, and remove the cover.
SM3454
Removing alternator cover
Removing through bolts

Remove the through bolts which secures front side
and rear side.
SM3455
Removing through bolt
Disassembling the alternator to front side and

rear side
1. Disassemble the alternator to front side and
rear side. Disassemble the alternator with
heating the rear bracket bearing case (1).
Disassembling the alternator without heating 1
the rear bracket bearing case cause the
damage of the alternator.
NOTE: be sure to heat the rear bracket bearing

case only. Do not heat the other parts.
SM3456
Disassembling alternator to front side and rear side (1)
2. Remove the rotor from the front bracket using

press.
Then, use the through bolt hole.
A
NOTE: do not hit the alternator with plastic hammer.
A - Protect the parts from damage
SM3457
Disassembling alternator to front side and rear side (2).
W5-12-19
Removing fan and pulley

Remove the nuts using an inpact wrench, then
remove the spring washer, the plain washer, the
pulley, the fan and the collar.
NOTE: fixing the rotor with vice could result the

deformation. Do not use the vice.
SM3458
Removing fan and pulley
Removing rotor
Remove the rotor from the front bracket.
NOTE:
(a) Remove the rotor using the press.
(b) When working with the rotor, place the buffer
under the rotor to prevent the damage.
SM3459
Removing rotor
Removing front bearing

1. Remove the screws, and remove the retainer.
SM3460
Removing retainer
2. Remove the front bearing from the front

bracket.
NOTE: do not reuse the removed front bearing.

Replace it with new one.
SM3461
Removing bearing
W5-12-20
Removing field coil

1. Unsolder the field coil and regulator.
NOTE: unsoldering must be finished by 5 seconds

or less.
SM3462
Removing field coil (1)
2. Remove the screws, and remove the field coil.
SM3463
Removing field coil (2)
Removing stator
1. Unsolder the stator coil and the rectifier.
SM3464
Removing stator (1)
2. Remove the stator from the rear bracket.
SM3465
Removing stator (2)
W5-12-21
Removing rear bracket locked-in parts

1. Remove the screws from the rear bracket.
2. Remove the screws from the regulator (3), and 1 2
remove the regulator.
4
3. Remove the screw from the terminal B (1), and
remove the terminal B.
4. Remove the screw from the condensor (4), and
remove the condensor. 3
5. Remove the rectifier (2) assembly.
SM3466
Removing rear bracket locked-in parts
W5-12-22
Inspecting alternator
Inspecting rectifier
Check the rectifier for resistance of forward direction
and reverse direction.
If the resistance of forward direction is low, and the
resistance of reverse direction is high, it is normal.
If test result is not as above, it is faulty. Replace the
rectifier with new one.
SM3467
Inspecting rectifier
Inspecting condensor
Charge the condensor with a tester.
(Range × 1000)
Connect the tester lead in reverse direction. It is
normal that the pointer moves slightly and return.
condensor with new one.
SM3468
Inspecting condensor
Inspecting regulator
Measure the resistance between the regulator
connector R and L with a tester.
(Range × 1000) If the diode of the regulator and
the resistor of the regulator are normal, the
resistance of the forward direction is low and the
resistance of the reverse direction is high.
regulator with new one.
SM3469
Inspecting regulator
W5-12-23
Inspecting field coil

1. Inspect the insulation of the field coil. Measure
the electrical continuity between the terminal
and the core with a tester.
(Range × 1000)
Replace the field coil with new one if electrical
continuity is indicated.
SM3470
Inspecting field coil (1)
2. Measure the resistance between the terminals

of field coil.
If measured resistance is Approx 6.62 (When
20°C - 68 °F), it is normal.
If test result is not as above, it is faulty. Replace
the field coil with new one.
SM3471
Inspecting field coil (2)
Inspecting stator coil

1. Inspect the insulation of the stator coil. Measure
the electrical continuity between the stator coil
and the core with a tester.
(Range × 1000)
Replace the stator coil with new one if electrical
continuity is indicated.
SM3472
Inspecting stator coil (1)
2. It is normal that the electrical continuity is

indicated between the stator coil lead N and
other three leads.
If test result is not as above, it is faulty. Replace
the stator coil with new one.
SM3473
Inspecting stator coil (2)
W5-12-24
Inspecting bearings
Inspect the bearing for smooth rotation and
abnormal noise. If abnormality is found, replace the
bearing with new one.
SM3474
Inspecting bearing
W5-12-25
Reassembling alternator
To reassemble the alternator, follow the disassembly in reverse order and observe bellow.
Installing rectifier
When reassembling the rectifier, apply rocktite to
the screws.
SM3475
Installing rectifier
Soldering field coil and regulator
Soldering field coil and regulator must be finished as
quickly as possible.
SM3476
Soldering field coil and regulator

Soldering stator coil and rectifier
Solder the stator coil and rectifier after caulking.
Soldering must be finished as quickly as possible.
SM3477
Soldering stator coil and rectifier

Reassembling front bearing
Reassemble the front bearing with heating the front
bearing case.
Reassembling the front bearing without heating the
front bearing case cause the damage of front
bearing.
SM3478
Reassembling front bearing
W5-12-26
Reassembling front bracket and rotor

Use a press to reassemble the front bracket and the
rotor.
1
NOTE: be careful not to forget to install the collar (1)
when reassembling.
SM3479
Reassembling front bracket and rotar
Installing rear bracket

Reassemble the rear bracket with heating the
bearing case.
NOTE:
(a) Reassembling the rear bracket without heating
the bearing case cause the damage of the
bearing.
(b) Be sure to heat the bearing case only. Do not
heat the other parts.
SM3480
Installing rear bracket
Installing through bolt

Install the through bolt with fixing the front side and
the rear side using the alternator installation hole.
SM3481
Installing through bolt
Inspecting after reassembling

After reassembling, rotate the pulley by hand to
check the smooth rotation.
SM3482
Inspecting alternator after reassembling
W5-12-27
Performance test of alternator

Measure the adjusting voltage and output current with wiring as schematic bellow.
1 2 SW1 SW2
CL (24V 3W)
+
V
-
SM3483
Electric schematic of IC regulator built-in alternator performace test.
1- Terminal R 2- Terminal L
Measuring regulator adjusting voltage Measuring output current

1. Close the SW1, and operate the alternator at Close the SW1 and SW2. Measure the maximaum
1500min-1 for 5 to 10 minutes until the ammeter output current with a variable resistor operating the
indicates 6 A or less. alternator at 5000min-1 and keeping the indication of
2. Make sure that ammeter indicates 2 to 6 A or voltmeter at 27 V. It is normal that the measured
less, then operate the alternator at 3000 to output current is 50A or more.
4000 min-1.
If the indication of voltmeter is within the CAUTION
standard value, the adjusting voltage of the (a) Do not disconnect the battery when operating
alternator is normal. the alternator.
(b) Do not connect the terminal L (2) when the
3. If the indication of ammeter is 6 A or more,
charge lamp (24V, 3W) is not used. The
charge the battery for a while or replace the
terminal L and circuit B must not be connected.
battery with fully charged one.
It causes damage of diode.
If the indication of voltmeter is out of the
standard value, replace the regulator with new
one.
Item Standard
Adjusting voltage 27.5 to 29.5 V (at 25°C - 77 °F)
W5-12-28
Installing electrical system
Installing starter
35.3 ± 5.9 Nm
[255.4 ± 42.6 lbf·ft]
SM3484
Installing starter
W5-12-29
Installing alternator
97 ± 9.7 Nm
[71.6 ± 7.2 lbf·ft]
SM3485
Installing alternator
W5-12-30
Replacing ECU
Removing ECU
1. Make sure that the ignition switch is in the OFF
position.
2. Uplift the lever of the connector, and pull out the
connector. Then, do not pull the harness. Pull
out the connector with holding the connector.
NOTE:
a) Do not forget to uplift the lever before pulling
out the connector. Do not pull the connector
forcedly.
b) Be careful for the removed connector not to SM3486
contact with other parts. Replacing ECU (1)
3. Remove the ECU mouting bolts.

