87694078NA W-Foldouts PDF

SHOP MANUAL
CRAWLER EXCAVATOR
SK485-8
TIER 3
Bur • Issued 01July 08

Printed in U.S.A. • Book/Form Number 87694078 NA
Copyright © 2008. Kobelco Construction Machinery America, LLC. All Rights Reserved
Kobelco Construction Machinery America, LLC reserves the right to make improvements in design or changes in specifications at any
time without incurring any obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not
necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer.
REVISION HISTORY
Issue Issue Date Applicable Machines Remarks
First Edition 01July 08 SK485-8 Tier 3 Crawler Excavator 87694078 NA
Any use of editorial or pictorial content is strictly prohibited without express written permission from
Kobelco Construction Machinery America, LLC . Carol Stream, IL 60188 U.S.A..
CRAWLER EXCAVATOR TIER 3
MAINTENANCE SPECIFICATIONS
SHOP
MANUAL Model SK485-8
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
Book Code No.87694078

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

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

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
0-5
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
1
1. OUTLINE
TABLE OF CONTENTS
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3

1.1.1 PREPARATION BEFORE DISASSEMBLING ..........................................................1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3
1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-4
1.1.5 HYDRAULIC PARTS ................................................................................................1-5
1.1.6 WELD REPAIR .........................................................................................................1-5
1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-5
1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-6
Book Code No. 87694078
1-1
1. OUTLINE
Issue Date of Issue Applicable Machines Remarks

SK330-8 : LC10-07001~ S5YN0118E01
First edition July, 2006 K
SK350LC-8 : YC10-03501~ (ASIA, OCE)
SK200-8 : YN11-45001~ ↑
↑ August, 2006 K
SK210LC-8 : YQ11-06001~ (ASIA, OCE)
SK250-8: LQ12-06001~ ↑
↑ October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)
↑
↑ ↑ SK235SRLC-2 : YU05-02001~ K
(North America)
E215B : YN11-45001~ ↑
↑ March, 2007 K
E215BLC : YQ11-06001~ (NHK Russia)
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK210LC-8 : YQ11-06001~ ASIA (HS Engine)
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
SK260LC–8 : LL12-05001~ ASIA (HS Engine)
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
SK460-8: LS10-02001~ ↑
↑ ↑ K
SK480LC–8 : YS10-01501~ (ASIA, OCE)
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
MAKING REPAIRS begin a meeting before starting the work.
3) Before starting inspection and maintenance
1.1.1 PREPARATION BEFORE stop the engine.
DISASSEMBLING
4) Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact
Read Operator's Manual for emergency measure and ambulance to
before disassembling
prepare for accidents and fire.

(1) Knowledge of operating procedure
5) Choose a hard, lever and safe place, and put
Read Operator’s Manual carefully to understand
attachment on the ground without fail.
the operating procedure.
6) Use hoist, etc. to remove parts of heavy weight
(2) Cleaning machines
(23kg [50 lb] or more).
Clean machines of soil, mud, and dust before
carrying into the service shop. 7) Use proper tools, and change or repair
Carrying a soiled machine into the service shop, defective tools.
causes making less efficient work and damage of 8) Machine and attachment required to work in the
parts. lifting condition should be supported with
(3) Inspecting machines supports or blocks securely.
Confirm the disassembling section before starting 1.1.3 DISASSEMBLING AND ASSEMBLING
work, determine the disassembly procedure taking HYDRAULIC EQUIPMENT
the conditions in work shop into account, and
request to procure necessary parts in advance.
(4) Recording
Record the following items to keep contact and (1) Removing hydraulic equipment assy
prevent malfunction from recurring. 1) Before removing pipes, release the pressure of
1) Inspecting date, place hydraulic oil tank, or open the cover on the
2) Model name, Serial number and Record on return side to tank, and take out the filter.
hour meter 2) Drain the oil in the removed pipes into pan to
3) Trouble condition, place, cause prevent the oil from spilling on the ground.
4) Visible oil leak, water leak and damage 3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness. 4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
6) Examine the problems on the basis of monthly
and gear oil before putting them on working
operation rate with the last inspection date and
bench.
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Since performance and function of hydraulic
1) Tools required for repair work.
equipment after disassembly and assembly
2) Prepare the places to put the disassembled
results in immunity from responsibility on the
parts.
manufacture’s side, disassembly, assembly
3) Prepare oil pans for leaking oil, etc. and modification without permission are strictly
prohibited.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING 2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
WARNING
3) Make match mark on parts for reassembling.
(1) Safety 4) Before disassembling, read Disassembling
1) Wear appropriate clothing, safety shoes, safety Instruction in advance, and determine if the
helmet, goggles, and clothes with long sleeves. disassembly and assembly are permitted or
not.
1-3
1. OUTLINE
5) For parts which are required to use jig and

tools, don’t fail to use the specified jig and tools.
6) For parts which can not be removed in the
If hydraulic oil and lubricating oil are not
specified procedure, never force removal. First
filled and also air bleed is not performed,
check for the cause.
the hydraulic equipment may be damaged.
7) The removed parts should be put in order and
tagged so as to install on proper places without 3) For air bleed of hydraulic pump and swing
confusion. motor, loosen drain plug on the upper part, start
8) For common parts, pay attention to the quantity engine, and run in low idling, then bleed air until
and places. hydraulic oil is comes out. After completion of
comes, tighten plug securely.
(3) Inspecting parts
4) For air bleed of travel motor and hydraulic
1) Check that the disassembled parts are free
cylinder, starts engine and operate it for 10
from adherence, interference and uneven
minutes or more at no-load and low speed.
working face.
2) Measure the wear of parts and clearance, and
record the measured values.
3) If an abnormality is detected, repair or replace For cylinder, don’t move it to the stroke end
the parts. at beginning.
(4) Reassembling hydraulic equipment
5) Air in pilot circuit can be bleed out by only
1) During the parts cleaning, ventilate the room. operating digging, swing and traveling motions
2) Before assembly, clean parts roughly first, and thoroughly.
then completely. 6) Check hydraulic oil level.
3) Remove adhering oil by compressed air, and Move attachments to hydraulic oil check
apply hydraulic oil or gear oil, and then position, and check hydraulic oil level of tank.
assemble them. Refill oil if the oil level is lower than the specified
4) Replace the removed O-ring, back-up rings and level.
oil seal with new ones, and apply grease oil on How to check oil level of hydraulic oil tank
them before assembling.

5) Removes dirt and water on the surface on
LEVEL GAUGE
which liquid sealant are applied, decrease
Oil level of hydraulic oil tank.
them, and apply liquid sealant on them. If the indicator is within
6) Before assembling, remove rust preventives on level marks, the oil quantity
is acceptable.
new parts.
7) Use special tools to fit bearings, bushing and oil 1.1.4 ELECTRICAL EQUIPMENT
seal.
8) Assemble parts matching to the marks.
9) After completion, check that there is no
(1) The disassembly of electrical equipment is not
omission of parts.
allowed.
(5) Installing hydraulic equipment
(2) Handle equipment with care so as not to drop it or
1) Confirm hydraulic oil and lubrication oil.
bump it.
2) Air release is required in the following cases ;
(3) Connector should be removed by unlocking while
1. Change of hydraulic oil holding the connector.
2. Replacement of parts on suction pipe side Never stress in tension to the caulked section by
3. Removing and attaching hydraulic pump pulling wire.
4. Removing and attaching swing motor (4) Check that connector is connected and locked
completely.
5. Removing and attaching travel motor
(5) Engine key off before removing and connecting
6. Removing and attaching hydraulic cylinder
connector.
1-4
1. OUTLINE
(6) Engine key off before touching terminals of starter (2) Flexible hose (F hose)
and alternator. • Even if the connector and length of hose are the
(7) Remove battery grounding terminal before same, the parts differ according to the
beginning work close to battery and battery relay withstanding pressure. Use proper parts.
with tools. • Tighten it to the specified torque, and check that
(8) Wash machine with care so as not to splash water it is free from twist, over tension, interference,
on electrical equipment and connector. and oil leak.
(9) When water has entered in the waterproofed
1.1.6 WELD REPAIR
connector, the removing of water is not easy. So
(1) The weld repair should be carried out by qualified
check the removed waterproofed connector with
personnel in the specified procedure after
care to protect it from entry of water. If moisture
disconnecting the grounding cable of battery. If the
adheres on it, dry it completely before connecting.
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
Battery fluid is dangerous. entry of spark beforehand.
The battery fluid is dilute sulfuric acid, and causes (3) Repair attachments which are damaged, giving
scald and loss of eyesight by adhering on eyes, particular attention to the plated section of piston
skin and clothes. When the fluid has adhered on rod to protect it from sparks, and don’t fail to cover
them, take an emergency measure immediately and the section with flame-proof clothes.
see a doctor for medical advice.
1.1.7 ENVIRONMENTAL ISSUES
• When it has adhered on skin ;
Wash with soap and water. (1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
• When it has got in eyes ;
Wash in water for 10 minutes or more (2) Waste disposal
immediately. The following parts follows the regulation.
• When it has spilled out in large quantity ; Waste oil, waste container and battery
Use sodium bicarbonate to neutralize, or wash (3) Precautions for handling hydraulic oil
away with water. Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it was swallowed ;
Drink milk or water. • When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it has adhered on clothes ;
Wash it immediately. • When it was swallowed ;
Don’t force him to vomit it, but immediately
1.1.5 HYDRAULIC PARTS receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
(1) O-ring For spare parts, grease and oil, use KOBELCO
• Check that O-ring is free from flaw and has genuine ones.
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-5
1. OUTLINE
1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
° (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro μ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3
1-6
1. OUTLINE
(6) Unit Conversion Table
QUANTITIES JIS SI REMARKS

Mass kg kg
Force kgf N 1kgf=9.807N
Torque kgf•m N•m 1kgf•m=9.807N•m
Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Motive power PS kW 1PS=0.7355kW
Revolution r.p.m min –1 1r.p.m=1min–1
1-7
1. OUTLINE
[MEMO]
1-8
2
2. SPECIFICATIONS
TABLE OF CONTENTS
2.1 NAME OF COMPONENTS................................................................................................2-3

2.2 GENERAL DIMENSIONS ..................................................................................................2-4
2.2.1 SK485-8
[7.00m (23ft-0in) Boom+3.45m (11ft-4in) Standard Arm+1.9m3 (2.48cu•yd) Bucket Shoe] ....2-4
2.2.2 SK485-8
[7.00m (23ft-0in) Boom+3.00m (9ft-10in) Short Arm+2.10m3 (2.75cu•yd) Bucket Shoe] .......2-4
2.2.3 SK485-8
[7.00m (23ft-0in) Boom+4.90m (16ft-1in) Long Arm+1.35m3 (1.77cu•yd) Bucket Shoe] ........2-5
2.3 WEIGHT OF COMPONENTS............................................................................................2-6
2.4 SPECIFICATIONS AND PERFORMANCE .......................................................................2-8
2.4.1 SPEED AND CLIMBING CAPABILITY .....................................................................2-8
2.4.2 ENGINE ....................................................................................................................2-8
2.4.3 HYDRAULIC COMPONENTS ..................................................................................2-8
2.4.4 WEIGHT ...................................................................................................................2-8
2.5 TYPE OF CRAWLER.........................................................................................................2-9
2.6 TYPE OF BUCKET ............................................................................................................2-9
2.7 COMBINATIONS OF ATTACHMENT................................................................................2-10
2.8 ENGINE SPECIFICATIONS ..............................................................................................2-11
2.8.1 SPECIFICATIONS....................................................................................................2-11
2.8.2 ENGINE CHARACTERISTIC CURVE (HINO P11C-UP) .........................................2-12
2-1
2. SPECIFICATIONS

SK460-8: LS10-02001~ S5LS0211E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
2-2
2. SPECIFICATIONS
2.1 NAME OF COMPONENTS

ARM CYLINDER
ARM
BOOM
BOOM CYLINDER
BUCKET
CYLINDER
SLEWING BEARING
CAB
SWIVEL
JOINT SLEWING MOTOR
IDLER LINK
FUEL TANK
CONTROL VALVE
BUCKET LINK
HYDRAULIC TANK
MUFFLER
HYDRAULIC
PUMP
BUCKET GUARD
MONITOR PANEL
SHOE AND TRACK LINK
FRONT IDLER
IDLER ADJUST ENGINE
UPPER ROLLER COUNTER WEIGHT

AIR CLEANER
TRACK GUIDE RADIATOR AND OIL COOLER

LOWER ROLLER
BATTERY
TRAVEL MOTOR
2-3
2. SPECIFICATIONS
2.2 GENERAL DIMENSIONS

2.2.1 SK485-8 [7.00m (23ft-0in) Boom+3.45m (11ft-4in) Standard Arm+1.9m3 (2.48cu•yd) Bucket Shoe]
Dimensions marked * do not include the height of the shoe lug.

[ ] include LC specifications.
2.2.2 SK485-8 [7.00m (23ft-0in) Boom+3.00m (9ft-10in) Short Arm+2.10m3 (2.75cu•yd) Bucket Shoe]
2-4
2. SPECIFICATIONS
2.2.3 SK485-8 [7.00m (23ft-0in) Boom+4.90m (16ft-1in) Long Arm+1.35m3 (1.77cu•yd) Bucket Shoe]
Dimensions marked * do not include the height of the shoe lug.

[ ] include LC specifications.
2-5
2. SPECIFICATIONS
2.3 WEIGHT OF COMPONENTS

Unit ; kg (lb)
Model
Item SK485-8
Machine complete 49,900 (110,000)
1. Upper frame assy (Assembly of following :) 20730 (45, 700)
1.1 Upper frame 4430 (9, 766)
1.2 Counter weight 10330 (22, 770)
1.3 Cab 265 (584)
1.4 Engine ∗1115 (2460)
1.5 Hydraulic oil tank ∗301 (664)
1.6 Fuel tank (Main) ∗235 (518)
1.7 Slewing motor (including reduction unit) ∗286 (630) x 2
1.8 Control valve ∗380 (838)
1.9 Boom cylinder ∗396 (873) x 2
1.10 Pin (for mounting boom) 110 (243)
1.11 Pump ∗240 (530)
1.12 Radiator (including intercooler) ∗192 (423)
2. Lower frame assy (Assembly of following :) 19,220 (42,370)
2.1 Lower frame 6,000 (13,230)
2.2 Slewing bearing 667 (1, 470)
2.3 Travel motor (including reduction unit) 650 (1, 433) x 2
2.4 Upper roller 30 (66) x 2
2.5 Lower roller 98 (216) x 18
2.6 Front idler 270 (595) x 2
2.7 Idler adjuster 307 (677) x 2
2.8 Sprocket 101 (223) x 2
2.9 Swivel joint ∗53 (110) x 2
2.10 Track guide 50 (110) x 8
2.11 Track link with 900mm ( 35.4in) shoes assy 3717 (8195) x 2
2.11.1 Track link assy 1,160 (2558) x 2
3. Attachment (Assembly of following / STD :) 9, 820 (21, 653)
{7.00m(23ft-0in) Boom + 3.45m(11ft-4in) Arm + 1.9m3 (2.48cu•yd) Bucket}
3.1 Bucket assy (STD) 1, 510 (3, 330)
3.2 STD Arm assy (Assembly of following :) 2, 575 (5, 678)
3.2.1 STD Arm 1, 646 (3, 629)
3.2.2 Bucket cylinder 364 (803)
3.2.3 Idler link 60 (132) x 2
3.2.4 Bucket link 161 (355)
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 159 (351)
3.3 Boom assy (Assembly of following :) 4, 630 (10, 209)
3.3.1 Boom 3, 640 (10, 209)
3.3.2 Arm cylinder 591 (1, 303)
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 128 (282)
2-6
2. SPECIFICATIONS
Unit ; kg (lb)
Model
Item SK485-8
4. Lubricant and water (Assembly of following :) 934 (2, 060)
4.1 Hydraulic oil 311 (686)
4.2 Engine oil 41 (90)
4.3 Fuel 541 (1, 193)
4.4 Water 41 (90)
Marks * show dry weight.
2-7
2. SPECIFICATIONS
2.4 SPECIFICATIONS AND PERFORMANCE

2.4.1 SPEED AND CLIMBING CAPABILITY
Area & Model

SK485-8
Item
Swing speed min-1 {rpm} 7.8 {7.8}
Travel speed (1-speed/2-
km/h (mile/h) 3.4 / 5.4 (2.1 / 3.4)
speed)
Gradeability % (degree) 70 (35)
2.4.2 ENGINE
Engine model HINO P11C-UP

Water-cooled, 4 cycle 6 cylinder direct injection type diesel engine
Type
with inter cooler turbo-charger
6 -ø122 mm × 150 mm
Number of cylinders—Bore× Stroke
(4.80 in × 5.91 in)
Total displacement 10.520 L (641.93 cu•in)
Rated output / Engine speed 243 kW (330 PS) / 1,850 min-1
Maximum torque / Engine speed 1,400 N•m (1,033 lbf•ft)/ 1,400 min-1
Starter 24 V / 6.0kW
Alternator 24 V / 60 A
2.4.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 6-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type
2.4.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 49,900 (110,000)
Upper structure 20, 700 (45, 600)
Lower machinery
19,200 (42,300)
(600mm grouser shoe)
Attachment
7.00m (23 ft-0in) Boom+3.45m (11ft-4in) Arm 9, 940 (21, 900)
+1.9m3 (2.48cu•yd) Bucket
2-8
2. SPECIFICATIONS
2.5 TYPE OF CRAWLER

Overall width of crawler Ground pressure
Shape Shoe width mm (in)
mm (ft-in) kPa (psi)
Grouser shoe
900 (35.4) LC 3,350 (10'12") 58 (8.26)
2.6 TYPE OF BUCKET

Heaped Outer width mm (ft-in) Availability
Struck Number W or W/O Weight
capacity With side Without side of face
m3(cu•yd) of tooth side cutter kg (lbs)
Hoe bucket m3(cu•yd) cutter cutter shovel
1.00 1,250
1.35 (1.77) 1,230 (4'0.5") 1,100 (3'7") 4 W YES
(1.31) (2,756)
1.15 1,330
1.60 (2.09) 1,380 (4'6") 1,250 (4'1") 5 W YES
(1.50) (2,933)
1.90 (2.48) 1.40 1,510
1,670 (5'6") 1,550 (5'1") 5 W NO
STD (1.83) (3,330)
1.50 1,560
2.10 (2.75) 1,750 (5'9") 1,630 (5'4") 5 W NO
(1.96) (3,440)
1.70 1,690
2.40 (3.14) 1,980 (6'6") 1,860 (6'1") 5 W/O NO
(2.22) (3,726)
2-9
2. SPECIFICATIONS
2.7 COMBINATIONS OF ATTACHMENT

Bucket Available Arm
Heaped capacity Struck 3.45m (11ft-4in) Arm 4.90m (16ft-1in) 3.00m (9ft-10in)
Type
m3 (cu•yd) m3 (cu•yd) (STD) Arm (Long) Arm (Short)
1.35 (1.77) 1.00 (1.31)
1.60 (2.09) 1.15 (1.50)
1.90 (2.48)
Hoe bucket 1.40 (1.83)
(STD)
2.10 (2.75) 1.50 (1.96)
2.40 (3.14) 1.70 (2.22)
Breaker — —
Nibbler — —
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
• Use the attachments recommended by KOBELCO.

The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2-10
2. SPECIFICATIONS
2.8 ENGINE SPECIFICATIONS

2.8.1 SPECIFICATIONS
Applicable machine SK485-8

Engine model HINO P11C-UP
Water-cooled, 4 cycle 6 cylinder direct injection type
Type
diesel engine with inter cooler turbo-charger
Number of cylinder× Bore× Stroke mm (in) 6 × 122 × 150 (4.80 × 5.91)
Total displacement cc (cu•in) 10,520 (642)
Compression ratio 17.0
Rated output kW (PS) at min -1
243 (330) at 1,850
N•m (lb•ft) at
Maximum torque 1,400 (1,033) at 1,400
min-1
High idling min-1 2,050 ± 30
Low idling min -1
800
Injection starting pressure MPa (psi) 3.2 (464)
Start/Full open
Thermostat action 350 (170) / 363 (194)
K (°F)
Firing order 1-4-2-6-3-5
MPa (psi)
Compression pressure 2.8~3.0 (406~435) at 200
at min-1
Fuel injection timing 0°
Valve clearance Open Close
11°before top 22°after bottom
Intake valve 0.45 mm at cool
Valve clearance dead point dead point
59°before bottom 13°after top dead
Exhaust valve 0.60 mm at cool
dead point point
Starter capacity V × kW 24 × 6.0
Generator capacity (Alternator) V× A 24 × 60
ø850 (33.5") × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.95
Full level 35.0 (9.25)
Engine oil quantity L (gal) Low level 27.0 (7.13)
Total 42.5 (11.2)
Dry weight kg (lbs) 1,150 (2,536)
Fuel consumption ratio g/kW•h (g/ps•h) 213 (157)
Allowable inclination
Front / Rear and Right / Left : 35°
(Limited by E/G lubrication)
Dimension (L× W× H) mm (in) 1,440 × 921 × 1,154 (4ft-8.7in × 36.3in × 3ft-9.4in)
Rotating direction Counterclockwise seeing from flywheel side
2-11
2. SPECIFICATIONS
2.8.2 ENGINE CHARACTERISTIC CURVE (HINO P11C-UP)
Condition to be measured: The net value is indicated, measuring without cooling fan.
marks show the rated point
SHAFT TORQUE
SHAFT OUTPUT
FUEL CONSUMPTION RATE
ENGINE SPEED (min-1)
Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
213g/kW.h
X 243kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
62.0
Fuel consumption in regular operation
(load factor 0.70~0.80)
43.4 L/h~49.6 L/h
2-12
3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
3.1 BOOM ................................................................................................................................3-3

3.1.1 BOOM DIMENSIONAL DRAWING...........................................................................3-3
3.1.2 BOOM MAINTENANCE STANDARD .......................................................................3-4
3.2 ARM ...................................................................................................................................3-6
3.2.1 ARM DIMENSIONAL DRAWING..............................................................................3-6
3.2.2 ARM MAINTENANCE STANDARD ..........................................................................3-7
3.3 BUCKET ............................................................................................................................3-10
3.3.1 BUCKET DIMENSIONAL DRAWING .......................................................................3-10
3.3.2 BUCKET DIMENSIONAL TABLE .............................................................................3-10
3.3.3 LUG SECTION DIMENSIONAL DRAWING .............................................................3-11
3.3.4 BOSS SECTION DIMENSIONAL DRAWING...........................................................3-12
3-1

SK460-8: LS10-02001~ S5LS0311E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
3-2
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING
J
d4
I
X
d3
d1
D C H
E B
F
G
X
d2
SECTION X-X
Fig. 3-1 Boom dimensional drawing
Unit : mm (ft-in)
STD —
7.0M (23ft) BOOM
LS02B00129F1 —
No NAME DIMENSION
A Boom length 7000 (23') —
B Boom foot width 926 (36.5") —
C Boom end inner width 449.8 (17.7") —
D Boom end outer width 627 (24.7") —
E Height of boom cylinder rod pin 1,162 (3'10") —
F Height of arm cylinder (head side) pin 1,476.8 (4'10") —
G Distance between pins of boss R3,069 (10'1") —
H Distance between pins of bracket R3,530 (11'7") —
I Arm cylinder (head side) inner width 166 (6.54") —
J Outer width of bracket on the arm cylinder (rod side) 638 (25.1") —
mounting
d1 Boom foot pin dia. ø 120 (4.72") —
d2 Boom cylinder (rod side) pin dia. ø 120 (4.72") —
d3 Pin dia. of boom end. ø 120 (4.72") —
d4 Arm cylinder (head side) pin dia. ø 120 (4.72") —
Weight kg (lb) 3,640 (8,026) —
3-3
3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section
A
C
Fig. 3-2 Clearance of pin and bushing on boom section
Unit : mm (in)
Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.020 + 0.205 + 0.225
ø 120 (+0.0008) (+0.0081) (+0.0089)
A Boom foot LS02B01341P1
(4.7244) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
0 + 0.229 + 0.269 More
Replace
Boom cylinder ø 110 (0) (+0.0090) (0.0106) than 2.5
B LS02B01344P1 bushing
(Head side) (4.3307) - 0.04 + 0.103 + 0.103 2.0 (0.1)
or pin
(-0.0016) (+0.0041) (+0.0041) (0.08)
Boom cylinder + 0.020 + 0.230 + 0.250
C LS02B01345P1
(Rod side) ø 120 (+0.0008) (+0.0091) (+0.0098)
Arm cylinder (4.7244) - 0.020 + 0.105 + 0.085
D LS02B01473P1
(Head side) (-0.0008) (+0.0041) (+0.0033)
3-4
(2) Clearance in thrust direction on the boom cylinder installation section
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
926
Boom
(36.5)
0.5 (0.02) 921
A-A Boom foot L1 PL1
932 or less (36.3)
Upper frame
2.0 2.5
(36.69 )
(0.08) (0.10)
150
Boom cylinder
Boom cylinder (5.91) 0.6~1.0 284
B-B L2 PL2
(Head side) 156±1 (0.02~0.04) (11.2) Shim
Upper frame
(6.15±0.04) adjust
140 ment
Boom cylinder L3
Boom cylinder (5.51) 0.6~2.0 3.0 4.0 810
C-C PL3
(Rod side) 638 (0.02~0.08) (0.12) (0.16) (31.9)
Boom L3'
(25.1)
160
Arm cylinder
Arm cylinder (6.30) 0.6~1.0 2.0 2.5 274
D-D L4 PL4
(Head side) 166 (0.02~0.04) (0.08) (0.10) (10.8)
Boom
(6.54)
3-5
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
SECTION Z-Z
SECTION Y-Y
Fig. 3-4 ARM DIMENSIONAL DRAWING
3.45m (11ft-4in) ARM LS12B00242F1 Unit : mm (ft-in)

Code NAME DIMENSION Code NAME DIMENSION
C Arm length 3,450 (11'4") N Arm cyl. rod inner width 166 (6.54")
Distance between pins of boss
D R1,140 (3'9") O Bracket cyl. head inner width 166 (6.54")
and bracket
D1 I.D of boss ø140 (5.51") P Idler link dimension 785 (30.9")
D2 I.D of boss ø115 (4.53") Q Bucket link dimension 680 (26.8")
Height between pins of boss and
D4 I.D of boss ø140 (5.51") R 48 (1.89")
center
E R2,728 (8'11") d1 Pin dia. ø100 (3.94")
and bracket
F R540 (21.3") d2 Pin dia. ø100 (3.94")
and boss
G 858 (33.8") d3 Pin dia. ø120 (4.72")
bracket
H 479 (18.9") d4 Pin dia. ø120 (4.72")
bracket
K Arm top end boss width 450 (17.7") d5 Pin dia. ø100 (3.94")
L Arm link section boss width 446 (17.6") Weight kg (lb) 1,650 (3,638)
M Boss width 444 (17.5")
3-6
3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
E F
D, D'
B
C
G
Fig. 3-5 Clearance of pin and bushing on arm section
Unit : mm (in)
Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.256 +0.316
(+0.0101) (+0.0124)
A Arm point
–0.020 +0.084 +0.104
(-0.0008) (+0.0033) (+0.0041)
LS12B01507P1
–0.060 +0.216 +0.276
Bucket link (-0.0024) (+0.0085) (+0.0109)
B
(Bucket side) +0.070 +0.090
(+0.0028) (+0.0035)
+0.233 +0.273
Idler link
(+0.0092) (+0.0107)
C (Connected part LS12B01508P1
+0.081 +0.081
of arm)
ø100 (+0.0032) (+0.0032)
(3.9370) 0 +0.220 +0.260
Bucket link (0) (+0.0087) (+0.0102)
D
(Idler link side) –0.04 +0.076 +0.076
Replace
(-0.0016) (+0.0030) (+0.0030) 2.0 2.5
LS12B01509P1 bushing
+0.231 +0.271 (0.08) (0.01)
or pin
Bucket cylinder (+0.0091) (+0.0107)
D'
(Rod side) +0.066 +0.066
(+0.0026) (+0.0026)
+0.233 +0.253
Bucket cylinder (+0.0092) (+0.0100)
E LS12B01510P1
(Head side) +0.070 +0.050
(+0.0028) (+0.0020)
+0.02 +0.230 +0.250
Arm cylinder (+0.0008) (+0.0091) (+0.0098)
F LS02B01347P1
(Rod side) –0.02 +0.105 +0.085
ø120 (-0.0008) (+0.0041) (+0.0033)
(4.7244) +0.206 +0.226
Arm foot
(+0.0081) (+0.0089)
G (Connected part LS12B01511P1
+0.099 +0.079
of boom)
(+0.0039) (+0.0031)
3-7
(2) Clearance of arm and cylinder installing sections in thrust direction
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
L3 PL5 X6 L6
X3
X5 L5
PL1 PL3 PL6

SECTION A-A SECTION C-C SECTION E-E SECTION F-F
X4 L4
X2 L2 PL7
X7 L7
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-8
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
450
Arm
(17.71) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
452 or less (0.08)
Bucket
(17.80) 702
450 (27.6)
Link side
(17.71)
B-B Bucket link L2 — — PL2
453
Bucket
(17.83)
446 With in 2.5
Idler link Arm 1.0
C-C L3 (17.56) 0.5 (0.10) PL3
(Arm connection) (0.04)
Link side - (0.02)
Bucket link Rod side -
D-D (Idler link L4 446 578
Link side
connection) (17.56) (22.8)
0.6~1.0 2.0 Shim
160 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (6.30)
D’-D’ L4’ -ment
(Rod side) 166
Link side
(6.54)
160
Head side
Bucket cylinder (6.30) 332
E-E L5 PL5
(Head side) 166 (13.1)
Arm
(6.54) 0.6~2.0 3.0 4.0
160 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (6.30) 367.5
F-F L6 PL6
(Rod side) 166 (14.5)
Arm
(6.54)
444
Arm With in
(17.48) 1.0 2.5 665
G-G Arm foot L7 0.5 PL7
449.8 (0.04) (0.10) (26.2)
Boom (0.02)
(17.71)
3-9
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Fig. 3-7 Bucket dimensional drawing
No. NAME No. NAME

A Distance between pin and bracket G Outer width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
3.3.2 BUCKET DIMENSIONAL TABLE
Unit : mm (ft-in)
Type Hoe bucket
[STD]
1.35m3 1.60m3 2.10m3 2.40m3
Capacity 1.90m3
(1.77 cu•yd) (2.09 cu•yd) (2.75 cu•yd) (3.14 cu•yd)
(2.48 cu•yd)
Part No. LS61B00045F1 LS61B00007F1 LS61B00008F1 LS61B00059F1 LS61B00062F1
A R630 (24.8") ← ← ← ←
B R1,780 (5'10") ← ← ← ←
C 1,475 (4'10") 1,033 (3'4.7") 1,183 (3'10.6") 1,559 (5'1.4") 1,788 (5'10.4")
D 552 (21.7") ← ← ← ←
E 452 (17.8") ← ← ← ←
F 1,667 (5'5.6") 1,225 (4'0.2") 1,375 (4'6.1") 1,751 (5'9") 1,980 (6'6")
G 1,339 (4'4.7") 890 (35") 1,040 (3'5") 1,423 (4'8") 1,652 (5'5")
H 1,546 (5'0.9") 1,096.5 (3'7.2") 1,246.5 (4'1.1") 1,630 (5'4.2") 1,859 (6'1.2")
I 339 (13.3") 303 (11.9") 353 (13.9") 360 (14.2") 417 (16.4")
IO 339 (13.3") 303 (11.9") 353 (13.9") 360 (14.2") 417 (16.4")
d1 ø 100 (3.94") ← ← ← ←
d2 ø 100 (3.94") ← ← ← ←
3-10
3.3.3 LUG SECTION DIMENSIONAL DRAWING
J
M
LS12B01054P1
VIEW I
E
N
A
F
Insert this pin flush with surface
H
9
25 (0.354")
(0.984")
SECTION A-A
Fig. 3-8 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Boss outer dia.
Boss outer dia.

Spring pin dia.
Pin hole dia.
Boss width.
Boss width.
Screw dia.
Capacity of
Hole dia.
Type of Part No. of

bucket
bucket bucket
m3 (cu.yd)
A B D E F G H J M N
[STD]
1.90 (2.48) LS61B00045F1
Hoe 1.35 (1.77) LS61B00007F1 100 36 120 16 220 22 195 28 170
bucket M20
(3.94") (1.42") (4.72") (0.63") (8.66") (0.87") (7.68") (1.10") (6.69")
1.60 (2.09) LS61B00008F1
2.10 (2.75) LS61B00059F1
2.40 (3.14) LS61B00062F1
3-11
3.3.4 BOSS SECTION DIMENSIONAL DRAWING
gh
ou
thr
ILL
DR
G
Fig. 3-9 Dimension of boss section
Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB E F øG
bucket bucket of boss
m3 (cu•yd)
1.90 (2.48) LS61B00045F1
1.35 (1.77) LS61B00007F1
Hoe 139.8 103.8 25 40 21
1.60 (2.09) LS61B00008F1 LS12B01054P1
bucket (5.50") (4.09") (0.984") (1.57") (0.827")
2.10 (2.75) LS61B00059F1
2.40 (3.14) LS61B00062F1
3-12
11. TOOLS
11
TABLE OF CONTENTS
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ............................................11-3

11.2 SCREW SIZE...................................................................................................................11-5
11.2.1 CAPSCREW (BOLT) ..............................................................................................11-5
11.2.2 CAPSCREW (SOCKET BOLT) ..............................................................................11-5
11.2.3 SOCKET SET SCREW...........................................................................................11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-6
11.3.1 JOINT (O-RING TYPE)...........................................................................................11-6
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6
11.3.3 JOINT (ORS TYPE) ................................................................................................11-6
11.3.4 SPLIT FLANGE ......................................................................................................11-6
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-7
11.5 PLUG ...............................................................................................................................11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11
11.7 SPECIAL TOOLS.............................................................................................................11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......11-14
11.9 SUCTION STOPPER.......................................................................................................11-15
11.9.1 COMPONENTS ......................................................................................................11-15
11.9.2 DIMENSION ...........................................................................................................11-15
11.9.3 APPLICABLE MODEL ............................................................................................11-15
11.10 UPPER FRAME LIFTING JIG..........................................................................................11-16
11.11 ENGINE MOUNTING PEDESTAL ...................................................................................11-17
11-1
11. TOOLS

SK460-8: LS10-02001~ S5LS1111E01
First edition June, 2007 K
SK480LC–8 : YS10-01501~ (ASIA, OCE)
11-2
11. TOOLS
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables Table11-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given.
Overtightening of bolts may result in a twist-off and a fracture under load.
Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.
Table11-1 Tightening torque for metric coarse threads (not plated)
Unit : N•m (lbf•ft)
Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9
M8 P=1.25
(7.9±0.8) (6.6±0.7) (17.3±1.5) (14.5±1.5) (31.1±2.9) (26.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9
M10 P=1.5
(15.9±1.4) (13.2±1.3) (34.0±3.6) (28.9±2.9) (61.5±6.5) (52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12
M12 P=1.75
(26.8±2.9) (23.2±2.1) (58.6±5.8) (49.2±5.1) (105±11) (89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19
M14 P=2
(42.7±4.4) (36.1±3.6) (92.9±9.6) (78.2±7.4) (167±15) (141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29
M16 P=2
(65.1±6.5) (55.0±5.1) (141±15) (119±12) (253±29) (209±21)
122±12 103±10 265±29 226±20 481±49 402±39
M18 P=2.5
(90.0±8.9) (75.8±7.2) (195±21) (167±15) (355±36) (297±29)
172±17 144±14 373±39 314±29 667±69 559±59
M20 P=2.5
(127±13) (106±10) (275±29) (232±21) (492±51) (412±44)
226±20 192±20 500±49 422±39 902±88 755±78
M22 P=2.5
(167±15) (142±15) (369±36) (311±29) (665±65) (557±58)
294±29 235±29 637±69 520±49 1160±118 941±98
M24 P=3
(217±21) (173±21) (470±51) (383±36) (856±87) (694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137
M27 P=3
(318±29) (260±29) (694±72) (564±58) (1250±123) (1010±101)
588±59 490±49 1285±127 1079±108 2300±235 1940±196
M30 P=3.5
(434±44) (361±36) (948±94) (796±80) (1700±173) (1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265
M33 P=3.5
(586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333
M36 P=4
(760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246)
11-3
11. TOOLS
Table11-2 Tightening torques for metric fine threads (not plated)

Torque value Unit : N•m (lbf•ft)
Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1.0
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9
M10 P=1.25
(16.7±1.5) (13.8±1.4) (35.5±3.6) (30.3±2.9) (64.4±6.5) (54.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13
M12 P=1.25
(28.9±2.9) (24.6±2.1) (62.9±6.5) (52.8±5.1) (114±12) (95.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29
M16 P=1.5
(68.0±6.5) (57.2±5.8) (145±15) (125±13) (268±29) (224±21)
186±19 155±16 402±39 333±29 726±69 608±59
M20 P=1.5
(137±14) (114±12) (297±29) (246±21) (535±51) (448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98
M24 P=2
(232±21) (195±21) (506±51) (420±44) (915±87) (760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206
M30 P=2
(470±44) (391±36) (1030±101) (853±87) (1840±188) (1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275
M33 P=2
(629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203)
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
(789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260)
11-4
11. TOOLS
11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 27 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
11.2.2 CAPSCREW (SOCKET BOLT)
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
11.2.3 SOCKET SET SCREW
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
11-5
11. TOOLS
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)
Size Wrench Tightening torque

(PF) (mm) N•m (lbf•ft) O-RING O-RING
1/8 14 17±2 (13±1.5)
1/4 19 36±2 (27±1.5)
3/8 22 74±5 (55±4)
1/2 27 108±9.8 (80.0±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)
Size Tightening torque

Wrench(mm) UNION NUT
(PF) N•m (lbf•ft)
1/8 17 15±2.0 (11±1.5)
1/4 19 29±4.9 (21±3.6)
3/8 22 49±4.9 (36±3.6)
1/2 27 78±4.9 (58±3.6)
3/4 36 118±9.8 (87±7.2)
1 41 137±15 (101±11)
11.3.3 JOINT (ORS TYPE)
Tightening Torque CONNECTOR FITTING

Unified screw size Opposing flats O-RING
N•m (lbf•ft)
1-14 UNS 30, 32 137±14 (101±10)
36 177±18 (131±13)
1 3 / 16-12 UN
41 206±26 (152±15)
41 206±26 (152±15)
1 7/ 16-12 UN
46 206±26 (152±15) NUT
11.3.4 SPLIT FLANGE
Tightening torque N•m (lbf•ft)

Standard pressure Hi pressure
Size Bolt Bolt
series series
size size
20.6 MPa 41.2 MPa
3/4 33.9±5.6 (25±4) M10 39.5±5.6 (29±4) M10
1 42.4±5.6 (31±4) M10 62.2±5.6 (46±4) M12
11/4 55.1±7.1 (41±5) M10 93.3±8.4 (69±6) M14
11/2 70.6±8.4 (52±6) M12 169±11 (125±8) M16
2 81.9±8.4 (60±6) M12 282±11 (208±8) M20
11-6
11. TOOLS
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table11-3 indicates standard tightening torques applicable to cases where no particular note is given.
Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe
connections.
Always tighten nuts and sleeves to proper torques.
Table11-3
Working Tube size Opposing Tightening torque
pressure OD × thickness flats N•m (lbf•ft)
Manufacturer's name
MPa (psi) mm (in) (HEX)
mm
ø10× 1.5
19 49.0±9.8 (36±7.2)
(0.394× 0.059)
ø15× 2.0
27 118±12 (87±8.7)
(0.591× 0.079)
ø18× 2.5
Nippon A.M.C. 29.4 (4270) 32 147±15 (110±11)
(0.709× 0.098)
ø22× 3.0
36 216±22 (160±16)
(0.866× 0.118)
ø28× 4.0
41 275±27 (200±20)
(1.10× 0.157)
ø35× 5.0
Ihara Koatu 29.4 (4270) 55 441±44 (330±33)
(1.38× 0.197)
SLEEVE NUT
B
d
d
Tube size Parts No. Tube size Opposing Parts No.

ød Ihara Koatu Nippon A.M.C. ød flats Ihara Koatu Nippon A.M.C.
(HEX) mm
6 ZF93S06000 — 6 14 ZF93N06000 —
8 ZF93S08000 — 8 17 ZF93N08000 —
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 — 12 22 ZF93N12000 —
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 — 32 50 ZF93N32000 —
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 — 38 60 ZF93N38000 —
11-7
11. TOOLS
11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
Applicable Cap nut parts Opposing flats

A tube T screw
No.
O. D : A H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41
(2) Plug (Tube plug)
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
A
d screw tube Nut parts No. d screw Opposing flats

O. D : A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
11-8
11. TOOLS
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
(3) Plug for (F) flare hose
PF screw
PF screw Plug parts No. B mm

PF1/4 2444Z2728D1 14
60
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
PF screw Plug parts No. E mm F mm

PF PF1/4 2444Z2729D1 14 19
60
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
(4) Plug for ORS joints

Male

$%
&
) *

"

- .,/01

'$ +,) #
( ' +,) ! # !
( ' +,) #
Female
%!

! & '#()*
"#
"#$
"#
(5) Plug for half clamp
4-oH For standard pressure : 20.6 MPa (2990 psi)

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

Plug O-ring
G Size part No. C mm D mm G mm H mm part No.
25.53~
1/2 ZE13Q08000 40.49 18.24 25.40 9 2445Z831D1
31.88~
3/4 ZE13Q12000 50.80 23.80 31.75 11 ZD12P02600
ZE13Q16000 57.15 39.75~ ZD12P03400

1 27.76 13
39.62
44.58~
1 1/4 ZE13Q20000 66.68 31.75 44.45 15 ZD12P03800
11-10
11. TOOLS
11.6 SPECIAL SPANNER FOR TUBE

Applicable tube
diameter Part No. HEX (mm) Drawing of a special spanner mm (in)
mm (in)
70(2.76)
16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)
40(1.57) 12.7 (0.500 )
70(2.76)
42(1.65)
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )

28 (1.10) 2421T231 46

32 (1.26) 2421T232 50

81(3.19) 90(3.54)
20.5(0.807)
35 (1.38) 2421T314 55 41 PART-No. 45

(1.61) (1.77)
HEX55 19.05 (0.750 )
11-11
11. TOOLS
11.7 SPECIAL TOOLS

Table11-4
No. Tools name Tools No. Shape Applicable
Additional M10 X 22
threading
for M10 eye bolt
Plug ZE72X16000 For slinging the
1
PF1 swing motor
O-ring
PF1
M12 Eye bolt
Eye bolt ZS91C01200

M12× 22 or For slinging the
2
commercial swing motor
equivalent
22
M12
M8 Eye bolt
Plug ZF83P22000
(Nominal
tube dia. 22)
3 Reference nut Flare hose
Reference
Eye bolt ZS91C00800
M8 X 18
Nut ZF93N22000 Addtional
threading for
M8 Eye bolt
M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
4 1 3/16-12UN HEX 36 Flare hose
Eye bolt ZS91C00800

1 3/16-12UN
M8 Eye bolt
M8 18
Additional
Plug YN01H01003P1 threading
Nominal
5 1 7/16-12UN HEX41 Flare hose
Eye bolt ZS91C00800

1 7/16-12UN
11-12
11. TOOLS
Table11-4
No. Tools name Tools No. Shape Applicable
M8 Eye bolt
M8 17
Plug ZE72X12000 Additional
PF3/4 threading For slinging the
6
swivel joint
Eye bolt ZS91C00800 PF 3/4
TORX driver 5.49

(with tamper
For instrument
7 proof) — Point shape
panel cover (RH)
T30
(For M6)
11-13
11. TOOLS
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING

COMPOUND
(1) For general use
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound
(2) For specific location
No. Use Manufacturer Name Equivalent Applicable

(Manufacturer ; Loctite)
# 1901 Anti-seizure Cylinder
Three-Bond # 1215 gray # 5699 Swing motor
# 1211 white # 5301J Swing motor
# 1303B # 211 Main pump
(Manufacturer ; Three-
Bond)
Sealing Loctite
# 222 # 1344N Main pump
compound
1 # 277 # 1307N Pilot valve
&
adhesive (Manufacturer ; Three-
Bond)
Loctite Parmatex 98D # 1121 Hydraulic oil tank :
Sumitomo
Chemical Co., Cyano Bond PO-1 Hose
Ltd.
Shell
Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease bath
petroleum
11-14
11. TOOLS
11.9 SUCTION STOPPER

11.9.1 COMPONENTS
No. NAME PARTS No. Q'TY

SUCTION STOPPER ASSY 24100P978F3
1 ROD 2420T4660D1 1
1 Rod
2 NUT ZN16C08007 1
3 COVER 2414T2123D3 1
4 O-RING 45Z91D7 1
2 Nut
3 Cover
4 O-ring
Fig. 11-1 Components of suction stopper
11.9.2 DIMENSION
50
(1.97")
R8
158 (6.22")
2
M8 NUT
O8 (1.315")
600 (23.6")
(0.374")
9.5
0 0
139 -0.3 (5.47" -0.012 )
M8
(0.787")
152 0.2
20
(5.98" 0.008)
ROD COVER
Fig. 11-2 Dimension of suction stopper
11.9.3 APPLICABLE MODEL

SK450(LC)-6
Applicable
SK460-8
model
Part No.
24100P978F3
11-15
11. TOOLS
11.10 UPPER FRAME LIFTING JIG
No. NAME Q'TY REMARKS

0m )
3. 10in MASTER LINK M 1
ft
(9 HIGH COUPLING HC 12
CHAIN 2 10 X 3.8m
CHAIN 2 10 X 2.5m
GRAB HOOK H 2
(14ft1in
4.3m
)
No. NAME MATERIAL Q'TY REMARKS

6"
) 6")
2.3 86
1 HOLDER POK40 2 FRONT SIDE ( (0. 22
(1.
60
30 ")
R
18
(1.
57
40 )
2 PIN S40C 2
"
(4.
12 2")
3 CAPSCREW - 2 M10 X 85
7
0
4 HOLDER POK40 2 REAR SIDE
19(0.748") 19(0.748")
(1 R50
")
.97
4
30(1.18")
(2.36")
60
(31.5")
800
1
(4.13")
19 100 19
105
1 (2.56")
(0.748") (3.94") (0.748") (5. 46 65
75 (1.97")
(1.18")
")
50
30
(5.91") (0.866")
22
(13.8")
350
(1.97") 50
130
(5.12")
150
22 22 50
40 +0.05 (1.5748" +0.0020 )
(0.866") (0.866") (1.97")

+0.1(1.5748" +0.0039)
120 120
+0.0079
(4.72") (4.72")
(2 60
2
")
11.5(0.453")
.36
DRILL
40+0.2
(2.36")
60
5
C ")
11.5(0.453") 7 178(7.01")
9
(1 R50
178(7.01") 1
")
DRILL 15 0. 125(4.92") 50
.97
(0.591") 125(4.92") (
30 19 19 10 (1.97")
(1.18") (0.748") (0.748") (0.394")
Fig. 11-3 Upper frame lifting jig
11-16
11. TOOLS
11.11 ENGINE MOUNTING PEDESTAL

Material : wood
5 Unit ; mm(inch)
(1.97)
(1.18)
(11.8)
3 2 1
1 1 piece 2 1 piece
1010 (39.8)
400 (15.7) 140 320 (12.6)
(5.51)
90 (3.54)
250 (9.84)
(10.04
R255
494 (19.45)
)
380 (15.0)
260 (10.24)
240 (9.45)
240 (9.45)
t40 (1.57) t40 (1.57)
480 (18.9)
3 1 piece 5 1 piece
1010 (39.8)
380 (15.0)
140 620 (24.4)

(5.51)
90 (3.54)
290 (11.4)
380 (15.0)
240 (9.45)
t40 (1.57)
t40 (1.57)
440 (17.3)
Fig. 11-4 Engine stand
11-17
11. TOOLS
[MEMO]
11-18
12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST
(TEMPORARY EDITION) ................................................................................................12-15
12.2.1 MEASURING METHOD .........................................................................................12-15
12.2.2 WORKING CONDITION .........................................................................................12-15
12.2.3 STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.4 MEANING OF WORDS IN USE .............................................................................12-17
12-1
12. STANDARD MAINTENANCE TIME TABLE

SK460-8: LS10-02001~ S5LS1211E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
12-2
PREFACE
(1) Working Conditions
1) Workers :
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
2) Equipment :
Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The
maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
3) Place :
A flat land where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance time x Preparation time
2) Direct maintenance time : Net time actually spent for maintenance
3) Spare time :
Time needed to move machines for service, prepare safety operations, discuss work, and process the needs
of the body.
(3) Extra time (not included in the standard service time)
1) Repair time :
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time :
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
3) Indirect time :
Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
(4) Applicable machine for estimation of standard maintenance time
1) Standard machine
2) A well maintained and controlled machine with a standard combination of attachments which is used in a
general environment.
12-3
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF

EXCAVATOR
(1) Standard maintenance time table
1) Units of working time : 6 minutes = 0.1 hour
2) Calculating method of standard maintenance time :
Maintenance time=Working time× Number of workers
(Working time=Maintenance time÷Number of workers)
3) When more than one operation is going on :
Add each standard service time. A pure time (readily started) is given except covers easily removed by hand.
Assy works include the following works marked with black dot •.
4) O/H : The removing and attaching time is not included.
5) Abbreviations in the table.
A/C : Air conditioner C/V : Control valve O/H : Over haul

ASSY : Assembly Cyl : Cylinder SOL : Solenoid
ATT : Attachment E/G : Engine SW : Switch
BRG : Bearing F hose : Flexible hose V : Valve
(2) Classification of working code
No. Group Remarks

01 Attachment Indicates installing, removing, replacement and overhaul.
02 Cab & Guard
03 Swing frame
04 Travel system
Electric Indicates the installing, removing and replacement of single items.
06
equipments
09 E/G relation Indicates overhaul of the single engine.
(Materials prepared by manufacturer )
(3) Conditions for standard service time of the engine

1) Tools designated by E/G maker are used
2) Genuine parts are changed
3) Correct working procedures are observed.
• The time required for works specified in this Chapter shows the total time for maintenance.
12-4
Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket Assy Detach/attach 1 pc. Include adjustment. 1.2
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.3
04 • Bucket drive pin Detach/attach 1 0.3
05 • Bucket sling and movement Preparation 1 pc. 0.3
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 5.0
07 • Tooth Replace 1 pc. 1.2
08 • Side cutter Replace 1 pc. 2.5
09 • Bushing Replace 1 pc. 1.2
10 Arm relation See 32.1.3

11 Arm Assy Detach/attach 1 pc. 2.7
12 • Bucket cylinder attaching and Preparation 1 pc. 0.8
detaching position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.3
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin 0.3
15 • Bucket cylinder assy Detach/attach 1 pc. 0.3
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.3
17 • Boom top pin Detach/attach 1 pc. Include wire stop pin. 0.3
01 Attachment
18 • Arm sling and movement Detach/attach 1 pc. 0.4
30 Boom relation See 32.1.4

31 Boom Assy Detach/attach 1 pc. 2.9
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.4
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.4
35 • Boom cylinder piping Detach/attach 2 pc. 0.4
36 • Arm & bucket piping Detach/attach 1 pc. 0.4
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.4
39 • Boom assy slinging Detach/attach 1 pc. 0.3
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 1.0
41 • Arm cylinder piping Detach/attach 1 pc. 0.4
42 • Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.3
43 • Arm cylinder slinging Detach/attach 1 pc. 0.3
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 1.4
51 • Boom cylinder piping Detach/attach 2 0.5
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.4
53 • Boom cylinder slinging Detach/attach 2 0.4
60 Bucket cylinder O/H 1 5.5
61 • Pin bushing Replace 1 Include seal. 2.0
70 Arm cylinder O/H 1 5.5
12-5
Work to be Unit :
done Hour
71 • Pin bushing Replace 1 set Include seal. 2.0
80 Boom cylinder O/H 2 10.0
01
81 • Pin bushing Replace 1 set Include seal. 2.0
10 Cab relation See 33.1.2

11 Cab Assy Detach/attach 1 pc. 1.4
12 • Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 • Seat rear cover top, bottom Detach/attach 4 places 0.2
14 • Seat rear cover top, bottom Detach/attach 1 pc. each 0.2
15 • Right side panel (include A/C duct) Detach/attach 3 0.3
16 • Cable and harness (electric) Detach/attach 6 0.2
17 • Cab mounting bolt Detach/attach 8 pcs. 0.2
18 • Cab slinging Detach/attach 3 places 0.2
20 Guard relation See 33.1.4

21 Bonnet assy (1), (2) Detach/attach 1 pc. each 0.5
22 Guard (7) Detach/attach 1 pc. 0.2
25 Beam (6) Detach/attach 1 pc. 0.2
02 Cab & Guard
26 Stay (63) Detach/attach 1 pc. 0.2

27 Cover assy (61) Detach/attach 1 pc. 0.2
28 Panel assy (71) Detach/attach 1 pc. 0.2
29 Panel assy (73) Detach/attach 1 pc. 0.2
30 Guard assy (72) Detach/attach 1 pc. 0.2
31 Panel (62) Detach/attach 1 pc. 0.2
33 Cover (19) Detach/attach 1 pc. 0.2
37 Beam (11) Detach/attach 1 pc. 0.2
38 Bracket (9) Detach/attach 1 pc. 0.2
39 Pillar (12) Detach/attach 1 pc. 0.2
41 Pillar (10), (14) Detach/attach 1 pc. each 0.2
45 Cover assy (84), (83) Detach/attach 1 pc. each 0.2
46 Guard assy (81), (82) Detach/attach 1 pc. each 0.2
Note: The numbers in the parenthesis like guard (17) match the guard numbers on the upper structure.
12-6
Work to be Unit :
done Hour
50 Under cover relation See 33.1.5
56 Cover assy (6) Detach/attach 1 pc. 0.1
02 Cab & Guard

59 Cover (9), (10), (11), (12), (13) Detach/attach 1 pc. each 0.1
60 Counterweight relation See 33.1.11

61 Counterweight Assy Detach/attach 1 pc. 0.6
62 • Counterweight temporary slinging Preparation 1 pc. 0.2
63 • Counterweight mounting bolt Detach/attach 1 pc. 0.2
64 • Counterweight slinging Detach/attach 1 pc. 0.1
10 Intake relation See 33.1.9

11 Air cleaner Assy Detach/attach 1 pc. 0.4
12 • Hose (3) Detach/attach 1 0.1
13 • Air cleaner mounting bolt Detach/attach 1 set 0.2
14 • Element Replace 1 0.1
20 Exhaust relation See 33.1.10

21 Muffler Assy Detach/attach 1 pc. 0.4
22 • U bolt Detach/attach 1 pc. 0.2
23 • Clamp Assy Detach/attach 1 pc. 0.2
03 Swing frame
30 Radiator relation See 33.1.12

31 Radiator Assy Detach/attach 1 pc. 6.0
32 • Coolant (LLC) Replace 1 pc. 0.4
33 • • Concentration of coolant Measuring 1 pc. 0.3
34 • A/C condenser Detach/attach 1 pc. 0.4
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.4
37 • Sub tank hose Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.4
39 • Water hose (radiator ~ E/G) Detach/attach 2 0.5
40 • Radiator mounting bolts removing Detach/attach 1 set 0.3
41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
43 • Hydraulic oil piping Detach/attach 1 pc. 0.6
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.
12-7
Work to be Unit :
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.5
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.3
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.2
50 Fuel relation See 33.1.6

51 Fuel tank Assy Detach/attach 1 pc. 2.4
52 • Fuel Replace 1 pc. 0.5
53 • Hose (water separator side) Detach/attach 2 0.1
54 • Water separator Detach/attach 1 pc. 0.1
55 • Tube (tank side) Detach/attach 1 0.1
57 • Fuel tank installing bolts Detach/attach 1 pc. 0.5
58 • Tank slinging Detach/attach 1 pc. 0.5
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.5
60 Hydraulic oil tank relation See 33.1.7

61 Hydraulic oil tank Assy Detach/attach 1 pc. 4.0
65 • Cover Detach/attach 1 pc. 0.3
03 Swing frame
66 • Hydraulic oil Replace 1 pc. 0.8

68 • Pilot drain hose Detach/attach 1 pc. 0.3
69 • Pump suction hose Detach/attach 1 pc. 0.7
70 • Mounting bolt Detach/attach 1 pc. 0.3
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.4
72 • Return filter Replace 1 0.3
73 • Suction filter Cleaning 1 0.3
80 Pump relation See 33.1.8

81 Pump Assy Detach/attach 1 pc. 3.8
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.4
83 • Strainer & stopper Detach/attach 1 pc. 0.4
84 • Piping Detach/attach 1 set 1.3
85 • Guard Detach/attach 5 pcs. 1.0
86 • Pump slinging Detach/attach 1 pc. 0.6
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc. 0.1
89 Pump Assy O/H 1 pc. 4.0
90 Swing motor unit relation See 33.1.19

91 Swing motor Assy Detach/attach 2 pcs. 4.0
93 • Clamp for drain hose Detach/attach 2 pcs. 0.6
95 • Unit slinging Detach/attach 1 pc. 1.0
12-8
Work to be Unit :
done Hour
96 • Cleaning and sealant Cleaning 1 set 0.4
97 Swing motor O/H 1 pc. 5.0
98 Swing reduction gear O/H 1 pc. 6.0
100 Swivel joint relation See 33.1.20

101 Swivel joint Assy Detach/attach 1 3.6
102 • Piping (Top part only) Detach/attach 1 set 0.7
103 • Whirl stop bolt Detach/attach 1 0.2
104 • Cover Detach/attach 1 0.5
105 • Joint & elbow Detach/attach 1 set 0.5
106 • Mounting bolt Detach/attach 1 set 0.5
107 • Swivel joint slinging Detach/attach 1 0.5
108 • Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing guard 4.0
Other necessary works Detach/attach 1 set Lower piping 0.6
110 Multi control valve (For Oceania) See 33.1.15

111 • Multi C/V Assy Detach/attach 1 After removing guard 1.7
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.3
03 Swing frame

115 • Cleaning Cleaning 1 set 0.2
Other necessary works Detach/attach 1 set Guard 0.4
120 Main control valve See 33.1.16

121 Main control valve Assy Detach/attach 1 pc. 3.0
122 • Attach tag to port name of pipe Preparation 1 pc. 0.6
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve Assy Detach/attach 1 set 8.4
Other necessary works Detach/attach 1 set Guard 0.5
130 Valve relation

131 Solenoid valve Assy Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
134 • Mounting bolt Detach/attach 1 0.3
140 Engine (E/G) mounting relation See 33.1.13

141 Engine Assy Detach/attach 1 pc. After removing pump & radiator 3.7
142 • Harness connector & grounding & Detach/attach 1 pc. 0.5
cable connection
12-9
Work to be Unit :
done Hour
143 • Fuel hose Detach/attach 1 pc. 0.1
144 • Others Detach/attach 1 set 0.7
146 • Engine slinging Detach/attach 1 set 0.4
148 Engine O/H 1 set Reference for engine (Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing guard 1.0
Detach/attach 1 set Removing and installing Counterweight 1.2
Detach/attach 1 set Removing and installing pump 3.5
Detach/attach 1 set Removing and installing air cleaner 0.5
1 set Removing and installing muffler 0.7
03 Swing frame
Detach/attach
Detach/attach 1 set Removing and installing radiator 7.0
150 Upper frame See 33.1.21

151 Upper frame Assy Detach/attach 1 pc. After removing swivel joint 2.8
153 • Upper frame slinging Detach/attach 1 pc. 0.8
155 • Sealant Apply 1 pc. 0.3
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 1.0
Detach/attach 1 set Counterweight 1.2
Detach/attach 1 set Boom 2.9
00 Travel relation See 34.1.2

01 Track link Assy Detach/attach One side Include adjustment of tension 3.0
02 • Track link attaching and detaching position Preparation One side 0.1
03 • Master pin Detach/attach One side 1.0
04 • Track link extending and winding Detach/attach One side 1.0
05 Shoe plate Replace 1 pc. 0.5
04 Travel system
10 Upper roller relation See 34.1.3

11 Upper roller Assy Detach/attach 1 After removing track link 0.4
12 Upper roller O/H 1 1.2
20 Lower roller relation See 34.1.4

21 Lower roller Assy Detach/attach 1 0.4
22 Lower roller O/H 1 1.8
30 Front idler relation See 34.1.5

31 Front idler Assy Detach/attach One side After removing track link 1.2
32 Front idler Assy slinging Detach/attach One side 0.3
33 Front idler Assy Detaching One side 0.7
12-10
Work to be Unit :
done Hour
34 Idler Assy O/H One side 2.0
40 Sprocket See 34.1.6

41 Sprocket Replace One side After removing track link 1.2
50 Travel motor relation See 34.1.7

51 Travel motor Assy Detach/attach One side After removing track link 3.0
52 • Motor cover Detach/attach One side 0.2
53 • Hydraulic piping Detach/attach One side 1.7
54 • Motor mounting bolt Detach/attach One side 0.7
04 Travel system
55 • Motor slinging Detach/attach One side 0.3

56 Motor cleaning Cleaning One side 0.2
57 Travel motor O/H One side 5.0
58 Travel reduction gear O/H One side 5.0
60 Swivel joint relation

61 Pipe on swivel joint travel side Detach/attach 1 pc. Include bonnet assy removing and installing. 0.7
62 Swivel joint O/H 1 pc. See 33.2.6 4.3
70 Swing bearing See 34.1.8

71 Swing bearing Assy Detach/attach 1 pc. After removing upper frame 1.2
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.7
73 Swing bearing slinging Detach/attach 1 pc. 0.5
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
Diode
06 Electric equipments
D-4 Diode Replace 1 0.3

12-11
Work to be Unit :
done Hour
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM (OPT) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include Counterweight removing and installing. 1.0
E-12 Battery Replace 2 0.4
E-13 Travel alarm (OPT) Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3

E-15 Fusible link Replace 1 0.2
E-24 GPS antenna Replace 1 0.5
E-25 PDC antenna (IT controller) Replace 1 0.7
E-27 Accel emergency mode volume Replace 1pair 0.5
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Swing flusher & work light (left) Replace 1 0.2
L-4 Swing flusher & work light (right) Replace 1 0.2
L-5 Room light Replace 1 0.2
L-6 Boom cylinder work light (right) Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include Counterweight removing and installing. 1.0
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor (OPT) Replace 1 0.5
M-9 Skylight wiper motor (OPT) Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.5
PSV-B P2 bypass cut proportional valve Replace 1 Include proportional valve block removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 bypass cut proportional valve Replace 1 0.5
12-12
Work to be Unit :
done Hour
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
R-31 Wiper motor relay arc prevention relay Replace 1 0.1

R-32 Washer motor relay Replace 1 0.1
R-39 Air-heater relay Replace 1 0.3
Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.5
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Engine water temperature sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-3 2-speed travel SOL Replace 1 Include proportional valve block removing and installing. 0.5
12-13
Work to be Unit :
done Hour
SV-4 Safety lever lock SOL Replace 1 Include proportional valve block removing and installing. 0.5
Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3

SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lever lock switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-20 Attachment power boost switch (right) Replace 1 0.3
SW-27 Engine cooling coolant level switch Replace 1 0.3
12-14
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

(TEMPORARY EDITION)
Preface
This standard working time is based on the work time required for service of engine like disassembly, check,
adjustment and assembly and so on under a following condition.
This standard working time is provided under the following conditions.
12.2.1 MEASURING METHOD

(1) The time from the worker beginning working at the regular position of machine to the returning to the regular
position after completion of the work is counted as working time.
(2) The measuring unit is in 0.1 minute, and then round up the fractions.
(3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted
as the working time. But light work which can be carried out easily by a person and the efficient is higher is
counted as a workman.
12.2.2 WORKING CONDITION
12.2.2.1 TOOLS, INSTRUMENT

(1) Hand tool ;
Tools which are commercially available and each workman usually carries
(2) Common tool ;
Tools which are commercially available and each workman do not usually carry but the storing place is specified
(3) Special tool ;
Tools especially prepared by HINO Motor’s Ltd. and the storing place is specified
(4) Machine tool ;
When measuring equipment and instrument are used, the time required to move parts to the specified place is
included but the time waiting for tool is not included as a general rule
12.2.2.2 WORKING PROCEDURE

The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor’s
Ltd. Service Technical Dept. Training Group.
12.2.2.3 STANDARD WORKMAN QUALIFICATION

Workmen shall basically acquire 2~3 years of maintenance experience of HINO
12.2.3 STANDARD TIME CONSTITUENT
12.2.3.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD
ALLOWANCE TIME
(1) Net working time
The time workman works actually and the time required for measurement, cleaning, and so on is included, but
the time required for troubleshooting is not included
(2) Standard time
Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts
and so on, and for the work site clean-up.
(3) Standard allowance time
Calculate the allowance time directly required for workmen from the following equation.
Net standard time × HINO allowance rate
Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position
and so on.
12-15
12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME
12.2.3.2.1 HINO allowance rate (0.15~0.75)

(1) Basic rate : 0.10
(2) Working posture allowance (Fatigue coefficient) : Take any one of the followings according to the work contents.
Standing work : 0.05
Work in bent posture : 0.10
Work while lying : 0.15
(3) Difficult work allowance : 0.30
(4) Seized rusted section (For new vehicle) : 0.50
Take any one of above (3) and (4).
Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.05 = 0.15
Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75
12.2.3.2.2 STANDARD WORKING TIME

(1) Working standard time : 3 minutes
(One time for a set of works)
(2) Special tool standard time : 3 minutes
(3) Standard time of non-portable machine : 3 minutes
(For single work)
(4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more)
(5) Test : 15 minutes
(6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes
(7) General cleaning : 2 minutes
(8) Safety treatment like wheel stopper, and so on : 3 minutes
(9) Visual checks : 2 minutes
The preparation time is classified into as described above, and only items required for the every work are
selected, calculated and counted as preparation time of the work.
12-16
12.2.4 MEANING OF WORDS IN USE

• Completed machine :
When detaching, replacing and adjusting the specified parts, it means the time which is determined by
addition of the preparation time, net working time and standard allowance time of the work.
• Single unit :
When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time
of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed
machine".
• Removal and installation :
The work to remove specified parts from machine and to attach the parts, and then to perform necessary
adjustment
• Simultaneous replacement :
The work to remove specified parts in 2 types or more from machine and to attach the spare parts, and then
to perform necessary adjustment
• Adjustment :
The work to carry out necessary adjustment with the specified parts removed or attached :
• Overhaul :
The work to remove specified assembled parts from machine, disassemble and check them, and then to
attach the spare parts to machine and to perform necessary adjustment
• Include :
Explains the contents of work to make the specified work range clear
• Exclude :
Shows the work which is not included in the specified primary work
• Unit :
Time is shown by hour.
12-17
SK485-8
Work No. Work Work unit Works Q'ty
Adding hour
1
by 1 each
Timing adjustment
Completed
1 00101 Engine adjustment A set Valve clearance adjustment 3.8
machine
Include; Replacing and installing retarder assy
Completed A set and nozzle adjustment.
2 00103 Engine adjustment B set —
machine Include; Replacing and installing retarder assy
Include; Engine warm-up, valve clearance
Completed adjustment, removing air cleaner element,
3 00111 Compression measuring 7.3
machine battery specific gravity measurement
and removing and installing retarder assy
4 00152 Compression measuring Single unit 2.7
Completed
5 00121 Removing and installing Engine Include; Function check 20.5
machine
Completed
6 00122 Removing and installing Engine Include; Function check and reprogramming 21.0
machine
Completed Exclude; Installation of accessory
7 00123 Reinstalling rebuild engine 21.0
machine Include; Function check and reprogramming
Include; Retightening of Water pump, Oil
pump, and Cylinder head, Valve lapping, Test
Completed run, Cleaning of air cleaner
8 00124 Engine overhaul 99.3
machine Exclude; Electric equipments, Water pressure
test, Overhaul of engine retarder assy and
clutch
Include; Removing and installing engine,
Replacing cylinder, block, piston, Completed
9 99012 function check, Retightening of head bolt, Air 75.7
ring and liner simultaneously machine
cleaner cleaning and test run
Replacing crank shaft, piston, Completed
10 99013 function check, Retightening of head bolt, Air 73.1
ring and liner machine
Completed
11 00125 Replacing cylinder block function check, Retightening of head bolt, Air 72.7
machine
Completed
12 00126 Replacing crank shaft function check, Retightening of head bolt, Air 67.7
machine
Include; Removing and installing of engine,
Replacing crank shaft main Completed Function check, Air cleaner cleaning and test
13 00127 67.7
bearing machine run, Removing and installing of engine retarder
assy
Replacing crank shaft thrust Completed
14 00128 Exclude ; Removing and installing of engine 2.7
bearing machine
From engine is removed condition
Include; Adjustment of water pump, oil pump,
valve clearance, valve lapping and
measurement/cleaning
16 00151 Engine overhaul Single unit 77.0
Exclude; Replacing of injection pump,
electrical equipment, water pressure test,
clutch overhaul, Replace of valve guide, and
Overhaul of engine retarder assy
17 00132 Engine retarder assy overhaul Single unit 2.3 1.9
18 00133 Engine retarder assy overhaul Single unit 4.2
From piston & connecting rod are removed
19 00153 Replacing piston Single unit 0.5 0.5
conditions
12-18
SK485-8
Adding hour
1
by 1 each

20 00154 Replacing piston ring Single unit 0.2 0.2
conditions
21 00155 Replacing cylinder liner Single unit 0.4 0.4
conditions
23 00157 Replacing connecting rod Single unit 0.3 0.3
conditions
From connecting rod is a single unit conditions
24 00158 Replacing piston pin bushing Single unit 0.4 0.4
Include; Reaming
29 00165 Replacing expansion plug Single unit 0.4
Removing and installing cylinder Completed
38 00202 Include; Function check 21.7
head and oil pan machine
Connecting rod & piston are connected
Replacing and installing piston Completed
39 00203 conditions 23.0 1.3
and connecting rod machine
Include; Function check
Completed
40 00211 Replacing cylinder liner Include; Function check 24.0 1.7
machine
Completed
43 00213 Replacing piston Include; Function check 23.7 1.8
machine
Completed
44 00214 Replacing piston ring Include; Function check 23.2 1.5
machine
Completed
45 00215 Replacing connecting rod Include; Function check 23.3 1.6
machine
Replacing piston and piston ring Completed
47 99014 34.9
liner machine
Completed
50 00302 Valve clearance adjustment 2.9
machine
Replacing rocker chamber upper Completed
53 00305 0.6
cover machine
Replacing rocker chamber upper Completed
54 00306 Include; Removal and installing upper 3.1
cover machine
Include; Valve clearance adjustment,
Removal and installing rocker Completed
57 00312 Removing and installing leakage pipe, injector 5.4
arm and support machine
harness, and Function check
One side of Include; Valve clearance adjustment,
58 00313 Replacing rocker arm completed Removing and installing leakage pipe, injector 6.0
machine harness, and Function check
59 00314 Replacing rocker arm support ↑ Removing and installing leakage pipe, injector 6.0
60 00315 Replacing rocker arm shaft ↑ Removing and installing leakage pipe, injector 6.0
One side of Include; Valve clearance adjustment,
61 00316 Replacing push rod completed Removing and installing leakage pipe, injector 5.4
machine harness, and Function check
Removal and installing cylinder Completed
head machine
One side of
Include; Valve lapping, Function check and
64 00323 Replacing cylinder head completed 24.3
Replacing valve guide
machine
12-19
SK485-8
Adding hour
1
by 1 each
Include; Valve lapping, Function check

Completed
65 00324 Cylinder head Overhaul Exclude; Replacing of valve guide, water 26.1
machine
pressurizing test and replacing valve seat
One side of
66 00332 Engine retarder assy overhaul completed 3.7 2.4
machine
Completed
67 00333 Engine retarder assy overhaul 6.1
machine
One side of
Removing and installing engine
68 00336 completed 1.7 0.5
retarder assy
machine
One side of
69 00337 completed 2.2
retarder assy
machine
Replacing cylinder head gasket
One side of
(Same time is required when one
70 00325 completed Include; Function check 19.0
side or complete machine is
machine
maintained)
Replacing valve (Same time is One side of
71 00326 required when one side or completed Include; Valve lapping, Function check 24.6
complete machine is maintained) machine
Replacing valve spring (Same One side of Include; Function check
72 00327 time is required when one side or completed Exclude; Removal and installing of cylinder 9.0
complete machine is maintained) machine head
Unit of 1 Exclude; Removing and installing of cylinder
73 99001 Replacing valve spring -
cylinder head
Replacing valve stem seal
One side of
(Same time is required when one Exclude; Removal and installing of cylinder
74 00328 completed 10.2
side or complete machine is head
machine
maintained)
One side of
Exclude; Removing and installing of cylinder
75 00331 Replacing tappet completed -
head
machine
Completed Exclude; Removing and installing of cylinder
76 00329 Replacing valve stem cap -
machine head
With manifold, Nozzle holder
Overhaul of cylinder head (Same Include; Valve lapping
77 00351 time is required when one side or Single unit Exclude; Removing and installing of cylinder 7.1
complete machine is maintained) head, Replacing valve guide, Water
pressurizing test, and Replacing valve seat
With manifold, nozzle holder
Replacing cylinder head
Include; Valve lapping
78 00352 Single unit Excluding; Removal and installing of cylinder 5.3
head, replacing valve guide, water
maintained)
pressurizing test and replacing valve seat
Unit of 1
81 00355 Replacing valve guide 1.0 1.0
cylinder
87 00361 Replacing expansion plug Single unit 0.4 0.4
Unit of 1
90 00373 Replacing rocker arm bushing 0.3 0.3
cylinder
Unit of 1
91 00374 Replacing valve From cylinder head is removed condition 0.6 0.6
cylinder
12-20
SK485-8
Adding hour
1
by 1 each
Unit of 1
92 00375 Replacing valve spring From cylinder head is removed condition 0.2 0.2
cylinder
93 00334 Overhaul of engine retarder assy A piece 2.3 1.9
94 00335 Overhaul of engine retarder assy Single unit 4.2
95 00338 Single piece 1.0 0.5
retarder assy
Removal and installing supply
100 00406 One set Include; Function check 6.0
pump
101 00402 Replacing tappet chamber cover One set 0.7 0.5
Replacing tappet chamber cover
102 00403 One set 0.7 0.5
gasket
Removing and installing oil
103 00404 One set 2.3
cooler assy
Completed Include; Removing and installing of engine
104 00411 Tightening oil pan 0.4
machine under cover
105 00412 Removal and installing oil pan *3.3
machine under cover
Completed Include; Cleaning of block bottom and
106 00413 Replacing oil pan *3.3
machine Removing and installing of engine under cover
107 00414 Replacing oil pan gasket *3.3
machine under cover
108 00421 Replacing oil pan drain cock One set 0.6
Replacing oil pan drain cock
109 00422 One set 0.6
gasket
113 00444 Replacing oil level gauge One set 0.2 0.2
124 00511 Replacing flywheel One set 9.0
125 00512 Replacing fly wheel housing One set 11.4
126 00513 Replacing ring gear One set 9.6
127 00514 Reposition of ring gear One set 9.6
Replacing crank shaft rear oil
128 00515 One set 9.4
seal
Replacing cam end plug (without
132 00519 One set 11.8
PTO)
143 00551 Replacing ring gear Single unit From flywheel is removed condition 0.6
144 00552 Single unit From fly wheel is removed condition 0.6
seal
145 00553 Single unit From flywheel is removed condition 0.4
seal retainer
146 00554 Single unit From flywheel is removed condition 0.4
seal retainer gasket
Removing and installing air
150 00601 One set 1.0
cleaner
151 00602 Replacing air cleaner One set 1.0
152 00603 Replacing air cleaner element One set 0.3
Cleaning of air cleaner element Note: Do not clean wet and viscous type air
153 00604 One set 0.4
(only dry type) cleaner
154 00605 Replacing air cleaner dust pan One set 0.2
155 00607 Replacing dust indicator One set 0.2
One side of
Removing and installing intake
156 00611 completed -
manifold
machine
12-21
SK485-8
Adding hour
1
by 1 each
Removing and installing intake Completed

157 00612 3.9
manifold machine
One side of
158 00613 Replacing intake manifold completed 3.9
machine
One side of
159 00614 Replacing intake manifold gasket completed 3.9
machine
164 00622 Replacing air intake hose One set 0.5 0.3
Replacing upper pipe of air
166 00624 One set Between intercooler and manifold 1.8
intake
168 00625 Replacing lower pipe of air intake One set Between intercooler and manifold 1.3
169 00626 Replacing air intake pipe One set Between turbocharger and intercooler 0.9
170 00627 Replacing air intake pipe One set Between air cleaner and turbocharger 1.0
Removing and installing Completed
174 00631 5.2
intercooler machine
Completed
175 00632 Replacing intercooler 5.2
machine
176 00633 Replacing intercooler air hose One set 0.7 0.3
Removal and installing exhaust Completed
179 00643 6.4
manifold machine
Replacing exhaust manifold
One side of
180 00644 Completed 6.4
machine
maintained)
Replacing exhaust manifold
One side of
gasket (Same time is required
181 00645 Completed 6.4
when one side or complete
machine
machine is maintained)
One side of
182 00646 Replacing exhaust heat insulator completed 0.3
machine
183 00651 Replacing exhaust pipe (RH) One set 2.0
Replacing exhaust pipe gasket
186 00653 One set 0.5 0.3
(RH)
Replacing exhaust pipe to Exclude; Removing and installing of
188 00655 One set 1.8
manifold (RH) turbocharger
Replacing exhaust pipe gasket to
190 00657 One set 0.7
manifold (RH)
Replacing exhaust connector
192 00660 One set 0.7
pipe
Include; Stopper adjustment, Removing and
Replacing exhaust brake
193 00663 One set installing of engine room side cover and 2.2
cylinder (RH)
Exhaust pipe insulator
One side of
Replacing exhaust brake Include; Removing and installing engine room
195 00665 completed 2.0
cylinder gasket (RH) side cover and Exhaust pipe insulator
machine
Include; Stopper adjustment, Removing and
Replacing exhaust brake Completed
197 99002 installing of engine room side cover and 2.2
cylinder machine
Exhaust pipe insulator
12-22
SK485-8
Adding hour
1
by 1 each
Adjusting exhaust brake cylinder Note: Adjustment range should be within

198 00667 One set 0.3
stopper bolt standard range.
Removing and installing exhaust Include; Removing and installing engine room
199 00671 One set 1.3
brake control cylinder side cover and Exhaust pipe insulator
Replacing exhaust brake control Include; Removing and installing engine room
200 00672 One set 1.4
cylinder side cover and Exhaust pipe insulator
202 00677 Replacing exhaust brake assy One set *2.5
203 00678 Replacing exhaust brake assy One set *2.5
205 00681 Replacing exhaust muffler One set (Replacing DPR cleaner) 1.2
206 00682 Replacing exhaust tail pipe One set 1.0
207 00683 Replacing exhaust pipe hanger One set 0.5 0.4
Removal and installing
210 00686 One set 5.0
turbocharger
211 00687 Replacing turbo charger One set 5.0
213 00688 Overhaul of turbocharger One set 7.3
216 00691 Overhaul of turbocharger Single unit Include; Measuring radial play and end play 2.3
Replacing turbocharger turbine
217 99007 Single unit Include; Measuring radial play and end play 1.5
casing
Replacing turbocharger blower
218 99008 Single unit Include; Measuring radial play and end play 1.2
casing
Measuring turbocharger radial
219 99009 Single unit 0.3
play and end play
DPR cleaner (Exhaust gas
222 00649 Diesel Particulate active One set 1.2
Reduction system)
DPR cleaner (Exhaust gas
223 00650 Diesel Particulate active One set 1.2
Reduction system)
Replacing differential pressure
sensor
Replacing exhaust gas
226 00669 One set Include; Function check 0.2 0.1
temperature sensor
227 00670 Replacing air flow meter One set Include; Function check 0.1
Removal and installing timing Completed
229 00701 28.7
gear cover machine
Removing and installing engine Completed
and timing gear cover machine
232 00711 Replacing timing gear cover One set Include; Function check 12.0
Replacing timing gear cover
gasket
Include; Function check, Removing and
Replacing timing gear cover
237 00718 One set installing of Engine in E13C engine, Head and 16.4
gasket
Oil pan
238 00725 Replacing idler gear One set installing of Engine in E13C engine, Head and 13.8
Oil pan
239 00726 Replacing idler gear shaft One set installing of Engine in E13C engine, Head and 14.2
Oil pan
Include; Removing and installing of Engine,
240 00727 Replacing crank shaft front gear One set 68.2
Crank shaft and Function test
12-23
SK485-8
Adding hour
1
by 1 each
Include; Removing and installing of Engine in

242 00728 Replacing oil pump drive gear One set 12.9
E13C engine, Crank shaft
Include; Removing and installing of Engine in
245 00731 Replacing cam shaft One set 35.2
P11C engine, and Function check
247 00732 Replacing cam shaft gear One set Include; Function check 14.2
Replacing tappet (Same time is
required when only one tappet or Completed Include; Removing and installing of Engine,
248 00733 35.8
more than one tappet is machine and Function check
replaced)
Replacing supply pump drive
gear
Replacing supply pump drive
shaft
252 00751 Replacing crank pulley One set 5.1
255 00754 Replacing crank damper One set 5.1
Replacing crank shaft front oil
256 00755 One set 5.3
seal
260 00801 Checking injection timing One set 0.6
261 00802 Adjusting injection timing One set 0.9
272 00829 Replacing drive shaft oil seal One set Include; Function check 6.2
276 00834 Replacing priming pump One set 0.5
277 00835 Cleaning fuel feed pump strainer One set 0.4
278 00836 Replacing through feed valve One set 0.4
279 00837 Cleaning through feed valve One set 0.4
Removing and installing rocker
280 00840 One set 0.6
chamber upper cover
281 00838 Replacing fuel injection pipe One set Include; Function check 1.7 0.1
288 00857 Replacing fuel filter cartridge One set 0.4
291 00861 Removing and installing fuel tank One set 1.7 1.5
292 00862 Replacing fuel tank One set 1.7 1.5
293 00863 Cleaning fuel tank One set Include; Removing and installing of fuel tank 1.8 1.6
295 00865 Replacing fuel tank drain cock One set 1.1 0.9
296 00866 Cleaning fuel tank strainer One set 1.1 0.9
297 00867 Replacing fuel tank cap One set 0.2 0.1
298 00868 Replacing fuel tank support band One set 0.4 0.2
300 00871 Replacing fuel pipe One set Between tank and pump 1.0
301 00872 Replacing fuel pipe One set 0.4 0.3
Nozzle part
305 00876 Replacing fuel leakage pipe One set 3.4
Include; Function check
306 00877 Replacing fuel return pipe One set Include; Function check 1.9
319 00891 Cleaning fuel tank One set 0.1 0.1
326 00904 Replacing oil filter element One set 0.5 0.1
327 00905 Cleaning oil filter element One set 0.5 0.1
328 00906 Replacing oil filter element cover One set 0.5 0.1
329 00907 Replacing oil filter relief valve One set 0.3
Replacing oil filter relief valve
330 00908 One set 0.3
spring
331 00909 Replacing oil filter safety valve One set 0.3
Replacing oil filter safety valve
332 00910 One set 0.3
spring
12-24
SK485-8
Adding hour
1
by 1 each
333 00911 Replacing O-ring of oil filter cover One set 0.5 0.1
Removing and installing oil
338 00931 One set 2.3
cooler
339 00932 Replacing oil cooler One set 2.3
340 00933 Replacing oil cooler casing One set 3.0
Replacing oil cooler casing
341 00934 One set 2.3
gasket
342 00935 Replacing oil cooler element One set 3.0
Replacing oil cooler element
343 00936 One set 3.0
gasket
344 00937 Replacing oil cooler safety valve One set 0.3
Replacing oil cooler safety valve
345 00938 One set 0.3
spring
346 00941 Removing and installing oil pan One set Include; Removing and installing of oil pan 1.9
347 00942 Replacing oil pump One set Include; Removing and installing of oil pan 2.5
348 00944 Replacing oil pump gear One set Include; Removing and installing of oil pan 2.5
349 00943 Overhaul of oil pump One set 3.2
350 00946 Replacing suction strainer One set 2.0
Replacing O-ring of suction
351 00947 One set 2.2
strainer
Completed
358 01001 Adjusting V-belt 0.3
machine
Completed
359 01002 Replacing fan belt Exclude; Removing and installing cooler belt 0.6
machine
Completed
361 01008 Replacing coolant *0.6
machine
Completed
362 01009 Refilling coolant 0.2
machine
Completed
363 01010 Replacing antifreeze *0.6
machine
Completed
364 01011 Refilling antifreeze 0.2
machine
Completed
365 01012 Filling antifreeze *0.6
machine
Completed
367 01014 Replacing long life coolant *0.6
machine
Completed
368 01015 Refilling long life coolant 0.2
machine
372 01021 Removing and installing radiator One set *7.8
373 01022 Replacing radiator One set *8.3
375 01024 Replacing drain cock One set 0.7
376 01025 Replacing radiator cap One set 0.2
Removing and installing fan Completed
377 01026 1.0
shroud machine
Completed
378 01027 Replacing fan shroud 1.0
machine
Removal and installing water
379 01028 One set *3.0
pump
380 01029 Replacing water pump One set *3.0
381 01030 Overhaul of water pump One set 2.8
384 01036 Replacing cooling fan One set 1.6
12-25
SK485-8
Adding hour
1
by 1 each
385 01037 Replacing fan clutch One set 1.6

386 01041 Replacing header tank One set 1.0
390 01044 Replacing thermostat casing One set 0.9
Replacing thermostat casing
391 01045 One set 0.9
gasket
392 01046 One set 0.6
cover
393 01047 One set 0.6
cover gasket
Include; Checking for temperature at valve
394 01048 Replacing thermostat One set 1.1
start opening
Include; Checking for temperature at valve
395 01049 Checking thermostat One set 1.1
start opening
396 01052 Replacing coolant pipe One set 0.6 0.4
397 01053 Replacing coolant hose One set 0.4 0.2
398 01054 Replacing radiator hose One set 1.0 0.2
399 01071 Replacing fan clutch Single unit From radiator is removed condition 0.4
400 01072 Replacing cooling fan Single unit From radiator is removed condition 0.4
401 01073 Replacing water pump Single unit From radiator is removed condition 0.5
402 01074 Overhaul of water pump Single unit 0.8
Removing and installing
407 01079 One set 0.3
reservoir tank
408 01080 Replacing reservoir tank One set 0.4
Removing and installing air
411 01101 One set 1.6
compressor
412 01102 Replacing air compressor One set 2.0
413 01103 Overhaul of air compressor One set Include; Replacing bushing 5.4
Replacing air compressor drive
414 01104 One set 2.0
gear
415 01106 Replacing air compressor O-ring One set 1.6
416 01107 Replacing air compressor head One set 1.0
417 01108 Replacing air compressor head One set 1.0
Replacing air compressor head
420 01109 One set 1.0
gasket
Replacing O-ring of air
421 01117 One set 1.0
compressor head
Replacing air compressor
422 01110 One set 3.1
cylinder liner
423 01111 One set 3.1
cylinder liner gasket (O-ring)
Replacing air compressor valve
424 01118 One set Note: With Delivery valve and Suction valve 1.0
seat
Replacing air compressor piston
426 01112 One set 3.1
ring
428 01114 One set 0.9
unloader valve
429 01121 One set 0.6
delivery pipe
430 01122 One set 0.6
unloader pipe
12-26
SK485-8
Adding hour
1
by 1 each
Replacing air compressor intake

431 01123 One set 0.6
pipe
432 01124 One set 0.3
coolant pipe
434 01151 Overhaul of air compressor Single unit Include; Replacing bushing 3.4
Adjusting height of acceleration Completed
pedal machine
Adjusting stopper bolt of Completed
acceleration pedal machine
Completed
438 01203 Replacing acceleration pedal Include; Function check 1.3
machine
Removing and installing starting
450 01301 One set 1.1
motor
451 01302 Replacing starting motor One set 1.1
452 01304 Replacing starter block relay One set 0.4
453 01306 Replacing starter switch One set 0.7
454 01307 Replacing sub-starter switch One set 0.3
455 01308 Replacing neutral switch One set 0.4
462 01401 Removal and installing alternator One set *1.0
463 01402 Replacing alternator One set *1.0
Replacing alternator support
464 01406 One set 1.0
bracket
465 01407 Replacing alternator adjust stay One set 0.3
Exclude; Removing and installing cooler belt or
466 01408 Replacing V-belt One set 0.6
Replacing it
Replacing intake air heater
474 01502 One set 2.0 2.0
(Electric heater)
475 01504 Replacing intake air heater relay One set 0.4
Replacing coolant level warning
476 01521 One set 0.4
switch
Replacing coolant temperature
478 01522 One set Exclude; Function test using DST-1 0.4 0.2
sensor (Overheat warning)
Removing and installing EGR 3-
479 01510 One set 2.0
section solenoid valve
Replacing EGR 3-section
480 01511 One set 2.0
solenoid valve
Removing and installing turbo 3-
481 01512 One set 2.0
section solenoid valve
Replacing turbo 3-section
482 01513 One set 2.0
solenoid valve
484 01601 One set 0.6 0.4
room side cover
Replacing engine room side
485 01602 One set 0.7 0.4
cover
486 01604 One set 0.4
room rear cover
Replacing engine room rear
487 01605 One set 0.5
cover
Removing and installing exhaust
490 01618 One set 0.7
noise insulator
12-27
SK485-8
Adding hour
1
by 1 each
Replacing exhaust noise

491 01619 One set 0.7
insulator
492 01606 One set 0.5 0.3
under cover
Replacing exhaust engine under
493 01620 One set 0.6 0.3
cover
494 01621 One set 0.6 0.4
under cover bracket
Replacing exhaust engine under
495 01608 One set 0.7 0.4
cover bracket
496 01622 One set 0.3 0.2
under side cover
Replacing engine under side
497 01623 One set 0.4 0.2
cover
Removing and installing front
engine mounting (Same time is
502 01611 One set 2.6
required when right and left them
are replaced simultaneously)
Replacing front engine mounting
(Same time is required when
503 01612 One set 2.9
right and left them are replaced
simultaneously)
Completed
504 99004 Replacing engine mounting 3.9
machine
Removal and installing supply
pump
507 01802 Replacing supply pump One set Include; Function check 7.0
Replacing common rail assy
508 01803 (With pressure sensor and One set Include; Function check 6.9
pressure limiter)
Replacing common rail assy
509 01804 (with pressure sensor, pressure One set Include; Function check 6.9
limiter)
Removal and installing injector Completed Include; Function test and Removing and
510 01805 *5.4
assy machine installing engine retarder assy
Completed Include; Function test, Removing and installing
511 01806 Replacing injector assy *6.5
machine engine retarder assy, and Reprogramming
Removal and installing injector Include; Function test and Removing and
512 01807 One set *3.9 0.3
assy installing engine retarder assy
Include; Function test, Removing and installing
513 01808 Replacing injector asly One set *4.5 *0.4
engine retarder assy, and Reprogramming
Removal and installing injector
sub harness assy
Replace injector sub harness
assy
Replacing main engine speed
sensor
sensor
Replacing fuel temperature
sensor
12-28
SK485-8
Adding hour
1
by 1 each
Completed
525 01820 Replacing acceleration sensor Include; Function check 1.5
machine
Removing and installing Completed
computer machine
Completed
527 01822 Replacing computer Include; Function test and Reprogramming 1.8
machine
Completed
530 01825 Check of System function Include; Use of DST-1 personal computer 1.0
machine
Replacing pressure pipe
Completed
532 01827 (Between Common rail and Include; Function check 1.5
machine
Supply pump)
Completed Include; Function check and Removing and
533 01828 Replacing fuel leakage pipe 3.4
machine installing of retarder assy in P11C engine
Completed
535 01830 Replacing supply pump coupling Include; Function check 6.4
machine
Completed
536 01831 Replacing supply pump bracket Include; Function check 6.4
machine
Checking of high pressure fuel Completed
leak machine
Replacing main engine speed
sensor
Replacing sub engine speed
sensor
sensor
542 01904 Replacing accel sensor One set Include; Function check 1.5
Removal and installing EGR
valve
544 01909 Replacing EGR valve One set Include; Function check 2.4
Removal and installing EGR
547 01916 One set 2.4
cooler
548 01917 Replacing EGR cooler One set 2.4
Removal and installing closed
549 01918 One set 0.5
ventilator
550 01919 Replacing closed ventilator One set 0.5
12-29
[MEMO]
12-30
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE .....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1 MEASUREMENT OF ENGINE SPEED ..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1 TRAVEL SPEED.....................................................................................................13-12
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6.1 SWING SPEED ......................................................................................................13-15
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS .........................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B ADJUSTMENT) 13-21
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO
CONTROLLER .......................................................................................................13-26
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

SK460-8: LS10-02001~ S5LS1311E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
13-2
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

EXERCISED
(1) Application
1) When the machine is new ;
Confirm that the performances are in accordance with standard specifications as compared to the
performance standards.
2) At specific self inspection ; (Rule by country)
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
3) When performances are deteriorated ;
Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for
safety and economical considerations.
4) When main components are replaced ;
For example, use data to restore performances of pumps and others.
(2) Terminology
1) Standard values ;
Values to be used to condition or assemble a new machine. Where special notes are not given, these values
represent standard specifications (machine with standard attachments and standard shoes).
2) Reference values for remedy ;
Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited
to use the machine over the specified values.
3) Service limit ;
This is the limit value at which reconditioning is impossible without replacement of parts. If the value is
expected to exceed the service limit before next inspection and correction are performed, replace the parts
immediately. The operation over the specified values causes increase of damage and requires the down time
of machine, and also causes safety problems.
(3) Cautions to be Exercised at Judgment
1) Evaluation of measured data ;
Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors
are to be evaluated. Determine generally at what levels measured values are located, instead of determining
whether or not values fall within or run out of the reference values.
2) Determining correction, adjustment or replacement ;
Machine performances deteriorate with time as parts wear and some deteriorated performances may be
restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the
operating hours, kind of work and circumstances in which the machine is placed, and condition the machine
performances to its most desirable levels.
(4) Other Cautions to be Exercised
1) Parts liable to degrade ;
Rubber products, such as, hydraulic hoses,
O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
2) Parts requiring regular replacement ;
Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and
recommend that they should be replaced regularly.
3) Inspection and replacement of oils and greases ;
In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine
safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as
well.
13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE
The mode is already "S" mode when power is thrown.