4. Remove the ECU.
Installing ECU
1. Make sure that the Q-Rank number attached on
the new ECU is same as the number attached
on the previous ECU.
NOTE: if the ECU which has different Q-Rank

number is installed, it causes the excess and
deficiency of the engine power. SM3487
Replacing ECU (2)

2. Install the ECU and tighten the ECU mouting
bolts to specified torque.
3. Push the connector into the ECU securely, and
push down the lever to lock. After connecting,
check the connector for excessive play.
Test operation after replacing ECU

1. Turn the ignition switch to ON position. If the
diagnosis code is not displayed on the monitor
for 2 to 3 minutes, start the engine and operate
the engine in low idle.
2. Inspect that the diagnosis code is displayed on
the monitor. Inspect the engine for noise, odor
and vibration.
W5-12-31
Installing sensors
2
25 ± 2 Nm
[18.1 ± 1.4 lbf·ft]
1
9 ± 1 Nm
[6.5 ± 0.7 lbf·ft] 3
21 ± 2 Nm
[15.2 ± 1.5 lbf·ft]
4
1.0 ± 2 Nm
[7.2 ± 1.4 lbf·ft]
5
6 9 ± 1 Nm
29.4 ± 4.9 Nm [6.5 ± 0.7 lbf·ft]
[212.8 ± 35.5 lbf·ft]
SM3488
1- Speed/timing sensor (crankshaft side) 4- Oil pressure switch

2- Inlet manifold pressure sensor 5- Speed/timing sensor (camshaft side)
3- Water temperature sensor 6- Pick up
W5-12-32
ADJUSTMENT AND OPERATION E135B
ADJUSTING ENGINE
Inspecting and adjusting valve clearance

Inspect and adjust the valve clearance.
The valve clearance should be inspected and
adjusted when the engine is cold.
NOTE:
a) The inlet values are on the left side and the
exhaust values are on the right side when the
cylinder head is viewed from the camshaft gear
side.
b) The valve clearance standard values are
indicated on the caution plate on the No.1
cylinder rocker cover.
Item Standard
Inlet 0.25 mm (0.0099 in)
Valve clearance
Exhaust 0.40 mm (0.0157 in)
Inspecting valve clearance

1. Inspect the valve clearance for all cylinders in Model Firing order Turning angle
the firing order by turning the crankshaft to the D04FR 1-3-4-2 180°
specified degrees in the normal direction
(clockwise when viewed from engine front side)
to bring each piston to the top dead center on
the compression stroke.
NOTE: to turn the crankshaft, fit a socket and

ratchet handle nut.
2. When the No. 1 piston is at the top dead center 1

on the compression stroke, the "0" graduation
mark on the periphery of the crankshaft pulley 0 40
(1) is aligned with the pointer on the timing gear
case, and neither the inlet Inspecting valve SM3489
clearance valve nor the exhaust valve is not Inspecting valve clearance
lifted off its seat by the push rod.
3. Insert a thickness gauge between the rocker
arm and valve cap to inspect the clearance.
Adjusting valve clearances

1. Insert the feeler gauge of the specified
thickness between the rocker arm and bridge
cap, then adjust the clearance by turning the
screw in either direction so that the gauge is
gripped softly between the rocker arm and
bridge cap.
2. After adjusting the clearance, tighten the lock
nut firmly, and inspect the clearance again.
SM3490
W5-13-1
E135B ADJUSTMENT AND OPERATION
Inspecting belt and adjusting belt tension
CAUTION
a) If defects such as cuts or surface separations
are found during inspection, replace the belt
1
(3).
b) Keep oil and grease away from the belt, since 2
they may cause the belt to slip and shorten the
service life.
c) Excessive belt tension can cause rapid wear of 3
the alternator (2) bearing and shorten the
service life of the belt. Adjust the belt tension
accurately by fol-lowing the procedures below.
SM3491
Adjusting belt tension
Checking the belt

1. Inspect the belt (3) visually for separation or
damage. If any abnormality is found, replace
the belt with a new one.
2. Inspect belt tension (deflection).
When pressing the belt strongly at the center of
its span, the deflection for a new belt should be
5±1 mm (0.20±0.04 in)and the deflection for the
belt that is reused should be 8±1 mm
(0.32±0.04 in)
Force on the belt: Approximately 98±10 N
(22±2.2 lbf)
If the deflection of belt is not within the
standard, adjust the belt tension.
Adjusting the belt tension

1. Remove the belt cover.
2. Loosen all retaining bolts of the alternator (2)
and adjusting plate.
3. Adjust V-belt tension properly with the adjusting
bolt (1).
4. Tighten all retaining bolts of the alternator and
adjusting plate.
5. Install the belt cover.
W5-13-2
BREAK-IN OPERATION
After the engine is overhauled, couple the engine to

the dynamometer, and run the engine for break-in
operation and inspection.
Starting up Break-in operation time

1. Before starting the engine, check the levels of The relationship between the load in break-in
coolant, engine oil and fuel. Bleed air from the operation and the operation time is as shown below.
fuel and cooling systems.
2. Stop the fuel supply, and crank the engine with Break-in operation time
the starter for about 10 seconds to lubricate the Duration
engine. Engine speed (min-1) Load
(min)
3. Move the control lever slightly in the fuel Low
1 rotation 800 to 1100 No-load 5
increase direction (but not to the "full injection"
speed
position), and then turn the starter switch key to
Medium
the [START] position to start the engine. 2 rotation 1200 to 1500 No-load 5
4. After the engine is started, adjust the control speed
lever to let the engine operate at a minimum no- High
1600 to rated
load speed (low idle speed). 3 rotation No-load 10
speed
speed
5. Turn the starter switch key to the [OFF] position 4 25 % 10
and make sure that the engine is stopped.
5 50 % 10
Rated speed
6 75 % 30
7 100 % 20
Inspecting engine condition after starting up
NOTE: the table above is provided solely for
During the break-in operation, check the followings.
reference purpose. Run the engine at appropriate
If any abnormality is found, stop the engine,
speed and load for the break-in operation of your
investigate the cause, and take appropriate
engine. Be sure to perform break-in operation after
measures.
overhaul or installation.
1. The oil pressure must be within the specified
value.
2. The coolant temperature must be within the
specified value. Inspection and adjustment after break-in
3. The engine must be free from any leakages operation
such as oil, coolant and fuel. Pay special 1. Valve clearance adjustment
attention to oil leakage from the fitting face of
turbocharger lube oil pipe. 2. Ignition timing inspection
4. Check for an abnormal noise. 3. Exterior bolt and nut tightness check
NOTE: knocking noise will disappear as the coolant

temperature rises.
5. Check for the color of smoke and odors.
W5-13-3
PERFORMANCE TEST (JIS STANDARD)
The following describes the procedures specified in

"Earth moving machinery - Engines - Part 1: Test
code of net power (JIS D0006-1)" and "Earth
moving machinery -Engines - Part 2: Standard
format of specifications and testing methods of
diesel engines (JIS D0006-2)."
Other test items may be required in some
applications. All test results should be evaluated
comprehensively in order to determine the engine
performance.
Engine equipment condition

The engine must be equipped with standard
auxiliary devices such as cooling fan, air cleaner
and alternator.
Test items and purposes

Operation load test
Conduct this test to evaluate the engine output,
torque, fuel consumption rate and governor
performance under various load conditions.
Continuous load test

Operate the engine continuously for 10 hours at
90% load (continuous load application) of nominal
net brake power while the engine speed is
maintained at revolutions corresponding to the
nominal brake power. In this test, evaluate the fuel
consumption rate and operating condition, and
confirm that the engine is capable of continuous
operation.
Low idle test

Conduct this test to confirm that the engine can
operate stably at the specified low idle speed.
Other inspections
Check for gas, coolant and oil leaks; abnormal
odors; and hunting. Make adjustment as needed.
Engine output adjustment

Diesel engine output is affected by atmospheric
pressure, temperature and humidity. Therefore,
correction calculations must be performed to obtain
the value of engine output under the standard
atmospheric conditions.
Standard atmospheric conditions:

Base temperature: 298 K (25°C) (77 °F)
Total pressure: 100 kPa (750 mmHg)
Dry pressure: 99 kPa (743 mmHg)
W5-13-4
Calculation of corrected power

Multiply the measured brake power or torque by the
calculated diesel engine correction factor to obtain a
corrected value.
If the applicable range of the correction formula is
exceeded, indicate the corrected values and record
the test conditions on the test record.
Colculation output = Correction factor c Measured brake power

Atmospheric conditions during test
Temperature(T ): T
Dry atmospheric pressure(Pd ): Pd
fm
c=( f a) f a:Atmospheric factor fm Engine factor
Range of correction equation use

c
0.9 c 1.1.
Calculation of engine factor fm
Calculation of correction factor( f a ) f m 0.036qc 1.14
Natural aspiration engine and engine with qc
mechanically driven air charger q
qc r
fa 99 T
z g/s
Pd 298 q=
l min-1
Turbocharged engine without air cooler z=120000 4
or with air-to-air cooler r
fa 99 T
Pd 298 r=1
Applicable range of engine factor fm
Turbocharged engine with air-to-liquid
37.2 qc 65mg l
cooler fm
99 T qc 37.2mg l
fa 65mg l qc f m
Pd 298
SM3538
W5-13-5
NOTE:
W5-13-6
TROUBLESHOOTING BY DIAGNOSIS CODES
Outline of control system Connecting scan tester and ECU

This engine is controlled by electronic control unit To see the diagnosis code, connect the scan tester
(ECU). to the ECU.
The engine has the control parts and the sensors 1. Turn the ignition switch to OFF position.
that monitors the engine operation.
2. Connect the scan tester connector to the
The ECU monitors the engine operation using the
service connector which is located on the
inputs from various sensors, and controls the
vehicle.
injectors and the fuel injection pump.
This control system can provide appropriate engine 3. Turn the ignition switch to ON position.
control for operating condition.
When ECU does not respond
Diagnosis codes
If the scan tester does not display with connecting to
When the ECU detects the abnormal engine the service connector, following conditions can be
operation receiving signal input from the sensors, concerned.
the ECU generates an error code which is called a • The harness and/or the connector between the
diagnosis code. The diagnosis code includes the service connector and the ECU are faulty.
one which warns the critical failure, and also the one • The ECU is faulty.
which warns the light fault. The diagnosis code can
At first, inspect the harness and connectors
be seen on the monitor located on the vehicle. It
between the service connector and the ECU. For
also can be seen by connecting the scan tester
the inspection, refer to "Inspecting wiring".
(32G91-00600) to the ECU directly.
If the harness and the connectors are not faulty,
replace the ECU. For the replacement of ECU, refer
to "Replacing ECU".
CAUTION
The engine may operates even if the ECU does not
respond with the scan tester. In this case, it is
possible that there are faults on the CAN circuit
(communica-tion circuit connecting the ECU and
vehicle control unit) inside the ECU. Do not operate
the engine except emergency situation, replace the
ECU.
W5-14-1
E135B TROUBLESHOOTING
SCAN TESTER
mastertech
2 3
YES NO ENTER
F1 F2 F3
HELP
1 2 3
F4 F5 F6
RCV
4 5 6 4 5
F7 F8 F9
SEND
7 8 9
F0 ON
EXIT
0 #
OFF
Vetronix
1
6
SM3492
Operation of scan tester

Use scan tester (1) to check the engine status and
the diagnosis codes.
Basic operation of scan tester

1. Make sure that ignition key is OFF position. 9. The menu screen of OBD II FUNCTIONS (3) is
2. Connect the scan tester to the service displayed.
connector on the vehicle. 10. Press EXIT key to return the previous screen.
3. Turn the ignition key to ON position to energize 11. With pressing ON key, press EXIT key to turn
the ECU. off the scan tester.
4. Press ON key located on the lower right section 12. Turn the ignition key to OFF position to turn off
of scan tester to energize the scan tester. When the ECU.
the scan tester is energized, startup screen (2)
is displayed.
5. Press ENTER key.
6. FUNCTION MENU (4) is dispalyed. Select
SCAN TEST and press ENTER key.
7. SELECT PROGRAM (6) is displayed. Select
GLOBAL OBD II and press ENTER key.
8. OBD II TEST MENU (5) is dispalyed. Select
OBD II FUNCTIONS and press ENTER key.
W5-14-2
Check engine status

1. Select DATA LIST from the OBD II
FUNCTIONS menu and press ENTER key. mastertech
2. The engine status is displayed. Check the

engine status.
Vetronix
SM3493
Engine status screen
Check diagnosis codes

1. Select DTCs from the OBD II FUNCTIONS
menu and press ENTER key. mastertech
2. DTC MENU is dispalyed. Select READ DTCs

and press ENTER key.
3. The diagnosis codes are displayed. The
diagnosis codes are displayed in the order of
generating. To display the previous generated
codes, press down key.
Vetronix
SM3494
Diagnosis code screen
Check freeze data

2. DTC MENU is dispalyed. Select FREEZE

DATA and press ENTER key.
3. The FREEZE DATA is displayed. The FREEZE
DATA is a backup data saving the engine
status screen of when the diagnosis code is
generated.
Vetronix
SM3495
Freeze data screen
Clear diagnosis codes

2. DTC MENU is dispalyed. Select CLEAR DIAG

INFO and press ENTER key.
3. The confirmation screen is displayed. Press
YES key, and press ENTER key to delete the
diagnosis codes. However, the diagnosis
codes cannot be deleted until the recovery is
completed. Vetronix
SM3496
Clear DIAG screen
W5-14-3
DIAGNOSIS CODE CROSS REFERENCE
The P code shown in the chart below is displayed by connecting the scan tester to the service connector.
The vehicle side code is displayed on the vehicle monitor. Check the correspoding codes by following chart.
For the detail and treatment of diagnosis codes, refer to "Troubleshooting reference chart".
Diagnosis code cross reference (1 / 4) Diagnosis code cross reference (2 / 4)

J1939 Vehicle J1939 Vehicle
P code Item code side P code Item code side
(DTC) code (DTC) code
Discrepancy between P0215 Shut off pass test 1110-12 1110-8
P0016 228-3 228-1
crank and cam signal MPROP power stage
P0230 2001-3 2001-1
Backup control using short-circuit to battery
P0021 635-3 635-1
cam side signal MPROP power stage
P0231 2002-4 2002-2
P0089 DBV valve opening 2041-3 2041-1 short-circuit to ground
P0089 DBV kick off 2042-4 2042-2 MPROP power stage
P0252 2000-2 2000-4
P0090 DBV closed fixation 2043-2 2043-4 open circuit
DBV pressure is too MPROP power stage

P0091 2045-4 2045-2 P0252 2000-12 2000-8
low overload
DBV pressure is too Inlet manifold pressure
P0092 2044-3 2044-1 P0235 102-12 102-8
high sensor
Water temperature Inlet manifold pressure
P0117 110-4 110-2 P0237 102-4 102-2
sensor sensor
Water temperature Inlet manifold pressure

P0118 110-3 110-1 P0238 102-3 102-1
sensor sensor
Accelerator signal P0261 Injector No.1 657-2 657-4

P0121 383-12 383-8 P0262 Injector No.1 657-3 657-1
comparison
P0122 Accelerator sensor 1 29-4 29-2 P0263 Injector No.1 657-12 657-8
P0123 Accelerator sensor 1 29-3 29-1 P0264 Injector No.2 659-2 659-4
Rail pressure governor P0265 Injector No.2 659-3 659-1
P0191 2013-3 2013-1
deviation P0266 Injector No.2 659-12 659-8
Rail pressure governor P0267 Injector No.3 661-2 661-4
P0191 2014-3 2014-1
deviation
P0268 Injector No.3 661-3 661-1
Rail pressure governor
P0191 2015-3 2015-1 P0269 Injector No.3 661-12 661-8
deviation
P0270 Injector No.4 663-2 663-4
P0192 Rail pressure SRC 2011-4 2011-2
P0271 Injector No.4 663-3 663-1
P0193 Rail pressure SRC 2011-3 2011-1
P0272 Injector No.4 663-12 663-8
Rail pressure sensor
P0192 2012-4 2012-2 Speed/timing sensor
offset monitoring P0336 637-4 637-2
(crankshaft side)
Rail pressure sensor
P0193 2012-3 2012-1 Speed/timing sensor
offset monitoring P0339 637-3 637-1
(crankshaft side)
P0194 Rail pressure governor 2016-3 2016-1
Speed/timing sensor
P0194 Rail pressure governor 2017-3 2017-1 P0341 636-4 636-2
(camshaft side)
P0201 Injector No.1 658-2 658-4
Speed/timing sensor
P0202 Injector No.2 660-2 660-4 P0344 636-3 636-1
(camshaft side)
P0203 Injector No.3 662-2 662-4 Air heater relay power
P0540 677-12 677-8
P0204 Injector No.4 664-2 664-4 stage
P0215 Shut off pass test 1110-4 1110-2
P0215 Shut off pass test 1110-2 1110-4
W5-14-4
Diagnosis code cross reference (3 / 4) Diagnosis code cross reference (4 / 4)