Unless otherwise specified, measure it on "H" mode.
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
NAS 9
Class
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23) °
C — Atmospheric temp
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — 50°C~-10°C (122°F~14°F)
H mode Lo idle 800 + 25 - 25 LOW throttle

Engine speed
H mode Hi idle 1850 + 30 - 70 Full throttle (HI idle)
not required
Adjustment
Measure the engine
B mode Hi idle 1850 + 30 - 70 Perform all
speed at multi display on min-1
A mode Hi idle 1850 + 30 - 70 measurement with
the gauge cluster.
Decel 850 + 25 - 25 the air-conditioner
S mode Hi idle 1750 + 30 - 70 "OFF".
Pilot primary pressure circuit G pump a3 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
P1 a1
valve pressure
ATT MR1 Boom up

Main relief
31.4 (4550) + 0.7 (+100) - 0.5 (-73)

P2 a2
P1 a1
Boost 34.3 (4970) + 1.0 (+145) - 0.5 (-73) MR1 Boom up
P2 a2
R 34.8 (5050) 0 - 1.0 (-145) OR4 Boom down
Boom a1
High pressure circuit
H 36.3 (5260) 0 - 2.5 (-360) OR3 Boom up

Over load relief valve pressure
R 36.3 (5260) 0 - 2.5 (-360) OR8 Arm out

Main pump
Arm a2
H PF1/4 34.8 (5050) 0 - 1.0 (-145) MPa OR7 Arm in
R 34.8 (5050) 0 - 1.0 (-145) (psi) OR2 Bucket dump
Bucket a1
H 36.3 (5260) 0 - 2.5 (-360) OR1 Bucket digging
RH 25.0 (3625) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 25.0 (3625) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 35.8 (5190) 0 - 2.0 (-290) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 35.8 (5190) 0 - 2.0 (-290) RH and LH
RV —
13-4
Standard
Inspection item Unit
value
1st speed 37.8 ~ 34.6
Track link revolution STD
2nd speed 22.7 ~ 20.7
(RH,LH) sec / 3 rev
1st speed 40.1 ~ 36.9
(H mode) LC
2nd speed 24.1 ~ 22.1
Up 3.3 ~ 3.9
Boom
Operating speed
Down 2.0 ~ 2.6

Operating time of
In 3.5 ~ 4.1
cylinder Arm sec (At no load)
Out 2.9 ~ 3.5
(At no load)
Digging 2.3 ~ 2.9
Bucket
Dumping 2.2 ~ 2.8
RH
Swing speed 23.1 ~ 25.1 sec / 3 rev
LH
1st speed Iron shoe 20 ~ 25
Travel speed sec / 20 m
2nd speed Iron shoe 12.7 ~ 14.7
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance
37 ~ 77 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 180
ATT amount of drift Boom cylinder 6.0 mm / 5min (At no load)
Arm cylinder 12
Amount of horizontal play at the bucket tooth 40 ~ 80 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out

13-5
13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED
(1) 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.
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 white range.
(2) Engine speed measured value through service

diagnosis (See Fig. 13-2)
1) Turn "ON" the starter switch with the buzzer stop
switch pressed.
2) A program No. and an actual engine revolution
are displayed as the No.2 Item.
3) The screen advances like No.2, No.3....each
time the "Wiper switch" on the gauge cluster is

pushed.
4) The screen returns like No.45, No.44....each
time the "Washer switch" is pushed.
5) The display does not disappear unless the

starter switch is turned to"OFF".

Fig. 13-1 Switch for E/G speed indication
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
Fig. 13-2 Service diagnosis for E/G speed

measuring (Example)
13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge : 1unit
49 MPa (7100psi) pressure gauge : 2 units
Pressure measuring equipment and instrument for
analysis : 1 set
(2) Measuring cleanliness of hydraulic oil
After releasing air in the hydraulic oil tank, open the

cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
Fig. 13-3 Gauge port on main pump
13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
After releasing the pressure in hydraulic oil tank
and system, replace plugs PF1/4 of main pump
gauge ports (a1) (a2) with plugs for pressure
measurement, and attach pressure gauge 49 MPa
(7100 psi).
(2) Pilot circuit
Replace pilot gauge plug (a3) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).
13-7
13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve

Fig. 13-4 Relief valve position on main control valve
13-8
(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
A3
PR1 ADJUST SCREW

FOR PILOT RELIEF
Dr3
a3
Fig. 13-5 Pilot relief valve position

(3) Swing over load relief
The swing motor is equipped with plugs GA,GB for pressure measurement, but the measurement is carried out
using gauge ports (a1) and (a2). (See Fig. 13-3)

!

Fig. 13-6 Swing over load relief position
13-9
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
No. of turns of adjust screw Pressure change MPa (psi)

1 turn Approx. 2.1 (305)
Fig. 13-7 Pilot relief valve
(2) Main relief valve
(Commom for travel and ATT sections)
Start from the boosting side, first. Loosen nut (1),
adjust the pressure with adjusting screw (2) and
tighten nut (1) after completion of the adjustment on
the boosting side.
Then, loosen nut (3), adjust the pressure on the
standard side with adjusting screw (4) and tighten
nut (3) after completion of the adjustment.
: 41 mm,
Tightening torque : 98 N•m (72.3 lbf•ft) Fig. 13-8 Main relief valve
(Travel section, ATT common section)
: 30 mm,
Tightening torque : 59 N•m (43.5 lbf•ft)
: 22, 27 mm, Adjust screw

Boosting side 1 turn Approx. 18.0 (2610)
STD side 1 turn Approx. 18.0 (2610)
(3) Over load relief valve

HEX13
(Boom, bucket, arm sections) 1 HEX4
Loosen lock nut (1) and adjust it with adjust screw 2
(2).
: 13 mm,
Tightening torque : 3.0 N•m (2.2 lbf•ft)
: 4 mm
Fig. 13-9 Over load relief valve

(Boom, bucket, arm sections)
1 turn Approx. 30 (4350)
13-10
(4) Over load relief valve (Swing)

This valve was adjusted by valve maker. If
adjustment is required, adjust with shim thickness.
When you cannot perform a check of setting
pressure, do not adjust pressure by any means.
Pressure change [by SIMM 0.1 mm] :

about 0.5 MPa (73 psi) Fig. 13-10 Swing over load relief valve
: 14 mm
Tightening torque : 157 N•m (116 lbf•ft)
(5) Travel over load relief valve
This valve was adjusted by valve maker. Do not
replace any inner parts except for O-ring.
Fig. 13-11 Travel over load relief valve
13-11
13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED
(1) Purposes
Measure the track link revolution and confirm the
performances between the hydraulic pump and the
travel motor of the travel drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation
Attach the reflection panel shoe plate. Fig. 13-12 One side lifted position
Swing the swing frame through 90°as shown in Fig.
13-12 and make the crawler on one side take off the
ground, using the attachment. REFLECTION
PANEL
(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st-speed and 2nd-speed
Measuring points ; Right and left
Method, example
Measure the revolutions visually.
Fig. 13-13 Adhering position of reflection panel
Track link revolution Unit : sec / 3 rev

Measurement item Standard Reference value Service
value for remedy limit
H mode 1st speed 34.6~37.8 44.3~48.4 54.3~
STD
H mode 2nd speed 20.7~22.7 26.5~29.1 32.6~
H mode 1st speed 36.9~40.1 47.2~51.3 57.8~
LC
H mode 2nd speed 22.1~24.1 28.3~30.8 34.7~
13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m (66ft) BOOM FOOT PIN
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the
travel drive system.
(2) Condition
Hydraulic oil temperature ; ARM TOP PIN
45~55°C (113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Fig. 13-14 Travel position
13-12
(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
1) Measure the max. deviation distance of the

circular arc in the 20m (66ft) length, excluding
Fig. 13-15 Measuring method
the preliminary run of 3~5m (10~16ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm (in) / 20m (66ft)
Measuring Reference value
position Standard value for remedy Service limit
A 240 (9.45) or less 480 (18.9) 720 (28.4)
13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 15 degree slope.
(2) Condition BOOM FOOT PIN
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position
ARM TOP PIN
(3) Preparation
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15 degree. 15 degree slope
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark Fig. 13-16 Parking brake operating position
(matching mark) on the shoe plate.
(4) Measurement
Five minutes after the engine stops, measure the
movement distance of the matching mark.
C
GUIDE FRAME
Fig. 13-17 Method of measurement
Parking brake Unit : mm(in)/5min

C 0 1 (0.04) 2 (0.08)
13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD 90 o 10
To measure the drain rate of the travel motor and to (3.54") (0.394")
confirm the performances of the travel motor. o 22 PIPE 40

(0.866") (1.57")
(2) Conditions
Hydraulic oil temperature ; RIB "A" STOPPER
150
(5.91")
45~55°C(113~131°F) "B"
(3) Preparation o 90
(3.54")
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel
sprockets. Fig. 13-18 Location of stopper applied to travel
2) Stop the engine and release pressure from the sprocket
hydraulic circuit.
3) Connect a hose with the drain port of the travel
motor and take drain in a container.
(4) Measurement ; at Travel Lock
Unless you observe the rotary force direction at

travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Fig. 13-18)
1) Start the engine and relieve pressure at the full

stroke of the travel lever. Fig. 13-19 Method of measuring the drain rate of
2) Measure the drain rate for 30 seconds of travel motor
relieving.
Travel deviation Unit : L/30sec
Drain rate 7.0 (1.8 gal) 14.0 (3.7 gal) 21.0 (5.5 gal)
13-14
13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump and the
swing motor of the swing drive system.
(2) Conditions
45~55°C (113~131°F)
Firm, level ground
(3) Preparation
Put the bucket empty and extend the boom, arm
and bucket cylinder fully. Fig. 13-20 Swing speed measuring position (at the
And the machine becomes a position of minimum min. reach)
reach.
Swing speed Unit : sec/3 rev
(4) Measurement Measuring Reference value
Swing the machine by bringing the swing lever to its position Standard value for remedy Service limit
full stroke. Measure the time required to make three Right 23.1~25.1 29.6~32.1 36.2~
turns after one turn of preliminary run. Left 23.1~25.1 29.6~32.1 36.2~
13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by the
swing relief valve.
(2) Conditions
45 ± 55°C (113±131°F)
Firm, level ground Fig. 13-21 Swing brake performance measuring

Engine revolution; Hi idle position
(3) 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.
13-15
(4) Measurement MEASURING THE LENGTH OF THE ARC OVER

1) When operating in regular swing speed, by THE OUTER CIRCUMFERENCE OF OUTER RACE
shifting lever to neutral position at pole position MATCHING MARKS ON

OUTER RACE
the swing operation stops.
2) Calculate the swing drift angle by the following
equation, after the upper swing body stops,
using the amount of deflection (m) of the
matching marks on the swing race and the length
MATCHING MARKS
(m) of the circumference of the swing race : ON INNER RACE

Fig. 13-22 Measuring position of swing brake
performances

Swing brake performance Unit : degree
Swing 180 77 or less 85 93
13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.
(2) Conditions
On a slope 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.
Fig. 13-23 Swing parking brake performance
measuring position
(3) Preparation MEASUREING THE LENGTH OF THE ARC OVER
Put the angle meter on the shoe plate and make THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
sure that the angle is more than 15 degree. OUTER RACE
Put a matching mark on the outer race side and on
the inner race side.
(4) Measurement
When five minutes has passed after the engine
stops, measure the length of the movement of the
MATCHING MARKS
matching marks. ON INNER RACE
Fig. 13-24 Measuring position of swing parking

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

C 0 1 (0.04) 2 (0.08)
13-16
13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
(2) Conditions
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take
oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock Fig. 13-25
1) Start the engine and put the side faces of bucket
Travel deviation Unit : L/30sec
against the inside of the right or left shoe plates. Measuring Reference value
2) Relieve the swing motor at full stroke of the
swing motion. Drain rate 1.5 (0.40 gal) 3.0 (0.79 gal) 4.5 (1.19 gal)
3) Collect the amount of drained oil in a container

for 30 seconds.
13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm and
bucket and confirm the performances between the
hydraulic pump and the cylinder of the attachment
drive system.
(2) Condition
Hydraulic oil temperature ; 45~55°C(113~131°F) Fig. 13-26 Measuring position for bucket digging
Engine revolution; Hi idle and dump
Operating time excluding the cushion stroke

(3) Preparation

Firm level ground with the bucket empty
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the bucket
between the ground surface and its highest
position.
Fig. 13-27 Measuring position for boom up and
down motions
When lowering the boom, allow the bucket onto a

soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other
solid material.
30cm (1ft)
Measurement 2 ; Arm in and out, bucket digging
and dump Fig. 13-28 Measuring position for arm in and out
In a position in which the tooth of the bucket rises to motions
a level of about 30cm (1ft) above ground, measure
Cylinder Operating time Unit : sec
the full stroke operating time required with the arm Measuring Reference value
and bucket operating levers at full stroke. position Standard value for remedy Service limit
2.3~2.9 2.9~3.7 3.9~
2.2~2.8 2.8~3.6 3.8~
3.3~3.9 4.2~5.0 5.4~
2.0~2.6 2.6~3.3 3.5~
3.5~4.1 4.5~5.2 5.7~
2.9~3.5 3.7~4.5 4.8~
13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the

moving length of the cylinder rods.
(2) Condition
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground

After cylinders are replaced, bleed off air from the
cylinders, before checking for oil tightness. Fig. 13-29
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range Oil tightness of cylinder Unit : mm/5min
of the cushioning mechanism. Measuring
Standard value
Reference value
Service limit
position for remedy
(3) Preparation A 6 (0.24 in) 7.5 (0.3 in) 10 (0.4 in)
Put the bucket empty. Extend the arm cylinder rod B 12 (0.47 in) 15 (0.59 in) 20 (0.79 in)
50mm (2in) from the most retracted position. And C - - -
extend the bucket cylinders fully. Then hold the D 180 (7.1 in) 225 (8.9 in) 300 (11.8 in)
boom so that the arm top pin is positioned at same
height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is
turned off.
13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose LOCATION OF BEARING
Measure the gap between the lower frame and the MOUNTING BOLTS
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
SWING BEARING
(2) Condition A
Firm, level ground
The swing bearing mounting bolts are not
DIAL INDICATOR
loosened.
The swing bearing is lubricated well, not making LOWER FLAME
abnormal sound during turning.

Fig. 13-30 How to measure the axial play of swing
bearing
(3) Preparation
1) Install a dial indicator to the magnetic base and
fix it to the lower frame.
90 ~100
2) Direct the upper swing body and the lower frame
toward the travel direction, bring the probe of the
dial indicator in contact with the bottom surface
30cm (1ft)
of the outer race on the swing body side and set
the reading at zero. Fig. 13-31 Measuring position 1
(4) Measurement 1 (Measuring position 1 and 2)
1) Measure the displacement of the outer race in ARM TOP BOOM FOOT
PIN PIN
the 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.
Fig. 13-32 Measuring position 2
Axial play of swing bearing Unit : mm (in)

0.8~1.8 2.3~3.3 3.6~
A (0.03~0.07) (0.09~0.13) (0.14)
(5) Measurement 2 (Measuring position 3)

1) With the arm cylinder most retracted and the ARM TOP BOOM FOOT
PIN PIN
bucket dump, lift the tip of the tooth of the bucket
about 10mm (0.4in) and swing the tip of the
bucket to the right and the left by the man power.
But in this case, the gap of the attachment is
included.
Fig. 13-33 Measuring position 3
Right and left movement of the tip of bucket Unit : mm (in)

Bucket 80 or less (3.15) 160 (6.3) 180 (7.1)
13-20
13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT
E-27:
C-8: EMERGENCY
ACCEL
ENGINE CONTROLLER
INJECTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
Fig. 13-34 INPUT / OUTPUT
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B ADJUSTMENT)
13.9.2.1 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 engine ("A" adjustment)
This adjustment is performed to set the relation between the acceleration command voltage output from
mechatro controller to engine controller and the engine speed.
(2) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
engine rated output.
13.9.2.2 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) Bypass cut proportional valve, spool of bypass cut valve
13-21
13.9.2.3 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, A015, A025
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.
For machines equipped with lifting magnet, turn the generator OFF.
13-22
13.9.2.4 ADJUSTING PROCEDURE
MULTI DISPLAY
BUZZER STOP SWITCH WORK MODE SELECT SWITCH
WASHER SWITCH
WIPER SWITCH
SELECTOR SWITCH
Fig. 13-35 Gauge cluster

(1) Adjustment of engine ("A" 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
ADJUST
READY
is not entered in mechatro controller, "READY" is indicated. If the adjustment FEED
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".
START ENG
"Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
1850rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140
4) After starting engine, press selector switch on gauge cluster, and "MEMORY
MEMORY ENG
ENG" is displayed, the engine speed is automatically increased, and the ENGINE SPEED
800rpm
adjustment of engine is performed. PUMP PRESSURE
C-1 01.0M C-2 01.0M
(When trying to limit engine speed, press selector switch on gauge cluster at STEP
140
the speed as it is, and the adjustment of engine is terminated. The torque
adjustment and unloading adjustment required later are not performed, and
default value is written.)
5) When normal HIGH idling speed is detected, the adjustment is completed. And
FINISH ENG
"FINISH ENG" is displayed. ENGINE SPEED
1850rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared, PUMP PRESSURE
C-1 2.0M C-2 2.0M
and the adjustment of engine is completed. The torque adjustment and STEP
400
unloading adjustment required later are not performed, and default value is
written.)
13-23
(2) Adjustment of pump ("B" adjustment)

Procedure
1) The adjustment automatically shifts from engine to pump, the speed shifts
MEMORY PUMP
from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the ENGINE SPEED
1850rpm
unloading proportional valve and pump proportional valve actuate, accordingly PUMP PRESSURE
C-1 2.0M C-2 2.0M
the loading of pump is increased. PROPO-VALVE

E-1 300mA E-2 300mA
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump

"PROPO-VALVE" current (command value) are indicated.
2) After detection of the engine rated speed, the adjustment of pump is
FINISH PUMP
automatically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
1850rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M
and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA
not performed, and default value is written.)
(3) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) In cases where the adjustment of engine can not be performed; And ERROR ENGINE SPEED
1850rpm
ENG" is displayed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
STEP
Judging condition: The read engine speed is 50rpm lower than the last value. 400
It is conceived that the error is caused by the speed read error, pump load
applied to the engine and unusual acceleration command voltage applied to
the engine controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed
due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal
increase of pump pressure during adjustment of engine through
adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration
command voltage output from mechatro controller to engine controller.
Check that signal is regularly input to the engine controller by actual
measurement of voltage or with failure diagnosis tool of engine controller.
13-24
2) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
1850rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
P1 and P2 average pump pressure at the time when the adjustment is PROPO-VALVE
E-1 300mA E-2 300mA
completed is 25MPa (3625 psi) or less.

Judging condition 2:
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 30~34MPa

(4350~4930psi).
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 normally.
And so on.
(4) 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.
For machines equipped with lifting magnet, turn the generator OFF.
13-25
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER

(1) Engine emergency mode
When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating
emergency acceleration (E-27) provided on the seat rear side. (See Fig. 13-34)
Operating procedure:
1) Set the emergency acceleration to NORMAL position.
2) Start engine.
3) Turn the emergency acceleration to HI side and control the engine speed.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
(2) Pump emergency mode

In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is
indicated on multi display provided on the gauge cluster, the full power control of pump and positive control
through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to
emergency mode, making the operation with the power shift control of pump and the constant power control by
means of self-pressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor,
the frequency of engine down is increased, and the engine stalls in LOW speed condition.
The emergency mode should be used in only case of emergency. We recommend that the defective section is
repaired by troubleshooting as early as possible.
13-26
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM.........................................................21-4

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..................................................21-4
21.1.2 POSITIVE CONTROL & P-Q CONTROL ...............................................................21-6
21
21.1.3 BOOM UP CONFLUX CONTROL ..........................................................................21-8
21.1.4 ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-9
21.1.5 ARM-IN ANTI-CAVITATION CONTROL ................................................................21-11
21.1.6 ARM-OUT CONFLUX CONTROL ..........................................................................21-12
21.1.7 BUCKET DIGGING (DUMP) CONFLUX CONTROL ..............................................21-13
21.1.8 BUCKET DIGGING ANTI-CAVITATION CONTROL ..............................................21-14
21.1.9 SWING PRIORITY CONTROL ...............................................................................21-16
21.1.10 TRAVEL INDEPENDENT CONTROL ....................................................................21-17
21.1.11 TRAVEL STRAIGHT CONTROL ............................................................................21-19
21.1.12 PRESSURE RELEASE CONTROL ........................................................................21-21
21.1.13 N&B SWITCH CONTROL (OPTION) .....................................................................21-22
21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................................21-23
21.2 MECHATRO CONTROLLER...........................................................................................21-24
21.2.1 SUMMARY OF MULTI DISPLAY ...........................................................................21-24
21.2.2 SELF DIAGNOSIS DISPLAY..................................................................................21-29
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-31
21.2.4 TROUBLE HISTORY DIAGNOSIS .........................................................................21-41
21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-42
21.2.6 ADJUSTING PROCEDURE OF DISPLAY .............................................................21-43
21.2.7 MECHATRO CONTROL EQUIPMENT ..................................................................21-47
21-1

SK460-8: LS10-02001~ S5LS2111E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
21-2
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
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.
Though this machine is equipped with the "Unload" valve as well as other series, the function of the "Unload" valve
of this machine is different from the "Unload" valve of other models. In the series (PDA in general) of other models,
the "Unload" function is used as hydraulic control. But in this machine, it is used only for the pressure release. The
meaning of "Unload" used in this machine differs from other models. And do not confuse it, though the same word
"Unload" is used.
21-3
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL
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21-4
MAIN CONTROL VALVE

L1
SE-29
ARM
OUT DOWN RIGHT DIGGING DOWN ARM OUT
(8) (4) (6) REVERSE REVERSE (1) (4) (8) SV-13
PL1
SELECTOR VALVE
TRAVEL STRAIGHT
)
P2 BYPASS CUT
P1 BYPASS CUT
(ATTACHMENT
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
BOOST
N&B
BUCKET
OPTION
SWING
SOL
P2 P1
(7) (3) (5) FORWORD FORWORD (2) (3)
ARM IN UP LEFT DOWN UP
L2
SOLENOID VALVE
L3
L4
SWING MOTOR PARKING RELEASE
TRAVEL MOTOR 1,2 SPEED SELECT
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
SAFETY LOCK LEVER

ATTACHMENT BOOST
TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED
P1 BYPASS CUT
P2 BYPASS CUT
L5
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
21-5
21.1.2 POSITIVE CONTROL & P-Q CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
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
PILOT SECONDARY PRESSURE
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
21-6
(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
21-7
21.1.3 BOOM UP CONFLUX CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
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
BOOM UP PILOT SECONDARY PRESSURE pi : PROPORTIONAL VALVE

SECONDARY PRESSURE
(1) On starting boom up operation, boom up operating pilot pressure switches boom 1 speed spool and boom 2
speed spool and is input to 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.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate.
(4) With original hydraulic pressure command, boom 1 speed spool and boom 2 speed spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps are switched and consequently the delivery oil on
P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-8
21.1.4 ARM IN RECIRCULATION & CONFLUX CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
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
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
21-9
(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
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 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.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps 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.
21-10
21.1.5 ARM-IN ANTI-CAVITATION CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE

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

SECONDARY PRESSURE
(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.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output 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.
21-11
21.1.6 ARM-OUT CONFLUX CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
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
ARM OUT PILOT SECONDARY PRESSURE
MECHATRO
SECONDARY PRESSURE
(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.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional 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 pump proportional valves are switched, and consequently
the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
21-12
21.1.7 BUCKET DIGGING (DUMP) CONFLUX CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
P2 P1
PILOT
VALVE
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 BYPASS CUT
PROPORTIONAL
VALVE PSV-B
MECHATRO
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.
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves and P2
bypass cut proportional valve.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P2 bypass cut valve of the
control valve.
(4) P2 pump delivery oil confluxes into parallel passage of center section because the center bypass passage of P2
is blocked.
21-13
21.1.8 BUCKET DIGGING ANTI-CAVITATION CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT
P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
ACCEL
POTENTIO BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROPORTIONAL
VALVE PSV-B
BUCKET DIGGING PILOT SECONDARY PRESSURE

PILOT SIGNAL
pi PROCESS
BUCKET ATT BOOST
ANTI-CAVITATION SOLENOID VALVE
PROCESS SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO
P1 PUMP PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-14
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump
delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the
pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the
stroke limit of bucket spool.
21-15
21.1.9 SWING PRIORITY CONTROL
PILOT
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
VALVE
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
SWUNG
PRIORITY P2 P1
VALVE
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
VALVE PSV-P1
pi
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
SWING PILOT SECONDARY PRESSURE

MECHATRO
SECONDARY PRESSURE
(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 swing priority valve, and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and inverse
proportional valve for arm 2 spool.
by mechatro controller and changes P1 and P2 pump delivery rate and switches arm 2 speed spool.
(4) Arm 1 speed spool, swing spool and swing priority valve are switched by pure hydraulic pressure command. And
also arm 2 spool is switched by the command of mechatro controller ; consequently the return oil on arm cylinder
rod side is recirculated into arm cylinder head side.
(5) Because the pump delivery circuit of arm head side is restricted and 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.
21-16
21.1.10 TRAVEL INDEPENDENT CONTROL
21-17
(1) Travel independent control

When travel independent switch is turned on, following controls are operated.
(2) Operation of each proportional valve
(Attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel independent
condition.)
1) Travel priority proportional valve
This proportional valve outputs pressure to switch spool to travel independent position.
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
operation.
6) P1 Bypass cut proportional valve
Switching travel independence on, this proportional valve outputs pressure so that the spool is in travel in-
dependence position.
7) P2 bypass cut proportional valve
Switching travel independence on, this proportional valve outputs pressure so that the spool is in travel in-
dependence position.
21-18
21.1.11 TRAVEL STRAIGHT CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
PILOT SECONDARY PRESSURE CONTROLLER
SECONDARY PRESSURE
21-19
(1) Judgment travel straight

1) During travel operation (right and left), pilot pressure switches each 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
(Boom, arm, bucket, swing, option) pilot pressure during operation.
operation.
ATT operation Boom Arm Bucket Swing Option

In left travel operation (P1)
In right travel operation (P2)
21-20
21.1.12 PRESSURE RELEASE CONTROL
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
GAUGE CLUSTER PILOT P2 P1
VALVE
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL 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 UNLOAD
DIRECTIONAL
VALVE SV-31
MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER SECONDARY PRESSURE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(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 and outputs command of pressure release control to ECU and fixes
engine speed to pressure release control speed.
3) Switches unload solenoid directional valve and open the opening of unload by pushing travel straight valve
from back side.
(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 opening of travel straight valve
opened.
21-21
21.1.13 N&B SWITCH CONTROL (OPTION)
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SWING
SE-29 VALVE
STRAIGHT
SOLENOID
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH MECHATRO

CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
(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.
21-22
21.1.14 OPTION CONFLUX CONTROL (OPTION)
BOOM 2 SPEED
BOOM 1 SPEED
TRAVEL RIGHT
P2 CUT VALVE
P1 CUT VALVE
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
STRAIGHT
SOLENOID
TRAVEL
PILOT VALVE
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
P1 BYPASS CUT
PROCESS PROPORTIONAL
VALVE PSV-D

MECHATRO
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.
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves and P1
bypass cut 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 bypass cut valve of the
control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the P1 bypass cut valve is switched and P1
pump delivery oil confluxes P2 pump delivery oil.
21-23
21.2 MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
EMERGECY ACCEL DIAL

SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
(2) Gauge cluster
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
21-24
(3) Screen selection by work mode select switch

Press the work mode selector switch ( ) in order, and "H" →"B" →"A" →"S" mode can be selected.
Select the effective work mode according to the work condition and working target from the table shown below.
For the selected work mode, refer to the table shown below.
• S mode: For standard excavating work

• H mode: For heavy duty excavating work
• B mode: For works with breaker
• A mode: For demolition works with crusher
(Nibbler)
10:25
S
• The initial setting (default) of work mode had been set
to "S" mode at factory.
As for the work mode after the 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.
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.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
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.
21-25
1) Pump flow rate adjustment (A mode /B mode)

1 2 3 4
No. Switches
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 7 6
8 Select switch
Fig. 21-1
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 370L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
Main screen Attachment mode (A mode)
10:25 Flow
rate 370 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
In Breaker mode (B mode)
Flow Flow Flow

rate 370 L/m rate 100 L/m rate 100 L/m
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 370 L/m rate 370 L/m
A B
(b) (c)
1. Turn starter key switch on and display 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
"MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or
decreases.
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
21-26
(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
ASIA 2,000 Hr
Hydraulic oil
OCEANIA 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 492Hr
replacement. 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 992Hr
replacement. HYD. FILTER
H
4. Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil 1992Hr
change. HYD. OIL
H
• 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 21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-27
(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
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
contents with the symbol and statement. (For warning contents, see items
shown below.)
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.
. Warning These descriptions indicate error codes.
CAUTION LOW ENG OIL

W009 W005 PREHEAT W011
ATTACHMENT PRESS.
HIGH ENG
AUTO IDLE STOP WATER TEMP.
W006 CHARGE ERROR
POWER BOOST LOW ENG WATER

ON LEVEL
W004 LOW FUEL LEVEL
WARM FINISH WARM-UP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 CHANGE ENG OIL
ERROR
SWING BRAKE
W001 ENGINE STOP
DISENGAGED
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
21-28
21.2.2 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 "C-1 Mechatro controller" explained later. Electric circuit diagram or harness
is available to identify wire No. and wire color.
(2) I/O configuration

!"

(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
A B C D E F G H I K P R
Last 2,3 Controller Low pressure High pressure Proportional Proportional Solenoid Speed sensor Potentiometer Communication Battery relay Engine ECU Relay output
digits memory sensor sensor valve for valves valve for pumps valve etc
Engine Boom up P1 pump P1 bypass cut P1 pump ATT boost Acceleration Battery relay Wiper ark
01 adjust data prevention relay
Torque Boom down P2 pump P2 bypass cut P2 pump Swing parking Boom angle Wiper ark forward
02 adjust data rotation relay
Arm out Boom head Travel straight Travel 1,2 Angle sensor Arm angle Wiper ark reverse
03 speed for shovel rotation relay
Boom up Arm in Boom rod Option Angle sensors for Washer motor
04 adjust data selector shovel & ECU
Arm in Bucket Bucket stroke
05 adjust data digging limit
Arm out Bucket Arm 2 spool
06 adjust data dump for arm in
Swing
07
08
Travel right Fuel sensor
09
Refer to next page (Engine)

Travel left
10
Selector position CAN
11 detection communication
12
Swing flasher
13 right relay
Swing flasher
14 left relay
Travel alarm
15 relay
P1 side option AIS relay 2
16
P2 side option Engine stop
17 relay
Safety lock
18 lever relay
19
Adjustment Safety relay
21 data sector 1
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust data
Cluster
31 communication
Refer to next page (Engine)
Larger than Larger than

0 normal range normal range
Transistor OFF CAN error
failure / Grounding
1 - short circuit
Wrong output Wrong output Transistor Transistor Over run
2 - ON failure ON failure
Disconnection Disconnection Disconnection Disconnection Transistor ON Disconnection Disconnection Time is over
failure /
3 - Disconnection
Power source Power source Power source Contact point is Power source
4 - short circuit short circuit short circuit melted and adhered short circuit
21-29
Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.
21-30
21.2.3 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.
21-31
(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

No.1 NO.6 PRESSURE SENSOR
MAIN CONT. PIN B-7 SWING
YN22E00001F1 P/No. indication 3.5V 2.6M
PROGRAM VERSION B-9 TRAVEL (R)
1-VER 11.11 Program version 3.5V 2.6M
2-VER 00.00 MERIT controller program version B-10 TRAVEL (L)
3.5V 2.6M
1 SERVICE DIAG 1 Service diagnosis mode 6 B-16 P1 (OPT) Sensor voltage/ pressure converted
3.5V 2.6M value
B-17 P2 (OPT)
3.5V 2.6M
B-18 DOZER 1
3.5V 2.6M
B-19 DOZER 2
3.5V 2.6M
NO. 2 ENG NO. 7 P. SENSOR PROPO-V
G-3 SPEED SET 2205 No load setting rpm C-1 PUMP P1
MEAS1 2201 Actual rpm 1 3.5V 32.6M
MEAS2 2201 Actual rpm 2 (Engine controller) C-2 PUMP 2
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 32.6M Sensor voltage/ Pressure converted
WATER TEMP 100 OFF Coolant temperature sensor C-3 BOOM-HEAD value
MODE HM Work mode 3.5V 32.6M
2 H-1 ACCEL VOLT 4.2V Potentiometer voltage 7 C-4 BOOM-ROD
POS 100% Voltage % indication 3.5V 32.6M
ECU OUTPUT 0.5V Accel output voltage to engine PROPO-VALVE Set value in computer/ Converted
E-3 OPT RELIEF 1 value from pressure
COMP. 600mA 14.5M
MEAS. 600mA 14.5M
Measured value/ Converted value
E-4 OPT RELIEF 2
COMP. 600mA 14.5M from pressure
NO. 3 SOL VALVE NO. 8 PROPO-VALVE
F-1 POWER BOOST D-1 P1 UNLOAD(BP-CUT)
COMP. OFF Set value in computer COMP. 600mA 4.5M
MEAS. OFF Measured value MEAS. 600mA 4.5M
Set value in computer/ Converted
SWITCH OFF Switch D-2 P2 UNLOAD (BP-CUT)
F-2 SWING-BRAKE COMP. 600mA 4.5M value from pressure
COMP. OFF Set value in computer MEAS. 600mA 4.5M
3 MEAS. OFF Measured value 8 D-3 S-TRAVEL Measured value/ Converted value
RELEASE SW OFF Switch COMP. 600mA 4.5M from pressure
F-3 1/2 TRAVEL MEAS. 600mA 4.5M
COMP. OFF Set value in computer D-6 ARM IN -2-SPEED
MEAS. OFF Measured value COMP. 600mA 4.5M
SWITCH OFF Switch MEAS. 600mA 4.5M
NO. 4 RELAY N0. 9 PROPO-VALVE

E-1 P1 PUMP Set value in computer/ Converted
K-1 AIS RELAY 2 OFF Indicated value COMP. 600mA 4.5M value from pressure
K-2 SAFETY RLY OFF Indicated value MEAS. 600mA 4.5M
Measured value/ Converted value
K-3 ENG STOP OFF Indicated value POWER SHIFT 100MA
KEY SWITCH OFF Key switch FLOW RATE 100L from pressure
START SWITCH OFF Starter switch Power shift
4 CHARGE LIVE Alternator 9 Flow rate of pump P1
K-4 LOCK LEVER OFF Indicated value E-2 P2 PUMP Set value in computer/ Converted
SWITCH OFF Switch COMP. 600mA 4.5M value from pressure
MEAS. 600mA 4.5M
POWER SHIFT 100MA Measured value/ Converted value
FLOW RATE 100L from pressure
Power shift
Flow rate of pump P2
NO. 5 PRESSURE SENSOR NO. 10 SENSOR, SWITCH
B-1 BOOM RAISE H-9 FUEL LEVEL
3.5V 2.6M 4.5V 90 Fuel level
B-2 BOOM LOWER H-10 HYD. OIL TEMP
3.5V 2.6M 4.5V 30°C (86°F) Hydraulic oil temperature
B-3 ARM OUT GLOW OFF Glow switch
3.5V 2.6M Sensor voltage/pressure AIR FILTER LIVE Air filter clogging
5 B-4 ARM IN 10 WATER SEPA. OFF Water separator clogging
converted value
3.5V 2.6M ENG OIL FLITER LIVE Engine oil filter clogging
B-5 BUCKET DIG FRONT WINDOW OFF Front window open/close switch
3.5V 2.6M DOUBLE FLOW ON Conflux/Single flow select switch
B-6 BUCKET DUMP KPSS SW OFF KPSS switch
3.5V 2.6M HEATER OFF Command from air heater
ENGINE OIL LEVEL OFF Engine oil level
COOLANT LEVEL LIVE Coolant level
21-32

NO. 11 SOL. VALVE NO. 19 DIGITAL INPUT
F-4 OPT SELECT DI15 OFF ON/OFF Indication
COMP. OFF Set value in computer DI16 OFF ON/OFF Indication
MEAS. OFF Measured value (Feedback value) DI17 OFF ON/OFF Indication
DI18 OFF ON/OFF Indication
SPOOL POS. NIB Spool position DI19 OFF ON/OFF Indication
SELECT SWITCH NIB Mode of selector value DI20 OFF ON/OFF Indication
11 F-5 FAN PUMP 19 DI21 OFF ON/OFF Indication
MEAS. OFF Measured value DI23 OFF ON/OFF Indication
F-6 DI24 OFF ON/OFF Indication
MEAS. OFF Measured value DI26 OFF ON/OFF Indication
NO. 12 POTENTIOMETER NO. 20 DIGITAL INPUT
H-2 BOOM Sent value from sensor/ DI29 OFF ON/OFF Indication
3.5V 137 DI30 OFF ON/OFF Indication
Converted value from angle DI31 OFF ON/OFF Indication
12 20 DI35 OFF ON/OFF Indication
H-3 ARM Sent value from sensor/ DI37 OFF ON/OFF Indication
3.5V 137 Converted value from angle DI38 OFF ON/OFF Indication
NO. 15 PROPO-VALVE NO.21 DIGITAL OUTPUT
D-11 PI I-TRAVEL DO1 COMP. OFF Set value in computer
COMP. 600mA 4.5M MEAS. OFF Measured value
MEAS. 600MA 4.5m DO2 COMP. OFF Set value in computer
D-12 P2 I-TRAVEL MEAS. OFF Measured value
Set value in computer/ Converted
COMP. 600mA 4.5M DO3 COMP. OFF Set value in computer
MEAS. 600MA 4.5m value form pressure MEAS. OFF Measured value
15 D-15 21 DO4 COMP. OFF Set value in computer
COMP. 600mA 4.5M Measured value/ Converted value MEAS. OFF Measured value
MEAS. 600MA 4.5m from pressure DO5 COMP. OFF Set value in computer
D-16 MEAS. OFF Measured value
COMP. 600mA 4.5M DO6 COMP. OFF Set value in computer
MEAS. 600MA 4.5m MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
NO. 16 PRESS. SENSOR NO.22 DIGITAL OUTPUT
B-11 DO8 COMP. OFF Set value in computer
3.5V 12.6M MEAS. OFF Measured value
B-12 DO COMP. OFF Set value in computer
3.5V 12.6M Sensor voltage/ Pressure MEAS. OFF Measured value
16 B-14 22 DO11 COMP. OFF Set value in computer
converted value
NO. 18 DIGITAL INPUT NO.23 DIGITAL OUTPUT
DI1 OFF ON/OFF INDICATION DO15 COMP. OFF Set value in computer
DI2 OFF ON/OFF INDICATION MEAS. OFF Measured value
DI6 OFF ON/OFF INDICATION See MEAS. OFF Measured value
18 DI7 OFF ON/OFF INDICATION Mechatro 23 DO18 COMP. OFF Set value in computer
DI8 OFF ON/OFF INDICATION controller MEAS. OFF Measured value
DI9 OFF ON/OFF INDICATION connecter DO19 COMP. OFF Set value in computer
DI1 4 OFF ON/OFF INDICATION MEAS. OFF Measured value
21-33

NO. 24 DIGITAL OUTPUT NO. 27 MERIT SYSTEM
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT
DO23 COMP. OFF Set value in computer 4 controller
MEAS. OFF Measured value 0412051200
24 DO25 COMP. OFF Set value in computer 27
NO. 25 WIPER SYSTEM NO. 28 ENG CONT.
TRANS. COUNT 100 Counted number of transmission
WIPER SW OFF Wiper switch RECEIVE COUNT. 100 Counted number of reception error
RISEUP SW OFF Wiper rise up switch DIAG STATUS 9 Diagnosis status
REVERSE SW OFF Wiper reverse rotation switch NUMBER OF DIAG 100 Numbers of error
PREVENT ARC OFF Wiper motor ark prevention relay BOOST PRESS. 100 Boost pressure
CW MOTOR RLY OFF Wiper normal rotation relay BOOST TEMP. -100 Boost temperature
25 CCW MOTOR RLY OFF Wiper reverse rotation relay *1
28 BAROMETRIC P. 100 Atmospheric pressure
WASHER SW OFF Washer switch FUEL TEMP. -100 Fuel temperature
MOTOR RELAY OFF Washer motor relay FUEL CONS. 200 Fuel consumption
INTAKE TEMP. -100 Intake air temperature
ENG PRESS. 300 Engine oil pressure
GLOW OFF Glow output from ECU
ENG STOP OFF Engine stop command from ECU
TORQUE 1000 Calculated torque of ECU
*1
NO DISPLAYS CONTENTS NO DISPLAYS CONTENTS

NO. 1 NO. 33 BUCKET
MAIN CONT P/N C-1 P1-PRESS 13.9M Pump pressure sensor
YN22E00001F1 P/No. indication C-2 P2 PRESS 13.9M Pump pressure sensor
PROGRAM VERSION Program version indication E-1 P1-PSV 600mA Command current
1-VER 11.11 MERIT controller program version E-2 P2-PSV 600mA Command current
2-VER 00.00 D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current
1 33 D-3 S-TRAVEL 600mA Command current
SERVICE DIAG 2 Service diagnosis mode B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current
NO. 31 BOOM NO. 34 TRAVEL

C-1 P1-PRESS 13.9M Pump pressure sensor C-1 P1-PRESS 13.9M Pump pressure sensor
C-2 P2 PRESS 13.9M Pump pressure sensor C-2 P2 PRESS 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
31 B-1 BOOM RAISE 1.9M Boom up pressure sensor 34 D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL (R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL (L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot press at travel straight (P1 side)
Pi-P2 13.9M Pilot press at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current
NO. 32 ARM, SWING NO. 35 OPT

C-1 P1-PRESS 13.9M Pump pressure sensor C-1 P1-PRESS 13.9M Pump pressure sensor
C-2 P2 PRESS 13.9M Pump pressure sensor C-2 P2 PRESS 13.9M Pump pressure sensor
32 D-3 S-TRAVEL 600mA Command current 35 D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current POWER SHIFT 100MA power shift current
21-34
NO DISPLAYS CONTENTS NO DISPLAYS CONTENTS

NO. 1 No. 43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00001F1 P/No indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 11.11 Program version indication TRAVEL 300 All accumulated travel time
2-VER 00.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker oper. time
1 43 CRANE 100 All accumulated high-reach crane
operating time
SERVICE DIAG 3 Service diagnosis mode STARTER 1200 All accumulated starter oper. time
NO. 41 ADJUSTMENT 1 NO. 44 MACHINE-INFORM.

ENG PUMP PRESS
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL 1 24% 22% Total/ In the last 10 hours
ACT 1 515mA Current at pump adjustment LEVEL 2 50% 50% Total/ In the last 10 hours
Δ 15mA Current correction pump adjustmnt LEVEL 3 25% 25% Total/ In the last 10 hours
PUMP P 35.0 M Pressure at pump adjustment LEVEL 4 1% 3%
41 ESS N 2040 Engine s[eed sensor rpm 44
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL 1 24% 22% Total/ In the last 10 hours
BOOM 137° 137° Angle adjustment LEVEL 2 50% 50% Total/ In the last 10 hours
ARM 137° 137° Angle adjustment LEVEL 3 25% 25% Total/ In the last 10 hours
OFFSET 137° 137° Angle adjustment LEVEL 4 1% 3% Total/ In the last 10 hours
INTER-B 137° 137° Angle adjustment
21-35
(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 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 300 mA D-1 P1-UL(BPC) 300 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 1820~1880 G-3 ENG SPEED 1820~1880
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 30.5~33.5 M C-1 P1-PRES 13.0~18.0 M
C-2 P2-PRES 30.5~33.5 M C-2 P2-PRES 13.0~18.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 600~750 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 600~750 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
21-36
Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 5.0~9.0 M
C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 650~681 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 300 mA
D-2 P2-UL(BPC) 300 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1800~2000
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 30.5~33.5 M C-1 P1-PRES 5.0~9.0 M
C-2 P2-PRES 30.5~33.5 M C-2 P2-PRES 5.0~9.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 720~750 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 720~750 mA
21-37
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 30.5~33.5 M C-1 P1-PRES 14.0~21.0 M
C-2 P2-PRES 30.5~33.5 M C-2 P2-PRES 14.0~21.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 580~750 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 580~750 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 24.0~33.5 M C-2 P2-PRES 3.0~10.0 M
E-2 P2-PSV 500~750 mA E-2 P2-PSV 750 mA
21-38

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 30.5~33.5 M C-1 P1-PRES 6.0~10.0 M
C-2 P2-PRES 30.5~33.5 M C-2 P2-PRES 8.0~12.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 700~750 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 700~750 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 30.5~33.5 M C-1 P1-PRES 7.0~15.0 M
C-2 P2-PRES 30.5~33.5 M C-2 P2-PRES 7.0~15.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 680~750 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 680~750 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
21-39

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 0.2~2.0 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~33.0 M
E-1 P1-PSV 480~630 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 480~630 mA E-2 P2-PSV 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 of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 7.0~13.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 7.0~13.0 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
21-40
21.2.4 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.
The warning content is stored partially in "Travel history screen".
The error code for self diagnosis is stored.
(1) How to display

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR
Error detected in the past
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 ( ), 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.
All the stored items are erased. It is impossible to erase data partially.
21-41
21.2.5 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

switch switch select switch
Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 2,000 Hr (ASIA) switch select switch
5,000 Hr (OCEANIA)
Procedure Operating Procedure Display on Multidisplay
After several seconds,

display is changed to 10:25
1 Turn starter key switch on.
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
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.
21-42
21.2.6 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Auto idling stop

1 2 3 4
No. Switchs
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 7 6
8 Select switch
Fig. 21-2
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
FEED FEED FEED
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
21-43
2) Clock Adjustment Switches

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop 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
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
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 (4) and FEED (5).
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).
21-44
3) Contrast Adjustment Switches

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop 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
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)
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).
21-45
(2) Function for service

Following items are provided for adjustment of service function.
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
21-46
21.2.7 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
2) List of connectors
Connector No. Pin No. Port Name Function Input/Output Signal Level
CN101 1 GA 0V
2 A1 Boom up Input 0.5 - 4.5 V
3 +5VA Power output 5V
5 A2 Boom down Input 0.5 - 4.5 V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5 - 4.5 V
11 A4 Arm out Input 0.5 - 4.5 V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5 - 4.5 V
17 A6 Bucket dump Input 0.5 - 4.5 V
18 GA 0V
19 TXD1 RS232C Communication
20 RXD1 Gauge cluster RS232C Communication
Input
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Transmission RS232C Communication
24 RXD3 Reception RS232C Communication
Down load
25 DL EARTH / OPEN (5V)
26 GP 0V
27 CANH1 E/G ECU CAN Communication
28 CANL1 E/G ECU CAN Communication
29 DO 20 Spare Output EARTH / OPEN
30 DO 21 Safety relay Output EARTH / OPEN
31 DO 22 Spare Output EARTH / OPEN
32 DO 23 Rotary light (yellow) Output EARTH / OPEN
33 D0 24 Rotary light (green) Output EARTH / OPEN
34 DI 36 Heavy lift Input EARTH / OPEN
21-47
CN102 1 GA 0V
2 A8 Travel right Input 0.5 - 4.5 V
5 A9 Travel left Input 0.5 - 4.5 V
6 GA 0V
7 GA 0V
8 A10 Acceleration Input 0.5 - 4.5 V
11 A13 P1 option Input 0.5 - 4.5 V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5 - 4.5 V
17 A27 Spare Input 0.5 - 4.5 V
18 GA 0V
19 GA 0V
22 D1 37 Travel independent switch Input GND/OPEN
CN103 1 GA 0V
2 A Swing Input 0.5 - 4.5 V
5 A11 P1 pump Input 0.5 - 4.5 V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5 - 4.5 V
11 A15 Boom angle Input 0.5 - 4.5 V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5 - 4.5 V
16 Reserved
21-48
CN104 1 GA 0V
2 A17 Boom head Input 0.5 - 4.5 V
5 A18 Boom rod Input 0.5 - 4.5 V
6 GA 0V
7 GA 0V
8 A19 Extra pressure sensor Input 0.5 - 4.5 V
12 GA 0V
13 A21 0V
Spare Input
14 GA 0.5 - 4.5 V
15 A22 Power output 5V
Fuel level Input
16 GP Power output 5V
17 A23 0.5 - 4.5 V
Spare
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5 - 4.5 V
24 GA 0V
25 GA 0V
28 DI 1 Cab slow up and down Input GND / OPEN
CN105 1 +24V Battery relay output side 20 - 32 V
Battery relay output side
2 +24V 20 - 32 V
(sensor analog output)
3 +24V Battery relay output side 20 - 32 V
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 Travel 1,2 speed select valve Output 24V / OPEN
7 DO 11 Attachment boost select valve Output 24V / OPEN
8 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0 - 800mA
11 D1+ +0 - 800mA
P1 bypass cut Output
12 D1- -0 - 800mA
13 D2+ +0 - 800mA
P2 bypass cut Output
14 D2- -0 - 800mA
15 D3+ +0 - 800mA
Travel straight Output
16 D3- -0 - 800mA
17 D4+ +0 - 800mA
Arm in Output
18 D4- -0 - 800mA
19 D5+ +0 - 800mA
P1 pump Output
20 D5- -0 - 800mA
22 D10- OPT changeable relief 1 Output -0 - 800mA
23 D6+ +0 - 800mA
P2 pump Output
24 D6- -0 - 800mA
25 D7+ +0 - 800mA
Cab slow stop valve Output
26 D7- -0 - 800mA
27 D8+ +0 - 800mA
P1 travel independent Output
28 D8- -0 - 800mA
29 D9+ -0 - 800mA
P2 travel independent Output
30 D9- +0 - 800mA
31 +24V Battery direct connection 20 - 32 V
21-49
CN106 1 +24V Battery relay secondary 0 20 - 32 V
2 SHGF Shield GND
3 F1+ Accel motor A phase Output +24V 1.5A
4 F1- Accel motor A phase Output +24V 1.5A
5 F2+ Accel motor B phase Output +24V 1.5A
6 F2- Accel motor B phase Output +24V 1.5A
7 OIL
Oil level (spare) 0
8 OILG
9 D11+ +0 - 800mA
OPT changeable relief 2 Output
10 D11- -0 - 800mA
11 D12+ +0 - 800mA
Spare Output
12 D12- -0 - 800mA
13 D13+ +0 - 800mA
Spare Output
14 D13- -0 - 800mA
15 D14+ +0 - 800mA
Spare Output
16 D14- -0 - 800mA
18 D12+ +0 - 800mA
Spare Output
19 D12- -0 - 800mA
20 E1+ XX-XXVp-p
21 E1- E/G speed sensor Input 0V
22 SHG3 Shield GND
23 CANH2 Proportional valve expand CAN communication
24 CANL2 unit CAN communication
CN107 1 DI 3 Key switch (GLOW) Input +24V / OPEN
2 DI 8 Spare Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Stroke end check Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
17 Reserved Input
21-50
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 Spare Input GND /OPEN
6 DI 16 Wiper rise up Input GND /OPEN
7 DI 17 Wiper reverse Input GND /OPEN
8 DI 18 ATT boost Input GND /OPEN
9 DI 19 Nibbler open check SW Input GND /OPEN
10 DI 21 Elevator cab up check Input +24V / OPEN
11 DI 22 HYD. VLC. Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation/ Input GND /OPEN
clamp open or close
14 DI 25 Front window open or close Input GND /OPEN
15 DI 26 Hand control breaker Input GND /OPEN
16 DI 27 Conflux / single select Input GND /OPEN
17 DI 29 Overload speed Input GND /OPEN
18 DI 30 Spare Input GND /OPEN
19 Reserved
20 GP
21 DI 33 Charge Input 12V / 12V
24 Reserved
25 H1+ 0 - 5V
Accel signal 1
26 H1- 0V
27 H2+ 0 - 5V
Accel signal 2
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 Bucket move limitation Output GND /OPEN
6 DO 6 Travel straight (Unload) Output GND /OPEN
7 DO 12 Rotary light (RH) Output GND /OPEN
8 DO 13 Swing flasher (RH) Output GND /OPEN
9 DO 14 Swing flasher (LH) Output GND /OPEN
10 DO 15 Travel alarm 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
14 DO 19 Spare Output GND /OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Transmission RS232C communication
18 RXD2 Reception RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shield GND
22 DO 10 Cab up & down switching valve 24V / OPEN
21-51
(2) Gauge cluster (symbol C-2)

1) General view
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
BUZZER STOP SWITCH WORK MODE SWIHCH
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 Reserved — 7 White
ON)
GND (RS232C
4 Reserved — 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 Monitar display LCD dot 120× 168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
7 Work mode select switch
8 Back light LED
21-52
(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
11 22 1 3 1 3
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
21-53
2) Circuit diagram
21-54
21-55
21-56
(4) High pressure sensor : LS52S00015P1
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)
(5) Low pressure sensor : LC52S00019P1
A AMP MQS CONNECTOR 3 POLE (B TYPE)

OPPOSITE CONNECTOR (FEMALE)
HOUSING 2-967642-1
TERMINAL (GOLD PLATED) 965906-5
CONNECTOR TERMINAL POSITION

TERMINAL No.
1 COM
2 OUT PUT (+)
3 POWER (+)
VIEW A
19 21.9 HEX
O-RING P11
PF1/4 Tightening torgue
34.3N.m (25.3lbf.ft)
DETAIL OF SENSOR CONNECTOR SPECIFICATION :

PRESSURE RANGE : 0 3.0 MPa (0 448 psi)
RATED VOLTAGE : 5.0+0.5V DC
INSURANCE RESISTANCE : 100M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
21-57
NOTES
21-58
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY.......................................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS ...............................................................22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-8
22.4 NEUTRAL CIRCUIT.........................................................................................................22-8 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-10
22.6 BUCKET CIRCUIT...........................................................................................................22-12
22.7 BOOM CIRCUIT ..............................................................................................................22-14
22.8 SWING CIRCUIT .............................................................................................................22-18
22.9 ARM CIRCUIT .................................................................................................................22-20
22.10 COMBINED CIRCUIT ......................................................................................................22-26
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ...........................................................22-30
22-1

SK460-8: LS10-02001~ S5LS2211E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
22-2
22.1 SUMMARY operability, safety, mass volume handling and low fuel
consumption.
The hydraulic circuits are built up with the following
functions and features in order to achieve easy
Table22-1
Perfor- Device
mance Function Features
Travel straight Travel straight at combined operation

Travel 2-speed change & Auto 1st (low) speed return 1-2 travel speed change and low speed / high torque at heavy duty
Travel
Auto parking brake Automatic braking when parking

Motor overrun protection Prevents overrunning of travel motor on the down hill slope.
Travel pilot operation Prevents hunting by the built in travel shockless mechanism
Reverse rotation protective function Easy positioning to protect it from swinging back when stops swinging.
Swing priority circuit Easy operation of stable swing speed, arm slanted leveling,
Swing
(simultaneous operation of arm in and swing motions) swing press digging

Easy operability and safety
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Attachment
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Multi control valve (Oceania) Changeable to 4 operating pattern with only 1 lever.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Return circuit To prevent hydraulic oil from contamination

Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being deteriorated.
Pressure draining circuit To release the main circuit pressure for piping repair work.
Main control valve with optional valve Optional piping and additional work are easy
Switching of return line for N&B machine in the cab Switching of return line for N&B machine is able to
(Option) change with a switch in the cab
Electric flow controlled variable displacement pump Pump delivery rate control by a current command to the
Mass handling capability
solenoid proportional valve of the variable displacement pump

Pump
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
Arm conflux circuit Speed up of arm operation

Bucket conflux circuit For speed-up of bucket operation (digging & dump)
Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes
consumption
Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel
Micro
speed when control lever is in neutral position.
22-3
22.2 HYDRAULIC CIRCUITS AND

COMPONENTS
STD. SCHEMATIC HYD. LINES LS01Z00052P1
Item Component name Part No. Model No.
LS10V00016F1 K5V200DPH (without PTO)
1 Hyd. pump assy
LS10V00014F1 K5V200DPH (with PTO)
2 Control valve (main) LS30V00009F1 UY36-114
3 Swing motor unit (L) LS15V00023F1 MFC160-065A
4 Swing motor unit (R) LS15V00024F1 MFC160-079
5 Travel motor unit LS15V00020F1 M4V290 / 170-RG10
6 Boom cylinder (RH & LH) LS01V00055F1 82B131-0
7 Arm cylinder LS01V00056F1 82A119-0
8 Bucket cylinder LS01V00057F1 82U118-0
9 Swivel joint LS55V00008F1
10 Pilot valve (ATT) YN30V00111F1 PV48K2
11 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
Multi control valve (lever less) YN30V00113F1 Australia : STD
12
Multi control valve (with lever) YN30V00115F1
13 Inline filter YN50V00020F1 Y-457400
14 Suction strainer LS50V00007F1
15 Bypass check valve LV21V00004F1 Y-533200
16 Boost check valve LS21V00008F1 VAG0002A001A
17 Return filter LS52V01001F2 FZ1F180A001A
18 Air breather YN57V00004F1 Y-748100
19 Solenoid valve assy YN35V00047F1 8KWE5A-30
20 Shuttle valve YB26V00002F1
21 Solenoid valve YN35V00010F2 16084-0000
22 Hyd. valve YN20V00008F1
23 Restrictor YN21V00005F1 07381-0000
24 Restrictor YN21V00005F6 07910-0000
25 Solenoid valve assembly YN35V00040F1
26 Control valve LB30V00004F1
The part numbers may be changed due to modification,

so use only the numbers for references.
22-4
22- HYDRAULIC SYSTEM 22 - HYDRAULIC SYSTEM
22.2.1 STANDARD
GRAPHIC_1D
2-5
22.2.2 N&B SPECIFICATION (OPTION)
N&B specification LS01Z00054P1

No. PARTS PART No. MODEL No.
50 SELECTOR VALVE LS30V00010F1 KYB-182
51 STOP VALVE 24100P3133F1
52 PILOT VALVE YN30V00080F1 16030-00000
53 RELIEF VALVE LS22V00009F1
R2 R1
M
MAIN CONTROL VALVE
P2
pc
P1
50
A DR
53
T
5pb3
5B3 OPTION 1
HYD.TANK 5pa3
5A3
Ps C PL
P SE29
51
RIGHT BREAKER
LEFT NIBBLER
Po
5pc2 dr1 4dc2
52
NIBBLER PILOT VALVE
P
T
B C1 C2 A
CLOSE P SE11
OPEN
S,W
SW29
NOTE:
1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
LEVER LOCK
SOL/V BLOCK A1 SV-4
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W: , W/O: )
CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 CUT P2 CUT
CONFLUX FLOW OF NIBBLER CONFLUX "ON"
P1 P2
SINGLE FLOW OF NIBBLER CONFLUX "OFF"
T BREAKER CONFLUX "OFF"
3. WHEN USING NIBBLER, ACCORDING TO SPECIFICATION OF NIBBLER INSTALLED,

CHOOSE CONFLUENCE OR SINGLE FLOW BY CONFLUENCE FLOW CHANGEOVER SWITCH. LS01Z00054P1 01
4. ADJUST OVERLOAD RELIEF VALVE OF OPTIONAL PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.
GRAPHIC_1D
2-6
This page is blank for editing convenience.
2-7
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS 22.4.2 PUMP POSITIVE FLOW CONTROL large bore of piston through the spool.
Blue 22.4 NEUTRAL CIRCUIT (1) Type : The delivery pressure P1 flows in the small
Feed, drain circuit This section describes the following. Electric flow controlled variable displacement bore of servo piston, but the servo piston
less than 0.44 MPa (64 psi) pump. moves rightward due to the difference of area,
(1) Safety lock lever and pilot circuit
Green (2) Principle : resulting in the reduction of tilt angle.
(2) Pump positive flow control Similarly, when the servo piston moves
Return, make up circuit, The current command I to the pump’s solenoid
0.44~0.59 MPa (64~86 psi) (3) Pump P-Q (Pressure-Quantity) curve control rightward, the spool (652) is moved leftward
proportional valve controls the delivery rate of the
Purple pump. by the feedback lever.
22.4.1 SAFETY LOCK LEVER AND PILOT The operation is maintained until the opening
Secondary pilot pressure, CIRCUIT (3) Operation :
(including proportional vlave) of spool sleeve is closed.
(1) Purpose : 1) Flow rate rise operation (Eg. P1 pump)
0.59~5 MPa (86~725 psi)
To protect attachment from unexpected By operating any of control levers, the 22.4.3 PUMP P-Q CURVE CONTROL
Red
movement for safety. operating secondary pressure of pilot valve OPERATION
Primary pilot pressure,
(2) Principle : rises, and the rising pressure is transformed (1) Type :
(including proportional vlave)
Cut pressure source of pilot valve for operation. to the rise of output voltage corresponding to Electrical flow control type variable pump
5 MPa (725 psi)
(3) Operation : the pressure input by the low pressure sensor. (2) Principle :
Orange
If the safety lock lever (red) is pushed forward Mechatro controller signal-processes this Perform an operation of the value from pump high
Main pump drive pressure,
after the engine starts, the limit switch (SW-11) is change of voltage, resulting in rise of pressure sensor to P-Q curve control value, and
5~34.3 MPa (725~4970 psi)
turned on. The timer relay is actuated one second command current value I to the pump send a command to the pump solenoid
Blue tone
later which causes the solenoid (SV-4) of the proportional solenoid valve and consequently proportional valve.
At valve operation
solenoid valve block (13) to be energized and the pump flow rate rises. This is called
Red valve (3) Operation :
makes the pilot operating circuit to stand by. "Positive Control System".
When solenoid proportional valve (reducing) The pump high pressure sensor converts the
As the pump command current value rises,
is operating pressure to the output voltage corresponding to
the secondary pressure of proportional
Red solenoid the pump delivery pressure.
solenoid valve also rises. On the regulator
In active and exciting The mechatro controller converts the voltage
attached on the pump, the spool (652)
Displaying the flow circuit and standby circuit when output by the high pressure sensor to the P-Q
through piston (643) is pushed leftward, and curve control value. On the other hand, select the
operating.
stops at the position where being in proportion pump positive control command current value
Regarding the electrical symbols in this manual, refer
to the force of pilot spring (646). from the low pressure sensor in lower order, and
to the electric circuit diagram.
The tank port connected to the large bore of the values are output to respective pump
servo piston (532) opens, and the piston proportional valve as a command current.
moves leftward by delivery pressure P1 of the With this operation, the pump power is controlled
small bore resulting in the increase of tilt angle so as not to be exceed the engine power,
( ). therefore engine dose not stall.
The servo piston and spool (652) are
connected to feedback lever (611). Therefore
when servo piston moves leftward, the spool
(652) also moves rightward by means of
feedback lever. With this movement, the
opening of spool sleeve closes gradually, and
the servo piston stops at the position the
opening closed completely.
2) Flow rate reduction operation
As the current value I of mechtro controller
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the
delivery pressure P1 usually flows into the
2-8
GRAPHIC_1D Figure 1
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
2-9
22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID COMMAND

This section describes the following. CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION
(1) Travel forward pilot simultaneous operation circuit (1) Purpose :
(2) 2 speed travel solenoid command circuit and auto Change travel motor speed with switch.
1-speed return function (2) Principle :
(3) Travel main circuit If the switch is turned, an electric signal is issued.
(4) Travel motor function It excites the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
22.5.1 TRAVEL FORWARD PILOT
pressure to a tilting angle of the variable
SIMULTANEOUS OPERATION CIRCUIT
(1) Purpose : displacement motor.
Light operating force and shockless operation (3) Operation :
(2) Mechatronics : If the rabbit marked switch on the gauge cluster is
pressed, the solenoid (SV-3) of the proportional
1) If the travel lever with damping mechanism is
valve block (19) is excited and changes the
operated for travel right, left and forward
proportional valve. Then the solenoid command
motions, the secondary pilot proportional
pressure is issued from port A3, enters the P port
pressure comes out of the 3, 1 ports of P/V
of the travel motor (5), opens the oil passage to
(11). The higher of the pressures is selected,
the 2nd speed select piston, and causes the
comes out of the 6, 5 ports and acts upon the
motor to run in the 2nd speed tilting mode by its
low pressure sensors (SE9) (SE-10).
self pressure. However, when the main circuit
2) The pilot secondary pressure flows to 5pb1 pressure rises above 28 MPa (4060 psi), the
and 4pa1 ports of the control valve (2), moves motor’s self pressure pushes the 2nd speed
the travel spool, and switches the main circuit. select piston back to the 1st speed.
3) The low pressure sensor output voltage is
input into mechatro controller. The mechatro 22.5.3 TRAVEL MAIN CIRCUIT
controller performs signal processing and (1) Operation :
outputs current corresponding to the increase The delivery oil from Pump A1 and A2 ports by
of flow rate to P1 pump proportional valve changing the travel spool with the operation of
(PSV-P1) and P2 pump proportional valve travel pilot flows in each VA port on the left side of
(PSV-P2). travel motor (4) through B,A ports of swivel joint
4) The secondary pressures output by P1 pump (9) from 5B1, 4A1 ports of C/V, and rotates the
proportional valve (PSV-P1) and P2 pump travel motor.
proportional valve (PSV-P2) exert on pump 22.5.4 TRAVEL MOTOR FUNCTION
regulator, actuating the pump on the delivery
(1) Function :
flow rate increase side.
1) Prevents the motor from over running on a
slope.
2) Check valve that prevents cavitation of the
hydraulic motor.
3) Shockless relief valve and anti cavitation
valve when inertia force stops.
4) High/Low 2 step speed change mechanism
and auto 1st speed return at high load.
5) Travel parking brake.
2-10
GRAPHIC_1D Figure 2\
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
2-11
22.6 BUCKET CIRCUIT 22.6.2 AUTO ACCELERATION OPERATION 3) With the function of pilot circuit, the oil flow is
This section describes the following. (1) Principle : switched from bucket spool, and is fed into
(1) Bucket digging pilot circuit Auto acceleration actuates according to signals bucket cylinder head side through AB2 port of
from low pressure sensor. C/V (2). On the other hand, the return oil from
(2) Auto accel operation
(2) Operation : cylinder rod (R) side is throttled by bucket
(3) Flow control in the work mode spool and returns to tank circuit from 4A2 port
<When lever is set to neutral position>
(4) Bucket digging travel straight main circuit of C/V (2).
In the event where the sensor does not receive
(5) Bucket spool stroke limiter signal for 4 seconds or more even though the References :
acceleration dial is set to MAX position, the • When dumping bucket, the P2 by-pass cut
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING engine speed should be raised to 850rpm. valve closes and the oil becomes conflux flow
(1) Mechatronics : <When lever is operated> in the same manner as bucket digging. But P1
1) When the operation for bucket digging is When the pressure 0.6MPa (87psi) is input to low pump on the conflux side delivers the minimum
performed, the pilot proportional secondary pressure sensor in STD specification (travel, flow rate.
pressure is delivered through port 1 of the bucket, swing, arm), proportional voltage from low • When bucket operation is combined with any
right pilot V (10), flows to 4pb2 port, and acts pressure sensor inputs in mechatro controller, other operation, P2 by-pass cut valve does not
on the low pressure sensor (SE-1), and at the and then the engine speed returns to the dial set work, and the bucket is controlled by single
same time the bucket spool is switched. position corresponding to the lever operation. flow.
2) The voltage output by low pressure sensor
inputs in mechatro controller. The mechatro 22.6.3 STAND-BY CURRENT CONSTANT 22.6.5 BUCKET SPOOL STROKE LIMITER
CONTROL
controller performs signal processing and (1) Purpose :
(1) Principle :
outputs current corresponding to the increase To secure simultaneous operability of boom and
When the engine speed is intermediate speed or
of pump flow rate to pump proportional valves arm on boosting up attachment pressure (Pump
lower, command current value to have the pump
(PSV-P1) and (PSV-P2) on the P1 and P2 flow rate decreases.) and to prevent cavitations at
delivery rate constant is output.
pump sides. low engine speed
And at the same time, the command current is (2) Operation :
(2) Operation :
output to P2 center bypass cut proportional Even if the engine speed specified by
On boosting up attachment pressure, pilot
valve (PSV-B). acceleration potentiometer is low speed, as the
primary pressure exerts on 4pc3 port of C/V(2)
In the following pages, the relation of delivery rate corresponds to the intermediate
through attachment booster solenoid valve,
operation of low pressure sensor to both the speed, the actuator moves earlier than the
operates stroke limiter of bucket spool, and
increase of pump flow rate and unloading movement equivalent to the control lever angle
throttle oil path of spool. As a result, P1 pump
proportional valve is the same. Therefore the rate in light load operation.
pressure increases, making the simultaneous
explanation is omitted. operation of boom up and bucket digging
22.6.4 BUCKET DIGGING CONFLUENCE
3) The secondary pressure output by P1 pump (CONFLUX) MAIN CIRCUIT possible.
proportional valve (PSV-P1) and P2 pump (1) Operation : Even though the engine speed is low, similarly the
proportional valve (PSV-P2) exerts on pump cavitations can be prevented by actuating the
1) The oil delivered through A1 port of P1 pump
regulator, actuating the pump onto the stroke limiter.
goes into P1 port of C/V (2), opens load check
delivery flow increase side.
valve through parallel circuit and enters in
bucket spool.
2) On the other hand, the oil delivered through
P2 port of P2 pump goes into P2 port of C/V
(2), and it flows to downstream via center
bypass. Because P2 center by-pass cut valve
is throttled or closed according to the bucket
operating pilot pressure. And the trapped oil
opens check valve, and then this oil confluxes
the P1 pump delivery oil at close to bucket
spool.
2-12
GRAPHIC_1D Figure 3
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Conflux), Auto-accelation and Standby flow rate constant control
2-13
22.7 BOOM CIRCUIT

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

(1) Operation :
1) If boom up operation is performed, the
secondary pilot proportional pressure from
the right pilot valve (10) gets out of port 3 and
acts upon the low pressure sensor (SE3). At
the same time, the pressure acts upon the
4pa3 and 5pb4 ports of C/V (2).
2) The secondary pressure which enters the
4pa3 port of C/V (2) shifts the boom spool.
The secondary pressure which enters the
5pb4 port shifts the boom 2-speed spool.
22.7.2 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 the
boom spool is moved and bypass circuit is
closed, the oil opens load check valve through
parallel circuit and flows into boom spool.
2) Then the oil passes through boom spool,
opens lock valve of boom lock valve, and is
led into H side of boom cylinder through C/V
(2) 4A3 port.
3) Meanwhile, the oil delivered from the A2 port
of the P2 pump enters the P2 port of C/V (2),
and bypass circuit is closed due to movement
of boom 2-speed spool. The oil flows from
parallel circuit through boom 2-speed spool,
and is combined internally with the delivered
oil by the P1 pump.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V
(2) 4B3 port.
2-14
GRAPHIC_1D Figure 4
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.
2-15
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down
main circuit (2) Principle :
The oil returning from the boom cylinder head (H)
22.7.3 BOOM DOWN PILOT CIRCUIT is recirculated to the rod (R).
(1) Operation :
(3) Operation :
1) If the boom down operation is performed, the
When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes
(R) side during boom down operation, the boom
out of port 4 of the right pilot valve (10) and
moves faster than it should do in some cases by
acts upon the low pressure sensor (SE-4).
the self weight of the attachment.
At the same time, the pressure acts upon the
On that occasion, the circuit pressure on the rod
4pb3 port of C/V (2).
(R) side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
3) Then, the proportionl secondary pressure fed and goes out of the 4B3 port.
into C/V (2) 4pb3 port and branches off in On that occasion, the oil returning from the head
three lines and switches boom 1-speed, boom (H) goes through the recirculation path in the
2-speed spool and releases boom lock valve. boom spool, pushes the check valve in the spool
open, is recirculated to the 4B3 port and is
22.7.4 PREVENTION OF NATURAL FALL BY
LOCK VALVE AND ACTUATION AT supplied to the rod (R). When the (R) pressure is
LOWERING larger than the head (H) pressure, the check valve
(1) Purpose : in spool closes.
Prevention of natural fall when the lever is neutral Consequently, the recirculation is stopped.
(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 lock valve is
changed over by the secondary proportional
pressure of 4pb3 port. Then the poppet spring
chamber of the lock valve 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 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.
2-16
GRAPHIC_1D Figure 5
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
2-17
22.8 SWING CIRCUIT 22.8.2 SWING AUTO PARKING BRAKE

This section describes the following operations. (1) Purpose :
Swing lock in neutral position and parking
(1) Swing left pilot circuit
(2) Principle :
(2) Swing auto parking brake
Release mechanical brake only when required to
(3) Swing main circuit operate swing and arm in.
(4) Swing motor circuit (3) Operation :
22.8.1 PILOT CIRCUIT FOR LEFT SWING 1) The swing parking system excites the swing
(1) Operation : parking SOL (SV-1) usually if the key switch is
1) When the left swing operation is performed, turned on and works by the action of the
the pilot proportional secondary pressure is mechanical brake.
delivered through port (5) of left pilot V (10), 2) The mechanical brake is released if the swing
and the secondary pressure acts on 5pb2 port parking solenoid is de-excited only when the
of secondary operating pressure in the swing
C/V (2), and simultaneously flows through and arm in actions acts upon any of the low
shuttle valve and acts on low pressure sensor pressure sensors (SE-5, 7).
(SE-5).
3) The swing parking solenoid (SV-1) is excited
2) The voltage output by the low pressure five seconds after the pressure of the swing
sensor is input in the mechatro controller, and low pressure sensors (SE-5) is reduced to
is signal-processed. zero.
3) Then, the secondary pressure led into 5pb2 In the case of arm in operation, the swing
port of C/V (2) switches the swing spool. 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.
22.8.3 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 as the
swing spool is shifted, the oil pushes the load
check valve open through the parallel circuit,
enters the A port of the swing motor via the 5B2
port of C/V (2), and the machine rotates
counterclockwise.
22.8.4 SWING MOTOR CIRCUIT