J1939 Vehicle J1939 Vehicle
P code Item code side P code Item code side
(DTC) code (DTC) code
Air heater relay power P060B ADC monitoring 2008-12 2008-8
P0541 677-4 677-2
stage P060D CAN accelerator 91-2 91-4
Air heater relay power APPREQ message
P0542 677-3 677-1 P060E 1674-2 1674-4
stage time out
Air heater relay power P061C Engine speed 2005-3 2005-1
P0543 677-2 677-4
stage
P062D Injector drive bank 1 651-12 651-8
Power supply unit
P0562 1543-4 1543-2 P062E Injector drive bank 2 653-12 653-8
voltage too low
P062F EEPROM 1235-4 1235-2
Power supply unit
P0563 1542-3 1542-1 P062F EEPROM 1235-2 1235-4
voltage too high
CAN transmitting time P062F EEPROM 1235-12 1235-8
P0600 2028-2 2028-4
out P0933 Oil pressure switch 19-12 19-8
P0600 CAN (A) pass off 1671-3 1671-1 P0933 Oil pressure switch 100-12 100-8
P0600 CAN (C) pass off 1673-3 1673-1 P2047 Injector drive bank 1 651-4 651-2
SPI communication P2049 Injector drive bank 1 651-3 651-1
P0606 1231-3 1231-1
error P2050 Injector drive bank 2 654-2 654-4
P0606 Super vision 1484-12 1484-8 P2051 Injector drive bank 2 653-4 653-2
P0607 Recovery occurred 1668-12 1668-8 P2052 Injector drive bank 2 653-3 653-1
P0607 Recovery occurred 1670-12 1670-8 Atomospheric pressure
P2228 108-4 108-2
P0607 SPI watch dog error 2010-12 2010-8 sensor
P0611 Injector IC 655-3 655-1 Atomospheric pressure
P2229 108-3 108-1
P0611 Injector IC 655-4 655-2 sensor
P0611 Injector IC 655-2 655-4
P0611 Injector IC 655-12 655-8
P0611 Injector IC 656-3 656-1
P0611 Injector IC 656-4 656-2
P0611 Injector IC 656-2 656-4
P0611 Injector IC 656-12 656-8
Sensor supply voltage
P0642 1079-4 1079-2
monitoring 1
P0643 1079-3 1079-1
monitoring 1
P0652 1080-4 1080-2
monitoring 2
P0653 1080-3 1080-1
monitoring 2
P0698 620-4 620-2
monitoring 3
P0699 620-3 620-1
monitoring 3
P060A TPU monitoring 2009-12 2009-8
P060B ADC monitoring 2008-3 2008-1
W5-14-5
TROUBLESHOOTING REFERENCE CHART
Troubleshooting with diagnosis code
NOTE: the diagnosis codes which has * mark in the "Recovery" column recovers when the cause of fault has
deleted and the engine has restarted.
P0016: Discrepancy between speed/timing sensor P0117 : Water temperature sensor

(crankshaft side/camshaft side) signal
Vehicle side code: 110-2
Vehicle side code: 222-8 Faulty part Water temperature sensor
Speed/timing sensor (crankshaft The ECU detectes a faulty
Faulty part
side/camshaft side) operation of the water
The ECU detects a discrepancy Detail temperature sensor (open cir-cuit,
between speed/timing sensor short circuit). The input voltage
Detail
(crankshaft side/ camshaft side) falls below the limiting value.
signal. Recovery *
Recovery * When engine is operated, the
The ECU controls the engine ECU controls the engine as
using speed/timing sensor overheated with fixing the
Control (crankshaft side) signal. temperature 120°C (warm mode).
Control
The ECU limits the maximum When starting the engine, the ECU
speed of the engine. controls the engine with fixing the
The maximum speed is limited to water temperature -20°C (cold
Speed limit mode).
50%.
Inspection Contact a dealer. When the water temperature is
Speed limit 100°C or above, the ECU controls
the engine as overheated.
P0021: Backup control using camshaft side signal Water temperature sensor, and
Vehicle side code: 635-1 Inspection wiring of water temperature
sensor.
Speed/timing sensor (crankshaft
Faulty part
side)
The engine is operating without P0118 : Water temperature sensor
speed/ timing sensor (crankshaft
Detail side) signal. The ECU controls the
engine using cam-shaft side Faulty part Water temperature sensor
signal. The input voltage exceeds the
Detail
Recovery * limiting value.
The ECU limits the maximum Recovery *
Control
speed of the engine. When engine is operated, the
The maximum speed is limited to ECU controls the engine as
Speed limit overheated with fixing the
50%.
temperature 120°C (warm mode).
Speed/timing sensor (crankshaft Control
When starting the engine, the ECU
Inspection side) and wiring of speed/timing
controls the engine with fixing the
sensor (crankshaft side).
water temperature -20°C (cold
mode).
When the water temperature is
Speed limit 100°C or above, the ECU controls
the engine as overheated.
Water temperature sensor, and
Inspection wiring of water temperature
sensor.
W5-14-6
P0121 : Accelerator signal comparison P0191 : Rail pressure governor deviation

Vehicle side code: 383-8 Vehicle side code: 2013-1
Accelerator signal (CAN signal, Faulty part Common rail
Faulty part
analog signal)
The rail pressure control is
The ECU compares the CAN Detail abnormal. The target pressure is
signal and analog signal, and not achieved.
Detail
detects a discrepacy between
Recovery -
them.
The ECU limits the maximum
When a discrepancy is deleted, it Control
Recovery speed of the engine.
recovers automatically.
The maximum speed is limited to
Control The ECU warns to the operator. Speed limit
75%.
Speed limit -
Inspection Damage on the common rail.
CAN signal and analog signal
Inspection
wiring.
P0122 : Accelerator sensor 1 Faulty part Common rail
The rail pressure control is
Vehicle side code: 29-2 abnormal. The target pressure is
Detail
Faulty part Accelerator signal (analog signal) not achieved even fully pressured
The ECU detects a faulty analog by fuel pump.
signal input from vehicle controller. Recovery *
Detail
The input voltage falls below the Control Engine stop
limiting value.
Speed limit -
When the input voltage recovers to
Recovery the specified value, it recovers
automatically.
When operating by CAN signal, P0192 : Rail pressure sensor offset monitoring
the ECU warns to the operator.
When operating by analog signal, Vehicle side code: 2012-2
Control
the ECU warns to the operator and Faulty part Rail pressure sensor
the engine operation switches to The input voltage falls below the
the redundancy operation. Detail
limiting value.
Speed limit - Recovery *
Inspection Accelerator signal (analog signal) The ECU limits the maximum
Control
speed of the engine.
P0123 : Accelerator sensor 1 Speed limit The engine speed is fixed to 8%.
Rail pressure sensor, and wiring of
Vehicle side code: 29-1 Inspection
rail pressure sensor.
Faulty part Accelerator signal (analog signal)
The ECU detects a faulty analog
signal input from vehicle controller.
Detail
The input voltage falls below the
limiting value.
When the input voltage recovers to
Recovery the specified value, it recovers
automatically.
When operating by CAN signal,
the ECU warns to the operator.
When operating by analog signal,
Control
the ECU warns to the operator and
the engine operation switches to
the redundancy operation.
Speed limit -
Inspection Accelerator signal (analog signal)
W5-14-7
P0193 : Rail pressure sensor offset monitoring P0202 : Injector No.2

Faulty part Rail pressure sensor Faulty part Injector No.2
The input voltage exceeds the The ECU detects an open circuit of
Detail Detail the injector and/or injector
limiting value.
Recovery * harness.
Control
speed of the engine. The engine keeps operating if only
Speed limit The engine speed is fixed to 8%. one injector is faulty. The engine
Control
stops if two or more injectors are
Rail pressure sensor, and wiring of faulty.
Inspection
There is no specific control by the
Speed limit ECU, but the engine speed
P0194 : Rail pressure governor decreases.
Inspection Injector, and wiring of injector.
Faulty part Common rail
P0203 : Injector No.3
The rail pressure falls below the
Detail
limiting value. Vehicle side code: 662-4
Recovery * Faulty part Injector No.3
Control Engine stop The ECU detects an open circuit of
Speed limit - Detail the injector and/or injector
Inspection Damage on the common rail. harness.
Recovery *
The engine keeps operating if only
one injector is faulty. The engine
Control
Vehicle side code: 658-4 stops if two or more injectors are
faulty.
Faulty part Injector No.1
The ECU detects an open circuit of
Detail the injector and/or injector
decreases.
harness.
Recovery *
one injector is faulty. The engine P0204 : Injector No.4
Control
faulty. Vehicle side code: 664-4
There is no specific control by the Faulty part Injector No.4
Speed limit ECU, but the engine speed The ECU detects an open circuit of
decreases. Detail the injector and/or injector
Inspection Injector, and wiring of injector. harness.
Recovery *
one injector is faulty. The engine
Control
faulty.
decreases.
W5-14-8
P0215 : Shut off pass test P0235 : Inlet manifold pressure sensor
Faulty part ECU Inlet manifold pressure sensor
Faulty part
The emergency injection stop power supply line
Detail circuit does not operate. The shut- The ECU detects an open circuit
off by watch dog is disabled. Detail or short circuit of the sensor power
Recovery * supply (5V).
Control The ECU warns to the operator. Recovery *
Speed limit - The ECU controls the engine
Control using the backup data. (Approx.
Inspection Contact a dealer.
1013 hpa)
Speed limit
Vehicle side code: 1110-4 75%.
Faulty part ECU Inlet manifold pressure sensor
Inspection
power supply line wiring.
The emergency injection stop
Detail circuit does not operate. The shut-
off by watch dog is disabled. P0237 : Inlet manifold pressure sensor
Recovery *
Control The ECU warns to the operator.
Faulty part Inlet manifold pressure sensor
Speed limit -
The ECU detects the faulty
Inspection Contact a dealer. operation of the inlet manifold
pressure sensor (open circuit,
Detail
short circuit, characteristic fault).
Faulty part ECU limiting value.
The emergency injection stop Recovery *
Detail circuit does not operate. The shut-
The ECU controls the engine
off by watch dog is disabled. Control
using the backup data.
Recovery *
Control The ECU warns to the operator. Speed limit
75%.
Speed limit - Inlet manifold pressure sensor,
Inspection Contact a dealer. Inspection and wiring of inlet manifold
pressure sensor.
P0231 : MPROP power stage short-circuit to ground