(1) Anti cavitation circuit at swing deceleration
(2) Shockless relief valve that prevents the swing
motor from being reversed.
2-18
GRAPHIC_1D Figure 6
Fig. 22-6 SWING CIRCUIT : Swing operation (LH)
2-19
22.9 ARM CIRCUIT 22.9.2 ARM IN, LIGHT-LOAD VARIABLE 22.9.3 ARM IN, HEAVY LOAD OPERATING 22.9.4 ARM IN, HEAVY LOAD OPERATING
This section describes the following operations. NORMAL RECIRCULATION, INTERNAL PILOT CIRCUIT RECIRCULATION CUT MAIN CIRCUIT
(1) Arm in, light-load operating pilot circuit CONFLUX MAIN CIRCUIT (1) Operation : (1) Purpose :
(1) Operation : 1) In arm-in operation, when the heavy loading is Speed up for arm in operation
(2) Arm in, light-load variable normal recirculation
1) The P2 pump delivery is branched off in by- applied to arm and the P2 pump pressure (2) Principle :
main circuit / internal conflux main circuit
pass circuit and parallel circuit, through P2 increases to the set pressure, the voltage Cut the recirculation and reduce rod pressure.
(3) Arm in, heavy load operating pilot circuit port of C/V (2) and but because arm 1 spool is output by P2 pump pressure sensor (SE-23) (3) Operation :
(recirculation cut) switched, the delivery oil which goes through is converted to signal (signal processing) by
(4) Arm in, heavy load operating sequence confluxed 1) P2 pump delivery oil is branched off in by-
parallel circuit opens load check valve and is mechatro controller, consequently the current
main circuit pass circuit and parallel circuit through P2 port
flowed into arm 1 spool. of arm 2 solenoid proportional valve is
of
22.9.1 ARM IN, LIGHT-LOAD OPERATING 2) On the other hand, P1 pump delivery oil flows controlled according to the load pressure and
C/V (2). Consequently the arm spool is
PILOT CIRCUIT in P1 port of C/V (2), and the flows in by-pass the arm variable recirculation is cut.
switched and pushes and opens load check
(1) Purpose : circuit and parallel circuit. Then because arm When the recirculation is cut, internal
valve through parallel circuit, and flows in the
Speed-up and Anticavitation when the arm is at 2 spool was switched, the delivery oil opens confluence is held similarly to that in light load
arm spool.
light loaded. load check valve, goes through arm 2 spool, operation.
2) On the other hand, P1 pump delivery oil flows
(2) Principle : and confluences with P2 pump delivery oil in 2) Left pilot valve actuation due to arm-in
in P1 port of C/V (2), and flow in by-pass
The oil returning from the arm cylinder rod (R) is the valve section, and then is flowed into arm operation is equivalent to that at light load
circuit and parallel circuit. Then because arm
recirculated variably to the head (H) at arm 2 cylinder head (H) side through 5B5 port of C/ operation.
2 spool was switched, the delivery oil opens
spool in C/V. V (2).
load check valve, and confluences with P2
(3) Operation : 3) The return oil from arm cylinder (R) side flows pump delivery oil in the valve section, and is
1) When the arm in operation is performed, the in 5A5 port of C/V (2) and passes through the flowed into arm cylinder head (H) side through
secondary pilot proportional pressure gets out 5A5 port because the arm lock valve is open, 5B5 port of
of port 7 of the left pilot valve (10) and acts and is flowed into arm 2 spool. C/V(2).
upon the low pressure sensor (SE-7). 4) Because arm 2 spool is switched to normal 3) The return oil from arm cylinder (R) side flows
At the same time, the pressure is branched off recirculation position, causing restriction of in 5A5 port of C/V(2) and is flowed to arm lock
in two flows, acts upon the 5pb5 port and the passage to tank, the return oil from arm valve, but because the arm lock valve is open,
5pc1 port, changes over the arm spool and cylinder (R) side flows into arm cylinder (H) the return oil flows in arm 2 spool.
the arm lock valve is released. side.
4) The return oil returns directly into tank circuit
2) The output voltage by the low pressure • Because, at light load, the pressure in because arm 2 spool is switched to
sensor is input into mechatro controller, and is cylinder rod (R) side is higher than that in recirculation cut position.
pilot signal-processed, and is output to P1, P2 the head (H) side, it opens the check
pump proportional valve (PSV-P1), (PSV-P2) valve housed-in arm 2 spool and is
and arm 2 inverse proportional valve (PSV-A). recirculated in the head (H) side, resulting
3) The secondary pressure from pilot in the speed up of arm-in operation at light
proportional valve, which is reduced by arm 2 load.
inverse proportional valve (PSV-A) switches 5) Cavitations prevention control in arm-in
arm 2 spool. operation
Command current is output to arm 2 solenoid
proportional valve by signal processing of E/G
speed and arm-in pilot pressure, accordingly
the arm 2 spool is switched to neutral
(cavitations prevention) position, resulting in
cavitations prevention.
2-20
GRAPHIC_1D Figure 7
Fig. 22-7 ARM CIRCUIT : Arm in (Light & heavy load) operation, Arm variable recirculation
2-21
This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH
(5) Arm out pilot circuit ARM LOCK VALVE
(6) Arm out 2 pumps conflux main circuit (1) Purpose :
To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve
weight of the arm & bucket.
22.9.5 ARM OUT PILOT CIRCUIT (2) Principle :
(1) Operation :
Complete seat of the return circuit against the arm
1) When the arm out operation is performed, the spool of the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out
(3) Operation :
of port 8 of the left pilot valve (10), and acts
1) When the secondary pressure for arm
upon the low pressure sensor (SE-8). At the
operation disappears and the arm cylinder
same time, the oil is branched off in two flows
stops, the pressure on the rod (R) side passes
and act upon the 5pa5 and 4pb4 ports of C/V
through the selector of the lock valve from the
(2).
5A5 port of C/V, acts the back pressure on the
2) The operating proportional secondary
lock valve and seats the lock valve.
pressure flowed in 5pa5 port of C/V (2)
2) Since the oil flow into the arm spool from the
switches the arm 1 spool.
lock valve is shut off completely, natural fall of
3) Then, the operating secondary pressure
the arm due to oil leaks through the arm spool
flowed in 4pb4 port of C/V (2) switches the
is prevented.
arm 2 spool valve.
22.9.6 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
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 with free
flow and is flowed into arm cylinder rod (R)
side through 5A5 port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in 5A5 port, and returns
into tank circuit through arm 1 spool and arm
2 spool.
2-22
GRAPHIC_1D Figure 8
Fig. 22-8 ARM CIRCUIT : Arm out operation, Confluence function
2-23
22.10 COMBINED CIRCUIT 22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT

This section describes only the difference in (1) Purpose :
combined operation. To ensure straight travel movement during travel
operation even if the attachment is operated.
(1) Boom up / travel, pilot circuit
(2) Principle :
(2) Boom up / travel, main circuit
The travel action and the attachment action are
22.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT actuated by separate pumps.
(1) Operation :
(3) Operation :
<Operation: Different point of pilot circuit from
1) P1 pump delivery oil flows through P1 port of
independent operation >
C/V(2) and branches off in P1 parallel circuit
1) The mechatro controller outputs command
and travel straight spool.
current to travel straight solenoid proportional
P2 pump delivery oil flows through P2 port of
valve after signal processing, and the
C/V(2) and branches off in P2 tandem circuit
solenoid valve outputs secondary pressure
and travel straight spool.
and acts on Pz1 port of C/V (2).
2) The delivery oil flowed into P1 parallel circuit
2) Then the pressure of Pz1 port switches the
of P1 pump opens check valve and flows in
travel straight valve two steps.
boom 1-speed spool, which exerts on boom
up operation.
The delivery oil flowed into travel straight
spool of P1 pump opens check valve because
the travel straight spool is shifted, and flows in
boom 2-speed spool and exerts on boom up
operation with the internal oil conflux.
(In travel straight operation, P1 pump delivery
oil exerts on swing operation of attachment.)
3) The delivery oil flowed into P2 tandem circuit
of P2 pump flows in left travel spool to travel
leftward.
spool of P2 pump flows in right travel spool
because the travel straight spool is shifted
and exerts on the right travel operation.
oil exerts on travel operation.)
4) However, a portion of the flow is led to the
travel straight spool notch restriction. The
speed of attachments like travel, boom, etc. is
adjusted by the circuit of restriction.
2-24
GRAPHIC_1D Figure 9
Fig. 22-9 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
2-25
22.10.3 TRAVEL INDEPENDENCE 22.10.5 BOOM UP / TRAVEL, MAIN CIRCUIT

The combined operation during travel independent (1) Purpose :
operation is described in this section. Even if the attachment is operated during travel
(3) Boom up / travel, pilot circuit operation, the travel speed does not change.
(4) Boom up / travel, main circuit (2) Principle :
The travel action and the attachment action are
22.10.4 BOOM UP/ TRAVEL, PILOT CIRCUIT
actuated by quite different pumps.
(1) Operation :
<Operation: Different point of pilot circuit from (3) Operation :
independent operation > 1) P1 pump delivery oil flows through P1 port of
1) The mechatro controller outputs command C/V(2) and branches off in P1 parallel circuit
current to travel straight solenoid proportional and travel straight spool.
valve after signal processing, and the P2 pump delivery oil flows through P2 port of
solenoid valve outputs secondary pressure C/V(2) and branches off in P2 tandem circuit
and acts on Pz1 port of C/V (2). and travel straight spool.
2) Then the pressure of Pz1 port moves spool of 2) The delivery oil flowed into P1 parallel circuit
travel priority valve to the end. of P1 pump opens check valve LCb and flows
in boom 1-speed spool, which exerts on boom
up operation.
spool of P1 pump opens check valve CT2
because the travel straight spool is shifted,
and flows in boom 2-speed spool and exerts
on boom up operation with the internal oil
conflux.
oil exerts on swing operation of attachment.)
3) The delivery oil flowed into P2 tandem circuit
of P2 pump flows in left travel spool to travel
leftward.
spool of P2 pump flows in right travel spool
because the travel straight spool is shifted
and exerts on the right travel operation.
oil exerts on travel operation.)
4) Some part of flow rate flows to the travel
straight spool notch restriction. But travel
speed is not affected by simultaneous attach-
ment operation like a boom etc. because the
flow is not led to notch while travel indepen-
dent operation is actuated.
2-26
GRAPHIC_1D Figure 10
Fig 22-10 TRAVEL INDEPENDENCE CIRCUIT: Boom up & Travel forward, Travel independence function.
2-27
In this section, the independent operation is omitted 22.10.7 SWING / ARM IN, SWING PRIORITY
and describes difference in combined operation. MAIN CIRCUIT
(5) Swing / Arm in light load, pilot circuit (1) Purpose :
(6) Swing / Arm in, swing priority main circuit Stable swing speed.
(2) Principle :
22.10.6 SWING / ARM IN LIGHT LOAD, PILOT
CIRCUIT Raise the oil pressure flowing to arm cylinder, and
(1) Operation : give a priority of the delivery of P2 pump to swing
1) In swing operation, swing pilot secondary operation.
pressure branches into two circuits and exerts (3) Operation :
on 5pb2 port and 5pc3 port respectively. 1) The swing main circuit operates with P2 pump
2) 5pb2 port pressure switches the swing spool flow. But on P2 pump circuit side, the flow
and 5pc3 port pressure acts upon the swing goes to the swing circuit and arm circuit
priority valve and throttles the arm spool inlet. simultaneously because the swing circuit and
3) Swing pilot secondary pressure acts upon the arm circuit make parallel circuit. But because
low pressure sensor SE-5 and arm-in pilot the arm spool inlet is throttled by swing priority
secondary pressure acts upon the low valve, the pump pressure rises and
pressure sensor SE-7. consequently the oil is fed into swing circuit of
The low pressure sensor voltage is processed which the working pressure is higher, too.
by mechatro controller and transformed into 2) And simultaneously P1 pump also delivers oil
signal, and switches arm 2-speed spool to the to arm through the arm 2-speed spool and
combined operation position through PSV-A. prevents the movement of arm from slowing
down.
(4) Releasing swing priority
In the following operation, the swing priority is
released.
1) When boom-down is operated,
In the swing + arm-in + boom-down
combining operation, this function is used to
prevent oil from becoming shortage of oil for
arm operation.
2) When arm-out is operated,
In the swing + arm-out combining operation,
this function is used to prevent swing
movement from slowing down.
2-28
Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
2-29
22.11 PRESSURE DRAINING 2) Unloading directional valves output

(RELEASING) CIRCUIT secondary pressure and the secondary
This section describes the following operations. pressure flows in Pz2 ports of C/V(2) and
(1) Pressure drain (releasing) pilot circuit switches the P1, P2 unloading valves to
(2) Pressure drain (releasing) main circuit OPEN position.
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT 22.11.2 PRESSURE RELEASE MAIN CIRCUIT
(1) Purpose : (1) Operation :
To release the pressure in main circuit for piping
When the hydraulic pressure releasing is
repair works.
performed, make sure to place bucket on the
(2) Principle : ground.
After the mode is switched to "Pressure Relief
When the operating lever is shifted to neutral
Mode" with switch on gauge cluster, mechatro
during engine running, "DRAINING HYD.
controller outputs the following commands.
PRESS." is displayed on the gauge cluster while
1) Minimum tilting command value to pump
the mode switch is changed to pressure relieving
proportional valve (PSV-P1, PSV-P2).
mode. In this time the intermittent buzzer sounds
2) Output "Pressure relief control speed continuously. When right and left operating levers
command value" at ECU. (Electric system) are operated 4 or 5 times to their full stroke,
3) Solenoid valve for unload directional valve is pressure is relieved.
excited. After draining pressure is completed, turn off the
starter key and buzzer sound stops. If the pump
How to switch to "Pressure release mode"
pressure is determined to be more than 1 MPa
1) Select the service diagnosis mode. (145 psi) by the output value of the high pressure
(Keeping pressing of the "BUZZER STOP sensor or the high pressure sensors (SE-22,23)
SWITCH" [ ] on gauge cluster, turn the are broken, "FAIL DRAIN HYD. PRESS" is
starter key on.) displayed and the buzzer sounds continuously. In
2) Select the service adjustment mode 1. that case, also the buzzer is not stopped unless
(Under the condition that "Screen No.1" of the engine key is turned to OFF. Repeat the
"Service diagnosis mode 1" is indicated, pressure releasing procedure once again.
keeping pressing of the "BUZZER STOP (2) Hydraulics :
SWITCH", press the selector switch [ ] 3 If the unload opening of travel straight spool is
times. When "LANGUAGE/LOGO", turned to the pressure release position, the oil
"ADJUSTING MODE 1" and "PRESET BY delivered by each pump is unloaded to the tank
FACTORY" are displayed, press [ ] or [ ] passage. If the spools are switched by pilot
switch, and highlight "ADJUSTING MODE operation, the remaining pressure from the
1", and then press "Selector Switch" again.) actuators may be relieved to the tank circuit, i.e.
3) When "ADJUSTING MODE 1" screen is the main circuit pressure may be released.
displayed, press [ ] or [ ] switch, and
"DRAIN HYD. OFF" screen appears.
4) Press "Selector Switch" and highlight "OFF",
and press [ ] switch to change to "DRAIN
HYD. ON", and then press "Selector Switch"
again.
(3) Operation :
1) Pump proportional valve reduces the pump
flow rate to the minimum.
2-30
Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
2-31
[MEMO]
2-32
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
23.1 ELECTRIC CIRCUIT DIAGRAM ......................................................................................23-3

23.2 ELECTRIC EQUIPMENT LIST ........................................................................................23-12
23.3 HARNESS........................................................................................................................23-13
23.3.1 HARNESS LIST......................................................................................................23-13
23.3.2 INSTRUMENT PANEL ASSY.................................................................................23-14
23.3.3 CONTROLLER INSTALL........................................................................................23-15 23
23.3.4 TUNER INSTALL....................................................................................................23-15
23.3.5 UPPER ELECTRIC ASSY ......................................................................................23-16
23.3.6 UPPER HARNESS ASSY ......................................................................................23-20
23.3.7 ENGINE HARNESS ASSY .....................................................................................23-42
23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) ..........................................................23-44
23.3.9 CAB HARNESS ASSY ...........................................................................................23-52
23.3.10 BOOM HARNESS ASSY........................................................................................23-56
23.3.11 INSTALLING BOOM LIGHT ...................................................................................23-56
23.3.12 INSTALLING UPPER LIGHT ..................................................................................23-58
23.3.13 TRAVEL ALARM ASSY ..........................................................................................23-60
23-1
23. ELECTRIC SYSTEM

SK460-8: LS10-02001~ S5LS2311E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
23-2
-
23 - ELECTRIC SYSTEM
23.1 ELECTRIC CIRCUIT DIAGRAM
R-34 :
PCV RELAY
APPLICABLE : LS10-02001 1 6 FUSE 5 FUSE E-33 :

PCV FUSE C-8 :
MACHINE No YS10-01501 17 32 FUSE ENG. CONTROLLER
ENG. HARNESS
10 15 FUSE
ENG. REVOLUTION
5 FUSE
E-12 : E-12 : SENSOR FOR ECU
BATTERY BATTERY
R-24 :
AUTO IDLE STOP RELAY 2 EGR VALVE
R-23 : 6 FUSE
AUTO IDLE STOP R-1 :
RELAY 1 BATTERY RELAY
R-39 : E-28 :
AIR HEATER RELAY INJECTOR 1
AIR HEATER
TO JC
E-15 : INJECTOR 2
E-2 :
FUSIBLE LINK
ALTERNATOR TO JC
M-1 :
STARTER MOTOR
6 FUSE INJECTOR 3
TO JC
D-13 : DIODE
INJECTOR 4
R-2 :
STARTER RELAY TO JC
7,8,9 FUSE
12 FUSE
INJECTOR 5
DIODE
R-4 :
D-9 :
SAFETY RELAY TO JC
INJECTOR 6
TO JC
ENG. HARNESS
E-22 : CYLINDER
DC-DCCONVERTER DISCRIMINATION G
SENSOR
ENG. CONTROLLER
CHECK CONNECTOR
BOOST SENSOR
E-44 : RESISTOR
E-27 :
ACCEL REDUNDANT VOLUME COMMON RAIL
SW-1 :
PRESS, SENSOR
KEY SW.
C-1 : R-25 : EGR COOLANT

MECHATRO CONTROLLER ENG. EMERGENCY STOP RELAY THERMO SENSOR
(TCO-60-2)
SUCTION AIR TEMP

SENSOR
D-14 : DIODE
R-25 :
ENG. EMERGENCY FUEL TEMP SENSOR
STOP RELAY
R-4 : SAFETY RELAY
ENG. COOLANT
D-13 : DIODE THERMO SENSOR
E-3 : HOUR METER (FOR ECU)
D-14 : DIODE
C-6 :
AUTO GREASE CONTROLLER
CHARGE
R-28 : ALTERNATOR RELAY
R-25 :
KEY ON
ENG. EMERGENCY STOP RELAY
C-5 : SW-27 :
CONTROL : RADIATOR COOLANT
RADIATOR COOLANT
(SENSOR POWER SOURCE, CPU) 1 FUSE LEVEL SW.
LEVEL CONTROLLER
R-19 :
FLASHER RELAY
OUT SOURCE :
(PSV, SOL., MOTOR) 3 FUSE
CONTROL :
(SENSOR POWER SOURCE, CPU) 1 FUSE
WATCH IC 10 FUSE
TO
(2/8)
(1/8)
LS03Z00021P1 02
GRAPHIC_1D Figure 1
23-3
- -
C-1 : MECHATRO CONTROLLER

(TCO-60-2)
FROM
(1/8)
ION
SIT
PO
TERMINAL
NOMAL
RELEASE
E-16 :
SW-4 : ONE WAY CALL AMP
SE-16 : ACCEL POTENTIO
SWING PARKING RELEASE SW.
R-19 :
FLASHER RELAY
SE-1 : SV-1 :
PRESS SENSOR : BUCKET DIGGING SWING PARKING SOL.
SE-2 : E-17 :
PRESS SENSOR : BUCKET DUMP MIC ONE WAY CALL SPEAKER
SV-3 : TWO-SPEED SELECT SOL.
SE-3 :
PRESS SENSOR : BOOM RAISING
ONE WAY CALL
SE-4 : SV-2 : POWER BOOST SOL.
PRESS SENSOR : BOOM LOWRING
SE-7 :
PRESS SENSOR : ARM IN PSV-B
P2 BYPASS CUT
SE-8 : PROPORTIONAL VALVE
PRESS SENSOR : ARM OUT
SE-5 : PSV-C
PRESS SENSOR : SWING TRAVEL PRIORITY
PROPORTIONAL VALVE 27 FUSE
SE-9 :
PRESS SENSOR : TRAVEL RIGHT
POSITION
TERMINAL
PSV-D
SE-10 : P1 BYPASS CUT M-9 : ROOF WINDOW MOTOR
PRESS SENSOR : TRAVEL LEFT PROPORTIONAL VALVE
SE-22 :
PRESS SENSOR : PUMP P1 PSV-A 27 FUSE SW-17 : ROOF WINDOW SW.
19 FUSE
13 FUSE
ARM TWO-APEED INVERSE

SE-23 : PROPORTIONAL VALVE
PRESS SENSOR : PUMP P2
PSV-P1 ROOF WINDOW

PUMP P1
PROPORTIONAL VALVE
SE-20 : PRESS SENSOR : P1 OPT.
PSV-P2
PUMP P2
SE-11 : PRESS SENSOR : P2 OPT. PROPORTIONAL VALVE
C-2 : GAUGE CLUSTER SW-16 : ENG. ROOM LIGHT SW. L-11 : ENG. ROOM LIGHT
OPT.
11 FUSE
ENG. WATER TEMP INDICATOR
SE-15 : FUEL SENSOR
PSV-E : OPT RELIEF ADJUSTMENT EU
PROPORTIONAL VALVE 1
FUEL METER SW-20 : POWER BOOST SW. RIGHT
SW-21 : POWER BOOST SW. LEFT PSV-I : OPT RELIEF ADJUSTMENT

PROPORTIONAL VALVE 2
SE-13 :
EU & KCMA OPT.
ENG. REVOLUTION SENSOR M-11 : FUEL SUPPLY PUMP
14 FUSE
C-1 : SE-28 :
MECHATRO C-2 : EXTRA PRESS SW-56 : FUEL SUPPLY AUTO STOP SW.
CONTROLLER GAUGE
(TCO-60-2) CLUSTER
EU OPT.
EXTRA DIS-PRESS EU
DISPLAY BUZZER MODE WASHER

SELECT STOP
SW. SW-7 : ENG. OIL PRESS SW.
LED LED
SW-8 : AIR FILTER RESTRICTION SW. SW-40 :

ENTER DESEL TRAVEL WIPER
2-SPEED ROTARY LIGHT SW. L-20 : ROTARY LIGHT
R-9 : CAB L-20 : SW-40 :
WORK LIGHT 1 ROTARY ROTARY LIGHT
LIGHT SW.
SW-77 : OIL FILTER RESTRICTION SW.
EU
SV-4 : LEVER LOCK SOL.

R-26 : LEVER LOCK RELAY

(GROUND OUTPUT)
SW-11 :
LEVER LOCK SW.
SV-31 :
TRAVEL PRIORITY UNLOAD RELAY TRAVEL PRIORITY
UNLOAD SOL.
TO
TRAVEL PRIORITY UNLOAD RELAY
(3/8) (2/8)
LS03Z00021P1 02
GRAPHIC_1D Figure 2
23-4
-

(TCO-60-2) FROM
(2/8)
R-31 (RL Y31) :

SW-15 : CONFLUX/SINGLE SELECT SW. PREVENT SPARK RELAY R-29 (RL Y29) :
C-1 : M-3 WIPER MOTOR
SW-15 : WIPER MOTOR RELAY
MECHATRO
CONTROLLER CONFLUX/SINGLE
SELECT SW. R-29 (RL Y29) :
(TCO-60-2) WIPER MOTOR RELAY
OPT.
R-30 (RL Y30) : R-30 (RL Y30) :
WIPER MOTOR WIPER MOTOR
SE-29 : REVERSING RELAY REVERSING RELAY
OPT.SELECTOR
DETECT SENSOR
R-32 (RL Y32) : R-32 (RL Y32) :
SV-13 : WINDOW WASHER WINDOW WASHER C-6 : AUTO GREASE CONTROLLER
OPT.SELECTOR SOL. MOTOR RELAY MOTOR RELAY
M-4 WASHER MOTOR TO FUSE &
OPT. RELAY BOX 15 FUSE
STOP C-1 :
MECHATRO M-8 : GREASE MOTOR
M-3 CONTROLLER
SW-37 : REVERSE WIPER MOTOR
(TCO-60-2)
INDEPENDENT TRAVEL SW.
SW-35 :
C-1 :
HEAVY LIFT SW. D-14 :
SW-19 MECHATRO
EU OPT. CONTROLLER DIODE
WIPER INTERLOCK SW.
(TCO-60-2)
SW-19 WIPER INTERLOCK SW.
SW-12 : OPT.
OVER LOAD ALARM AUTO
SELECT SW. GREASE
SE-26 : SW-13 TRAVEL ALARM SW.
PRESS. SENSOR : BOOM HEAD R-8
EU(FOR OVER LOAD ALARM) TRAVEL ALARM RELAY E-13
R-8 TRAVEL ALARM RELAY TRAVEL ALARM
EU OPT.
KCMA STD
R-52 :
TILT WARNING RELAY
L-6 : BOOM WORKING RESERVE CONNECTOR
LIGHT RIGHT 31 FUSE
EU
SV-14 : QUICK COUPLER OPERATION SOL. R-6 : R-6 :
WORKING WORKING L-1 : BOOM WORKING 31 FUSE
21 FUSE LIGHT RELAY LIGHT RELAY LIGHT LEFT R-52 : TILT SW-80 :
WARNING RELAY TILT SW.
L-2 : FRAME WORKING TO FUSE &
21 FUSE LIGHT RIGHT RELAY BOX
N
ITIO
POS SW-55 : BOOM, DECK WORKING LIGHT SW. R-52 :
TERMINAL
RELEASE
TILT WARNING RELAY

LOCK
OFF
E-43 :
L-31 : TILT ALARM
EU OPT.
29 FUSE TILT ALARM LIGHT
TO FUSE &
SW-59 : QUICK COUPLER OPERATION SW. RELAY BOX
E-16 :
ONE WAY CALL AMP L-3 : SWING FLASHER LEFT & REAR WORKING LIGHT RESERVE CONNECTOR
C-5 : R-52 :
RADIATOR COOLANT TILT WARNING RELAY
PSV-M : LEVEL CONTROLLER
P1 INDEPENDENT TRAVEL TILT WARNING (LMN OPT.)
PROPORTIONAL VALVE
PSV-N :
P2 INDEPENDENT TRAVEL
PROPORTIONAL VALVE 31 FUSE RESERVE CONNECTOR
SW-66 :
KCMA STD
WATER SPRAY SW. SV-32 : WATER SPRAY SOL.
31 FUSE
R-12 : SV-6 : R-19 : FLASHER RELAY
REVOLUTION REVOLUTION RIGHT SOL.
RESERVE
RIGHT RELAY SW-33 : TO FUSE & CONNECTOR
REVOLUTION RIGHT SW. RELAY BOX
D-16/D-17 : TO FUSE &
DIODE RELAY BOX
SV-7 : L-4 : SWING FLASHER RIGHT & REAR WORKING LIGHT

R-13 :
REVOLUTION REVOLUTION LEFT SOL.
WATER SPRAY EQUIPMENT (LMN OPT.)
LEFT RELAY SW-34 :
REVOLUTION LEFT SW. SWING FLASHER & WORKING LIGHT
REVOLUTION N&B
SW-37 :
INDEPENDENT TRAVEL SW.
SV-9 : SW-35 :
R-15 : NIBBLER OPEN SOL. HEAVY LIFT SW.
NIBBLER OPEN
RELAY SW-18 :
LMN/BH SELECT SW.
SW-29 : KCMA
NIBBLER OPEN SW.
(CASE OF HAND CONTOROL NIBBLER CONNECT WITH 571)
D-5/D-6 : DIODE C-1 :

MECHATRO
(CASE OF HAND CONTOROL BREAKER CONNECT WITH 572) 6P 9P
CONTROLLER
CONNECTOR CONNECTOR
(TCO-60-2)
SV-10 :
R-16 : NIBBLER CLOSE SOL.
NIBBLER CLOSE SW-30 :
RELAY NIBBLER CLOSE SW. DOWNLOAD
TO
(4/8) (3/8)
EASY OPERATING NIBBLER LS03Z00021P1 02
GRAPHIC_1D Figure 3
23-5
- -

(TCO-60-2)
FROM (3/8)
R-36 : ROTARY LIGHT R-36 : ROTARY LIGHT

31 FUSE RELAY (RED) RELAY (RED)
R-36 : ROTARY LIGHT R-37 : ROTARY LIGHT
RELAY (RED) RELAY (YELLOW)
R-37 : ROTARY LIGHT
RELAY (YELLOW) R-38 : ROTARY LIGHT
RELAY (GREEN)
R-37 : ROTARY LIGHT L-19 :
RELAY (YELLOW) HIGH REACH THREE L-5 : ROOM LIGHT
11 FUSE C-1 : MECHATRO CONTROLLER
R-38 : ROTARY LIGHT COLORS ROTARY LIGHT
R-36 : ROTARY LIGHT SW-78 : SV-40 : CRAWLER STRETCH SOL.
RELAY (GREEN)
RELAY (RED) HYDRAULIC VLC SW.
R-38 : ROTARY LIGHT
RELAY (GREEN) R-37 : ROTARY LIGHT 31 FUSE
RESERVE CONNECTOR RELAY (YELLOW)
7 FUSE E-14 : CIGARETTE LIGHTER
TO FUSE & R-38 : ROTARY LIGHT
RELAY BOX RESERVE CONNECTOR RELAY (GREEN)
31 FUSE
OPT. AGAINST OVERTURNING RESERVE CONNECTOR SV-41 :

E-5 : HORN HIGH CRAWLER CONTRACT SOL.
POSITION
TERMINAL
OFF
LO
HI
SW-41 : E-6 : HORN LOW
R-5 : TO FUSE &
HIGH REACH CRANE HORN RELAY RELAY BOX
SW. SW-5 : HORN SW. RIGHT
RESERVE CONNECTOR
TO FUSE &
SW-10 : HORN SW. LEFT RELAY BOX
OPT. HIGH REACH CRANE HYDRAULIC VLC(OPT.)

(B133 HAS NO SETUP.)
SV-14 : QUICK COUPLER

OPERATION SOL. C-7 :
SV-8 : ITCONTROLLER (DoPa)
D-29 : DIODE ARM PUSH/PULL PORT SELECT SOL. E-25 : R-9 : L-7 :
PDC ANTENNA CAB WORKING LIGHT CAB WORKING LIGHT FRONT 1
21 FUSE 13 FUSE RELAY 1
R-9,11 : L-8 :
E-24 : CAB WORKING LIGHT CAB WORKING LIGHT FRONT 2
GPS ANTENNA RELAY 1,2 SW-26 : L-15 :
SW-29 : D-15 : D-15 : CAB WORKING SW. CAB WORKING LIGHT FRONT 3
NIBBLER OPEN SW. DIODE DIODE
SW-18 :
R-11 :
LMN/BH SELECT SW. L-16 :
CAB WORKING LIGHT
RELAY 2 CAB WORKING LIGHT FRONT 4
SE-17 : BOOM POTENTIO. L-18 :
CAB WORKING LIGHT BACK
L-17 : BACK LIGHT

SE-18 : INTER BOOM POTENTIO.
EU
SE-19 : ARM POTENTIO. E-7 :

TUNER AM & FM
SW-22 : SWITCHES TO JUDGE THE LENGTH E-8 : E-8 :

SPEAKER LEFT E-7 :
OF INSERT BOOM SW. 1 TUNER SPEAKER LEFT
AM & FM
SW-79 : SWITCHES TO JUDGE THE LENGTH 9 FUSE E-9 : E-9 :
OF INSERT BOOM SW. 2 (BACK UP) SPEAKER RIGHT SPEAKER RIGHT
SV-16 : 11 FUSE
R-10 : BACKET CONTROL RELAY BACKET
CONTROL SOL.
R-10 : BACKET CONTROL RELAY E-23 :
E-22 : DC-DC CONVERTER 12V SOCKET
E-22 :
E-23 :
SW-39 : NIBBLER OPEN PRESSURE SW. 28 FUSE DC-DC CONVERTER
12V SOCKET
ENG. CONTROLLER
SW-32 : STROKE-END PROXIMILITY SW. CHECK CONNECTOR
30 FUSE
PSV-F :
JIB STRETCH REVERSE
ROPORTIONAL VALVE
C-4 : AIR CONDITIONER UNIT
R-6 : E-10 : C-4 :
WORKING RELAY RECEIVER DRIER AIR CONDITIONER
PSV-G : UNIT
JIB CONTRACT REVERSE 25 FUSE E-10 : RECEIVER DRIER E-11 : AIR COMPRESSOR CLUTCH
PROPORTIONAL VALVE
26 FUSE
18 FUSE
PSV-J :
ARM ONE-SPEED REVERSE
PROPORTIONAL VALVE
COOLING
UNIT
SW-43 : JIB PRESSURE SW.
OPT. SEPARATE
OPT. AGAINST OVERTURNING

(4/8)
LS03Z00021P1 02
GRAPHIC_1D Figure 4
23-6
GRAPHIC_1D
SW-30:
NIBBLER CLOSE SW.
SH6-E45 SPLICE
SV-9:
SW-39: NIBBLER OPEN SOL.
NIBBLER OPEN PRESSURE SW.
SV-10:
C-7: NIBBLER CLOSE SOL.
ITCONTROLLER (DoPa)
M-4: SV-6:
WASHER MOTOR REVOLUTION RIGHT SOL.
E-22: SV-7:
DC-D CCONVERTER REVOLUTION LEFT SOL.
SW-21: SV-16:
POWER BOOST SW. LEFT BACKET CONTROL SOL.
SW-10: SW-8:
HORN SW. LEFT AIR FILTER RESTRICTION SW.
SW-34: SW-27:
REVOLUTION LEFT SW. RADIATOR COOLANT LEVEL SW.
SW-43:
JIB PRESSURE SW. R-1:
BATTERY RELAY
SW-18:
LMN/BH SELECT SW. D-4:
DIODE
SW-5:
R-3:
HORN SW. RIGHT
GLOW RELAY
SW-20: SV-31:
POWER BOOST SW. RIGHT TRAVEL PRIORITY UNLOAD SOL.
SW-33:
REVOLUTION RIGHT SW.
SW-35:
HEAVY LIFT SW.
SW-12: C-1:
OVER LOAD ALARM SELECT SW. MECHATRO CONTROLLER (TCO-60-2)
C-1:
E-7:
MECHATRO CONTROLLER (TCO-60-2)
TUNER AM & FM
C-1:
C-1:
R-19:
FLASHER RELAY
FRAME EARTH (GND)
L-8:
CAB WORKING LIGHT FRONT 2
M-11:
L-7:
FUEL SUPPLY PUMP
L-20:
ROTARY LIGHT
SW-15: E-6:
CONFLUX/SINGLE SELECT SW. HORN LOW
E-5:
HORN HIGH
M-9:
ROOF WINDOW MOTOR
E-23: C-5:
12V SOCKET RADIATOR COOLANT LEVEL CONTROLLER
E-14:
CIGARETTE LIGHTER
M-3:
WIPER MOTOR
E-3:
HOUR METER
L-3:
SW-19:
SWING FLASHER LEFT & REAR WORKING LIGHT
WIPER INTERLOCK SW.
SW-55: L-2:
BOOM,DECK WORKING LIGHT SW. DECK WORKING LIGHT RIGHT
L-15:
L-17:
BACK LIGHT E-13:
L-18: TRAVEL ALARM
CAB WORKING LIGHT BACK L-4:
L-16: SWING FLASHER RIGHT & REAR WORKING LIGHT
C-4:
AIR CONDITIONER UNIT
SW-41:
HIGH REACH CRANE SW.
SW-26: SV-4:
CAB WORKING LIGHT SW. LEVER LOCK SOL.
C-2: SV-2:
GAUGE CLUSTER POWER BOOST SOL.
SV-3:
TWO-SPEED SELECT SOL.
E-16: SV-1:
ONE WAY CALL AMP SWING PARKING SOL.
SW-22:
SWITCHES TO JUDGE THE LENGTH OF INSERT BOOM 1
SW-32:
STROKE-END PROXIMILITY SW.
SV-13:
OPT SELECTOR SOL.
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
C-8:
ENG. CONTROLLER
EGR VALVE
ENG. CONTROLLER CHECK CONNECTOR
R-34:
PVC RELAY
SHIELD
SHIELD
SHIELD
SHIELD
SHIELD
SHIELD
-
Figure 5
23-7
23-8
GRAPHIC_1D
R-1 :
BATTERY RELAY
(SECONDARY PRESSURE) C-1 :
MECHATRO CONTROLLER
(POWER SUPPLY FOR CONTROL)
R-25 (RL Y25) :

C-8 :
ENG. EMERGENCY STOPRELAY ENG. CONTROLLER
C-1 :
MECHATRO CONTROLLER
R-1 :
R-1 : BATTERY RELAY
BATTERY RELAY
SW-1 :
KEY SW.
R-24 (RL Y24) : R-23 (RL Y23) :
AUTO IDLE AUTO IDLE
STOP RELAY 2 STOP RELAY 1
C-1 :
MECHATRO CONTROLLER
C-1 : C-1 :
MECHATRO CONTROLLER MECHATRO CONTROLLER
E-3 :
HOUR METER
C-1 :
MECHATRO CONTROLLER FRAME EARTH (GND)
-
E-2 :
ALTERNATOR
R-29 (RL Y21) :
TILT WARNING
R-28 (RL Y28) : WIPER MOTOR RELAY
ALTERNATOR RELAY R-30 (RL Y11) :
WATER SPRAY EQUIPMENT
WIPER MOTOR REVERSING RELAY
R-41 (RL Y27) : THREE COLORS ROTARY LIGHT
TRAVEL PRIORITY
R-4 (RL Y4) : UNLOAD RELAY
SAFETY RELAY HYDRAULIC VLC
R-35 (RL Y35) :
OPT. RELAY 8 TILT WARNING
R-2 :
STARTER RELAY WATER SPRAY EQUIPMENT
HYDRAULIC VLC
C-6 :
AUTO GREASE CONTROLLER
C-1 :
MECHATRO CONTROLLER
SW-11 :
LEVER LOCK SW.
C-1 :
MECHATRO CONTROLLER
SV-4
LEVER LOCK SOL.
C-1 :
MECHATRO CONTROLLER
R-26 (RL Y26) :
LEVER LOCK RELAY
C-8 :
ENG. CONTROLLER
R-34
PCV RELAY
EGR VALVE
C-8 :
ENG. CONTROLLER
SW-1 :
KEY SW. E-14 :
CIGARETTE LIGHTER
E-5/6 :
HORN HIGH/LOW
SW-10/20 :
R-5 (RL Y5) : HORN SW. LEFT/RIGHT
HORN RELAY
E-7 :
TUNER AM & FM
R-1 : C-1 :
BATTERY RELAY MECHATRO CONTROLLER (BACK UP)
L-5 :
ROOM LIGHT
SW-16 :
ENG. ROOM LIGHT SW.
E-7 :
TUNER AM & FM
SW-1 :
KEY SW.
C-7 :
ITMECHATRO CONTROLLER (POWER SUPPLY)
C-2 :
GAUGE CLUSTER
M-11 :
FUEL SUPPLY PUMP
C-6 :
AUTO GREASE
SV-6 :
R-12 (RL Y12) : REVOLUTION RIGHT SOL.
REVOLUTION RIGHT RELAY
SW-33 :
REVOLUTION RIGHT SW.
C-1 :
R-13 (RL Y13) : MECHATRO CONTROLLER
REVOLUTION LEFT RELAY SV-7 :
REVOLUTION LEFT SOL.
SW-34 :
REVOLUTION LEFT SW.
R-15 (RL Y15) : SV-9 :

NIBBLER OPEN RELAY NIBBLER OPEN SOL.
SW-29 :
NIBBLER OPEN SW.
C-1 :
MECHATRO CONTROLLER
R-16 (RL Y16) :
NIBBLER CLOSE RELAY SV-10 :
NIBBLER CLOSE SOL.
SW-30 :
NIBBLER CLOSE SW.
(5/8)
LS03Z00021P1 02
Figure 6
-
GRAPHIC_1D
R-41 (RL Y27) :
TRAVEL PRIORITY UNLOAD RELAY
C-1 :
MECHATRO CONTROLLER
SV-31 :
TRAVEL PRIORITY UNLOAD SOL.
R-1 : R-35 (RL Y35) :
BATTERY RELAY OPT. RELAY 8
(SECONDARY PRESSURE)
C-4 :
AIR CONDITINER UNIT (AMP)
C-2 :
GAUGE CLUSTER
R-31 (RL Y31) :

PREVENT SPARK RELAY
R-29 (RL Y29) :
WIPER MOTOR RELAY M-3 :
WIPER MOTOR
C-1 :
MECHATRO CONTROLLER
R-30 (RL Y30) :

WIPER MOTOR
REVERSING RELAY
M-3 :
WIPER MOTOR
C-1 : R-32 (RL Y32) :

MECHATRO CONTROLLER WINDOW WASHER
MOTOR RELAY
M-4 :
WASHER MOTOR
SV-8 :
ARM PUSH/PULL PORT SELECT SOL.
SV-5 :
BACKET DUMP CUT SOL.
C-1 :
MECHATRO CONTROLLER
SW-18 :
LMN/BH SELECT SW.
SW-41 :
HIGH REACH CRANE SW.
R-17 (RL Y17) :
EXTRA DIS-PRESS RELAY
SV-16 :
BACKET CONTROL SOL.
R-10 (RL Y10) : C-1 :

BACKET CONTROL RELAY MECHATRO CONTROLLER
OPT. RELAY 2
THREE COLORS ROTARY LIGHT

L-19 :
THREE COLORS ROTARY LIGHT HIGH REACH THREE COLORS ROTARY LIGHT
R-36 : C-1 :
ROTARY LIGHT RELAY (RED) (OPT. RELAY 1) MECHATRO CONTROLLER

L-19 :
HIGH REACH THREE COLORS ROTARY LIGHT
R-37 : C-1 :
ROTARY LIGHT RELAY (YELLOW) (OPT. RELAY 3) MECHATRO CONTROLLER

L-19 :
THREE COLORS ROTARY LIGHT HIGH REACH THREE COLORS ROTARY LIGHT
R-38 : C-1 :
ROTARY LIGHT RELAY (GREEN) (OPT. RELAY 4) MECHATRO CONTROLLER
L-1/2/6 :
WORK LIGHT
C-4 :
AIR CONDITIONER AMP
R-6 (RL Y6) : SW-55 :

WORK LIGHT RELAY BOOM, DECK WORKING LIGHT SW.
SW-40 :
ROTARY LIGHT SW.
R-9 (RL Y9) :
CAB WORK LIGHT RELAY 1 L-7/8/15 :
CAB WORKING LIGHT
SW-26 :
CAB WORKING LIGHT SW.
R-11 (RL Y11) :
CAB WORK LIGHT RELAY 2
L-16/17/18 :
CAB WORKING LIGHT/BACK LIGHT
C-4 :
AIR CONDITINER UNIT (MAIN)
C-4 :
AIR CONDITINER UNIT (COMPRESSOR)
SW-17 :
ROOF WIPER SW.
M-9 :
ROOF WIPER MOTOR
E-22 :
DC-DC CONVERTER
R-19 :
FLASHER RELAY
E-13 :
TRAVEL ALARM
C-1 :
R-8 (RL Y8) : MECHATRO CONTROLLER
TRAVEL ALARM RELAY
SW-32 :
STROKE-END PROXIMILITY SW.
TILT WARNING
HYDRAULIC VLC
TILT WARNING
RESERVE
HYDRAULIC VLC
-
Figure 7
23-9
23-10
GRAPHIC_1D
-
C-1 :
MECHATRO CONTROLLER 9P CONNECTOR
C-2 : C-1 :
GAUGE CLUSTER MECHATRO CONTROLLER
C-1 : SW-15 :
MECHATRO CONTROLLER CONFLUX/SINGLE SELECT SW.
M-3 : C-1 :
WIPER MOTOR MECHATRO CONTROLLER
C-4 : E-10 :
AIR CONDITINER UNIT RECEIVER DRIER
SW-19 : C-1 :
WIPER INTERLOCK MECHATRO CONTROLLER
SW.
E-22 : E-23 :
DC-DC CONVERTER 12V SOCKET
SW-40 : L-20 :
ROTARY LIGHT SW. ROTARY LIGHT
E-8 :
SPEAKER LEFT
E-7 :
TUNER AM & FM
E-9 :
SPEAKER RIGHT
OPT. RELAY 5
R-52 :
L-31 :
TILT WARNING RELAY
TILT ALARM LIGHT
RESERVE CONNECTOR
SW-80 :
TILT SW. L-31 :
TILT ALARM LIGHT
Figure 8
-
- -
THIS PAGE IS BLANK FOR EDITING CONVENIENCE
23-11
- -
23.2 ELECTRICAL EQUIPMENT LIST
GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
C-1 MECHATRO CONTROLLER (TCO-60-2) YN22E00214F1 (HARD) PSV-A ARM 2 SPEED REAR PROPO. VALVE YN35V00047F1 SE-23 PRESSURE SENSOR ; P2 PUMP LS52S00015P1
(SE) SENSOR
(P) PROPORTIONAL SOLENOID VALVE
(C) CONTROLLER
C-2 GAUGE CLUSTER YN59S00021F2 PSV-B P2 BYPASS CUT PROPO. VALVE SE-24 PRESSURE SENSOR ; BOOM HEAD
C-4 AIR-CON CONTROLLER AIR CON ACCESSORY PSV-C TRAVEL STRAIGHT PROPO. VALVE SE-26 PRESSURE SENSOR ; BOOM HEAD (FOR OVER LOAD ALARM)
C-5 ENGINE COOLANT LEVEL CONTROLLER ENGINE ACCESSORY PSV-D P1 BYPASS CUT PROPO. VALVE SE-29 OPT. SELECTOR PROXIMILITY SENSOR LC52S00019P1
C-6 AUTO GREASE CONTROLLER LC22E00081P1 PSV-E OPT. RELIEF ADJSTMENT PROPO. VALVE 1
C-7 IT CONTROLLER YN22E00230F1 PSV-F JIB STRETCH REVERSE PROPO. VALVE SV-1 SLEWING PARKING BRAKE SOL YN35V00047F1
C-8 ENGINE CONTROLLER ENGINE ACCESSORY PSV-G JIB CONTACT REVERSE PROPO. VALVE SV-2 POWER BOOST SOL
D-4 DIODE HARNESS ACCESSORY PSV-I OPT. RELIEF ADJSTMENT PROPO. VALVE 2 SV-3 TWO SPEED SOL
D-5 DIODE ACCESORY OF FUSE & RELAY BOX PSV-J ARM 1 SPEED REAR PROPO. VALVE SV-4 LEVER LOCK SOL
D-6 DIODE PSV-M P1 TRAVEL INDEPENDENT PROPO. VALVE SV-6 RIGHT ROTARY SOL LE35V00001F2
D-9 DIODE PSV-N P2 TRAVEL INDEPENDENT PROPO. VALVE SV-7 LEFT ROTARY SOL
(SV) SOLENOID
D-10 DIODE PSV-P1 P1 PUMP PROPO. VALVE YN35V00052F1 SV-8 ARM OUT / IN PORT TURNS REVERSE SOL 2436R1745F1
D-12 DIODE PSV-P2 P2 PUMP PROPO. VALVE SV-9 NIBBLER OPEN SOL
(D) DIODE
D-13 DIODE R-1 BATTERY RELAY YN24S00008F1 SV-10 NIBBLER CLOSE SOL
D-14 DIODE R-2 STARTER RELAY ENGINE ACCESSORY SV-13 OPT. SELECTOR SELECT SOL
D-15 DIODE R-4 SAFETY RELAY YN24S00010P1 SV-14 QUICK COUPLER OPERATION SOL
D-16 DIODE R-5 HORN RELAY SV-16 BUCKET REGULATION SOL LE35V00001F1
D-17 DIODE R-6 WORK LIGHT RELAY SV-31 TRAVEL STRAIGHT UNLOAD SOL
D-18 DIODE YN02D01001P1 R-8 TRAVEL ALARM RELAY SV-32 SPRINKLING SOL
D-19 DIODE R-10 BUCKET REGULATION RELAY SV-40 CRAWLER GROWTH SOL
D-20 DIODE R-12 RIGHT ROTARY RELAY SV-41 CRAWLER SHRINKAGE SOL
D-25 DIODE HARNESS ACCESSORY R-13 LEFT ROTARY RELAY SW-1 KEY SWITCH YN50S00029F1
E-1 FUSE & RELAY BOX YN24E00016F2 R-15 NIBBLER OPEN RELAY SW-4 SWING PARKING RELEASE SWITCH YN50S00047P1
E-2 ALTERNATOR ENGINE ACCESSORY R-16 NIBBLER CLOSE RELAY SW-5 HORN SWITCH RIGHT (OPT.) YN50E00017P1
E-3 HOUR METER YT58S00006P1 R-19 FLASHER RELAY YY24S00001P1 SW-7 ENGINE HYDRAULIC PRESSURE SWITCH ENGINE ACCESSORY
(R) RELAY
E-5 HORN HIGH LV53S00001F1 R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1 SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
E-6 HORN LOW LV53S00001F2 R-24 AUTO IDLE STOP RELAY 2 SW-10 HORN SWITCH LEFT YN50E00017P1
E-7 TUNER AM&FM YN54S00044P1 R-25 EMERGENCY STOP RELAY SW-11 LEVER LOCK SWITCH YN50S00041F1
E-8 SPEAKER LEFT YN54S00050P1 R-26 LEVER LOCK RELAY SW-12 OVER LOAD ALARM SELECT SWITCH YN50S00040D6
E-9 SPEAKER RIGHT R-27 GREASING RELAY (NORMAL ROTATION) SW-13 TRAVEL ALARM SWITCH YN50S00040DF
(E) ELECTRIC FITTINGS
E-10 RECEIVER DRYER YN54S00041P1 R-28 ALTERNATOR RELAY SW-15 CONFLUX / SINGLE SELECT SWITCH YN50S00040D3
E-11 AIR-CON COMPRESSOR YX91V00001F1 R-29 WIPER MOTOR RELAY (NORMAL ROTATION) YN24S00012P2 SW-17 ROOF WINDOW WIPER SWITCH YN50S00040D9
E-12 BATTERY YN72S00016P1 R-30 WIPER MOTOR REVERSING RELAY (REVERSE ROTATION) SW-18 LMN/BH SELECT SWITCH YN50S00040D8
E-13 TRAVEL ALARM (OPT.) YN53S00004F1 R-31 WIPER MOTOR ARK PREVENTION RELAY SW-19 WIPER INTER LOCK SWITCH YT50S00004P1
E-14 CIGARETTE LIGHTER YN81S00003P1 R-32 WASHER MOTOR RELAY SW-20 POWER BOOST SWITCH RIGHT YN50E00017P1
E-15 FUSIBLE LINK LC13E01175S002 R-36 ROTARY LIGHT RELAY (RED) YN24S00010P1 SW-21 POWER BOOST SWITCH LEFT (OPT.)
E-16 ONEWAY CALL AMPLIFIER 2447R145 R-37 ROTARY LIGHT RELAY (YELLOW) SW-22 SWITCHES TO JUDGE THE LENGTH OF INSERT BOOM SW. 1
E-17 ONEWAY CALL SPEAKER LC54S00004P1 R-38 ROTARY LIGHT RELAY (GREEN) SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
(SW) SWITCH
E-22 DC-DC COMVERTER YN77S00005F1 R-34 PCV RELAY ENGINE ACCESSORY SW-27 COOLANT LEVEL SWITCH ENGINE ACCESSORY
E-23 12V SOURCE SOCKET YN81S01002P1 R-39 AIR HEATER RELAY SW-29 NIBBLER OPEN SWITCH 2406P5872
E-24 GPS ANNTENA YN54S00047P1 SE-1 PRESSURE SENSOR ; BUCKET DIGGING LC52S00019P1 SW-30 NIBBLER CLOSE SWITCH
E-25 PDC ANNTENA & CONTROLLER YN22E00230F1 SE-2 PRESSURE SENSOR ; BUCKET DUMP SW-32 STROKE END PROXIMILITY SWITCH YN50S00019P1
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 SE-3 PRESSURE SENSOR ; BOOM UP SW-33 RIGHT ROTARY SWITCH (OPT.) YN03M01231P3
E-33 PCV FUSE HARNESS ACCESSORY SE-4 PRESSURE SENSOR ; BOOM DOWN SW-34 LEFT ROTARY SWITCH (OPT.)
E-44 RESISTER SE-5 PRESSURE SENSOR ; SLEWING SW-35 HEVY LIFT SWITCH YN50S00040D5
L-1 BOOM WORKING LIGHT LEFT YW80S00001F1 SE-7 PRESSURE SENSOR ; ARM IN SW-39 NIBBLER OPEN PRESSURE SWITCH GB50S00049F2
L-2 DECK WORKING LIGHT RIGHT YT80S00002F2 SE-8 PRESSURE SENSOR ; ARM OUT SW-40 ROTARY LIGHT SWITCH YN50S00040D2
(SE) SENSOR
L-3 SLEWING FLASHER LEFT & WORK LIGHT UNIT YM80S00001F1 SE-9 PRESSURE SENSOR ; TRAVEL RIGHT SW-41 HIGH REACH CRANE SWITCH PY50S00003P2
(L) LIGHT
L-4 SLEWING FLASHER RIGHT & WORK LIGHT UNIT YM80S00001F2 SE-10 PRESSURE SENSOR ; TRAVEL LEFT SW-43 JIB PRESSURE SWITCH GB50S00049F2
L-5 ROOM LIGHT YT80S00001P1 SE-11 PRESSURE SENSOR ; P2 SIDE OPT. SW-55 BOOM DECK WORK LIGHT SWITCH YN50S00040D1
L-6 BOOM WORKING LIGHT RIGHT YW80S00001F1 SE-13 ENGINE SPEED SENSOR ENGINE ACCESSORY SW-77 OIL FILTER CLOGGING SWITCH ENGINE ACCESSORY
L-10 HIGH REACH RATARY LIGHT 2456R457 SE-15 FUEL SENSOR YN52S00045F1
L-19 HIGH REACH THREE COLORS ROTARY LIGHT EZ53E00013F1 SE-16 ACCEL POTENTIO YN52S00032P1
M-1 STARTER MOTOR ENGINE ACCESSORY SE-17 BOOM POTENTIO YR52S00016P1
(M) MOTOR
M-3 WIPER MOTOR YN53C00012F2 SE-18 INTER BOOM POTENTIO

M-4 WASHER MOTOR YN54C00001F1 SE-19 ARM POTENTIO YR52S00016P1
M-8 GREASING MOTOR LC71V00001P1 SE-20 PRESSURE SENSOR ; P1 SIDE OPT. LC52S00019P1
M-9 ROOF WINDOW WIPER MOTOR YN76S00005P1 SE-22 PRESSURE SENSOR ; P1 PUMP LS52S00015P1
LS03Z00021P1 02
GRAPHIC_1D Figure 9
23-12
-
23.3 HARNESS
23.3.1 HARNESS LIST
DIVISION DRAWING No. HARNESS
ASSEMBLY No. DRAWING No. REMARKS

POSITION ITEM NAME CODE No. NAME
SE. ASIA OCEANIA SE. ASIA OCEANIA
3.2 INSTRUMENT PANEL ASSY YN17M00053F1 YN17M00054F1

3.3 CONTROLLER INSTALL (ENGINE) YN22E00220F1
CONTROLLER INSTALL YN22E00219F1
3.4 RADIO INSTALLATION YN54E00008F1 YN54E00017F1
3.5 UPPER ELEC ASSY LS03E00001F1
3.6 UPPER HARNESS ASSY LS13E00020F1 1 HARNESS LS13E01082P2 UPPER
2 HARNESS LS13E01097P1 ECU HARNESS

UPPER FRAME
3 CABLE LE13E01006P1 FLOOR TO UPPER FRAME GROUND
4 CABLE LS13E01151P1 STARTER
5 CABLE LS13E01052P1 BATTERY TO RELAY
6 CABLE LS13E01087P1 ENGINE GROUND
7 CABLE LS13E01091P1 BATTERY TO GROUND
8 CABLE LS13E01110P1 BATTERY TO BATTERY
9 CABLE LC13E01180P2 GLOW RELAY TO STARTER RELAY
3.7 ENGINE HARNESS ASSY LS16E00008F1 1 HARNESS LS16E01013P2 ENGINE SUB
3.8 UPPER HARNESS ASSY LS13E00023F1 1 HARNESS LS13E01092P3 FLOOR
(FLOOR PLATE) 4 HARNESS LC13E01186P1 CAB SUB
8 CABLE LE13E01005P1 FLOOR GROUND

3.9 CAB HARNESS LC14E00023F1 1 HARNESS YN14E01102P4 CAB
CAB
6 HARNESS YN14E01106P1
BOOM 3.10 BOOM HARNESS ASSY LS15E00001F1 1 HARNESS LS15E01001D1 BOOM LIGHT
LIGHT
3.11 BOOM LIGHT INSTALL LC80E00004F1 BOOM LIGHT

3.12 DECK LIGHT INSTALL LS80E00004F1 DECK LIGHT
ALARM 3.13 TRAVEL ALARM ASSY LS53E00002F1
NOTE: The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-13
- -
23.3.2 INSTRUMENT PANEL ASSY
TIGHTENING TORQUE :
YN17M00053F1 (12) SE. Asia 1.5N.m (1.1lbf.ft)
INSTRUMENT PANEL ASSY TIGHTENING TORQUE : SEMS BOLT TIGHTENING TORQUE :
YN17M00054F1 (12) Oceania
5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS 2 PLACES INSTALL TO CAB
TAPPING SCREW
3-2 POTENTIO METER YN52S00032P1 1 TAPPING
SEMS BOLT DUCT ASSY SCREW
3-10 KEY SWITCH YN50S00026F1 1 K250 2 PLACES
TIGHTENING TORQUE : TAPPING SCREW
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2.8N m (2.1lbf.ft)
. TIGHTENING TORQUE :
5.2N.m (3.8lbf.ft)
5-2 HOUR METER YT58S00006P1 1
SECTION BB SECTION DD SECTION EE
10 GAUGE CLUSTER YN59S00021F3 1
46-3 SPEAKER YN54S00050P1 2
TIGHTENING TORQUE : TIGHTENING TORQUE :
TIGHTENING TORQUE : 5.0N.m (3.7lbf.ft) 8.5N.m (6.3lbf.ft)
TIGHTENING TORQUE : 5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT TO CAB
INSTALL SEMS BOLT
INSTALL SEMS TO CAB
TIGHTENING TORQUE : TO CAB
4.1N.m (3.0lbf.ft) BOLT TO CAB
2 PLACES
SEMS BOLT
TIGHTENING TORQUE :
4.1N.m (3.0lbf.ft)
TIGHTENING TORQUE : TIGHTENING TORQUE :

23.5N.m (17.3lbf.ft) 5.0N.m (3.7lbf.ft)
3 PLACES
SEMS BOLT
SECTION AA
VIEW
SEMS BOLT
TIGHTENING TORQUE :
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE :
TIGHTENING TORQUE : 0.43N.m (0.32lbf.ft) TIGHTENING TORQUE :
TIGHTENING TORQUE :
TIGHTENING TORQUE :
. .
8.5N m (6.3lbf ft) 8 PLACES 5.0N.m (3.7lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE :
4 PLACES
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT TAPPING SCREW
SEMS BOLT TIGHTENING TORQUE : INSTALL SEMS BOLT
SEMS BOLT . . TO CAB
12.0N m (8.9lbf ft)
INSTALL
SEMS BOLT
TO CAB
SEMS BOLT
4 PLACES
TIGHTENING TORQUE :
5.0N.m (3.7lbf.ft)
SECTION CC
TIGHTENING TORQUE :
5.2N.m (3.8lbf.ft) SEMS BOLT VIEW
INSTALL TAPPING SCREW TIGHTENING TORQUE :
TO A/C 5.0N.m (3.7lbf.ft)
23-14
- -
23.3.3 CONTROLLER INSTALL 23.3.4 TUNER INSTALL
23-15
-
ELECTRIC SYSTEM
23.3.5 UPPER ELECTRIC ASSY (1/2)
NO. ITEM DESCRIPTION QTY

1 Relay, Battery 1
2 Horn 1
3 Horn 1
4 Sems-bolt Torque: 10.7± 1.1 Nm (7.9 ± 0.8 pound-ft) 6
5 Sems-bolt Torque: 15.2 ± 2 Nm (11.2 ± 1.4 pound-ft) 2
6 Bracket 1
7 Washer 2
8 Nut Torque: 17.5 ± 0.5 Nm (12.9 ± 0.37 pound-ft) 2
9 Cover 1
10 Sems-bolt Torque: 11.7 Nm (8.6 pound-ft) Max. 2
11 Weather strip 1
12 Grommet 1
13 E-6 Horn low
14 E-5 Horn high
15 Battery relay box
Connect as shown so as to avoid short circuits on
16 Connector 2
power source line
Set the ground terminal between the hone stay and
17 Connector 2
the sems-bolt (4)
18 Upper harness
23-16
-
UPPER ELECTRIC ASSY (1/2)
13
14
16
17
4
17
16
3
15
18
12
23-17
-
ELECTRIC SYSTEM
NO. ITEM DESCRIPTION QTY

1 Relay, Battery 1
2 Horn 1
3 Horn 1
4 Sems-bolt Torque: 10.7± 1.1 Nm (7.9 ± 0.8 pound-ft) 6
5 Sems-bolt Torque: 15.2 ± 2 Nm (11.2 ± 1.4 pound-ft) 2
6 Bracket 1
7 Washer 2
8 Nut Torque: 17.5 ± 0.5 Nm (12.9 ± 0.37 pound-ft) 2
9 Cover 1
10 Sems-bolt Torque: 11.7 Nm (8.6 pound-ft) Max. 2
11 Weather strip 1
12 Grommet 1
13 E-6 Horn low
14 E-5 Horn high
15 Battery relay box
Connect as shown so as to avoid short circuits on
16 Connector 2
power source line
Set the ground terminal between the hone stay and
17 Connector 2
the sems-bolt (4)
18 Upper harness
19 Air heater relay
20 Starter relay
21 B terminal
22 C terminal
23-18
-
19
6
5 20
8 7 21
22
11
10 9
23-19
-
ELECTRIC SYSTEM
23.3.6 UPPER HARNESS ASSEMBLY (1/7)
ITEM DESCRIPTION ITEM DESCRIPTION

1 Harness Upper 59 C Terminal Starter motor
2 Harness ECU 60 To swing pressure sensor
3 Cable Floor ground 61 To alternator
4 Cable Starter 62 To radiator coolant lever switch
To swing flasher left and rear working
5 Cable Battery relay 63
light
7 Cable Ground 64 Receiver Dryer
8 Cable Battery 65 To air filter restriction switch
13 Plate 66 Battery Relay Box
14 Clip 67 To cab
Torque: 10.7 ± 1.1 Nm Floor Ground
32 Sems-bolt 68
(7.9 ± 0.8 pound-ft) Cable
Torque:38.2 ± 3.8 Nm
33 Sems-bolt 69 To ATT harness
(28.2 ± 2.8 pound-ft)
43 E-6 Horn low 70 Upper harness
44 E-5 Horn high 71 To ATT harness
45 SE-15 Fuel sensor 72 To air filter restriction switch
46 L-2 Frame working light: right 73 To receiver dryer
47 SV-13 Selector solenoid (opt) 74 To radiator cool and level switch
48 SE-29 Pressure sensor- selector detection 75 To engine
Independent travel proportional To swing flasher left and rear working
49 PSV-N P2 76
solenoid light
Independent travel proportional
50 PSV-M P1 77 Cable Starter
solenoid
51 Solenoid To solenoid block 78 Cable Battery relay
52 SE-23 Pressure sensor: pump P2 79 To battery relay box
To detail of fuse & relay box
53 PVS-P2: P2 Pump P2 proportional solenoid 80
connection
54 SE-22 Pressure sensor: pump P1 81 ECU Harness
55 PVS-P1: P1 Pump P1 proportional solenoid 82 Upper Harness
To independent travel proportional
56 To travel alarm 83
solenoid
57 SE-13 Engine revolution sensor 84 To frame working light: right
58 B terminal Starter motor 85 To starter motor
23-20
-
UPPER HARNESS ASSY (1/7)
45 46 47 48 49 50 51 52 53 54
43
55
44 56
57
59
58
1
5
7
60
8
61
69
4
62
84
14 13
33 14
68
85
14 2 67
14 66 65 64 63
14
72
71
73
74 76 83
32
3
82 81 14 79 77
80 78 75
23-21
-
ELECTRIC SYSTEM
UPPER HARNESS ASSEMBLY (2/7)

9 Cable Air heater relay- Starter relay 98 Battery Relay
Connect this terminal with batter
10 Bracket 99
cable
14 Clip 100 Harness
Battery Relay
16 Clip 101
Cable
19 Clip 102 To center section
23 Clip 103 Upper Harness
31 Sems-bolt Torque: 104 To alternator
Torque: 10.7 ± 1.1 Nm
32 Sems-bolt 105 To starter motor
(7.9 ± 0.8 pound-ft)
33 Sems-bolt Torque: 106 ECU Harness
36 Trim 107 To ATT harness
39 Bracket 108 Upper Harness
40 Sems-bolt Torque 109 Fix connector to the bracket
86 Air Heater Relay 110 To battery relay box
Connect to 2P connector for harness
87 111 Starter Cable
of attached air heater relay
Torque: 3.92 - 6.86 Nm
88 F Terminal 112 Upper Harness
(2.4 - 5.1 pound-feet)
Torque: 3.92 - 6.86 Nm
89 S Terminal 113 Frame working light: right
90 Connect the White taping harness 114 Fuel sensor
91 Connect the Red taping harness 115 Connect A harness with A cap
Torque: 3.2 - 4.4 Nm
92 C Terminal 117 To horn
93 B Terminal 118 Upper frame
94 Starter Relay
Adjust the lock of the fuse box cover
95
to the upper side
Connect this terminal with the starter
96
cable
97 Starter Cable
23-22
-
86 88 89 108
90
87 109
9
93
16 14
94 19 33
111
92
36 91 19 33
39 40
95 33 38 112
10 31 98
16 14
14 16
14
96 99 110
97
16
113 14 14 14 16
32
118
107
14 115 114
102
14
116
14
103 14 14
117
14
14
104
106
105 14
23-23
-
ELECTRIC SYSTEM
UPPER HARNESS (3/7)

6 Cable Engine earth cable 127 To swing pressure sensor
11 Bracket 128 Starter motor
12 Bracket 129 Starter cable
14 Clip 130 Fix connector to bracket
16 Clip 131 B Terminal
(2.4 - 3.2 pound-ft)
18 Clip 132 L & R Terminal
19 Clip 133 Alternator
20 Clip 134 To upper frame
22 Clip 135 Nut (use existing)
(2.4 - 3.2 pound-ft)
26 Sems-bolt 136 SV-13 (Opt) Selector solenoid
(2.6 - 4.0 pound-ft)
27 Washer 137 SE-29 Pressure sensor: Selector detection
28 Washer 138 To frame working light: right
29 Washer 139 Starter cable
30 Sems-bolt 140 To upper harness
(2.4 - 3.2 pound-ft)
Torque: 25.5 ± 2.5 Nm
31 Sems-bolt 141 B Terminal
(18.8 ± 1.9 pound-ft)
Torque: 10.7 ± 1.1 Nm
32 Sems-bolt 142 C Terminal
(7.9 ± 0.8 pound-ft)
Torque: 38.2 ± 3.8 Nm
33 Sems-bolt 143 ECU harness
(28.2 ± 2.8 pound-ft)
Torque: 10.7 ± 1.1 Nm Engine earth
34 Nut 144
(7.9 ± 0.8 pound-ft) harness
Torque: 16 - 22 Nm Fix a connector by engine harness
35 Nut 145
(11.8 - 16.2 pound-ft) attachment, clip on bracket
38 Clip 146 Use the clip at attached engine
Engine accessories
41 Clip 147
harness
119 To alternator 148 To Starter motor
120 Air heater 149 Starter Cable
121 Upper harness 150 Fix a connector on bracket
122 ECU harness 151 Engine earth Cable
Engine Revolution Engine Accessory
123 152
harness harness
124 Upper harness 153 Upper harness
Engine sub
125 To pump 154
harness
126 To Solenoid block 155 ECU harness
23-24
-
152
151
119 131
132 28 34
22 27 30
32
18 32
120 150
133
33 19 31 153
6 155
135 134
14
35 41 14
16
121 122 11 149
19
154 33
123 14 148 147
32 146
19
19 32 32
145
124 12
33 144
129
141
125 128
140 29 35
14
38 33
26 32 20 143
142
136
14 19 33 139
126 138
127 137 14
23-25
-
ELECTRIC SYSTEM
UPPER HARNESS (4/7)
ITEM DESCRIPTION
14 Clip
16 Clip
18 Clip
19 Clip
33 Sems-bolt Torque: 38.2 ± 3.8 Nm (28.2 ± 2.8 pound-ft)
155 PSV-P1: P1 Pump P1 Proportional solenoid
156 SE-23 Pressure sensor pump P2
157 PSV-P2: P2 Pump P2 proportional solenoid
158 Side of engine
159 SW-8 Air filter restriction plate
160 To battery relay
161 L-3 Swing flasher left & rear working light
162 To travel alarm
163 SE-22 Pressure sensor: pump P1
164 SW-27 Radiator coolant level switch
165 To swing flasher left & rear working light
166 Fix a harness to air conditioner hose
167 E-10 Receiver dryer
168 SW-77 Oil filter restriction switch
169 L-4 Swing flasher right & rear working light
170 E-13 Travel alarm (opt)
23-26
-
155 158 14 16
19 33 16 14
157
16 14
19 33
16 14
14
162 169 170
33 18
33 18
19 33 14
18
156 33
163 168
14
164
14
159 14 14
14 14 16
161 14
16 14
14 16
167
166
16 14
165
14 16
14
16 14
160
23-27
-
ELECTRIC SYSTEM
NO. ITEM DESCRIPTION NO. ITEM DESCRIPTION

14 Clip 190 Fix the PCV fuse to the bracket
15 Clip 191 C-8 Engine controller
16 Clip 192 Cab sub harness
Connect 1P connector with CNT-e
21 Clip 193
tag of cab sub harness
24 Grommet 194 Floor harness
25 Grommet 195 ECU harness
Torque: 5.0 ± 0.5 Nm
26 Sems-bolt 196 Upper harness
(3.7 ± 0.4 pound -ft)
Torque: 10.7 ± 1.1 Nm
Upper harness
32 Sems-bolt (7.9 ± 0.8 pound-ft) 197
earth
Tighten in six places
37 Bracket 198 ECU harness earth
ECU upper
171 E-33 PCV fuse 199
harness earth
Connect a connector with CNT-1 tag Engine controller
172 200
to floor harness check connector
Connect a connector with CNT-5 tag
173 201 R-34 PCV PCV relay- (engine part)
of ECU harness
Connect a connector with CN4-1tag
174 202 Radiator coolant level controller
of item 1:harness
Connect a connector with CN5 tag of
175 203 Flasher relay
item 2:harness
CNT-2 connect A connector w/ CNT-
176 E-1 Fuse & relay box 204
2 tag to floor harness
Connect a connector with CN1 tag of Connect with blue connector to Accel
177 205
item 1: harness redundant volume
Connect a connector with CN4-2 tag
178 206 C-1 Mechatro Controller
of item 1:harness
179 16p 16P connector 207 E-1 Fuse and relay box
180 28P 28P connector
184 C-8 Engine controller
34P connector: CN-1F with CN-1F
185 34P
tag
35P (A) connector: CN-2F with
186 35P (A)
CN-2F tag
187 32P
tag
35P (B) connector: CN-4F with Cn-4f
188 35P (B)
tag
189 31P
tag
23-28
-
171 207
206
190
14 205
191
26
21 37
14 16 204
172
192
173
15
193
203
15
194 15
174 175
176
198
199 202
25
32
14
16
178 177 195 197 201
184
196 26
14
200
24
185 186 187 188 189
179 180 181 182 183
23-29
-
ELECTRIC SYSTEM
ITEM DESCRIPTION
14 Clip
16 Clip
19 Clip
33 Sems-bolt Torque: 38.2 ± 3.8 Nm (28.2 ± 2.8 pound-ft)
208 SV-4 Operating lever lock solenoid
209 SV-1 Swing parking brake solenoid
210 SV-3 Two speed select solenoid
211 SV-2 Power boost solenoid
212 PSV-B P2 bypass cut proportional solenoid
213 PSV-C Travel priority proportional solenoid
214 PSV-D P1 bypass cut proportional solenoid
215 SV-31 Travel priority unload solenoid
216 PSV-A Arm two speed proportional solenoid
217 PSV-M: P1 P1 independent travel proportional solenoid
218 Connect the connector with PSV-N tag to the solenoid in front side of machine
219 PSV-N P2 independent travel proportional solenoid
220 SE-5 Pressure sensor: Swing
221 To solenoid block
222 C-1 Mechatro controller
223 Fix upper harness ECU harness to the floor harness with clip
224 Fix white taping position of upper harness and ECU harness to the floor harness with clip
225 Harness
226 Floor Harness
227 ECU Harness
228 To under floor
229 Bundle upper harness, floor harness, ECU harness and cab sub harness.
230 CNT-2 with tag connector, connect to floor harness
231 Connect to rotation parking cancel switch
232 Cab Sub Harness
233 Fuse & Relay Box
234 Clip
235 Harness
23-30
-
211 212 213 214

209 210
208
14
14 16 234
14
216
215 14
235
217
219
218
233
220 222
14 14 16 232
231
223
230
224
229
225
19 33
226
221
227
33 19
228
23-31
-
ELECTRIC SYSTEM
Upper Harness Assembly Diagram (7/7)
ITEM DESCRIPTION
14 Clip
42 Harness
224 E-6 Horn low
225 E-5 Horn high
23-32
- -
14
42
225
224
23-33
- -
23.3.6.1 UPPER HARNESS: LS13E01096P1 (1/5)
23-34
-
23-35
- -
23-36
-
23-37
- -
23-38
-
23.3.6.2 ECU HARNESS (1/2) : LS13E01097P1
23-39
- -
23 - ELECTRIC SYSTEM 23 - ELECTRIC SYSTEM
23.3.6.2 ECU HARNESS (2/2) : LS13E01097P1 23.3.6-3 FLOOR GROUNDING CABLE : LE13E01006P1
100 (3.94")
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
23.3.6-4 STARTER CABLE : LS13E01151P1
3900
70 (12'9.5") 70
(2.76") (2.76")
23.3.6-5 BATTERY RELAY CABLE : LS13E01152P1
2000
(6'6.7")
40
(1.59")
GRAPHIC_1D Figure 29 GRAPHIC_1D Figure 32
23-40
- -
23.3.6-6 ENGINE GROUNDING CABLE : LS13E01087P1 23.3.6.9 RELAY CABLE : LC13E01180P2
180 (7.10")
GRAPHIC_1D Figure 33 GRAPHIC_1D Figure 36
23.3.6-7 BATTERY GROUNDING CABLE : LS13E01091P1
440 (17.3")
40
(1.57")
23.3.6-8 BATTERY CABLE : LS13E01110P1
270 (10.6")
50 50
(1.97") (1.97")
23-41
- -
23.3.7 ENGINE HARNESS ASSY
ENGINE HARNESS ASSY LS16E00008F1 (02)

TIGHTENING TORQUE :
ITEM PART NAME PART No. Q'TY REMARKS 25.5N.m (18.8 lbf.ft) SE-13: ENGINE REVOLUTION SENSOR
1 HARNESS LS16E01013P2 1 ENGINE SUB SEMS BOLT
NOTES :
1.UNLESS OTHERWISE SPECIFIED
TIGHTENING TORQUE IS SHOWN BELOW.
SEMS BOLT M12 : 79.4N.m (58.6 lbf.ft)
TIGHTENING TORQUE : M10 : 46.1N.m (34.0 lbf.ft)
25.5N.m (18.8 lbf.ft) M8 : 23.5N.m (17.3 lbf.ft)
FIX WHITE TAPING POSITION.
UPPER HARNESS
1
DETAIL aa
TO AIR-COMPRESSOR
SEMS BOLT
CLIP
TIGHTENING TORQUE : 25.5N.m (18.8 lbf.ft)
SW-7: ENGINE OIL PRESS SW.

TO UPPER HARNESS
FRONT SIDE
OF MACHINE
FIX A WOVEN BRAID PART OF
TIGHTENING HARNESS ON ENGINE OIL
TORQUE : PRESS. SW. BY CLIP.
25.5N.m (18.8 lbf.ft)
TO AIR-COMPRESSOR
SEMS BOLT
CLIP
SEMS BOLT DETAIL bb
CLIP
TIGHTENING TORQUE : FIX A HEARER HOSE AND AIR-CON.
38.2N.m (28.2 lbf.ft) ACCESSORY HARNESS BY CLIP OF INI.
SEMS BOLT
FIX A HEATER HOSE AND
AIR-CON ACCESSORY
HARNESS BY CLIP NEAR CLIP
THE BRED.

TIGHTENING TORQUE : VIEW I
25.5N.m (18.8 lbf.ft)
CLIP
INSTALL WELD NUT OF ENGINE MOUNT.
CONNECT AIR-CON
ACCESSORY HARNESS CLIP
SW-7: ENGINE OIL PRESS SW. WITH ENGINE SUB HARNESS. TOGETHER INSTALL CLIP
BY BOLT OF AIR COMPRESSOR.
CONNECT TO UPPER HARNESS
CLIP DETAIL OF AIR COMPRESSOR
FIX A WOVEN BRAID PART OF HARNESS ON ENGINE OIL PRESS. SW. BY CLIP.
23-42
-
23.3.7.1 ENGINE SUB-HARNESS : LS16E01013P2
SW-7 :
ENGINE OIL PRESS. SW.
WHITE TAPING
TO UPPER HARNESS E-11 :

AIR-COMPRESSOR
WHITE TAPING WHITE TAPING WHITE TAPING WHITE TAPING
23-43
-
ELECTRIC SYSTEM
23.3.8 UPPER HARNESS ASSEMBLY (FLOOR PLATE) (1/2)
ITEM DESCRIPTION
2 Clip
3 Clip
7 Clip
11 SE-16 Acceleration potentiometer
12 E-1 Fuse and relay
13 SW-1 Key switch
14 Cab Harness
SW-10 Horn switch left (blue taping)
SW-21 Power boost switch left (opt) (Yellow)
15
SW-33 Revolution right switch (opt)
SW-34 Revolution left switch (opt)
16 SW-11 Lever lock switch
17 E-7 Tuner
SW-20 Power boost switch right (yellow)
SW-29 Nibbler open switch (opt)
18
SW-30 Nibbler close switch (opt)
SW-5 Horn Switch right (opt) (Blue taping)
19 SE-8 Pressure sensor arm out
20 SE-7 Pressure sensor arm in
21 SE-4 Pressure sensor boom lowering
22 SE-3 Pressure sensor boom raising
23 SE-2 Pressure sensor bucket dump
24 SE-1 Pressure sensor bucket digging
23-44
-
Upper Harness Assembly (Floor Plate) Diagram (1/2)
12
11
13
2 3
13
14
24
23
22
3 2 21
19
20
2 3
15
3 2
16
3 2
2
3 2 2 3
2 2 3
17
3 2
7 2 3
GRAPHIC_1D
23-45
-
ELECTRIC SYSTEM
UPPER HARNESS ASSEMBLY (FLOOR PLATE) (2/2)
ITEM DESCRIPTION
1 Harness
2 Clip
3 Clip
4 Harness
5 Lock Washer
6 Nut
7 Clip
9 Cable
10 Washer
12 E-1 Fuse and relay box
25 34P Connector
26 22P Connector
27 28P Connector
28 22P Connector
29 C-8 Engine Controller
30 C-1 Mechatro controller
31 E-22 DC-DC converter
32 SE-11 Pressure sensor: P2 (opt)
33 SE-9 Pressure sensor: travel right
34 SE-10 Pressure sensor: travel left
35 SE-20 Pressure sensor: P1 (opt)
36 Connector Connect CNT-4 tag of harness with CNT-4 Tag of cab harness
37 Connector Connect to cab harness
38 Connector Connect to right instrument panel
39 Connector To under floor
40 Connector Connect CNT-1tag connector with ECU harness
41 Connector Connect CNT-3 tag of connector with upper harness
42 Connector To left instrument panel
43 Connector To IT controller panel
44 Connector Connect to DC-DC converter
45 Connector Connect the CNT-2 tag of connector with upper harness
46 Connector Connect to rotation parking cancel switch
47 Connector Connect to rotation parking cancel switch
48 Connector Connect to CNT-2 tag of connector with upper harness
49 Connector Connect connector with CN3-1 tag of item 4: harness
54 Connector Connect with ground cable of upper frame
55 Connector To pressure sensor multi-washer motor
56 To under floor
23-46
-
UPPER HARNESS ASSEMBLY (FLOOR PLATE) DIAGRAM (2/2)
35 2 55
2
12
30 10 6
45 5
54
29
46 4
9
34
2
4 33
36 31 32
37
12
2
44 2
38 1
39 53 52
30
7 2
40 41 3 4
43
47
25 26 27 28
48
1 49
50 51
56
23-47
- -
23.3.8-1 FLOOR HARNESS (1/3) : LS13E01092P3
23-48
-
23-49
- -
23-50
-
23.3.8-4 CAB SUB-HARNESS : LC13E01186P1
TO HARNESS (UPPER)
E-1 :
FUSE & RELAY BOX
TO CAB HARNESS
23.3.8-8 FLOOR GROUNDING CABLE : LE13E01005P1
100 (3.94")
1PAF
YAZAKI 7123-3010
23-51
-
ELECTRIC SYSTEM
23.3.9 CAB HARNESS ASSY

1 Harness 27 Coonnect with cab work light
2 Clip 28 Connect to floor harness
3 Clip 29 Connect to cab sub harness
Torque: 4 ± 0.5 Nm
4 Sems-bolt 30 Cab harness
(2.945 ± 0.37 pound-ft)
5 Clip 31 Floor harness
6 Harness 32 Connect to upper harness
7 Floor harness 33 To air conditioner unit
8 C-2 Cluster guage 34 Upper harness
9 E-3 Hour meter 35 E-1 Fuse & relay box
10 M-3 Wiper motor 36 Cab sub harness
11 SW-1 Key switch 37 WR (+) terminal
12 SW-55 Boom deck working light switch 38 B (-) terminal
13 SW-15 Conflux/single select switch 39 To air conditioner
14 SW-35 Heavy lift switch 40 SW-55 Boom deck working light
Connect a blue connector with boom
15 SW-12 Overload alarm select switch 41
deck tag.
Connect a green connector with
16 SW-37 Indepenent travel switch 42
conflux tag
17 E-14 Cigarette lighter 43 SW-15 Conflux/single slect switch
18 E-23 12 Volt socket 44 SW-35 Heavy lift switch
Connect a connector with a heavy
19 E-9 Speaker right 45
tag
Connect a connector with overload
20 Connect with cab work light 46
tag
21 Connect with room light 47 SW-12 Overload alarm select switch
22 Connect with wiper motor 48 Connect a connector with travel tag
23 SW-1 Key switch 49 SW-37 Independent travel switch
24 C-1 Mechatro controller 50 E-14 Cigarette lighter
25 E-8 Speaker left 51 E-14 Cigarette lighter
26 Cab sub harness
23-52
-
CAB HARNESS ASSY
18 35
36
19
23
3 20 24
17 2
21
4 22
3
16
15 25
14
29
13 26 28
5
12 30
27
11
6
7 31
3
8 32
3
33
34
9
42 45 46
41 44 48 51
43 47
10 40 49
50
3 2
39
1
3 3
2
37 38
23-53
- -
23.3.9-1 CAB HARNESS (1/2) : YN14E01102P4
23-54
-
23.3.9-1 CAB HARNESS (2/2) : YN14E01102P4
23-55
- -
23 - ELECTRIC SYSTEM 23 - ELECTRIC SYSTEM
23.3.10 BOOM HARNESS ASSY 23.3.11 INSTALLING BOOM LIGHT
BOOM HARNESS ASSY LS15E00001F1 (04) INSTALLING BOOM LIGHT LC80E00004F1 (04)
ITEM PART NAME PART No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
4 HARNESS LS15E01001D1 1 BOOM LIGHT 1 LIGHT YW80S00001F1 1
FIX WHITE
TAPING
POSITION
1
CLIP
CLAMP TO THE TUBE
FOR GREASE
TO UPPER POINT THIS LAMP TO BUCKET BOTTOM CENTER.

HARNESS INSTALL THE LAMP SO THAT THE LIGHT BEAM POINTS THE
BOTTOM OF BUCKET, IN THE CONDITION THAT AREM IS
EXTENDED FULLY (ARM OUT) AND BUCKET IS CLOSED FULLY.
23.3.10-1 BOOM HARNESS : LS15E01001D1
1
CB104
YAZAKI
CAP : 7120-1010
TERMINAL : 7115-1050-02
TIGHTENING TORQUE : 18.6N.m

1300 (4'3.2")
(13.7 lbf.ft)
1 PAM
WHITE TAPING 1300
(4'3.2")
SECTION AA
1300 (4'3.2")
CB104
YAZAKI GRAPHIC_1D Figure 50

CAP : 7120-1010 3900
YAZAKI
TERMINAL : 7115-1050-02 (12'9.5")
SEPARATE HOUSING : 7122-2215
AT SPLICE TERMINAL : 7114-2020
23-56
-
THIS PAGE IS BLANK FOR EDITING CONVENIENCE
23-57
-
ELECTRIC SYSTEM
23.3.12 INSTALLING UPPER LIGHT
ITEM DESCRIPTION
1 E-13 Alarm assy
M8 Torque: 23.5 ±2.4 Nm (17.3 ± 1.75 pound-ft)
2 Sems-bolt M10 Torque: 46.1 ± 4.6 Nm (34 ± 3.4 pound-ft)
M12 Torque: 79.4 ± 7.9 Nm (58.5 ± 5.9 pound-ft)
3 Plate
4 Harness
5 Relay
6 Clip
Right console
7
box
8 Connect with main tube of Alarm and fix after bundled
23-58
-
INSTALLING UPPER LIGHT
6
3
7 1 2
8
6
4
23-59
-
ELECTRIC SYSTEM
23.3.13 TRAVEL ALARM ASSY
ITEM DESCRIPTION
1 Nut Torque: 18.6 ± 1.0 Nm (13.7 ± 0.7 pound-ft)
2 Upper harness
3 Light
23-60
-
TRAVEL ALARM ASSY
23-61
-
ELECTRIC SYSTEM
NOTES
23-62
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS .........................................................................................24-3

24.1.1 HYDRAULIC PUMP • REGULATOR ......................................................................24-3
24.1.2 CONTROL VALVE..................................................................................................24-23
24.1.3 PILOT VALVE (ATT)...............................................................................................24-57
24.1.4 PILOT VALVE (TRAVEL) .......................................................................................24-61
24.1.5 SWING MOTOR UNIT............................................................................................24-63
24.1.6 TRAVEL MOTOR ...................................................................................................24-71
24
24.1.7 SWIVEL JOINT.......................................................................................................24-85
24.1.8 CYLINDER..............................................................................................................24-87
24.2 ELECTRIC EQUIPMENT.................................................................................................24-93
24.2.1 ELECTRIC EQUIPMENT LIST ...............................................................................24-93
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS...................................................24-96
24-1

SK460-8: LS10-02001~ S5LS2411E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
24-2
24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP • REGULATOR
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
a5 a5 4-M16
a2 PS2 EYE BOLT (M12) PS2 Depth 24
Dr1 Dr1
Z a2
D1 a3 Dr2 D1 a3
Dr2 B1
Z A3 A3
PSV2
A2 B1
a7
a7
A2
X X
A1 PB Do
A1
a6 PSV1
a6
SECTON X-X
(Water outlet)
PS1 a1
2 1-M10 Depth 18
a1 PS1 (For attaching bracket)
a4 EYE BOLT M12 a4
12- 11 Through
EYE BOLT M10

5 SECTION Z-Z
PSV1,PSV2 4 2-M10 Depth 25

a6,a7 2
A1,A2
Hydraulic ports
3 Code Ports name Ports size-Depth
A1,2 Delivery port SAE 6000psi 1"
PS1(PS2)
a1(a2) B1 Suction port SAE 2500psi 3"
Dr1 Drain port PF3/4-20
a4(a5)
PB
Ps1,Ps2 Side branch port PF1 1/4-24
Do B1 PSV1,PSV2 Serve assist port PF1/4-13
1
a4,a5 Sensor port PF3/8-17
No. Parts Q'ty a1,a2,a6,a7 Gauge port PF1/4-15
1 Main pump assy 1 D1,Do Oil filling port, Outlet port PF3/4-20
2 Regulator assy 2 PB Gauge port Rc1/8
3 Gear pump assy (for pilot) 1 A3 Gear pump delivery port PF1/2-19
4 Solenoid proportional reducing valve 2 a3 Gear pump gauge port PF1/4-14
5 PTO unit (For Oceania) 1 Dr2 Gear pump drain port PF3/8-15
Fig. 24-1 Hydraulic pump • regulator
24-3
(2) Hydraulic circuit diagram

(DRIVE) (DRIVEN)
(KDRDE5K) (KR3D-YTOK-HV) PSV1 a1 A1 a4 a2 A2 a5 PSV2 (KR3D-YTOK-HV) (KDRDE5K)
Soleroid proportional Soleroid proportional

reducing valve PSV-1 reducing valve PSV-2
Regulator
a6 a7
PB
PTO Gear case Regulator
(For Oceania) PS2
D1
Dr1
Main pump
PS1 Do B1 Dr2
A3 B3 Gear pump for pilot
Fig. 24-2 Hydraulic circuit diagram of pump

(3) Specifications
Item Main pump Gear pump

SE. Asia Oceania
Pump assy LS10V00016F1
LS10V00014F1
(With PTO unit)
Parts No.
Single pump LS10V00017F1 LS10V00018F1
Pump model K5V200DPH1KLR-YT0K-HV ZX15LDLZ2-07G
Max. displacement capacity cm3 200X2 15
Revolution Rated min-1 1850
(Clockwise seen from shaft end)
Rated 31.4 (4553)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 34.3 (4980)
Max. flow L/min (gal/min) 370 (98)X2 at 7.8MPa (1130 psi) 27.8 (7.3)
Max. input horse power kW (PS) 235.4 (320) 2.85 (3.9)
Max. input torque N m (lbt ft) 1153 (850) 14.7 (10.8)
Part No. LS10V01006F1
Model KR3D-YT0K-HV
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control
Others With solenoid proportional reducing valve(KDRDE5K-31/30C50-123)
Weight kg (lbs) 240 (529) 260 (573)
(Include the Gear pump)
24-4
24-5
24.1.1.2 HYDRAULIC PUMP
24.1.1.2.1 CONSTRUCTION
(1) Main pump
Apply adhesive (No.1305 N of Threebond MAKE)

702 732
534 792 532 531 157 789 901 535 491 493 807 954 412
548 981 885

406 983
214
806
953 X
536
889
405
A A
724 262
888 409
156
886 153 709
251 491
491 490 212 211 152 728 469 151 141 752 410
492
Tightening torque
Tightening torque
Item number Thread size
N m (lbf
405 M8 34 (25) 543 545
406,408 M12 98 (72)
410,411,412 M22 630 (465)
409 M10 57 (42) 725 724
466 PF 1 1/4 270 (199) 541
467 PF 1/4 36 (27)
468 M18X1.5 64 (47)
469 PF 3/4 170 (125) 887
490,492 NPTF1/16 8.8 (6.5) 726
491 Rc 1/8 12 (8.9)
493 Rc 1/4 22 (16)
531,532 M30X2 480 (354)
806,807 M20 240 (177) SECTION X-X SECTION B-B
24-6
Identification groove on Valve plate for Frange socket (5-M10X1.5)

outer surface of outer ring. 469 469 c. clockwise rotation 466 Tightening torque
408 824 828 128 123 728 113 728 271 490 314 729 124 : 33 N m (24.3 lbf.ft)
171
127
823
192
191
711
827 B B
774 04
Apply (sealub L101)
to the oil seal surface
circumferential.
130
111
830
124,125
261
312
825
313 Valve plate for clockwise rotation.
126
752 122 824 411
129
889 468,731 467,725
128
733
SECTION A-A
05
ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty
111 Drive shaft 1 214 Tilting bushing 2 493 Plug 2 774 Oil seal 1
113 Driven shaft 1 251 Swash plate support 2 531 Tilting pin ; M30X2 2 789 Backup ring ; P21 2
122 Roller bearing 1 261 Front cover 1 532 Servo piston ; M30X2 2 792 Backup ring ; G40 2
123 Roller bearing 1 262 Cover 1 534 Stopper (L) 2 806 Nut : M20 2
124 Needle bearing 2 271 Pump casing 1 535 Stopper (S) 2 807 Nut ; M20 2
125 Inner ring 1 312 Valve cover 1 536 Servo cover 2 823 Snap ring 1
126 Spacer 2 313 Valve plate (R) 1 541 Seat 2 824 Snap ring 3
127 Spacer 1 314 Valve plate (L) 1 543 Stopper 1 2 825 Snap ring 2
128 Bearing spacer 3 405 Socket bolt 8 545 Steel ball 2 827 Snap ring 1
129 Bearing spacer 2 406 Socket bolt ; M12X35 8 548 Feed back pin 2 828 Snap ring 2
130 Booster 7 408 Socket bolt ; M12X55 11 702 O-ring ; 1B G40 2 830 Snap ring 1
141 Cylinder block 2 409 Socket bolt ; M10X16 2 709 O-ring ; 1B G85 1 885 Valve plate pin 2
151 Piston 18 410 Socket bolt ; M22X60 9 711 O-ring ; 1B G95 1 886 Spring pin 4
152 Shoe 18 411 Socket bolt ; M22X95 2 724 O-ring ; 1B P8 9 887 Pin 1
153 Retainer plate 2 412 Socket bolt ; M22X180 1 725 O-ring ; 1B P11 2 888 Pin 2
156 Spherical bushing 2 466 RO Plug ; PF1 1/4 2 726 O-ring ; 1B P10 2 889 Pin 4
157 Cylinder spring 18 467 ROH Plug ; PF1/4 2 728 O-ring ; 1B P24 3 901 Eye bolt ; M12 2
171 Front casing 1 468 Adapter 2 729 O-ring ; 1B P38 2 953 Set screw 2
191 Drive gear 1 469 ROH Plug ; PF3/4 3 731 O-ring ; 1B P16 2 954 Set screw 2
192 Driven gear 1 490 Plug 20 732 O-ring; 1B P21 2 04 Gear pump 1
211 Shoe plate 2 491 Plug 12 733 O-ring; 1B G170 1 05 PTO unit 1
212 Swash plate 2 492 Restrictor 4 752 Seat packing 2
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-7
(2) Gear pump (For pilot)
728
700 353 351 433

354 468
434
311
312
361
732 Delivery port
PF1/2
Drain port PF3/8 307 310 308 309 434 466 355 850 Tightening
709 435 Tightening torque; 887
725 torque ; 53N.m
34N.m (25.1lbf.ft) (39.1lbf.ft)
SECTION Y-Y
Tightening torque
Tightening torque
N m (lbf ft)
312 M14X1.5 29 (21)
433,434 M8 17 (12.5)
435 M10 33 (24)
466 PF 1/4 16 (12)
468 PF 3/4 74 (55)
No. Parts Q’ty No. Parts Q’ty

307 Poppet 1 434 Flange socket ; M8× 65 2
308 Seat 1 435 Flange socket ; M10× 30 5
309 Ring 1 466 VP plug ; PF1/4 1
310 Spring 1 468 VP plug ; PF3/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14× 1.5 1 709 O-ring ; 1B G160 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 728 O-ring ; 1B P24 1
354 Driven gear 1 732 O-ring ; 1B P16 1
355 Filter 1 850 Locking ring 1
361 Front case 1 887 Pin 2
433 Flange socket ; M8× 50 2
24-8
(3) PTO gear case (For Oceania)
117
128 Z
126
825
128
886
416
711
826
115
118
710
409 901
125
316
Tightening torque Z
709 Tightening torque
SECTIONZ-Z Item number Thread size
N m (lbf
409 M10 57 (42)
326 284 414
414 M16 240 (177)
416 M12 98 (72)

115 Idle shaft 1 414 Socket bolt ; M16× 35 3
117 2nd gear 1 416 Socket bolt ; M12× 35 8
118 3rd gear 1 709 O-ring ; 1B G85 1
125 Ball bearing 2 710 O-ring ; 1B G170 1
126 Roller bearing 1 711 O-ring ; 1B G30 1
128 Bearing spacer 3 825 Snap ring 1
284 Bearing case 1 826 Snap ring 1
316 Cover 1 886 Pin 2
326 Gear case 1 901 Eye bolt ; M10 1
409 Socket bolt ; M10× 16 2
24-9
24.1.1.2.2 OPERATION
(See the sectional drawings of pump on 24-6, 24-7)
The pump assembly is constructed with two pumps
which are arranged parallel, and the two pumps are
connected via drive gear (191) and driven gear
(192). The rotating power of engine is transmitted to
the driven shaft (113) via drive shaft (111), drive
gear (191) and driven gear (192) and the two
pumps are driven by this rotating power.
Furthermore this pump has the construction that
can attach pilot gear pump to rear end of driven
gear (113), 4th pump to rear end of drive gear (111),
and 5th pump to PTO gear casing via drive gear
(191).
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the
swash plate group that changes the delivery rate;
the valve cover group that selects between oil
suction and delivery; and the PTO group that
transmits the drive power to 5th pump.
(1) Rotary group
The rotary group consists of drive shaft (111),
cylinder block (141), piston shoe (151, 152),
retainer plate (153), spherical bearing (156),
bearing spacer (126, 127, 128, and 129), drive gear
(191), driven gear (192) and cylinder spring (157),
etc. The shaft is supported by bearings (123) and
(124) at its both ends. The shoe (152), which is
caulked to the piston (151), forms a spherical joint
and relieves it of thrust force that is generated by
load pressure. Further, the piston is provided with a
pocket so it moves lightly on shoe plate (211),
taking hydraulic balance.
The sub group of the piston shoe (151, 152) is
pressed against the shoe plate (211) by the cylinder
spring (157), via the retainer plate (153) and the
spherical bushing (156), so that it moves smoothly
over the shoe plate (211). The cylinder block (141)
is also pressed against valve plate (313, 314) by
the action of cylinder spring (157).
24-10
(2) Swash plate group

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
tilting bushing (214), tilting pin (531), and servo
piston (532). The swash plate (212) is the
cylindrical part that is formed on the opposite side
of the shoe sliding surface and is supported by the
swash plate support. The hydraulic force controlled
by the regulator flows into the hydraulic chamber
that is provided on both sides of the servo piston
(532). This moves the servo piston (532) to the right
and left. The result is that the swash plate (212)
swings on the swash plate support (251) via the
spherical part of the tilting pin and changes the
tilting angle ( ).
(3) Valve cover group
The valve cover group consists of valve cover D
(312), valve plates (313 or 314), and valve plate pin
(885). The valve plates having two crescent-
shaped ports are installed to valve cover (312) to
feed oil and recycle it from cylinder block (141). The
oil switched over by the valve plate (313, 314) is
connected to the external pipe via the valve cover
(312).
(4) PTO group (For Oceania)
The PTO group is composed of 2nd gear and 3rd
gear. This PTO group rotates each gear to drive 5th
pump.
Now, if the drive shaft (111) is driven by the engine,
the cylinder block (141) rotates together by the
spline linkage.
Similarly, driven shaft (113) and cylinder block (141)
rotate via drive gear (191) and cylinder block (141).
If the swash plate (212) is inclined, the piston-sub
(151, 152) arranged in the cylinder block (141)
make reciprocating motion with respect to the
cylinder block (141) while rotating with the cylinder
block (141). If we keep an eye on a single piston-
sub (151, 152), it makes a motion away from the
valve plate (313,314) (oil suction process) in the
first 180 degree and a motion toward the valve plate
(313, 314) (oil delivery process) in the remaining
180 degree. If the swash plate is not inclined (zero
tilting angle ( ), the piston-sub (151, 152) does not
stroke i.e. delivers no oil.
The driven shaft (113) rotation is transmitted to the
pilot gear pump (04) via spline. Similarly, the drive
shaft (111) rotation is transmitted to the 4th pump
via spline, and is transmitted to the 5th pump via
drive gear. Consequently, these rotations of gear
train drive pilot gear pump (04), 4th pump, and 5th
pump.
24-11
24.1.1.3 REGULATOR

&$! $% !.56 /%
'.#'. /!0

'.#'. /!0
#!$% &'(
!
" - 12 3-34
/!$2 " )" 1- 4"
" )" 1-4"
" )" - 1-4"
" * + " 1-4"
" *+" - 1-4
" ),-" 14"
) 1-4

) 1 4
Fig. 24-4
24-12
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty

412 Socket bolt ; M8X50 2 628 Adjusting screw (C) 1 730 O-ring ; 1B P22 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 732 O-ring ; 1B P16 1
418 Socket bolt ; M5X12 6 630 Lock nut ; M30X1.5 1 733 O-ring ; 1B P20 1
436 Socket bolt ; M6X25 5 631 Sleeve (For PF) 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 641 Pilot cover 1 735 O-ring ; 1B P12.5 1
467 VP plug ; PF1/4 3 642 Spool 1 753 O-ring ; 1B P9 1
496 Plug ; NPTF1/16 18 643 Pilot piston 1 755 O-ring ; 1B P11 7
541 Seat 1 644 Spring seat (Q) 1 756 O-ring ; 1B P26 1
543 Stopper 1 1 645 Adjusting stem (Q) 1 763 O-ring ; 1B G35 1
545 Ball 1 646 Pilot spring 1 801 Nut ; M8 1
601 Casing 1 651 Sleeve 1 802 Nut ; M10 1
611 Feed back lever 1 652 Spool 1 814 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 836 Snap ring 1
613 Lever (2) 1 654 Return spring 1 874 Pin ; 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; 4X8L 2
615 Adjusting plug 1 656 Block cover 1 876 Pin ; 5X8L 2
621 Compensating piston 1 662 Spring 1 887 Pin 1
622 Piston case 1 698 Cover 1 897 Pin ; 5X19L 1
623 Compensating rod 1 708 O-ring ; 1B G75 1 898 Pin ; 11.5X11.8L 1
624 Spring seat (C) 1 722 O-ring ; 1B P6 3 924 Socket screw ; M8X20 1
625 Outer spring 1 724 O-ring ; 1B P8 8 041 Sub-check valve 2
626 Inner spring 1 725 O-ring ; 1B P10 1 079 Solenoid proportional reducing valve 1
627 Adjusting stem (C) 1 728 O-ring ; 1B P18 1
The codes in a rectangle represent adjust screws.
Do not tamper with the adjust screws as much as possible.
24-13
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
•Total horsepower control.
Emergency mode control.
•Hydraulic positive control.
•Hydraulic total horsepower control
(2) Summary
The regulator KR3D-YTOK for the in-line type axial piston pump K5V series is composed of the control
mechanism as mentioned below:
1) Electric flow control: At normal operation
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value (I) of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate (Q) as the current command value (I) rises. When inputting
the current according to required flow rate for work, by this function, the pump delivers only the necessary oil
flow, the machine does not consume excessive power.
2) Horse power control (+power shift control) : at emergency mode (at current fail)
In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift
pressure Pf (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power
control section of regulator on each pump through pump inside passage and shifts respective control to the
same power set value.
In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is
automatically reduced; consequently the input torque is controlled to the constant value or less. (When the
rotation is constant, the input power is also constant.)
This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is
controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in
the condition where the power is controlled, the overloading of engine is automatically prevented regardless
of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power
control is not worked.
With this mechanism, it is possible to obtain proper power for the working condition.
This regulator is made up of the above two kinds of control system, but when both controls are actuated
together, the low tilt angle (low flow rate) command precede on mechanical operation described later.
(3) Explanation of operation

1) Flow rate electrical control
The pump delivery rate is controlled according to
Delivery flow rate Q
the command current value corresponding to the

movement of control devices. This relation is
shown in right figure.
Command current I
Fig. 24-5
24-14
a. Flow rate increase (See Fig. 24-6)

As the command current value I rises, the CL port :
Connect with large
secondary pressure P2 of electromagnetic diameter chamber of
servo piston
proportional pressure-reducing valve rises, and 652
by pressing pilot piston (643) in (A) direction it 646
stops at the position the secondary pressure P2 B 613
balances the pilot spring force (646). The D 876 F 897
movement of pilot piston is transferred to lever 2 875
611
(613) through pin (875), and rotates at (B) A
643
fulcrum in arrow direction. Furthermore the lever C
2 movement is transferred to feedback lever
(611) through pin (897) and rotates at (C) fulcrum E 532
Psv A
in the same arrow direction as (B). Consequently (KDRDE5K)
the spool (652) connected to feedback lever
moves towards (D). When the spool moves
towards (D), the port CL connected to tank port
is open and the pressure in servo piston large
bore diameter chamber is released,
consequently the servo piston (532) moves
towards (E) according to delivery pressure Pd1
in small bore diameter piston chamber, resulting Pd1
in the rise of flow rate. Since the feed back lever CL port
is connected to the servo piston and spool, the a3
feed back lever rotates at (F) fulcrums with the Hydraulic circuit diagram
B
movement of the servo piston towards (E),
consequently the spool is returned to the original Fig. 24-6
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
24-15
b. Flow rate decrease (See Fig. 24-7)

As the command current value I is reduced, the

secondary pressure P2 of electromagnetic

proportional pressure-reducing valve is reduced, #
and by pressing pilot piston (643) in (G) direction
it stops at the position the pilot spring force (646) !
balances the secondary pressure P2. The %
movement of pilot piston is transferred to lever 2
(613) through pin (875), and rotates at (H)
fulcrum in arrow direction. Furthermore the lever
$
2 movement is transferred to feedback lever "

(611) through pin (897) and rotates at (I) fulcrum
in the same arrow direction as (H). Consequently (")*)+", - .
the spool (652) connected to the feedback lever

moves towards (J). When the spool moves
towards (J), the delivery pressure Pd1 is led in
servo piston large bore diameter chamber
through spool and port CL. The servo piston
small bore diameter chamber constantly
receives delivery the pressure Pd1,
consequently the servo piston moves towards -
(K) according to the difference of area resulting

in the reduction of tilt angle, and finally the flow
rate is reduced. Since the feed back lever is !&' '
connected to servo piston and spool, the feed /
back lever rotates at (L) fulcrum with the Fig. 24-7

movement of servo piston towards (K),
consequently the spool is returned to the original
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
2) Power control (In emergency mode)
When the load pressure rises, the pump tilt angle
is reduced preventing the overloading of engine
as shown in Fig. 24-8.

The operation of power control is the same as
the flow rate control, and is explained below.
Delivery output (Pd1)

Fig. 24-8
24-16
a. Overload prevention operation (See Fig. 24-9)

Because the delivery pressure Pd1 acts on the

compensating rod stepped section with the rise

of self pump delivery pressure Pd1 the %
compensating rod (623) is pushed towards (M),
and moves to the position the delivery pressure "
!
Pd1 balances the spring force of outer spring
' $
(625) and inner spring (626). The movement of (
compensating rod is transferred to lever 1 (612)

through pin (875), and rotates at (N) fulcrum in
&
arrow direction. Furthermore the lever 1 (612)
#
movement is transferred to feedback lever (611) (
through pin (897) and rotates at (O) fulcrum in +,--.,/ ' 0
the same arrow direction as (N). Consequently
the spool (652) connected with feedback lever
moves towards (P). When the spool moves
towards (P), the delivery pressure Pd1 is led in
servo piston large bore diameter chamber
through spool and CL port. Since the delivery
pressure Pd1 is constantly led to servo piston
large bore diameter chamber, the servo piston '
moves towards (Q) according to the difference of

(
area, resulting in the reduction of tilt angle,
consequently the flow rate is also reduced. Since ")* *
1
the feed back lever is connected with servo
piston and spool, the feed back lever rotates at Fig. 24-9
(R) fulcrum with the movement of the servo
piston towards (Q), consequently the spool is
returned to the original position. With this
movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
24-17
b. Flow rate recovery operation (See Fig. 24-10) 625

897 876
Because the compensating rod (623) is pushed X 612 626
CL port : T S
towards (S) with the force of outer spring (625) Connect with large
diameter chamber of
and inner spring (626) with reduction of self servo piston G
pump delivery pressure Pd1, and moves to the 652
position the spring force of outer spring (625) H
and inner spring (626) balances the delivery
V J 875
pressure Pd1. The movement of compensating
623
rod is transferred to lever 1 (612) through pin 621
611
(875), and rotates at (T) fulcrum in arrow
direction. U
W
Furthermore the lever 1 (612) movement is
532
transferred to feedback lever (611) through pin (KDRDE5K) Psv A
(897) and rotates at (T) fulcrum in the same
arrow direction as (N). Consequently the spool
(652) connected to feedback lever moves
towards (V).
As the spool moves towards (V), CL port is open
and connected to tank port, the pressure of servo
piston large bore diameter chamber is released
and the servo piston (532) moves towards (W) Pd1
with delivery pressure Pd1 in small bore CL port
diameter chamber, and consequently the flow a3
rate is raised. Since the feed back lever is Hydraulic circuit daigram
B
connected to servo piston and spool, the feed
back lever rotates at (X) fulcrum with the Fig. 24-10
movement of the servo piston towards (W),
consequently the spool is returned to the original
position.
With this movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
3) Priority mechanism of low tilt angle (low flow
rate) command
As the said explanation, the tilting commands of
flow rate control and power control are
transferred to feedback lever (611) and spool
(652) through the large bore section of lever 1
(612) and lever 2 (613), but because the pin (dia
5) is extruded in large bore (dia 9), pin (897) on
the side where making tilt angle smaller contacts
with it, consequently the bore (dia 9) of lever on
the side where larger tilt angle command is given
is free without contact with pin (897). In this
mechanical selecting manner, the command on
the side of low tilt angle of the flow rate control
and power control has a priority.
24-18
4) Power shift control

As shown in Fig. 24-11, the pump set power is
controlled according to the movement of control

by power shift pressure Pf.
As power pressure Pf rises, the compensating
rod (623) moves rightward through pin (898) and
compensating piston (621). Consequently like
the overloading prevention operation of power
control, the pump tilt angle becomes smaller and
the power setting value is reduced. Conversely,
if the power shift pressure Pf is reduced, the Delivery pressure (Pd1)
power set value is raised. Fig. 24-11
The power shift pressure Pf of this pump is
ordinary set to 0MPa, but in emergency mode,
the power shift pressure Pf is raised to 4.9MPa.
24.1.1.3.3 ADJUSTING THE REGULATOR

The regulator may be adjusted in terms of maximum
flow, minimum flow, horsepower (at emergency mode
control) control characteristics, flow control
characteristics using the adjust screw.
(1) Adjusting the maximum flow (See Fig. 24-3)
Adjust the maximum flow by loosening nut (806)
and by tightening set screw (953) (or loosening it).
Tightening set screw (953) decreases the delivery

rate, as indicated in Fig. 24-12.
Only the maximum flow varies, but other control
characteristics remain unchanged.
Adjust screw no. 953

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change Input current I (Pilot pressure Pi)
Min. increase in delivery flow L/min 7.1 Fig. 24-12 Adjusting the max. delivery flow
(2) Adjusting the minimum flow (See Fig. 24-3)

Adjust the minimum flow by loosening nut (807) and
by tightening socket screw (954) (or loosening it).
Tightening socket screw increases the delivery

rate, as indicated in Fig. 24-13.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care
should be used of the fact that overtightening may
increase a required power at the maximum delivery
pressure (at relieving action).
Input current I (Pilot pressure Pi)
Fig. 24-13 Adjusting the min. delivery flow
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 7.1
24-19
(3) Adjusting the input horsepower

(At emergency mode)
Since the regulator is of total horsepower control
type, turn the adjust screws of both the drive (No.1)
and driven (No.2) pumps when changing
horsepower set values. Adjust the horsepower
settings of both pumps to a same level. The
pressure change values by adjustment are based
on two pumps pressurized at the same time, and
the values will by halved when only one pump is
loaded.
1) Adjusting the Outer Spring (See Fig. 24-4)
(At emergency mode)
Adjust it by loosening lock nut (630) and by

tightening adjust screw (628) (or loosening it).
Tightening the adjust screw shifts the control
chart to the right and increases the input
horsepower, as indicated in Fig. 24-14.
Since turning the adjust screw C (628) by N turns
changes the setting of the inner spring (626),
return the adjust screw C (627) by NX1.44 turns
at first. Delivery pressure (Pd1)
Fig. 24-14 Adjusting the input horsepower (1)
Increase delivery pressure MPa 1.88
Increase in input torque N.m 99.6
2) Adjusting the Inner Spring (See Fig. 24-4)

Adjust it by loosening nut (802) and by adjust
screw (C) (627) (or loosening it). Tightening the
adjust screw increases the flow and then the

input horsepower, as indicated in Fig. 24-15. And
the input torque raises.

Increase inflow L/min 21
Delivery pressre (Pd1)
Increase in input torque N.m 123.7
Fig. 24-15 Adjusting the input horsepower (2)
(4) Adjusting the flow control characteristics (See Fig.
24-4)
Adjust them by loosening nut (801) and socket bolt
(924) (or loosening it). Socket bolt causes the

control chart to move to the right as shown in Fig.
24-16.

Increase Pilot pressure MPa 0.18
Input current I (Pilot pressure Pi)
Decrease in delivery flow L/min 31.6
Fig. 24-16 Adjusting the flow control
characteristics
24-20
24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble
and inspect it referring to "Chapter YN33-II"
(1) When the engine is overloaded,
Load every unit of pump, and check on pumps on
the drive and driven 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) Stick of compensating piston (621) and
compensating rod (623)
• Disassemble and clean it.
4) Stick of pin (898)
(2) The max. flow rate is not delivered.
1) Check that pilot differential pressure Pi is normal.
2) Stick of pilot piston (643)
3) Stick of spool (652)
4) Stick of pin (898)
Note : When the damage of part is severe, replace the
part with new one.
24-21
24.1.1.4 CONTROL CURVE OF PUMP
500
[1] 247kW E/G horse power
[2] 198kW : At emergency mode Reference value in ( )
Input revolution ; 1850 min-1 Two pumps are loaded at the same time
Input horse power ; 247 kW Pf:Power shift pressure (Reference value)
Input torque ; 1275 N.m
12.2MPa 700mA
400 367L 370L
Q 1850min-1 Pd=7.8MPa at Qmax
[a]
Delivery flow rate Q [ L/min ]
[2] [1]
349L
[b]
300 2942
200 1961
22.9MPa
186L 34.3MPa
122L
100 981
400mA
Input torque
50L
Tin N m
Min.Flow(at 1850min-1)
Tin
0 5 10 15 20 25 30 35 40[MPa]
Delivery pressure Pd
0 1 2 3 4 [MPa]
Pilot pressure Pi
24-22
24.1.2 CONTROL VALVE
24.1.2.1 SPECIFICATIONS
(1) Outside view and hydraulic ports
3-M16X2 DEPTH 29
TAP FOR LIFTING BOLT ( MARK)
4-M20X2.5 DEPTH 26
FOR ATTACHING MACHINE ( MARK)
VIEW A
Fig. 24-17 Control valve outside view and hydraulic port
24-23
Port Tightening torque Port

Group Description
size N.m (lbf.ft) name
P1 Pump P1 port
P2 Pump P2 port
4A2 Bucket digging port
4B2 Bucket dump port
32 (M14) 147 (110) 4A3 Boom up side port
4B3 Boom down side port
5A3 Option 1 port
Flange port
5B3 Option 1 port

5A5 Arm out port
5B5 Arm in port
4A1 Travel left forward port
4B1 Travel left reverse port
5A1 Travel right reverse port
26 (M12) 98.1 (72)
5B1 Travel right forward port
5A2 Swing right port
5B2 Swing left port
R1 Tank port
50 (M12) 98.1 (72)
R2 Tank port
4PC1 Boom down lock valve release pilot port
4PC2 P1 bypass cut select port
4PC3 Bucket (H) stroke limiter pilot port
5pc1 Arm in lock valve release pilot port
5pc2 P2 bypass cut valve select port
5pc3 Lock valve pilot port for swing priority
a Arm 2 spool select command port at arm in
PF1/4 36.3 (27)
b Sequence pilot secondary pressure port at arm in
c Arm variable recirculation cut command port at arm in
dr1 Drain port
O-ring port
dr4 Drain port

dr5 Drain port
Pc ATT power boost pressure port
4pa1~4 Travel left, Bucket, Boom 1, Arm 2 pilot port
4pb1~4 Travel left, Bucket, Boom 1, Arm 2 pilot port
PZ1 Travel straight pilot port
dr Drain port
PF3/8 73.5 (54)
PZ2 Unload valve pilot port
5pa1~5 Travel right, Swing, OPT1, Boom 2, Arm 1 pilot port
5pb1~5 Travel right, Swing, OPT1, Boom 2, Arm 1 pilot port
dr3 Drain port
RS1 Swing motor 1 boost circuit port
G1 255 (190) Swing motor 2 boost circuit port
RS2
(2) Specifications
ITEM SPECIFICATIONS
Part no. LS30V00009F1
Model UY36-114
Rated flow 370× 2 L/min (98× 2 gal/min)
31.4 MPa at 380L/min (4550 psi at 100gal/min)
Main relief valve set pressure
When power boost
34.3 MPa at 340L/min (4980 psi at 90gal/min)
Overload relief valve set pressure
Boom H, Bucket H, Arm R 36.3 MPa at 30L/min (5260 psi at 7.9gal/min)
Boom R, Bucket R, Arm H 34.8 MPa at 30L/min (5050 psi at 7.9gal/min)
24-24
24.1.2.2 CONSTRUCTION
(1) Control valve
87
14 75
76
88
89
Over load relief valve

[BM-1,BKT]
67,63
Center by pass valve
[OPT Conflax]
Plug
Lood holding valve pirot 49 50

79,92 70
106 51,52
90,91,92 142
47
93,41
Check valve
102
98
95 97 { Poppet
Spring
99
52 81
Main relief valve
Fig. 24-18 Construction of control valve (Bucket side valve)
24-25
Main plunger 1
65,66 66 Housing
5 4 14
83
15
Cover [BKT] Cover [BM-1] Plug
65,66
16
17
21 16 Cover
Cover
20
111
112
18
Socket bolt 18
Socket bolt
16
Socket bolt O-ring O-ring
Washer
19 70
O-ring Cover
49 85 8 7 6 79,92
Socket bolt
47 51,52 Washer
86
Check valve
[BM-],BKT]
Check valve
[AM-2]
24-26
59 59
O-ring 61 Flange O-ring
(1 place) (1 place) 61
60 60
O-ring O-ring
(6 places) (6 places)
O-ring
(4 places) O-ring
(4 places)
19 19
O-ring O-ring
(2 places) (3 places)
(SW side mating surface) (BKT side mating surface)
Fig. 24-19 Construction of control valve (Manifold assy)
24-27
62,63
(9 Places)
Socket bolt 63,64
(5 Places) 56
Washer 3 65,66
Socket bolt 55
Washer
57
BM Boost check
BKT Conflux check
OPT Conflux check
Manifold
24-28
121,122
123,124
125
126
127
137,138 128,129
136 130
135 131
134 132
133
Center bypass valve Priority valve

[BKT Conflux]
71,72 63,67
Plug
Load holding valve pilot

106
90,91,92 142
Flange
Socket bolt
93,41 Washer
102
98
95 97 Poppet
99
Spring
Fig. 24-20 Construction of control valve (Swing side valve)
24-29
Main plunger
2
15 11 10 Housing
plug
17
Cover 21
Cover
18 18
Socket bolt Socket bolt
16 16
O-ring O-ring
53,54
7 13 12
37
44,46
Plug for over load relief hole
[SW, OPT, BM-2]
140 75-BM-H,BKT-H,AM-R Check valve

139 60 76-BM-R,BKT-R,AM-H [SW, OPT, BM-2]
Over load relief valve

[SW, OPT, BM-2]
24-30
Tightening Tightening
torque No. NAME Q’ty REMARK torque No. NAME Q’ty REMARK
N•m (lbf•ft) N•m (lbf•ft)
1 HOUSING 1 36 SPRING 1
OVERLOAD
2 HOUSING 1 37 PLUG 2 RELIEF HOLE
3 MANIFOLD 1 38 CHECK 1
4 PLUNGER ; AM-2 1 Include 22,32~35 39 SPRING 3
5 PLUNGER ; BM-1 1 Include 23,32~35,38~43 40 SPACER 3
6 PLUNGER ; BUCKET 1 Include 32~35 41 O-RING 7 1B P18
7 PLUNGER ; TRAVEL L&R 2 Include 32~35 42 BACKUP RING 3
8 PLUNGER ; TRAVEL STRAIGHT 1 Include 26,32~34,36 78.4 (58) 43 CAP 3
9 — 44 BACKUP RING 2
10 PLUNGER ; AM-1 1 Include 28,32~35,39~43,45 45 CHECK 2
11 PLUNGER ; BM-2 Include 29,32~35 46 O-RING 2 1B P20
12 PLUNGER ; OPT-1 1 47 CHECK 10
13 PLUNGER ; SWING 1 48 SPRING 2
14 O-RING 4 1B P36 49 SPRING 10
245 (180) 15 CAP 2 343 (250) 50 CAP 7
16 O-RING 20 51 BACKUP RING 9
17 COVER 10 52 O-RING 13 1B P31
98.1 (72) 18 SOCKET BOLT 40 M12× 30 53 O-RING 2 1B P29
19 O-RING 8 54 CAP 2
20 COVER 1 55 O-RING 2
21 COVER 8 56 FLANGE 2
22 PLUNGER ; AM-2 1 98.1 (72) 57 SOCKET BOLT 8 M12× 25
23 PLUNGER ; BM-1 1 58 —
24 PLUNGER ; BUCKET 1 59 O-RING 2 1B P10
25 PLUNGER ; TRAVEL L&R 2 60 O-RING 18 1B P29
26 PLUNGER ; TRAVEL STRAIGHT 1 61 O-RING 8 1B G45
27 — 245 (180) 62 SOCKET BOLT 9 M16× 90
28 PLUNGER ; AM-1 1 63 WASHER CD 26 M16
29 PLUNGER ; BM-2 1 245 (180) 64 SOCKET BOLT 5 M16× 45
30 PLUNGER ; OPT-1 1 29.4 (22) 65 CAP 5
31 PLUNGER ; SWING 1 66 O-RING 8 1B P11
98.1 (72) 32 CAP 10 245 (180) 67 SOCKET BOLT 12 M16× 100
33 SPRING GUIDE 20 147 (110) 68 CAP 1 Include 69
34 SLEEVE 10 69 O-RING 1 1B P24
35 SPRING 1 70 COVER 1
24-31
torque No. NAME Q’ty REMARK torque No. NAME Q’ty REMARK
147 (110) 71 CAP 2 107 FLANGE 1
72 O-RING 3 1B P22.4 98.1 (72) 108 SOCKET BOLT 4 M12× 40
73 — 109 WASHER CD 4 M12
74 — 110 O-RING 1
78.5 (58) 75 OVERLOAD RELIEF ASSY 3 Include 60,139,140 111 COVER 1
78.5 (58) 76 OVERLOAD RELIEF ASSY 3 Include 60,139,140 112 PISTON 1
77 — 113 BACKUP RING 3
78 FLANGE 2 114 O-RING 2 1B P25
147 (110) 79 SOCKET BOLT 12 M14× 45 115 SLEEVE 1
80 O-RING 2 78.5 (58) 116 CAP 1
98.1 (72) 81 MAIN RELIEF ASSY 1 Include 52 117 POPPET 1
343 (250) 82 CAP 1 118 SPRING 1
78.5 (58) 83 PLUG 1 119 —
84 — 24.5 (18) 120 CAP 1
343 (250) 85 CAP 1 121 CAP 1
86 CAP 1 122 O-RING 1 1B P8
245 (180) 87 CAP 2 123 COVER 1
88 SPRING 2 177 (130) 124 SOCKET BOLT 4 M14× 80
89 CENTER BYPASS SPOOL 2 125 PISTON 1
90 COVER 2 LOAD HOLDING VALVE 126 SPRING 1
177 (130) 91 SOCKET BOLT 8 M14× 40 127 PLATE 1
92 WASHER 12 M14 128 BACKUP RING 1
93 CAP 4 129 O-RING 1 1B G30
94 — 130 SPRING 1
95 O-RING 2 1B P10 131 SPRING GUIDE 1
96 — 132 SLEEVE 1
97 O-RING 2 1B G45 133 POPPET 1
98 POPPET 2 LOAD HOLDING VALVE 134 CHECK 1
99 SPRING 2 135 SPRING 1
100 SLEEVE 2 34.3 (25) 136 CAP 1
101 POPPET 2 LOAD HOLDING VALVE 137 O-RING 1
102 SPRING 2 138 BACKUP RING 1
103 BACKUP RING 2 139 BACKUP RING 6
104 O-RING 2 1B P12.5 140 O-RING 6 1B P20
105 BACKUP RING 2 141 SPRING 6
106 PISTON 2 LOAD HOLDING VALVE 142 POPPET 2
24-32
(2) Detail of parts

1) Main plunger
Plunger
Plunger
Plunger
Travel straight
No. NAME Q’ty No. NAME Q’ty

1 PLUNGER 1 8 O-RING 1
2 SPRING GUIDE 2 9 SPACER 1
3 SLEEVE 1 10 SPRING 1
4 SPRING 1 11 CHECK 1
5 PLUNGER CAP 1 12 CAP 1
6 CAP 1 13 O-RING 1
7 BACKUP RING 1
1. BM-1, Travel switch spool : The overall lengths of spools differ from other spools.
2. Only the plungers AM-1, 2 and BM-1 equip check valve on one side end.
3. The return springs differ by the type of plunger.
24-33
2) Cover section (BM-1 Whipl-stop)
No. NAME Q’ty

1 COVER 1
2 PLUG 1
3 O-RING 1
3) Cover section (BKT Stroke limitter)
No. NAME Q’ty

1 COVER 1
2 PISTON 1
3 CAP 1
4 O-RING 1
4) Over load relief valve (AM-1, BM-1, BKT)
No. NAME Q’ty

1 RELIEF SLEEVE 1
2 PILOT POPPET 1
3 O-RING 1
4 CAP 1
5 NUT 1
6 ADJUST SCREW 1
7 O-RING 1
8 SPRING 1
9 SPRING 1
10 BACKUP RING 2
11 O-RING 1
12 SPRING 1
13 MAIN POPPET 1
14 O-RING 1
15 BACKUP RING 1
16 PISTON 1
17 O-RING 1
24-34
5) Center bypass valve (OPT Conflux, for BKT Conflux)
No. NAME Q’ty

1 SPRING 1
2 O-RING 1
3 CAP 1
4 SPOOL 1
6) Load holding valve pilot section (AM-1, BM-1)
VIEW Z

1 SOCKET BOLT 4 9 BACKUP RING 1
2 WASHER 4 10 O-RING 1
3 COVER 1 11 O-RING 1
4 CAP 2 12 BACKUP RING 1
5 O-RING 2 13 POPPET 1
6 O-RING 1 14 SLEEVE 1
7 O-RING 1 15 SPRING 1
8 PISTON 1
24-35
7) Main relief valve
No. NAME Q’ty

1 SLEEVE 1
2 NUT 1
3 CAP 1
4 O-RING 1
5 O-RING 1
6 BACKUP RING 1
7 O-RING 1
8 MAIN POPPET 1
9 SLEEVE 1
10 ADJUST SCREW 1
11 NUT 1
12 O-RING 1
13 PISTON 1
14 O-RING 1
15 SPRING 1
16 PILOT SEAT 1
17 PILOT POPPET 1
18 SPRING 1
8) Check valve (BKT, BM-1, -2, SW, OPT, etc)
No. NAME Q’ty

1 CAP 1
2 BACKUP RING 1
3 O-RING 1
4 CHECK 1
5 SPRING 1
9) Check valve (AM-2)
No. NAME Q’ty

1 CAP 1
2 BACKUP RING 1
3 O-RING 1
4 CHECK 1
5 SPRING 1
6 CHECK 1
24-36
10) Priority valve
No. NAME Q’ty

1 SOCKET BOLT 4
2 COVER 1
3 CAP 1
4 O-RING 1
5 PISTON 1
6 SPRING 1
7 PLATE 1
8 BACKUP RING 1
9 O-RING 1
10 O-RING 1
11 BACKUP RING 1
12 CAP 1
13 SPRING 1
14 POPPET 1
15 CHECK 1
16 SPRING GUIDE 1
17 SLEEVE 1
18 SPRING 1
11) Over load relief hole plug (OPT)
No. NAME Q’ty

1 CAP 1
2 O-RING 1
3 PLUG 1
4 BACKUP RING 1
5 O-RING 1
24-37
12) BKT Conflux check
No. NAME Q’ty

1 CHECK 1
2 SPRING 1
3 O-RING 1
4 BACKUP RING 1
5 SLEEVE 1
6 O-RING 1
7 FLANGE 1
8 SOCKET BOLT 4
9 WASHER 4
13) OPT Conflux check
No. NAME Q’ty

1 CAP 1
2 O-RING 1
3 SPRING 1
4 BACKUP RING 1
5 O-RING 1
6 CHECK 1
14) BM Boost check
No. NAME Q’ty

1 CAP 1
2 O-RING 1
3 SPRING 1
4 POPPET 1
24-38
24-39
24.1.2.3 OPERATION
(1) Travel straight circuit
This circuit is provided to retain the straightness on traveling even if several actuators (Arm, Boom, Bucket,
Swing, Opt.) other than traveling are operated simultaneously with traveling straight.
1) Where traveling straight while operating travel plunger on right and left sides.
When only travel plunger is operated, pilot pressure of travel straight selector valve does not actuate on Pz1
port. Consequently oil from P1 port is fed to left travel and oil from P2 port is fed to right travel to allow driving
them individually for traveling straight.
SINGLE OPERATION OF TRAVEL
24-40
Parallel passage
Parallel passage
Fig. 24-21 Travel straight circuit (1/2)
24-41
2) When swing motion is operated under the above travel straight conditions.
Operate swing plunger, and pilot pressure of travel straight selector valve actuates on Pz1 port.
Consequently the travel straight spool is switched, P1 port is connected to right and left parallel passages,
and P2 port is connected to oil supply passage of plunger for right and left traveling.
Therefore oil from P1 port flows through parallel passage and drives swing motor, and oil from P2 port drives
right and left travel motors to hold it traveling straight.
COMBINED OPERATION
OF TRAVEL AND SWING
24-42
Parallel passage
Parallel passage
Fig. 24-22 Travel straight circuit (2/2)
24-43
(2) Bucket conflux circuit

Bucket digging operation
Oil from P1 port passes through parallel passage and flows into head of cylinder.
Oil from P2 port passes through center bypass and flows into center bypass valve. But bucket switching pilot
pressure presses 5Pc2 port of center bypass valve, and center bypass valve spool cuts off the switching oil
passage. Consequently oil opens bucket conflux check valve placed on the inside of manifold and flows in
bucket oil supply passage, resulting in conflux of oil separately delivered by 2 pumps.
BUCKET : DIGGING OPERATION
24-44
Parallel passage
Center bypass valve
Parallel
passage
Bucket conflux
check valve
Fig. 24-23 Bucket conflux circuit
24-45
(3) Optional conflux circuit

Machines in which optional conflux system is incorporated
Oil from P2 port passes through parallel passage and flows into cylinder port 5A3.
Oil from P1 port passes through center bypass passage and flows into center bypass valve. But since optional
switching pilot pressure presses 4pc2 port of center bypass valve, center bypass valve spool therefore cuts off
the oil passage for switchover.
Consequently oil opens optional conflux check valve placed on the inside of manifold and flows into optional oil
supply passage, resulting in conflux of oil separately delivered by 2 pumps.
Option cunflux
check valve
FOR MACHINE OF OPTIONAL CONFLUX
24-46
Parallel passage
Center
bypass
valve
Parallel
passage
Fig. 24-24 Optional conflux circuit
24-47
(4) Operation of components

1) Main relief valve
a. Where being set to ordinary position, (Low pressure) (Pc pilot signal: OFF)
*Piston D is moved to the right side by spring C force.
a-1. Pressure oil from pump passes through orifice (2) of main poppet A, and flows into chamber (3). Since
d1 is larger than d2 (d1>d2), the main poppet is securely seated.
Pilot poppet B Pilot signal ; OFF
Main poppet A Spring C

Spring D
From pump port
Tank passage
a-2. When the pressure oil reaches to the pressure set by spring C, pilot poppet B opens, consequently oil
passes through side hole (4) and flows into tank passage.
Pilot poppet B
Spring C
Tank passage
a-3. Oil starts flowing to allow to reduce the pressure before and after orifice (2), and when the pressure of
chamber (1) pressure x d2 becomes higher than that of chamber (3) x d1 (chamber (1) pressure x
d2>chamber (3) pressure x d1), main poppet A opens and oil flows into tank passage to control the circuit
pressure to constant value.
Main poppet A
From pump port
Tank passage
24-48
b. Where being set to high pressure (Pc pilot signal: ON)

Piston D moves leftward to allow raising the set pressure of spring C, resulting in high-pressure condition.
Pilot signal ; OFF
Spring C
Piston D
2) Overload relief valve

a. Overload operation
a-1. Pressure oil in cylinder port passes through orifice (2) of piston A, and flows into chamber (3). Since d1
is larger than d2 (d1>d2), the main poppet B is securely seated.
Main poppet B Pilot poppet D
Piston A Spring C
From cylinder port
Circular
passage
Tank passage
a-2. When the pressure oil reaches to the pressure set by spring C, pilot poppet D opens. Consequently oil
passes through side hole (4) and circular passage, and the oil flows into tank oil passage.
Pilot poppet D
Spring C
Circular
passage
Tank passage
24-49
a-3. Oil starts flowing to allow reducing the pressure before and after orifice (2), and piston A moves
rightward to allow seating it to top end of pilot poppet D.
The oil in chamber (1) passes through orifice (5) of pilot poppet D, side hole (4) and circular passage,
and flows into tank passage.
Pilot poppet D
Piston A
From cylinder port
Circular
passage
Tank passage
a-4. The pressure before and after orifice (5) of pilot poppet D is reduced, and when the pressure of chamber
(1) pressure x d2 becomes higher than that of chamber (3) x d1 (Chamber (1) pressure x d2>Chamber
(3) pressure x d1), main poppet B opens and pressure oil in cylinder port flows into tank passage to
protect actuator.
Main poppet B Pilot poppet D
Tank passage
b. Make up operation
Since main poppet B is retained in d1>d2 conditions, cylinder port pressure is generally higher than that
of tank pressure to allow securely seating.
When the pressure of cylinder port lowers to the pressure less than tank pressure (Cylinder port
pressure<tank pressure) (comes closer to negative pressure), main poppet B is opened by receiving the
pressure corresponding to difference of areas of d1 and d2, and oil flows into cylinder port through tank
passage to prevent cavitations.
Main poppet B
To cylinder port
Tank passage
24-50
3) Holding valve
Boom holding valve is taken as example for explanation.
a. Where plunger at neutral position, (4pc1 pilot signal: OFF)
Piston A and poppet B are retained at positions shown in figure, and passage (5) and drain port (dr2) are
blocked by poppet B. And since chamber (1) is connected to chamber (2) through orifice (4), the pressure
is equivalent to pressure Pc.
Consequently since d1 is larger than d2 (d1>d2), poppet C is seated to allow completely blocking
chambers (2) and (3).
Drain port Poppet B
Piston A
Poppet C
Pilot signal port
Boom 1 PL
To cylinder port High pressure

Tank passage supply passage
b. When plunger is operated,

b-1. Boom up (Pv>Pc) (4pc1 Pilot signal: OFF)
Plunger moves rightward and oil in high-pressure oil supply passage flows into chamber (3). Since
chamber (1) is connected to chamber (2) through orifice (4), the pressure is retained to pressure Pc.
Consequently the poppet C is opened by pressure Pv and oil in high-pressure oil supply passage is fed
into cylinder head side.
Drain port Poppet B
Piston A
Poppet C
Pilot signal port
Boom 1 PL
To cylinder port High pressure

Tank passage
supply passage
24-51
b-2. Boom down (Pc>Pv)(4pc1 Pilot signal: ON)

Plunger moves leftward and chamber (3) is connected to tank passage. Then the plunger operating
pressure acts on 4pc1 port. Consequently Piston A moves rightward and poppet B opens to allow
communicating passage (5) to drain port (dr2). And the pressure in chamber (1) decreases, and
pressure Pc acts on the area equivalent to the difference of areas of d1 and d2 to allow being open
poppet C. Consequently the return oil from head side flows into tank passage.
Drain port
Poppet B
Piston A
Poppet C
Pilot signal port
Boom 1 PL
From cylinder port High pressure

Tank passage
supply passage
24-52
4) Priority valve
Swing priority valve provided on arm section
a. Where swing plunger is not operated,
a-1. Where parallel passage pressure Oil supply passage pressure,
Piston (1), poppet (2), and check valve (3) are positioned as shown in the figure and securely seated.
Drain port Pilot port (5pc3)

(dr4)
Piston
Spring A
Spring B
Spring C
Poppet
Check valve
Supply passage
parallel passage
a-2. Where parallel passage pressure>Oil supply passage pressure,

The forces of springs B and C are low, poppet (2) and check valve (3) are lifted, and oil in parallel
passage connected to pump flows through oil supply passage and is fed into arm cylinder.
Spring C Spring B
Poppet
Check valve
Supply passage
parallel passage
24-53
b. When swing plunger is operated,

b-1. Where parallel passage pressure Oil supply passage pressure,
Swing plunger operating pilot pressure acts on pilot port (5pc3), and after the pressure goes up to an
extent of 0.1 to 0.15MPa {14.5 to 22psi} or higher, piston (1) moves to the position shown in figure, and
presses down poppet (2) through spring guide. Check valve (3) is retained at the position C by force of
spring C as shown in figure, and securely seated.
Drain port Pilot port (5pc3)

(dr4)
Piston
Spring A
Spring guide
Spring B
Spring C
Poppet
Check valve
Supply passage
parallel passage
b-2. Where parallel passage pressure>Oil supply passage pressure,

The seat diameter (d1) is larger than poppet diameter (d2), but they are almost equivalent (d1 d2). Pilot
pressure therefore works to press down poppet (2) and the poppet cannot be lifted even if the pressure
is relatively low. Then check valve (3) is lifted and oil flows into arm cylinder through oil supply passage.
But since the flow rate is low due to the restriction of orifice provided on poppet (2), a large part of oil flow
rate delivered by pump is fed to swing motor in preference to others.
Spring guide
Poppet
Check valve
Supply passage
parallel passage
Orifice
24-54
5) Arm recirculation
Arm digging operation
a. AM-1
Plunger moves leftward and center bypass passage is blocked, consequently oil from pump passes
through parallel passage and opens poppet valve A, and is fed to head side of cylinder through high-
pressure oil supply passage.
The return oil from rod side opens the poppet of load holding valve and continues to flow. But all flow opens
the check valve C in plunger and is recirculated into head side because the tank passage is blocked by
sleeve B in manifold.
b. AM-2
Plunger moves leftward and center bypass passage is blocked, consequently oil from pump passes
through center passage and opens check valve D, and is fed to head side of cylinder through high-
pressure oil supply passage.
The return oil from rod side flows to tank passage. But the flow opens the check valve E in plunger and
recirculated into head side because the opening is restricted by plunger and the pressure increases.
Poppet A
Parallel passage
Sleeve B
Check valve C
High pressure supply passage
Center by-pass passage
Tank passage
Check valve D
Check valve E
24-55
6) Boom recirculation
Boom down operation
Plunger moves leftward and center bypass passage is blocked, consequently oil from pump opens check
valve A through parallel passage, and is fed to rod side of cylinder through high-pressure oil supply passage.
The return oil from head side opens the poppet of load holding valve and flows to tank passage through boost
check valve in manifold. But the flow opens the check valve B and recirculated into rod side because the
pressure is increased by boost check valve.
Check valve A
Parallel passage
Check valve B
High pressure supply passage

Boost check valve
Center by-pass passage
Tank passage
24-56
24.1.3 PILOT VALVE (ATT)
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
The adjust nut

(opposing flats : 22) :
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
Part No. YN30V00111F1

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
HYDLAULIC SYMBOL
24-57
Apply Loctite #277

312
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
PORT 2,4 PORT 1,3
Fig. 24-25 Pilot valve (ATT)
torque No. Name Q’ty torque No. Name Q’ty
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
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 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-58
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-26)
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)
Fig. 24-26 Lever in neutral

(2) When the pilot lever is tilted (See Fig. 24-27 )
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 a pressure.

Fig. 24-27 When the lever is tilted
(3) Lever held (See Fig. 24-28)
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, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT
PORT (2,4) PORT (1,3)

Fig. 24-28 When the lever is held
24-59
(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.
24-60
24.1.4 PILOT VALVE (TRAVEL)
24.1.4.1 OUTLINE
(1) 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
(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
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
(3) 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
24-61
24.1.4.2 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 dumper system is made up of plunger (8), orifice (9) and return spring (10).
In stationary condition, the pedal is held in neutral position by return spring (10).
In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for
dumper system.
The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the
operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the
hydraulic 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
24-62
24.1.5 SWING MOTOR UNIT
24.1.5.1 SPECIFICATION
(1) General view
Port Tightening torque

L, AR
Symbol Port name Dr GIN
size N.m (lbf.ft)
A,B Main port PF3/4 162 (119.5)

THREAD FOR
Dr Drain port PF3/8 74 (55) GB
EYE BOLT
2-M12 DEPTH 24
Mu Make-up port PF1 255 (188) B
GA,GB Pressure measuring port PF1/4 29 (21)

P Parking brake release port PF1/4 36 (27)
Gear oil level gauge
L,AR Air breather port PT1/2 65 (48)
GIN Gear oil lubrication port PT3/4 98 (72)

A
Au Air breather port PF1/4 29 (21)
GA
Au
P
Mu
Au Mu GA(GB)
A(B)
AIR BREATHER P
PORT
Au
Dr
GB GA
B Mu A
HYDRAULIC DIAGRAM
* This drawing shows the left use.
24-63
(2) Specifications
Swing motor unit part No. LS15V00023F1, LS15V00024F1

Type MFC160-065A, MFC160-079
Part No. LS15V00018F1, LS15V00019F1
Displacement cm (in ) 151 (9.2)
Hydraulic motor
3 3
Working pressure MPa (psi) 25.0 (3,625)

Max. flow L/min (gal/min) 253 (66.8)
Braking torque N•m (lbf•ft) 685~891 (505~657)
Release pressure MPa (psi) 3.1 (450)
Relief set pressure MPa (psi) 25.2 (3,654)
Weight kg (lbs) 53 (117)
Part No. LS32W00012F1
Speed reduction type Planetary 2-stage
Reduction unit
Reduction ratio 16.81

Lubicate oil Gear oil SAE90 (API class GL-4 grade)
Lubicate oil volume L (gal) 7.0 (1.8)
Grease Extreme pressure lithum base #2 grease
Grease volume kg (lbs) Approx. 1.4 (3.1)
Weight kg (lbs) 222 (490)
Total weight kg (lbs) Approx. 275 (606)
(3) Explanation of construction

1) The rotary group of the swing motor consists of a cylinder (24) which is integral with the drive shaft and nine
piston assy (7) arranged in the cylinder bores. The cylinder (24) is supported by bearings (3) (22) on both
ends.
Each piston assy (7) is guided by a return plate (6) and retaining spring (4) so as to slide smoothly on the
cam plate (5).
The balance plate (21) is forced against the end of the cylinder by the force of the disc spring (18) and the
hydraulic force acting on the bushing (20).
A mechanical brake is installed between the cylinder exterior and the housing (25).
A relief valve to cushion hydraulic shock and a backup valve to prevent cavitation are built in to the cover
(32).
2) The reduction gear system consists of two stage planetary gears. The system decelerates high-speed rotary
motion of the swing motor and coverts it to low-speed large-torque motion in order to rotate the pinion shaft.
Swing unit
Swash plate type Two-stage planetary

axial piston motor gear reduction unit
Mechanical brake
Relife valve
Make-up valve
By-pass valve
24-64
(1) Swing motor
17
41
42
SECTION A-A
15,16
32 33
A PORT SIDE
RELIEF VALVE
A PORT
b 34
g
TOP DEAD POINT h BOTTOM DEAD POINT
i
B PORT
B PORT SIDE
31 RELIEF VALVE
30 a DRAIN PORT
29
28 34 39 38 37 36 35
MAKEUP PORT
16 15
17 18
14 19
13 20
43 b
c 21
12
MECHANICAL BRAKE
11
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
24-65
torque No. Parts Q’ty torque No. Parts Q’ty
1 INNER RING 1 23 SNAP RING 1
2 OIL SEAL 1 24 CYLINDER 1
TAPERED ROLLER
3 1 25 HOUSING 1
BEARING
4 BACKING SPRING 1 26 COLLAR 1
5 CAM PLATE 1 27 SNAP RING 1
6 RETURN PLATE 1 78 (58) 28 BYPASS VALVE ASSY 2
7 PISTON ASSY 9 29 BACK-UP RING 2
8 LINING PLATE 3 30 O-RING ; 1B P18 2
9 PLATE 3 31 O-RING ; 1B P12 2
10 O-RING 1 32 COVER 1
11 PISTON 1 78 (58) 33 RELIFE VALVE ASSY 2
12 O-RING 1 34 O-RING ; 1B P26 4
13 SPRING 19 284 (209) 35 SOCKET BOLT ; M16× 60 4
14 PISTON 2 36 CHECK VALVE 2
29 (22) 15 CAP 3 37 SPRING 2
16 O-RING ; 1B P11 3 137 (101) 38 CAP 2
17 PARALLEL PIN 2 39 BACK-UP RING ; T2 P26 2
18 SCROWAVE 4 40 PLUG 1
19 TEFLON RING 4 41 PISTON 2
20 BUSH 4 42 TEFLON RING 2
21 BALANCE PLATE 1 43 O-RING 1
22 NEEDLE BEARING 1
24-66
(2) Swing reduction unit
Caulk these 2 places

with punch.
R
Be careful about installation
OIL FILLING PORT PT3/4 direction of retaining ring.
Tightening torque LEVEL PORT PT1/2 Be careful about

181 +- 20 N.m (134 +
- 15 lbf.ft) installation direction
Apply Three Bond #1360. of thrust washer. Be careful about
R
installation direction
of spring pin.
Apply Loctite #515. VIEW (II) (4 places)
SURFACE OF
LUBE OIL
Apply Loctite #515.

Drive spring
pin (8) into 1mm
lower than the
R surface of spider.
Be careful about installation Paint this
direction of retaining ring. plane.
Apply Loctite #515.
SECTION A-A
Fill up this space

with grease.
Tightening torque Tightening torque

1 PINION SHAFT 1 13 SPHERICAL BEARING 1
2 #1 SUNGEAR 1 14 OIL SEAL 1
3 #1 PINION 4 15 HOUSING 1
4 SPIDER ASSY 1 16 OIL SEAL 1
5 #2 SUNGEAR 1 17 SLEEVE 1
6 #2 PINION 4 18 THRUST WASHER 8
7 RING GEAR 1 19 THRUST WASHER 8
8 SPIDER 1 20 RETAINING RING 4
9 SHAFT 4 21 RETAINING RING 1
10 NEEDLE BEARING 4 22 SPRING PIN 4
11 NEEDLE BEARING 4 181 (134) 23 CAPSCREW ; M14X150 16
12 SPHERICAL BEARING 1 24 CAP 2
24-67
24.1.5.3 OPERATION
24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR

(1) Swing motor
The pressure oil fed by the pump via the control valve, etc. enters the motor through port A (or port B) installed
on cover (32), and is discharged from port B (or port A).
Also the oil leaking through the sliding section or clearance returns to the tank through drain port Dr installed on
cover (32).
The pressure oil fed to port A goes through passage (b) inside of cover (32) and to the passage on bushing (20)
section installed cover, then is fed to piston bore (f) on the cylinder through balance plate (21) passage (b) which
contains crescent shaped port switching supply and discharge by 180° degree of core rotation of motor, and
cylinder (24) passage (e).
The pressure oil exerts on piston assy (7), then the piston assy is pushed against cam plate (5) through a part
of the shoe. Since the shoe sliding surface of cam plate (5) is inclined at a uniform angle, the pushing force of
piston assy (7) on which pressure oil is exerted is converted into sliding power for the shoe on the swash plate.
In addition, the shoe bulb is similarly joined to universal joint. As a result, the shoe sliding power on the swash
plate is converted into rotating power through piston assy (7) and cylinder assy (24) and transmitted to the motor
output shaft section.
In this way, every piston assy (7) receives the pressure oil within the stroke from top dead point to bottom dead
point on a grade, the oil pressure is converted to rotating power to rotate cylinder assy (24), resulting in
discharging oil in the stroke from bottom dead end and top dead point.
The discharge line function in reverse of the supply line, and the oil is discharged from port B.
As described above, the hydraulic motor is operated, and the output torque of hydraulic motor is determined by
oil pressure, and speed of revolution by supply flow rate.
(2) Parking brake
Friction plate (8) is fitted to the external section of cylinder assy (24) with spline.
Separator plate (9) is fitted to housing (25). When the primary pilot pressure of brake release port is Zero, brake
piston (11) locks the cylinder (24) (output shaft) which is rotated by the force of the spring (12) pushing separator
plate and friction plate.
Conversely, when pressure of 3.2 to 4.9 MPa (464 to 710 psi) exerted on the brake relief port, brake piston power
exceeds the force of spring and strokes to the contact with cover end. Then space is generated between mating
parts, and the mechanical brake released.
16 15 MAKEUP PORT
17 18
14 19
13
20
43 b
c
21
12
11 MECHANICAL BRAKE
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
Fig. 24-29 Operation of swing motor
24-68
(3) Relief valve

1) Starting
With operation of the lever, the oil fed to port A at first escapes and is discharged to port B without obtaining
regular revolution because the force of inertia of the upper structure is larger. The hydraulic oil from port A
to passage (i) of relief valve, opens poppet (44), and is discharged to port B.
2) Braking (Cushion)
By returning the lever to neutral position, the return circuit of motor discharge oil close, and immediately
after this operation, the motor is rotated by the force of inertia resulting in pumping function, and the oil is
sucked from port A and discharged to port B side. Then, since the return circuit of the control valve is closed,
the pressure of port B is raised. The raised pressure of port B opposes the spring (45) force and opens
poppet (44), and check valve (37) through passage (9) (h), and flows into passage (c). The movement stops
while absorbing the force of inertia in this process. In the above-mentioned process of pressure increase,
the oil at port 8 enters the piston (L) chamber past the circumference orifice "j" of poppet (44), through the
small hole of piston (49) to move till it hits the liner (48). In this period, the poppet (44) is already open, so
that the cushion relief action operates first at a little lower pressure, and the pressure rises in a moment to
set pressure. By these two operations, the shocks are absorbed at starting and stopping of swing motor.
43 44 45 46 47 48 49
j
Piston chamber "L"
53 52 51 50
Fig. 24-30 Detail of relief valve (34)
(4) Make-up valve
1) Operation in half lever position
(When cushion relief valve does not function.)
After accelerating slewing of the upper structure, when the speed is being reduced by half-lever with the
function of control valve, the supply flow rate from pump to port A is lowered. But if the upper structure is
slewed at a comparatively high speed, the pressure in the (C) section is lowered to negative pressure making
lubrication necessary. However, when the pressure of port B is equal to or lower than the working pressure
of cushion relief valve the all oil of (C) section led through port B is discharged to the control valve. As a
result, the flow rate from the control valve (Since the valve is in the half-lever position, the flow rate from
pump is limited.) does not satisfy the specified oil quantity. To prevent this, the make-up check valve (42) is
installed to supply necessary oil into the (C) section.
2) Braking
(When cushion relief valve is functioned)
When the lever is moved to neutral position rapidly as described in item 1), the pump does not supply oil to
port A, but the upper structure is slewed by the force of inertia. In this case, the cushion relief valve on port
B side functions, and the oil from relief valve goes through the passage (i) (h) and opens make-up check
(37) valve on the port A side to flow into passage (b) (c). But the oil quantity is insufficient due to the leakage.
Therefore oil opens make-up check valve (37) through the make-up port, and flows into passage (b) (c) to
prevent cavitation.
24-69
24.1.5.3.2 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the rotating RING GEAR (FIXED) PLANETARY SHAFT
speed which is transmitted by the hydraulic motor and
to convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
SPIDER
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear, SUN GEAR
planetary pinion, planetary shaft, spider and ring gear,
as shown in Fig. 24-31.
For the operation of the 1st stage planetary, the

hydraulic motor rotates #1 sun gear (2). Sun gear (2) is
engaged with planetary pinion (3) and rotates, but since PLANETARY PINION
ring gear (7) is fixed, planetary pinion (3) revolves about Fig. 24-31 Planetary mechanism
sun gear (2) with the planetary shaft and spider (4). SWING MOTOR
The role of spider is to hold the planetary pinion and 3 2
planetary shaft and transmits the power from the 7
planetary pinion to the spider through the planetary
shaft. 4
The #1 spider (4) is linked with #2 sun gear (5) by the 5
involute spline, and transmits the power to the 2nd 8
stage planetary mechanism.
For the operation of the 2nd stage planetary, the power
is transmitted to sun gear (5)→planetary pinion (6) 6
→spider (8) similarly to the 1st stage. 13
The #2 spider (8) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with the
HOUSING
swing gear fixed on the undercarriage (lower frame)
and rotates.
BEARING 1
Fig. 24-32 Function of reduction unit
24-70
24.1.6 TRAVEL MOTOR
24.1.6.1 SPECIFICATION
(1) Appearance
PRESSURE MEASUREMENT PORT

2-G (PF)1/4
(MB,MA)
PILOT PORT
G(PF) 1/4 (P)
BEARING CENTER
VALVE PORT
2-G (PF) 1
(VA,VB)
DRAIN PORT
27-M24 2-G (PF)1/2
(D1,D2)
G (PF) 3/4
FILL PORT
LEVEL PORT OIL LEVEL
G (PF) 3/4
DRAIN PORT VIEW Y
Fig. 24-33 Travel motor
Rotation direction
Tightening
Oil inlet Oil outlet Rotation direction Port
Port size torque Function
port port (Viewed from valve port side) name
N•m (lbf•ft)
VA VB Right (Clockwise) P PF1/4 36 (26.6) Pilot (2 speed changeover) port
VB VA Left (counter clockwise) D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement
24-71
(2) SPECIFICATIONS

TRAVEL MOTOR UNIT
Type M4V290 / 170A-RG10T
Part No. LS53D00007F1
Type RG10T
Reduction ratio 60.652
Reduction unit Number of reduction stages 2
Lube oil capacity L (gal) 15.0 (4.0)
Lube oil capacity specification Gear oil SAE90API GL4 or GL5
Weight kg (lbs) —
Type M4V290 / 170A
cc/rev
Max. displacement 290.7 (17.7)
(cu•in/rev)
cc/rev
Min. displacement 170.1 (10.4)
(cu•in/rev)
Relief valve set pressure MPa (psi) 34.3 (4974)
Travel motor
2 peed changeover pilot
MPa (psi) 5.0 (725)
pressure
Parking brake torque N•m (lbf•ft) 902 or more (665)
Parking brake release pressure MPa (psi) Less than 1.54 (223)
Working 0.2 (29)
Allowable drain pressure MPa (psi)
Surge 0.98 (142)
Weight kg (lb) —
Unit weight (with oil) kg (lb) 650 (1433)
24-72
24.1.6.2.1 TRAVEL MOTOR
No. NAME No. NAME No. NAME

1 Casing 21 D-ring (small dia.) 41 G1/8 plug
2 NPT 1/16 plug 22 D-ring (big dia.) 42 O-ring 1B P8
3 Oil seal 23 Rear cover 43 Check valve
4 Retaining ring IRTW68 24 NPT 1/16 plug (MEC) 44 Check valve spring
5 Shifter piston 25 Spool assy (M4V RBV) 45 M6 restrictor (0.6)
6 Piston seal 26 Spring holder (M4V260BV) 46 O-ring 1B P12.5
7 Steel ball 25 27 Spring (M4V150RBV) 47 M8 restrictor (0.8)
8 Shaft 28 M42 plug (M4V260RBV) 48 O-ring 1B P15
9 Bearing HR32209J 29 O-ring 1B G40 49 O-ring 215.57× 2.62
10 Pivot 30 Pilot valve spool dia. ø10 (M4V290) 50 Bearing HR32207C
11 Swash plate 31 Pin (MRC03) 51 Shim
12 Cylinder block 32 Spring holder (MRC03) 52 Parallel pin M68× 12
13 Cylinder spring 33 Spring (MRC03) 53 Valve plate
14 Spring holder 34 G3/8 pilot valve plug 54 Brake spring
15 Ball joint 35 O-ring 1B P14 55 HEX. socket head bolt M18× 50
16 Shoe retainer 36 Connector (MRC03) 56 Overload relief valve ORV-240L
17 Piston assy 37 G1/4 plug 57 Coupling
18 Separating plate 38 O-ring 1B P11 58 Retaining ring C-type 40
19 Friction plate 39 Restrictor (brake valve) 59 G1/2 plug
20 Brake piston 40 Restrictor spring (brake valve) 60 O-ring 1B P18
24-73
24.1.6.2.2 REDUCTION UNIT
Fig. 24-35 Reduction unit

1 Housing 11 Carrier 2 21 Thrust washer 1
2 Bearing 280BA40GS 12 Planetary gear 2 22 Needle bearing FBNP-406040
3 Ring gear 13 Retaining ring 23 Carrier pin 1
HEX. socket head bolt
4 14 Bearing 22213EAE4 24 Spring pin 6× 36
M20× 120
5 Seal cover 15 Carrier pin 2 25 Sun gear 1
6 16 Spring pin 10× 63 26 Thrust plate
M10× 25
7 Floating seal 368 17 Spacer 27 Cover
8 Shim 18 Sun gear 2 28
M12× 30
9 Lock washer 19 Carrier 1 29 Plug G3/4
10 Support ring 20 Planetary gear 1 30 O-ring 1B P24
24-74
24.1.6.3 MAKEUP OF TRAVEL MOTOR

The travel motor consists mainly of the rotary group that generates rotating power, the parking brake that prevents
the machine from moving by itself while it is parked, the variable displacement mechanism that switches over the
motor capacity to the large or small mode, the overload relief valve that is built in the rear cover, and the brake valve
(counterbalance valve) that controls the hydraulic circuits.
(1) Rotary group
Cylinder block (12) is inserted in the gear tooth grooves of the spline of shaft (8) that is supported by bearings
(9, 50) at it both ends. The Cylinder block (12) is pressed against rear cover (23) with valve plate (53) by the
action of spring (13).
9 piston assy (17) slide over shoe plate (11), while stroking in Cylinder block (12).
A bearing retainer is arranged at the end face of piston assy (17) to reduce the sliding resistance. The action of
spring (13) is transmitted to spring retainer (14), ball joint (15), and shoe retainer (16) and presses the end face
of piston assy (17) against shoe plate (11) so the piston assy moves close to the surface of shoe plate (11).
(2) Parking brake

Five separator plates (18) and four friction plates (19) are inserted by turns in the spline grooves in the outer
surface of cylinder block (12) and are pressed against casing (1) by the action of 14 springs (54) via brake piston
(20).
(3) Variable displacement mechanism

The variable displacement mechanism consists of pivot (10) supporting shoe plate (11) that is put in two
semispherical concaves provided in shoe plate tilting piston (5) that tilts shoe plate on pivot (10) tilting stopper
(1-1) supporting the piston at a certain position; the pilot valve that admits the pressurised oil to the tilting piston
(5) by an external command; and three check valves (43) that take out the highest of the external command
activated pilot pressure, the motor inlet pressure and the motor outlet pressure and that sends it to the pilot valve.
(4) Overload relief valve

The overload relief valve consists of socket (56-1) that has valve seat (56-3) metallically seating rear cover (23)
of the motor and screwed up in rear cover (23) valve (56-2) engaged with socket (56-1) that is tangential in
contact with valve seat (56-3) by the action of adjust spring (56-9) connecting piston (56-4) that is inserted in
valve (56-2) and serves also as an oil path to pilot body (56-6) piston (56-7) that is put in pilot body (56-6) and
pressed against plug (56-5) and shim (56-8).
No. NAME No. NAME

56-2 56-9 56-13 56-8 56-10 56-6 56-7 56-1 SOCKET 56-8 SHIM
56-3 56-1 56-12 56-4 56-12 56-11 56-5 56-2 VALVE 56-9 SPRING
56-3 VALVE SEAT 56-10 O RING 1B P7
56-4 CONNECTING PISTON 56-11 BACKUP RING
56-5 PLUG 56-12 O RING 1B G25
56-6 PILOT BODY 56-13 BACKUP RING
56-7 PISTON
Fig. 24-36 Construction of overload relief valve
24-75
(5) Brake valve portion

1) Spool
By shifting the spool (25), the discharged oil from hydraulic motor is automatically shut off or restricted
according to the condition and give the effect of holding, accelerating, stopping and counterbalance
operations.
2) Check valve (built in the spool)

This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to lock
oil displacement. Therefore, this valve serves as not only a suction valve but also a holding valve for
hydraulic motor.
Spool control pressure : 0.59~0.95 MPa (86~138 psi)

Check valve cracking pressure : 0.015 MPa (2.2 psi)
CHECK VALVE
59 60 28 29 27 26 25 39 40 42 41
Fig. 24-37 Brake valve portion
24-76
24.1.6.4 FUNCTIONS OF TRAVEL MOTOR

(1) Motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake valve portion and,
through the rear cover (23) and valve plate (53), led to cylinder block (12).
As shown in Fig. 24-38 (a), high pressure oil is supplied to the pistons which are on one side of the line Y–Y that
connects upper and lower dead points and produces force F1.
F1=P× A (P : pressure, A : area of piston section)
The swash plate (11) with inclined angle of divides this force F1 into thrust force F2 and radial force F31-F34
(or F35). (Fig. 24-38 (b)) This radial force is applied to axis Y-Y as turning force and generate drive torque of T.
T=r1•F31+r2•F32+r3•F33+r4•F34
(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block (12) to driving shaft (8).
Fig. 24-38
(2) Parking Brake
Parking brake is released when high pressure oil, selected by the brake valve portion that is connected directly
to the rear cover (23), is applied to the brake piston (20). Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates (18), inserted into the casing (1),
and friction plates (19), coupled to cylinder block (12) by the outer splines.
When no pressure is activated on the brake piston (20), it is pushed by the brake springs (54) and it pushes
friction plates (19) and separating plates (18) towards casing (1) and generates the friction force which brakes
the rotation of cylinder block (12) and hence the shaft (8).
& & ' #" !
Fig. 24-39 Parking brake portion
24-77
(3) Capacity Control Mechanism

Fig. 24-40 typically shows the capacity control mechanism.
When high speed pilot line is charged with the pressure PA that overcome the spring (33), the spring (33) is
compressed and spool (30) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve (43) from inlet and outlet pressure of the motor and
high speed pilot line pressure and pushes shifter piston (5). As a result, swash plate (11) turns around the line
L which connect the two pivots (10) as shown by dotted lines. The turn stops at the stopper (1-1) of casing and
swash plate (11) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor rotates faster,
around 1.71 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool (30) is pushed back by the spring (33) and pressure
that pressed the shifter piston (5) is released to the hydraulic tank through restrictor (45).
Here, nine pistons are there and they equally spaced on the swash plate (11). The force that summed up those
of pistons comes to almost the center of the swash plate (11) as shown. Since the pivots (10) are off-set by S
from the center, the rotating force of product S and the force moves swash plate (11) to the former position and
the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at high speed
mode, the system step down to the low speed automatically. The mechanism is that: pump pressure is led to the
port PB (Fig. 24-40) and this pressure activate on pin (31). When the pressure at PB exceeds predetermined
value, spool (30) returns to the left by the counter-pressure against pin (31) and the pressure on the shifter piston
(5) through port C is released to the tank and the motor comes to low speed.
When PB goes down, the spool (30) moves to the right and the speed become high.
TO COUNTERBALANCE VALVE
(BRAKE VALVE)
HIGH SPEED PILOT LINE

(EXTERNAL PILOT)
43 43 43
9 5 1-1 17
30
LOAD
APPLICATION POINT
10 10 11 45 33 31
Fig. 24-40 Capacity control Mechanism
24-78
(4) Function of overload relief valve

Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and
have the following functions:
1) When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating,
bypasses surplus oil to return line.
2) When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under the
predetermined value to stop the inertial force.
3) To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these purposes,
the developed pressure is kept comparatively low for a short period, then keep the line pressure as normal
value. While the pressure is low, meshing of reduction gears, crawler and sprocket etc. can be smoothly
done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective diameter
of valve (56-2) which seats on the valve seat (56-3) and, at the same time, is delivered, via small hole, to the
connecting piston (56-4) located inside the valve (56-2) and the piston bore pressure increases up to "A" port
pressure. The valve (56-2) opposes to adjusting spring (56-9) by the force of the pressure exerted on the area
difference between valve seat's effective diameter and piston bore and keep the predetermined pressure.
When hydraulically braking, the piston (56-7) is at the left position by the driving pressure, and when "A" port
pressure increases, the pressure is applied also to the piston (56-7) through the small hole in the valve (56-2)
and piston (56-7) moves rightward until it touches the cap (56-5). In this while, the valve (56-2) maintains "A"
port pressure at comparatively low against the adjusting spring (56-9) force and exhaust oil to "B" port side. After
the piston reached to the plug, the valve acts the same as at starting.
CAP
CONNECTING PISTON (56-5)
PORT B (56-4)
VALVE SEAT
(56-3)
PORT A
VALVE ADJUSTING SPRING PISTON

SMALL HOLE (56-2) (56-9) (56-7)
Fig. 24-41 Function of overload relief valve
24-79
(5) Function of brake valve

1) Holding operation (see Fig. 24-42)
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (27)
located on both spool ends holds the spool (25) at central position. Therefore, the passages from VA to MA
and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is equal to the
tank pressure and the brake is applied by the springs. Thus, the rotation of the motor is mechanically
prevented. If external torque is exerted on the motor shaft, the motor would not rotate as usual by this parking
brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But, due to oil
leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit and motor rotates a
bit. So, the cavitation tends to occur in the lower pressure side of the closed circuit. Then, the check valve,
built in the spool (25), operates to avoid the cavitation and opens the passage from VA to MA or from VB to
MB. Then the oil equivalent to the leakage is sucked from the tank line to the closed circuit.
SPRING SPRING
Fig. 24-42 Holding Operation
24-80
2) Accelerating operation (see Fig. 24-43)

When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic
oil from pump is forwarded through VA port to push open the check valve provided inside spool (25), and oil
flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from pump. At
the same time, the pressure of pilot chamber increases to push and move the spool (25) leftwards,
overcoming the spring (27) force. Thus, the return line from MB to VB opens to rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of relief valve
and high pressure oil is being relieved while the motor gains the rotational speed. As the rotational speed
goes up, the relieved volume decreases, and finally the motor rotates at a fixed speed.

Fig. 24-43 Accelerating Operation
24-81
3) Stopping operation (see Fig. 24-44)

Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and
VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends
become equal, and the spool (25) returns to the neutral position by spring (27) force. Thus, the passage from
MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here, the motor
functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure
increases. Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last
the motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and
the motor is mechanically stopped.

Fig. 24-44 Stopping operation
24-82
4) Counterbalance operation (see Fig. 24-45)

Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends
to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on
MB to VB side decreases and the spring (27) force moves the spool (25) leftwards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side rises due to
increased resistance in the passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber pressure on
VB port increases, and spool (25) moves rightwards to enlarge the area of passage from MA to VA.
Therefore the braking effect becomes smaller and the rotational speed of motor is controlled to correspond
to the volume of supplied oil. In order to give stable counterbalance operation, the restrictors (40) are set in
the pilot chamber to damp the spool (25) movement.
The parking brake is released during pressure adjusting action of the spool (25).
CHECK VALVE CHECK VALVE WITH RESTRICTOR

WITH RESTRICTOR
PILOT CHAMBER PILOT CHAMBER
SPRING
SPRING
Fig. 24-45 Counterbalance operation
24-83
24.1.6.5 FUNCTION OF REDUCTION GEAR

Reduction unit slows down the rotating speed of motor

and converts motor torque to strong rotating force.
This reduction unit utilizes two stages, planetary
reduction system.

Planetary reduction system consists of sun gear,

planetary gears, (planetary) carriers, and ring gear.
When the sun gear (s) is driven through input shaft,
planetary pinions (b), rotating on their center, also
move, meshing with fixed ring gear (a), around sun
gear (s).

This movement is transferred to carrier (k) and deliver
the torque.
This mechanism is called planetary gear mechanism.