P0238 : Inlet manifold pressure sensor
Faulty part Faulty part MPROP Vehicle side code: 102-1
The ECU detects a short circuit on Faulty part Inlet manifold pressure sensor
Detail the ground line of the MPROP The input voltage exceeds the
Detail
harness. limiting value.
Recovery * Recovery *
The ECU limits the maximum The ECU controls the engine
Control Control
speed of the engine. using the backup data.
Speed limit The engine speed is fixed to 8%. The maximum speed is limited to
Speed limit
Inspection MPROP, and wiring of MPROP. 75%.
Inlet manifold pressure sensor,
Inspection and wiring of inlet manifold
pressure sensor.
W5-14-9
P0261 : Injector No.1 P0265: Injector No.2

Faulty part Injector No.1 Faulty part Injector No.2
The ECU detects a short circuit of The injector is faulty. The low side
Detail
the injector and/or injector is a short circuit to the battery.
Detail
harness. There are short circuits Recovery *
on the high side and low side. Control Engine stop
Recovery * Speed limit -
Control Engine stop Inspection Injector, and wiring of injector
Speed limit -
Inspection Injector, and wiring of injector
P0266: Injector No.2
Vehicle side code: 657-1 Unclassifiable error in the injector
Faulty part Injector No.1 Detail and/ or the injector harness. The
The injector is faulty. The low side injector is disabled.
Detail
is a short circuit to the battery. Recovery *
Recovery * Control Engine stop
Control Engine stop Speed limit -
Speed limit - Inspection Injector, and wiring of injector
Vehicle side code: 657-8 Faulty part Injector No.3
Faulty part Injector No.1 The ECU detects a short circuit of
Unclassifiable error in the injector the injector and/or injector
Detail
Detail and/ or the injector harness. The harness. There are short circuits
injector is disabled. on the high side and low side.
Control Engine stop Control Engine stop
Speed limit - Speed limit -
Inspection Injector, and wiring of injector Inspection Injector, and wiring of injector
P0264: Injector No.2 P0268: Injector No.3

Faulty part Injector No.2 Faulty part Injector No.3
The ECU detects a short circuit of The injector is faulty. The low side
Detail
the injector and/or injector is a short circuit to the battery.
Detail
harness. There are short circuits Recovery *
on the high side and low side. Control Engine stop
Control Engine stop Inspection Injector, and wiring of injector
Speed limit -
W5-14-10
P0269: Injector No.3 P0336: Speed/timing sensor (crankshaft side)

Faulty part Injector No.3 Speed/timing sensor (crankshaft
Faulty part
Unclassifiable error in the injector side)
Detail and/ or the injector harness. The The ECU detects the fault of
injector is disabled. speed/tim-ing sensor (crankshaft
Recovery * side)(open cir-cuit, short circuit,
Detail
Control Engine stop tooth brakage). The number of
crank pulse and/or crank pulse
Speed limit - position are faulty.
Inspection Injector, and wiring of injector Recovery *
P0270: Injector No.4 Control using the speed/timing sensor
(camshaft side) signal.
Faulty part Injector No.4 Speed limit 50% only when starting the
The ECU detects a short circuit of engine.
the injector and/or injector Speed/timing sensor (crankshaft
Detail
harness. There are short circuits Inspection side), and wiring of speed/timing
on the high side and low side. sensor (crankshaft side).
Recovery *
Control Engine stop
P0339: Speed/timing sensor (crankshaft side)
Speed limit -
Faulty part
side)
P0271: Injector No.4 The speed/timing sensor
Vehicle side code: 663-1 (crankshaft side) is faulty. The
Detail
ECU is not receiving the crank
pulse.
The injector is faulty. The low side
Detail Recovery *
is a short circuit to the battery.
Recovery *
Control using the speed/timing sensor
Control Engine stop (camshaft side) signal.
Speed limit - The maximum speed is limited to
Inspection Injector, and wiring of injector Speed limit 50% only when starting the
engine.
Inspection side), and wiring of speed/timing
Vehicle side code: 663-8 sensor (crankshaft side).
Unclassifiable error in the injector
Detail and/ or the injector harness. The
injector is disabled.
Recovery *
Control Engine stop
Speed limit -
W5-14-11
P0341: Speed/timing sensor (camshaft side) P0541: Air heater relay power stage
Speed/timing sensor (camshaft Faulty part Air heater relay
Faulty part
side)
The air heater relay and/or
The ECU detects the fault of Detail connecting harness are short
speed/timing sensor (camshaft circuits to the ground.
side) (open circuit, short circuit,
Detail Recovery *
tooth breakage). The number of
cam pulse and/or cam pulse The air heater is disabled. The
Control
position are faulty. ECU warns to the operator.
The ECU controls the engine Air heater relay, and wiring of air
Inspection
using speed/timing sensor heater.
Control
(crankshaft side) signal.
The ECU warns to the operator.
P0542: Air heater relay power stage
Speed limit -
Speed/timing sensor (camshaft
Inspection side), and wiring of speed/timing Faulty part Air heater relay
sensor (camshaft side). The air heater relay is faulty. The
Detail air heater relay is a short circuit to
the battery.
P0344: Speed/timing sensor (camshaft side)
Recovery *
Vehicle side code: 636-1 The air heater is disabled. The
Control
Speed/timing sensor (camshaft ECU warns to the operator.
Faulty part
side) Speed limit -
The speed/timing sensor Air heater relay, and wiring of air
Detail (camshaft side) is faulty. The ECU Inspection
heater.
is not receiving the cam pulse.
Recovery *
P0543: Air heater relay power stage
using speed/timing sensor Vehicle side code: 677-4
Control
(crankshaft side) signal. Faulty part Air heater relay
The ECU warns to the operator.
Speed limit - Detail air heater relay and/or connecting
Speed/timing sensor (camshaft harness.
Inspection side), and wiring of speed/timing Recovery *
sensor (camshaft side).
The air heater is disabled. The
Control
ECU warns to the operator.
P0540: Air heater relay power stage Speed limit -
Vehicle side code: 677-8 Air heater relay, and wiring of air
Inspection
heater.
Faulty part Air heater relay
The ECU detects an overload of
Detail air heater relay and/or connecting P0562: Power supply unit voltage too low
harness.
Recovery *
Faulty part ECU
The air heater is disabled. The
Control The voltage of the power supply
ECU warns to the operator.
Detail unit inside the ECU falls below the
Speed limit - limiting value.
Air heater relay, and wiring of air Recovery *
Inspection
heater.
Control Engine stop
Speed limit -
Inspection Replace the ECU.
W5-14-12
P0563: Power supply unit voltage too high P0600: CAN (C) pass off
Faulty part ECU Faulty part CAN communication line
The voltage of the power supply The CAN communication is faulty.
Detail unit inside the ECU exceeds the Detail The ECU detects the CAN (C)
limiting value. pass off.
Control Engine stop The ECU uses the analog signal
Speed limit - Control for backup control. The ECU
warns to the operator.
Speed limit -
CAN comunnication line, and
P0600: CAN transmitting time out Inspection
ECU.
Faulty part CAN communication line P0606: SPI communication error
The CAN message cannot be
Detail Vehicle side code: 1231-1
tranmitted.
Faulty part ECU
Recovery *
There are serial communication
The ECU uses the analog signal Detail
Control errors between CPU and other IC.
for backup control.
Recovery *
Speed limit -
Control Engine stop
Inspection Speed limit -
ECU.
P0600: CAN (A) pass off

P0606: Super vision
Faulty part CAN communication line Vehicle side code: 1484-8
The CAN communication is faulty. Faulty part ECU
Detail The ECU detects an open circuit The ECU detects an abnormality
Detail
or short cir-cuit of CAN line. by using self-diagnosis function.
The ECU uses the analog signal Control Engine stop
Control for backup control. The ECU Speed limit -
Speed limit -
Inspection P0607: Recovery occurred
ECU.
Faulty part ECU
The recovery occurred by the fault
Detail
of the ECU.
Recovery *
Control The ECU warns to the operator
Speed limit -
Inspection -
W5-14-13