Fig. 24-46 Planetary gear mechanism

See Fig. 24-47 on the right.
a
When the sun gear S1 is driven by input shaft,
planetary action occurs among gears S1, a and b and
b d
revolution of gear b transfers the rotation of carrier K1
to second sun gear S2, and also evokes planetary
action between gear S2, a and d. S1 S2
This time, because carrier K2 is fixed to frame, gear d
drives ring gear a and then ring gear a rotates to drive
sprocket.
K1 K2
Fig. 24-47 Two stages reduction gear
24-84
24.1.7 SWIVEL JOINT
24.1.7.1 GENERAL VIEW
(M24X2)
VIEW Y PLUG
Do not leak oil
Tighting torque
: 36.3N.m (26.8 lbf.ft)
VIEW Z
Fig. 24-48 General view of swivel joint
Item Specifications
Assy parts No. LS55V00008F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 370 L/min (98 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
E, F Rated flow 40 L/min (11 gal/min)
Low pressure ports Working pressure 490 kPa (71 psi)
G Rated flow 12 L/min (3.2 gal/min)
Revolution speed 12 min-1 (12 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF1
Ports size
E, F PF1/4
G PF3/4
Length : L 405.5 mm (16.0")
Weight 53 kg (117 lbs)
24-85
16,17
5 (0.197")
Apply Three Bond
6 #1805 to stem
2 places
5
6 places
7 8 9
10,14
4 places 3 4 2 places 4 places
Fig. 24-49 Construction

1 Body 1 8 Capscrew (M8× 20) 2
2 Stem 1 9 Capscrew (M8× 30) 4
3 Cover 1 10 Plug : PF3/4 4
4 Thrust plate 1 11 Plug : PT1/4 1
5 Seal 6 14 O-ring (1B P24) 4
6 O-ring 2 16 Plug : PF1/2 1
7 O-ring (1B G125) 1 17 O-ring (1B P18) 1
24.1.7.4 OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (4) preventing both
components from falling off, cover (3) closing one side of body (1), seal (5) that partitions off the circuits and O-ring
(6), (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.
24-86
24.1.8 CYLINDER
(1) General view
B A
ngth ngth
e d le d le
nd cte
exte r e tra
lly lly
Fu Fu
Part No. and Manufacturing No.

Stamp position
Fig. 24-50 General view of cylinder

(2) Specifications
Unit : mm (ft-in)
Center distance of pins

Part No. of Cylinder bore / Dry weight
Use Stroke Full extend B / Full Cushion
cylinder assy Rod Dia. kg (lbs)
retract A
ø170 / ø115 1,590 3,790 / 2,200 With cushion on
Boom LC01V00055F1 395 (871)
(6.70" / 4.53") (5-2.6) (12-5.2 / 7-2.6) rod side

Arm LS01V00056F1 584 (1288)
(7.48" / 5.12") (6-5.6) (15-1.1 / 8-7.5) both sides

Bucket LS01V00057F1 359 (792)
(6.30" / 4.33") (4-7.5) (11-3.0 / 6-7.5) rod side
24-87
24.1.8.2 CONSTRUCTION AND FUNCTION
(1) Boom cylinder
T=Tightening torque : N.m (lbf.ft)
)
)
( 5.51"-0.020"
( 5.91"-0.020"
8-M12XP1.75 DP17 MIN
0
2
0
26
-0.5
-0.5
140 0
150 0
25 4
T=14.7 (10.8) T=353~382 (260~282)

Apply Loctite #242 T=1860 (1370) T=981 (724) Apply Loctite #242
PT1/8 23 22 19 18 17 16 20,21 15 1 3 5 12,13 7 6 14 8 9,10 24 11 PT1/4
27
PT1/8
Fig. 24-51 Construction of boom cylinder
P/No LS01V00055F1
No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING: 1B G100 1
3 PISTON ROD 1 12 O-RING: 1B G160 2 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 3 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING 1 23 SETSCREW 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M18 16
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2 27 PLUG: PT1/8 1
24-88
(2) Arm cylinder
)
160 0 ( 6.30"-0.039"
( 6.30"-0.039"
2
0
Z
0
4
-1.0
-1.0
160 0
32 32
BORING
8-M14XP2 DP20 MIN 27
T=49 (36)
28
VIEW Z 29
31
30
DETAIL A T=353~382 (260~282)
T=14.7 (10.8) Apply Loctite #242
Apply Loctite #242 T=1860 (1370) T=981 (724)
12,13
PT1/4 24,25 23 22 19 18 17 16 20,21 15 1 3 5 7 14 6 8 26 9,10 11
PT1/8
A
ORIFICE
Fig. 24-52 Construction of arm cylinder
P/No LS01V00056F1
1 CYLINDER TUBE 1 12 O-RING : 1B G180 2 23 SETSCREW : M8 1
2 PIN BUSHING 1 13 BACKUP RING 2 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING 1 25 STOP RING 1
4 PIN BUSHING 1 15 CUSHION RING 1 26 SOCKET BOLT : M18 20
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 3 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING : 1B G115 1 31 PLUG : PT3/8 1
10 BACKUP RING 1 21 BACKUP RING 2 32 WIPER PIN 4
11 DUST WIPER 1 22 PISTON NUT 1
24-89
(3) Bucket cylinder

)
)
160 0 ( 6.30"-0.039"
160 0 ( 6.30"-0.039"
4 2X4-M12XP1.75 DP18 MIN
0
0
-1.0
-1.0
2
25 25
T=255~275 (188~203)
T=14.7 (10.8)
Apply Loctite #242
T=981 (724) T=1860 (1370) Apply Loctite #242
PT1/8 11 9,10 24 8 6 14 7 5 12,13 3 1 15 20,21 16 17 18 19 22 23
PT1/8
Fig. 24-53 Construction of bucket cylinder
P/No LS01V00057F1
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 2 11 DUST WIPER 1 20 O-RING: 1B G95 1
3 PISTON ROD 1 12 O-RING: 1B G150 2 21 BACKUP RING 2
4 PIN BUSHING 2 13 BACKUP RING 2 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING 1 23 SETSCREW: M8 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M18 16
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 4
8 BUFFER SEAL 1 17 SLIPPER SEAL 1
9 U-PACKING 1 18 WEAR RING 2
24-90
Hydraulic cylinder construction (See Fig. 24-51, Fig. 24-52, Fig. 24-53)
By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (3) that takes out the
motion of pistons reciprocating in the cylinder tube assy, and rod cover (5) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a piston mount (clevis) that connects piston rod assy (3) with other parts.
In addition to these main components, slipper seal (17) and ware ring (18) are located between, cylinder tube assy
(1) and piston rod assy (3) ; buffer seal (8), rod packing (9) and dust seal (11) are located between piston rod assy
(3) and rod cover (5) ; and an O-ring and a back-up ring are placed between cylinder tube assy (1) and rod cover (5).
If pressurized oil is fed alternatively to the oil inlet and
CUSHION RING (15) CHAMBER "A" PATH "B"
outlet provided in the cylinder, force acts on the piston TANK
which in turn causes the piston rod (3) to extend and PISTON (16)
retract. ROD (3)
ROD SIDE
HEAD
(1) Operation of cylinder with cushion
SIDE
1) Cushion on rod side
The cushion mechanism is provided to prevent (5)
CUSHION STROKE ROD COVER
the generation of shock when the moving speed
of piston (16) is not reduced and strikes rod Fig. 24-54 Cushion mechanism on the rod side
cover (5).
An oil in chamber "A" returns to the tank by RESTRICTED PATH "C"
TANK
passing through paths "B" and "C" at a fixed flow CLEARANCE "D"
rate in a intermediate stroke state (Fig. 24-54) of
pressing bottom side. Next, in a state of just
before stroke end (Fig. 24-55), cushion ring (15)
plunges into path "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-55 Cushioning action on the rod side

Fig. 24-56 Rod side cushion
24-91
2) Cushion on head side

PLUNGER
This construction is similar to the one of cushion
TANK
on rod side. In a state of intermediate stroke CHAMBER "A"
pressing rod side, an oil in chamber "A" returns
to tank by passing through paths "B" and "C" at a
fixed flow rate.
Next, in a state of just before stroke end, plunger
plunges into path "B". At this time, an oil in
chamber "A" path clearance "D" and restricted
PATH "B" CLEARANCE "D"
path "C", an oil flow volume returning to tank E
suddenly drops and the piston part movement RESTRICTED PATH "C"
slows down. RESTRICTOR VALVE
SPRING
SPRING SEAT
PLUG
O-RING
DETAIL E
Fig. 24-57 Cushioning action on the head side
24-92
24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST
Group Code Name Parts No.

C - 1 Mechatro controller YN22E00214F1
(C) Controller
C - 2 Gauge cluster YN59S00021F3

C - 4 Air-con controler (including panel) YN20M01468P1
C - 5 Engine coolant level controller VHS834701230A
C - 8 Engine controller VH89661E0010
D - 4 Diode Harness accessory
D - 5 Diode Accessory of relay box
D - 6 Diode ↑
D - 9 Diode ↑
(D) Diode
D - 10 Diode ↑
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
E - 1 Fuse and Relay box YN24E00016F2
E - 2 Alternator VH27060E0190
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LV53S00001F1
E - 6 Horn low LV53S00001F2
(E) Electric fittings
E - 7 Tuner AM / FM (For Oceania) YN54S00046P1

E - 8 Speaker left (For Oceania) YN54S00050P1
E - 9 Speaker right (For Oceania) ↑
E - 10 Receiver dryer YN54S00041P1
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery YN72S00016P1
E - 13 Travel alarm (For Australia) YN53S00004F1
E - 14 Cigaratte lighter YN81S00003P1
E - 15 Fusible link LC13E01175S002
E - 27 Accel redundant volume YN52S00052P1
L - 1 Boom work light (LH) YW80S00001F1
L - 2 Deck work light (RH) YT80S00002F2
L - 3 Swing flasher (LH) & rear work light YM80S00001F1
(L) Light
L - 4 Swing flasher (RH) & rear work light YM80S00001F2

L - 5 Room light YT80S00001P1
L - 6 Boom work light (RH) YW80S00001F1
L - 7 Cab work light (For SE. Asia) YT80S00002F1
(M) Motor
M - 1 Starter motor VHS28100E0010

M - 3 Wiper motor YN53C00012F2
M - 4 Washer motor YN54C00001F1
24-93

Arm 2 speed inverse propo.
PSV - A YN35V00049F1
(P) Proportional
valve
solenoid valve
(YN35V00047F1)
PSV - B P2 unload propo. valve YN35V00048F1
Solenoid valve assy
PSV - C Travel straight propo. valve ↑
PSV - D P1 unload propo. valve ↑
PSV - P1 P1 pump propo. valve (LS10V00016F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay VHS283001271A
R - 4 Safety relay YN24S00010P1
R - 5 Horn relay ↑
R - 6 Working light relay ↑
R - 8 Travel alarm relay ↑
R - 9 Cab working light relay (For SE. Asia) ↑
R - 19 Flasher relay YY24S00001P1
(R) Reray
R - 23 Auto idle stop relay 1 YN24S00010P1

R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation) ↑
R - 31 Wiper motor relay (Arc prevention) ↑
R - 32 Washer motor relay ↑
R - 39 Air heater relay VH286201430A
SE - 1 Pressure sensor : Bucket digging LC52S00019P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 5 Pressure sensor : Swing ↑
SE - 7 Pressure sensor : Arm in ↑
(SE) Sensor
SE - 8 Pressure sensor : Arm out ↑

SE - 9 Pressure sensor : Travel RH ↑
SE - 10 Pressure sensor : Travel LH ↑
SE - 11 Pressure sensor : P2 OPT. ↑
SE - 13 E/G speed sensor VHS894101290A
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 Pressure sensor : P1 OPT. LC52S00019P1
SE - 22 Pressure sensor : Pump P1 YN52S00048P1
SE - 23 Pressure sensor : Pump P2 ↑
SV - 1 Swing parking brake SOL. YN35V00051F1
(SV) Solenoid
SV - 2 Power boost SOL (YN35V00047F1) YN35V00050F1

SV - 3 Two speed select SOL Solenoid valve assy ↑
SV - 4 Safety lock lever SOL ↑
24-94

SW - 1 Key switch YN50S00026F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 7 E/G oil pressure switch VHS83530E0220
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
(SW) Switch
SW - 11 Safety lock lever switch YN50S00041F1

SW - 13 Travel alarm switch (For Australia) YN50S00040DF
SW - 15 Conflux/single select switch YN50S00040DD
SW - 17 Skylight wiper switch YN50S00040D9
SW - 19 Wiper interlock switch YT50S00004P1
SW - 20 Power boost switch (RH) YN50E00017P1
SW - 21 Power boost switch (LH) ↑
SW - 26 Cab work light switch (For SE. Asia) YN50S00040D4
SW - 27 Coolant level switch VHS834601510A
SW - 55 Boom work light switch YN50S00040D1
24-95
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F3
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
C-4
Controller
YN20M01468P1

Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-96
File No.
Name of part
Use
Applicable Machine
C-5
Rated voltage DC24V
Controller
Maker's (Hino) P/No. S8347-01230A
VHS834701230A
Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
Hino P/No. : 82580-8050A
YS10 - 01501 ~ (YAZAKI : 7382-1680)
Hino P/No. : 82580-8870A
(YAZAKI : 7283-1080)
Measurement circuit Pin arrangement
C-8
Controller Maker's P/No. 89661-E0010
VH89661E0010 Rated voltage 24V (DC)
Engine controller Working voltage 16~32V (DC)
YN11 - 45001 ~ Operating voltage
(at starter ON) 9~32V (DC)
YQ11 - 06001 ~ Back-up source
(reference value) 5mA MAX (BAT=24V)
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
Connector 167 pins Male
24-97
File No.
Name of part
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F2
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~ Front side of machine
E-2
Alternator
VH27060E0190
Generator
LS10 - 02001 ~
YS10 - 01501 ~
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-98
File No.
Name of part
Use
Applicable Machine
E - 5, 6
Type ULM-24V
Horn
Rated voltage DC24V 2-o 8.5
LC53S00001F1 (High)
Operating voltage range DC26V
LC53S00001F2 (Low)
Sound level 113~118dB(A)/2m
Warning sound T2
330+20Hz high sound
LY01 - 00101 ~ Basic frequency 280+20Hz low sound
LS10 - 02001 ~ Insulation resistance More than 3M /DC500V
T1
YS10 - 01501 ~
NAME PLATE
Hi : BLUE
Lo : RED
E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00046P1
Radio (AM & FM)
(Oceania)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
E - 8, 9
Maker SOKEN Co., Ltd.
Speaker
Maker parts No. SOK104A004
YN54S00050P1
Rated input 10W
Radio
Impedance 8
LY01 - 00101 ~
Frequency 33.3Hz
LS10 - 02001 ~
YS10 - 01501 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~ 17% or over than the
Desiccant moisture
YQ11 - 06001 ~ adsorption capability weight of desiccant
(Include initial absorption 2%)
LC10 - 07001 ~
Refrigerant HFC-134a
YC10 - 03501 ~
LQ12 - 06001 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-99
File No.
Name of part
Use
Applicable Machine
E - 11
Air-con compressor
!"#$"###
YX91V00001F1

%&'
Air-con

'### (
YX03 - 01601 ~

)* +
YX04 - 01773 ~
$,!'
YX05 - 02001 ~ -.$&#/,!0
YN11 - 45001 ~

YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
E - 12
Type 145F51
Battery
Voltage 12V
YN72S00016P1
Capacity (5HR) 112Ah
Power
Weight (Incl. fluid) Approx. 33kg (72.8 lbs)
LS10 - 02001 ~
Electrolyte Approx. 9.0 L (2.38 gal)
YS10 - 01501 ~
Negative Positive
terminal terminal
(0.67")
(0.67")
Taper
Taper
17
17
17.9 19.5
(0.705") (0.768")
504 (19.84")
182 (7.17")
257 (10.1")
212 (8.35")
24-100
File No.
Name of part
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V
YN53S00004F1 Power AV 0.5 Red / Green
Travel alarm AMP Econoseal J series Mark II water-proof

Housing : 174354-2 Harness seal : 172888-2
(Australia) Terminal : 171661-1 Retainer : 1-174355-1
YN11 - 45001 ~ VIEW A
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ Vinyl tube
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
E - 14
Cigarette lighter !
YN81S00003P1

"# $%
&! - +
Cigarette lighter ./
YN11 - 45001 ~

' (
YQ11 - 06001 ~ )&%
LC10 - 07001 ~ * + (,$&
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~ 01 +
LS10 - 02001 ~
YS10 - 01501 ~
E - 15
Fusible link

LC13E01175S002
Fuse
LS10 - 02001 ~
YS10 - 01501 ~
E - 27
Resistance 2
Rated voltage DC 5V
Accel redundant volume
Resistance 2 TOCOS
YN52S00052P1 Parts E-27 RA30YME20FB202
Accel redundant volume
YN11 - 45001 ~ After soldering,
insulate this part
YQ11 - 06001 ~ with heat shrinkable tube
LC10 - 07001 ~ Clip
YC10 - 03501 ~ Adhesive
LQ12 - 06001 ~
LL12 - 05001 ~
Fix this resistance with tape HOUSING : 172131-5
LS10 - 02001 ~ PVC tube (Black) TERMINAL : 170340-1
Dial
YS10 - 01501 ~ VIEW I
24-101
File No.
Name of part
Use
Applicable Machine
L - 1, 6
Light (Halogen)

YW80S00001F1
Boom work light (LH, RH)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
L - 2,7
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Deck work light
Cab working light front
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
L-3
Meker Knight beam (Imasen)
Light
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Flasher lamp (LH)
Lighting cycle 90 times / min
Rear work light
YN11 - 45001 ~
AV0.85 W
YQ11 - 06001 ~
AV0.85 Y REAR WORKING
LC10 - 07001 ~ SWING LIGHT LIGHT
YC10 - 03501 ~
AMP PART NO.
LQ12 - 06001 ~
HOUSING : 174259-2
LL12 - 05001 ~ TERMINAL : 171661-1
LS10 - 02001 ~ AV0.85 R
HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
YS10 - 01501 ~ LOCK PLATE : 1-174260-1 GND
VIEW I
L-4
Light
YM80S00001F2
Flasher lamp (RH)
Rear work light
YN11 - 45001 ~
YQ11 - 06001 ~ SECTION A-A
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-102
File No.
Name of part
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Bulb
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~ SECTION A-A Door
Switch
YS10 - 01501 ~
M-1
Motor
VHS28100E0010
Starter motor
LS10 - 02001 ~
YS10 - 01501 ~
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller
YQ11 - 06001 ~ Wiper motor 24V

LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
Wiper sw
LL12 - 05001 ~ OFF-Stop
Stop signal ON-Start
LS10 - 02001 ~
Reverse signal
YS10 - 01501 ~ Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-103
File No.
Name of part
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less GND terminal
HOUSING AMP
LC10 - 07001 ~ 174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
YC10 - 03501 ~ 1-174360-7
TERMINAL AMP
LQ12 - 06001 ~ 171661-1
WIRE PROOF PLUG AMP
LL12 - 05001 ~ 172888-2
LS10 - 02001 ~ VIEW Z Terminal L

YS10 - 01501 ~ Flowing direction of
main current F HOUSING YAZAKI
o 9 X 30L
Terminal A Terminal B Terminal B 7123-4210-30
Heart shrinkage tube
AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)
R-2 Length of coupler harness

Hino P/No. S2830-1271
Relay (From outlet to coupler)
Rated voltage DC24V L=215mm
VHS283001271A
Rated time 30 sec 18 o4 MAX
Starter relay Vynil tube (Red)
Exciting current 3A or more (at 20 )
YN11 - 45001 ~
YQ11 - 06001 ~ Min operating voltage DC18V or less (at 20 )
LC10 - 07001 ~ Insulation resistance 1M or more
YC10 - 03501 ~
Black
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
Blue
Vynil tube (Red) M6
Terminal C Terminal B
Electric diagram
E (AVX 0.85mm2 Black)

E (AVX 0.85mm2 Blue)
Tape
M6
24-104
File No.
Name of part
Use
Applicable Machine
R - 4,5,6,8,9,23,24,25,
26,28,45 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Travel alarm relay
Cab working light relay
Auto idle stop relay 1, 2
Engine emergency stop relay Pin assignment
Lever lock relay
Alternator relay
Boom cyl. working light relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~ Terminal arrangement
YS10 - 01501 ~
R - 19
Relay
YY24S00001P1 UPPER
Flasher relay
YN11 - 45001 ~
YQ11 - 06001 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
TERMINAL NUMBER
R - 29,30,31,32
Maker's P/No. V23134-A0053-C643
Relay
Parts name Relay
YN24S00012P2
Rated voltage DV 24V
Wiper motor relay
Contact 1C
Washer motor relay
YN11 - 45001 ~ * Accessory of relay box
YQ11 - 06001 ~
Pin assignment
LC10 - 07001 ~
YC10 - 03501 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-105
File No.
Name of part
Use
Applicable Machine
R - 39
Relay
VH286201430A
Air heater relay
LS10 - 02001 ~
YS10 - 01501 ~
SE - 1 ~ 5, 7 ~ 11,20
Pressure sensor
(Low pressure)

! " !
LC52S00019P1
Bucket dig and dump,
) *+ ,- . #%%. ,#
Boom up and down, ( ,- .

# #+,. #%%. ,#
/.)0.
Swing, ,.
%)0 % #%%. ,#% 1#2+%& 3 4$56764$'
,.
%)0 3 5656$
Arm in and out, ' # 1.8 '5 &#0 0),.
Travel RH and LH and other 4 #2, 2, 1)
%.++ +.)0 3 56767$'
YN11 - 45001 ~ #9.

YQ11 - 06001 ~
#$
%& /'"
LC10 - 07001 ~ '( ''
YC10 - 03501 ~
LS10 - 02001 ~
YS10 - 01501 ~
SE - 13
Output voltage 2.8V or more
Speed sensor
Clearance 1.0mm
VHS894101290A Sumitomo : 090-II (4P : B)
E/G speed sensor P/No. : 6188-0265
Hino. P/No.
YN11 - 45001 ~ Sensor side : 82580-6120A (B)
YQ11 - 06001 ~ Harness side : 82580-6130A (B)
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~ M16 x 1 Hex. : 17
LS10 - 02001 ~
Hex. : 22
YS10 - 01501 ~ Tightening torque : 47N.m (34.7 lbf.ft)
24-106
File No.
Name of part
Use
Applicable Machine
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
YQ11 - 06001 ~ 1/2 32+5
LC10 - 07001 ~ 1/4 (49.5)
YC10 - 03501 ~ EMPTY 85 +10
0
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
Machine side controller
Float
Electric diagram VIEW A
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YN11 - 45001 ~
YQ11 - 06001 ~ Notch part
LC10 - 07001 ~
YC10 - 03501 ~ Potentio
LQ12 - 06001 ~ 3MA JM II + AMP
Bracket
HOUSING : 174359-2
LL12 - 05001 ~ TERMINAL : 171661-1
LS10 - 02001 ~
YS10 - 01501 ~ Dial
SE - 22, 23 Electric diagram (Arrangement)

Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
YN52S00048P1
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ P3/8 Source (+)
Tightening torque Output (+) Econo seal J series
LQ12 - 06001 ~ : 73.5 N.m O ring P14 (Mark II (+)
Common (+)
LL12 - 05001 ~ (54.2 lbf.ft) JIS B2401 3 pole
LS10 - 02001 ~
YS10 - 01501 ~
24-107
File No.
Name of part
Use
Applicable Machine
PSV - A, B, C, D
Proportional solenoid valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F1)
YN35V00048F1
YN35V00049F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
HYDRAULIC SYMBOL
Arm 2 speed
P1 unload
Travel straight
P2 unload
Attachment boost
Travel 1,2 speed
Swing parking
Lever lock
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
YQ11 - 06001 ~ Rated voltage DC 24V
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~ Sleeve O-ring Solenoid Seal nut
LL12 - 05001 ~ 1B P20
LS10 - 02001 ~
YS10 - 01501 ~
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
valve (8 spool) assy pressure
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-108
File No.
Name of part
Use
Applicable Machine
SW - 1 Auto return
Switch Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
VIEW A Terminal
YC10 - 03501 ~
arrangement
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
YN11 - 45001 ~ Vinyl tube
T No. YAZAKI
YQ11 - 06001 ~ Contact construction : Position Red (2) 7122-2237
LC10 - 07001 ~ 7114-2020
Swing parking release
YC10 - 03501 ~
Normal
LQ12 - 06001 ~
LL12 - 05001 ~
White (3) Blue (1)
LS10 - 02001 ~
YS10 - 01501 ~
SW - 5, 10, 20, 21
*+ ,-
Switch -

).

YN03M01861F1
!" #$ $%
(Right grip)
&
& '
YN03M01862F1 (%" )
(Left grip)
Horn, ATT Power boost
LC10 - 07001 ~
YC10 - 03501 ~
)) ) - /012-, 34+# 5! )6
LQ12 - 06001 ~ )) ) - &$7-, 8!#+9!8!
LL12 - 05001 ~ 7 5)) ) : ( #6
LS10 - 02001 ~
YS10 - 01501 ~
SW - 7
Type Normal close
Switch
Working pressure 39.258.8kPa (5.7~8.5psi)
VHS83530E0220
Rating DC24V / 12W
E/G oil pressure switch More than 100M /
Insuration resistance DC500V megger
LS10 - 02001 ~
YS10 - 01501 ~
24-109
File No.
Name of part
Use
Applicable Machine
SW - 8
Switch

YR11P00008S005

Air cleaner
Clogging switch !
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~

LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 11
Switch

YN50S00041F1

Lock lever
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ ! "
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
! "
#$
SW - 13
Switch
Single pole single throw
YN50S00040DF Type (alternate)
Travel alarm (Australia) Insulation resistance More than 1M /
DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~
Terminal connector
LC10 - 07001 ~ Connector
YC10 - 03501 ~ Position
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 15
Switch
YN50S00040DD Type (alternate)
Conflux / single flow Insulation resistance More than 1M /
DC500V megger UP
switching (OPT)
YN11 - 45001 ~
Terminal connector
YQ11 - 06001 ~ Connector
LC10 - 07001 ~
Position
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-110
File No.
Name of part
Use
Applicable Machine
SW - 17
Switch
YN50S00040D9 Type (alternate)
Roof window wiper Insulation resistance More than 1M /
DC500V megger UP
switch (OPT)
YN11 - 45001 ~
Terminal connector
YQ11 - 06001 ~ Connector
LC10 - 07001 ~
Position
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 19
Switch
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
YN11 - 45001 ~
Insulation resistance 5M or more
YQ11 - 06001 ~
Operation force Initial motion 0.8+0.3
0 kg
LC10 - 07001 ~
YC10 - 03501 ~
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
Max. stroke
SW - 26
Switch
YN50S00040D4 Type (alternate)
Cab work light switch Insulation resistance More than 1M /
DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~
Terminal connector
LC10 - 07001 ~ Connector
YC10 - 03501 ~ Position
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
SW - 27
Purpose Coolant level detection
Switch
Working temperature -40 ~130
VHS834601510A
Coolant level switch Hino P/No. : 82580-71708
Sumitomo P/No. : 6188-0110
YN11 - 45001 ~
YQ11 - 06001 ~ Electrode side
LC10 - 07001 ~
YC10 - 03501 ~ CONNECTOR
LQ12 - 06001 ~
Housing side
LL12 - 05001 ~ (To ground) Mating connector
LS10 - 02001 ~ M18, P=1.5 Hino P/No. : 82580-71808
YS10 - 01501 ~ Sumitomo P/No. : 6189-0189
24-111
File No.
Name of part
Use
Applicable Machine
SW - 55
Switch

YN50S00040D1
Boom work light switch !
"## &%
$

YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
$

YC10 - 03501 ~ %
LQ12 - 06001 ~
LL12 - 05001 ~
LS10 - 02001 ~
YS10 - 01501 ~
24-112
25. AIR CONDITIONER SYSTEM
TABLE OF CONTENTS
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-3

25.1.1 AIR CYCLE.............................................................................................................25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2.1 COMPONENT ........................................................................................................25-5
25.2.2 CONSTRUCTION ...................................................................................................25-6
25.3 PIPING.............................................................................................................................25-9
25.3.1 AIR CONDITIONER................................................................................................25-9
25.3.2 AIR DRYER ASSY..................................................................................................25-11 25
25.4 FUNCTION ......................................................................................................................25-12
25.4.1 MECHANISM OF COOLING CIRCUIT...................................................................25-12
25.4.2 COOLING CIRCUIT................................................................................................25-14
25.4.3 COMPONENT PARTS ...........................................................................................25-15
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.6 CHARGING REFRIGERANT...........................................................................................25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-24
25.6.2 OPERATING PROCEDURE...................................................................................25-25
25.6.3 CHARGING PROCEDURE ....................................................................................25-26
25.7 ELECTRIC CIRCUIT........................................................................................................25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS .............................................................25-32
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION ...25-34
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE ...................................................................25-46
25-1

SK460-8: LS10-02001~ S5LS2511E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
25-2
25.1 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.
25.1.1 AIR CYCLE

• Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.
• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.
• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.
25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE
AIR CONDITIONER CONTROL PANEL
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
25-4
25.2 COMPONENT AND CONSTRUCTION

25.2.1 COMPONENT
27
33 30
27-1
40
32
39
27-3 27-4
27-2
35
35-8 35-6
35-1
35-2 35-5 35-12
34 35-7
35-10 35-9
Fig. 25-1 Air-conditioner group
A/C ASSY LS20M00027F1 (04)
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 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 35–12 L tube 1
30 Panel assy 1 35–5 S hose 1 39 Filter 1
32 Compressor 1 35–6 D hose 1 40 Solar radiation sensor 1
25-5
25.2.2 CONSTRUCTION
(1) Air conditioner unit
49
47
48
46 44
31
42 31
41
50
3 1
45 1
A
1 32 43
39
37
38
36
40
B
2
33
Fig. 25-2 Air conditioner unit (1/2)
25-6
14 16
6 1 1 31
1
5
15
1
31
62
1 3
1 1
D
E 4
7
28 1
A 1 1
27
1
20
26
13
C 60
11
29
23
21 22
24 82
24
83
51 54 79
9 63
78 23 C 84 61
17
E
18
31
D
B
10
19
12
1 25
3
31
77
Fig. 25-3 Air conditioner unit (2/2)
25-7
Air-con. unit YN20M00107F2 (03)
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 Screw M5× 16 23 22 O-ring 1 45 Foot lever 1
2 Main harness 1 23 O-ring 2 46 Face lever cam 1
3 MA air mix 3 24 Screw M5× 40 2 47 Vent lever cam 1
4 Blower controller 1 25 Thermistor 1 48 Face rod 1
5 Upper casing 1 26 Thermistor holder 1 49 Vent rod 1
6 Air mix door 1 27 Heater core 1 50 Foot rod 1
7 Air mix lever 1 28 Pipe holder 1 51 Plate 1
9 Air mix door sub 1 29 Thermistor 1 54 Capscrew 1
10 Air mix lever sub 1 31 Screw M4× 30 9 60 Casing packing A 1
11 Blower 1 32 Upper casing 1 61 Casing packing B 1
12 Lever MA air mix 1 33 Lower casing 1 62 Casing packing C 1
13 Intake door 1 36 Foot door 1 63 O-ring 1
14 MA intake lever 1 37 Vent door 1 77 Packing 1
15 Intake lever 1 38 Face door 1 78 Tube 1
16 Intake rod 1 39 KK box upper packing 1 79 Tube 1
17 Air mix rod 1 40 KK-box lower packing 1 82 Tube 1
18 Air mix rod sub 1 41 Vent lever 1 83 Bracket 1
19 Relay 2 42 Face lever 1 84 Lower casing 1
20 Evaporator 1 43 Foot joint lever 1
21 Expansion valve 1 44 MA mode lever 1
(2) Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
Fig. 25-4 Receiver dryer
25-8
25.3 PIPING
25.3.1 AIR CONDITIONER
30
NOTE
40 1. Apply oil for refrigerant R134a to the
O-rings of all air-conditioner hose fittings.
2. Refrigerant volume : 1010 50g
3. T : Tightening torque N.m(lbf.ft)
27
C 2
B
A
15
17 6
1
12
25
2
13 59
25
39
58 25
25
24 25 25
D 1
49
24
17
6
6
8
15
A 8
55 17
1
2
24
5
8
8
6
8 54
B 63
62 25
JAM NUT FOR 49
TENSION PULLEY 14
T=46.5 (34.3) 61
32 6
60 34
21 9
L 10
33 18
13
4 2 25
INITIAL BELT
TENSION 22 5
When the belt is 15
pushed by the 35
force of 27N,
adjust the 25 7
deflection of 14 8
L part to be 56
2mm (0.079in). 57
12 3
1
5 25
17
61
C D
Fig. 25-5
25-9
Air conditioner LS20M00027F1 (04)
1 Hose : L = 3200 1 27 Air conditioner assy 1
2 Hose : L = 4300 1 30 Panel 1
3 Bracket 1 32 Compressor assy 1
4 V-belt : B-42 1 33 Pulley assy 1
3.92~4.9 (2.9~3.6) 5 Clip 4 34 Condenser 1
46.5 (34.3) 6 Sems bolt : M10× 25 6 35 Air dryer assy 1
4.9 (3.6) 7 Sems bolt : M6× 20 2 39 Filter 1
8 Sems bolt : M8× 20 7 40 Solar radiation sensor 1
23.0 (17.0) 9 Capscrew : M8× 100 4 49 Clip 3
10 Washer 4 54 Grommet 1
12 Tube for heater : L = 2300 1 55 Grommet 1
13 Tube for heater : L = 3300 1 4.4 (3.2) 56 Capscrew : M6× 50 4
14 Tube for D hose : L = 3000 1 57 Washer 4
15 Tube for S hose : L = 2300 1 58 Tube for L hose : L=100 1
17 Tube for L hose : L = 2700 1 59 Clip 1
18 Tube for L hose : L = 1200 1 60 Clip 1
21 Bracket 1 46.5 (34.3) 61 Sems bolt : M10× 30 2
46.5 (34.3) 22 Sems bolt : M10× 35 3 62 Plate 1
24 Clip 4 23.0 (17.0) 63 Sems bolt : M8× 25 2
25 Clip 19
UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT
UNIT CONNECTION BOLT

S TUBE (9)
27 AIR CONDITIONER ASSY D HOSE (6)

S
32 COMPRESSOR ASSY
RECEIVER CONNECTION BOLT

S HOSE (5)
L TUBE (10)
L HOSE (8) L HOSE (7) 34 CONDENSER

Note : 35 RECEIVER DRYER
Numbers in ( ) shows the number in Fig. 25-6. RECEIVER DRYER MOUNTING BRACKET
25-10
25.3.2 AIR DRYER ASSY
C
6
A 7 5
12
6
5
8
8 B
8
5
A
4
7 9
3
10
2 5
1
6
8
B C
Fig. 25-6
Air dryer assy LS96V00010F1 (01)
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew 2 9 S tube 1
4 Capscrew 2 10 L tube 1
5 S hose 1 12 L tube 1
6 D hose 1
25-11
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Specific volume of saturated
Many kinds of refrigerants that change in that 0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• 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 R134a refrigerant that is used in this
machine.
25-12
(3) Characteristics of Refrigerant (Fig. 25-7) PRESSURE

In general, the fluid (general term of gas and liquid) MPa(psi)
R134a
has the following qualities: 4(580)
1) As a gas under certain pressure is cooled down,

3(435)
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
2(290)
condensation begins is unique to each
substance (fluid) at a given pressure. The 1(145) GAS
temperature determined by a given pressure is 0.5(75)
TEMPERATURE
called saturation temperature. [ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-7 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-7 illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in
the air-conditioner. At the temperature and the
pressure on the lower righthand side of the curve
in Fig. 25-7 the refrigerant take a gaseous state,
while at the temperature and the pressure on the
upper lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order to
cool the inside of the compartment down to 25°C
(77°F), the refrigerant must transform
(evaporate) from a liquid to a gaseous state at a
lower temperature. It can be seen from Fig. 25-7
that R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the circuits,
thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous
refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer
air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 MPa
(145psi), as seen from Fig. 25-7.
25-13
25.4.2 COOLING CIRCUIT

Fig. 25-8 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB)
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 EVAPORATOR EXPANSION
VALVE
vaporization of the refrigerant takes place is the BLOWER
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In INSIDE OF ENGINE
the meantime, liquid refrigerant (slightly wet vaporized S D ROOM
refrigerant) is fed into the evaporator, when "cooling" COMPRESSOR COOLING FAN
effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-7 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-8 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
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.
25-14
25.4.3 COMPONENT PARTS

(1) Evaporator (See Fig. 25-9.)
The evaporator is an important heat exchanger that
EVAPORATOR
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
O-RING
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air.
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator EXPANSION VALVE
as water drops. The cooling effect deteriorates if
the water drops freeze. Therefore, how to
discharge water is an important point. SOCKET BOLT M5X40(2 PCS.)
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve Fig. 25-9
which is described in the following. In order to attain
proper control, it is necessary to reduce the
pressure drop of the refrigerant of the evaporator.
Accordingly, reducing the pressure drop is one
element that makes the evaporator attain its full
performances.
(2) Expansion Valve
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is
too high, unvaporized liquid refrigerant returns to
the compressor (liquid back). This not only
deteriorates the cooling effect, but also damages
the compressor valves.
The expansion valve feeds the flowing high-
pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the
refrigerant at the same time.
25-15
Fig. 25-10 shows how the block type expansion

valve is constructed. The temperature sensing
DIAPHRAGM
part is provided in the shaft of the expansion
valve to directly detect the refrigerant
temperature at the outlet of the evaporator.
The diaphragm contains R134a in saturated REFRIGERANT
state. The pressure in the diaphragm changes EVAPORATOR OUTLET
SIDE
according to the temperature detected by the
sensor. The change in the pressure causes the SHAFT
force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side REFRIGERANT
INLET
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
BALL
occasion, part of the refrigerant evaporates by VALVE
the very heat of the refrigerant and cooled off. SPRING
The result is that low-pressure low-temperature
damp refrigerant vapor is fed to the evaporator. Fig. 25-10 Block type expansion valve
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that
under the pressure in the evaporator, the
refrigerant is properly overheated (3~8 degrees
C) and goes out of the evaporator. This action is
carried out by sensing the refrigerant
temperature at the outlet of the evaporator as
against the inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure drop
in the evaporator is excessive, it is difficult to
control the overheating or the feed rate of the
refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
and the refrigerant supply to the evaporator more
Fig. 25-11 Expansion valve outside view
securely. The air-conditioner of this machine
adopts a block type expansion valve.
25-16
(3) Compressor (See Fig. 25-12.)

D HOSE
The compressor performs the following three
functions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-12
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use
of an outer air of 35°C (95°F) and liquefy it. The
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only for
a short period, the refrigerant hardly exchanges
heat with outer air. That is to say, it takes a near
form of thermally insulated compression, so that
the refrigerant discharged by the compressor
turns into high-temperature high-pressure vapor
and is delivered to the condenser.
(4) Condenser ( See Fig. 25-13.)
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.
Fig. 25-13 Condenser
25-17
(5) Receiver dryer ( See Fig. 25-14.) SIGHT GLASS

REFRIGERANT
1) Receiver Tank INLET
On the air-conditioner, the revolution of the REFRIGERANT
compressor varies greatly which causes the OUTLET
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it when
the cooling circuit needs much refrigerant. The
PRESSURE SWITCH
receiver tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil, DESICCANT
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion SUCTION
valve. It is desirable that the amount of water PIPE
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for FILTER
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 RECEIVER
TANK
only means of confirming the inside of the circuit
visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by Fig. 25-14
cutting off the power supply to the compressor
when high pressure increases abnormally high
[more than 3.14MPa (460psi) ].
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit falls
below 0.2MPa (28psi).
25-18
25.5 DISASSEMBLY AND ASSEMBLY

25.5.1 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 other PIPE FASTENING PART TIGHTENING TORQUE
than SP20 may not be used. Since SP20 tends to
D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
absorb moisture and may corrode paint and resin,
the following points must be noted: D hose and condenser 19.6~24.5 (14~18)
1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)
2) Use care so SP20 does not adhere to the

painted surface and resin parts. In case SP20 Unit : N.m (lbf.ft)
has adhered to such surfaces, wipe it off SCREW SIZE TIGHTENING TORQUE
immediately.
N4,T4 machine screw, M4 0.78~1.18 (0.58~0.87)
(2) The receiver dryer is filled with desiccant to absorb
moisture in the circuit. Therefore, remove the valve N5,T5 machine screw, M5 1.96~2.45 (1.4~1.8)
at the pipe port immediately before connecting M6 (mounting part of L hose joint) 7.85~11.8 (5.8~8.7)
pipes.
M6 (except mounting part of L hose joint) 9.8~11.8 (7.2~8.7)
(3) Tightening Torque
M8 (mounting part of S,D hose joints) 19.6~24.5 (14~18)
1) Pipe Joints
When connecting pipe joints, coat the O-ring with M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
special oil (SP20) and fasten to the tightening
M8 (other than those mentioned above) 11.8~15.7 (8.7~12)
torque indicated in the table, using a double
spanner. M10 39.2~53.9 (29~40)
2) Screws and Bolts

Fasten to the tightening torque indicated in the
table REPLACED PARTS AMOUNT TO BE FILLED IN
(4) Amount of Oil for Compressor
EVAPORATOR 40 cc (2.4cu.in)
The compressor SD7H (HD type) is filled with
135cc (8.2cu•in) of oil. If the oil volume is small, CONDENSER 40 cc (2.4cu.in)
seizure at high revolution and shortening of service
Drain out the volume of oil left in
life will occur. If the oil volume is large, the cooling
COMPRESSOR the compressor to be replaced,
ability will be deteriorated.
from the new compressor.
Once the air-conditioner is operated, part of the oil
is dispersed in the refrigeration circuit. Therefore,
RECEIVER DRYER 20 cc (1.2cu.in)
when replacing the parts in right Table, adjust the oil
level to that of table. HOSES 20 cc (1.2cu.in)
(5) Before performing operation, stop the engine and
turn off all power supplies to the equipment related
to the air-conditioner.
(6) After the operation is over, confirm that all faults
have been repaired completely, by operating the
air-conditioner.
25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter
Slide the inner air filter leftward and remove it from

the unit.

Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
LOWER UNIT CASING
Fig. 25-17
25-20
(5) Replacing blower controller UPPER UNIT CASING

1) Remove 2 plus screws and remove the blower
controller from the upper unit casing.
2) Install new blower controller by the reverse
procedure of removal.
* Do not disassemble the blower controller.
PLUS SCREW BLOWER CONTROLLER
Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
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 from
the lower unit casing.
* Do not remove the fan from the blower motor.
LOWER UNIT CASING

2) Install it by the reverse procedure of removal.
Fig. 25-19
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off
EVAPORATOR
from the lower casing.
2) Remove evaporator sensor with sensor holder
from the removed evaporator. SENSOR HOLDER
3) Insert the sensor holder into the new evaporator 105mm
at the position shown in Fig. 25-20 and install the (4.1 inch)
evaporator sensor again.
11TH ROWS OF FIN
EVAPORATION SENSOR
Fig. 25-20
25-21
4) Remove 2 socket bolts M5× 40 with Allen wrench

(4mm) and remove the expansion valve from the
EVAPORATOR
evaporator.
5) Fit O-ring (NF O-ring 5/8 and 1/2 one each) to
A
new evaporator.
* When assembling again, fit O-ring paying

attention so as not to be caught with others. O-RING
(Socket bolt M5× 40 (2 pcs.) Tightening torque :
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. EXPANSION VALVE
Moreover, when tube assembly (78),(79) (see
Fig. 25-3) connected with expansion valve is
SOCKET BOLT M5X40(2 PCS.)
disconnected from expansion valve, similar
careful work is necessary.
Fig. 25-21
(9) Replacing motor actuator VENT ROD

1) Replacing mode actuator FACE ROD
a) Remove connector connected to the motor MA MODE
actuator. LEVER
CONNECTOR
b) Remove FACE rod and VENT rod which is PLUS SCREW
3PCS.
used to connect MA mode lever and mode
MODE
cam from the holder. ACTUATOR
c) Remove 3 plus screws and remove the
motor actuator with lever MA mode from the
unit.
d) Remove the lever MA mode from the
removed motor actuator, and install it on new Fig. 25-22
motor actuator by the reverse procedure of
removal.
2) Replacing air mixing actuator
AIR MIX ROD
a) Remove connector connected to the motor MA AIR MIX LEVER
actuator.
b) Remove rod air MIX which is used to connect
CONNECTOR
the motor actuator and the lever MA air MIX.
motor actuator with MA lever air MIX from the
unit.
d) Remove the MA lever air MIX from the
removed motor actuator, and install it on new
removal. PLUS SCREW 3PCS.
AIR MIX ACTUATOR
Fig. 25-23
25-22
3) Replacing inner and outer air switching actuator

a) Disconnect connector connected to the

motor actuator.

b) Remove intake rod from MA intake lever.

motor actuator with MA intake lever from the

unit.
d) Remove the MA intake lever from the
removed motor actuator, and install it on new
removal.

Fig. 25-24
25-23
25.6 CHARGING REFRIGERANT

25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar
with how work is done for handling refrigerant.
• 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.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6) Store cans beyond the reach of children.
(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.
• Be careful about overcharge of gas.

• Fasten pipes to a specified torque.
25-24
25.6.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas charge
operation".
1) The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water
remains in the circuit, the small holes of the expansion valve are frozen during operation. This causes the
circuit to clog up or rust, resulting in a variety of malfunctions. Therefore, before filling refrigerant in the
circuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus
eliminated.
2) The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not
only depends upon the cooling performances of the air-conditioner, but also affects the service life of the
component parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes
the cooling performance to deteriorate. On the contrary, undercharge causes poor circulation of the
lubricating oil of the compressor and causes seizure of the moving parts of the compressor.
The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation
procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in
this manual.
(2) Operation Chart
Vacuum making operation 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
-750mmHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1MPa (14 psi)
(3) Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side
Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter
25-25
25.6.3 CHARGING PROCEDURE
25.6.3.1 VACUUM MAKING OPERATION

(1) Connecting gauge manifold (See Fig. 25-25)
HIGH
1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE
pressure valve (LO) of the gauge manifold. GAUGE GAUGE MANIFOLD
(CLOSED)LOW HIGH PRESSURE
2) Connect the charging hoses (red and blue) with PRESSURE VALVE VALVE(CLOSED)
the service valves of the compressor. RED
BLUE
Red hose :
High pressure side (HI) of the gauge HIGH
PRESSURE YELLOW
manifold→high pressure side (DIS) of SIDE
compressor DIS
LOW
Blue hose : PRESSURE
Low pressure side (LO) of gauge manifold→low SIDE
SUC
pressure side (SUC) of compressor
COMPRESSOR VACUUM PUMP(STOP)
Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when
connecting them. Put the hose in firmly till a clicking

sound is heard.

3) Connect the center valve of the gauge manifold
with the charging hose of the vacuum pump.
Fig. 25-26 Connecting gauge manifold
Some kinds of gauge manifolds are not equipped with

an open/close valve in the center.
25-26
(2) Vacuum making (See Fig. 25-27)

LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and

make vacuum for more than 30 minutes. GAUGE MANIFOLD
3) When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
DIS
4) Then turn off the vacuum pump.
(3) Air-tightness Check
Close the high pressure valve and the low pressure
valve of the gauge manifold, leave it as it is for more SUC
than five minutes and make sure that the gauge
indication does not return toward 0.
Fig. 25-27 Vacuum making operation
If the gauge indication swings toward 0, there is

somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.
25-27
25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See Fig. 25-28.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge AIR PURGE
manifold.) Then push the gas valve of the side CLOSE
service port on the low pressure side of the SCREW DRIVER OPEN SERVICE
gauge manifold, using a screw driver, in order to YELLOW CAN VALVE
let out the air in the charging hose by the
pressure of the refrigerant. (See Fig. 25-28.)
BLUE RED
(The operation ends when a hissing sound is
heard.)
Fig. 25-28 Gas charging operation

3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).] LOW PRESSURE HIGH PRESSURE VALVE
VALVE(CLOSE)
After charging, close the high pressure valve of (OPEN) (CLOSE)
RED FILL IN 1~1.5 CANS
the gauge manifold and the service and valve. BLUE OF REFRIGERANT
(See Fig. 25-29.)
DIS
YELLOW
SERVICE CAN
VALVE
(OPEN) (CLOSE)
• Do not run the compressor during this work,
CHARGE
(Otherwise the refrigerant flow in reverse
direction which causes the service can and the SUC
hoses to rupture. This is very dangerous.)

(2) Checking for gas leak (High pressure side)
Check for gas leak in the cycle, using a gas leak
detector (electric type). Retighten and correct
leaking points.
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-28
(3) Charging from low pressure side (See Fig. 25-30)

1) Make sure that the high-pressure and low-
pressure valves of the gauge manifold and the
service can valve are closed. LOW PRESSURE HIGH PRESSURE
VALVE VALVE(CLOSE)
2) Start the engine and run the revolution to OPEN CLOSE
WHEN AIR RED (CLOSE SECURELY)
1500±100rpm and fully close the cab door and BUBBLES IN THE
SIGHT GLASS
the windows. DISAPPEAR
YELLOW
DIS
3) Turn on the air-conditioner switch, set the fan BLUE
switch to Max and the temperature control switch
to cool Max. SERVICE CAN
VALVE(OPEN)
4) When charging gas, set the discharge pressure
SUC
of the compressor to 1.4~1.6 MPa (200~230psi).
COMPRESSOR SERVICE CAN
OPERATION (DO NOT TURN IT OVER)

(Low pressure side)
5) Open the low pressure valve of the gauge
SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver go away. (See Fig. 25-30)
[Total amount of gas to be charged :
1010g±50g (2.2±0.11 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
RECEIVER DRYER
• Do not open the high pressure valve of the

gauge manifold in any circumstances. Fig. 25-31 Receiver dryer
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state.)
25-29
(4) Criterion for checking the amount of refrigerant

filled in
JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER
After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.
After A/C is turned on,

OVERCHARGE no air bubbles are seen.
After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.
• If the air-conditioner is run with poor refrigerant

R134a, it has adverse effect on the compressor.
• If the refrigerant is charged too much
(overcharged), the cooling performance is
deteriorated. Moreover, the circuit pressure
gets abnormally high : Always keep a proper
level.
(5) Removing Gauge Manifold

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1. Press the "L" shape metal fitting of the charging
hose (blue) on the low pressure side against the
service valve of the compressor so the
refrigerant does not leak out and loosen the nut.
As soon as the nut has been removed,
disconnect the charging hose from the service
valve.
2. Leave the high pressure side as it is till the high
pressure gauge reading falls. [below 1MPa
(140psi)].
3. Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.
25-30
25-31
25.7 ELECTRIC CIRCUIT

25.7.1 WIRING DIAGRAM AND CONNECTORS
JAE : JAPAN AVIATION ELECTRONICS
JAE JAE INDUSTRY, LTD.
HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000
MAKER : YAZAKI CORP.

MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40 REAR HOLDER : 7157-6260-30
TERMINAL : 7116-2871 TERMINAL : 7114-2871
NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING
MAKER : YAZAKI CORP. MAKER : YAZAKI CORP. A/C MAIN POWER

HOUSING No. : 7123-2249 FUSE 5A
HOUSING No. : 7123-6020 MAIN KEY SW POWER SUPPLY FOR
TERMINAL : 17111 TERMINAL : 7116-2871 COMPRESSOR CLUTCH
FUSE 15A
FUSE 5A
MAKER : YAZAKI CORP. MAKER : YAZAKI CORP.

HOUSING No. : 7123-2237 HOUSING No. : 7123-2228
TERMINAL : 17111 TERMINAL : 17111 FUSE BOX
MAKER : YAZAKI CORP.

JAE IL-AG5-7S-S3C1 HOUSING No. : 7123-2228
TERMINAL : AG5-C1-5000 TERMINAL : 17111
COMPRESSOR
NIPPON AMP KK 174056-2 JAE IL-AG5-7S-S3C1

TERMINAL : 175062-1 TERMINAL : AG5-C1-5000
JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111
NOTE) 1. THe double chain lines indicate the wiring

on the excavator side. MACHINE SIDE WIRING (PARTS)
2. The connector colors indicate the cord colors seen
from the connecting part.
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
Fig. 25-32 Electric diagram (1/2)
25-32
CCU (OPERATION PANEL + CONTROLLER)
EVA SENSOR
AIR INLET SENSOR
SUN SENSOR
MOTOR ACTUATER
(FOR AIR MIX)
MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)
BLOWER MOTOR
BLOWER AMP
MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY
AIR CONDITIONER SIDE

WIRING (PARTS) IN THE CAB
Fig. 25-33 Electric diagram (2/2)
25-33
25.7.2 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
Fig. 25-34
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 control B
unit.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.
25-34
(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.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
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 CONTROL AMPLIFIER MOTOR ACTUATOR
through the temperature control switch, the control LIMITER

COOL
unit reads the level of potentiometer of the actuator, POTENTIO 5V
and determines the rotating direction of motor in

POTENTIO
POTENTIO GND
either normal rotation or reverse rotation. Then as

the motor rotates, the contact point is moved, and HOT
when the contact point is detached or the output

signal of control unit turns OFF, the motor stops
rotating. Fig. 25-37
25-35
(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. AMPLIFIER MOTOR 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 position
detection switch in the actuator and determines the INNER AIR SIDE
rotation direction of motor in either normal rotation OUTER AIR SIDE
or reverse rotation. Then as the motor rotates, the LIMITER
position detection switch also rotates and makes it

stop at the set position of the inner and outer air Fig. 25-38
damper.
(6) Evaporator sensor
This sensor is used to control the evaporator outlet
temperature with the compressor ON-OFF to
protect the evaporator from freezing, and this
evaporator sensor functions as a sensor of this
control.
• Evaporator sensor inspecting items
(Specification)
Terminal resistance : Fig. 25-39
at 0 degree C : 7.2 k
at 25 degree C : 2.2k
(7) Dual pressure switch
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.
Fig. 25-40
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(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
Fig. 25-41
terminals.
25-36
25.8 TROUBLESHOOTING
Air temperature does not fall. Note : M/A is motor

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.

* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on 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
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.
See section monitor mode.

Inspect and correct or replace parts.
A
NO YES
Blowout temp. falls if temp. is set . Evaporation sensor connector

at 18.0 (64.4 ) (COOLMAX) and the is disconnected or in poor contact.
blowout mode is changed to vent mode. . Evaporation sensor is disconnected or shorted.
NO YES Inspect and correct or replace parts.
Air mix damper is Cool air flowing

in COOLMAX. into inner air sensor Inspect and correct or replace parts.
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (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 failed or controller

M/A lever link. is out of order.
. After cleaning lever link,
apply grease.
Replace.
25-37
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.

* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
. Inner air sensor or harness is disconnected or shorted.
. Inner air sensor connector is disconnected or in poor contact. Inspect and correct or replace parts.
NO YES
NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES
Air mix damper is Warm air is flowing into

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

replace M/A lever link. is out of order.
. Clean lever link and apply grease.
Replace.
25-38
Blower motor does not run.
At air flow HI, battery voltage acts across

Note 1) both terminals (+) and (-) of blower motor.
NO YES
Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.
Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES
Controller is out of order. Remove blower amplifier and check for

Wire harness is Replace continuity across light green wire
faulty. Inspect and black wires ; you get continuity.
and correct or replace.
NO YES
Battery voltage acts across white /

red wire and body of blower motor relay. Eliminate cause Inspect and
and replace repair harness.
NO YES blower amplifier.
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.
25-39
Blower motor speed does not change.
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES
Replace blower . Inner air sensor or harness is disconnected or shorted.

amplifier controller. . Inner air sensor connector is disconnected or in poor contact.
CASE (2)
Does not blower motor speed

change because the setting mode
is other face mode?
YES NO
Is door or front window open? See CASE (1).
YES NO
The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch.
25-40
Magnet clutch does not engage.
Snow mark ( ) lights

if A/C switch is pressed.
No Yes
Snow mark ( ) flickers and E is Voltage acts upon clutch.

shown on panel display.
No Yes
To A On page 25-37. Voltage is applied to Clutch faulty.

pressure switch harness.
No Yes
Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.
No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes
Replace harness. Replace controller.
Inner air and outer air do not change over.
Inner / outer air mode display on

operation panel is flickering.
No Yes
M/A lever includes foreign matter Connector of inner/outer air

or is broken. M/A is disconnected or in poor
No Yes contact.
Or M/A failed or main harness failed.
M/A failed Remove foreign matter

and replace parts. Inspect or replace.
Replace
25-41
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
No Yes
contact or M/A failed or main
harness is faulty.
Repair. Each damper lever does not disengage.
No Yes Inspect or replace.
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
Replace. dirty grease.
. Remove foreign matter or replace parts.

. Clean cam and apply new grease.
25-42
Trouble with refrigeration cycle.
Both high and low pressures are lower.

Low pressure is higher.
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES
Cooling does not work Oil comes out from

if run at high speed. piping and parts. Compressor cylinder Compressor cylinder
does not get hot. gets very hot.
NO YES NO YES
Expansion valve Expansion valve Natural Gas leaks
is clogged or is frozen or leak from from pipe
maladjusted. intruded by water. hose. joints and
parts. Expansion valve is Compressor does
maladjusted. not discharge well.
(too much open)
Adjust or replace After making
expansion valve. vacuum, refill Retighten
refrigerant Charge gas. or replace
and replace parts.
receiver. Replace Replace compres
expansion valve.
High pressure
is lower.
Air bubbles are seen in sight glass.
NO YES
High pressure gets Condenser is

lower slowly. fouled or clogged.
High pressure YES NO

circuit before
receiver is Air bubbles are hard to
clogged up. go out even if water
is poured on condenser.
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.
25-43
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

The failure of motor actuator and each sensor can be identified on the display of panel.
25.9.1 POSITION OF INDICATION FOR FAILURE.
The error is indicated on 3 digits segment.
25.9.2 EXPLANATION OF INDICATION FOR FAILURE.

(1) 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.
2) MODE is flickering.
Check harness or connector to motor actuator

for the air outlet damper for disconnection.
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 main switch is not switched from
OFF to ON the error indication and flickering are not released.
25-44
(2) 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.
(* 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.
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.
(3) Communication error of control amplifier and panel

1) E is indicated on the only use segment of display.

25-45
25.9.3 EXPLANATION OF MONITOR MODE

When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition
(disconnection, short circuit).
(1) Position of monitor mode indication
SEGMENT FOR ONLY MONITOR INDICATION

3 DIGITS SEGMENT
(2) Operation of monitor mode
SPEED UP AND DOWN

INNER OR OUTER
SWITCH FOR BLOWER
AIR INLET SELECT
SWITCH (R/F)
ON/OFF SW
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch.
(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, and the required sensor is selected from the list below.
SEGMENT ASSIGNMENT LIST

0 INNER AIR SENSOR
1 EVAPORATOR SENSOR
2 SOLAR RADIATION SENSOR
(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 (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.
Notes)
1. 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.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
(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
THIRD SEGMENT
SECOND SEGMENT
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.
2) Example 2

(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.
3) Example 3

(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 condition.
4) List of 3 segments
SECOND SEGMENT
INNER AIR SENSOR DISCONNECTION (0CH0 INDICATED)

EVAPORATOR SENSOR DISCONNECTION (0CH1 INDICATED)
SOLAR RADIATION SHORT-CIRCUITING (0CH2 INDICATED)
THIRD SEGMENT
EACH SENSOR IS NORMAL
SOLAR SENSOR 5V SIDE SHORT-CIRCUITING (C7H2 INDICATED)
INNER AIR SENSOR SHORT-CIRCUITING (F6H0 INDICATED)

EVAPORATOR SENSOR SHORT-CIRCUITING (F6H1 INDICATED)
25-47
[MEMO]
25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ...........................31-3

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ..................................31-3
31.1.2 INDICATION OF TIGHTENING TORQUE .............................................................31-3
31
31-1

SK330–8 : LC10-07001~ S5YN3118E01
SK350LC–8 : YC10-03501~ (ASIA, OCE)
SK200–8 : YN11-45001~ ↑
↑ August, 2006 K
SK210LC–8 : YQ11-06001~ (ASIA, OCE)
SK250-8: LQ12-06001~ ↑
↑ October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)
↑
↑ ↑ SK235SRLC-2 : YU05-02001~ K
(North America)
E215B : YN11-45001~ ↑
↑ March, 2007 K
E215BLC : YQ11-06001~ (NHK Russia)
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK210LC-8 : YQ11-06001~ ASIA (HS Engine)
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
SK260LC–8 : LL12-05001~ ASIA (HS Engine)
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
SK460-8: LS10-02001~ ↑
↑ ↑ K
SK480LC–8 : YS10-01501~ (ASIA, OCE)
31-2
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY
This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .................................................................Chapter 32
1) Removing and Installing
2) Disassembling and Assembling
a. Cylinder
(2) UPPER STRUCTURE ........................................................Chapter 33
a. Hydraulic pump
b. Control Valve
c. Pilot Valve (ATT)
d. Pilot Valve (Travel)
e. Slewing Motor
f. Swivel Joint
(3) TRAVEL SYSTEM ..............................................................Chapter 34
a. Travel Motor
31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N•m(72 lbf•ft)
Tolerance is ±10% unless otherwise specified.
• Refer to "Chapter 11 TOOLS" for standard tightening torque.
31-3
[MEMO]
31-4
32. ATTACHMENT
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING.......................................................................................32-3

32.1.1 ATTACHMENT ASSY.............................................................................................32-3
32.1.2 BUCKET .................................................................................................................32-3
32.1.3 ARM........................................................................................................................32-6
32.1.4 BOOM.....................................................................................................................32-9
32.2 DISASSEMBLING AND ASSEMBLING...........................................................................32-13
32.2.1 CYLINDER..............................................................................................................32-13
32
32-1
32. ATTACHMENT

SK460-8: LS10-02001~ S5LS3211E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
32-2
32. ATTACHMENT
32.1 REMOVING AND INSTALLING

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

2. BUCKET
3. ARM
(G) BUCKET CYLINDER (J) BUCKET DRIVE PIN

HEAD PIN
BUCKET LINK
BUCKET CYLINDER (B) BOOM CYLINDER
(I) IDLER LINK PIN (K) BUCKET ATTACHING PIN HEAD PIN
IDLER LINK
(H) BUCKET CYLINDER ROD PIN
Fig. 32-1 Front attachment and position
32.1.2 BUCKET
32.1.2.1 REMOVING BUCKET

(1) Put the machine in position to remove bucket.
Fig. 32-2 Position to remove bucket

(2) Removing pin (2) 1
Loosen nut (2) of capscrew M20× 180 (1), and
remove capscrew (1) from pin. 2
TIGHTENING
TORQUE
SECTION A-A : 181N.m
: 30mm (133 lbf.ft)
Fig. 32-3 Removing pin (2)
32-3
32. ATTACHMENT
(3) Removing bucket attaching pin (K)

Lift up bucket, position it so that bucket attaching
pin (K) is not loaded, adjust bucket link, and pull out
K
bucket attaching pin (K).
Fig. 32-4 Removing bucket attaching pin

(4) Removing bucket drive pin (J)
Put bucket on the ground, position it so that the
bucket drive pin (J) is not loaded, adjust bucket link, J
and pull out pin (J).
Store the removed pin (J) in original position again.
Fig. 32-5 Removing bucket drive pin
32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in the
reverse procedure of removing.
J
• When aligning the pin holes, do not put your

finger in the pin holes, but align them visually.
• Check the seals for damaged and replace as
necessary.
• When inserting the pin, coat the shaft with
grease.
Fig. 32-6 Attaching bucket
32-4
32. ATTACHMENT
32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm

(1) Shift O-ring (3A) toward the bucket boss, using a
!"

spatula. (a→b) #
$ ) *+,&
$ - .*-&,) $ %&'(
(2) When adjusting clearance (B), bring the non-
/
adjusting side of the bucket in contact with the arm.
(3) Measure clearance (B) and check that it is within

1.0mm (0.04in). 0 $ #1*+'(
$ .2 3,
' / 5

(4) Adjust clearance (B) where it is more than 1.0mm 6

6/!
(0.04in). $ *+'4 5 5 7

$ .'
(5) An average of 5 shims (10) of 1mm (0.04in)

thickness are set in the plate (7) fixed by the three
capscrews (9). The clearance can be decreased by
Fig. 32-7 Adjusting clearance between bucket and
1mm (0.04in) if one shim is removed.
arm
: 30mm,
Tightening torque : 314N•m (232 lbf•ft)
(6) After adjustment, tighten the capscrews evenly.

• The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).
(8) Replace O-ring (3A) on its original position.
• When shifting O-ring (3A) by means of a spatula,

use care so as not to damage O-ring (3A).
• Remove shims (10), push out bushing (6)
rightwards by means of four capscrews (9) and
adjust clearance (B) so it settles within the standard
value evenly all round.
32-5
32. ATTACHMENT
32.1.3 ARM
32.1.3.1 REMOVING ARM

(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket cylinder
and bring the arm down on the ground.
Fig. 32-8 Position to remove arm

(2) Disconnecting piping of bucket cylinder
Release pressure of hydraulic tank, place oil pan to
prepare for oil leaking, and disconnect pipes.
Plug both end of disconnected pipes.

Plug : Tools section 11.5.2-(5)
OIL PAN
When the removal of bucket cylinder is not
required, skip to procedure (6).
Fig. 32-9 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H)
SHIM SHIM SHIM
Loosen nut (9), remove capscrew M20× 180 (8), 8
and push out pin (H).
H
: 30mm 9
G After adjustment of shim,

the total gap should be
H D
within 0.6~1.0mm (0.02~0.04in).
A A
Install plastic shims
D to bucket link side.
SECTION D-D
Fig. 32-10 Detail of bucket cylinder rod pin (H)

(4) Removing cylinder head pin (G) Apply grease to inner wall of bushing 2
Loosen nut (3), remove capscrew M20× 180 (2),
and push out pin (G). G
: 30mm
3
Install plastic After adjustment of shim, the total gap

shims to bucket should be within 0.6~2.0mm (0.02~0.08in).
link side. SHIM SECTION A-A
Fig. 32-11 Detail of bucket cylinder head pin (G)
32-6
32. ATTACHMENT
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight : 385 kg (880 lbs)
Fig. 32-12 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Apply grease to inner wall
Put a wooden block between the arm cylinder and of bushing
the boom. Install plastic shims 2
Loosen nut (3), remove capscrew M20× 200 (2), to bucket link side.
SHIM
and push out arm cylinder rod pin (E). E
: 30mm
Retract arm cylinder rod, and return pin (E) to the 3

SHIM
original position (hole). After adjustment of shim, the total gap
should be within 0.6~2.0mm (0.02~0.08in).
E SECTION A-A
Fig. 32-13 Detail of arm cylinder rod pin (E)

BLOCK
B
B
F
(7) Removing boom top pin (F)

F 2
Loosen capscrew M20× 40 (2), and pull out boom
top pin (F).
After adjustment of SHIM

: 30 mm shim, the total gap Install plastic
should be within shims to arm
0.5mm (0.02in). side.
Insert pin (F) into the original hole. SHIM
Apply grease
to inner wall
of bushing
SECTION B-B
Fig. 32-14 Detail of boom top pin (F)
32-7
32. ATTACHMENT
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight includubg tube : 1670 kg (3,680 lbs)
Fig. 32-15 Slinging arm assy
32.1.3.2 ATTACHING ARM

Instal the arm in the reverse order of removing, paying
attention to the following :
1) When aligning the pin holes, do not put your
2) Check the seals for damage and replace as
necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Pin lock nut handling procedure
(0.02")
CLEARANCE
: 32 mm
5) When installing the arm and the cylinder, inspect

the clearance in the thrust direction of the pins
and decide the thickness of shims by referring to
the Maintenance Standard.
6) Tightening torque
Tightening torque
Classification Size
N.m (lbf.ft)
Metric Boom top pin use M20 539 (398)
threads Double nut use M20 181 (134)
PF,PT threads 1/8" 16.7 (12.3)
32-8
32. ATTACHMENT
32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

When removing and attaching boom in the position
shown in Fig. 32-16, to remove and attach boom foot
pin (A), removing and attaching of cab and guard are
required.
32.1.4.2 REMOVING BOOM

(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc. giving
attention for arm cylinder rod not to be extended.
BLOCK
Fig. 32-16 Position to remove boom

(2) Lifting up boom cylinder temporarily
Remove the right and left boom cylinders one side
by one side according to the following procedure:
Lift up boom cylinder temporarily to prevent it from
B
dropping.
B
STAND
Fig. 32-17 Lifting up boom cylinder temporarily

(3) Press the boom cylinder rod pin (C) After adjustment of shim,
At the one side of pin (C), loosen nut (5), remove the total gap should be within
0.6~2.0mm (0.02~0.08in).
capscrew (4) (M16X150), and remove boss (3).
And push pin (C) to the end of boom boss.
4 4
3 3
: 24 mm C
(4) Preparing for disconnecting cylinder pipes 5 5

Retract the above mentioned cylinder rod, and
place one side of cylinder on stand. (See Fig. 32-
Apply grease
17) inside of bushing.
Install plastic
shim to cylinder side.
SECTION B-B SHIM
Fig. 32-18 Detail of boom cylinder rod pin (C)
32-9
32. ATTACHMENT
(5) Disconnecting the arm cylinder and bucket cylinder

pipings
Release pressure from arm and bucket circuit and
bleed air in hydraulic tank, and then disconnect
pipe at (A1), (A2), (A3), (A4) and hose (A7), (A8),
(A9), (A17).
:8, 12, 14 mm A4
A3
After disconnection of pipe, plug every pipe.
A1
Half clamp plug : See Tools 11.5.2-(5) O-RING
A2 A17
A7
O-RING ARM (H)
A9 ARM (R)
A8
BUCKET (H)
BUCKET (R)
Fig. 32-19 Boom piping disconnection

(6) Lifting up boom assy temporarily
Lift up boom cylinder with nylon sling so that boom
foot pin (A) is not loaded.
Weight of single boom : 3,770 kg (8,310 lbs)
A A
Boom assy temporary lift up procedure
(7) Removing boom foot pin (A) Apply molybdenum addition

1) Remove capscrew (3) M24× 60 and plate (2). grease to inner wall of bushing.
2 3
: 36 mm
2) Draw out pin (A).

A
SHIM
SHIM After adjustment of shim,
Install plastic the total gap should be
within 0.5mm (0.02in).
shim to boom
side.
SECTION A-A
Fig. 32-20 Details of boom foot pin (A) section
32-10
32. ATTACHMENT
(8) Hoisting boom assy

Hoist and remove boom assy.
Weight of single boom : 4,430 kg (8,770 lbs)
D
D
Boom assy hoisting procedure
(9) Completion of removal of front attachments

2
When the removing and attaching of cylinder are
not required, the work is finished.
(10)Removing and installing arm cylinder F1

1) Lift up arm cylinder (2) with nylon sling so that
the head of cylinder is not loaded. Install plastic shim to
cylinder side.
2) Disconnect hose (F1) and (F2) at position A. SHIM
After disconnection of hose, plug both ends of
hose. F2
3
2 A
Plug : TOOLS
11.5.2-(5) Plugs for half clamp
:12, 14 mm
SHIM
After adjustment
of shim, the total
gap should be
3) Removing arm cylinder head pin (D) Apply grease
with in 0.6~1.0mm
(0.02~0.04in).
Loosen nut (3), remove capscrew M20× 200 (2) to inner wall
of bushing D
and pull out pin (D). SECTION D-D
Fig. 32-21 Removing arm cylinder
: 30mm
4) Removing arm cylinder (2)

Weight of arm cylinder : 630kg (1,390 lbs)
32-11
32. ATTACHMENT
(11)Removing and installing boom cylinder

1) Release pressure from boom circuit and bleed
air in hydraulic tank.
2) Sling boom cylinder (2) using nylon sling
temporally not to act the weight of cylinder upon
the cylinder head. 2
3) Disconnect each four hoses (C2). And plug their
both ends. 2
B
Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting
: 36,41mm C2
C2
C2
Fig. 32-22 Removing and installing boom cylinder
4) Removing boom cylinder foot pin (B) After adjustment of shim,
(See Fig. 32-23,Fig. 32-24) the total gap should be within
0.6~2.0mm (0.02~0.08in).
Loosen nut (5), remove capscrews M20× 200 (4) SHIM
and pull out pin (B).
4
B B
: 30mm
5
5) Remove boom cylinder (2). Apply grease to
inner wall of bushing
Weight of boom cylinder : 420 kg (926 lbs)
6) Remove another boom cylinder the same way. SHIM
SECTION B-B Install plastic shim
to cylinder side.
Fig. 32-23 Removing and installing boom cylinder

head pin (B)
32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the
boom assy.
Attach it in the reverse procedure of removing,
paying attention to the following points.
A
1) When aligning the pin holes, do not put your
2) Check that the dust seals is not damaged and
replace as necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Refer to paragraph 32.1.3.2 (page 32-8) about
B
installing of jam nut.
5) When installing boom and cylinder, check the
clearance of mounting section in thrust direction,
Fig. 32-24 Boom foot pin (A)
and decide the thickness of shim according to
the maintenance standard.
Install plastic shim first, and insert iron shim into
remaining gap.
Regarding the position of shim, refer to Fig. 32-
20.
32-12
32. ATTACHMENT
32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLY

Before assembly, secure a dust free workshop and necessary equipment and facilities.
32.2.1.1.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this
reason, the first condition is that the working area is long enough for the work. In terms of width, it is also
necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work
can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic
materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in
particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is
assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube
inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding
operation should not be performed in the neighborhood of the working area to keep it clean.
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigidity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-13
32. ATTACHMENT
32.2.1.1.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table32-1 as a guideline.
Table32-1 List of Tools and Jigs
Tool / Jig Remarks Tool / Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic mallet
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place of a
gimlet.
Chisel Flat chisel Special jig 1. For piston nut and piston.
2. For inserting and reforming seal.
3. For inserting rod-cover.
4. For press-fitting bushing.
See para 32.2.1.9 for detail)
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches
3. Cylinder gauge ( Fig. 32-25)
4. V-block
• For the details of special tools and jigs, refer to the back pages of this manual.
32.2.1.1.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to the
clevis part. For this reason, remove external soil and
contamination from the cylinder with water and steam Fig. 32-25 Cylinder gauge
before bringing it into the workshop.
• The following describes the construction of boom
cylinder. When disassembling and servicing the
cylinder, confirm the construction of cylinder
referring to Parts Manual.
32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and place the WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time, V BLOCK
connect a suitable hose to each port so that the
hydraulic oil may not gush out. PORT A
AIR
OIL PAN
Fig. 32-26 Preparation
32-14
32. ATTACHMENT
32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)
)
160 0 ( 6.30"-0.039"
( 6.30"-0.039"
2
0
Z
0
4
-1.0
-1.0
160 0
32 32
BORING
8-M14XP2 DP20 MIN 27
T=49 (36)
28
VIEW Z 29
31
30
DETAIL A T=353~382 (260~282)
T=14.7 (10.8) Apply Loctite #242
Apply Loctite #242 T=1860 (1370) T=981 (724)
12,13
PT1/4 24,25 23 22 19 18 17 16 20,21 15 1 3 5 7 14 6 8 26 9,10 11
PT1/8
A
ORIFICE
Fig. 32-27 Construction of arm cylinder
P/No LS01V00056F1
1 CYLINDER TUBE 1 12 O-RING : 1B G180 2 23 SETSCREW : M8 1
2 PIN BUSHING 1 13 BACKUP RING 2 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING 1 25 STOP RING 1
4 PIN BUSHING 1 15 CUSHION RING 1 26 SOCKET BOLT : M18 20
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 3 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING : 1B G115 1 31 PLUG : PT3/8 1
10 BACKUP RING 1 21 BACKUP RING 2 32 WIPER PIN 4
11 DUST WIPER 1 22 PISTON NUT 1
32-15
32. ATTACHMENT
32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in .
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.
32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Hold the clevis section of the tube in a vise.
Use mouth pieces so as not to damage the machined

surface of the cylinder tube. Do not make use of the
outside piping as a locking means.
(2) Pull out piston rod (3) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (26) of the rod
cover in sequence.
Fig. 32-28
Cover the extended piston rod (3) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 26
(4) Strike the corner of the rod cover flange by means

of a plastic mallet till rod cover (5) comes off.
Turn counterclockwise
5
Cover here with cloths
3
Fig. 32-29
32-16
32. ATTACHMENT
• At this time, the weight of piston rod (3) is loaded KNOCK THIS EDGE
on rod cover (5). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.
5
3
Fig. 32-30 Drawing out piston rod assy (3).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
tip of the piston rod (3) with a hoist and draw it out.
However, when piston rod (3) has been drawing out to
approximately two thirds of its length, lift it in its center OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out the piston rod
of piston rod (3) is lifted, do not use a wire rope which
assy
may score the surface, but use a strong cloth belt or a
rope.
(6) Place the removed piston rod on a horaizontal

wooden V-block.
PISTON ROD ASSY
• Cover a V-block with cloths.

WOODEN V-BLOCK
(PLACE CLOTHS)
Fig. 32-32 Method of placing the piston rod

(7) Remove wear ring (18) and dust ring (19) from 16
piston (16). Remove slide ring by
widening the slit toward
the arrow
19
18
Fig. 32-33 Remove wear ring (18) and dust ring (19)
32-17
32. ATTACHMENT
32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (3) by holding its clevis section in a 5 WOODEN BLOCK
vise. Fix the piston rod (3) securely as piston nut 3
(22) is tightened to a high torque. 16
22
• Note that the tightening torque differs with the type,

the working pressure and the mounting method of
the piston (16), though the rod diameter remains
the same.
• It is also necessary to place a suitable supporting
block near the piston (16). In case a V-block is
WOODEN V-BLOCK
used, put cloths or something over the rod to (PLACE CLOTHS)
prevent it from damage.
Fig. 32-34 How to loosen piston nut (22)
(2) Scrape off the caulked part of setscrew (23) of
DRILL
piston nut (22) by means of a hand drill and loosen
setscrew (23).
22
23
Fig. 32-35 Removing setscrew (23)

(3) Loosen and remove piston nut (22).
TURN COUNTER
Since piston nut (22) is tightened to a high torque, use
CLOCKWISE.
a hook wrench suitable for the outside diameter of 16
piston nut (22) . Use care so the hook of the wrench is EYE WRENCH
22
positively fixed in the groove of the piston nut perimeter.
Fig. 32-36 How to loosen piston nut (22)
(4) Loosen piston (16) with a pin wrench as shown in

Fig. 32-37, utilizing the two holes in the side face of
the piston. If the O-ring (20) section comes off, the
piston may be turned easily by hand. When TURN COUNTER
removing the last thread of the piston, hold the CLOCKWISE.
piston by hand to receive the weight. WRENCH

3 16
Fig. 32-37 Removing piston (16)

If the piston is dropped with a bang, the O-ring seal face
on the piston interior may be damaged with the threads.
32-18
32. ATTACHMENT
(5) After removing cushion ring (15), separate rod

LIFT WITH A HOIST. STRIKE WITH
cover (5) from piston rod (3). If it is too hard to slide A PLASTIC MALLET.
it, knock the flanged part of rod cover (5) with a
PULL STRAIGHT.
plastic mallet. But when drawing it out, lift rod cover
(5) by hoist and pull it straight horizontally.
NOTE:
DO NOT
DAMAGE
PISTON ROD
SURFACE.
Take care so rod bushing (6) and the lip of packings
(8,9,10,11) may not be damaged by thread of the piston
rod (3).
5 6 8 9,10 11 3
Fig. 32-38 Removing rod cover (5)
32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1) Remove piston seal (17).
HAMMER
Cut the seal ring (17-1) by tapping it with a screwdriver SCREWDRIVER (OR CHISEL)
or a chisel. Take care not to strike it too hard, otherwise
SEAL
the groove may be damaged. BACK-UP RING RING
(NYLON) 17-3 (TEFLON)
17-1
USE CARE NOT 17-2

16 TO DAMAGE BACK-RING
THE GROOVE. (RUBBER)
Fig. 32-39 Removing piston seal (17)
(2) Separate O-ring (20) and back-up ring (21) from
21 17-1 17-3 17-2
piston (16).
After removing two back-up rings (21), remove O- 16
ring (20). The back-up ring (21) comes off easily if
the slit on its circumference is extended. O-ring (20)
can be taken off by stretching it with an earpick-like
spatula.
20
Fig. 32-40 Removing back-up ring (21) and

O-ring (20)
32-19
32. ATTACHMENT
32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (12) and back-up ring (13). SPATULA
Remove back-up ring (13) and O-ring (12) in that
order. Remove back-up ring (13) and O-ring (12) by 12
pulling and stretching them with an spatula like
earpick. 13
Fig. 32-41 Removing the outer circumferential seal

of rod cover (5)
(2) Remove buffer seal (8), rod-picking (9) and back-up GIMLET
ring (10). Each seal is fixed in the groove on the
bore and removing in flawless is impossible.
10
Stab each seal with a gimlet and pull it out of the
5 9
groove.
8
Take care in this operation not to damage the grooves.
Fig. 32-42 Removing the inner circumferential seal

of rod cover (5)
(3) Remove dust seal (11). When taking out dust seal HAMMER SCREW- 5
(11), fix rod cover (5) in a vise. DRIVER
11
WOOD PIECE
WOOD PIECE
VISE
Fig. 32-43 Removing dust seal (11)

(4) Remove circlip (7) and rod bushing (6). After taking 7 6
out snap ring (7) in the same way as mentioned
3
above, remove rod bushing (6). Rod bushing (6) is
impossible to remove as it is press fitted in rod
cover (3). Machine the bushing thin on a lathe,
SPATULA
insert a steel spatula hard into the gap at the
chamfered edge of the remaining bushing and pry WOOD PIECE WOOD PIECE
it up. VISE
Center the work on a lathe sufficiently so the bushing

may be shave on a lathe as thin as possible.
Fig. 32-44 Removing rod bushing (6)
32-20
32. ATTACHMENT
32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (32) of cylinder tube (1) PUSH WITH A PRESS.
and piston rod (3), and strike it by hammer lightly. METAL PIECE (JIG J)
(2) Push out pin bushing (4) press fitted in cylinder tube
(1) and piston rod (3) with press.
4 BASE
Fig. 32-45 Drawing out pin bushing (4)
32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.
Never use benzene(gasoline, thinner, etc.) because it

may be damage the rubber, etc.
(2) Do not use the used oil seal, O-ring, back-up ring,
etc. even if they are not damaged after inspection.
(3) After cleaning, dry all parts by compressed air, and
put them on the working bench taking care not to
damage them.
32.2.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
• Cylinder tube assy
• Piston assy
• Rod cover assy
32.2.1.5.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (4) in cylinder tube (1) and PUSH WITH A PRESS
piston rod (3) respectively with press. 3
4
(2) Press fit wiper ring (32) in the upper and lower sides
of cylinder tube (1) and piston rod (3) respectively
with press.
• Before press fitting, apply grease on wiper ring and

boss hole. OIL HOLE LOCATION
• Before press fitting the pin bushing, align the Fig. 32-46 Press fitting of pin bushing (4)
position of oil hole.
32-21
32. ATTACHMENT
32.2.1.5.2 ASSEMBLING OF PISTON ASSY

(1) Fit back ring (17-2) of piston seal as if it slips in with

driver the corner is rounded.

(2) And fit seal ring (17-1) with fitting jig.

Since it is hard to deform seal ring (17-1) in room
temperature, immerse and soften it in hydraulic oil
heated about 150 to 180 C degrees. Therefore slip it in
piston seal groove quickly with fitting jig so as not to be
cooled. Fig. 32-47 Attaching seal ring (17-1)
To avoid burn, wear gloves when fitting the heated seal
ring (17-1), and fit it quickly. And the hydraulic oil must
be heated with electric heater. (Do not use fire. There is
a danger.)
(3) Shrink the seal ring (17-1) to the original size using
correcting jig.

(4) Fit back-up rings (17-3) to both sides of seal ring.
Fig. 32-48 Correction of seal ring (17-1)

Make sure about the fitting direction of back-up ring.

(5) Fit O-ring and back-up ring (2 places) to the bore

side. Fig. 32-49 Direction of components
32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (6) in rod cover (5) with bushing PRESS HERE. (STRAIGHT DOWN)
press-fitting jig. Then, fit snap ring (7) in the groove. PRESS-FITTING JIG
Apply hydraulic oil on internal surface of rod cover 6 (Make O. D. smaller
than rod bushing O. D.)
(5).
GROOVE FOR
FIXING CIRCLIP (18)
Press bushing till bushing

The snap ring (7) can not be fitted when the bushing (6) comes in contact with
5
is not press-fitted fully to the stop end. this face.
(2) Apply grease to dust seal (11), or the hole of rod PRESS HERE. (STRAIGHT DOWN)
cover (5), and fit dust seal (11) to the bottom of the
PRESSING JIG Press metal
hole. At this moment, press the metal ring of dust
ring.
seal (11) with a jig.
11
RUBBER
CLIP
METAL RING
Fig. 32-50 Pressing in rod bushing (6)
32-22
32. ATTACHMENT
(3) Fit buffer seal (8), back-up ring (10) and rod- INSERT U-RING INTO GROOVE FROM THIS SIDE.
packing (9) in their grooves in that order. Before
setting packings, coat them with hydraulic oil (or
vaseline if not available). If you forget the coating,
the packings may be scored. When attaching seals,
deform them in a heart shape as illustrated.
• Rod-packing (9) is harder than other packing and it

would be difficult to deform them in a heart shape.
In such a case, put a U-ring in the groove obliquely Fig. 32-51 Inserting a seal into the inner
by hand as deep as possible and push in the last circumference of rod cover.
part with a push bar till it is set with a click.
PUSH BAR (WOOD OR PLASTIC)
• Buffer seal (8) should be fitted taking care of the 12
fitting direction. The reverse fitting may cause
13
deformation, damage, etc. of the piston due to high Tube side
pressure generated between the buffer ring and 5
rod-packing.
• If rod-packing (9) is set upside down, the lip may be
damaged. Check that it is positioned correctly.
• Attach back-up ring (13) on the open air side of O-
ring (12). (See Fig. 32-52).
9
10
11
Fig. 32-52 How to fit rod-packing (9)
32.2.1.5.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (5) to piston rod assy by the
5
following procedure. INSERT GUIDE JIG
(1) Fix piston rod assy on working bench. PUSH
(2) Install rod cover (5) on piston rod (3) with inserting
guide jig as shown in Fig. 32-53 paying attention for 3
the lip section of dust seal not to be caught on the
stepped section.
Fig. 32-53 Inserting rod cover (5)
• For the rod the outer diameter of piston installing

section is small, insert spacer on the faucet section
of rod first, and attach inserting guide jig.
• Apply hydraulic oil on the inserting guide jig and
outer surface of piston rod lightly to make the
insertion smooth.
32-23
32. ATTACHMENT
32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Insert cushion ring (15). Then install the piston assy Check that back-up ring
in piston rod (3). is not out the groove. 15 3
(2) Apply hydraulic oil or grease to the inside of the

piston assy and to the piston mounting part of
piston rod (3). Then install the piston assy as shown
in Fig. 32-54, exercising care not to damage O-ring
(20) and the seal.
Turn
Always tighten the piston to a specified torque.
clockwise. V-BLOCK
20
Hold the point as close
PISTON ASSY to the piston as possible.
Fig. 32-54 Tightening piston assy
(3) Turn in piston nut (22) till it gets tight.
Always tighten the piston nut (22) to a specified
torque.
(Refer to 32.2.1.7.3).
HOOK WRENCH
22
1.0~1.5m Turn clockwise.

(3'3"~4'11")
Always correct the threads of the tapped hole in piston
nut (22) before fixing piston nut, using a tap.
Fig. 32-55 Tightening piston nut (22)
(4) Screw in and set setscrew (23). ANTI-LOOSENING
23 CAULKING
3
: 4mm
After tightening the setscrew to a specified torque
of 15N•m (11ft•lbs), caulk the two places of the
thread of the piston nut side to secure the setscrew.
(5) Attach two wear rings (18) and dust rings (19). Take
off vinyl tape wound around the perimeter of piston V-BLOCK
(16), apply high-quality grease (or vaseline) to wear 22
ring (18) and dust ring (19) and attach the wear Fig. 32-56 Attaching setscrew (23)
rings in a manner that they may be coiled around
the groove. Set the wear rings about 90 degrees 23 18 19
3
apart with each other so that the slits may not point
to the same direction.
22 V-BLOCK
Fig. 32-57 Attaching wear ring (18)
32-24
32. ATTACHMENT
32.2.1.5.6 OVERALL ASSEMBLY

(1) Place a V-block on a work bench (A wooden V-
1
block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar LIFT
through the clevis pin hole to lock the assy.
(2) Insert the piston rod assy into the cylinder tube
assy, while lifting and moving the piston rod assy
with a hoist. In this operation, apply hydraulic oil (or STRAIGHT
PREVENT TURNING
vaseline) to the inner surface of the tube mouth and WITH WOODEN BAR.
the circumference of the piston. Align the center of
the piston rod assy with the center of the cylinder
tube assy and put it in straight forward. When Fig. 32-58 Inserting piston rod assy
inserting, make sure that wear rings (18), dust ring
(19) on the perimeter of the piston is not out of the
groove.
(3) Tighten socket bolt (26). Match the bolt holes of the 26
rod cover flange to the threaded holes in the
cylinder assy, and screw in socket bolts (26) one by PLACE CLOTH
one. Tighten the bolts to a specified torque, taking
care so the bolts may not be tightened unevenly.
See para. 32.2.1.7.3 for torque.
: 14 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-59 Tightening socket bolts (26)
Take care so as not to damage the rod surface by

accidentally slip a wrench. Covering the rod surface
with cloth is recommended to prevent damage to it.
32-25
32. ATTACHMENT
32.2.1.6 INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load, operate the
piston rod 5 to 6 strokes by the directional valve and DIRECTIONAL VALVE
make sure that it operates without failure. PUMP
• Do not raise the hydraulic pressure above the H R

maximum pressure of 34.3MPa (4975psi) for the
cylinder of the machine.
• Grease coated on the O-rings and the seals of the
HYDRAULIC CYLINDER
rod cover may come out. Wipe it off and retest the
Fig. 32-60 External leak test
cylinder in such a case.
(2) Leak test MEASURE THE

1) Apply a test pressure to the retracting and INTERNAL LEAK.
extending sides of the cylinder for three minutes
independently, and check that the rod section
and the welds have external leaks and
permanent deformation. For an internal leak test,
connect the cylinder with a test unit as shown in
FROM DIRECTIONAL VALVE
Fig. 32-61.
Fig. 32-61 Internal leak test
2) After completing the test, apply a plug to each

port and store the cylinder. (Fig. 32-62)
• For storage, place the cylinder on wooden V-

blocks and bring the cylinder to the most
retracted condition. Fig. 32-62 How to store the cylinder
32-26
32. ATTACHMENT
32.2.1.7 MAINTENANCE STANDARDS
32.2.1.7.1 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
Table32-2
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
Presence of crack Replace.
piston is attached
4. Threads Presence of seizure Recondition or replace
Measure degree of bend (See
5. Bend Refer to (Table32-3)
Fig. 32-63)
Piston rod 6. Plated surface Check that:
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on plating. 2) Replace or replate
3) Recondition, replate or
3) Scratches are not present.
replace.
7. Rod Wear of O. D. Recondition, replate or replace.
8. Bushing at mounting part Wear of I. D. Replace.
1. Weld on bottom Presence of crack Replace.
2. Weld on head Presence of crack Replace.
Cylindertube 3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of damage Replace if oil leak is seen.
5. Bushing at mounting part Wear on inner surface Replace.
1. Bushing 1) Wear on inner surface 1) See para. 32.2.1.7.2
Rod cover 2) Replace if score is deeper than
2) Flaw on inner surface
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 an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone.
If the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
32-27
32. ATTACHMENT
32.2.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the
sliding surfaces of the cylinder tube and the rod that
have no such damage as may degrade the sealing
effect.
(1) Clearance between piston rod and rod bushing
Replace the bushing if the clearance between the
piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm /
1m (0.04"/3’3"). For measurement, support both
ends of the parallel section of the piston rod with V-
blocks, set a dial indicator in the center between the
two V-block turn the piston rod, and read the
difference between the maximum and minimum Fig. 32-63 Measuring Method
deflection on the dial indicator.
Table32-3 shows an example of measurement.
Table32-3 Example of Measurement

Distance between Deflection of the dial indicator
V-blocks in the middle of the rod. Remedy
m (ft-in) mm (in)
1 (3’3") 1 (0.04") Replace
Even if the bend is within the above limit, the cylinder

may not operate smoothly because of localized bend.
Beware of it during function test after assembly.
Replace the rod if the cylinder makes a squeaking
noise or dose not operate smoothly.
32.2.1.7.3 TIGHTENING TORQUE
D A B C Unit : N.m (lbf.ft)

A B C D
Cylinder
Piston nut Piston Socket bolt Setscrew
Boom 1,860 (1,372) 981 (724) 368 (271) 14.7 (10.8)
Arm 1,860 (1,372) 981 (724) 368 (271) 14.7 (10.8)
Bucket 1,860 (1,372) 981 (724) 260 (192) 14.7 (10.8)
32.2.1.7.4 VOLUME OF OIL LEAK

The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION AFTER
ASSEMBLY32.2.1.6 (2).
Cylinder Volume of Internal Oil Leak

Boom 5.95cc (0.36 cu•in) or below / 10min
Arm 6.65cc (0.41 cu•in) or below / 10min
Bucket 5.00cc (0.31 cu•in) or below / 10min
32-28
32. ATTACHMENT
32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Rod-packing 1. Foreign matter is trapped in the 1.Remove foreign matter.
surface of piston rod. Oil bore of rod packing.
ring is formed on piston 2. Score is present on the bore of rod 2. Replace rod packing.
rod, and the ring grows up packing.
to oil drops, and they drip. 3. Other rod packings are failed. 3. Replace rod packing.
2. Buffer seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of buffer seal.
OIL LEAKS FROM HERE 2. Score is present on the bore of 2. Replace buffer seal.
buffer seal.
3. Other buffer seal are failed. 3. Replace buffer seal.
3. Dust seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of dust seal.
2. Lip on the bore of dust seal is 2. Replace dust seal.
scored.
3. Another dust seal is failed. 3. Replace dust seal.
4. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.
OIL LEAKS FROM HERE

3. Oil leaks from welds. 1. Cylinder tube 1. Welds of cylinder are broken. 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of slipper seal.
a static load equal to the 2. Score is present on the sliding 2. Replace slipper seal.
maximum working pressure surface of slipper seal.
multiplied by the area of the 3. Other back-up ring are failed. 3. Replace back-up ring.
cylinder bore, the maximum 1. Sliding surface of wear rings is
movement of the piston is 2. Wear ring scored.
1. Replace wear ring.
more than 0.5mm (0.02") in
3. O-ring 1. O-ring is damaged. 1. Replace O-ring.
ten minutes.]
32-29
32. ATTACHMENT
32.2.1.9 TOOLS AND JIGS LIST

The tool and jig list provides the materials and the dimensions of tools and jigs so that they may be utilized in
manufacturing in a service shop. Follow the directions given below in selecting, manufacturing and using the tools
and jigs.
(1) For the rod cover, piston nut and others that require large tightening torques, use eye wrenches as much as
possible.
The tools and the jigs are so designed dimensionally that they can withstand the maximum tightening torques
even if material SS400 (JIS) is used. However, the hook of the tool may be distorted if struck with a hammer. If
such occurs, apply reinforcement weld and finish it by grinding.
(2) The pin section of pin wrenches and pin hook wrenches is loaded with large shearing force. Therefore, take care
when selecting pin material and welding the pin to the body. It is recommended to use the shank section of
disused drills (Fig. 32-64)
USE THIS PORTION.
Fig. 32-64
32.2.1.9.1 ALLEN WRENCH

(FOR ROD COVER SOCKET BOLT)
B
A
MATERIAL : SNCM6 OR SCM3
SURFACE TREATMENT : PARKERIZING
C
Fig. 32-65
Table32-5
Unit : mm (inch)
CYLINDER USED A B C SOCKET BOLT
BOOM, ARM, BUCKET 140 (5.51) 56 (2.20) 14 (0.551) M16
32.2.1.9.2 DUST SEAL PRESSING JIG

(FOR ROD COVER)
E
C1 C1 (0.04")
(0.04")
I
H J MATERIAL : SS400 (JIS)
F G
A
B
C
D
Fig. 32-66 Dust seal pressing jig

Table32-6
Unit : mm (inch)
CYLINDER USED A B C D E F G H I J
ARM 135 (5.32) 140 (5.51) 145 (5.71) 159 (6.26)
80 5 5 15 5 25
BOOM 120 (4.72) 125 (4.92) 130 (5.12) 144 (5.67)
(3.15) (0.197) (0.197) (0.59) (0.197) (0.98)
BUCKET 115 (4.53) 120 (4.72) 125 (4.92) 139 (5.47)
32-30
32. ATTACHMENT
32.2.1.9.3 EYE WRENCH (FOR PISTON NUT)

C
MATERIAL : SS400 (JIS),
FINISH BY GRINDING
AFTER GAS CUTTING
B A
D
E
Plate thickness :
Fig. 32-67 Eye wrench

Table32-7
Unit : mm (inch)
CYLINDER USED A B C D E F G T Common use bolts
140 200 128 15 300 70 40 12~15
ARM
(5.51) (7.87) (5.04) (0.59) (11.8) (2.76) (1.58) (0.47~0.59)
129 189 117 15 300 70 40 12~15
BOOM
(5.08) (7.44) (4.61) (0.59) (11.8) (2.76) (1.58) (0.47~0.59)
124 184 112 11 300 70 40 12~15
BUCKET
(4.88) (7.24) (4.41) (0.43) (11.8) (2.76) (1.58) (0.47~0.59)
32.2.1.9.4 WRENCH (FOR PISTON)

C
MATERIAL : SS400 (JIS),
FINISH BY GRINDING
hole
AFTER GAS CUTTING
D B A
Plate thickness :
Fig. 32-68 Wrench

Table32-8
Unit : mm (inch)
CYLINDER USED A B C D E F G T Common use bolts
115 200 166 14 300 70 40 12~15
ARM
(4.53) (7.87) (6.54) (0.55) (11.8) (2.76) (1.58) (0.47~0.59)
100 180 140 14 300 70 40 12~15 M12× 20
BOOM
(3.94) (7.09) (5.51) (0.55) (11.8) (2.76) (1.58) (0.47~0.59) (2 pieces)
80 170 130 14 300 70 40 12~15
BUCKET
(3.15) (6.69) (5.12) (0.55) (11.8) (2.76) (1.58) (0.47~0.59)
32-31
32. ATTACHMENT
32.2.1.9.5 ROD COVER INSERTING JIG
MATERIAL : SS400 (JIS)

G
R0.5 About
(0.02") E F
5~10
R0.5 (0.02")
R10
(0.39")
D
C
B
Fig. 32-69 Rod cover inserting jig
Table32-9
Unit : mm (inch)
CYLINDER USED A B C D E F G
115.5 120 124.3±0.1 130 28 28.5 200

ARM
(4.55) (4.72) (4.894±0.004) (1.1) (1.12) (7.87)
(5.118 )
100.5 105 109.3±0.1 115 45 28.5 190

BOOM
(3.96) (4.13) (4.303±0.004) (1.77) (1.12) (7.48)
(4.528 )
95.5 100 104.3±0.1 110 28 28.5 190

BUCKET
(3.76) (3.94) (4.106±0.004) (1.1) (1.12) (7.48)
(4.331 )
32.2.1.9.6 PISTON (SLIPPER) SEAL FIXING JIG

C MATERIAL : SS400 (JIS)
D
About 12 F
R10
(0.39") G
A
B
Fig. 32-70 Piston (slipper) seal fixing jig

Table32-10
Unit : mm (inch)
189.5±0.1 191±0.1 162 147 31.0 68 104
ARM
(7.461"±0.004) (7.52±0.004) (6.38) (5.79) (1.22) (2.68) (4.09)
169.5±0.1 171±0.1 142 127 31.0 68 104
BOOM
(6.673±0.004) (6.732±0.004) (5.59) (5.0) (1.22) (2.68) (4.09)
159.5±0.1 161±0.1 132 117 31.0 68 104
BUCKET
(6.28±0.004) (6.339±0.004) (5.20) (4.61) (1.22) (2.68) (4.09)
32-32
32. ATTACHMENT
32.2.1.9.7 SLIPPER SEAL HOLDING-DOWN JIG

C MATERIAL : SS400 (JIS)
R10
F (0.39")
E
HANDLE
D
G
A About 5~ 10
B
Fig. 32-71 Piston seal holding-down jig

Table32-11
Unit : mm (inch)
200 208 192±0.1 46 75 10~15 100
ARM
(7.87) (8.19) (7.559±0.004) (1.81) (2.95) (0.39~0.59) (3.94)
180 188 172±0.1 46 75 10~15 100
BOOM
(7.09) (7.4) (6.772±0.004) (1.81) (2.95) (0.39~0.59) (3.94)
170 178 162±0.2 46 75 10~15 100
BUCKET
(6.69) (7.01) (6.378±0.004) (1.81) (2.95) (0.39~0.59) (3.94)
32.2.1.9.8 BUSHING PRESS-FITTING JIG
C1 (0.039") MATERIAL : SS400 (JIS)
Inner diameter : A1 A-20 (0.878")

A1
D
C
A
B
(Even if there is not the bore A1,

there is no problem.)
C1 E
(0.039")
F G H
I
Fig. 32-72 Bushing press-fitting jig

Table32-12
Unit : mm
(inch)
CYLINDER USED A B C D E F G H I
119.5 139.5±0.1 160 140 5±0.1 96 20 10 126

ARM
(5.492±0.004) (6.30) (5.51) (0.197±0.004) (3.78) (0.79) (0.39) (4.96)
(4.705 )
119.5 139.5±0.1 160 140 5±0.1 96 20 10 126

ROD SIDE
(5.492±0.004) (6.30) (5.51) (0.197±0.004) (3.78) (0.79) (0.39) (4.96)
(4.705 )
BOOM
109.5 129.5±0.1 150 130 5±0.1 96 20 10 126
HEAD SIDE
(5.098±0.004) (5.91) (5.12) (0.197±0.004) (3.78) (0.79) (0.39) (4.96)
(4.311 )
99.5 114.5±0.1 135 115 5±0.1 96 20 10 126

BUCKET
(4.508±0.004) (5.32) (4.53) (0.197±0.004) (3.78) (0.79) (0.39) (4.96)
(3.917 )
32-33
32. ATTACHMENT
32.2.1.9.9 BUSHING PRESS-FITTING JIG
MATERIAL : SS400 (JIS)

C1 (0.039")
A1 Inner diameter : A1 A-20 (0.878")

B
A
(Even if there is not the bore A1,

there is no problem.)
C1
(0.039") C D
E
Fig. 32-73 Bushing press-fitting jig

Table32-13
Unit : mm (inch)
CYLINDER USED A B C D E
130 134.8±0.1 49 100 149

ARM
(5.307±0.004) (1.93) (3.94) (5.87)
(5.118 )
115 119.8±0.1 39 100 139

BOOM
(4.717±0.004) (1.54) (3.94) (5.47)
(4.528 )
110 109.8±0.1 39 100 139

BUCKET
(4.323±0.004) (1.54) (3.94) (5.47)
(4.331 )
32-34
33. UPPER STRUCTURE
TABLE OF CONTENTS

33.1.1 OPERATOR SEAT .................................................................................................33-3
33.1.2 CAB ........................................................................................................................33-4
33.1.3 BATTERY ...............................................................................................................33-6
33.1.4 GUARD...................................................................................................................33-7
33.1.5 UNDER COVER .....................................................................................................33-12
33.1.6 FUEL TANK ............................................................................................................33-13
33.1.7 HYDRAULIC TANK ................................................................................................33-15
33.1.8 HYDRAULIC PUMP................................................................................................33-19
33.1.9 AIR CLEANER........................................................................................................33-24
33.1.10 MUFFLER...............................................................................................................33-25
33.1.11 COUNTERWEIGHT................................................................................................33-27
33.1.12 RADIATOR & OIL COOLER ...................................................................................33-28
33.1.13 ENGINE ..................................................................................................................33-34
33.1.14 CONSOLE COVER ................................................................................................33-37
33
33.1.15 MULTI CONTROL VALVE (Only for Oceania) .......................................................33-38
33.1.16 CONTROL VALVE..................................................................................................33-39
33.1.17 PILOT VALVE (FOR ATT) ......................................................................................33-42
33.1.18 PILOT VALVE (FOR TRAVEL) ...............................................................................33-43
33.1.19 SWING MOTOR UNIT............................................................................................33-45
33.1.20 SWIVEL JOINT.......................................................................................................33-47
33.1.21 UPPER FRAME......................................................................................................33-50
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-52
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................33-52
33.2.2 CONTROL VALVE..................................................................................................33-77
33.2.3 PILOT VALVE (ATT)...............................................................................................33-91
33.2.4 PILOT VALVE (FOR TRAVEL) ...............................................................................33-101
33.2.5 SWING MOTOR UNIT............................................................................................33-110
33.2.6 SWIVEL JOINT.......................................................................................................33-141
33-1
33. UPPER STRUCTURE

SK460-8: LS10-02001~ S5LS3311E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
(4) The removing and installing procedure does not completely cover all possible situations because of differences
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.
33-2
33. UPPER STRUCTURE

33.1.1 OPERATOR SEAT
33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
A1-1
seat (A1) to ease handling.
2) Move the whole control stand to its foremost A1
position.
3) Move the operator’s seat to its forward end. C1
4) Incline the reclining seat as forward as possible. C2
B2
(2) Remove operator’s seat. (Include upper rail.)
C1
1) With the above-mentioned condition, remove C2
two cap screws (B2) M8× 20 from the upper rail.
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8× 20.
1
: 6 mm
2) Remove the operator’s seat. [about 20kg (44 8
lbs).]
Carry out the following operations as required.
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (8).
Fig. 33-1 Disassembling and Assembling seat
33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
A4 A5
Allen Tightening torque
Tightening position wrench
HEX N·m (lbf·ft)
A2
Capscrew (B2) 6 23.5 (17.3)
A6
Sems bolt (C2) 17 46.1 (34)
Sems bolt (A5,A6) 13 23.5 (17.3)
A1
Reference : Movement on rail

A3
Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
A5
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height
[Up; 23mm (0.07in), down; 37mm (0.16in)] Fig. 33-2 Disassembling and Assembling armrest
33-3
33. UPPER STRUCTURE
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6× 16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6× 25 and 1 sems bolt (A39) M6× 16. And right A3
A14
panels (A4) and (A4-1B) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-1H) of inside on right A40
A4-1H
panel (A4-1B). And free the harnesses A29
A4
connected to key switch. A4-1H A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-1H
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-1B
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-1B). (See Chapter 23)
6) Loosen sems bolts (A22) M6× 16 and (A23)
M6× 40 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2
A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-1B), (A3) and (A5-2)
33-4
33. UPPER STRUCTURE
RELAY BOX
ASSY
Fig. 33-5 Move switch cover assy

(7) Remove cab attaching bolt
1) 5 capscrews (A1) M12× 65 and 1 capscrew (A3)
M12× 30. (Mark ) B4
2) 2 nuts (B4) M16 (Mark )

(8) Slinging cab
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling with A3
eye rings and a hook around the cab, as shown
in Fig. 33-7.
A1
2) Then lift up slowly avoiding interference with
surroundings. Fig. 33-6 Removing and installing cab mounting
Wire with hook ; bolts.
Length 1.5m (4ft 11in)× Dia. 8mm
(0.315in)× 3pcs.
Weight of cab ; Approx. 250kg (550 lbs)
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
Fig. 33-7 Slinging cab
33-5
33. UPPER STRUCTURE
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open left panel assy (71), (73).
1) Open it with starter key.
2) Open left panel assy (71), (73).
3) Fix it with stay.
(2) Remove battery cover (2)

Loosen nut (7) M10 and remove battery cover (2).
: 17 mm
(3) Remove battery cable
1) Remove cable (A7) [between the earth and 73
battery (–)]. 71
(Always remove (-) terminal first and install it at
Fig. 33-8
last.)
2) Cable (A8) [between battery (+) and (-)] 2 7
3) Cable (A5) [between battery (+) and battery
relay]
: 13 mm
3
A8 4
Follow the battery removal order.

Start removing battery from grounding side, and finish A7
attaching to grounding side. If this order is missed,
short-circuits may occur.
(4) Remove battery (B1)

A5
1) Loosen 2 capscrews (4) M10× 235.
: 17 mm
2) Remove plate (3).
3) Remove battery (B1). B1
Fig. 33-9 Removing and installing battery
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (3) against battery (B1), and
tighten capscrew (4).
: 17 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (A7) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
33-6
33. UPPER STRUCTURE
33.1.4 GUARD
33.1.4.1 PREPARATION FOR REMOVAL

(1) Remove guard in the following procedure.
61 63
Remove the guards in the order of (1) →(2) →(7) →
(8) →(44) →(6) →(63) →(71) →(73) →(72) and (5). 8,44
(2) All the locked cover, open them using starter key. 7
72
5
73 2
6 1
71
Fig. 33-10 Arrangement of guard assy
33.1.4.2 REMOVE GUARD

(1) Remove bonnet assy (1), (2) 1 2
A
1) Unlock catches (3), (4) and unlatch catches (3), B 6
(4), and open bonnet (1), (2).
2) Remove four nuts (8) M12.
3) Remove bonnet (1). 3
6 4
: 19 mm
8
Weight : 74kg (163 lbs) 8
4) Remove 6 sems bolts (6) M12× 30. A B
5) Remove bonnet (2). Fig. 33-11 Removing bonnet assy (1), (2)
: 19 mm
Weight : 24kg (53 lbs)
(2) Remove guard (7)
38 7
38
1) Remove 6 sems bolts (38) M12× 25.
2) Remove guard (7)
: 19 mm
Weight : 27kg (59.5 lbs)
Fig. 33-12 Removing guard (7)
33-7
33. UPPER STRUCTURE
(3) Remove guard (8) and (44).

34
2) Remove guard (8).
8
: 19 mm 34
Weight :11kg (22 lbs)
3) Remove 5 sems bolts (38) M12× 25. 38
4) Remove guard assy (44). 38
: 19 mm
44
Fig. 33-13 Removing guard (8) and (44)

(4) Remove beam (6)
2) Remove beam (6).
: 19 mm
6 38
Fig. 33-14 Removing beam (6)

(5) Remove stay (3)
00
(6) Remove cover assy (1)

1
Weight : 43 kg (95 lbs)
Fig. 33-15 Removing stay (63) and cover assy (61)

(7) Remove panel assy (71)
1) Unlock and open panel assy (71).
2) Remove 4 nuts (74) M10.
3) Remove panel assy (71).
: 17 mm
74
71
Fig. 33-16 Removing panel assy (71)
33-8
33. UPPER STRUCTURE
(8) Remove panel assy (73)

: 17 mm 74
73
(9) Remove panel assy (72). 72
1) Unlock and open panel assy (72).
: 17 mm
74

(10)Skip
(11)Remove guard (17) and cover (19) 19

1) Remove each 4, 8 in total sems bolts (38)
M12× 25. 38
17
2) Remove guard (17) and cover (19).
: 19 mm
Fig. 33-20 Removing guard (17) and cover (19)
33-9
33. UPPER STRUCTURE
(12)Remove guard (15),(16) 38

1) Loosen 5 sems bolts (38) M12× 25, and remove
38
guard (15).
guard (16).
: 19 mm
38
16
15
38
Fig. 33-21 Removing guard (15),(16)
(13)Remove panel (4), beam (11), bracket (9) and pillar
(12) 38
39
panel (4).
11
3) Remove beam (11).
4) Loosen 4 sems bolts (39) M12× 30, and remove 38
12
bracket (9). 9
38 39
Fig. 33-22 Removing panel (4), beam (11),
pillar (12).
bracket (9) and pillar (12)
: 19 mm
(14)Remove panel (4), pillar (10) and (14)
14
2) Remove panel (4).
pillar (10). 10 4
4) Loosen 4 sems bolts (38) M12× 25, and remove 38
pillar (14).
: 19 mm
39
Fig. 33-23 Removing panel (4), pillar (10), (14)
33-10
33. UPPER STRUCTURE
(15)Remove guard assy (5), (42) and guard (13)

5
1) While air cleaner is removed, loosen hose clamp
of engine intake and disconnect the hose. 38
guard assy (5).
guard assy (42).
guard (13).
38
: 19 mm
Weight : 28kg (62 lbs) : guard assy (5) 13
42
12kg (26 lbs) : guard assy (42)
16kg (35 lbs) : guard (13)
38
38
Fig. 33-24 Removing guard assy (5), (42)

and guard (13)
(16)Remove guard assy (84), (83) 82
guard assy (84). 81
guard assy (83).
: 19 mm
Weight : 10kg (22 lbs) : guard assy (83) 85 85
84 85
86
(17)Remove guard assy (81), (82) 83
1) Loosen 2 sems bolts (85) M12× 25, 4 sems bolts 85
(86) M12× 30 and remove guard assy (81).
guard assy (82).
: 19 mm 85
Weight : 21kg (46 lbs) : guard assy (81)
13kg (29 lbs) : guard assy (82) Fig. 33-25 Removing guard assy (84), (83), (81) and
(82)
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
Unit : N.m (lbf.ft)
SIZE CAPSCREW SEMS BOLT NUT
M8 - 23.0 (17.0) -
M10 - 46.5 (34.3) 46.5 (34.3)
M12 144 (106) 80.0 (59.0) -
33-11
33. UPPER STRUCTURE
33.1.5 UNDER COVER
33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8,9,10,11,12,13)
1) Remove attaching sems bolts (14) M12× 30 and sems bolts (15) M12× 25.
2) Remove covers.
: 19 mm
Fig. 33-26 Under cover assy
(1) Install under cover (1,2,3,4,5,6,7,8,12)
: 19 mm
33-12
33. UPPER STRUCTURE
33.1.6 FUEL TANK

(1) Draining fuel. (See Fig. 33-28)
28
1) Unlock cap (B2) with a starter key and open it. 13
2) Loosen valve (A7) under the tank.
37
3) Draining fuel 29 29
Capacity of tank : 650L (172gal) 4 12
(2) Remove stay (63) and guard assy (61). 28
(See 33.1.4 GUARD) 33
(3) Remove the connector for level sensor (A4).

(See Fig. 33-28) 29
7
(4) Remove fuel hose
1) Loosen clip (28),(29) and draw out hoses (4), Fig. 33-27 Removing fuel hose (4),(12),(13),(7)
(12), (13) and (7).
2) Put in plugs that match the hose bore.
3) Loosen clip (A9), and disconnect the hose which
joins between the front and rear tank.
clip (33).
33.1.6.2 REMOVAL
(1) Remove 6 capscrews (A1) M16× 45.
: 24 mm
(2) Hook the wire to the lifting eye on the fuel tank assy
and remove the fuel tank. B2
(3) Remove shim (A3).
A3
Record the shim locations.
A1
Fig. 33-28 Removing fuel tank
33-13
33. UPPER STRUCTURE
Tank attaching bolt (A1) M16× 45
: 24 mm, Apply Loctite #262

Tightening torque : 46.5 ± 4.6 N•m (34.3 ± 3.4 lbf•ft)
If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim (A3)
and tighten capscrew (A1) to install the tank.
Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 10 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Cock 2 34 (25)
33-14
33. UPPER STRUCTURE
33.1.7 HYDRAULIC TANK

(1) Remove panel assy (72), guard (8), (44) and other 8,44
guards necessary to remove the hydraulic oil tank. 72
(See 33.1.4 GUARD.)
Fig. 33-29 Remove guard

(2) Release internal pressure of tank
Remove cap on air breather and push valve (head
of bolt) by your finger.

Keep pressing until the hissing stops.
Fig. 33-30 Bleeding internal pressure of tank
(3) Remove cover (C1). C4 C4
1) Remove 6 sems bolts (C4) M10× 25.
C2
: 17 mm
C1
2) Remove cover (C1).
3) Remove suction strainer (B1).
(4) Remove cover (C2).

1) Remove 6 capscrews (C4) M10× 25.
B
: 17 mm
Air B1
2) Remove cover (C1). C breather
3) Remove filter element (B5).
D
(5) Turn the handle of element assy (B), and

D
disassemble the removed filter element (B5). B5
Disassemble parts : (B), (C), (D)× 3, (E), (F)
D
(6) Draining hydraulic oil
Place pump in tank and draw up hydraulic oil. E Hyd.tank
Capacity of tank : 427 L (113gal) F
Fig. 33-31 Remove cover (C1), (C2)
33-15
33. UPPER STRUCTURE
33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3)
1) Remove 2 sems bolts (A19) M12× 35 for tube
(A8) installation.
A34
A8
: 19 mm
2) Remove 2 clips (A34) of the tank side and pull
out hose (A3).
2 : Flat-blade screwdriver
A3
A19
Fig. 33-32 Removing and installing the suction

hose
(2) Disconnecting the main pipe return hose (A2), (A3).
A10 A2
Remove sems bolt (A20) M12× 40 and remove A3
A20
return hose (A2), (A3).
: 19 mm
(3) Remove drain hose (A11) of pump

A11
: 36 mm
(4) Remove drain hose (A10) of swing motor O/C

C/V
R1
: 36 mm
Fig. 33-33 Removing main piping return hose
(5) Disconnecting pilot return hose

1) Remove pilot hose (A9).
: 22 mm
2) Remove pilot hose (A3).
: 22 mm
3) Remove pilot hose (A17). A3
A9 S/V
C/V
: 22 mm C1 A4 A17 Dr2
T
PT S/V
4) Remove pilot hose (A4). H/V T
T
Dr
: 22 mm Fig. 33-34 Remove pilot return hose

5) Remove pilot hose (C1).
: 22 mm
(6) Remove drain hose (1) of pilot pump
: 22 mm
Fig. 33-35 Removing pump drain hose
33-16
33. UPPER STRUCTURE
(7) Removing fuel filter

Loosen 4 capscrews (38) M10× 35, and remove 2
38
fuel filters (1).
Fig. 33-36 Removing fuel filter

(8) Remove hydraulic tank attaching bolt
Remove 4 capscrews (A1) M20× 45.
: 30 mm
(9) Slinging hydraulic oil tank

Place a wire sling, using the lifting plate on top of
the tank.
Tank weight : Approx : 291kg (642 lbs)
(10)Remove shim (A3).
A3
Record the shim locations.
A1 A1
Fig. 33-37 Removing hydraulic tank
33-17
33. UPPER STRUCTURE
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M20× 45 with
Loctite #262. (See Fig. 33-36.)
: 30 mm, Apply Loctite # 262

If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim (A3)
and tighten capscrew (A1) to install the tank.
(5) Connection of suction hose (A3)(See Fig. 33-32) O-RING

1) Apply PERMATEX on pipe side of hose
connection and insert it.
2) Put the hose with clip (A34).
C
(6) Assembling return element
Assemble filter element by the use of element kit
(B-100). (See Fig. 33-31,Fig. 33-38)
D
B2 SUCTION
1. Three elements (D) are used as one set. STRAINER
LS50V00007F1
2. Replace O-ring (C) and packing (F) with new ones
respectively.
(7) Install return element (B5). (See Fig. 33-31) F

ELEMENT KIT
(8) Installing suction strainer (B1) (B-100)
(9) Tighten sems bolts (C4) M10× 25 that attach tank LS52V01001R300
covers (C1), (C2). Fig. 33-38 Element & suction strainer
M10 Tightening torque : 46.5 N•m (34 lbf•ft)
Replace O-ring fitted on the back side of tank cover with

new one.
33-18
33. UPPER STRUCTURE
33.1.8 HYDRAULIC PUMP

(1) Release pressure in hydraulic oil tank.
C4
(See 33.1.7HYDRAULIC TANK)
(2) Remove six capscrews (C4) M10× 25.
C1
(3) Remove cover (C1)
Suction
: 17 mm stopper
(4) Take out suction strainer.

(5) Install suction stopper.
Suction
For suction stopper, see chapter 11. Tools. strainer
Hyd.tank
Fig. 33-39 Suction stopper installing

(6) Remove guards (See 33.1.4 GUARD.) 1 2
A
1) Remove bonnet assy (2). B 6
2) Remove guard (7), (15) and guard (16).
3) Remove those parts that are required to remove
the hydraulic pump such as the fuel filter assy. 3
6 4
4) Remove drain hose at the bottom of the muffler.
8
8
A B
38 7
38
39
16
15
38
Fig. 33-40 Removing guards
33-19
33. UPPER STRUCTURE
33.1.8.2 REMOVAL
(1) Loosen capscrews (A21) M12× 40, (A42) M12× 110 A5 A42
A6
and remove half clamp (A36). And disconnect 2 A36
hoses (A5), (A6) from the delivery side. A21
A36
: 19 mm a5
A1
(2) Remove side branch hose (A1), (A2). Ps2
a2
Dr1
: 41 mm a1 Ps1
(3) Remove suction hose (A4) and drain hose (1) a5
1) Remove 4 capscrews (A25) M16× 35.
: 14 mm A2
2) Remove elbow (A7) of suction hose (A4) from
pump.
A25
3) Remove drain hose (1) (Dr).
(See Fig. 33-42)
A7
: 22 mm
A4
Fig. 33-41 Removing hoses
(4) Removing other hoses
Psv1- A16
1) Disconnect hoses of the following ports. FILTER- Psv2 S/V P1-
Psv2 3 PUMP A3
2
Hose
Port No. Tool Remarks
*Psv1 3 19 Pilot primary pressure P1 side
*Psv2 2 19 Pilot primary pressure P2 side
Psv1 A16 22 Pilot pump delivery
1 TANK-
PUMP Dr2
Remove the parts marked * only if necessary.
Fig. 33-42 Removing other hoses
2) Attach tags to hoses to identify.
3) Put a plug in the hoses and the pump.
33-20
33. UPPER STRUCTURE
(5) Remove connector

Remove 4 connectors of all pressure sensors and
proportional valves.
PSV-P1: Using Zip-tie, clamp
P1 pump proportional the corrugated part of SEMS BOLT
valve harness to the solenoid. Tightening torque
38.2N.m (28 lbf.ft)
PSV-P2:
P2 pump proportional
valve
Engine side
SE-23:
Pressure sensor :
P2 pump
SEMS BOLT Using Zip-tie,
Using Zip-tie,
clamp the corrugated Tightening torque SE-22: clamp the corrugated part of
part of harness to the 38.2N.m (28 lbf.ft) Pressure sensor : harness to the pressure sensor.
P1 pump
pressure sensor. Pressure sensor: Pressure sensor:
Installing part of P2 pump Installing part of P1 pump
Fig. 33-43 Removing connector

(6) Remove main pump 0
4
1) Put a wire sling on the hydraulic pump and 2
tension the wire sling a little. Loosen 8
3
capscrews (2) M10× 35 and 4 capscrews (3)
M10× 45.
: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of
the wire rope.
1-4 1-5
On that occasion, the assembly is drawn out with
the insert NA (1-3) remaining on the flywheel
side.
3) Remove element (1-1) from the tip of the spline 1-6 1-5
shaft. 1-2 1-3
4) Remove 4 capscrews (1-5) M20× 65 that fasten

insert R (1-4) and remove insert R (1-4).
1-7 1-1
: 17 mm 1
1-7
5) Remove hub (1-2)
If you loosen 2 set screws (1-6) M20× 25, hub
Fig. 33-44 Removing pump
comes off from the spline shaft of the pump.
: 10 mm
6) Remove 4 capscrews (1-5) M20× 65 that fasten
the insert NA (1-3) with the engine side flywheel,
as necessary. Then remove and spring pin (1-7)
from insert NA (1-3).
: 17 mm
33-21
33. UPPER STRUCTURE
(1) Installing hub (1-2)
Put hub (1-2) into the pump spline till it enters
16.5mm (0.65in) from the end face of the spline
(See Fig. 33-45 Detail aa). Then install two set
screws (1-6) and fix them together.
: 10 mm
(2) Installing insert R (1-4)
Install insert R (1-4) into hub (1-2) by means of
capscrews (1-5).
: 17 mm
(3) Installing element (1-1)
Put element (1-1) into hub (1-2) and insert R (1-4).
(4) Installing insert NA (1-3)
Put spring pin (1-7) into insert NA (1-3) and install it
to the engine flywheel by means of capscrews (1-
5).
: 17 mm
(See Fig. 33-44 about above mentioned (1) ~ (4).)
33-22
33. UPPER STRUCTURE
(5) Installing the pump (See Fig. 33-44,Fig. 33-45)

T=68.6N.m (51 lbf.ft)
Lift the pump with bracket. Place coupling (1) in the 2 Apply Loctite #262
groove of element (1-1) so as to receive insert NA
1
(1-3). DELIVERY
(6) Coat 8 capscrews (2) M10× 35, 4 capscrews (3)

M10× 45 with Loctite #262 and put them in place.
aa
: 17 mm
Tightening torque : 68.6N•m (51 lbf•ft)
T=210N.m
(7) Fasten hoses (A5), (A6) on the delivery side with (155 lbf.ft)
1-6
half clamp (A36) and capcrew (A21) M12× 40. SPRING PIN
(4 places)
(See Fig. 33-41)
1-5 SUCTION
T=465N.m (343 lbf.ft)
: 19 mm Do not use Loctite
Tightening torque : 121N•m (89 lbf•ft) (The attached bolts are coated
with micro capsule coating)
(8) Install suction hose (A4) with 4 capscrews (A25)

80(3.15")
M16× 35. (See Fig. 33-41) 45 (1.78")
: 14 mm
Tightening torque : 143 N•m (105 lbf•ft) 16.5 0.5
(0.65" 0.02")
(9) Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
4
(10)Installing the hose (See Fig. 33-42) 3
T=68.6N.m (51 lbf.ft)
Apply Loctite #262
DETAIL aa VIEW I
Tool Tightening torque
Port
mm N m (lbf ft)
Fig. 33-45 Installing hydraulic pump
Cap nut Dr3 22 34.3 (25.3)
Cap nut Psv1,2 19 29 (22)
(11)Installing pressure sensor connector and

proportional valve connector.
(12)Remove suction stopper
(13)Install suction strainer
When the pump is replaced, replenish more than 1L

(0.26gal) of hydraulic oil from the drain port (D1).
(14)Bleed air in pump D1

Bleed air by loosening the drain port (D1).
(15)Check hydraulic oil level.
(16)Start engine and check it for oil leak and noise.
(17)Attach drain down pipe under engine muffler.
(18)Install guards
(See Fig. 33-40,Fig. 33-18)

Tightening position
mm N m (lbf ft) Fig. 33-46 Bleed air port (D1) in pump
Sems bolt M12 19 80 (59)
33-23
33. UPPER STRUCTURE
33.1.9 AIR CLEANER

(1) Opening panel assy (71) and (73).
(See 33.1.4 GUARD)
(2) Open bonnet assy (1).
(See 33.1.4 GUARD)
(3) Remove Panel assy (5).
(See 33.1.4 GUARD)
(4) Unplug terminals on indicator (1-8) wiring. 5
(See Fig. 33-48) 73
71 1
Fig. 33-47 Preparation for removal
33.1.9.2 REMOVAL
(1) Pulling out hose (3).
35 (1.38")
5
1) Loosen clips (5), (6) on both sides of hose (3). Insert width
of hose
2) Pulling out hose (3)
(2) Remove air cleaner assy (1) 7

1) Remove 4 sems bolts (7) M10× 30
DETAIL aa
Insert width of hose
: 17 mm
45 45
(1.77") (1.77") cc
2) Remove air cleaner assy (1) from plate (4). 6
bb
3
6
DETAIL bb
40 8")
5
(1.
Insert width aa 1 1-8 4 2

of hose
DETAIL cc
Fig. 33-48 Removing air cleaner
(1) Installing is the reverse order of removing with Replacing parts
attention paid to the following items:
1) Put in air hoses to the end as shown in Fig. 33-
48.
2) Tightening torque :
O RING (1-6)
No. Name Tightening torque N.m (lbf.ft) (LS11P00014S006)
1-8 Indicator 3.9 (2.9) FILTER ELEMENT (1-3)

(LS11P00014S003)
7 Sems bolt 39.2 (29) (Apply Loctite #262)
5,6 Clip 11 (8.1) FILTER ELEMENT (1-2)
(LS11P00014S002)
33-24
33. UPPER STRUCTURE
33.1.10 MUFFLER

(1) Remove bonnet assy (1) and guard (7).
1
(2) Remove panel assy (72). 7
(3) Remove guard (16) and (15). 72
(See Fig. 33-18)
33.1.10.2 REMOVAL
(1) Remove U bolt (6). 6
11
1) Remove 4 nuts (11) M8. 1
6
: 13 mm
10
2) Remove 2 U bolts (6).
11
(2) Remove clamp assy (7)
1) Remove 2 capscrews (10) M10× 35
7
: 17 mm 2
2) Separate clamp assy (7) from muffler (1).
(3) Removing other parts
Remove brackets (2) and (3) as necessary.
: 19 mm, 22 mm
3
Attach washer (14) to nut side.

Tightening torque: 68.6~98 N.m (51~72lbf.ft)
Tighten nut till the no gap is here between
plates of clamp.
SPACE 10,12,14
10mm (0.4 in) from
the tip of muffler slit
B
C
A
Procedure of
fastening U bolt Installing clamp side (7)
Fig. 33-50 Removing and installing the muffler
33-25
33. UPPER STRUCTURE
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (6) (See Fig. 33-50)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (7)
1) Place the end of clamp (7) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-50)
2) Install the clamp assy (7) in the illustrated
direction.
(3) Tightening torque :
No. Name Tightening torque N.m (lbf.ft)

9 Capscrew 144 (106) (Apply Loctite #262)
15 Sems bolt 66.7 (49) (Apply Loctite #262)
(4) Replacing parts
Name Part No.

Muffler (1) LS12P00016P1
33-26
33. UPPER STRUCTURE
33.1.11 COUNTERWEIGHT
33.1.11.1 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it and stretch
wire rope to the degree where it is providing no
slack temporarily.
Weight of counterweight ;
Approx. 9,700kg (21,390 lb)
Wire more than ø24 (0.95 inch) ;
2.0m (6ft)× 2 pcs.
(2) Removing counterweight
1) Remove 4 capscrews (A1) M42× 400.
Fig. 33-51 Lifting up counterweight
: 65 mm
2) Remove shim (A4), (A5), (A6). (Select)
3) Remove counterweight (C1).
A4
A5
A6
C1
A1
A2
Fig. 33-52 Removing counterweight
(1) Install counterweight in the reverse order of
removing.
Using shims of less than 2
(2) Install shim (A4), (A5), (A6) as it was. (select) sheets, and adjust clearance
(3) Slinging counterweight to 10mm (0.39") between
counterweight and guard.
Check that the attaching bolts can be screwed in by
A6,A5,A4
hand.
(4) Apply Loctite #262 on capscrews (A1), and tighten
them with washers (A2).
: 65 mm
(5) Remove slinging tools.
A2,A1
Fig. 33-53 Fastening the counterweight attaching

capscrew
33-27
33. UPPER STRUCTURE
33.1.12 RADIATOR & OIL COOLER

(1) Bleed air from the hydraulic tank and install the
suction stopper. (See 33.1.7 and 33.1.8)
(2) Remove bonnet assy (1), (2)
(See 33.1.4 GUARD)
(3) Remove battery (See 33.1.3 BATTERY)
(4) Remove beam (6). (See 33.1.4 GUARD)
(5) Open panel assy (71). (See 33.1.4 GUARD)
(6) Removing under cover installed on lower side of 15
radiator. 4

Fig. 33-54 Removing under cover (4)
2) Remove cover (4).
: 19 mm
(7) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose
for draining water. Clip
10
[Water capacity of radiator : 16.4L (4.3gal)]
1
(8) Remove hose from radiator sub tank (1)
Remove clip of radiator cap side and disconnect
hose (10).
Fig. 33-55 Removing hose of sub tank (1)
Do not loosen the joints of the hoses related to the air-

conditioner. Otherwise the refrigerant leaks.
34
(9) Move air-conditioner condenser and receiver tank
1) Loosen 4 capscrews (56) M6× 50 and 4 sems
bolts (8) M8× 20. 35
7
8
: 10 mm, 13 mm 56
2) Move air-conditioner condenser and receiver
tank separately.
(10)Disconnect connector of coolant level switch (B9).
(See Fig. 33-57) Fig. 33-56 Moving condensers and receiver tank
33-28
33. UPPER STRUCTURE
33.1.12.2 REMOVAL
(1) Remove radiator stay (A1), (A2).
1) Remove 4 sems bolts (A3) M12× 35.
: 19 mm
2) Remove 2 stays (A1), (A2). B1 B2
B A2 B4-2
(2) Remove water hose (2),(3) A3
1) Loosen the hose bands (23) for water hose (2). B9

: Flat-blade screwdriver
2) Remove hose (2).
3) Loosen hose band (23) on water hose (3) and
A3
remove capscrew (32) M10× 25.
: Flat-blade screwdriver A1
: 17 mm
A
4) Remove hose (3).
B
A4
Fig. 33-57 Removing radiator assy
(3) Remove hoses (6), (8) for inter-cooler
1) Remove a fixing U-bolt (20) from tube (13). 17
31
: 13 mm
24
2) Loosen sems bolt (30) M12× 20. 2 39
16 5
: 19 mm 31 36
3) Loosen hose bands (21) and remove hose (6). 33 21
3
4) Loosen hose bands (21), (39) and remove hose 23 31
20
23 13
(5). 32
5) Remove a fixing U-bolt (20) from tube (11). 34
21
35
29 7
: 13 mm 32
6) Loosen sems bolt (30) M12× 20. 23 30
8 21
: 19 mm 21
7) Loosen hose bands (21) and remove hose (6). 21
6
8) Loosen hose bands (21) and remove hose (7). 11
20
Fig. 33-58 Removing hose for radiator/inter-cooler

(4) Remove guard (16), (17) (See Fig. 33-55)
2) Remove guard (16), (17).
: 13 mm
33-29
33. UPPER STRUCTURE
(5) Disconnecting hydraulic oil tube (29), (30) 29

19
1) Loosen 2 capscrews (23) M12× 60 for attaching 13 23
clamp (13). (2-places)
2) Place an oil pan under the hose joint. Loosen 4
sems bolts (19) M12× 35, and remove tubes (29)
30
and (30).
23
(6) Remove radiator assy. (See Fig. 33-57) 13
1) Remove 4 sems bolts (A4) M20× 50.
: 30 mm 19
: 30 mm
2) When lifting the engine fan, shift the radiator so
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc.
4) Removing radiator A4
Place a wire sling in the lifting eyes of the radiator Fig. 33-59 Removing hydraulic oil tube (29), (30)
assy and remove the assy by crane.
33-30
33. UPPER STRUCTURE
(1) Installing is done in the reverse order of removing. Insert width CLIP Tightening torque
of hose
And removed clips of hose should be clamped at 11N.m (8 lbf.ft)
50(1.97")
original position.
Insert
(2) Install radiator assy width
Insert width
of hose
of hose
Place a wire sling in the lifting eyes of the radiator
50
(1.
25
(0.98")
97
") CLIP
and move it to original position temporally. And Tightening torque
11N.m (8 lbf.ft)
install hydraulic hose, radiator hose and hose of Insert width
of hose
inter-cooler. Regarding Inserting width of hose.
50(
(See Fig. 33-60)
1 .9
7")
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A4) M20× 56.
: 30 mm
(4) Adjust the clearance between the fan and the
(1.57") 40
radiator shroud all around the circumference, as Insert
width of hose CLIP Tightening torque
5.9N.m (4.4 lbf.ft)
below :
Insert width
Circumferential direction: of hose
18±3mm (0.7in±0.1in)
50(1.97")
(1.57") 40
44±5mm (1.7in±0.2in)
(5) Clean the plastering area of the insulation
thoroughly before plastering it.
50(1.97")
(6) Making up hydraulic oil and LLC (Long Life
(1.57")
40
Coolant)
After completion of other installation, make up Insert width
of hose
(1.97")(1.97")
hydraulic oil and water.

50
Coolant volume of engine body : 21 L (5.5gal)

50
Insert width
Coolant capacity of radiator : 16.4 L (4.3gal) of hose
Hydraulic oil capacity of oil cooler : 16 L (4.2gal)

CLIP
Tightening torque
11N.m (8 lbf.ft)
50
(1.97")50 (1.97") CLIP Tightening torque
Insert width of hose 11N.m (8 lbf.ft)
Fig. 33-60 Inserting width of hose

Adjust the engine fan
so its rear end sticks
out 44mm (1.7 in) from
the radiator shroud.
44 5
0.2in) (1.7in
Fig. 33-61 Back-and-forth adjusting position of

radiator
33-31
33. UPPER STRUCTURE
33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE

(1) Preparation for disassembly and assembly
1) Remove one under cover at the bottom of the
radiator.
2) Wait till the engine coolant cools down so you do
not get burned. Then remove the cap of the
radiator, discharge the coolant by opening the
drain valve located at the back bottom and
receive it in a container.
* In case of removing inter cooler only, the above 27 7
Tightening torque
Tightening torque
mentioned work is not necessary. 88N.m (64.9 lbf.ft) 23.5N.m
(17.3 lbf.ft)
Tightening torque
(2) Disassembly 88N.m (64.9 lbf.ft) Tightening torque
28 23.5N.m (17.3 lbf.ft)
COOLANT LEVEL 28 B2
1) Disconnect wiring connector of radiator coolant SWITCH
B7
level switch.
2) Loosen 5 sems bolts (B7) M8× 20 attaching plate
assy (B2), remove plate assy (B2).
3) Loosen 2 capscrews (27) attaching radiator core.
4) After confirming that the coolant has been
drained out completely, loosen and remove only A
the radiator side of hose bands (23) at the top RADIATOR
OIL
COOLER
and bottom of the radiator. (See Fig. 33-58)
5) Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Confirm the missing of rubber bushing (26)
under the radiator core.
6) Loosen 3 capscrews (29), 3 capscrews (30) and DRAIN VALVE
4 capscrews (31) attaching the inter-cooler core
(with fuel cooler). 26
7) Loosen and remove only the inter-cooler side of 31
DETAIL OF RADIATOR
hose bands (21) at the top and bottom of the CORE MOUNTING PART
inter-cooler. (See Fig. 33-58)
8) Lift and remove inter-cooler using lifting eyes.
29
Tightening torque
88N.m (64.9 lbf.ft)
INTER-COOLER
(w/FUEL COOLER)
30
VIEW A
Fig. 33-62 Removing radiator and inter-cooler
33-32
33. UPPER STRUCTURE
9) Disconnection of oil cooler tube

Disconnect tube (29), (30) from upper and lower
of cooler, and drain hydraulic oil. (See Fig. 33-
59)
10) Lift cooler temporally using cooler head flange
for slinging.
11) Loosen 4 bolts (28) attaching oil cooler.
12) Lift the oil cooler.
There is no predetermined sequential order in

removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as
necessary.
(3) Installing
33-33
33. UPPER STRUCTURE
33.1.13 ENGINE
33.1.13.1 PREPARATION FOR REMOVING

(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1) Remove E/G ground cable
2) Starter cable-Starter B terminal
3) Remove the connector that connects the upper harness with the engine and ECU harness.
4) Upper harness
CN-206-E/G sub harness
P21,22-Alternator B terminal
CN-26-Alternator L&R terminal
CN-136-E/G speed sensor
CN-141, CN142-Pump proportional valve
CN-139, CN-140-P1,P2 pump pressure sensor
P12-Air heater
P4-Starter motor C terminal
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)
STARTER
OIL FILTER
ELEMENT
THERMOSTAT
FUEL FILTER ROTATION

ELEMENT SENSOR
ALTERNATOR
Fig. 33-63 Outside view of engine
33-34
33. UPPER STRUCTURE
33.1.13.2 REMOVAL
Fig. 33-64 Dismantling and mounting engine

(1) Remove hose of engine oil filter
Place oil pan under the connection of filter (1), and disconnect hoses (6), (7), (8) at positions.
: 17 mm, 41 mm
(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
1) Loosen 2 nuts (28) M18 and 2 nuts (29) M27.
: 27 mm, 41 mm
2) Loosen 2 capscrews (23) M18× 150 and 2 capscrews (24) M27× 170.
3) Remove 2 plates (18) and 2 plates (19).
4) Remove upper rubber mounts (14) and (15) 2 each.
(4) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 1,150 kg (2,536 lbs)
Wire: ø10 (0.394")× 1m (3ft 3in) - 2pcs.
(5) Position engine on the stand stably.
33-35
33. UPPER STRUCTURE
Tightening torque
No. Name Remarks
N.m (lbf.ft)
5 Bolt 26.5 (20)
Apply Loctite
23 Capscrew 226 (167) #262
Apply Loctite
24 Capscrew 765 (564) #262
Apply Loctite
25 Capscrew 115 (85) #262
Apply Loctite
26 Capscrew 172 (127) #262
35 Sems bolt 46.1 (34)
36 Sems bolt 46.1 (34)
37 Sems bolt 46.1 (34)
Tightening torque of Seperated engine oil filter piping

ORS Joint Hose
Thread Torque Torque
size Nm (pound-ft) Nm (pound-ft)
PF1 78 (57.5) 137 (101)
M12 - 26.5 (20)
33-36
33. UPPER STRUCTURE
33.1.14 CONSOLE COVER
33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
2) Loosen 3 sems bolts (10D) M6× 16.

: Plus screw driver
3) During lifting right upper console cover (9D) up;
disconnect connector of tuner and antenna.

Move boot (3) upwards and remove console
cover (9D).
• Removing of boot and lever is unnecessary. Fig. 33-65 Removing plate (4)
4) Loosen 3 sems bolts (16A) M6× 16 and remove 10D
lower console (4). 9D
: Plus screw driver 10D
(2) Removing left-hand console cover 16A
16B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 5 16B 4 16A
65) 16B
16C
2) Loosen 2 sems bolts (A6) M8× 20 and remove
left armrest assy.
6
: 13 mm
3) Loosen 4 sems bolts (16B) M6× 16.
: Plus screw driver
4) Remove the left upper console cover (5) in the
same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M6× 16 while lifting
left under console cover (6) up, and remove left Fig. 33-66 Removing console covers
lower console cover.
Install it in reverse order of removing according to the
tightening torque table.
A6
Item Bolts Tightening torque N.m (lbf.ft)
16~16C Sems bolt M6 5.0 (3.7)

A6 Sems bolt M6 23.5 (17.3)
Fig. 33-67 Removing left armrest
33-37
33. UPPER STRUCTURE
33.1.15 MULTI CONTROL VALVE (Only for Oceania)

(1) Bleed pressure air in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (3). (See 33.1.5 UNDER
COVER)
(3) Open the left panel assy (23) located at rear of cab.
(See 33.1.4 GUARD)
Fig. 33-68 Removing multi control valve
33.1.15.2 REMOVAL
(1) Attach tag on which hose name is entered to the
2
remote control hoses between multi control valve 8 P/V 5
and pilot V, and write numbers P1 to P8 on it. P/V P/V 1
See Tools 11.5 PLUG (3) P/V
4 P2 P5
: 19 mm, 22 mm P/V
P8 0 P1
(2) Attach tag on which hose name is entered to the 7 6
remote control hoses between multi control valve P/V P4 P6 P/V
and main control valve, and write numbers C1 to C8
P7
on it. 3
See Tools 11.5 PLUG (3) P/V P3
: 19 mm, 22 mm
(3) Remove 4 sems bolts (B18) M8× 20, and remove Fig. 33-69 Removing hoses between P/V
multi control valve (0) with bracket (B10) from and multi C/V
machine.
(1) Installing is done in the reverse order of removing 4Pc1
4Pa2 B3
(2) Relations between pilot valve and multi control C/V C/V 5Pb2
valve hose C4 C/V
C2
C5 C1
P/V Hose ISO Multi Mark-
Port Size Color Control pattern port ing C6
1 3/8 Red Bucket digging P1 1 0 5Pa5
2 3/8 Blue
Right side
Bucket dump P2 2
C / V C / V C4Pb2
/V
3 3/8 Green Boom up P3 3 5Pa2
4 3/8 Gray Boom down P4 4 C8
P 1/4 Black Pilot primary - -
T 3/8 Black C3
Drain - - C/V
5 3/8 Gray Swing left P5 5 4Pa3
C7
6 3/8 Red Swing right P6 6 C/V
Left side
5Pb5
7 3/8 Blue Arm in P7 7
8 3/8 Green Arm out P8 8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - -
B7
B18
Fig. 33-70 Connection between multi control valve
Tightening position
mm N.m (lbf.ft) and main C/V
Sems bolt (B18) 13 35.3 (26.0)
33-38
33. UPPER STRUCTURE

(1) Remove guard (8), (44)
3
(See 33.1.4 GUARD)
(2) Remove under cover (5).
(See 33.1.5 UNDER COVER) 7
(3) Install the suction stopper to the hydraulic oil tank.
(4) Remove the hoses in Fig. 33-72 and Fig. 33-73. 1
2 6
Mark each hose with a port name before removing it.
7
6
Fig. 33-71 Removing the standard main control

valve
33.1.16.2 REMOVAL
(1) Remove 4 capscrews (7) M20× 40, and remove
control valve (3) by hoist.
: 30 mm
Weight :Approx. 385kg (849 lbs)
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 4 capscrews (7) M20× 40.
: 30 mm
2)
Connector / Bolt Hose nut
Tread Tightening Tightening
Opposing torque Opposing torque Remarks
Name
size Ports flats N.m (lbf.ft) flats N.m (lbf.ft)
4pc1,4pc2,4pc3,4pf1,5pc1 36.3 2
PF1/4
5pc2,5pc3,5pf1,dr1,dr4,pc 19 (26.8 1.5) 19 29 (21)
4pa1~4,4pb1~4,pz1,dr2 73.5 5
PF3/8 ORS Joint
pz2,5pa1~5,5pb1~5,dr3 22 (54.2 3.7) 22 49 (36)
Rs,Rs2
PF1
41 255 (188) 41 137 (101)
M12 4A1,4B1,5A1,5B1,5A2,5B2 10 98.1 (72.4)
Capscrew
M14 P1,P2,4A2,4B2,4A3,4B3,5A5,5B5 12 147 (108)
R1,R2
M12 Sems bolt
19 98.1 (72.4)
(2) Check for oil leak and operation.
33-39
33. UPPER STRUCTURE
Functions Ports Ports on upper sides Ports Functions

LEFT RIGHT
Arm out 4pb4 5pa5 Arm 1 out
Boom (R) relief valve 5pc1 Arm out lock release
Boom down 4pb3 Arm (R) relief valve
Bucket (H) relief valve 5pa4 Boom 2 up
Bucket digging 4pb2 5pa3 Option

Travel left reverse 4pb1 5pa2 Swing right
Unload Pz2 5pa1 Travel right reverse
Ports on rear sides (on machine)

LEFT RIGHT
R1 Tank return
R2 Tank return
Ports on right sides (on machine)

UPPER LOWER
SIDE SIDE
Drain dr4 5pc2 P2 bypass cut
Drain dr3 5B5 Arm in
Arm out 5A5 5pc3 Arm lock reverse
Option 5A3 5B3 Option
Swing right 5A2 5B2 Swing left
Travel right reverse 5A1 5B1 Travel right forward
P2 P2 pump
Fig. 33-72 Control valve ports (1/2)
33-40
33. UPPER STRUCTURE
Function Ports Ports on left side (on machine) Function

LOWER UPPER
SIDE SIDE
Boom up 4A3 4pc2 P1 bypass cut
4B3 Boom down
Drain dr2 4B2 Bucket digging
Bucket dump 4A2 4B1 Travel left reverse
Travel left forward 4A1 pc ATT power boost
P1 pump P1
Ports on lower side (on machine)

LEFT RIGHT
4pa4 Arm in
SIDE SIDE
Arm in 5pb5
Bucket (H) relief valve
Arm (H) relief valve
4pc1 Boom down lock release
Boom 2 down 5pb4
4pa3 Boom down
Option 5pb3
Boom (R) relief valve
Swing left 5pb2 4pc3 Boom (H) stroke limit
Travel right forward 5pb1 4pa1 Travel left forward
Bucket dump 4pa2 Pz1 Travel straight
Swing motor 2 boost Rs2
Drain dr1
Tank return R3
Swing motor 1 boost Rs1
Fig. 33-73 Control valve ports (2/2)
33-41
33. UPPER STRUCTURE
33.1.17 PILOT VALVE (FOR ATT)

The removing procedure for right and left is the same,
so the preparation for left side is described here.
(1) Put attachment on ground, stop engine and release
pressure in tank.
(2) Remove left console cover (5), (6) assy referring to
Section 33.1.14CONSOLE COVER.
3
(3) Disconnect harness connector for horn at 2-1
position.
5
(4) Attach a tag to the hose to make assembly work
easier. *
Fig. 33-74 Installing and removing boot

and lever part
33.1.17.2 REMOVAL
(1) Remove hoses from your side to far side in order. !
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-74)

: 22 mm

(3) Turn and loosen lever (2-1) tightened in pilot valve,

and remove lever assy in a set. (See Fig. 33-74) *+,
%& '
( ""'
*!+
(4) Remove 4 capscrews (A14) M6× 25. (See Fig. 33- % ' ""'

75) % ' !
: 5 mm -%. /*/
(5) Remove pilot valve. *+, *!+
(6) Plug hose ends. " ##
Plug PF1/4, PF3/8 )' '
( $

! 01 0 " ##
Fig. 33-75 Pilot valve connector
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Swing (R)
Bucket (R)
(Blue)
(Red)
Swing (L)
(Gray)
Make sure the tightening torque for capscrews, Bucket (H) P

(Red)
because pilot valve is made of aluminum. Arm (H) (Blue) P
Boom (H) (Green)
LEFT SIDE RIGHT SIDE
Fig. 33-76 Pilot valve port position
(from upper side)
33-42
33. UPPER STRUCTURE
33.1.18 PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (1) (See 33.1.5 UNDER
COVER)
A1
(3) Remove floor mat (B1). A8
A2 A7
A6
A7
A5
B1
A8
Fig. 33-77 Removing floor mat, pedal and and lever
33.1.18.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and
SE-10 (A9) at the connector. %
4 () "56)
: 24 mm 27 &82*
0%
(2) Attach tag, and discount connectors and hoses .
(A2), (A3), (A4), (A5) 1.23 &*
% - 1/ &*
: 19 mm (P port)
: 22 mm (T port, 1~4 port) 0/
-

(3) Plug hose ends
1/ &* "
Plug PF1/4, PF3/8

(4) Remove 4 sems bolts (A8) M8× 25, and remove
+,
+/
right and left pedals (A5), (A6).

+,
: 13 mm +

(5) Remove 4 sems bolts (A7) M10× 20 and remove
right and left lever (A1), (A2).

: 17 mm

(6) Remove 4 sems bolts (A11) M10× 30.

: 17 mm
% !"# $$
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.

&'( )"*
Fig. 33-78 Installing and Removing pilot valve
33-43
33. UPPER STRUCTURE
Install it in the reverse order of removal and tighten it.
Sems bolt (A11)
: 17 mm T = 37 N•m (27.3 lbf•ft)

Sems bolt (A7)
: 17 mm T = 46.1 N•m (34.0 lbf•ft)

Sems bolt (A8)
: 13 mm T = 23.5 N•m (17.3 lbf•ft)

Pressure sensor
: 24 mm T = 16.7 N•m (12.3 lbf•ft)
33-44
33. UPPER STRUCTURE

(1) Park machine on firm level ground and place attachment on ground.
(2) Remove the guard (8), (44).
(See 33.1.4 GUARD)
(3) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure
in circuit by operating control lever.
(See 22.11 HYDRAULIC SYSTEM PRESSURE DRAINING(RELEASING) CIRCUIT)
(4) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other information.
* This machine has two swing motors, but we explain the right swing motor here. Because right motor and left motors
are same, disassemble and assemble the motor in the same way.
33.1.19.2 REMOVAL
(1) Remove hose. A24
1) Remove hose (A7) from the connector in the
makeup port M.
A24
: 41 mm A16
A53 B
2) Remove 2 hoses (A8), (A10) from the Tee in the A
drain port Dr.
: 36 mm A15
A14 B
3) Remove hose (A40) from the elbow of the PG A
port (For swing parking brake) (See Fig. 33-80)
: 19 mm
4) Remove 2 hoses (A16), (A53) from the
connectors of the A, B port.
: 36 mm
Put in plugs PF3/4, PF1/2, and PF1/4 into the
removed ports.
A8 Fig. 33-79 Removing swing unit piping
A17
A9 HYD
%
TANK
% %
S/J
A7
%
C/V A10
Rs2
C/V
A6 DR Rs1
A40
M
A88 DR
A2
A77
Fig. 33-80 Removing swing unit
33-45
33. UPPER STRUCTURE
(2) Removing the swing unit

Remove 14 capscrews (11) M20× 65.
: 30 mm
1) Remove two plastic caps (7) M12 at the top of
the swing motor and install eye bolts.
2) Put a wire sling in the eye bolts and remove the
swing motor unit.
Weight of swing motor unit ;
Approx. 286kg (631 lbs) (Include reduction assy)
33.1.19.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.
Install the swing motor unit in the reverse order of 11
Coat all the mounting surface of
disassembly, confirming the orientation of the swing the swing motor with Loctite #515
equivalent.
motor unit.
(1) Tighten 14 capscrews (11) M20× 65.
: 30 mm Detail of swing motor unit assy mount

Tightening torque : 539N•m (400 lbf•ft) Apply
Apply Loctite #262
Loctite #262 equivalent. Tightening Tightening
Tightening torque torque torque
(2) Fill inside from motor drain port to casing with 539N.m (400 lbf.ft) 46.1N.m 46.1N.m
(34 lbf.ft) (34 lbf.ft)
hydraulic oil before piping for drain 11
Put sealing 2 7 10 10
tape on the
both sides of
thread portion
of filling tube.
Tightening torque
108 N.m (80 lbf.ft)
FILLING PORT
LEVEL GAUGE
Put sealing tape
on the thread
portion of tube for
level gauge. Fix the plug at the
7
Tightening torque 10 drain hose edge on
69.1 N.m (51 lbf.ft) Tightening torquethe hole of the upper
46.1N.m (34 lbf.ft) frame bottom plate.
Fig. 33-81 Installing swing motor unit
33.1.19.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient.
Amount of oil : 7L (1.8gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leak and noise.
33-46
33. UPPER STRUCTURE
33.1.20 SWIVEL JOINT

Remove boom piping hose
33.1.20.2 REMOVAL
(1) Remove travel motor hose
1) Remove 2 hoses (A4). (G port : PF3/4)
: 36 mm, Tightening torque : 118 N•m (87 lbf•ft)

2) Remove tubes (A1), (A15). (C, D port : PF1)

3) Remove tubes (A2), (A15). (A, B port : PF1)

4) Remove 2 hoses (A5). (E,F port : PF1/4)
: 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft)
(TRAVEL MOTOR) (TRAVEL MOTOR)

VA (UPPER) VB (UPPER)
FORWARD FORWARD (RH)
(LH)
VB (LOWER) A, B, C, D-PF1 VA (LOWER)
REVERSE E,F-PF1/4 REVERSE
G-PF3/4
T : Tightening torque
of connector
T=255 N.m (lbf.ft)
T=36.3 (26.8) A5
B1 (188)
SWIVEL JOINT
A15
F
B
B1 D
T=36.3 (26.8) E
T=255 (188)
C
A4
A2 A
G
A1
A5
T=162 (119)
A4
Fig. 33-82 Removing piping (lower side)
33-47
33. UPPER STRUCTURE
(2) Disconnecting the hoses on the top part of swivel

joint A11
1) Remove drain hose (A9). (G port : PF3/4) A10
: 36 mm
Tightening torque : 118 N•m (87 lbf•ft) C/V
C 5A1 A13
2) Remove hoses (A10), (A12).
C/V
(A, C port : 1-3/16-12UN) 4B1
: 36 mm A
C/V
Tightening torque : 177 N•m (130 lbf•ft) D
5B1
3) Remove hoses (A11), (A13). A12

B
(B, D port : 1-3/16-12UN)

C/V
: 36 mm 4A1
Tightening torque : 177 N•m (130 lbf•ft) A22 A9

E
4) Remove hose (A12). G
(Travel 2-speed change over port : PF1/4)
: 19 mm S/V 3
A3
Fig. 33-83 Disconnecting the hoses on the top part

of swivel joint
(3) Remove whirl-stop of swivel joint.
36 Tightening torque 35
1) Loosen the nut (36) M24. 235N.m (173 lbf.ft)
2) Remove a capscrew (35) M24× 160.
: 36 mm
mm
3.5At assembling,
this distance
should be 3.5mm (0.138in).
Fig. 33-84 Removing whirl-stop nut & the capscrew

(4) Remove joint for piping (See Fig. 33-82,Fig. 33-83) Tightening torque B9
6.8N.m (5 lbf.ft)
1) Remove 2 connectors (B1). (E, F port)
2) Remove connector (3) (G port) for drain. (PF3/4) Tightening torque B8
14.7N.m (11 lbf.ft)
To prevent from
: 19 mm, 36 mm entering water,
apply Loctite 572
(5) Remove seal (B4) or 577 around
this plate (B5).
1) Remove 8 sems bolts (B8) M10× 25. B5
: 17 mm Before mounting the seal

(B4), apply adhesive to the
2) Remove clip (B9). adhering surface of S/J B4
and the upper frame.
3) Remove seal (B4).
Fig. 33-85 Removing seal (B4)
33-48
33. UPPER STRUCTURE
(6) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and remove 4
capscrews (C2) M16× 40.
: 24 mm EYE BOLT
(See 11.7 SPECIAL TOOLS No.9 Plug)
LOWER FRAME
C2
CAPSCREW
M16 40
Loctite #262
T=279N.m C1
(206 lbf.ft) SWIVEL JOINT
Fig. 33-86 Removing capscrew for installation

(7) Slinging the swivel joint
Weight : Approx. 48kg (106 lbs)
Piping tightening torque
Tightening torque N.m (lbf.ft)

Size Tool.
PF HEX O-ring type Hydraulic hose
Connector
1/4 19 36 (27) 29 (22)
3/8 22 74 (54) 49 (36)
1/2 27 108 (80) 78 (58)
3/4 36 162 (120) 118 (87)
1 41 255 (180) 137 (100)
1-3/16-12UN 36 - 177 (130)
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
33-49
33. UPPER STRUCTURE
33.1.21 UPPER FRAME

(1) Remove attachment
(See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight WIRE ROPE
(See 33.1.11 COUNTERWEIGHT)
(5) Remove swivel joint
(See 33.1.20 SWIVEL JOINT) LIFTING JIG
LIFTING
JIG
C1
Fig. 33-87 Temporarily lift upper frame
33.1.21.2 REMOVAL
(1) Lifting up upper frame temporarily

Insert two upper swing body lifting jigs and two
counterweight mounting capscrews (C1) M42× 410
into the upper frame center section from above.
Then lift it tentatively at four points by using a
special fixture or by installing two chain blocks to
the boom foot.
Wire rope; ø16 (0.630")× 4m(13ft-1in), 2pcs.
ø16 (0.630")× 2.5m(8ft-2in), 2pcs.
Chain block; For 3,200kg (7,050 lb) 2pcs.
Fig. 33-88 Matching mark on swing bearing and
(2) Marking match marks on swing bearing
upper frame
Put match marks on upper frame and swing
bearing.
(3) Removing upper frame attaching bolts
Remove 35 capscrews (10) M27× 143 and a
reamer bolt (11) used to install swing bearing and
upper frame.
: 41 mm
(4) Slinging upper frame
Sling according to Fig. 33-87, and remove upper
frame and put it on a stand.
Weight : Approx. 6ton (13,200lbs)
Fig. 33-89 Removing upper frame attaching bolts
33-50
33. UPPER STRUCTURE
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (11)
temporarily.
Apply Loctite #262
equivalent.
T=1180N.m
Confirm the reamer bolt positions referring to Fig. 33- .
11 (870 lbf ft)
91.
Fig. 33-90 Bearing mount
OUTER (S) ZONE POSITION
: 41 mm Apply Loctite #262
Apply Loctite #262
(5) Install swing bearing *
Install 35 capscrews (10) M27× 143.
: 41 mm Apply Loctite #262

Install a reamer bolt (11).
: 41 mm
Fig. 33-91 Reamer bolt position (*) Apply Loctite to

shaded area
33-51
33. UPPER STRUCTURE
33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP • REGULATOR
33.2.1.1 HYDRAULIC PUMP
33.2.1.1.1 Structural exploded view

(1) Main pump
Apply adhesive (No.1305 N of Threebond MAKE)

702 732
534 792 532 531 157 789 901 535 491 493 807 954 412
548 981 885

406 983
214
806
953 X
536
889
405
A A
724 262
888 409
156
886 153 709
251 491
491 490 212 211 152 728 469 151 141 752 410
492
Tightening torque
Tightening torque
N m (lbf
405 M8 34 (25) 543 545
406,408 M12 98 (72)
410,411,412 M22 630 (465)
409 M10 57 (42) 725 724
466 PF 1 1/4 270 (199) 541
467 PF 1/4 36 (27)
468 M18X1.5 64 (47)
469 PF 3/4 170 (125) 887
490,492 NPTF1/16 8.8 (6.5) 726
491 Rc 1/8 12 (8.9)
493 Rc 1/4 22 (16)
531,532 M30X2 480 (354)
806,807 M20 240 (177) SECTION X-X SECTION B-B
33-52
33. UPPER STRUCTURE
Identification groove on Valve plate for Frange socket (5-M10X1.5)

outer surface of outer ring. 469 469 c. clockwise rotation 466 Tightening torque
408 824 828 128 123 728 113 728 271 490 314 729 124 : 33 N m (24.3 lbf.ft)
171
127
823
192
191
711
827 B B
774 04
Apply (sealub L101)
to the oil seal surface
circumferential.
130
111
830
124,125
261
312
825
313 Valve plate for clockwise rotation.
126
752 122 824 411
129
889 468,731 467,725
128
733
SECTION A-A
05
ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty ITEM PARTS Q'ty
111 Drive shaft 1 214 Tilting bushing 2 493 Plug 2 774 Oil seal 1
113 Driven shaft 1 251 Swash plate support 2 531 Tilting pin ; M30X2 2 789 Backup ring ; P21 2
122 Roller bearing 1 261 Front cover 1 532 Servo piston ; M30X2 2 792 Backup ring ; G40 2
123 Roller bearing 1 262 Cover 1 534 Stopper (L) 2 806 Nut : M20 2
124 Needle bearing 2 271 Pump casing 1 535 Stopper (S) 2 807 Nut ; M20 2
125 Inner ring 1 312 Valve cover 1 536 Servo cover 2 823 Snap ring 1
126 Spacer 2 313 Valve plate (R) 1 541 Seat 2 824 Snap ring 3
127 Spacer 1 314 Valve plate (L) 1 543 Stopper 1 2 825 Snap ring 2
128 Bearing spacer 3 405 Socket bolt 8 545 Steel ball 2 827 Snap ring 1
129 Bearing spacer 2 406 Socket bolt ; M12X35 8 548 Feed back pin 2 828 Snap ring 2
130 Booster 7 408 Socket bolt ; M12X55 11 702 O-ring ; 1B G40 2 830 Snap ring 1
141 Cylinder block 2 409 Socket bolt ; M10X16 2 709 O-ring ; 1B G85 1 885 Valve plate pin 2
151 Piston 18 410 Socket bolt ; M22X60 9 711 O-ring ; 1B G95 1 886 Spring pin 4
152 Shoe 18 411 Socket bolt ; M22X95 2 724 O-ring ; 1B P8 9 887 Pin 1
153 Retainer plate 2 412 Socket bolt ; M22X180 1 725 O-ring ; 1B P11 2 888 Pin 2
156 Spherical bushing 2 466 RO Plug ; PF1 1/4 2 726 O-ring ; 1B P10 2 889 Pin 4
157 Cylinder spring 18 467 ROH Plug ; PF1/4 2 728 O-ring ; 1B P24 3 901 Eye bolt ; M12 2
171 Front casing 1 468 Adapter 2 729 O-ring ; 1B P38 2 953 Set screw 2
191 Drive gear 1 469 ROH Plug ; PF3/4 3 731 O-ring ; 1B P16 2 954 Set screw 2
192 Driven gear 1 490 Plug 20 732 O-ring; 1B P21 2 04 Gear pump 1
211 Shoe plate 2 491 Plug 12 733 O-ring; 1B G170 1 05 PTO unit 1
212 Swash plate 2 492 Restrictor 4 752 Seat packing 2
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 33-92
33-53
33. UPPER STRUCTURE
(2) Gear pump (For pilot)
728
700 353 351 433

354 468
434
311
312
361
732 Delivery port
PF1/2
Drain port PF3/8 307 310 308 309 434 466 355 850 Tightening
709 435 Tightening torque; 887
725 torque ; 53N.m
34N.m (25.1lbf.ft) (39.1lbf.ft)
SECTION Y-Y
Tightening torque
Tightening torque
N m (lbf ft)
312 M14X1.5 29 (21)
433,434 M8 17 (12.5)
435 M10 33 (24)
466 PF 1/4 16 (12)
468 PF 3/4 74 (55)

307 Poppet 1 434 Flange socket ; M8× 65 2
308 Seat 1 435 Flange socket ; M10× 30 5
309 Ring 1 466 VP plug ; PF1/4 1
310 Spring 1 468 VP plug ; PF3/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14× 1.5 1 709 O-ring ; 1B G160 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 728 O-ring ; 1B P24 1
354 Driven gear 1 732 O-ring ; 1B P16 1
355 Filter 1 850 Locking ring 1
361 Front case 1 887 Pin 2
433 Flange socket ; M8× 50 2
33-54
33. UPPER STRUCTURE
33.2.1.1.2 Disassembly and assembly of main pump

(1) Tools
Tool Part
The right list shows the tools required for remove
and install. Name Size mm Size Item No.
5 M6 491
(2) Disassembling procedure 6 M8 467, 493
1) Selecting a place for disassembly. 8 M10 409
• Choose a clean place. Allen wrench 10 M12 406,408
12 M14 469
• Spread rubber sheet or cloth on work bench
to protect parts from damaging. 17 M20 806,807
19 M24 466
Eye wrench 27 M18 468
2) Cleaning Socket wrench
Remove dust and rust, etc. on pump surface with 30 M20 806, 807
Wrench ; Double
wash oil. single
Crescent wrench Medium size 1pc.
Driver Flat bladed 2pcs.