Faulty part ECU Faulty part ECU
The recovery occurred by the fault The injector control IC inside the
Detail Detail
of the ECU. ECU is faulty.
Control The ECU warns to the operator Control Engine stop
Speed limit - Speed limit -
Inspection - Inspection Replace the ECU.
P0607: SPI watch dog error Vehicle side code: 655-8

Vehicle side code: 2010-8 Faulty part ECU
Faulty part ECU The injector control IC inside the
Detail
ECU is faulty.
The ECU detects an abnormality
Detail by using self-diagnosis function. Recovery *
Watch dog error. Control Engine stop
Recovery occurs. It recovers Speed limit -
automati-cally if an error occurs Inspection Replace the ECU.
Recovery three times in two seconds. The
engine stops if an error occurs four
times or more in two seconds. Vehicle side code: 656-1
Control Engine stop Faulty part ECU
Speed limit - The injector control IC inside the
Detail
Inspection Replace the ECU. ECU is faulty.
Recovery *
P0611: Injector IC Control Engine stop
Speed limit -
Faulty part ECU
The injector control IC inside the
Detail
ECU is faulty. Vehicle side code: 656-2
Recovery * Faulty part ECU
Control Engine stop The injector control IC inside the
Detail
Speed limit - ECU is faulty.
Inspection Replace the ECU. Recovery *
Control Engine stop
Speed limit -
Faulty part ECU
Detail
ECU is faulty.
Recovery *
Control Engine stop
Speed limit -
W5-14-14
P0652: Sensor supply voltage monitoring 2

The injector control IC inside the The 5V power supply to the inlet
Detail
ECU is faulty. manifold pressure sensor is faulty.
Detail
Recovery * The supply voltage falls below the
limiting value.
Control Engine stop
Recovery *
Speed limit -
Inspection Replace the ECU. Control
Speed limit
Vehicle side code: 656-8 75 %.
Faulty part ECU Inspection Replace the ECU.
Detail
ECU is faulty. P0653: Sensor supply voltage monitoring 2
Recovery *
Control Engine stop
Faulty part ECU
Speed limit -
Detail The 5V power supply to the
Inspection Replace the ECU. inlet manifold pressure sensor is
Detail
faulty. The supply voltage exceeds
P0642: Sensor supply voltage monitoring 1 the limiting value.
Recovery *
Faulty part ECU Control
The 5V power supply to the PTO The maximum speed is limited to
accelerator signal is faulty. The Speed limit
Detail 75 %.
supply voltage falls below the
limiting value.
Recovery *
Control The ECU warns to the operator. P0698: Sensor supply voltage monitoring 3
Speed limit - Vehicle side code: 620-2
Inspection Replace the ECU. Faulty part ECU
The 5V power supply to the rail
P0643 : Sensor supply voltage monitoring 1 pressure sensor is faulty. The
Detail
supply voltage falls below the
Vehicle side code: 1079-1 limiting value.
Faulty part ECU Recovery *
The 5V power supply to the PTO Control The ECU warns to the operator.
accelerator signal is faulty. The Speed limit -
Detail
supply voltage exceeds the
limiting value.
Recovery *
Speed limit -
W5-14-15
P0699: Sensor supply voltage monitoring 3

The 5V power supply to the rail The AD converter inside the ECU
pressure sensor is faulty. The Detail is faulty. The standard voltage falls
Detail
supply voltage exceeds the below the limiting value.
limiting value. Recovery occurs. It recovers
Recovery * automatically if an error occurs
Control The ECU warns to the operator. Recovery three times in two seconds. The
Speed limit -
times or more in two seconds.
Control Engine stop
Speed limit -
P060A : TPU monitoring Inspection Replace the ECU.
Faulty part ECU Vehicle side code: 2008-4
The ECU detects a fault of rotating Faulty part ECU
Detail pulse arithmetic circuit inside the
The AD converter inside the ECU
ECU.
is faulty. The ECU detects the
Recovery occurs. It recovers Detail
conversion error by using a test
automatically if an error occurs pulse.
Recovery occurs. It recovers
automatically if an error occurs
Control Engine stop engine stops if an error occurs four
Speed limit - times or more in two seconds.
Inspection Replace the ECU. Control Engine stop
Speed limit -
P060B: ADC monitoring Inspection Replace the ECU.

Faulty part ECU Vehicle side code: 2008-8
The AD converter inside the ECU Faulty part ECU
Detail is faulty. The standard voltage The AD converter inside the ECU
exceeds the limiting value. Detail is faulty. The conversion time is
Recovery occurs. It recovers abnormal.
automatically if an error occurs Recovery occurs. It recovers
Recovery three times in two seconds. The automatically if an error occurs
engine stops if an error occurs four Recovery three times in two seconds. The
times or more in two seconds. engine stops if an error occurs four
Control Engine stop times or more in two seconds.
Speed limit - Control Engine stop
Inspection Replace the ECU. Speed limit -
W5-14-16
P060D: CAN accelerator P062D: Injector drive bank 1

Faulty part ECU communication circuit Faulty part ECU
The ECU detects a fault of The ECU detects the short circuit
Detail accelerator opening (APPREQ) Detail of the injector drive circuit inside
receiving from CAN. the ECU.
The ECU uses the analog signal Control Engine stop
Control for backup control. The ECU Speed limit -
Inspection Replace the ECU
Speed limit -
Inspection CAN communication circuit
P062E: Injector drive bank 2
P060E: APPREQ message time out Vehicle side code: 653-8

Faulty part ECU
The ECU detects the short circuit
Faulty part ECU communication circuit Detail of the injector drive circuit inside
The ECU cannot receive the the ECU.
Detail accelerator opening (APPREQ) Recovery *
signal.
Control Engine stop
Recovery *
Speed limit -
The ECU uses the analog signal
Control for backup control. The ECU
Speed limit - P062F: EEPROM
Inspection CAN communication circuit Vehicle side code: 1235-2
Faulty part ECU
P061C: Engine speed The ECU detects a read-write
error of the data memory bank
Vehicle side code: 2005-1 Detail
inside the ECU. The ECU cannot
Faulty part ECU read the data.
The ECU is faulty. The engine Recovery *
Detail
speed data is faulty.
Recovery occurs. It recovers
Speed limit -
automatically if an error occurs
Recovery three times in two seconds. The Inspection Replace the ECU
Faulty part ECU
Speed limit -
The ECU detects a read-write
error of the data memory bank
Detail
inside the ECU. The ECU cannot
write to the data memory.
Recovery *
Speed limit -
W5-14-17
P2047: Injector drive bank 1

The ECU detects a read-write The ECU detects an open circuit of
error of the data memory bank Detail the injector drive circuit inside the
Detail
inside the ECU. The ECU is using ECU.
the substitute data.
Recovery *
Recovery *
Control Engine stop
Speed limit -
Speed limit -
P2048: Injector drive bank 1

P0933: Oil pressure switch
Faulty part ECU
Faulty part Oil pressure switch
The ECU detects a short circuit of
The oil pressure switch remains Detail the injector drive circuit inside the
Detail OFF position even the engine ECU.
speed reaches 500min-1. Recovery *
Recovery * Control Engine stop
The ECU keeps the engine low Speed limit -
Control
idling.
Speed limit -
Oil pressure switch, and wiring of
Inspection P2049: Injector drive bank 1
oil pressure switch.
Vehicle side code: 100-8 Faulty part ECU
Faulty part Oil pressure switch The ECU detects a short circuit of
Detail the injector drive circuit inside the
The oil pressure switch remains
ECU.
OFF position for 30 second after
Detail engine starting. The oil pressure Recovery *
switch remains OFF position Control Engine stop
during engine operation. Speed limit -
Recovery * Inspection Replace the ECU.
Control Engine stop
Speed limit - P2050 : Injector drive bank 2
Oil pressure switch, and wiring of
Inspection Vehicle side code: 654-4
oil pressure switch.
Faulty part ECU
ECU.
Recovery *
Control Engine stop
Speed limit -
W5-14-18
P2051: Injector drive bank 2 P2229: Atomospheric pressure sensor

The ECU detects a short circuit of The ECU detects a faulty
Detail the injector drive circuit inside the operation of the atomospheric
ECU. pressure sensor (open circuit,
Detail
Recovery * short circuit, characteristic fault).
Control Engine stop The input voltage exceeds the
limiting value.
Speed limit -
Recovery *
The ECU controls the engine by
Control
using backup data.
P2052: Injector drive bank 2 The maximum speed is limited to
Speed limit
75 %.
Faulty part ECU
The ECU detects a short circuit of
ECU.
Recovery *
Control Engine stop
Speed limit -
P2228: Atomospheric pressure sensor