Hammer Plastic
Plier Snap ring
Steel bar 10X8X200
Torque wrench
3) Drain oil
REGULATOR
Drain out the oil in the pump casing by removing
drain port plug (469).
: 12 mm
• Remove filling port (469: located at side of

regulator mounting) to drain oil easily.
4) Removing regulator and PTO gear casing

Remove the socket bolts [412, 416, 435 (See
Fig. 33-111)]. Then remove the regulator and the
PTO cover (326).
: 6 mm, 8 mm, 10 mm
• Regarding the disassembly of the regulator,

refer to article of Regulator.
33-55
33. UPPER STRUCTURE
5) Place pump on the level work bench, and

remove valve cover (312) from pump casing
(271).
: 17 mm
• Be careful to remove valve cover (312),

because it is heavy {Approx. 60 kg (130 lbs)}
to handle with.
• Spring pin (886) and solid pin (889) are fixed
between valve cover (312) and pump casing
(271) as positioning pin.
Because valve cover (312) and pump casing
(271) were fixed tightly, tap lightly the fixed Fig. 33-93
surface with plastic hammer. In this case,
draw the cover out along drive shaft (111)
and driven shaft (113) straightly.
• At this time, do not damage mating face
(271).
• When removing valve cover (312), valve
plate (313, 314), check valve sub (541, 543,
545), O-ring (725), and seat packing (752)
are removed with valve cover (312) together.
But in this case, take care that those inner
parts tend to fall.
6) Remove needle bearing (124) from valve cover
(312) if necessary.
• Do not remove needle bearing unless
otherwise the bearing reaches to end of life.
• Do not loosen nut (807) to keep the correct
set of flow rate.
7) Draw out cylinder (141) from pump casing (271)
along drive shaft (111) and driven shaft (113)
straightly. Remove cylinders (141), and remove
piston sub (151, 152), retainer plate (153),
spherical bushing (156), and cylinder spring
(157) at the same time.
• At this time, do not damage sliding surface of

cylinder (141), spherical bushing (156), shoe
(152) and swash plate (212).
Fig. 33-94
33-56
33. UPPER STRUCTURE
8) Remove shoe plate (211) and swash plate (212)

from pump casing (271).
Fig. 33-95
9) If necessary, remove stopper (L: 534), stopper
(S: 535), servo piston (532), tilting pin (531), and
servo cover (536) from pump casing (271).
• Using suitable jig to prevent damage tilting
pin head, and remove tilting pin (531).
• Fitted part of tilting pin (531) and servo piston
(532) was applied adhesive (Three Bond
#1305N). Do not damage servo piston at
removal, because it is hard to remove due to
interference of adherence.
• Do not loosen hex nut (806) located on servo
cover (536) to keep the correct set of flow
rate.
10) Remove snap ring (827) and remove front
cover (261).
• Always fix the front cover for this operation.
When fixing it, do not damage mating face of
front cover.
• A groove is provided on the periphery of front
cover (261). Apply flat-bladed screw driver to
groove and pry the front cover (261) to
remove it along drive shaft (111) straightly.
• Front cover (261) has oil seal (774), do not
damage lip of oil seal (774) when removing.
Fig. 33-96
11) Loosen socket bolts (408) that are fastening
front casing (171).
• Always fix the front cover for this operation.
When fixing it, do not damage mating face of
front cover.
33-57
33. UPPER STRUCTURE
12) Remove front casing (171) from pump casing

(271).
• Be careful to remove front casing (171),
to handle with.
• Spring pin (886) and solid pin (889) are fixed
between front casing (171) and pump casing
(271) as positioning pin.
Because front casing (171) and pump casing
(271) were fixed tightly, tap lightly the fixed
surface with plastic hammer. In this case,
draw the front casing (171) out along drive
shaft (111) straightly. Do not damage oil seal
sliding surface of drive shaft (111) at Fig. 33-97
removing.
(271).
• There is seat packing (752) between front
casing (171) and pump casing (271).
13) Remove snap ring (823, 825) and remove
spacer (126, 127), drive gear (191), and driven
gear (192).
Fig. 33-98
33-58
33. UPPER STRUCTURE
(3) Installing procedure

1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly, but
notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and dry
them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O-
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
2) Install swash plate support (251) in pump casing
(271) and fasten it with socket bolts (405).
• There are O-rings (724) on the mating face

between swash plate support (251) and
pump casing (271). Using thin film of grease,
attach O-ring to prevent O-rings from falling.
• Positioning pin (888) is located on the pump
casing (271) side. Adjust pin position so it
enters into groove of swash plate support
(251) and install swash plate support.
• Install swash plate support (251) so it enters
straight, while tapping it lightly. Do not install
Fig. 33-99
it aslant.
3) Install drive shaft (111) and driven shaft (113)
with roller bearings (122, 123), bearing spacers
(128, 129), and snap rings (824) to pump casing
(271) and fix them with snap rings (828).
• Direct sharp edge side of snap rings (824) to

outside of pump.
• Do not hammer drive shaft (111) and driven
shaft (113).
• Install roller bearing (122, 123) by tapping
outer race of bearings with plastic hammer.
And install bearings to the bottom by using
steel bar as an auxiliary tool.
Fig. 33-100
• When installing snap rings (828), direct
sharp edge side of snap rings (828) to
outside of pump.
33-59
33. UPPER STRUCTURE
4) Install drive gear (191) and driven gear (192) and

bearing spacers (126, 127) to drive shaft (111)
and driven shaft (113). Then fix them with snap
rings (823, 825).
• Verify the installing direction of drive gear

(191) before installation.
• When installing snap rings (823, 825), direct
sharp edge side of snap rings (823, 825) to
outside of pump.
Fig. 33-101
5) Install front casing (171) to pump casing (271)
and fasten them with socket bolts (408).
: 17mm
• Be careful to install front casing (171),

to handle with.
• Each 2 spring pins (886) and solid pins (889)
are fixed between front casing (171) and
pump casing (271) as positioning pin.
Always install spring pins (886) and solid
pins (889) to pump casing (271) side.
• Because front casing (171) is fitted tightly
with spring pin (886) and solid pin (889), to
install the front casing (171) tap lightly with
plastic hammer. In this case, insert the front
casing (171) into drive shaft (111) straightly.
Do not damage oil seal sliding surface of
drive shaft (111) when installing.
(271).
• There is seat packing (752) between front
casing (171) and pump casing (271). To
prevent from falling easily, apply grease to Fig. 33-102
seat packing (752). Consequently it makes
assembly easier.
33-60
33. UPPER STRUCTURE
6) Install front cover (261) in front casing (171) and

fasten them with snap ring (827).
• Be careful not to damage lip of oil seal (774)
when installing it.
• When installing snap rings (827), direct
sharp edge side of snap rings (827) to
outside of pump.
7) Place pump casing on the level work bench, and
install servo piston (532), tilting pin (531),
stopper (L: 534), and stopper (S: 535). And
install servo cover (536) and fasten with socket
bolts (406).
• Using the holes of front casing (171) for
Fig. 33-103
mounting to engine, fix the front casing (171)
and install the above-mentioned parts. When
fixing it, do not damage mating face of
engine.
• When tightening a servo piston (532) and a
tilting pin (531), use proper jig so as not to
damage head of tilting pin (531) and feed
back pin (548). Apply adhesive (Three Bond
#1305N) to threaded part of servo piston
(532).
8) Insert tilting bushing (214) of swash plate (212)
into tilting pin (531) and install swash plate (212)
in swash plate support (251).
• Do not mix component for drive shaft with
that of driven shaft.
• After installation, swash plate (212) may fall
from swash plate support (251). To prevent
from falling easily, apply grease to sliding
surface between swash plate (212) and
swash plate support (251). Consequently it
makes assembly easier.
• Make sure that swash plate (212) is moved
by finger tip smoothly.
Fig. 33-104
9) Assemble piston-cylinder sub assy [cylinder
block (141), piston sub (151, 152), retainer plate
(153), spherical bushing (156), and cylinder
spring (157)]. Align phases of spherical bushing
(156) and spline of cylinder block (141), and
insert them into pump casing (271) straightly.
• Do not mix component for drive shaft with
that of driven shaft.
• Make sure that failure of assembly between
swash plate (212) and swash plate support
(251) or tilting pin (531) is not there.
Fig. 33-105
33-61
33. UPPER STRUCTURE
10) Align valve plates (313, 314) with valve plate

pin (885), and install valve plates (313, 314) on
valve cover (312).
• Be careful no to mistake suction for delivery
side of valve plates (313, 314). (Drive side:
clockwise as seen from shaft end, Driven
side: counterclockwise as seen from shaft
end)
• Since valve plates (313, 314) tend to fall,
apply grease to mating face of valve cover
(312) to prevent from falling. Consequently it
makes assembly easier.
Fig. 33-106
11) Insert check valve sub (541, 543, 545) and
needle bearing (124) into valve cover (312).
• Insert check valve sub (541, 543, 545) into
valve cover (312) in the correct order.
• Since check valve sub (541, 543, 545) tend
to fall, apply grease to inserting part of valve
cover (312) to prevent from falling.
Consequently it makes assembly easier.
Fig. 33-107
12) Put O-rings (724, 726, 735) and seat packing
(752) on the mating face of pump casing (271)
and valve cover (312).
• Since O-rings (724, 726, 735) and seat
packing (752) tend to fall, apply grease to
attaching surface to prevent from falling.
Consequently it makes assembly easier.
Fig. 33-108
33-62
33. UPPER STRUCTURE
13) Install valve cover (312) on pump casing (271)

and fasten them with socket bolts (410, 412).
• Be careful to install valve cover (312),
to handle with.
• Make sure that failure of assembly between
swash plate (212) and swash plate support
(251) or tilting pin (531) is not there.
Each 2 spring pins (886) and solid pins (889)
are fixed between valve cover (312) and
pump casing (271) as positioning pin.
Always install spring pins (886) and solid
pins (889) to pump casing (271) side.
• Needle bearing (124) is located in valve
cover (312) side. To avoid damage of needle
bearing, install valve cover (312) carefully.
• When installing valve cover (312), valve
plate (313, 314), check valve sub (541, 543,
545), O-ring (735) and seat packing (752)
tend to fall. Be careful of falling.
• Because valve cover (312) is fitted tightly
with spring pin (886) and solid pin (889), to
install the valve cover (312) tap lightly with
plastic hammer. In this case, insert the valve
cover (312) into drive shaft (111) and driven
shaft (113) straightly
Fig. 33-109
(271).
14) Place feed back pin (548) of tilting pin (531) in
feed back lever of regulator and fasten regulator
with socket bolts.
: 6mm
• The regulator of drive side and the driven

side have different pressure setting and flow
setting. So do not mix up one for another.
15) Install gear pump (04) and fasten it with socket
bolts. In case that PTO is attached, install PTO
(05) and fasten it with socket bolts.
: 8, 10mm Fig. 33-110

Tightening torque : 33 N•m (24 lbf•ft) (435)
Tightening torque : 98 N•m (72 lbf•ft) (416)
• Since gear pump (04) casing is made of

aluminum, be careful about tightening torque
for flange socket bolts differs from that of
ordinary same size socket bolt.
33-63
33. UPPER STRUCTURE
33.2.1.1.3 Maintenance standards

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the following standards of wear.
However, always replace such parts that show excessive damage on appearance.
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.0375 0.078
bore Replace piston or cylinder.
(0.0015") (0.0031")
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.35
Replace piston shoe assy.
(0.004") (0.014")
( )
Thickness of shoe 5.4 5.0
Replace piston shoe assy.
(t) (0.213") (0.197")
Free height of cylinder spring 40.9 40.1
Replace cylinder spring.
(L) (1.610") (1.579")
Combined height of retainer plate and
23.8 22.8 Replace a set of spherical bushing or
spherical bushing
(0.937") (0.898") retainer plate.
(H-h)
Cylinder over pin dia. (spline in cylinder) 35.17 35.57
Replace cylinder, spherical bushing.
spline in spherical bushing (1.385") (1.400")

(2) 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 0.4Z (lapping)
Roughness of each surface (correction value)
33-64
33. UPPER STRUCTURE
33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
Cause Remedy Remarks

1. Revolution and pressure are higher 1) Set pressure to specified value.
than set values.
2. Regulator torque is set higher than 2) Readjust regulator. 2)Refer to Regulator Manual.
normal.
3. Pump’s internal parts are seized or 3) Replace damaged parts. 3) Check filter and drain oil to see if
broken. abnormal wear particles are present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.
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 seized or 2)Replace damaged parts. 2)Check filter and drain oil.
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.
5. Regulator is piped incorrectly. 5) Pipe correctly.
6. Damage of the gear. 6) Replace the gear.
33-65
33. UPPER STRUCTURE
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 trouble.
clouded. 1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2)Replace piston shoe and shoe
plate.
3. Cylinder is cracked 3) Replace cylinder.
4. Pump is installed improperly. 4) Correct installation.
5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual.
6. Relief valve in attached valve is 6) Replace attached valve.
hunting.
7. Damage of the gear. 7) Replace the gear.
33-66
33. UPPER STRUCTURE
33-67
33. UPPER STRUCTURE
33.2.1.2 REGULATOR
33.2.1.2.1 Structural exploded view
626
625
624
753
627
623
621 D 728
B 645
611
622 F
874 646
733 613
732 875 644
631 612
898
652 875
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 735
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722
466 496 734
755 G
887
F
708
A 876
662 B 724 614
436 C
642 730 725 8-724 755
041 755
755 467
467 755
641
Fig. 33-111 Structural exploded view of regulator
33-68
33. UPPER STRUCTURE
Marks in Fig. 33-111 show the position where regulator is installed.
No. Name Q'ty No. Name Q'ty No. Name Q'ty

412 Socket bolt ; M8X50 2 628 Adjust screw (C) 1 730 O-ring ; 1B P22 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 732 O-ring ; 1B P16 1
418 Socket bolt ; M5X12 6 630 Lock nut ; M30X1.5 1 733 O-ring ; 1B P20 1
436 Socket bolt ; M6X25 5 631 Sleeve (For PF) 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 641 Pilot cover 1 735 O-ring ; 1B P12.5 1
467 VP plug ; PF1/4 3 642 Spool 1 753 O-ring ; 1B P9 1
496 Plug ; NPTF1/16 18 643 Pilot piston 1 755 O-ring ; 1B P11 7
541 Seat 1 644 Spring seat (Q) 1 756 O-ring ; 1B P26 1
543 Stopper 1 1 645 Adjust stem (Q) 1 763 O-ring ; 1B G35 1
545 Ball 1 646 Pilot spring 1 801 Nut ; M8 1
601 Casing 1 651 Sleeve 1 802 Nut ; M10 1
611 Feed back lever 1 652 Spool 1 814 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 836 Snap ring 1
613 Lever (2) 1 654 Return spring 1 874 Pin ; 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; 4X8L 2
615 Adjust plug 1 656 Block cover 1 876 Pin ; 5X8L 2
621 Compensating rod 1 662 Spring 1 887 Pin 1
622 Piston case 1 698 Cover 1 897 Pin ; 5X19L 1
623 Compensating rod 1 708 O-ring ; 1B G75 1 898 Pin ; 11.5X11.8L 1
624 Spring seat (C) 1 722 O-ring ; 1B P6 3 924 Socket screw ; M8X20 1
625 Outer spring 1 724 O-ring ; 1B P8 8 041 Check valve sub 2
626 Inner spring 1 725 O-ring ; 1B P10 1 079 Solenoid proportional 1
627 Adjusting stem (C) 1 728 O-ring ; 1B P18 1 reducing valve
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Tightening torque of bolt, plug and nut

Tightening torque
No. Thread size
N.m (lbf.ft)
412,413 M8 29 (21)
436,438 M6 12 (8.9)
418 M5 6.9 (5)
467 PF 1/4 36 (26)
496 NPTF1/16 8.8 (6.5)
630 M30X1.5 160 (118)
801 M8 15 (11)
802 M10 19 (14)
33-69
33. UPPER STRUCTURE
33.2.1.2.2 Disassembly and assembly

(1) Tools
Tool Part
The right list shows the tools required for remove
and install. Name Size mm Size Item No.
4 M5 418
(2) Disassembling procedure Allen wrench 5 M6 436,438
1) Selecting a place for disassembly. 6 M8 412,413
Socket wrench 19 PF1/4 467
• Choose a clean place. Crescent wrench Small size 1pc. Max 36mm
• Spread rubber sheet or cloth on work bench
Driver Flat bladed
to protect parts from damaging.
Hammer Plastic
2) Cleaning Torque wrench
Remove dust and rust, etc. on regulator surface Plier Snap ring
with wash oil. Steel bar 4X100
Pin set
Bolt M4X50
3) Remove regulator (SeeFig. 33-111)

438 656 413 412
Remove socket bolts (412, 413) and separate
the regulator from the pump body.
629
: 6 mm
4) Remove port plate (See Fig. 33-111)

Remove socket bolt (438) and separate the port
438
plate (656).
601
: 5 mm
Fig. 33-112 Removing regulator

5) Remove cover (See Fig. 33-111)
Remove socket bolts (438) and remove cover
(C) (629).
: 5 mm
• The cover is equipped with adjust screws 624,625,626

(628), adjust stem (627), lock nut (630), hex 627
nut (801) and set screw (924). Do not loosen
801
those screws and nuts. If they are loosened,
preadjusted set pressure and flow values 629( 628 )
change.
630 924
Fig. 33-113 Removing cover (C) (629)
33-70
33. UPPER STRUCTURE
6) Remove compensating parts

M4 BOLT 645
(See Fig. 33-111 (D) section, See Fig. 33-113,
644,646
Fig. 33-114)
After removing the cover (C) (629) sub assy, take
out outer spring (625), inner spring (626) and
629
spring seat (624) from the compensating part.
Then take out adjust stem (645), pilot spring
(646) and spring seat (644) from the pilot part.
• Adjust stem (645) comes out easily if an M4

bolt is used.
Fig. 33-114 Removing compensating parts
7) Remove pilot cover and the set spring
Remove socket bolt (436) and pilot cover (641).
Once the pilot cover (641) comes off, separate
set spring (655) from the pilot section.
(Fig. 33-111 (A) and (B) section)
: 5 mm
436
641
Fig. 33-115 Removing pilot cover (641) and set

spring (655)
8)Remove spring seat, return spring and sleeve
(Fig. 33-111 (A) section)
Remove snap ring (814). Then remove spring
814(653)
seat (653), return spring (654) and sleeve (651).
• Sleeve (651) is equipped with snap ring 654,

(836). 651(836)
• When removing snap ring (814), return
spring (654) comes out : Use care so as not
to lose it.
Fig. 33-116 Removing spring seat (653), return

spring (654) and sleeve (651)
9) Remove adjust plug (Fig. 33-111 (F),(G) section)
Remove socket bolt (418) and remove cover
(698), and take out fulcrum plug (614) and adjust
plug (615).
615
• Fulcrum plug (614) and adjust plug (615)
come off easily if a M6 bolt is used. 614
Fig. 33-117 Removing adjust plug (615)
33-71
33. UPPER STRUCTURE
$"
Fig. 33-118 Removing fulcrum plug (614)

10) Remove lever (Fig. 33-111 (G) section)
Remove lever 2 (613).
Do not draw out pin (875).
• The work is eased if tweezers is used.
$!&%#
Fig. 33-119 Removing lever 2 (613)

11) Remove feedback lever
Draw out pin (874) and remove feedback lever &%"
(611).
• Push out pin (874) [pin dia : ø4mm (0.157in)]

from above with a slender steel rod so as not
to interfere with lever 1 (612). $
Fig. 33-120 Removing feedback lever (611) [1]
$
Fig. 33-121 Removing feedback lever (611) [2]
33-72
33. UPPER STRUCTURE
12)Remove lever (Fig. 33-111 (F) section)

Remove lever 1 (612). $
$
Do not draw out pin (875). &%"
&'%
&%# $!
13) Remove pilot piston and spool &%#
(Fig. 33-111 (C),(A) section)
Draw out pilot piston (643) and spool (652).
14) Remove piston casing, compensating piston

and compensating rod (Fig. 33-111 (B) section)
Draw out piston casing (622), compensating $"!
piston (621) and compensating rod (623).
• Piston casing (622) comes out from the

$ !
opposite side of the piston casing (622) if $ $
compensating rod (623) is pushed out. %!!
%!
$!
&'& $#
$#
&!$
$##
$#"
$#!
&"
Fig. 33-122 Part of exploded view of regulator

15) Remove spool (642) and spring (662) 466
Remove VP plug (467) from pilot cover (641),
and draw out spool (642) and spring (662).
This completes disassembly.

662
642
467
641
33-73
33. UPPER STRUCTURE
(3) Installing procedure :

Assembly is the reverse order of disassembly. Do
the work paying attention to the following :
• Repair those parts that were damaged during
disassembly and prepare replacement parts
beforehand.
• If foreign matter enters, it causes malfunction;
clean parts thoroughly in cleaning oil, blow them
with jet air and assemble parts in a clean place.
• Always tighten bolts and plugs to the specified
torque. The tolerance of torque should be within
10%.
• Do not fail to coat the moving parts with clean
hydraulic oil, before assembly.
• In principle, replace seals such as O-ring.
1) Installing compensating rod (Fig. 33-111 (B)
section)

Assemble compensating rod (623) into the
compensating hole of casing (601).

2) Assembling lever
Put the pin pressed in lever 1 (612) into the
groove of the compensating rod (623). Then
assemble the lever 1 (612) to the pin (875) that
is pressed in the casing.
3) Assembling spool and sleeve (See Fig. 33-111
PIN (874)
(A) section)
Assemble spool (652) and sleeve (651) into the
spool hole of the casing.
• Make sure that the spool and the sleeve (652) SPOOL FEEDBACKLEVER (611)
move smoothly in the casing.
• Beware of the direction of the spool. Fig. 33-125 Direction of the spool (652)
4) Assembling feedback lever

Assemble feedback lever (611). Then put pin
(874) into the pin hole of the feedback lever.

• The work is eased if the pin is put in the

feedback lever a little, beforehand.
• Take care so as not to mistake the direction
of the feedback lever.
Fig. 33-126 Assembling feedback lever (611)
33-74
33. UPPER STRUCTURE
5) Assembling pilot piston (See Fig. 33-111 (C)

section)
Assemble pilot piston (643) into the pilot control
hole of the casing.
• Make sure that the pilot piston moves $!&%#

smoothly.
6) Assembling lever (See Fig. 33-111 (G) section)

Place pin (875) pressed in lever 2 (613) into the
groove of the pilot piston and assemble lever 2
(613). Fig. 33-127 Assembling lever 2 (613)
7) Installing fulcrum plug (See Fig. 33-111 (F)

section)
Assemble fulcrum plug (614) so pin (875) 614(875)
pressed in the fulcrum comes in the pin hole of
lever 2 (613).
Fig. 33-128 Installing fulcrum plug (614)

8) Installing adjust plug (See Fig. 33-111 (G)
section)
Insert adjust plug (615). Insert the fulcrum and
adjust plug, and attach cover (698). Then fasten
them with socket bolt (418).
615
: 5 mm
Tightening torque : 12 N•m (8.9 lbf•ft) 614
• Use care so as not to mistake the holes into

which the fulcrum and adjust plug are
inserted.
Fig. 33-129 Installing adjust plug (615)
• At this point, operate the feedback lever and
make sure that the gap is not large and that

the lever moves smoothly.

9) Installing return spring and the spring seat
(See Fig. 33-111 (A) section)

Assemble return spring (654) and spring seat
(653) into the spool hole and fit snap ring (814).
Fig. 33-130 Installing return spring (654) and spring

seat (653)
33-75
33. UPPER STRUCTURE
10) Assembling compensating parts (See Fig. 33-

111 (A),(B) section)
Assemble set spring (655) into the spool hole.
Place compensating piston (621) and piston
casing (622) into the compensating hole and
attach pilot cover (641). Then fasten them
together with socket bolts (438), (436).
: 5 mm
Tightening torque : 12 N•m (8.9 lbf•ft) $ $
Fig. 33-131 Assembling compensating parts
11) Installing spool and spring 466
Assemble spool (642) and spring (662) into pilot
cover (641), and tighten VP plugs (467).
662
642
467
641
Fig. 33-132 Assembling spool (642)
12) Assembling into the pilot hole and the
compensating hole
(See Fig. 33-111 (E),(D) section)
Put spring seat (644), pilot spring (646) and
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.
• Do not mistake the direction of the spring

Fig. 33-133 Assembling into the pilot hole and
seat.
compensating hole
13) Installing cover

Attach cover (C) (629) fitted with adjust screws
(628), (925), adjust stem (627), lock nut (630),
nut (801) and socket bolt (924). Then fasten
them with socket bolts (438).
: 5 mm

14) Installing block cover (See Fig. 33-112)

Attach block cover (656).
: 5 mm

Fig. 33-134 Installing cover (C) (629)
This completes assembly.
33-76
33. UPPER STRUCTURE
33.2.2.1 PREPARATION FOR DISASSEMBLY

(1) General cautions
1) Since hydraulic components are finished to precision
with small clearance, it is necessary to disassemble
and reassemble them in clean, less dusty place.
Use clean tools and cleaning oil and handle
components with sufficient care.
2) If the control valve is removed from the machine,
clean ports thoroughly and put a plug in each port so
as to prevent entry of dust and water.
When installing the control valve back to the
machine, do not remove plugs until the valve is
properly piped.
3) Study the structural drawing before beginning work
and prepare necessary parts according to the
purpose and the scope of the work. Some parts are
not available loosely but in assemblies. Therefore,
prepare parts beforehand according to the Parts
Manual.
(2) Cautions to be exercised in disassembly
1) Since components are finished to high precision,
handle them with sufficient care. Use care so as not
to bump components against each other or drop
them.
2) Do not strike or twist components by force even if
they are tight, or the components develop burrs or
are broken. This makes the components impossible
to be assembled and results in oil leakage and
deterioration in performances. Therefore, handle
components with full care.
3) Attach a tag to each component so it is reassembled
in a correct position.
4) Once disassembled, do not reuse O-rings and
backup rings.
(Remove them with the tip of a steel wire shaped in
a spatula. Take care so the groove is not scored.)
5) If parts are left, as they are halfway during
disassembly or after disassembly, they may rust due
to moisture and dust. When interrupting the work for
unavoidable reason, use care so as to prevent parts
from rusting or being exposed to dust.
• Replacing the main plungers
Since the main plunger is selectively fitted to the
housing, it is designated as "not service part".
Therefore, note that in principle the main plunger
cannot be replaced in the field. In case the
plunger must be replaced for some reason,
inform us with the model and the manufacturing
number that are stamped on the nameplate.
33-77
33. UPPER STRUCTURE
(3) Tools and jigs

Holder
Material ; brass
2 DIVISIONS
D L B H
For main plunger 36 90 50 25
For priority valve poppet 25 30 35 20
assembly
Fig. 33-135 Tools and jigs
Fig. 33-136 Name plate
The figures in parentheses after part names in this
manual represent those item numbers in the structural
drawing under 24. COMPONENTS SYSTEM.
The disassembly procedure is explained as below.
Assembly is the reverse order of disassembly.
Before disassembly, attach tags to parts so they are

reassembled properly.
33-78
33. UPPER STRUCTURE
(1) Disassembling the main plunger

1) Remove socket bolt (18) and cover (17) in that 32 17 18
order.
: 10 mm
Fig. 33-137 Removing cover (17)

Before reassembling the cover, make certain that an O-
ring is placed on the mouth of the housing.
2) Draw out the plunger sub-assy.
• Do not draw out the plunger in a breath, but rotate

it slowly while drawing it out and confirming the
contact with the housing.
• When reassembling BM-1, match the keyway at the
Fig. 33-138 Draw out the plunger sub-assy
tip of the plunger to the plug in whirl-stop cover.
3) Hold the plunger by the tool (holder), hold it in a

HOLDER
vise and loosen plunger cap (32).
: 10 mm
32
Degrease the plunger and the holder thoroughly.
Fig. 33-139 Removing plunger cap (32)

4) Remove plunger cap (32). Then separate spring
guide (33), springs (35), (36) and sleeve (34), in
that order.
33
Note that the travel straight select spool has a different 34
spring.
35,36
33
32
Fig. 33-140 Removing plunger and spring
33-79
33. UPPER STRUCTURE
5) Regarding the BM-1 and AM-1 plungers, remove 39

38 40
cap (43) on the opposite side.
Then draw out spacer (40), spring (39) and
checks (38), (45).
: 10 mm 43
AM-2
45 39 40
40
39
38
40
AM-2
39
45
Fig. 33-141 Disassembling the plunger and check
(2) Disassembling the center bypass
Remove cap (87). Then take out spool (89) and
spring (88). 87 88 89
: 46 mm
88
89
Fig. 33-142 Disassembling the center bypass
33-80
33. UPPER STRUCTURE
(3) Disassembling the load hold valve 91

1) Disassembling the main poppet 90
1. Remove socket bolt (91) and cover assy (90)
in that order.
: 12 mm
Tightening torque : 176.5 N•m (130 lbf•ft) 93 90 106 100 101 102 93

ring is placed on the matching surface of the cover. 89
99
98
Fig. 33-143 Load hold valve

2. Take out spring (99) and poppet (98).
99
98
Fig. 33-144 Removing spring (99) and poppet (98)
2) Disassembling the cover (90)
1. Remove cap (93) and take out piston (106).
: 10 mm
2. Remove cap (93), spring (102) and poppet
(101) in that order.
106
: 10 mm
93
After a long period of operation, the poppet does not

come off in some cases because of the edge on the 93
seat surface. Do not disassemble it by force. 102
Fig. 33-145 Disassembling the cover (90)
3. Knock sleeve (100) out by lightly tapping it to PIPE
the left, using a pipe of ø10mm (0.394in) bore
diameter and ø14mm (0.551in) OD.
Work carefully to avoid damaging the sleeve inner edge

100
(ø8).
Fig. 33-146 Removing sleeve (100)
33-81
33. UPPER STRUCTURE
(4) Disassembling the over load relief valve PRESSURE

Boom H, Bucket H, Arm R side ADJUSTING PART
Boom R, Bucket R, Arm H side
Since it is hard to adjust pressure on the actual

machine, do not disassemble the pressure adjusting
part.
1
5 4 3 2
RELIEF SLEEVE
Fig. 33-147 Removing over load relief valve

1) Loosen relief sleeve (1) and remove the
cartridge.
: 36 mm
• When installing the body:
Set pressure differs depending on assembling

positions; always reassemble parts where they
were.
Fig. 33-148 Removing cap (1)

2) Loosen cap (1) and remove the sub-assembly.
Take out spring (2), (3) and pilot poppet (5).
: 36 mm
Tightening torque : 98 N•m (72 lbf•ft) (Tightening
with sleeve)
2
5
Fig. 33-149 Disassembling relief sleeve (1)
33-82
33. UPPER STRUCTURE
(5) Disassembling the cover (whirl-stop) 18

18
1) Removing BM-1 socket bolt (18) and cover (20). 20 111
: 10 mm
(BM-1) (BKT)
Before reassembling the cover, make certain that an O

ring is placed on the mouth of the housing. 83 112
Further, match the keyway of the plunger to the tip of Fig. 33-150 Disassembling the cover (whirl-stop)
the plug.
2) Removing plug (83).
: 19 mm
83
Fig. 33-151
3) BKT
Remove socket bolt (18), cover (111) and piston
(112) in that order.
: 10 mm
112
Fig. 33-152
(6) Disassembling the check valve 50 85
(7) Disassembling the double check valve
AM-2 (double check) is explained hereafter:
49 49
Remove cap (85). Then take out spring (49) and 86
check (47), (86).
47
: 14 mm (BM-1, BM-2, SW)
47
Tightening torque : 343 N•m (250 lbf•ft) (BKT, OPT-1 or other)
(AM-2)
Fig. 33-153 Check valve, double check valve
86
49
47
Fig. 33-154 Disassembling the double check valve
33-83
33. UPPER STRUCTURE
(8) Disassembling the main relief valve

4 3 2 1
1) Loosen nut (2).
2) Loosen nut (3).
Fig. 33-155 Removing main relief valve

3) Loosen cap (4) and remove the cartridge. 7
6 8
Fig. 33-156
4) Draw out poppet sub-assy (A). Then take out
main poppet (7) and spring (8) from sleeve (6).
NAME OPPOSING
FLATS
1 Adjusting screw 22
2 Nut 30 8
3 Nut 41 7
4 Cap 41
5 Sleeve 27 6
Fig. 33-157 Removing sleeve (6)

5) Remove adjusting screw (B). Then take out 10 9 B
spring (9) and pilot poppet (10).
Do not disassemble pilot seat (C) as it is press fitted to

the cap.
10
PILOT C
ADJUSTING SUB-ASSY B
Fig. 33-158
33-84
33. UPPER STRUCTURE
(9) Disassembling the priority valve 123

124
1) Remove socket bolt (124) and take out cover
(123).
: 12 mm
130
ring is placed on the mouth of the housing.
131
132
133
Fig. 33-159 Removing priority valve cover (123)

2) Take out spring (130), spring guide (131), sleeve
(132) and poppet sub-assembly (133).
130
131
132
133
Fig. 33-160 Removing priority valve
3) Hold poppet sub-assembly (133) in the holder,
hold it further in a vise, remove cap (136), and HOLDER
separate spring (135) and check (134).
: 6 mm
Degrease the poppet and the holder thoroughly. 133 POPPET SUB ASSY
136
135
134
Fig. 33-161 Disassembling the poppet (133)
33-85
33. UPPER STRUCTURE
4) Remove cap (121). Draw out plate (127), using a 121

123
round-bar rod of 8mm to 9mm (0.3in to 0.4in) in
diameter and a press. Then separate spring
(126) and piston (125). 125
: 5 mm
126
127
The spring has repulsive force. Take care so parts do
not fly off when the plate comes off.
125
126
127
Fig. 33-162 Disassembling cover (123)
(10)Disassembling the optional conflux check valve 120 49 47
Remove cap (120). Then take out spring (49) and
check valve (47).
: 41 mm
47
49
Fig. 33-163 Disassembling the optional conflux
check valve
33-86
33. UPPER STRUCTURE
(11)Disassembling boom boost check valve 1 2 3
Fig. 33-164 Disassembling boom boost check valve

1) Remove cap (1), then take out spring (2) and
poppet (3).
: 32 mm
2
Fig. 33-165
(12)Disassembling bucket conflux check valve
TAPPING M6
1) Loosen socket bolt (1) and remove flange (2).
: 10 mm 5 4 3
Fig. 33-166
2) Draw out sleeve (3). Then remove spring (4) and
check (5).
5
Fig. 33-167
33-87
33. UPPER STRUCTURE
(13)Disassembling the plug for over load relief
TAPPING M8
Fig. 33-168
1) Remove cap (1). Then draw out plug (2).
: 17 mm
Fig. 33-169
2) Attach the setup over load relief valve. Then
tighten to specified torque.
: 36 mm
3
Fig. 33-170
33-88
33. UPPER STRUCTURE
33.2.2.3 ASSEMBLY
(1) Cautions to be exercised in assembly
1) Exercise care the same way as in disassembly.
2) Before proceeding to assembly, clean parts free from metallic particles and foreign matter and make sure
that the parts are free from burrs and dents. Eliminate burrs and dents with an oilstone or the like.
3) Replace O-rings and backup rings with new ones.
4) Handle O-rings and backup rings with care so as not to score them.
(Apply a little grease to make the surface smooth.)
5) Tighten bolts and caps to specified torque.
(2) Disassembly procedure
Assembly is the reverse order of disassembly.
33.2.2.4 PRESSURE SETTING OF MAIN RELIEF VALVE
If the pressure of the relief valve is not set properly, the hydraulic device may be destroyed in some cases.
This is dangerous. Therefore, never raise the pressure above a level that is specified for each machine
model.
(1) Temporary setting

1) Tighten adjust screw (10) till piston (A) hits the (Z) surface of sleeve (1).
2) Confirm the set pressure "0" position.
Loosen sleeve (1) with the adjust screw facing downward. Then tighten it again till the pilot poppet (B) comes
in contact with the seat or the pressure adjusting spring (C) begins to work. Set the pressure at that point
temporarily.
3) Assemble the temporarily assembled cartridge to the valve body and tighten cap (3).
(Z) SURFACE
(A) PISTON
(B)
PILOT POPPET 3 2 1 11 10
(C)
PRESSURE ADJUSTING SPRING
Fig. 33-171 Pressure setting of relief valve
33-89
33. UPPER STRUCTURE
(2) High pressure setting

1) Install a correct pressure gauge to the delivery port of the hydraulic pump.
2) Run the pump at rated revolution.
3) Move the plunger either for boom, arm or bucket action to full stroke and read the pressure gauge.
4) Turn sleeve (1) clockwise and adjust the pressure, while looking at the pressure gauge.
The pressure changes by about 4.5MPa (653 psi) in 1/4 turn.
Do not tighten the relief jerkily as it is extremely sensitive.
5) Fix sleeve (1) and tighten nut (2) after setting the pressure.
Operate the plunger and confirm the set pressure.
(3) Low pressure setting

1) After the high pressure setting mentioned above has been completed, adjust pressure while loosening the
adjust screw (10) (counterclockwise).
2) Fix adjusting screw (10) and tighten up nut (11) after the pressure setting.
Operate the plunger and confirm the set pressure.
33-90
33. UPPER STRUCTURE
33.2.3 PILOT VALVE (ATT)
33.2.3.1 CROSS-SECTIONAL VIEW
312
302
Apply grease on
rotating and
501
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc
PORT PORT
2,4 1,3
Fig. 33-172 Pilot valve (For ATT)
Apply loctite #277 to areas marked

101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
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 *246 Spring 4
213 Seal 4 47.1 (35) 301 Joint : M14 1
214 O-ring ; 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (51) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * might not be equipped depending on valve type.
33-91
33. UPPER STRUCTURE
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
Fig. 33-173 Removing boot (501)

(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
312
: 22mm, 32mm
302
Fig. 33-174 Removing adjusting nut (312)

(4) Remove circular plate (302)
302
: 32mm
Fig. 33-175 Removing circular plate (302)
Fig. 33-176 Circular plate is removed
33-92
33. UPPER STRUCTURE
Fig. 33-177 Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig A to
remove.
Jig A : See page 33-100.
: 24mm
301
When the force of return springs (221) is strong, never

loosen joint (301). If loosened, it might result in jumping
out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with
two fingers. Fig. 33-178 Removing joint (301)
(6) Remove plate (151)

• When the force of return springs (221) are 151
strong, press plate to let it come up slowly.
Fig. 33-179 Removing plate (151)

• When the force of return springs (221) are weak,
plug is left in casing (101) due to sliding
resistance of O-ring (214).
Pull plug (211) out with a driver.
To prevent personal injury, plug (211) must be removed

slowly and evenly until the return spring (221) force is
completely released.
211
Fig. 33-180 Removing plug (211)
33-93
33. UPPER STRUCTURE
(7) Remove push rod (212), plug (211), pressure

reducing valve assy (spool), return springs (221)
212
from casing (101).
211
Record combination of port holes on casing and the 221

pulled out parts. The stroke differs according to
direction.
101
Fig. 33-181 Removing push rod, plug, pressure

reducing valve and spring
(8) Push springs (241-1), (241-2) in the range of 7mm
(0.276in) that the movement of spring seats (216- 216-1
216-2
1), (216-2) and shift the seats (216) in a side
direction, and remove spools (201-1), (201-2)
through the larger hole of seat.
Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
201-1
Never push down spring seat (216-2) in 9.4mm
201-2
(0.370in) or more. (For port 2,4)
Fig. 33-182 Removing spool (201)
(9) Remove spool (201-1), (201-2), spring seats (216-
1), (216-2), spring (241-1), (241-2) and washer 241-1 216-1
(217). 241-2 216-2
217
201-1
201-2
Fig. 33-183 Disassembling pressure reducing valve

(10)Remove spring (*246), spring seat (*218-1), (*218-
2) from push rod (212). *218-1 *246 214
*218-2
The parts marked * might not be equipped depending

on valve type.
212
211
Fig. 33-184 Disassembling push rod
33-94
33. UPPER STRUCTURE
(11)Pull out push rod (212) from plug (211).

(12)Remove O-ring (214) from plug (211).
212
Fig. 33-185 Removing push rod (212)

(13)Remove inside seal (213) from plug (211) with
small driver.
213
Fig. 33-186 Removing seal (213)
33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.
33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2
217
Fig. 33-187 Assembling pressure reducing valve
33-95
33. UPPER STRUCTURE
(2) Push spring (241-1), (241-2) in the range of that the

movement of spring seats (216-1), (216-2) in a side 216-1
216-2
direction, and install spools (201-1) through the
larger hole of spring seat. (See Fig. 33-182)
Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4mm 201-1
201-2
(0.370in) or more. (For port 2,4)
Fig. 33-188 Installing spools (201-1), (201-2)

(3) Place spring (221) into ports 1,3 of casing (101),
and then install pressure reducing valve assy in it. PRESSURE REDUCING
VALVE ASSY
Place springs (221) into ports 2,4 and install it.
221
Install the removed respective assy into respective

holes. 101
Fig. 33-189 Installing pressure reducing valve assy

(4) Fit O-ring (214) and seal (213) into plug (211).
• Apply hydraulic oil on surface of push rod. 211
214 213
PLUG (211)
SEAL (213)
-RING (214)
PUSH ROD
(212) Apply hydraulic oil
For the assembling

direction of seal (213). Fig. 33-190 Installing O-ring (214) and seal (213)
(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.
The parts marked * might not be equipped depending

on valve type.
212 211 246 218-1
Fig. 33-191 Assembling push rod, spring (246) and

seat (218)
33-96
33. UPPER STRUCTURE
(6) Fit plug (211) assy to casing (101).

1) When the force of spring (211) is weak, it stops
at the position where it is pushed in by the sliding
resistance of O-ring (214).
101 211
Fig. 33-192 Installing plug assy

2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the 301
same time, and tighten joint (301) temporarily.
• Install spool (201) straight and evenly into the
hole of casing (101).
• Take care so that plug (211) and plate (151) do
not jump out of casing (101).
151
Fig. 33-193 Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A securely.
Jig A : See page 33-100.
Tightening torque : 47.1 N•m (35±2.2 lbf•ft)
101
A
Fig. 33-194 Installing joint (301)
33-97
33. UPPER STRUCTURE
(8) Install circular plate (302) to joint (301)
• Screw it in until it comes in contact with 4 push rods 312

(212) equally.
• The exceeding of screw in may cause malfunction
of machine. 302
(9) Screw adjusting nut (312) in until it touches circular

plate (302), and tighten it applying spanner to stop
circular plate returning.
Fig. 33-195 Installing circular plate (302)
: 32mm
: 22mm
• Apply Loctite #277 to threads of joint.
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE
(12)Spray rust preventives through each port and

attach plug respectively.
301
212
Fig. 33-196 Applying grease to joint section and

push rod
33-98
33. UPPER STRUCTURE
Check item Standard Remarks

When leakage quantity reaches to 1000cc/ min.
or more where handle is set in neutral position,
Conditions
or to 2000cc/min. or more in operation, replace
Leakage Primary pressure 2.94 MPa (426 psi)
spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced, replace
pilot valve assy with new one.
When the wear of sliding section is 10 more
This condition may be the same as the
Spool than the that of non sliding section, replace it
above.
with new one.
Push rod When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on
In case of the looseness due to the
Looseness of control circular plate (302) on control section and joint
loosening on tightening section, adjust
section section (301) due to wear is produced, replace
it.
them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6 (
TROUBLESHOOTING), replace pilot valve
assy with new one.
• O-ring, etc. should be replaced with new one at every disassembling.

• If socket bolt (125) was loosened, seal washer (121) should be replaced.
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.
Trouble Cause Remarks

1) Primary pressure is insufficient. 1) Secure primary pressure.
2) Secondary pressure springs (241) are
2) Replace with new ones.
broken or fatigued.
Secondary pressure
3) Clearance between spool (201) and
does not rise . 3) Replace spool (201).
cas-ing (101 ) is abnormally large.
4) Disassembly and reassembly or
4) Handle has a looseness.
replace handle section.
1) Sliding parts are caught. 1) Repair the unsmoothed section.
Secondary pressure is
2) Tank line pressure varies. 2) Bring pressure directly to oil tank.
unstable.
3) Air has mixed into pipeline. 3) Bleed air by operating it several times.
Secondary pressure is 1) Tank line pressure is high. 1) Bring pressure directly to oil tank.
high 2) Sliding parts are caught. 2) Correct.
33-99
33. UPPER STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2) BUSHING
Material ; S45C
SECTION AA
A A
Installing condition on joint
* (1) and (2) are tight fitted
Sectional drawing of jig
Material ; SCM415 (N)

Carburizing and Quenching
Q'ty ; 2
Detail of bushing
33-100
33. UPPER STRUCTURE
33.2.4 PILOT VALVE (FOR TRAVEL)
T=Tightening torgue
N.m (lbf.ft) 12-o
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3
g
14
q 11
T=5 (3.7) r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3~5 (2.2~3.7)
Fig. 33-197 Exploded view of pilot valve

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 M5× 8 4 14-q Plug M8 2
7 Retaining plate kit (1) 14-r Ball M6, 35 2
7-h Plate 1 15 Orifice (4)
7-i Capscrew M10× 20 2 15-u Plug M6 4
7-j Shaft 2 15-t Orifice M6, ø0.6 4
7-k Set screw M4× 10 2 17 Shuttle valve kit (2)
8 Flange kit 4 17-w’ Shuttle valve & orifice 2
10 Control spool 4 17-r Ball M6, 35 2
11 Return spring 4 17-z Orifice M5, ø0.8 2
12 Damper flange kit (4) 21 Plug 4
12-o Damper plunger ø14 4
33-101
33. UPPER STRUCTURE
33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement

The pilot control unit does not need to be removed from

the machine to perform this operation.
1) Remove both faulty boots.

(using a flat screw driver if necessary)
2) Replace both boots with a new one.
* Reassembly :

• First fit the lower part of the rubber boot on
the retaining plate between the 2 switch
plates
• 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.
Fig. 33-198
(2) Switch plate removal
1) Remove :

• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-199 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the

locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)
3) Fit a M3 screw on the switch plate axis in order
to remove it
(Using pliers if necessary). (See Fig. 33-199
No.2)

* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-199 No.3)
4) Mark out the position of the switch plate before
removing it.
Fig. 33-199
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.
33-102
33. UPPER STRUCTURE
(3) Switch plate adjustment
If the switch plate is replaced, it is necessary to adjust

the regulation screws.

1) Unscrew the 2 locking screws using a 2,5mm
socket wrench (See Fig. 33-200)
* Reassembly :
locking screw thread.
• Torque :3 N•m 2.2 (lbf•ft)
2) Set the switch plate horizontally.
3) Screw on simultaneously both regulation screws
using a flat screw driver (5,5× 150) until feeling Fig. 33-200
some resistance.
Do not misadjust the two damping screws. (See Fig.

33-201)
Regulation Damping screws
screws to already adjusted
4) Tighten the locking screws to hold the regulation adjust and glued
screws in position.
5) Repeat the operation for the second switch plate
making sure both switch plates are parallel. (See
Fig. 33-200) SWITCH PLATE
The figure is shown
from the backside.
(4) Retaining plate removal
Fig. 33-201
1) Remove
• Both switch plates (See 33.2.4.2 (2))
2) Unscrew simultaneously both screws holding the
retaining plate using a 8mm socket wrench.
(See Fig. 33-202)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread.
• Torque :30 N•m (22 lbf•ft)
Fig. 33-202
33-103
33. UPPER STRUCTURE
3) Lift the retaining plate to remove it.

(See Fig. 33-203)
* Reassembly :
• Use the retaining plate to insert the 4 guides
into the body simultaneously and
perpendicularly.
(See Fig. 33-203 left side)
5) Drain the pilot control unit (See 33.2.4.3).
Fig. 33-203
(5) Damping plunger seals replacement
1) Remove
• Both rubber boots. (See 33.2.4.2 (1))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-204 No.1) Fig. 33-204
* Reassembly :
• Replace with a new wiper ring.

Always place the damping plunger prior to the wiper

ring, and make sure the wiper ring is correctly

positionned.

3) Remove the damping plunger (2).

(Fig. 33-204 No.2)
Fig. 33-205
4) Using a needle, remove the seal placed inside

the body (See Fig. 33-206 No.3, 4)

* Reassembly :
• Replace with a new seal and grease it.
3 4
Fig. 33-206
33-104
33. UPPER STRUCTURE
• Squeeze the seal between your fingers to

obtain a 8-shape.
(See Fig. 33-207 No.5)
• Insert the seal within the groove with your
fingers (lip in bottom position).
(See Fig. 33-207 No.6, 7)
• Push the seal against the side using the 5 6
round head of a small socket wrench. (Fig.
33-207 No.8)
During the reassembly, make sure the seal is correctly

positionned, and pay attention not to damage nor twist
it. 7 8
5) Repeat the operation for the other 3 assemblies. Fig. 33-207
6) Extract the damping springs from the body (using

flat nose pliers).
7) Inspect the damping springs. If defects are
detected, replace the 4 springs.
(6) Guide/plunger and regulation unit replacement
1) Remove
DAMPER
PLUNGER
2) Guide/plunger replacement :
BODY
• Insert the end of a thin screwdriver between
the guide and the body, carefully lift the guide
to remove it from the body.
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.
Fig. 33-208
33-105
33. UPPER STRUCTURE
6) Guide/plunger and relulation unit replacement

• Extract the regulation units from the body
(using flat nose pliers).
• Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7) Return spring replacement :
• Extract the return springs from the body
(using flat nose pliers).
Fig. 33-209
• Inspect the return springs. If defects are
detected, replace the 4 springs.
Fig. 33-210
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• The damping plungers and springs (See
33.2.4.2 (5))
Fig. 33-211
33-106
33. UPPER STRUCTURE
2) Unscrew the screw using a 3mm socket wrench.

(See Fig. 33-211)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread
• Screw on until it sets just above the body.
(See Fig. 33-212)
3) Unscrew the throttle using a 3mm socket
wrench.
* Reassembly :
4) Repeat the operation for the other 3 assemblies.
SCREW
5) Replace with new screws and new throttles.
THROTTLE
Fig. 33-212
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled

to perform this operation.
2) Unscrew the shuttle valve using a 4mm socket

wrench. (See Fig. 33-213 and Fig. 33-214)
* Reassembly :
• Thoroughly clean the body to remove any
trace of loctite. Fig. 33-213

shuttle valve thread.
Wait for 8 hours before using the machine to let the

Loctite #242 dry completely.
Fig. 33-214
33-107
33. UPPER STRUCTURE
3) Put the body up-side-down to remove the shuttle

valve and the ball. (See Fig. 33-216)
4) Unscrew the throttle using a 2,5mm socket
wrench.
* Reassembly:
• Hand tighten.
5) Repeat the operation for the other
subassemblies.
6) Inspect the shuttle valves, balls and throttles. If
defects are detected, replace all the assemblies.
Fig. 33-215

Fig. 33-216
(9) Check valve kit removal
1) Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled

to perform this operation.
2) Unscrew the check valve plug using a 4mm

socket wrench.
(See Fig. 33-217)
* Reassembly :
• Drain the pilot control unit
(See 33.2.4.3)
Fig. 33-217
• Torque :5 N•m (3.7lbf•ft)
3) Put the body up-side-down to remove the ball.
4) Repeat the operation for the second check valve
kit.
5) Inspect the check valve plugs, O-rings and balls.
If defects are detected, replace all the
assemblies. (See Fig. 33-218)

Fig. 33-218
33-108
33. UPPER STRUCTURE
33.2.4.3 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.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug using a 4mm
socket wrench. (See Fig. 33-219)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
• Torque : 5 N•m (3.7 lbf•ft)
(8) Repeat the operation for the other check valve plug.
Fig. 33-219
33-109
33. UPPER STRUCTURE
(1) Swing motor
17
41
42
SECTION A-A
15,16
32 33
A PORT SIDE
RELIEF VALVE
A PORT
b 34
g
TOP DEAD POINT h BOTTOM DEAD POINT
i
B PORT
B PORT SIDE
31 RELIEF VALVE
30 a DRAIN PORT
29
28 34 39 38 37 36 35
MAKEUP PORT
16 15
17 18
14 19
13 20
43 b
c 21
12
MECHANICAL BRAKE
11
RELEASE CHAMBER
10 d 22
9 e 23
8 f 24
7 25
6 26
5 40
4
3 2 1 27
33-110
33. UPPER STRUCTURE
1 INNER RING 1 23 SNAP RING 1
2 OIL SEAL 1 24 CYLINDER 1
TAPERED ROLLER
3 1 25 HOUSING 1
BEARING
4 BACKING SPRING 1 26 COLLAR 1
5 CAM PLATE 1 27 SNAP RING 1
6 RETURN PLATE 1 78 (58) 28 BYPASS VALVE ASSY 2
7 PISTON ASSY 9 29 BACK-UP RING 2
8 LINING PLATE 3 30 O-RING ; 1B P18 2
9 PLATE 3 31 O-RING ; 1B P12 2
10 O-RING 1 32 COVER 1
11 PISTON 1 78 (58) 33 RELIFE VALVE ASSY 2
12 O-RING 1 34 O-RING ; 1B P26 4
13 SPRING 19 284 (209) 35 SOCKET BOLT ; M16× 60 4
14 PISTON 2 36 CHECK VALVE 2
29 (22) 15 CAP 3 37 SPRING 2
16 O-RING ; 1B P11 3 137 (101) 38 CAP 2
17 PARALLEL PIN 2 39 BACK-UP RING ; T2 P26 2
18 SCROWAVE 4 40 PLUG 1
19 TEFLON RING 4 41 PISTON 2
20 BUSH 4 42 TEFLON RING 2
21 BALANCE PLATE 1 43 O-RING 1
22 NEEDLE BEARING 1
33-111
33. UPPER STRUCTURE
(2) Swing reduction unit
Caulk these 2 places

with punch.
R
Be careful about installation
OIL FILLING PORT PT3/4 direction of retaining ring.
Tightening torque LEVEL PORT PT1/2 Be careful about

181 +- 20 N.m (134 +
- 15 lbf.ft) installation direction
Apply Three Bond #1360. of thrust washer. Be careful about
R
installation direction
of spring pin.
Apply Loctite #515. VIEW (II) (4 places)
SURFACE OF
LUBE OIL
Apply Loctite #515.

Drive spring
pin (8) into 1mm
lower than the
R surface of spider.
Be careful about installation Paint this
direction of retaining ring. plane.
Apply Loctite #515.
SECTION A-A
Fill up this space

with grease.

1 PINION SHAFT 1 13 SPHERICAL BEARING 1
2 #1 SUNGEAR 1 14 OIL SEAL 1
3 #1 PINION 4 15 HOUSING 1
4 SPIDER ASSY 1 16 OIL SEAL 1
5 #2 SUNGEAR 1 17 SLEEVE 1
6 #2 PINION 4 18 THRUST WASHER 8
7 RING GEAR 1 19 THRUST WASHER 8
8 SPIDER 1 20 RETAINING RING 4
9 SHAFT 4 21 RETAINING RING 1
10 NEEDLE BEARING 4 22 SPRING PIN 4
11 NEEDLE BEARING 4 181 (134) 23 CAPSCREW ; M14X150 16
12 SPHERICAL BEARING 1 24 CAP 2
33-112
33. UPPER STRUCTURE
33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

(1) Disassembly 33 38
1) Removal of relief valve assembly etc.
Remove relief valve assembly (33), cap (38),
spring (37) and check (36) from cover (32). 37
: 14 mm, 10 mm
36
Assemble removed parts to original state when

reassembling.
32 28
Fig. 33-220 Removing relief valve, bypass valve
2) Marking at swing motor 32
Before disassembling motor, make a matching
mark between cover (32) and housing (25). This
precaution will assist in reassembly.
25
Fig. 33-221 Making a matching mark

3) Removal of cover assembly
Loosen hexagon socket bolt (35) and place shaft 35
of motor assembly to downward and take cover
(32) out. 32
: 14 mm
25
Fig. 33-222 Removing cover

4) Remove balance plate 23
Remove snap ring (23) with steel pointer and
remove inner race of needle-bearing (22) and 22
balance plate (21) by bearing puller.
In this time, remove balance plate (21) with 21
attaching gear puller to crescent shaped hole of
14
balance plate (21) and shaft of cover (32),
42
because inner race of needle bearing (22) is
41
press fitted into the shaft.
Remove piston (14) and piston (41) and teflon
ring (42) from balance plate (21). 32
Fig. 33-223 Removing balance plate
33-113
33. UPPER STRUCTURE
Work carefully to avoid damaging the sliding face of the

balance plate (21).
Before removing, check and record location of balance

plate (21) to prevent misassembling
5) Remove O-ring (43) from cover (32).

43
32
Fig. 33-224 Removing O-ring

6) Remove bushing (20) with teflon ring (19) and 20
scrowave (18).
19
18
32
Fig. 33-225 Removing bushing

7) Removal of spring ((13), brake area)
13
Remove spring (13) from piston (11).
Check and record original position of each spring (13)

for correct assembling. 25
Fig. 33-226 Removing spring
33-114
33. UPPER STRUCTURE
8) Removal of brake piston

When removing piston (11) from housing (25),

there is a sliding resistance against tightening of

O-rings (10) (12).
Use tap holes (M6) on piston (11) to take them
out, as shown in the diagram.
Remove O-rings (10) (12) from housing (25) and
piston (11).

Set a block outside the inside diameter of housing (25).
Fig. 33-227 Removing brake piston

9) Remove friction plate (8) and lining plate (9) from 9
housing (25).
25
Fig. 33-228 Removing friction plate & lining plate

10) Removal of cylinder assembly
Holding end of cylinder assembly (24) with hand,
draw out cylinder assembly from housing (25).
24
Be careful to keep cylinder (24), as it is slippery with oil.
Oil seal (2) and outer race of taper roller bearing (3) are
left inside of housing (25).
25
End surface A of cylinder (24) is sliding face. So,

protect the surface with a soft cloth against damage.
Fig. 33-229 Removing cylinder assy
Make a matching mark on piston hole of cylinder (24)

and piston assembly (7) to fit piston into the same hole
when reassembling.
33-115
33. UPPER STRUCTURE
11) Separate outer race of taper roller bearing (3)

from housing (25). 3
Remove oil seal (2) from housing (25) with driver 2
and hammer.
25
Do not reuse oil seal (2) after removal.
Fig. 33-230 Removing outer race & oil seal

12) Disassembly of the cylinder assembly
1. Remove snap ring (27) with steel pointer and
remove inner ring (1) and inner race of taper
27
roller bearing (3).
Lift out cylinder (24) with 2 inner race (1) of
roller bearing (3) by applying gear puller at the
1
end of spline in the cylinder.
3
SOFT CLOTH
ETC. 24
Fig. 33-231 Removing inner race

2. Remove collar (26) from cylinder (24).
26
Separate cam plate (5), piston assembly (7),
return plate (6) from cylinder (24). 5
6
7
24
Fig. 33-232 Removing piston assy etc.

3. Get cam plate (5) slide on sliding face of piston
5
assembly (7) and remove it.
6
Work carefully to avoid damaging the sliding face of the

cam plate (5) and piston assy (7).
7
Fig. 33-233 Removing cam plate
33-116
33. UPPER STRUCTURE
4. Remove backing spring (4) from cylinder (24).

4
This completes disassembly.
24
Fig. 33-234 Removing backing springs

(2) Assembly
1) Preparation 7
Before reassembling, perform below procedure.
1. Check each part for damage caused by using
or disassembling. If damaged, remove
scratches by rubbing with "wet and dry"
sandpaper of appropriate coarseness. Clean
each part with clean washing oil and dry with
an air jet.
2. Replace all seals.
3. Paper lap the sliding face of piston assembly 21
(7), balance plate (21), and cam plate (5) with
sandpaper #2000 on a true flat surface.
4. When assembling, lubricate the sliding parts

with specified clean hydraulic oil. 5
Fig. 33-235 Lapping the piston assy etc.
33-117
33. UPPER STRUCTURE
2) Assembling of cylinder assembly

4
1. Lubricate grease on round area (contacting
area with spring (4)) of cylinder (24) and
assemble spring (4).
ROUND AREA
24
Fig. 33-236 Assembling backing spring

2. Insert piston assembly (7) in hole of return
plate (6).
7
Fig. 33-237 Inserting piston assy

3. Assemble piston assembly (7) and return plate
(6) to cylinder (24). 6
When assembling, check matching mark between

them. Before assembling.
Before assembling lubricate specified hydraulic oil 24

inside of each piston hole of cylinder (24).
Fig. 33-238 Assembling piston assy

4. Lubricate specified hydraulic oil on shoe
26
sliding face of piston assembly (7) and
assemble cam plate (5) and collar (26).
5
24
Fig. 33-239 Assembling cam plate
33-118
33. UPPER STRUCTURE
5. Assemble inner race of taper roller bearing (3)

to cylinder (24). Jig 1
(Refer to (3) Tools)
3
(INNER RACE)
End surface of cylinder (24) is sliding face. So, protect
the surface with a soft cloth against damage.
24
Fig. 33-240 Assembling bearing

6. Apply Loctite (515 or 518) to bearing mounting
area of inner race of cylinder (24) lightly. JIG 1
Assemble inner ring (1) and snap ring (27) to
cylinder (24). 1
27
Be careful not to attach a bond to the roller of bearing
(3). Apply Loctite
Wipe off the bond which came out between a inner ring
24
(1) and bearing (3).
Fig. 33-241 Assembling snap ring

3) Assembly of oil seal
Apply three bond (kk "1211") of white color on
outer surface of oil seal (2) and use the seal
press insertion jig to press it into housing (25).
JIG 2
Be cautions of assembling direction of oil seal (2).

2

25

Fig. 33-242 Assembling oil seal
33-119
33. UPPER STRUCTURE
4) Assembly outer race of taper roller bearing

Assemble outer race of taper roller bearing (3)
into the housing (25).

Fig. 33-243 Assembling outer race

5) Assembly of cylinder assembly
The end of cylinder assy
Hold the end of cylinder assembly (24) with
hands and assemble cylinder assembly to
housing (25).
24
Lubricate oil seal (2) with grease.
JIG 3
Be careful to keep cylinder (24), as it is slippery with oil. Top of housing
25
Check that backing spring (4) is held in place by the
probe part of the return plate (6).
30~40
When assemble cylinder assembly, splined shaft of the (1.18~1.58 in)
PAD
cylinder (24) is protruded from the end of housing,
therefore put pad with length 30~40 mm (1.18~1.58 in) Fig. 33-244 Assembling cylinder assy
under bottom of housing (25).
Check that end surface of cylinder is about 15.5 mm

(0.61 in) lower than top of housing.
If the sinkage of the end of cylinder assy is small, it
means that camplate (5) is not set correctly into counter
bore. Lay housing (5) facing the higher slope side
down, and place camplate (5) into the position by
moving cylinder (24) up and down slightly.
33-120
33. UPPER STRUCTURE
6) Assembly friction plate and lining plate 9

Assemble friction plate (8) and lining plate (9).
8
Apply hydraulic oil to each side.
25
Fig. 33-245 Assembling friction plate & lining

7) Insert O-rings
12
Insert O-rings (10) into housing (25). Insert O-
ring (12) into piston (11).
11
10
Lubricate O-rings (10), (12) with grease.
25
Fig. 33-246 Inserting O-rings

8) Assembly of brake piston
Lubricate specified hydraulic oil on outer sliding
face of piston (11) and assemble brake piston to
housing (25).
It is too tight to assemble piston (11) because O-rings

(10) (12) are fitted, therefore it is recommended to push
piston (11) horizontally by hands at once.
Fig. 33-247 Assembling brake piston

9) Assembly of spring ((13), brake unit) 13
Assemble spring (13) to piston (11) of brake unit.
Insert spring (13) into original position.

25
Fig. 33-248 Assembling springs
33-121
33. UPPER STRUCTURE
10) Assembly of balance plate 21

Assemble scrowave (18) and bushing (20) with
teflon ring (19) to bushing hole of cover (33). 14
Grease teflon ring (42) and piston (14) (41).
42
Assemble teflon ring (42) and piston (14) (41) to
balance plate (21). 41
Assemble balance plate (21) to cover (32). 20
19
18
Be cautions of assembling direction of balance plate
(21).
PORT A, B SIDE (MFC 160-059)

V NOTCH 32
Fig. 33-249 Assembling balance plate
RELIEF VALVE SIDE (MFC 160-059)
11) Assembly of inner race of needle bearing 23

Assemble inner race of needle bearing (22) and
snap ring (23) to cover (32).
22
(INNER RACE)
32
Fig. 33-250 Assembling inner race

12) Assembly O-rings 43
Assemble O-ring (43) to cover (32).
Lubricate O-ring (43) with grease.
32
Fig. 33-251 Assembling O-ring
33-122
33. UPPER STRUCTURE
13) Assembly of cover

32
After cleaning the matching surface between
cover (32) and housing (25) and degreasing it,
assemble cover (32) to housing (25) lightly,
holding them up with hands.
Fit matching marks on housing (25) and cover (32)

made before disassembling. 25
At this stage, there is 4.5mm (0.18in) distance between

the housing (25) and the cover (32). Fig. 33-252 Assembling cover
14) Tighten cover (32) and housing (25) with

hexagonal socket bolt (35).
35
: 14 mm
Tightening torque ; 284 N•m {209 kgf•m}
32
The 4 bolts (35) should be tightened equally, straight

and slowly. 25
Fig. 33-253 Tightening socket bolt

15) Assembly of valve assembly, check bypass 33 38
valve assembly, and time delay valve
• Assemble relief valve assembly (33) to cover
(32).
37
: 14 mm
Tightening torque ; 78 N•m {(58 lbf•ft}
• Assemble check (36), spring (37) and cap (38) to 36
cover (32).
: 14 mm
Tightening torque ; 137 N•m {101 lbf•ft}
• Assemble bypass valve assembly (28) to cover
(32).
28
32
: 10 mm
Tightening torque ; 78 N•m {58 lbf•ft} Fig. 33-254 Assembling valve assy
Assemble removed parts to original state when

reassembling.
33-123
33. UPPER STRUCTURE
16) Check of assembly 32

Load pilot pressure of 3.2~4.9 MPa (464~711psi)
to brake release port after opening inlet and
outlet port.
Check if output shaft is rotated smoothly around
torque of 30~40 N•m (22~30 lbf•ft). P PORT
25
If not rotated, disassemble and check.
At this time, open the drain port
Fig. 33-255 Check of assembly
This completes assembly.
Check the relief valves (33) setting to the regulation

pressure.
(3) Tools
Jig 1 Jig 3
(For assmbling roller bearing (3) and inner race (1)) (For assembling cylinder assembly (24))
Jig 2 Jig 4
(For assembling oil seal (2)) (For assembling brake piston (11))
(0.04")
33-124
33. UPPER STRUCTURE
33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
33.2.5.3.1 Tools
Unit : mm (in)
Code Tool name Remarks
450 (17.7)
Material : Mild steel
330 (13.0)
a Stand
280 (11.0)
22 (0.9)
216 (8.5)
250 (9.8)
13- 24
Spherical bearing (13) (0.9)
b (Position
removing jig (I) space equally)
P.C.D 170
(6.7) VIEW X
X
Material : Mild steel 196 (7.7) 10

(0.4)
Spherical bearing (12)
c
110 (4.3)
removing jig (II)
Material : Mild steel t=4.5 (0.2)

d 85 4)
removing jig (I) .
(3
Material : Mild steel 200 (7.9)
Oil seal (16) (0.4)

e 160 (6.3)
installing jig
9
115 (4.5) t=10 (0.4)

or more
170 (6.7) or more

f
press-fit jig
160 (6.3)
Oil seal (14)
(0.4)
110 (4.3)
g
9
installing jig

(5.1)
130
(4.3)
110

h
press-fit jig 100(3.9)
178(7.0)
33-125
33. UPPER STRUCTURE
Code Tool name Remarks

i Snap ring plier For shaft
j Torque wrench 200 N•m (148 lbf•ft) class
k Plastic hammer (Wooden mallet)
m Press 30 ton (66150 lb) class
n Flat-bladed screw driver
p General tools Allen wrench, Steel bar
Thread sealant Three Bond #1360K
q
Sealant Loctite #515
33.2.5.3.2 Disassembly
The numbers in parentheses correspond to the ones in
construction drawings .
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain hose.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the joining parts of the housing
before disassembly.
(2) Disassembling swing motor from reduction unit

1) Preparation for disassembly
Place the reduction unit assy on a stable work
bench as shown in Fig. 33-256, remove plug
(26), drain out oil and put a matching mark on the
matching surface of the figure on the right.
23
2) Removing swing motor assy
Loosen all socket bolt (23) (M14). Attach eye MATCHING
bolts (M12) in the lifting bolt holes in the top MARK
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. Fig. 33-256 Removing swing motor assy
4
: 12 mm
2
(3) Disassembling reduction unit

1) Remove #1 sun gear (2). 7
2) Removing #1 spider assy (4).
The spider assy (4) [consisting of thrust washer
(15), #1 pinion (3), needle bearing (10) and
15
retaining ring (20)] can be removed from the
spline easily if it is lifted up in that condition.
Fig. 33-257 Removing #1 sun gear and
#1 spider assy
33-126
33. UPPER STRUCTURE
3) Removing ring gear (7)

Attach eye bolts (M12) to the top surface of ring
gear (7) and lift the ring gear lightly by a wire #2SPIDER ASSY
sling.
Put a flat-blade screwdriver (n) into the matching
surface of ring gear (7) and housing (15) and 7
remove ring gear (7) by lightly tapping the outer

n
circumference of the ring gear with a plastic
mallet (k). 15
Fig. 33-258 Removing ring gear (7)

4) Remove #2 sun gear and #2 spider assy. #2 SPIDER ASSY
Draw out #2 sun gear (5) and remove the #2
5
spider assy.
Regarding the disassembly of the #2 assy, refer
to par. (4) which will come up later.
Fig. 33-259 Removing #2 spider assy

• Particularly if no failure is found, the further 21
disassembly (under condition shown in Fig.
33-260) is not allowed.
Check on parts for possible failure according
to the inspection procedure shown in item
33.2.5.4.2 separately in this condition.
And we recommend that the pinion shaft and
housing assy are replaced together as one
set. But if it is unavoidably necessary to
replace a part of them, follow the procedure
shown below.
• If no failure is found in this step, the
disassembly later is not required.
Fig. 33-260
5) Remove retaining ring (21) from pinion shaft (1).
33-127
33. UPPER STRUCTURE
6) Pulling out pinion shaft

PRESS
Pull pinion shaft (1), sleeve (17), oil seal (16) and
spherical bearing (lower) (12) out by means of
press while supporting housing (15) as shown in
the figure. 13
14
1
• Spherical bearing (upper) (13) and oil seal 12
(14) are left in the housing.
15
16
17
JIG (a)
Fig. 33-261 Pulling out pinion shaft (1)

7) Removing spherical bearing (lower) (12)
Pull oil seal (16), sleeve (17) and spherical PRESS
bearing (lower) (12) out by means of jigs (b) (c)
while supporting pinion shaft assy as shown in
the figure. JIG (b)
Press force : 30t (66,150 lb)
• Do not use the removed oil seal and bearing.
JIG (c)
17
16
12
Fig. 33-262 Removing spherical bearing (lower) (12)
33-128
33. UPPER STRUCTURE
8) Removing spherical bearing (upper) HAMMER(k)

Set housing (15) as shown in the figure, insert jig
(d) between bearing (13) and oil seal (14) and FLAT-BLADE
remove bearing (13) by striking from the upper SCREWDRIVER (n)
side. STEEL BAR
9) Remove oil seal (14) from housing (15).
14
• Do not use the removed oil seal and bearing.
13
15
JIG (d)
Fig. 33-263 Removing spherical bearing

(upper) (13) and oil seal (14)
(4) Disassembling spider assy
4 3 20 10 18
1) Disassembling #1 spider assy
1. Remove retaining ring (20) with a plier (i).
2. Remove thrust washers (18), pinion (3) needle
bearing (10).
18
Fig. 33-264 Disassembling #1 spider assy
• The shaft attached to spider assy (4) is caulked.

When replacing parts, replace the spider assy as a
set.
• Pinions (3) can not be replaced singly. Replace
them it in a set of four.
2) Disassembling #2 spider assy

9
1. Draw out spring pin (22). 19
2. Draw out shaft (9) from spider (8) and remove
11
thrust washer (19), pinion (6) and needle
bearing (11).
6
19
8 22
Pinions (6) can not be replaced singly. Replace them it
Fig. 33-265 Disassembling #2 spider assy
in a set of four.
33-129
33. UPPER STRUCTURE
33.2.5.3.3 Assembly
(1) Preparation
1) Sufficiently clean every part with wash oil and dry
it with compressed air.
2) Check on every part for failure.
(2) Assembling pinion shaft assy

1) Attaching oil seal
JIG (e)
Attach oil seal (16) to sleeve (17) by means of jig
(e).
16
Apply Loctite #515 17
Fig. 33-266 Attaching oil seal (16)

2) Inserting sleeve
1
Insert sleeve (17) and oils seal (16) assy in
pinion shaft (1).
16
3) Applying gear oil

Apply gear oil to the perimeter of axis of pinion
17
shaft (1) lightly to prevent seizure.
Fig. 33-267 Inserting sleeve (17) in pinion shaft (1)

4) Fitting spherical bearing (lower)
PRESS
Seal sufficient grease in spherical bearing
(lower) (12) and force it in pinion shaft (1) by
means of jig (f).
Press force : 4~5t (8820~11025 lb)
JIG (f)
• Since the bearing is formed with a partition at
the center section, seal grease in it from both
sides.
12
Fig. 33-268 Fitting spherical bearing (lower) (12)
33-130
33. UPPER STRUCTURE
5) Apply sufficient grease to the pinion shaft assy.

Grease : Lithium extreme-pressure grease
(SHELL Albania EP2 or equivalent)
GREASE
(3) Placing pinion shaft assy in

1) Place housing (15) on level bench.
2) Attach eye bolt to screw (M10) at the axis end of
pinion shaft assy, and perpendicularly hang up
pinion shaft assy and place it in the housing.
• Horizontally orient the outer race of spherical

bearing and insert it in by striking lightly.
If the outer race is tilted, it is hard to insert Fig. 33-269 Apply grease
even if striking. Then do not force to insert it
in, but take it away once and horizontally
orient the outer race twice and insert it in
again.
15
Fig. 33-270 Placing pinion shaft assy in

3) Set housing assy so that the pinion directs
downward. JIG (g)
4) Fit oil seal (14) in housing (15) by means of jig

(g).
14
• Apply Loctite #515 to the perimeter of oil
15
seal.
• Fill one third (1/3) of the space of the groove-
shaped section provided on the oil seal (14)
lip with grease.
• Insert it horizontally giving attention to the lip
of oil seal so as not be damaged.
Fig. 33-271
33-131
33. UPPER STRUCTURE
5) Press fit spherical bearing (upper) (13) in pinion

PRESS JIG (h)
shaft (1) and housing (15) at the same time by
means of jig (h). 1
13
15
Fig. 33-272 Spherical bearing (upper) Press-fitting

6) Attach retaining ring (21).
21
Fig. 33-273 Attach retaining ring
33-132
33. UPPER STRUCTURE
(4) Assembling spider assy

4 3 20 10 18
1) Assembling #1 Spider assy
a. Coat the bore surface of pinion (3) with
grease. Put pinion (3) on thrust washer (18)
and assemble needle bearing (10) into the
18
bore surface
b. Fit thrust washers (18) and pinion (3) as in Fig. Fig. 33-274 Assembling #1 spider assy
33-275 and fit retaining ring (20) by means of
pliers (i).
i
Fix the snap ring with the sharp edge on the motor side
(top side in the position of Fig. 33-275).
18
4
SNAP RING (20)
Motor side 3
20
Fig. 33-275 Fixing snap ring
2) Assembling #2 Spider assy Caulk two

a. Coat the bore surface of pinion (5) with points with
a punch.
grease. Put pinion (5) on thrust washer (18)
and fit needle bearing (17) to the bore surface.
b. Fit thrust washer (18) and pinion (5) as in Fig.
33-276 insert shaft (9) into spider (8) and drive
spring pin (22). 6~7mm 6~7mm
(0.24~0.28 in) (0.24~0.28 in)
VIEW I (Direction of spring pin)
9
19
Insert shaft (6) into spider (8) so spring pin hole (22) is 11
aligned.
6
19
8 22
Fig. 33-276 Assembling #2 spider assy

(5) Installing #2 spider assy
#2 SPIDER ASSY
Insert #2 spider assy in spline axis of pinion shaft
(1).
Fig. 33-277 Assembling #2 spider assy
33-133
33. UPPER STRUCTURE
(6) Installing #2 sun gear (2)

2
Install #2 sun gear (2) directing the spline upward.
Fig. 33-278 Installing #2 sun gear (2)

(7) Installing ring gear (7)
Apply a thin film of sealant Loctite #515 to the
matching surface of housing (15) and ring gear (7)
7 #2 SPIDER ASSY
and assemble them, aligning the gear teeth and
according to the matching marks given. Alligen
maching marks
15
Fig. 33-279 Installing ring gear (6)

(8) Installing #1 spider assy
1) Mesh the #1 spider assy with ring gear (7) and 2
#1 SPIDER ASSY
set them in place.
2) Mesh #1 sun gear (2) with #1 pinion (3) and set 7
them in place.
3
(9) Fit drain hose and plug.
: 27mm
15
(10)Filling Lube Oil
Fill in 7.0L 1.9gal) of gear oil SAE90 (API Service Fig. 33-280 Installing #1 spider assy
Grade GL-4).
(11)Installing swing motor assy

Attach eye bolts (M12) in the tapped holes of the
swing motor and put a wire sling in them
Coat the matching surface of ring gear (7) with
sealant Loctite #515, insert the spline joint of the
swing motor and match the matching marks. M14X150
Coat socket bolts (23) with sealant Three-Bond 23
1360K and fasten them.
MACHING
: 12 mm, MARKS
Fig. 33-281 Installing swing motor assy
33-134
33. UPPER STRUCTURE
33.2.5.4.1 SWING MOTOR
Parts Name Check and Measuring Reference Value

Measuring Instrument Correction
Point (Allowable limit)
Wear of shoe sliding
Piston Assembly (7) Rmax 0.8μm Surface gauge Lap
surface
Height of hollow of
Min 0.4mm Dial depth gauge replace with new one
shoe sliding surface
The amount of ball
joint part movements Min 0.4mm Dial gauge replace with new one
of a piston and shoe
Piston diameter Hardly worn.
If damage or seizure is evident, replace with new one.
Cam plate (5) Surface Rmax 0.8μm Surface gauge Lap
Cylinder assembly (24) End surface Rmax 0.4μm Surface gauge Lap
Piston hole Hardly worn.
If damage or seizure is evident, replace with new one.
Balance plate (21) Surface Rmax 0.8μm Surface gauge Lap
Part Name Service standards

Tapered Roller Bearing (3) A bearing in service for 3,000 hours should be replaced with new one even
Needle bearing (22) if it is good.
Even a bearing in service for less than 3,000 hours should be replaced with
anew one, any minor defects in the rolling surfaces of the roller and needle
are found at disassembly.
Since a bearing may easily be damaged at disassembly, it is preferable to
replace with a new one at reassembly.
Oil Seal (2) If the lip is damaged, replace with a new one.
Even if there is no leakage and the lips are good, the oil seal should be
replaced with a new one every 3,000 hours.
Once removed, it should be replaced with a new one at reassembly.
O-ring (10) (12) (16) (30) (34) Damaged O-ring should be replaced with new one.
Even if there is no leakage and nothing wrong is evident, the O-ring should
be replaced every 3,000 hours.
Once removed, it should be replaced with a new one at reassembly.
Backup Ring (29) (39) Once removed, it should be replaced with a new one at reassembly.
33-135
33. UPPER STRUCTURE
33.2.5.4.2 Swing reduction gear

(1) Inspection at disassembly
1) Spacer and thrust washer
a. Inspect that the parts are not seized or worn abnormally or unevenly.
b. Inspect and measure the parts to see that the wear does not exceed the allowable values.
2) Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
3) Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing
4) O-rings and oil seals

Do not reuse O-rings and oil seals; always replace them with new ones at reassembly.
(2) Inspection after assembly

1) Operation
Check to see that #1 sun gear (2) is not faulty when turned by hand.
2) Checking for oil leak and oil condition

Check for oil leak.
Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish gear oil
SAE90 (API Service Grade GL-4).
33-136
33. UPPER STRUCTURE
(3) Maintenance standards
Lube oil level
Unit : mm (in)
Code Item Repairable level Service Limit Remedy
A Wear in #1 planetary shaft ø40
0
(1.57 -0.0004 ) Replace entire spider assy.
No flaking
B Wear in #2 planetary shaft ø40
0
(1.57 -0.0004 ) Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
D Thickness of thrust washer 1.6±0.1 (0.06 ±0.0039) 1.3 (0.0512) Replace
E Thickness of thrust washer 2.0±0.1 (0.08 ±0.0039) 1.6 (0.063) Replace
Wear in shaft
F (Diameter of part coming in contact ø105 0
(4.13 -0.003 ) ø104.9 (4.13) Replace
with oil seal )
Apply Three-Bond 1360K and
G Socket bolt tightening torque M14- 181 N•m (130 lbf•ft)
tighten to specified torque.
Gear oil SAE90
H Lube oil 7.0 L (1.9 gal) Replenish or replace.
(API Service Grade GL-4)
33-137
33. UPPER STRUCTURE
33.2.5.5.1 Swing motor

Table A
Symp-tom Cause External Inspection Action Repair

Breakage of internal Measure the drain volume Where the motor supply volume See table B.
parts largely equals the drain volume
it is highly likely that a sliding
part is broken so disassemble
the motor to investigate.
Breakage of internal Open the motor inlet and outlet If the output shaft does not turn Replace the broken
Does not turn
parts ports and apply a pilot pressure smoothly at a torque of 30~40 parts or the whole motor
of 3.2~4.9 MPa (464~711 psi) N•m (22~30 lbf•ft) it is assembly.
to the brake release port then highlylikely that an internal
check that the output shaft can parts in broken so disassemble
be turned through at by a the motor to investigate.
torque of approximately 30~40
N•m (22~30 lbf•ft).
Miss-setting of the relief Use a pressure gauge to Reset to the regulation
valve in the circuit measure loaded pressure. pressure setting.
Measure the drain volume. If the drain volume is 2.5 L/min See table B.
Excessive slippage
Wear or breakage of (0.66 gal/min) or more the

motor sliding parts or leakage volume is
high-pressure seals excessive.Disassembly and
investigation is required.
Excessively high oil Measure the oil temperature. Reduce the oil temperature.
temperature with high
internal oil leakage
Wear or seizure of the Open the motor inlet and outlet If the output shaft does not turn Inspect the parts and
motor sliding surfaces ports and apply a pilot pressure smoothly at a torque of bearings in parts a~e of
of 3.2~4.9MPa (464~711psi) to 30~40N•m (22~30 lbf•ft) it is table B and replace any
the brake release port then highly likely that an internal defective parts.
check that the output shaft can parts is broken so disassemble
Poor torque performance or abnormal noise
be turned through at by a the motor to investigate.

torque of approximately
30~40N•m (22~30 lbf•ft).
Miss-setting of the relief Use a pressure gauge to Reset to the regulation
valve in the circuit measure loaded pressure. pressure setting,
Wear or seizure of the Look for metallic foreign bodies If you find a metallic foreign Repair or replace any
motor sliding surfaces in the motor drain oil or trapped bodies it is highly likely that an damaged part.
in the drain filter. internal parts is broken so Replace the motor
disassemble the motor to assembly.
investigate.
Mixture of large Investigate the oil in the tank Thoroughly expel air from the
amounts of air in the and inside the motor case. circuit.
hydraulic oil
Loose bolts etc. Inspect for loose pipe fittings or Tighten all bolts etc. to the
looseness of fitting attachment correct torque.
bolts, motor attachment bolts,
or any other motor-related bolts
33-138
33. UPPER STRUCTURE
Symp-tom Cause External Inspection Action Repair

Seizure of the motor Look for metallic foreign bodies If you find a metallic foreign Repair or replace
sliding surfaces in the in the motor drain oil or trapped bodies, or if the output shaft damaged parts.
Abnormal temperature rise
circuit in the drain filter.Open the does not turn smoothly at a Replace the motor
motor inlet and outlet ports and torque of 30~40N•m (22~30 assembly.
apply a pilot pressure of lbf•ft), it is highly likely that an
3.2~4.9 MPa (464~711 psi) to internal part is broken so
the brake release port then disassemble the motor to
check that the output shaft can investigate.
be turned through at by a
torque of approximately 30~40
N•m (22~30 lbf•ft).
Oil leakage from joints
Damaged O-ring Replace O-ring (s).
Damage to seal Repair the seal faces or

surfaces replace.
Loose bolts Inspect for loose bolts. Tighten to the correct torque.
Damage or wear to the Replace the oil seals.

lip parts of oil seal
Oil leakage from oil seals
Damage or wear to seal Repair, or replace the

surfaces motor assembly.
Abnormal pressure Investigate the pressure in the Reduce pressure within the Replace the oil seal.
inside the case case and the drain volume. case to 0.3 MPa (44 psi) or less. Repair or replace
If the drain volume is excessive, damaged parts.
disassembly and investigation Replace the motor
is required. assembly.
Table B
No. Inspection Point Repair

A Wear to the sliding surface of balance plate (21). Repair or replace the part concerned.
B Damage to the sliding surface of cam plate (5). Repair the part concerned or replace the motor.
Damage to the sliding surface of piston assembly Repair the part concerned or replace the motor.
C
(7).
D Wear to the exterior of pistons assembly (7). Repair the part concerned or replace the motor.
E Wear to the piston holes in cylinder assembly (24). Replace the motor.
F Damage to the teflon rings (19). Replace the teflon rings.
33-139
33. UPPER STRUCTURE
33.2.5.5.2 Reduction unit

()

*)

# $

%

$

% & $

%

+)

!