Faulty part ECU
The ECU detects a faulty
operation of the atomospheric
pressure sensor (open circuit,
Detail
short circuit, characteristic fault).
limiting value.
Recovery *
The ECU controls the engine by
Control
using backup data.
Speed limit
75 %.
W5-14-19
Related diagnosis code

There are diagnosis codes which are caused by other diagnosis codes, for example, the diagnosis code
generated by the fault of the common rail causes the diagnosis code related to the DBV (pressure limiting
valve). These codes can be recovered by eliminating the fault of the causal diagnosis code.
Causal diagnosis code in the following chart must be checked when Related diagnosis code is generated.
Related diagnosis code can be recovered by eliminating the fault of Causal diagnosis code.
Also Related diagnosis code B can be generated by Related diagnosis code A. In this case, Causal diagnosis
code and Related diagnosis code A must be checked.
Related diagnosis code (1 / 2)

Related
Causal diagnosis Related diagnosis
diagnosis code Cause A Cause B Remark
code code B
A
There is an open
circuit on the MPROP.
P0089 The MPROP is fully
Vehicle side code: opened and the
- - -
2041-1 DBV common rail receives
P0252 Vehicle side opening excessive pressure.
code : 2000-4 MPROP The DBV will be
open circuit opened.
P0089
Pressure shock is P0090 Vehicle side The ECU clears
Vehicle side code: The DBV does not
requested to open the code : 2043-4 DBV P0089 when P0090 is
2042-2 DBV kick open.
DBV closed fixation generated.
off
There is an overload
on the MPROP. The
P0089 MPROP is fully
- - -
2041-1 DBV com¬mon rail
P0252 Vehicle side opening receives excessive
code : 2000-8 MPROP pressure. The DBV
overload will be opened.
P0089
Pressure shock is P0090 Vehicle side The ECU clears
Vehicle side code: The DBV does not
requested to open the code : 2043-4 DBV P0089 when P0090 is
2042-2 DBV kick open.
DBV closed fixation generated.
off
There is a short circuit
on the MPROP. The
P0089 MPROP is fully
- - -
P0230 Vehicle side 2041-1 DBV common rail receives
code : 2001-1 MPROP opening excessive pressure.
power stage short The DBV will be
circuit to battery opened.
P0089 P0090
Pressure shock is The ECU clears
Vehicle side code: Vehicle side code: The DBV does not
requested to open the P0089 when P0090 is
2042-2 DBV kick 2043-4 DBV closed open.
DBV generated.
off fixation
The pressure in the
P0089 common rail keeps The ECU clears
Vehicle side code: exceeding the limiting P0089(2042-2) when
- -
2041-1 DBV value, the engine P0089(2041-1) is
P0089 opening operation switches to generated.
Vehicle side code: the limp home mode.
2042-2 DBV kick off
P0090
Vehicle side code:
requested to open the - - P0089 when P0090 is
2043-4 DBV
DBV generated.
closed fixation
W5-14-20
Related diagnosis code (2 / 2)

Related
Causal diagnosis Related diagnosis
diagnosis code Cause A Cause B Remark
code code B
A
The pressure in the
P0089 common rail keeps
Vehicle side code: exceeding the limiting
P0191 - - -
2041-1 DBV value, the engine
Vehicle side cod : opening operation switches to
2015-1 the limp home mode.
Rail pressure
governor deviation P0089 P0090
DBV generated.
off fixation
The pressure in the
P0089 common rail keeps
If DBV does not open,
Vehicle side code: exceeding the limiting
- - the ECU generates
P0194 2041-1 DBV value, the engine
P0090, not 0089.
Vehicle side code: opening operation switches to
2017-1 Rail pressure the limp home mode.
governor P0089 P0090
DBV generated.
off fixation
An error is detected by
SRC. The ECU cannot
control the engine by
P0192 P0089 In this case, P0192
feedback from the
Vehicle side code: Vehicle side code: and P0089 are
common rail pressure - -
2011-2 Rail pressure 2041-1 DBV generated at the same
sensor. The DBV will
SRC opening time.
be opened. The ECU
controls the engine
using backup data.
An error is detected by
SRC. The ECU cannot
control the engine by
P0193 P0089 In this case, P0192
feedback from the
Vehicle side code: Vehicle side code: and P0089 are
common rail pressure - -
2011-1 Rail pressure 2041-1 DBV generated at the same
sensor. The DBV will
SRC opening time.
be opened. The ECU
controls the engine
using backup data.
After the ECU
P0091 determined that DBV
Vehicle side code: has been opened, the
P0091 is not
2045-2 DBV common rail pressure - -
generated separately.
pressure is too exceeds the limiting
high value during backup
P0089 operation.
Vehicle side code:
2041-1 DBV opening After the ECU
P0092 determined that DBV
Vehicle side code: has been opened, the
P0092 is not
2044-1 DBV common rail pressure - -
generated separately.
pressure is too exceeds the limiting
high value during backup
operation.
W5-14-21
P0089: DBV valve opening P0092: DBV pressure is too high.

Faulty part DBV Faulty part DBV
Detail The DBV is opening. The DBV pressure is abnormal.
Detail
Recovery * (too high)
Control
speed of the engine. Control Engine stop
Speed limit The engine speed is fixed to 8 %. Speed limit -
Inspection Contact a dealer. Inspection Contact a dealer.
P0089: DBV kick off P0191: Rail pressure governor deviation

Faulty part DBV Faulty part Common rail
Pressure shock requested to The rail pressure control is
Detail
apply limp home mode. Detail abnormal. The pressure exceeds
Recovery * the target value.
Control
speed of the engine. The ECU limits the maximum
Control
Speed limit The engine speed is fixed to 8 %. speed of the engine.
Inspection Contact a dealer. Speed limit The engine speed is fixed to 8 %.
P0090: DBV closed fixation

P0192: Rail pressure sensor SRC (Signal Range
Check)
Faulty part DBV
The DBV does not open. Closed
Detail Faulty part Rail pressure sensor
fixation.
Recovery * The ECU detects an open or short
circuit of rail pressure sensor and/
Control Engine stop
Detail or sensor harness. The input
Speed limit - voltage falls below the limiting
Inspection Contact a dealer. value.
Recovery *
P0091: DBV pressure is too low The ECU limits the maximum
Control
Vehicle side code: 2045-2 Speed limit The engine speed is fixed to 8 %.
Faulty part DBV Rail pressure sensor, and wiring of
Inspection
The DBV pressure is abnormal. rail pressure sensor.
Detail
(too low)
Recovery *
Control Engine stop
Speed limit -
Inspection Contact a dealer.
W5-14-22
P0193: Rail pressure sensor SRC (Signal Range P0252: MPROP power stage overload
Check)
Vehicle side code: 2011-1 Faulty part MPROP
Faulty part Rail pressure sensor The ECU detects an overload of
Detail
The input voltage exceeds the MPROP and/or MPROP harness.
Detail
limiting value. Recovery *
Recovery * The ECU limits the maximum
Control
The ECU limits the maximum speed of the engine.
Control
speed of the engine. Speed limit The engine speed is fixed to 8 %.
Speed limit The engine speed is fixed to 8 %. Inspection MPROP, and wiring of MPROP.
Rail pressure sensor, and wiring of
Inspection
P0194: Rail pressure governor

Faulty part Common rail
The rail pressure exceeds the
Detail
limiting value.
Recovery *
Control
Speed limit The engine speed is fixed to 8 %.
P0230: MPROP power stage short-circuit to battery

Faulty part MPROP
The ECU detects a short circuit on
Detail the battery line of the MPROP
harness.
Recovery *
Control
Inspection MPROP, and wiring of MPROP.
P0252: MPROP power stage open circuit

Faulty part MPROP
Detail the MPROP and/or MPROP
harness.
Recovery *
Control
Inspection MPROP, and wiring of MPROP.
W5-14-23
INSPECTING SENSORS
Speed/timing sensor (crank, cam)

Measure the resistance between terminal A - B.
Standard value : 860±86
If measured value is out of standard, replace the
sensor with a new one.
C B A
SM3497
Speed/timing sensor (crank, cam)

Inlet manifold pressure sensor
With applying pressure using an air compressor (1),
measure the voltage between terminal B - C.
Standard value
• at 0 MPa (0 psi): 0.5 V
C A
• at 0.34 MPa (49.31 psi): 4.5 V
sensor with a new one.
B
1
SM3498
Inspecting inlet manifold pressure sensor (1)
A - Air pressure Mpa

B - Output voltage Vdc 0.5
0.4
0.3
0.2
0.1
0
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

SM3499
Inspecting inlet manifold pressure sensor (2)

Water temperature sensor
Put the water temperature sensor to the container
filled with water, measure the output resistance
between terminal 1 - 2.
Standard value
• 20 °C : 2.38 ~ 2.63 k
• 80 °C : 0.30 ~ 0.34 k
If the sensor is an open circuit, its resistance is
infinity. If measured value is out of standard, replace
the sensor with a new one. 1 2
SM3500
Inspecting water temperature sensor
W5-14-24
Engine oil pressure switch

Apply 50 ± 10 kPa pressure to the sensor using an
air compressor.
Check that the micro switch is in OFF position.
If the switch is not operate, replace the engine oil
pressure switch with a new one. Air compressor
50 ± 10 kPa
[7.11 ± 1.42 psi]
On-Off differences
30 kPa
[4.27 psi]
SM3501
Inspecting oil pressure switch

Common rail pressure sensor
Apply 5 V between terminal A - C, and measure the
voltage at terminal B.
Standard value: Approx. 0.5V
common rail with a new one.
A B C
SM3502
Inspecting common rail pressure sensor

Injector solenoid
Measure the resistance between terminal 1 - 2.
Standard (at 20 to 70 °C [68 to 158 °F]):
0.215 to 0.295
injector with a new one.
2 1
SM3503
Inspecting injector solenoid
High pressure pump solenoid sensor (MPROP)
Measure the resistance between terminal 1 - 2.
Standard (at 20 °C [68 °F]) : 2.6 to 3.15
If measured value is out of standard, replace the fuel
pump with a new one.
2 1
SM3504
Inspecting high pressure pump solenoid sensor (MPROP)
W5-14-25
INSPECTING WIRING
Inspecting connector and harness

When the ECU generates the diagnosis code for the
sensors, the ECU and the relays, check the wiring
that connects these parts.
The looseness of the harness connection and/or
poor connection of connector may cause the
electrical faults. In these cases, reconnecting the
connector and/or the repairing the harness deletes
the fault. Inspect the wiring connecting to the sensor
which causes diagnosis code.
Inspecting the intermittent fault SM3505
Inspecting intermittent fault

Wiggle the harness and connector in order to
reproduce the intermittent fault. If the diagnosis
code is generated, reset the ECU and repeat the
above procedure. If the intermittent fault exists,
replace the connector and harness.
1
Inspecting connectors
1. Disconnect the connector and inspect the
connector for moisture and wear.
2. Inspect that the terminals are correctly located
in the connector. Inspect that the terminals are SM3506
not lost. Inspect that the terminals does not Inspecting connector
rattle.
3. Inspect that the locking wedge works correctly.
Inspecting harness 2
1. Inspect harness visually for wear, nicks (2) and

cuts. Especially the part which is exposed to the
engine must be inspected.
1
2. Inspect the harness for pinch point (1) caused
by cramp.
SM3507
Inspecting harness
Inspect open circuit and short circuit

1. Remove the connector from either end of the
harness. Measure the resistance between both
ends of the harness using tester. If measured
value is between 0.1~ 0.3 , it is normal. If
measured value is not in this range, it is an
open circuit.
2. Remove the connector from either end of the
harness. Measure the resistance between all
terminals in the connector. If measured value is
100 k or more, it is normal. If measured value SM3508
is 100 k or less, it is a short circuit. Inspecting open circuit and short circuit
W5-14-26
Inspecting open circuit and short circuit

Pin location of the ECU connector and extension harness connector
The wirings of the sensors, the injectors and the fuel pump are connected to the ECU through the extension
harness connector. Inspect the pin of the ECU connector and extension harness connector when inspecting
the wiring of the sensors, the injectors and the fuel pump.
A B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
3 4
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
5 6
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
SM3509
Pin location of ECU connector
A - ECU terminal A B - ECU terminal B

1- Injector 3, + 1- ECU power supply, + (1)
2- Injector 2, + 2- ECU ground, - (1)
7- Speed/timing sensor (crankshaft side), shield 3- ECU power supply, + (2)
8- Rail pressure sensor, ground 4- ECU ground, - (2)
10 - Speed/timing sensor (camshaft side) 5- ECU power supply, + (3)
12 - Speed/timing sensor (crankshaft side) 6- ECU ground, - (3)
14 - Inlet manifold pressure sensor, power supply 9- Accelerator (1)
15 - Heater relay 12 - PTO accelerator, ground
16 - Injector 1, + 23 - PTO accelerator, power supply
17 - Injector 4, + 25 - K-LINE
19 - MPROP, + 28 - Ignition switch
20 - Speed/timing sensor (camshaft side), shield 36 - PTO accelerator
23 - Inlet manifold pressure sensor, ground 41 - Signal, ground
24 - Heater relay, power supply 54 - Oil pressure switch
26 - Rail pressure sensor, power supply 61 - CAN-L1
27 - Speed/timing sensor (crankshaft side) 62 - CAN-H1
31 - Injector 2, - 72 - Main relay
33 - Injector 4, - 73 - 24V power supply
40 - Inlet manifold pressure sensor
41 - Water temperature sensor, ground C - Point of view
43 - Rail pressure sensor
46 - Injector 3, -
47 - Injector 1, -
49 - MPROP, -
50 - Speed/timing sensor (camshaft side)
58 - Water temperature sensor
W5-14-27
A B
4 3 2 1
4 3 2 1
8 7 6 5
8 7 6 5
12 11 10 9
12 11 10 9
16 15 14 13
C D E
SM3510
Pin location of extension harness connector
A - Extension harness connector, 16 terminals B - Extension harness connector, 12 teminals

1- Speed/timing sensor (camshaft side), power 1- Injector 1, +
supply 2- Injector 1, -
2- Speed/timing sensor (camshaft side) 3- Injector 4, +
3- Speed/timing sensor (camshaft side), shield. 4- Injector 4, -
5- Speed/timing sensor (crankshaft side), power 5- Injector 3, +
supply 6- Injector 3, -
6- Speed/timing sensor (crankshaft side) 7- Injector 2, +
7- Speed/timing sensor (crankshaft side), shield 8- Injector 2, -
8- MPROP, - 9- Water temperature sensor
9- Rail pressure sensor, power supply 10 - Water temperature sensor, ground
10 - Rail pressure sensor 11 - Oil pressure switch
11 - Rail pressure sensor, ground 12 - Oil pressure switch
12 - MPROP, +
13 - Inlet manifold pressure sensor, power supply
14 - Inlet manifold pressure sensor. C - Point of view for 16 teminals
16 - Inlet manifold pressure sensor, ground D - Connector location
E - Point of view for 12 terminals
W5-14-28
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A.

Product Support
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY
Reproduction of text or illustrations,

in whole or in part, is strictly prohibited
Print No. 84136002 - XI - 2008
Printed by Satiz - Turin (Italy)

Coordinamento Editoriale Satiz - Torino

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Print No.84136002 Print No.84136002

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

- Be sure to thoroughly read this manual for NEW HOLLAND KOBELCO

• Please refer to the materials listed below in

- Operation and Maintenance Instruction

WORKSHOP MANUAL COMPOSITION

Consecutive page number for each group

Group number (if exist))

This is the safety alert symbol.

SI Units (International System of Units) are used in this manual.

Example: 24.5 MPa (250 kgf/cm2)

mm ft 0.003281 MPa psi 145.0

Volume L US gal 0.2642 Power kW CV-PS 1.360

m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32

Mass kg lb 2.205 Velocity km/h mph 0.6214

Force N kgf 0.10197 min-1 rpm 1.0

N lbf 0.2248 Flow rate L/min US gpm 0.2642

Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0

N.m lbf.ft 0.7375

SAFETY PRECAUTIONS Page

Section 1 GENERALITIES ..................................................................... S1

Section 3 COMPONENT OPERATION

OPERATIONAL PERFORMANCE TEST

Section 1 GENERAL INFORMATION

Section 4 FRONT ATTACHMENT

Section 2 SAFETY PRECAUTIONS

Section 3 SAFETY PLATES

Always keep head, body, limbs, feet, hands, and

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL

- When you see this symbol on your machine or

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words

DANGER: indicates an imminent hazardous

WARNING: indicated a potential hazardous

CAUTION: indicates a potential hazardous situation IMPORTANT

NOTE: indicates an additional explanation for

• This Manual also contains this symbol

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal

- When you get on and off the machine, always

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

- The seat should be adjusted whenever machine

FASTEN SEAT BELT

• Should the machine overturn, the operator may

- Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

- Pay the utmost attention not to run over

OPERATE ONLY FROM THE DRIVER'S SEAT

• Inappropriate engine starting procedures may

DO NOT CARRY PERSON ON THE MACHINE