"
'

33-140
33. UPPER STRUCTURE
33.2.6 SWIVEL JOINT
33.2.6.1 CONSTRUCTION VIEW
16,17
5 (0.197")
Apply Three Bond
6 #1805 to stem
2 places
5
6 places
7 8 9
10,14
4 places 3 4 2 places 4 places
Fig. 33-282 Construction of swivel joint

1 Body 1 8 Capscrew (M8× 20) 2
2 Stem 1 9 Capscrew (M8× 30) 4
3 Cover 1 10 Plug : PF3/4 4
4 Thrust plate 1 11 Plug : PT1/4 1
5 Seal 6 14 O-ring (1B P24) 4
6 O-ring 2 16 Plug : PF1/2 1
7 O-ring (1B G125) 1 17 O-ring (1B P18) 1
33-141
33. UPPER STRUCTURE
33.2.6.2.1 Tools
No. Tool Name Used for Remarks

Hammer 1. Steel hammer
a
2. Wooden or plastic mallet
b Rubber mat Disassembly 750 mm (30in) square or more
Wrench Assembly 1. Allen wrench
c 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Pin Grind the tip of "a nail" to shape
as a screwdriver.
e Disassembly
Spatula Make from a hack-saw blade
Disassembly Approx. 120mm (4.72in)

f
Assembly
Remove the edge completely

Vinyl tape and make corner round smooth.
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m× 1.5m (4ft× 5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.
• Keep all ports plugged up while cleaning.
33-142
33. UPPER STRUCTURE
33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure 2
1
correspond to those of a construction drawing in Fig.
3
33-282.
9
(1) Removing cover
1) Mark cover (3) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt
ALLEN WRENCH
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2) V-BLOCK PIPE
in a vise.
: 6 mm Fig. 33-283 Removing cover (3)

3) Remove cover (3) from body (1) and draw out O-
ring (7) from cover (3).
7
Fig. 33-284 Removing O-ring (7)

(2) Removing thrust plate 1 BODY
Loosen socket bolt (8) fastening thrust plate (4), in 4 THRUST PLATE
the same manner as the removing of the above- 8 SOCKET BOLT
mentioned cover.
: 6 mm
PIPE
When removing thrust plate (4) by fixing body (1),

support stem (2) so it may not fall down.
2
STEM
Fig. 33-285 Removing thrust plate (4)

(3) Removing stem % &'
Place body (1) on a V-block. Put a wooden block !
against stem (2) via the body so about half of the " #$
stem is covered by the wooden block and knock it
out using a mallet.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand.
Stem weight : 27 kg (60 lbs)

Fig. 33-286 Drawing out stem (2)
33-143
33. UPPER STRUCTURE
(4) Removing sealing parts SPATULA (f)

1) Remove O-rings (6) of seal assemblies (5) with
spatula (f).
6
Pay attention to the body (1) not to be damaged by the

top edge of spatula (f).
Fig. 33-287 Removing O-ring (6)

2) Pierce slipper ring of seal assemblies (5) with pin
(e) and remove them from the seal groove. Fig. SLIPPER RING
33-288 shows only one pin, but use two pins to
remove it securely.
As the back up ring is made of rubber, remove BACKUP RING
this in the same procedure as O-ring (6). DETAIL (5)
O-RING
GROOVE
SEAL (5) PIN (e) SEAL GROOVE
OIL GROOVE
SEAL (5) SEAL GROOVE
Fig. 33-288 Removing out seal assy (5)
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (6) thinly and insert
it in O-ring groove.
Check the twist of O-ring
2) Slipper ring is assembled, after first inserting the
backup ring, by slightly-distorting the shape as
shown in Fig. 33-289. Also after inserting all of
the seals, be certain that these are installed in
the seal groove by use of the spatula.
3) Apply grease to seal (5) top.
Remove grease, hydraulic oil and vaseline from the

Fig. 33-289 Inserting slipper ring (5)
groove of seal.
And insert seal (5).
33-144
33. UPPER STRUCTURE
(2) Assembling stem

Press in by applying your weight by your hands.
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).
2 STEM
• If stem (2) is pressed in too fast, the seal may be

O-RING 6
damaged. Do it slowly.
• The clearance between body (1) and stem (2) is 1 BODY
about 0.1mm (0.004in). Push stem straight along
the shaft center. SEAL 5
WORK BENC
Fig. 33-290 Inserting stem (2)

(3) Assembling thrust plate
8 4 2
1) While holding stem (2) and body (1), match the
hole of thrust plate (4) and the stem (2) hole.
2) Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite #242 and
tighten to stem (2).
: 6 mm,
Fig. 33-291 Tightening socket bolt (8)

(4) Assembling cover
1
After installing O-ring (7) to cover (3) and aligning MATCHING MARK
the matching marks of the cover (3) and body (1),
9
coat socket bolt (9) with Loctite #242 and tighten it
which will then complete assembly.
3
: 6 mm,
ALLEN WRENCH
PIPE
Fig. 33-292 Tightening socket bolt (9)
33-145
33. UPPER STRUCTURE
33.2.6.3.1 Inspection procedure and remedy
Interval Check Item Checking Procedure Remedy

Seal for oil leakage Replace O-ring or dust seal , if any oil
2,000hr Check oil leakage outside
outside leakage can be found.
4,000hr All sealing parts Replace all sealing parts such as slipper
In principle, seal with back-up ring and O-ring.
disassemble All sliding parts
and check re- Check abnormal wear, scoringor
Repair or replace referring to their
gardless of corrosion caused by foreignmatters or
limit of service.
oil leakage or seizure.
not.
When All parts Repair or replace referring to their limit of
Check them for seizure, foreignmatters,
disassembled service.
abnormal wear, anddefect of seals.
for repair O-rings and dust seal should be replaced.
33.2.6.3.2 Service limit of the parts
Parts Maintenance Standards Remedy

Sliding surface with
Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface between 1) Worn abnormally or damaged more than 0.1mm
Replace
body and stem other than (0.004in) in depth due to seizure or contamination.
Body, Stem sealing sections 2) Damaged less than 0.1mm (0.004in) in depth. Smooth with oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
plate 3) Damage due to seizure or contamination repairable
Smooth
within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
Cover
plate 3) Damage due to seizure or contamination
Smooth
repairable within wear limit 0.5mm (0.02in).
33-146
33. UPPER STRUCTURE
Parts Maintenance Standards Remedy

1) Protruded excessively from seal groove.

Replace
(With back-up ring)

2) Slipper ring 1.5mm (0.06in) narrower than seal groove,
or narrower than back-up ring.
Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)

Replace

(With back-up ring)
33-147
33. UPPER STRUCTURE
33.2.6.3.3 Inspection after assembly

After completion of assembly, inspection for oil leakage,
pressure resistance, etc., using a device as shown in
Fig. 33-293.
(1) High pressure port (A,B,C,D and F port)
Install a directional valve and pressure gauge to the

stem side port and body side port respectively, and
while watching the pressure gauge (for high
pressure) installed on the body side and also by
regulating high pressure relief valve (7), gradually

increase the pressure and when the pressure has
reached 1.5 times the maximum working pressure,
close stop valve (3) and lock in the hydraulic oil in
the swivel. Keep stop valve (6) on the low pressure
relief valve side closed at this time.
Check that it is free from looseness, deformation,
breakage, etc. under three minutes pressurizing.
And, the oil leakage must be checked for the first 1
minute, and if there be a pressure drop for any
reason, the pressure drop should be in 10% of the
trapped pressure.
This checking must be carried out for every circuit.

Fig. 33-293 Hydraulic circuit for inspection
equipment
(2) Low pressure port (E port)
Similar to the high pressure port, install a directional
valve and pressure gauge on each port of the stem '$ ( )

side and body side. *(&
Open stop valve (6) on the side of low pressure !
relief valve (5) and while watching the pressure "
gauge (for low pressure) connected to the body
# " # +
side and also by regulating low pressure relief valve
,&-. /
0
(5), gradually increase the pressure and check for
outside leakage with a color check at a pressure of "
0.49MPa (71psi). # " #

$$ /1 2 &0
"
% &
33.2.6.3.4 Troubleshooting
Trouble Cause Remedy

1. External leakage of hydraulic oil Defective O-ring & seal Replace all seals.
2. Internal leakage of hydraulic oil 1) Defective slipper seal 1) Replace all seals.
2) Sliding face worn excessively 2) Replace assy.
3. Swivel stem seized 1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body are too loose
and causing oil leakage.
2) Inappropriate swivel stopper bracket 2) Reinstall
Secure 2~3mm (0.08~0.12in) allowance for
bolt stopper.
4. Loose swivel stem and cover Socket bolt tightened insufficiently. Retighten.
33-148
34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1.1 TRAVEL SYSTEM .................................................................................................34-3
34.1.2 CRAWLER..............................................................................................................34-3
34.1.3 UPPER ROLLER ....................................................................................................34-7
34.1.4 LOWER ROLLER ...................................................................................................34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-21
34.1.6 SPROCKET ............................................................................................................34-27
34.1.7 TRAVEL MOTOR ..................................................................................................34-30
34.1.8 SWING BEARING ..................................................................................................34-32
34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT ..............................................34-35
34.2.1 TRAVEL MOTOR ...................................................................................................34-35
34.2.2 CONSTRUCTION OF REDUCTION UNIT .............................................................34-37
34.2.3 TRAVEL MOTOR ASSEMBLY ...............................................................................34-38
34.2.4 TRAVEL MOTOR ASSEMBLY ...............................................................................34-46
34.2.5 TRAVEL MOTOR ...................................................................................................34-51
34.2.6 TRAVEL MOTOR TROUBLESHOOTING ..............................................................34-54
34.2.7 REDUCTION UNIT DISASSEMBLY.......................................................................34-56 34
34.2.8 ASSEMBLING ........................................................................................................34-62
34.2.9 MAINTENANCE STANDARD.................................................................................34-68
34-1
34. TRAVEL SYSTEM

SK460-8: LS10-02001~ S5LS3411E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
34-2
34. TRAVEL SYSTEM

34.1.1 TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER
6. SPROCKET
TRACK GUIDE LOWER FRAME
GREASE NIPPLE OF THE
3. UPPER ROLLER
TRACK SPRING ADJUSTER
4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage
34.1.2 CRAWLER
34.1.2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Find the master pin and place it in its removing/
fixing position in Fig. 34-3.
2) Loosen the grease nipple, discharge grease and
loosen the crawler.
: 19 mm
Fig. 34-2 Crawler removing position

• When loosening the grease nipple of the adjuster,
do not loosen it more than one turn.
• Where grease does not come out well, move the
machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring
STOPPER PIN
danger of injury. So be careful not to over loosen
the grease nipple.
3) Pushing out master pin

Apply jig on master pin and strike it out with a
mallet.
(Refer to Fig. 34-7 Press fitting of master pin)
REMOVING /
FIXING POSITION
OF MASTER PIN
Fig. 34-3 Removing/fixing position of master pin
When using a big hammer, wear protective goggles
and a long-sleeved uniform so you do not injure
yourself by flying objects.
34-3
34. TRAVEL SYSTEM
(3) Removing crawler

REMOVING
Put attachment on ground so that weight is not MASTER PIN
loaded to the lower frame, and remove track link
assy rotating sprocket.
Crawler end section may fall on the ground just before

extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
Fig. 34-4 Removing crawler
34.1.2.2 INSTALLING
(1) Checking crawler installation direction.
Place the track links on the ground so they

converge, facing the front idler, as shown in the
figure on the right.
(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
Fig. 34-5 Installing direction of crawler
2) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm above the ground level by
holding it by hand so the machine body weight is
not exerted on the shoe. Retract the sprocket to
help push the back winding of the crawler.
(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine Fig. 34-6 Winding crawler
adjustment turning sprocket.
• When using a big hammer, exercise care so you

are not injured by flying objects the same way as
when pushing out the master pin.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in.
(4) Press fitting of master pin

Apply press fitting jig on master pin, and strike it

with a mallet to press fit. Fig. 34-7 Press fitting of master pin
34-4
34. TRAVEL SYSTEM
(5) Adjusting crawler tension (See Fig. 34-8)

After installing, adjust tension of crawler.
: 19 mm
Standard dimension A
Dimension of iron crawler in 380~410mm
a max. slackened condition (15.0~16.1in)
Fig. 34-8 Adjusting crawler tension
1-3
1-8 1
1-1
1-7 3
1-4
1-2 4,5,6
1-6
1-5
1-9 1-10
1-11 2
Fig. 34-9 Track link assy and shoe plate
SK485LC-8
LS60D00009F3
Shoe
LS60D00009F2
assy
LS60D00009F1
No. NAME Q'TY
1 •LINK ASSY LS62D00004F2 1 1 1
1–1 ••TRACK LINK R 48 48 48
1–2 ••TRACK LINK L 48 48 48
1–3 ••MASTER LINK R 2 2 2
1–4 ••MASTER LINK L 2 2 2
1–5 ••TRACK BUSHING 48 48 48
1–6 ••TRACK PIN 48 48 48
1–7 ••MASTER BUSHING 2 2 2
1–8 ••MASTER PIN 2 2 2
1–9 ••COLLAR 4 4 4
1–10 ••SEAL 96 96 96
1–11 ••PIN 2 2 2
2 •BOLT LS60D01001P1 200 200 200
3 •NUT LS60D01002P1 200 200 200
4 •SHOE 600mm 50 — —
5 •SHOE 600mm (HD) — 50 —
6 •SHOE 800mm (HD) — — 50
34-5
34. TRAVEL SYSTEM
34.1.2.4 MAINTENANCE STANDARD

E F
G D D
B
C
H
Fig. 34-10
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Link pitch 228.6 (9.0) 232 (9.13) 234 (9.21) Replace the link
B O.D. of bushing ø 73.33 (2.887) ø 69 (2.717) ø 68 (2.677) assy if the service
C Height of link 129 (5.08) 123 (4.84) 121 (4.76) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.1
D Interference Interference
and link ø 73.33 (+0.0039)
Shaft 0.30 0.26
(2.887) 0
(0.012) (0.010) Replace
(0)
+ 0.1
Interference Interference
Interference between track pin ø 48.83 (+0.0039)
E Shaft 0.30 0.26
and link (1.922) 0
(0.012) (0.010)
(0)
+ 0.03
Interference Interference
Interference between master ø 48.58 (+0.00118)
F Shaft 0.05 0.03 Replace Link
pin and link (1.913) 0
(0.0020) (0.0012)
(0)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 1370 N•m (1010 lbf•ft) Reassembly
34.1.2.5 TOOLS AND JIGS

(1) Tightening tools
Unit : mm (in)
NAME OPPOSING FLATS
19, 36
Socket
(2) Jig
NAME SHAPE
Master pin fixing jig for iron

crawler
34-6
34. TRAVEL SYSTEM
34.1.3 UPPER ROLLER
34.1.3.1 UPPER ROLLER ASSY
Upper roller assy LC64D00003F1

Item Name Q’ty Remarks
1 Roller assy 4 24100N7035F3
2 Capscrew 4 M20× 150
3 Washer 8
4 Nut 4
34.1.3.2 REMOVING
(1) Preparation for removal " ! !
Remove crawler (Above mentioned).
(2) Removing upper roller (1)

1) Remove nuts on support tightening section, and
also remove capscrew (2) M20 × 150.
: 30 mm
Fig. 34-11 Removing upper roller
34.1.3.3 INSTALLING
Installing is done in the reverse order of removing. Center of machine
(1) Inspection
Before reassembling, check it that it rotates smooth
manually and for leakage.
3,4
1
(2) Installing upper roller (1)
1) To install the upper roller, turn up nut (4) toward
the center of machine.
2,3
2) Insert it until collar comes in contact with support.
3) Apply Loctite #262 on capscrew M20× 150, and

tighten it to the specified torque.
: 30 mm
Fig. 34-12 Installing upper roller
34-7
34. TRAVEL SYSTEM
Roller assy part No. 24100N7035F3 5 4 1 13 3 2

No. Name Q'ty No. Name Q'ty
1 Roller 1 8 -ring 1A P95 1
2 Shaft 1 9 Socket bolt 2
3 Collar 1 M12X30 10
4 Plate 1 10 Plug PT1/4 1
5 Cover 1 11 Snap ring 1
6 Bushing 2 13 Floating seal 1
11 8 6
Fig. 34-13 Construction of upper roller

(1) Disassembly 11
1) Draining out oil 9 8
Remove plug (10) and drain out oil. 4
10
: 6mm 5
2) Removing snap ring (11)

Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (11), using
snap ring pliers.
f
3) Removing cover (5)
Take off cover (5) upwards, utilizing the screwed
hole for the plug.
4) Removing O-ring (8)

Separate O-ring (8) from cover (5). Fig. 34-14 Preparation for disassembly
5) Removing plate (4)

Loosen two socket bolts (9) and draw out plate
h
(4) from roller (1).
: 10mm
2
13
6) Removing shaft (2)
Put the extrusion jig (h) against the end face of 3
shaft (2) and push shaft (2) with collar (3) for
floating seal (13), using a press or hammer.
f
Fig. 34-15 Extruding shaft
34-8
34. TRAVEL SYSTEM
7) Removing floating seal (13). (Upper roller side)

Take out floating seal (13) from roller (1). 13
Fig. 34-16 Taking out floating seal

8)Removing floating seal (13). (Shaft side)
Remove from collar (3), floating seal (13) that is
13
located on the side from which shaft (2) was
disparted. 3
Collar (3) is press fitted into shaft (2). Therefore do not

disassemble it.
Fig. 34-17 Removing floating seal

9) Removing bushing (6)
Push with press.
Since the bushing is thin, machine it on a lathe or
i
scrape it off, exercise care so as not to damage
the bore of roller (1).
6
If the bushing is not worn much, mount upper
roller (1) on jig (f), insert jig (g) into the end face
of bushing (6) and push it out with a press.
1
(2) Assembly f
Assembly of the upper roller is done in the reverse
order of disassembly.
1) Place upper roller (1) on the top end face of jig
(f), with its floating seal setting side facing down.
2) Confirm that the outer surface of bushing (6) is Fig. 34-18 Pushing in bushing
not seized and coat the outer surface of the
inserting side of the bushing, with molybdenum 13
13
disulfide grease.
3 1
3) Put jig (i) into bushing (6) and press it in, using
2
the bore of the bushing and the bore of the roller
as guides.
If you fail in this operation by pressing the bushing

unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing Fig. 34-19 Fixing floating seal
as it may develop malfunctioning after assembly.
34-9
34. TRAVEL SYSTEM
4) Installing floating seals (13).

Two floating seals (13) make a pair. Attach one 2
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1).
1
• Prior to placing floating seal (13) in, apply

engine oil lightly to seal surface.
5) Inserting shaft (2).

Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).
6) Installing plate (4). Fig. 34-20 Inserting shaft

Mount upper roller (1) on the stand jig (f) and
11
attach plate (4) to the end face of the shaft with
bolt (9). 9 8
4
: 10mm,
Tightening torque : 114.7N•m (85 lbf•ft) 5
• Apply lOCTITE #262.
1
7)Installing O-ring (8).
Fit O-ring (8) to the groove of cover (5).
• Apply grease to O-ring.
8) Installing cover (5).

Attach cover (5) to upper roller (1). Use a press f
in this operation as a press fit is used.
9) Installing snap ring (11).

Fix snap ring (11) into upper roller (1), using snap Fig. 34-21 Installing cover
ring pliers.
10) Filling oil

Fill in 100cc (6.1cu•in) of engine oil API grade
CD #30 through the plug hole in cover (5).
5
11) Installing plug (10).
Wind seal tape around plug (10) and screw it into 1
the plug hole of cover (4).
: 6mm,
• After assembling the upper roller, confirm that f

oil is not leaking from it and that it rotates
smoothly by hand.
Fig. 34-22 Filling oil
34-10
34. TRAVEL SYSTEM
C
D D
F
J H
Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
A Dia. ø 185 (7.28) ø 177 (6.97) ø 174 (6.85)
Reinforcement
B Tread dia. ø 160 (6.30) ø 152 (5.98) ø 149 (5.87)
weld, repair or
C Width 95 (3.74) 90 (3.54) 85 (3.35)
replace
D Flange width 19 (0.748) 17 (0.669) 15 (0.591)
Basic
Tolerance Standard Limit
dimension
Clearance between shaft and -0.025
E
bushing ø 65 (-0.0010) Clearance Clearance
Shaft
(2.5591) -0.040 — 0.8 (0.0315) Replace bushing.

(-0.0016)
+ 0.030
Interference between roller ø 70 Interference Clearance
Hole
F (+0.0012)
and bushing (2.7559) — 0
0
Tightening torque of socket
H 114.7 N•m (85 lbf•ft) Apply loctite #262
bolt
J Oil Engine oil API grade CD #30, 100cc (6.1cu•in) Refill or replace
Roller rotation Roller rotates smoothly by hand.
34-11
34. TRAVEL SYSTEM

Unit : mm
Name Opposing flats
30
Socket
Allen wrench 6,10
(2) Jigs
Unit : mm (in)
No. Name Shape
160 (6.30")
120 (4.72") 200 (7.87")
f Stand jig
65 (2.56")
For extruding
g
(0.787")
bushing
20
50 (1.97")
For extruding
h
(1.18")
shaft
(1.953" +0.004" )
+0.1
0
0
69.5
(2.74")
64.6
Bushing fixing
i
jig
20 65 (2.56")
(0.787")
85
(3.35")
34-12
34. TRAVEL SYSTEM
34.1.4 LOWER ROLLER
34.1.4.1 LOWER ROLLER ASSY
ROLLER STD LS64D00001F1

ASSY LC LS64D00001F2
ITEM NAME Q'TY REMARKS
1 LOW ROLLER - 16 24100N7039F3
LOW ROLLER 18 - 24100N7039F3
1
2 CAPSCREW 72 64 M22X115(P=2.5)
2
Apply Loctite #262
T=74.5kgf.m (540 lbf.ft)
Fig. 34-23 Lower roller assy
34.1.4.2 REMOVAL
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame.

(2) Removing track guide

Remove capscrews (B7) and remove track guide Fig. 34-24 Preparation for removal
(B2), (B3).
: 36mm,
Weight of track guide : B2 : Approx. 49kg (108 lbs)
B3 : Approx. 54kg (119 lbs)
ROLLER
SK460-8 STD LS01F00021F1

LOW
SK480LC-8 LC LS01F00013F1
ITEM NAME Q'TY
B7 B3 B2 B7
B2 TRACK GUIDE : LS63D00001P1 2
B3 TRACK GUIDE : LS63D00002P1 2
This drawing shows LC specification.
B7 CAPSCREW : M24X60(P=2.5) 16 STD,LC
(3) Remove lower roller Fig. 34-25 Installing track guide

Remove capscrews (2) and remove lower roller (1).
: 32 mm,
Weight of lower roller : Approx. 97kg (214 lbs)
Fig. 34-26 Installing lower roller
34-13
34. TRAVEL SYSTEM
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all 4 capscrews temporarily. Then tighten
them to a specified torque.
: 32 mm,
(2) Installation of track guide
Capscrews (B7) with Loctite #262 and fasten all 4
capscrews temporarily. Then tighten them to a
specified torque.
: 36 mm,
(3) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
: 19 mm,
34-14
34. TRAVEL SYSTEM
LOWER ROLLER 24100N7039F3

REMARKS 9
No. NAME Q'TY
1 ROLLER 1
2 COLLAR 1
3 COLLAR 1
4 SHAFT 1
5 BUSHING 2 3 1 5 4 11 8 6 2
6 PIN 2
8 O RING 2 1A G85 Fig. 34-27 Construction of lower roller
9 PLUG 2 PT1/4
11 FLOATING SEAL 2

(1) Disassembly
1) Drain oil
Remove plug (9) and drain out oil.
L
: 6mm
2,3
2) Removing pin (6)

Put both ends of lower roller assy on the V- 6
shaped blocks (K), apply push-out bar (L) on
upper end face of pin (6), and push pin (6) out
striking with mallet.
K
3) Removing collar (2) or (3), O-ring (8)

Put lower roller on jig (M) for repair stand so that
the shaft (4) is perpendicularly located, apply
Fig. 34-28 Pushing out collar fixing pin (6)
push-out jig (P) on shaft end on upper side, and
push shaft (4) until the O-ring (8) separate from PRESS
collar (2) or (3) with press or mallet, and take out
collar (2) or (3) and O-ring (8).
8 JIG P
4) Removing shaft (4)
In addition, push out and remove shaft (4) 2 or 3
together with the lower collar (2) or (3) and O-ring 1

(8).
4
JIG M
The shaft (4) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.
3 or 2
Fig. 34-29 Removing shaft (4), collar (2) or (3),

O-ring (8)
34-15
34. TRAVEL SYSTEM
5) Removing collar (2) or (3), O-ring (8)

Remove collar (2) or (3), O-ring (8) from shaft (4) 11
that was drawn out in the previous paragraph.
6) Removing floating seal (11)

Remove floating seal (11) from collar (2) or (3).
2,3
7) Removing floating seal (11)

Remove floating seal (11) from roller (1).
Fig. 34-30 Removing floating seal (11)
11

Since thickness of bushing (5) is thin [thickness
is 2.0mm (0.079in)], remove it through lathe or N
strip it with care not damage inner hole of roller.
When the wear of bushing is not large, place
1
upper roller (1) on jig (M) for repair stand and
apply the end of push-out jig on the end face of
bushing (5) end, and push it out striking it with
5
mallet.
JIG M
Hammer the inside surface of roller lightly so as not to

damage the surface. Put the extrusion jig (N) uniformly Fig. 34-32 Extruding bushing (5)
over the circumference of bushing (5) and extrude it
perpendicularly little by little.
34-16
34. TRAVEL SYSTEM
(2) Installing 8 4
1) Attach O-ring (8) to one side
Install O-ring (8) to groove on shaft.
• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-33 Attach O-ring (8) to one side
reassembling.
2) Press fitting bushing (5)

JIG Q
Align inner hole of roller (1) and bushing (5) and
press fit it vertically in capacity of press fit load,
5ton (11000 lbs), in the condition that bushing 5
push-in jig (Q) is inserted into bushing (5).
• Apply molybdenum disulfide grease on press-

fit section of bushing, and press fit it in
ordinary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted. Fig. 34-34 Press fitting bushing (5)
3) Press fitting collar (2) or (3) PRESS

Fit O-ring (8) to the one side of shaft (4) mating
pin hole of collar (2) or (3) on which floating seal PIN HOLE
(11) is fit with pin hole of shaft (4) in advance. 11 2,3
Use the press of capacity 17 ton (37500 lbs) or
more. PIN HOLE
4 8
• Care should be taken not to damage O-ring

(8) while press-fitting collar (2) or (3) to shaft
(4).
Fig. 34-35 Press fitting collar (2), (3)
4) Inserting pin (6)

11
Press-fit pin (6) to pin hole on aligning pin holes
of shaft (4) and collar (2) or (3) . 6
2,3
Fig. 34-36 Inserting pin (6)
34-17
34. TRAVEL SYSTEM
5) Attach floating seal (11) to roller side

Fit floating seal (11) to inner holes on both ends 1
of roller (1).
11
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
4
6) Inserting roller (1)
Insert roller (1) from the side where collar (2) or 2,3
8
(3), O-ring (8) is not press-fitted to the shaft (4).
Fig. 34-37 Inserting roller (1)
7) Installing O-ring (8)
PRESS
Install O-ring (8) to groove on shaft.
• Grease O-ring.
2 or 3
• Replace O-ring with new one without fail at
reassembling. 8
8) Press fitting collar (2) or (3)

Press-fit collar (2) or (3) to shaft (4). 4
• Press-fit collar (2) or (3) on aligning pin (6)

hole.
9) Inserting pin (6)

Press-fit pin (6) in to the pin hole mating pin hole
of collar (2) or (3) with pin hole on the end side of
shaft (4).
Fig. 34-38 Installing O-ring (8), collar (2) or (3)

10) Filling oil
9 TIGHTENING
Remove plug (9) and fill in 500cc (30.5cu•in) of TORQUE
engine oil API grade CD #30. 23N.m
(17 lbf.ft)
11) Check it for leakage
Before tightening plug (9), check it for leakage in
the condition of air pressure 0.2 MPa (29 psi).
12) Installing plug (9)
Apply oil resistant sealant on plug (9), and
tighten it in the plug hole on the collar (2) or (3) 2
end face.
: 6 mm,
Tightening torque : 21.6~24.5 N•m Fig. 34-39 Installing filling oil plug (9)
(16~18.1 lbf•ft)
After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.
34-18
34. TRAVEL SYSTEM
C C
D
A
Fig. 34-40 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A O.D. of flange ø 268 (10.6) — — Reinforcement weld,
B Tread dia. ø 220 (8.66) ø 205 (8.07) ø 204 (8.03) repair or replace
C Flange width 23.5 (0.925) — —
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 89.94 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft
(3.5409) - 0.090 0.7 (0.276) 1.0 (0.394) Replace bushing
(-0.00354)
+ 0.035
Interference between ø 93.94 (+0.0014) Interference Interference
E Hole
roller and bushing (3.6984) 0 0.18 (0.0071) 0.16 (0.0063)
(0)
F Oil Engine oil API grade CD #30, 500cc (30.5 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (9)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
34-19
34. TRAVEL SYSTEM

Unit : mm
NAME OPPOSING FLATS
19, 32, 36
Socket
Allen wrench 6
(2) Jig
Unit : mm (in)
No. NAME SHAPE
K V-block
180(7.09)
Pin (6)
(0.630)
L
extrusion rod
16
16 (0.630)
360(14.2)
Bushing
N
extrusion rod
450(17.7)
260(10.2)
M Stand jig
(8.66)
220
450(17.7)
Shaft
P
extrusion jig
(3.39)
86
(0.984)
25
120(4.72)
100(3.94)
Bushing
75(2.95)
Q
fixing jig
+0.1
89.6 0
(3.53 +0.004
0 )
34-20
34. TRAVEL SYSTEM
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)
34.1.5.1 FRONT IDLER ASSY
Apply loctite #262 or equivalent

FRONT IDLER ASSY LS52D00003F3
T=930N.m (1,320 lbf.ft)
No. NAME Q'TY REMARKS 3 6
1 IDLER ASSY 1 LS52D00002F1
3 CAPSCREW 2 M24X70
4 GREASE NIPPLE 1
6 IDLER ADJUSTER ASSY 1 LS54D00001F3
1 4
The grease nipple is on the outer
side of the frame.
T=60N.m (43 lbf.ft)
Fig. 34-41 Front idler assy
34.1.5.2 REMOVING
Remove crawler. (Above mentioned)
(2) Removing idler assy

Sling idler assy, and push it forward with bar.
Weight of crawler. idler assy (one side) : 583kg BAR
(1286 lbs)
Keep away from the front side of front idler.
(3) Installing
(4) Where idling assy (1) has to be separated

Loosen capscrew (3), and separate idler assy (1)
from idler adjuster assy (6). Fig. 34-42 Removing and installation the front idler
1
: 24 mm
Weight of idler assy : 271kg (598 lbs)
Weight of idler adjuster assy : 311kg (686 lbs)
• The separated idler assy (1) should be placed on 6

square timbers.
3 4
Fig. 34-43 Separating idler assy (1) from idler

adjuster
34-21
34. TRAVEL SYSTEM
34.1.5.3 IDLER ASSY
IDLER ASSY LS52D00002F1 1

6
1 IDLER 1 2413N500 8
2 COLLAR 2 4
3 SHAFT 1 5
4 BUSHING 2 3
5 PIN 2 2
6 FLOATING SEAL 2 7
7 O-RING 2 1A G105
8 PLUG 2 PT1/8 VIEW I
Fig. 34-44 Idler assy
34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing 5
R
1) Drain oil
Remove plug (8) on the side of collar (2) to drain.
: 5 mm
2) Removing pin (5)

Apply pin push bar (jig R) to the top of pin, and
push out striking bar (jig R) lightly by hammer. Fig. 34-45 Removing pin (5)
PUSH WITH PRESS

3) Removing collar (2)
S
Put idler (1) on stand (U), apply push-out jig (S) 3
2
on shaft (3), push out shaft (3) with collar (2),
then remove collar (2).
U
2
Fig. 34-46 Removing collar (2)

4) Removing collar (2) from shaft (3)
PUSH WITH PRESS
If removal of collar (2) on the opposite side is
S
required, turn over front idler and proceed with 3
2
the procedure described in Par. 3).
Fig. 34-47 Removing collar (2)
34-22
34. TRAVEL SYSTEM

1 T 4
With idler (1) mounted on the stand, tap bushing
(4) lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing
(4) evenly all round, till it comes out.
6) Removing floating seals (6)

Take out floating seals (6) from idler (1), collar
U
(2). If you intend to re-use floating seals (6),
confirm that there is no scoring and rusting on
the contact surface and store the floating seals
Fig. 34-48 Removing bushing (4)
in pairs by placing card board between the
sealing faces.
7) Removing O-ring (7)

Separate O-ring (7) from shaft (3).
(2) Assembly PUSH WITH PRESS V 1
1) Pressing in bushing (4) 4
Align inner hole of idler (1) and bushing (4) and
press fit it vertically with press so that jig (V) for
bushing press-fitting is inserted into bushing (4).
2) Installing O-ring (7)

Fit O-ring (7) to O-ring groove on shaft (3).
Fig. 34-49 Pressing in bushing (4)
• Apply grease to O-ring
3) Installing collar (2) (See ) PRESSING

Press fit the O-ring (7) installed side of shaft (3)
into collar (2), and drive pin (5). 3
4) Installing floating seal (6)

2
Fit the half of floating seal (6) on each side of
5
collar (2) and idler (1).
5) Inserting idler (1)

Fig. 34-50 Installing collar (2), shaft (3)
Insert floating seal (6) fitted side of idler (1) into
shaft (3). 3
6
6) Installing floating seal (6)

Fit floating seal (6) on the other side of idler (1). 1
Fig. 34-51 Inserting idler (1) and installing floating

seal (6)
34-23
34. TRAVEL SYSTEM
7) Installing collar (2)

Fit the half of floating seal (6) on the other collar 8 2
(2), press fit it in shaft (3), and drive pin (5) in with 5
hummer.
8) Filling oil•Inspection 1
Fill in 400cc (24.41cu•in) of engine oil API grade
CD #30 through the plug hole of collar (2), wind
seal tape and tighten plug (8).
: 5 mm
Tightening torque : 11N•m (8.8 lbf•ft) Fig. 34-52 Installing collar (2) and filling oil
• After installing the idler assy to the idler

adjuster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.
34.1.5.3.3 MAINTENANCE STANDARD

210(8.27")
C
F
D
E
B
A
Fig. 34-53 Front idler
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. of idler projection ø 726 (28.6) — —
B Tread dia. ø 676 (26.6) ø 665 (26.2) ø 662 (26.1) Replace
C Flange width 107 (4.21) 101 (3.98) 99 (3.90)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 110 (-0.00118) Clearance Clearance
Shaft Replace
(4.3307) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
+ 0.035 Clearance
Interference between idler and ø 125 Interference
E Hole (+0.00138) 0.01
bushing (4.9212) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 400cc (24.4cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
34-24
34. TRAVEL SYSTEM
34.1.5.3.4 TOOLS AND JIGS

Unit : mm
NAME OPPOSING FLATS
36
Socket
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
(0.709)
(1.18)
18
30
R Pin striking jig
(0.591)
160(6.30) 15
450 (17.7)
S Shaft push out jig

(4.09)
104
(0.630)
16
400(15.7)
T Bushing drawing rod
Approx.200
(8)
Approx.900
(36)
U Stand
Approx.
500(20)
2 pcs.
(0.787)
160(6.30)
20
110(4.33)
Bushing press fitting

V
90(3.54)
jig
+0.1
109.6 0
(4.315 +0.004
0 )
34-25
34. TRAVEL SYSTEM
34.1.5.4 IDLER ADJUSTER ASSY
IDLER ADJUSTER ASSY LS54D00001F3 4 5 6 2 13 1 8 9

1 GREASE CYLINDER 1
2 COLLAR 1
4 BRACKET 1
5 NUT 1
6 SPRING PIN 1 13X110
7 U-PACKING 1 7 10
11 (Both side)
8 DUST SEAL 1
Fig. 34-54 Idler adjuster assy
9 PISTON 1
10 PIN 2
11 COVER 1
13 SPRING 1 LS54D01008P2
34.1.5.4.2 MAINTENANCE STANDARD
No. ITEM STANDARD VALUE

A Installed length of spring 680mm (26.8 in)
B Free length of spring Approx. 809.4mm 31.9 in)
C Stroke 57.0mm (2.24in)
D Set length 1175mm (46.3in)
ød Spring diameter ø64 (2.52in)
E Outside view of piston Nor scoring and rusting
Tightening torque of
F 59N•m (43 lbf•ft)
grease nipple
H d E
C
A,B F
BRACKET
Install a herical spling,

whose starting point at
bracket side to be 35 10 .
SECTION H-H
Fig. 34-55
34-26
34. TRAVEL SYSTEM
34.1.6 SPROCKET
34.1.6.1 REMOVING
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize.

(2) Removing sprocket
Loosen 24 capscrews (3) M24× 70, for the
attaching of the sprocket by means of a socket and
remove the sprocket (2).
Weight of sprocket : 102kg (225 lbs)
: 36 mm
Fig. 34-57 Removing sprocket
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.
(2) Installing sprocket temporarily

Coat the sprocket attaching capscrews with Loctite
#262 and fasten the sprocket temporarily.
(3) Installing sprocket completely

Remove the wooden blocks under the truck frame,
bring the machine down on the ground and tighten
the sprocket.
: 36 mm
Fig. 34-58 Installing sprocket completely
34-27
34. TRAVEL SYSTEM
34.1.6.3 MAINTENANCE STANDARD (LS51D01001P1)
115.4mm NUMBER OF
PITCH 23
(4.54in) TEETH
SPECIFICATION
ø73.33mm 847.304
ROLLER DIA. PITCH DIA.
(2.89in) (33.4in)
B
R .23
6 6
(0
67 (2.64")
")
R 46"
(1
37 )
.
R5 ")
7
. 19
(0
A
Fig. 34-59 Sprocket
Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
Reinforcement weld,
A O.D. of sprocket ø 876 (34.5) ø 868 (34.2) ø 866 (34.1)
repair or replace.
B Width of sprocket teeth 89 (3.504 ) 83 (3.27) 81 (3.19) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 773.3 (30.4) ø 765 (30.1) ø 763 (30.0)
repair or replace.

(1) Tools
Unit : mm
NAME OPPOSING FLATS
36
Socket
34-28
34. TRAVEL SYSTEM
(2) Sprocket tooth profile gauge : W
Unit : mm (in)
Fig. 34-60 Tooth profile gauge (Full scale)
34-29
34. TRAVEL SYSTEM
34.1.7 TRAVEL MOTOR
34.1.7.1 TRAVEL MOTOR
INSTALL ASSY LS53D00005F1

1 TRAVEL MOTOR ASSY 2 LS53D00006F1 APPLY LOCTITE #262
OR EQUIVALENT
2 CAPSCREW 54 M24X75 TIGHTENING TORQUE:
932 N.m(687 lbf.ft)
2
Fig. 34-61 Installing travel motor
34.1.7.2 REMOVING
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (14) M12× 25 and also remove
covers (1).
14
: 19 mm
1
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Release pressure from travel circuit, and bleed air Fig. 34-62 Removing and installing cover (1)
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.
: 19mm, 27mm, 32mm, 41mm

Refer to "Hydraulic pipe plug" 5.1
(See Chapter 11. TOOLS)
"Plug for ORS" 5.2 (3) (See Chapter 11. TOOLS)
Fig. 34-63 Removing and installing hydraulic pipe
34-30
34. TRAVEL SYSTEM
(5) Removing sprocket

Removing 24 (one side) capscrews (3) M24× 70.
: 36 mm
Fig. 34-64 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (2) REMOVE PIPES (DISCONNECT)
Apply match marks on travel motor and crawler
frame, and remove 27 (one side) capscrews (2)
M24× 75.
: 36 mm
2
Fig. 34-65 Removing and installing travel motor

attaching bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.
Weight of motor : About. 650kg (1430 lbs)
Fig. 34-66 Slinging travel motor
34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the TOOLS TIGHTEING
NAME SIZE HEX NO.
TORQUE REMARKS
reverse order of removal. N.m(lbf.ft)
1) Cleaning SEMS BOLT M12 19 6 83.4(61) Apply

Check that contact surface of travel motor and M22 32 2 730(538)
loctite
CAPSCREW #262
crawler frame is free from burr and stain. M24 36 3 932(690)
2) Tightening torque FLARELESS 10X1.5 19 - 49(36)
NUT FOR
Tighten capscrew and hydraulic pipes to the PIPES, 18X2.5 32 - 147(110)
torque specified in "Tightening Torque". SLEEVE 35 55 - 441(325)
3) Fill inside from motor drain port to casing with HOSE PF1/4 19 - 29.4(21.7)
CAP PF3/4 27 - 118(87)
hydraulic oil before piping for drain. When
"ORS" JOINT 1 7/16-12UN 41 - 206(152)
starting operation, operate motor in low idling
CONNECTOR PF1/4 19 - 36.3 2(27 1.5)
and at low speed for several minutes, and check
PF3/4 29 - 162 15(120 11)
it for possible oil leakage and noise. PF1 41 - 255 10(190 10)
34-31
34. TRAVEL SYSTEM
34.1.8 SWING BEARING
34.1.8.1 SWING BEARING ASSY
SWING BEARING ASSY LS40F00009F1

1 SWING BEARING 1 LS40F00008F1
2 CAPSCREW 36 M27XP1.5X90
FRONT A A
INNER S ZONE POSITION OF

SWING BEARING
2
Apply Loctite #262 or equivalent
Tightening torque 1177 N.m (868 lbf.ft)
SECTION AA
Fig. 34-67 Swing bearing assy
34.1.8.2 REMOVING
(1) Matchmarks SWING BEARING
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. OUTER RACE
INNER RACE
(2) Remove 36 capscrews (2) M27× 90 for installation
inner race. MATCHMARKS
: 41 mm
(3) Removing grease

Remove grease in grease bath.
Fig. 34-68 Matchmarks
(4) Removing swing bearing SWING BEARING

Attach eyebolt on swing bearing and sling it. EYE BOLT
Weight of swing bearing : 665kg (1466 lbs)
GREASE BATH
Fig. 34-69 Removing and installing swing bearing
34-32
34. TRAVEL SYSTEM
34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and dirt.
(2) Installing
Install swing bearing on lower frame meeting the FRONT A A
matchmarks and positioning the S mark on inner
race as shown in Fig. 34-70.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.
: 41 mm
INNER S ZONE POSITION OF
(4) Regular tightening of inner race SWING BEARING
Tighten the capscrews (2) at 180 degrees intervals Fig. 34-70 Location of S mark on swing bearing
alternately to a specified torque.
: 41 mm,
(5) Filling grease 1
Fill grease bath with 22kg (48.5 lbs) of grease
LOCTITE #262 OR
(NIHON GREASE CO.LTD EP-2K) or equivalent. 2 EQUIVALENT
TO BE APPLIED
SECTION AA T=564N.m (416 lbf.ft)
Fig. 34-71 Removing and installing capscrew (2)
6
SWING BEARING LS40F00008F1
1 1-2
No. NAME Q'TY No. NAME Q'TY
9
1 OUTER RACE 1 4 RETAINER 107
1-3
1-2 PLUG 1 5 SEAL 1 3
1-3 TAPER PIN 1 6 SEAL 1
5
2 INNER RACE 1 9 GREASE NIPPLE(PT1/8) 1 2
3 BALL 107
Fig. 34-72 Sectional view of swing bearing

(1) Disassembly
1) Remove seal (5) fitted in the groove in the outer EYE BOLT
6 2
circumference under inner race (2) and seal (6) 1-3
fitted in the groove in the inner circumference on
1
top of outer race (1) and place them level on a SQUARE WOODEN
square wooden block or something. BLOCK
2) Remove taper pin (1-3), using a hammer and an

extrusion rod. 1-2
3) Remove plug (1-2), utilizing an pull bolt inserted 5
in the screwed hole (M10) in the center of the
plug and using a puller. Fig. 34-73 Disassembling swing bearing
34-33
34. TRAVEL SYSTEM
4) While rotating outer race (1) little by little, take out 1

ball (3) and retainer (4) through plug hole, in that
order.
2
4
3
Fig. 34-74 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with 1
adhesive Cyano Bond PX-3000 equivalent, fit PUSH ROD 6
seal (5) and place it on a surface plate.
2) Lower outer race (1) to the position where upper 2
surface of inner race (2) and lower portion of seal SQUARE 3
WOODEN BLOCK 5
groove is mated, put adjusting washer under
outer race (1) so that outer raceway surface of Fig. 34-75 Fitting balls (3)
ball (3) aligns with inner raceway, and support it.
EYE BOLT
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (8) hole on outer race
(1), alternately.
HOOKED ROD
To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into 4
plug hole. SQUARE
WOODEN BLOCK
4) Fit plug (1-2) to outer race (1) while checking it Fig. 34-76 Fitting retainer (4)
for direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 equivalent and fit it in the groove of outer
race (1).
6) After completion of assembly, caulk the edge of
taper pin (1-3) by punching.
7) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 330cc (20.1cu•in)

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING
PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.
34-34
34. TRAVEL SYSTEM
34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT

34.2.1 TRAVEL MOTOR

1 Casing 21 D-ring (small dia.) 41 G1/8 plug
2 NPT 1/16 plug 22 D-ring (big dia.) 42 O-ring 1B P8
3 Oil seal 23 Rear cover 43 Check valve
4 Retaining ring IRTW68 24 NPT 1/16 plug (MEC) 44 Check valve spring
5 Shifter piston 25 Spool assy (M4V260RBV) 45 M6 restrictor (0.6)
6 Piston seal 26 Spring holder (M4V260RBV) 46 O-ring 1B P12.5
7 Steel ball 25 27 Spring (M4V150RBV) 47 M8 restrictor (0.8)
8 Shaft 28 M42 plug (M4V260RBV) 48 O-ring 1B P15
9 Bearing HR32209J 29 O-ring 1B G40 49 O-ring 215.57× 2.62
10 Pivot 30 Pilot valve spool dia. ø10 (M4V290) 50 Bearing HR32207C
11 Swash plate 31 Pin (MRC03) 51 Shim
12 Cylinder block 32 Spring holder (MRC03) 52 Parallel pin M6 8× 12
13 Cylinder spring 33 Spring (MRC03) 53 Valve plate
14 spring holder 34 G3/8 pilot valve plug 54 Brake spring
15 Ball joint 35 O-ring 1B P14 55 HEX. socket head bolt M18× 50
16 Shoe retainer 36 Connector (MRC03) 56 Overload relief valve ORV-240L6
17 Piston assy 37 G1/4 plug 57 Coupling
18 Separating plate 38 O-ring 1B P11 58 Retaining ring C-type 40
19 Friction plate 39 Restrictor (brake valve) 59 G1/2 plug
20 Breake piston 40 Restrictor spring (brake valve) 60 O-ring 1B P18
34-35
34. TRAVEL SYSTEM
• Overload relief valve
56-3 56-2 56-1 56-12 56-13 56-4 56-9 56-8 56-12 56-10 56-11 56-6 56-7 56-5
Fig. 34-78 Structure of overload relief valve
No. Name No. Name

56-1 Socket 56-8 Shim
56-2 Valve 56-9 Adjusting spring
56-3 Valve seat 56-10 O-ring 1B P7
56-4 Coupling piston 56-11 Backup ring T2 P7
56-5 Cap 56-12 O-ring 1B G25
56-6 Pilot body 56-13 Backup ring T2 G25
56-7 Piston
34-36
34. TRAVEL SYSTEM
34.2.2 CONSTRUCTION OF REDUCTION UNIT
Fig. 34-79 Reduction unit

1 Housing 11 Carrier 2 21 Thrust washer 1
2 Bearing 280BA40GS 12 Planetary gear 2 22 Needle bearing FBNP-406040
3 Ring gear 13 Retaining ring C-type 23 Carrier pin 1
4 14 Bearing 22213EAE4 24 Spring pin 6× 36
M20× 120
5 Cover 15 Carrier pin 2 25 Sun gear 1
6 Hex.socket head bolt M10× 25 16 Spring pin 10× 63 26 Thrust plate
7 Floating seal 368 17 Spacer 27 Cover
8 Shim 18 Sun gear 2 28
M12× 30
9 Lock washer 19 Carrier 1 29 Plug G3/4
10 Support ring 20 Planetary gear 1 30 O-ring 1B P24
34-37
34. TRAVEL SYSTEM
34.2.3 TRAVEL MOTOR ASSEMBLY
34.2.3.1 TOOLS
Name Specifications etc.

Hex. key Width across flat 5, 6, 8, 10, 14 mm
Snap ring prier For bore Dia. 32mm - 58mm, for shaft….. Dia. 60mm - 80mm
Plastic hammer 1 piece
Screw driver Minus (-), medium size, 2 pieces
Torque wrench For 98.1N•m, 324N•m, 441N•m (72.4 lbf•ft, 239 lbf•ft, 325 lbf•ft)
Gear (bearing) puller Work size : dia. 75 X width 45 can be handled (e.g. Asahi-tool GP75)
Seal tape, kerosene, grease, hydraulic oil, waists, Compressed air,
Others
etc.
21 (0.83") e.g. Supertool co., ltd unicrump FT-6
10 (0.394") 160 (6.3")
(2.76")
(0.79")
20
70
100 (3.94")
(1.46")
37
P.C.D. 251 (9.88")
o 280 (11.0")
o 215 (8.47")
o 195 (7.68")
Jig for pulling out brake piston (2pieces)
Hex. socket head bolt 2-M6 X100 (3.94") o 12 (0.47")

o 60 (2.36")
(1.58")
(0.95")
o 40
o 24
2-M18X35 (1.38")
(0.26")
o 6.5
2 - 20 (0.79")
drill hole
20 (0.79")
100 (3.94")
Jig for pulling out brake piston (2pieces)
25 (0.98") ")
0.08
R2(
In case of using Hex. socket
head bolt for mounting
100 (3.94")
rear cover M18 32

50
(1.97") 100 (1.26")
15 (0.59") (3.94")
Guide pin for rear cover (2 pieces)
10 - Plain washer 18
120 (4.72")
2-M18X50 (1.97")
o 42 (1.65")
10mm (0.394")
(1.42")
7.7 (0.30")
.5 )
o 36
Jig for inserting brake piston R0 .02"

More than
o 67.5 (2.66")
(0
o 90 (3.54")
3
(0.12")
Jig for inserting oil seal
Jig for inserting rear bearing
34-38
34. TRAVEL SYSTEM
a. GENERAL INSTRUCTIONS
(1) Generally, hydraulic equipment is precisely
manufactured and clearances between each parts
are very narrow.
Therefore, disassembling and assembling works
should be performed on the clean place where
dusts hardly gather.
Tools and kerosene to wash parts should also be
clean and handled with great care.
(2) When motor is removed from the host machine,
wash around the ports sufficiently, and put the
plugs so that no dust and / or water may invade.
Take off these plugs just before the piping works
when re-attach it to the host machine.
(3) Before disassembling, review the sectional drawing
and prepare the required parts, depending on the
purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not
reusable. There are some parts that should be
replaced as a sub-assembly.
Consult with the parts book in advance.
(4) The piston can be inserted to whichever cylinder
block for the initial assembling.
However, their combination should not be changed
if they are once used. To reuse them, put the
matching mark on both pistons and cylinder block
before disassembling.
(5) Take great care not to pinch your hand between
parts while disassembling nor let fall parts on your
foot while lifting them.
b. DISASSEMBLY PROCEDURES
(1) Removing accessory valves
Before disassembling motor, remove accessory
valves.
According to disassembling purpose, select the valves

to be removed.
However, you cannot disassemble the motor without
removing overload relief valve (56).
There is dread of the burn, disassemble motor after

cooling it to ambient temperature.
34-39
34. TRAVEL SYSTEM
1) Remove M42 plug (28) and O-ring (29).
2) Remove spring (27), spring holder (26) and

spool assy (25).
Put the matching mark on both spool assy (25) and rear
cover (23) so that spool assy (25) should not be
reversed on re-assembling.
It is impossible to disassemble this spool assy (25)
further because spool assy (25) is fixed by adhesive.
3) Remove plug (41), O-ring (42), check restrictor

spring (40) and restrictor (39).
4) Remove overload relief valves (56).
When removing overload relief valve (56), valve seat

(56-3) easily comes off, so take great care not to fall into
the rear cover (23) or lose.
5) Remove pilot valve plug (34) and then, remove

O-ring (35), pilot valve spring (33), spring holder
(32), pilot valve spool (30) and pin (31).
6) Remove coupling (57).
34-40
34. TRAVEL SYSTEM
(2) Disassembling motor

1) Place the motor with the shaft horizontal, remove
Hex. socket head bolts M18× 50 (55) of rear
cover (23) leaving two on diagonally upper and
lower position.
: 14mm
2) Install two guide pins diagonally into rear cover

(23).
(Purpose: Prevention of falling rear cover)
3) Loosen slowly and simultaneously the remaining

two Hex. socket head bolts M18× 50 (55).
4) Remove rear cover (23) and brake springs (54)

taking care cylinder block (12) is not coming out
stuck with rear cover (23). Fig. 34-80 Removing rear cover
• Do not fall, at this moment, valve plate (53), brake

springs (54), outer race of rear bearing (50) and/or
O-rings (49), (46), (48).
• There are shims (51) under the outer race of rear
bearing (50). Take a great care not to lose.
5) Remove valve plate (53) without pulling out

cylinder block (12).
Put the matching mark on both valve plate (53) and rear
cover (23) so that valve plate (53) should not be
reversed on re-assembling.
6) Using removed He× . socket head bolts M18 ×

50 (55), fasten two mount metals so as to push
in cylinder block (12) without damaging it then
inner race of rear bearing (50) comes out. (See
Fig. 34-81)
7) Put two fingers of gear (bearing) puller under the

inner race of rear bearing (50) and remove the
race.
50
Fig. 34-81 Removing rear bearing
34-41
34. TRAVEL SYSTEM
8) Attaching a hand on brake piston (20), supply

plant air through oil hole for releasing brake and
push out the piston (20). Hole for releasing brake
Be aware of brake piston (20) popping out.

In case of using jig for pulling out brake piston (20),
install jigs to M6 thread (2 places) of brake piston (20)
and pull out brake piston (20).
9) Put as a mark on a piston assy (17) such as a

paper pipe and put a matching mark on cylinder Fig. 34-82 Enlargement figure of matching surface
block (12) so that they can be re-assembled at of casing
the same position as before.
10) Remove rotary group (cylinder block (12),

spring holder (14), nine piston assys (17), shoe
retainer (16), ball joint (15) and cylinder spring
(13) as an assembly.
11) Remove separating plates (18) and friction

plates (19).
12) Remove nine piston assys (17), shoe retainer

(16) and ball joint (15) from rotary group
simultaneously.
13) Remove spring holder (14) and cylinder springs

(13).
• Put piston assys (17) into the cylinder block (12)
matching the matching mark with shoe retainer (16)
as if assembled.

The purpose is to put piston assys (17) in the same
bore of cylinder block (12) as before when
reassembled.
• Take care not to scratch sliding surfaces.
Do not reuse damaged ones. Fig. 34-83 Removing cylinder block
• It is impossible to disassemble piston and shoe
because they are calked together.
Above disassembling is mentioned as a motor only and

naturally can be applied to the motor with reduction
gears.
The situation is rather easier for with reduction gears
because the shaft is rather restricted by a gear to move.
34-42
34. TRAVEL SYSTEM
14) Remove swash plate (11).
Hole for shifting shifter piston

15) Do not detach shifter piston assy (5), (6), (7).
If it needs to detach, attach a hand on shifter
piston and supply plant air through the hole
shown in Fig. 34-84 and push it out.
Be aware of shifter piston (5) popping out. Fig. 34-84 Enlargement figure of matching surface
of casing
16) Shaft (8) can comes out now.
17) If front bearing (9) happen to be changed,

remove inner races and outer races using
bearing puller if needed and exchange to new
ones as an assembly.
• When changing bearings (9), (50), shaft (8),

casing(1) or rear cover (23), it affects the clearance
of the bearings.
Therefore, shim (51) should be adjusted.
• Shim (51) adjustment should be performed by
measuring correctly the clearance for shim and
change shim that meets the clearance. (See Fig. 34-
86)
Other jigs and tools are needed to measure and
decide the thickness of the shim.
• Do not remove pivots (10). If it needs to disassemble Fig. 34-85 Remove swash plate
them, put matching mark on pivots (10) with swash
plate (11).
• Never detach oil seal (3) only for the purpose of
inspecting it. If disassembled, remove retaining ring
IRTW68 (4) first and remove oil seal (3).Never fail to
replace oil seal (3) with new one.
34-43
34. TRAVEL SYSTEM
18) Deciding shim (51) thickness for tapered roller

bearings.
This work should be done only when you have changed

bearings (9), (50), shaft (8), casing (1) or rear cover
(23).
1. Measure the assembling width "E" (See ).
Fig. 34-86 Deciding shim thickness
Take care not to incline shaft (8).
2. Measure the depth "F" of rear cover (23)
Measure them at crossed 4 places on the circuit, then

calculate their mean value.
3. When thickness of shim (51) to be used is

placed as "S", the clearance "Y" can be
calculated as follows :
Y=F-(E+S)
4. Select one or two shim (51) so as the

clearance "Y" to come to 0-0.1 mm (0~0.004")
(clearance) on this unit.
(3) Disassembling overload relief valve

As a rule, overload relief valve (56) should be
handled as one service part. If there are any trouble
on overload relief valve (56) , replace as an
assembly.
56-3 56-2 56-1 56-12 56-13 56-4 56-9 56-8 56-12 56-10 56-11 56-6 56-7 56-5
Fig. 34-87 Disassembling overload relief valve
34-44
34. TRAVEL SYSTEM
GREASE
Valve seat (56-3) is fitted in bore of socket (56-1) at

clearance fit.
When removing overload relief valve (56), valve seat
(56-3) easily comes off, so take great care not to lose.
When assembling overload relief valve (56) to rear
cover (23), apply grease sufficiently on engagement
part not to drop valve seat (56-3).
Fig. 34-88 Engagement part
34-45
34. TRAVEL SYSTEM
34.2.4 TRAVEL MOTOR ASSEMBLY
34.2.4.1 GENERAL INSTRUCTIONS

(1) Wash each parts sufficiently with kerosene, and
blow them by plant air.
(2) Assemble sliding parts after coating clean hydraulic
oil on them.
(3) Take great care not to pinch your hand between
parts or tools while assembling nor let fall parts on
your foot while lifting them.
34.2.4.2 ASSEMBLING PROCEDURES

(1) Coat outer surface of oil seal (3) and inner face of
casing (1) with grease. Using jig, rightly and evenly
press in the oil seal (3) into casing (1).
Jig for lnserting oil seal
(2) Fix oil seal (3) by retaining ring (4).
(3) Put the outer race of bearing (9) on casing (1) (this
fit is loose), and press the inner race on shaft (8)
(this fit is tight).
It is easier to fit inner race if the inner race is heated or

boiled under 100 degrees centigrade.
Never over heat!
(4) Insert shaft (8) into casing (1) after coating grease
on the contact surface to oil seal (3) lip.
(5) Put shifter piston assy (5), (6), (7) into casing (1).
Fig. 34-89 Inserting oil seal

• Insert shifter piston assy (5) not to incline
• When inserting shifter piston assy (5), apply grease
sufficiently on piston seal (6) and take a great care
not to cut piston seal (6).
(6) Insert pivots (10) into the casing (1).

• Take care to match the matching mark with
casing (1) and also to coincide the direction of
sliding trace on sphere surface with those
contact trace on swash plate (11) if the motor
was operated a certain hours.
(7) Apply grease sufficiently on three spherical recess

of swash plate (11) and assemble it in casing (1).
Fig. 34-90 Assembling swash plate
34-46
34. TRAVEL SYSTEM
(8) Insert piston assys (17), shoe retainer (16), ball

joint (15), spring holder (14), cylinder spring (13) on
to cylinder block (12) as shown and then insert the
whole assembly to shaft (8).
Piston assys (17) should be inserted into the same bore

as before.
(9) Rightly knock in the inner race of rear bearing (50)

to the rear end of shaft (8) by using jig (A1) and
plastic hammer (A2).
(10)Install all the separating plates (18) and friction

plates (19) alternately between casing (1) and Fig. 34-91 Assembling rotary group
cylinder block (12) adjusting on the notches and
splines. Separating plates (18) comes both first and
last.
(11)Insert brake piston (20) into casing (1) using Plastic hammer
inserting jig (B) after attaching D-rings (21), (22) to
brake piston (20).
Apply grease sufficiently on D-rings (21), (22). Insert

brake piston (20) by using inserting jig not to incline.
Two kinds of D-rings are used on brake piston (20). The
larger one (22) is first inserted into the hole, then the
smaller one (21) enters.
It is impossible to see how the smaller ring goes into the
hole. Therefore, never push it forcibly into the hole.
Otherwise, it may be scraped off by the edge of the hole
of casing (1).
Jig for inserting

rear bearing Or
Jig for inserting

brake piston
10- Plain washer 18
Fig. 34-92 Inserting brake piston
34-47
34. TRAVEL SYSTEM
Guide pin
When changing bearings (9), (50), shaft (8), casing (1)

or rear cover (23), it affects the clearance of the
bearings. Therefore, shim (51) should be adjusted.
Refer to Chapter 34.2.3.2 b (2)-18) "Deciding shim (51)
thickness for tapered roller bearings" 34-44 and decide
shim (51) thickness.
(12)Install two guide pins diagonally on casing (1).

(Purpose: Guide for installing rear cover)
(13)Lay down rear cover (23) to mount valve plate (53)

coinciding matching mark made prior to
disassembling and also place brake springs (54)
with ample grease to be attached to rear cover (23)
while assembling. Also set shim (51), outer race of Fig. 34-93 Inserting brake piston
rear bearing (50) and O-rings (49), (46), (48) on
rear cover (23).
(14)Insert rear cover (23) to casing (1) along the guide

pin, and install two Hex. socket head bolts M18× 50
(55) diagonally upper and lower position and tight
them to assemble rear cover (23) parallely.
Then, install the rest of Hex. socket head bolts
M18× 50 (55) and remove guide pin and install two
the remainder.
: 14mm
When removing outer race of rear bearing (50), install

shim (51) without fail.
Confirm that O-rings (46), (48), (49) are installed to rear
cover (23).
(15)Assemble coupling (57).
34-48
34. TRAVEL SYSTEM
(16)Assemble spring (33), spring holder (32), pilot

valve spool (30) and pin (31) to rear cover (23), and
then install pilot valve plug (34) with O-ring (35).
Tightening torque : 49.0~58.8N•m (36.1~43.4 lbf•ft)
(17)Assemble overload relief valves (56).
: 32 mm
Tightening torque : 98~117.6N•m (72.3~86.7 lbf•ft)
Valve seat (56-3) is fitted in bore of socket (56-1) at

clearance fit. When assembling overload relief valve
(56) to rear cover (23), valve seat (56-3) easily comes Fig. 34-94 Assembling accessory valves
off, so take great care not to lose and apply grease
sufficiently on engagement part not to drop valve seat
(56-3).
(18)Assemble restrictor (39) and restrictor spring (40)

to rear cover (23), and then install G1/8 plug (41)
with O-ring (42).
In case of assembling NEW restrictor (39), fit valve seat

of restrictor (39) with rear cover (23).
(After inserting restrictor (39) to rear cover (23), knock
restrictor (39) slightly by hammer.)
(19)Inserting spool assy (25) to rear cover (23)

coinciding matching mark made prior to
disassembling, and then assemble spring holder
(26) and spring (27).
Spool assy (25) is unsymmetry. Insert spool assy (25)

in an appropriate direction.
(20)Assemble M42 plug (28) with O-ring (29).

Tightening torque : 441~461N•m (325~329 lbf•ft)
34-49
34. TRAVEL SYSTEM
34.2.4.3 INITIAL PRE-CONDITIONING OPERATION

(1) Drain charge
Fill up hydraulic oil in the motor casing after
assembling.
M4V290/170A motor has two drain ports (G1/2).
Bleed air in motor casing from un-piping port (upper
side).
(2) Initial Pre-conditioning operation

Operate motor 5 minutes at low speed mode and
low-idle, check if there are abnormal noise or leak
of oil.
34-50
34. TRAVEL SYSTEM
34.2.5 TRAVEL MOTOR
34.2.5.1 MAINTENANCE STANDARD OF PARTS

The followings are the general maintenance standards. However, it is the most important to determine which parts
should be replaced, depending on the characteristics before disassembling, damages and discoloration of exterior
view, the purpose of disassembling, the expected remaining service life, etc..
ITEM & MEASURING METHOD JUDGING CRITERIA & DISPOSITION

(1) Sliding surface of: cylinder block, Allowable
Check Items Criteria Disposition
valve plate and swash plate Roughness
Measure the surface roughness by Surface roughness;
roughness tester. cylinder block Replace or
below 0.4Z below 3.0Z
Measure the surface hardness of valve plate Repair
swash plate by hardness tester. swash plate
Lap together the surfaces of both cylinder block and valve plate to remedy
their roughness. (Lap with #1200 powder)
Measure the surface hardness of swash Allowable

plate by hardness tester. Hardness
Swash plate Over HS78 HS74 Replace
(2) Clearance between piston and Allowable
cylinder block Clearance
Outer diameter of 0.01mm (0.0004") 0.05mm
Measure outer dia. of piston and piston d max - d min (0.0020")
bore of cylinder block at least 3 Inner diameter of 0.01mm (0.0004") 0.022mm
Replace piston
places in the longitudinal direction cylinder bore (0.0009")
or cylinder block
with micrometer, and obtain: D max - D min
Clearance D-d 0.037~0.047mm 0.065mm
max. outer dia. = d max (0.0015"~0.0019") (0.0026")
min. outer dia. = d min
min. inner dia. = D min
max. inner dia. = D max
In exchanging pistons, replace all of nine pistons at the same time
34-51
34. TRAVEL SYSTEM

(3) Play between piston and shoe Allowable
Roughness
With the jig of Fig, hold down the
shoe on work stand, and pull up
the piston vertical direction to Play between calked 0~0.1mm
0.5mm (0.02") Replace piston
measure the play between piston piston and shoe (0~0.004")
and shoe.
(See Fig)
(1.34" +0.008"
+0.004" )
Dial gauge o34 ( +0.2
+0.1)
85 (3.35")
Piston
Jig
MagnetStand
26 (1.02")
Shoe
Work stand
o32 (1.26")
Method Play
o43 (1.69")
Jig
Fig. 34-95 Method & Play & Jig
Allowable
ITEM & MEASURING METHOD Check Items Criteria Disposition
Roughness
(4) Parking brake torque
Replace all
After completion of assembly, set
902N•m 812N•m separator and
the torque wrench on the shaft Parking brake torque
(670 lbf•ft) (600 lbf•ft) friction plates
end, and measure the braking
springs
torque generated when the shaft
starts to rotate.
Standard of replacing friction and
separating plate.
Standard of replacing friction and separating plate

When measuring parking brake
torque, it needs to disassemble
Measure the total thickness of 4 pieces of friction plate and 5 pieces of
traveling unit to motor and
separating plate. And if the total thickness is below the following allowable
reduction gear portion, and it’s so
value, replace all separating and friction plates and springs.
hard.
The right allowable value is a
Criteria: 22.76 mm (0.90") (Dimension in the drawing)
standard of replacing friction and
Allowable Thickness : 21.3 mm (0.84")
separating plate
If it is impossible to disassemble
traveling unit, refer to the right
value.
34-52
34. TRAVEL SYSTEM

(5) Shaft If the depth of shaft wear is less than 0.05 mm (0.002"), the shaft is reusable.
Measure the wear at contacting
surface of oil seal (3) with the
surface roughness tester.
• In case of replacing the shaft (8), replace oil seal (3) at the same time.
(6) Bearing Replace bearings (9), (50) before hour meter of host machine indicates
10,000 hours.
Replace bearing (9), (50) after
decided hours.
• In case replacing the bearings(9), (50), replace both inner and outer races
at the same time.
• Also the bearing shims (51) must be re-adjusted when replaced shaft (8)
and/or bearings (9), (50). Contact dealers for jigs and tools required.
(7) Splines If the wear of splines is less than 0.3 mm (0.012"), the spline is reusable.
Replace if the wear of splines
exceeds the allowable value.
(8)Overload relief valve Replace relief valve part as an assembly each time the host machine works
for 10,000 hours.
Do not try to adjust the valve,
since special hydraulic test bench
is required for inspecting and
adjusting the pressure.
34.2.5.2 TIGHTENING TORQUE
Item Description Size Tightening torque N•m (lbf•ft)

(28) Plug M42 441~461 (325~340)
(34) Plug (Pilot valve) G3/8 49.0~58.8 (36.1~43.4)
(37) Plug G1/4 29.4 (21.7)
(41) Plug G1/8 14.7 (10.8)
(55) Hex. socket head bolt M18 324±32.4 (239±23.9)
(56) Overload relief valve M27 98.1~118 (72.4~87.0)
(59) Plug G1/2 98.1 (72.4)
34-53
34. TRAVEL SYSTEM
34.2.6 TRAVEL MOTOR TROUBLESHOOTING

CAUSE OF TROUBLE AND REMEDY
The followings are the general instructions to be followed when some troubles occur with hydraulic motors.
34.2.6.1 GENERAL INSTRUCTIONS

(1) Judge the nature of abnormality before trouble shooting, and ascertain if the same symptom has occurred before
or not.
Review if the motor itself is actually troubled.
(2) In many cases, the wear is caused by dusts.
Take great care to prevent dusts in disassembling and assembling.
(3) All the parts especially those of moving parts should be carefully handled, and be careful not to score or scratch
the sliding surfaces.
(4) Be careful not to score the seating surface for O-ring, etc..
We recommend you to replace O-rings with the new ones, if once disassembled.
34.2.6.2 CAUSE OF TROUBLE AND REMEDY

(1) Hydraulic motor never starts
Symptom Cause Remedy

Pressure never Malfunction of built-in relief valve. Repair or replace relief valve
increases
Pressure 1. Parking brake is not released 1. After inspection of clogging, repair or replace
increases (Clogging of restrictor)
2. Parking brake is not released 2. Re-install the spool in correct direction
(Spool is installed in wrong direction)
3. Stuck friction or separating plate of parking 3. Replace friction and separating plate
brake portion
4. Stuck brake piston 4. Repair outer dia. of brake piston or replace it.
5. Seizure of sliding portion 5. Check, repair or replace piston shoe, swash
plate, cylinder block valve plate etc..
6. Malfunction of spool 6. Repair or replace
(Stick between spool and body)
(Clogging of restrictor)
(2) Hydraulic motor rotates weakly

Set pressure of Malfunction of spool Repair or replace
overloadvalve is (Stick between spool and body)
correct, but brake
is released
belatedly
Parking brake is High oil viscosity. Raise oil temperature or change the hydraulic
released, but oil
motor is hard to
start
Parking brake is 1. Check clogging of choke
1. Parking brake is not completely released.
released, but
(Clogging of choke of pressure release
motor starts
passage)
weakly
2. Relief valve catches small particles 2. Wash relief valve, check or replace seat of it
3. Seizure of sliding portion 3. Check, repair or replace sliding portion
34-54
34. TRAVEL SYSTEM
(3) Drive shaft never rotate up to the set value

Rotation of drive 1. Shortage of oil coming in 1. Check oil flow or hydraulic circuit to motor.
shaft never
reaches the set
value
2. Large wear or flaw made on shoe, cylinder 2. Check, repair or replace the parts
block or valve plate
(4) Brake refuses to work

Brake refuses to Malfunction of parking brake Check, repair or replace brake piston, friction
work plate, spring, etc.
1. Worn friction plate
2. Broken spring
Brake works on Repair or replace or clean up
counter lever Malfunction of spool
operation
1. Stick between spool and body
2. Stick of check valve or that by small particle
3. Clogging of restrictor
(5) Oil leakage

Oil leakage 1. Loose Hex. socket head bolt or plug 1. Fasten it with given torque
2. O-ring is torn off 2. Replace O-ring
3. Oil leaks inside gear casing 3. Replace oil seal
(6) Would not shift from high to low

Would not shift Stick of spool of pilot valve Replace pilot valve assy.
from high to low
(7) Abnormal noise

Abnormal noise appear Malfunction of spool Bleed air
together with big vibration when Air is caught inside brake valve
brake is slowly applied or oil is Stick between spool and body Repair or replace
supplied to other circuits while
motor is running
(8) Hunting occurs while descending the slope

Severe hunting Malfunction of spool Repair or replace
while inching • Stick between spool and body
• Restrictor is not seated completely
Interference with parking brake Repair or replace
• Permanent set or broken spring
34-55
34. TRAVEL SYSTEM
34.2.7 REDUCTION UNIT DISASSEMBLY
34.2.7.1 TOOLS
jigs and measuring instruments.
No. Tools Application

1 Torque wrench 0~490N•m (0~360 lbf•ft)
2 Allen wrench Opposing flats 8mm, 10mm, 17mm
3 Stand
530 or more
200 or more
(20.9")
(7.87")
415
(16.3")
t=16 (0.63") or more
4 Micro depth meter 0~25mm (0~0.984")

5 Caliper 0~250mm (0~9.84")
6 Eye bolt M10, M12, M24 3pcs. each
7 Pin Spring pin (16), (24) ø5.5× 60 (2.36"), ø9.5× 75 (2.95")
8 Press machine It is used to insert the angular bearing and fix the lock washer.Capacity 3 tons
(6610 lb)
9 Others Cleaning oil, Detergent, Gear oil, Grease,
Loctite#242, #515, Seal tape, rag and others
(1) Preparation before removal
1) The travel unit removed from the machine has dust and mud. Wash them with cleaning oil.
2) Loosen drain or oil filling plug (29) and drain the oil out of the reduction unit.
When oil is hot, pressure is built up inside. Take care as the oil gushes out in some cases.
3) Putting matching marks

Put a matching mark on the outside of each matching surface so it may be installed where it was.
• The numbers in the parentheses after part names correspond to those in the assembly drawing on Fig. 34-
79.
34-56
34. TRAVEL SYSTEM
(2) Setting reduction unit (or whole propelling unit) on

work stand
1) Remove Hex. socket head bolts M12× 30 (28) at
3 places from cover (27) almost equally apart
each other, then install M10 eye bolts. Lift up the
unit using them and place it on work stand with
cover (27) upward.
Take great care not to pinch your hand between parts

while disassembling nor let fall parts on your foot while
lifting them.
Lift the parts up horizontally.
Fig. 34-96 Setting propelling unit on work stand

(3) Removing cover
1) Remove the rest of Hex. socket head bolts
M12× 30 (28) that secure cover (27).
: 8mm
28
2) As the cover (27) is adhered to ring gear (3), 27

remove cover (27) by lightly hammering
slantwise upward by wooden bar aiming at
projection of cover (27).
Fig. 34-97 Removing bolts
27
Fig. 34-98 Removing cover
34-57
34. TRAVEL SYSTEM
(4) Removing carrier 1 assy

1) Remove thrust plate (26).
2) Screw three M10 eye bolts in carrier 1 (19) and 19

lift up and remove carrier 1 as sub-assy (19),
(20), (21), (22), (23), (24). 20
(21,22,23,24)
3) Remove sun gear 1 (25).
Fig. 34-99 Removing carrier 1 assy

(5) Removing carrier 2 assy
1) Remove sun gear 2 (18).
11
2) Screw three M10 eye bolts in carrier 2 (11) and
lift up and remove carrier 2 as sub-assy (11),
(12), (13), (14), (15), (16), (17).
12
(13,14,15,16)
Fig. 34-100 Removing carrier 2 assy

(6) Disassembling housing assy
1) Remove support ring (10).
10
Fig. 34-101 Removing support ring

2) Take off lock washers (9) by tapping on screw
driver or on similar tool placed at parting surface
of them.
Fig. 34-102 Removing lock washer
34-58
34. TRAVEL SYSTEM
3) Screw three M12 eye bolts in ring gear (3) almost

equally apart each other, then lift it up
horizontally and remove housing ass'y including
ring gear (3), housing (1), angular bearing (2),
seal cover (5), floating seal (7) and Hex. socket
head bolts M20× 120 (4) together.
Fig. 34-103 Removing housing assy

(7) Disassembling housing assy
1) Screw three M24 eye bolts in housing (1) almost
equally apart each other. Lift up the housing assy
and place it on work stand with housing (1)
upward.
Put a mating mark outside of housing (1) and ring
gear (3).
over 300
2) Remove floating seal (7) from seal cover (5).
3) Remove Hex. socket head bolts M10× 25 (6),

and remove seal cover (5) from housing (1).
4) Remove Hex. socket head bolts M20× 120 (4), Fig. 34-104 Disassembling housing assy
leaving two of them diagonally.
: 17mm
5) Loosen the rest two Hex. socket head bolts

M20× 120 (4) and tap lightly the head of them
then ring gear (3) can be easily removed from
housing (1).
• Take care not to damage the sliding surface of

floating seal (7) or its O-ring.
• Bearings (2) have been tightly press fitted in housing
(1). Don't remove the bearings (2) unless otherwise
their exchange is needed.
In case bearings (2) removed, don't re-use them.
New bearings (2) should be used and shim (8)
adjusting be required.
34-59
34. TRAVEL SYSTEM
(8) Removing floating seal

1) Remove a piece of floating seal (7) of motor side.

(9) Disassembling carrier 1 assy
23
When carrier pins 1 (23) are to be re-used, mark each 19

pin with its mated hole of carrier 1 (19) to assure the
same combination as before.
Fig. 34-106 Disassembling carrier 1 assy

1) Knock spring pins 6× 36 (24) fully into carrier pins
1 (23). 24
23
2) Tap carrier pins 1 (23) out from carrier 1 (19).
19
3) Remove thrust washers 1 (21), planetary gears
1 (20) and needle bearings (22) from carrier 1
(19). 19
19
4) Knock out spring pins 6× 36 (24) from carrier pins
1 (23) for re-assembling.
21
When carrier pin 1 (23) or planetary gear 1 (20) is

needed to be exchanged, three pins or three gears 20 22
should be all exchanged. 20
Fig. 34-107 Disassembling carrier 1 assy
34-60
34. TRAVEL SYSTEM
(10) Disassembling carrier 2 assy
16
15
When carrier pins 2 (15) are to be re-used, mark each 11
pin with its mated hole of carrier 2 (11) to assure the 11
same combination as before.
1) Knock spring pins 10× 63 (16) fully into carrier

pins 2 (15).
11 12
2) Tap carrier pins 2 (15) out from carrier 2 (11).
3) Remove planetary gears 2 (12), bearing (14) and

retaining ring C-type (13) from carrier 2 (11).
4) Remove spacer (17) from carrier 2 (11).

5) Knock out spring pins 10× 63 (16) from carrier 14
pins 2 (15) for re-assembling. Fig. 34-108 Disassembling carrier 2 assy
When carrier pin 2 (15) or planetary gear 2 (12) is

needed to be exchanged, three pins or three gears
should be all exchanged.
34-61
34. TRAVEL SYSTEM
34.2.8 ASSEMBLING
(1) GENERAL INSTRUCTIONS
11
1) Clean every part by kerosene and dry them by air
blow. Surfaces to be applied by Loctite must be
degreased by solvent.
12(13,14)
2) Check every parts for any abnormals.
3) Each Hex. socket head bolt should be used with

Loctite #242 applied on its threads.
Fig. 34-109 Assembling carrier assy
4) Apply gear oil slightly on each part before
assembling.
5) Remove the refuse of Loctite #242 in thread

holes by tap and degrease by solvent.
6) Take great core not to pinch your hand between

parts while assembling nor let fall parts on your
foot while lifting them.
(2) Assembling carrier 2 assy

12 (13,14)
1) Install spacer (17), planetary gears 2 (12),
needle bearings (14) and retaining ring C-type
(13) into carrier 2 (11).
16
2) Install carrier pins 2 (15) into carrier 2 (11) where
the holes for spring pins 10× 63 (16) are to be in 11
line with those of carrier 2 (11).
3) Install spring pins 10× 63 (16) into carrier 2 (11) Fig. 34-110 Drive spring pin
and at the same time into carrier pins 2 (15).
(Sink spring pins of 1 - 2 mm (0.04"~0.08") from
surface)
4) Calk carrier 2 (11) on diagonally position to

prevent spring pin 10× 63 (16) from coming out.
34-62
34. TRAVEL SYSTEM
(3) Assembling carrier 1 assy (See Fig. 34-109).

1) Install planetary gears 1 (20), needle bearings
(22) and thrust washers 1 (21) into carrier 1 (19).
2) Install carrier pins 1 (23) into carrier 1 (19) where

the holes for spring pins are to be in line with
Cauking
those of carrier 1 (19). position
3) Install spring pins 6× 36 (24) into carrier 1 (19)

16
and at the same time into carrier pins 1 (23).
(Sink spring pins of 1 - 2 mm (0.04"~0.08")from Fig. 34-111 Caulking the spring pin
surface)
4) Calk carrier 1 (19) on diagonally position to

prevent spring pin 6× 36 (24) from coming out.
(4) Installing main bearing and floating seal
7
1) Install main bearing (2) to inner surface of
housing (1).
2) Install a piece of floating seal (7) on motor casing

and also install another piece of floating seal (7)
on seal cover (5).
3) Apply Loctite #515 on mating surfaces of
housing (1) and seal cover (5) without a gap.
4) Install seal cover (5) on housing (1).
Then, after applying Loctite #242 on the threads Fig. 34-112 Install floating seal (7)
of 16 pieces of Hex. socket head bolts M10× 25 Correct Incorrect Incorrect
(6) without removing rust preventive agent,
tighten them with torque wrench.
: 8mm
Fig. 34-113 Install direction of floating seal (7)
34-63
34. TRAVEL SYSTEM
(5) Assembling housing assy

1) Apply Loctite #515 on mating surfaces of LOCTITE#515
housing (1) and ring gear (3) without a gap.
2) Install three M24 eye bolts equally apart on LOCTITE#515

housing (1). Using the eye bolts, hang the 3
5
housing (1) by wire rope and place it on ring gear
(3), coinciding mating marks.
3) After applying Loctite #242 on the threads of 26

pieces of Hex. socket head bolts M20× 120 (4),
tighten them with torque wrench.
: 17mm
• Clean the groove for floating seals (7) to eliminate

oil, dust, paint or other foreign material. Fig. 34-114 Assembling housing assy
• Apply gear oil slightly on sliding surfaces of floating 20 (0.79") 20 (0.79")

seals (7) before assembling but strictly dry on O-
rings and on its grooves.
• Confirm that O-ring of floating seals (7) are not
twisted and that floating seals are correctly installed.
i.e. parallel as shown each other between housing Sork 20mm (0.79") length from the
tip of bolt in Loctite #242.
(1) and motor casing after assembled. (See Fig. 34-
113) Fig. 34-115 How to apply Loctite #242
• It is recommended to use jig to install floating seal.
(6) Deciding shim thickness for angular bearings
This work should be done only when you have to

change motor casing, housing (1), bearings (2) or lock
washers (9). Unless otherwise use the same shim (8)
as before.
34-64
34. TRAVEL SYSTEM
1) Fit in two bearings (2) on housing (1) pressing

their outer laces.
2) Press inner laces of two bearings (2) lightly and
evenly, measure the assembling width "A" of
inner laces.
S
When measuring the assembling width "A", rotate D A
bearing (2) at least 5 times and become the width "A"

C B
stably.
3) Measure the motor side assembling width "B" for Fig. 34-116 Deciding shim thickness
bearings (2).
4) Measure the groove width "C" of motor casing.
5) Measure the thickness "D" of lock washers (9).
Measure them at 4 places evenly apart on the

circumferences then calculate and use those mean
values.
Measure them to the accuracy of 0.01 mm (0.0004").
6) When thickness of shim (8) to be used is placed

as "S", the clearance "X" can be calculated as
follows :
X=(B+C)-(A+D+S)
7) Select a shim (8) so as the clearance X to come

to -0.08 mm (interference)~ +0.02 mm
(clearance) (-0.0031"~0.0008") on this unit.
(7) Installing housing assy Press
1) Place motor on work stand with the shaft upward,
and put the selected shim (8) on the bearing
mating surface of motor casing.
2) Install three M12 eye bolts on ring gear (3)

almost equally apart and lift it up. Descend it
concentric with motor and put bearings (2) on
housing (1) into motor casing. Use press
machine and press inner lace of bearing (2) into
full depth.
Fig. 34-117 Pressing housing assy in
34-65
34. TRAVEL SYSTEM
3) While pressing inner lace of bearing (2), install

lock washers (9) into groove.
Fig. 34-118 Installing lock washer

4) Install support ring (10) over outside of lock
9 10
washers (9).
Fig. 34-119 Installing support ring

(8) Assembling carrier 2 assy CARRIER 2 PLANETARY GEAR 2
1) Install three M10 eye bolts equally apart on
carrier 2 (11).
Using the eye bolts, hang the carrier 2 assy by
wire rope and place three planetary gears 2 (12)
as shown on Fig. 34-120, put carrier 2 assy into
ring gear (3) and mesh the splines to those of
motor.
VB VA
2) Insert and mesh sun gear 2 (18) on center.

NOTCH (CARRIER 2) PORT
Fig. 34-120 Installing direction of carrier 2
Positioning carrier 2 assy as Fig. 34-120 is important to

11
obtain better lubrication.
SUN GEAR 2 (18)
Fig. 34-121 Assembling carrier 2 assy
34-66
34. TRAVEL SYSTEM
(9) Assembling carrier 1 assy

19
1) Install three M10 eye bolts equally apart on
carrier 1 (19). Using the eye bolts, hang the
carrier 1 assy by wire rope and place it in ring
gear (3), rotate planetary gears 1 (20) by hand
and adjust carrier 1 (19) to mesh with sun gear 2
(18).
2) Making sure that coupling is on the shaft end,

SUN GEAR 1 (25)
install sun gear 1 (25) on center.
3) Place thrust plate (26) on carrier 1 (19).

19
SHARP EDGE R
26
THRUST PLATE
Face sharp edged side to cover (27). (See Fig. 34-122)
COVER
Fig. 34-122 Assembling carrier 1 assy
(10)Installing cover
1) Apply Loctite#515 on mating surfaces of cover 27
(27) and ring gear (3) and install cover (27) on
ring gear (3). LOCTITE #515
3
2) After applying Loctite #242 on the threads of 25

pieces of Hex. socket head bolts M12× 30 (28),
tighten them with torque wrench. 28
Fig. 34-123 Installing cover (27)

: 10mm,
(11)Filling gear oil

1) Fill gear oil (SAE #90 API class GL-4 or GL-5, 15
litters (4.0 gal)) from two G3/4 ports.
2) Tighten taper screw plugs (29).
: 14mm
Tightening torque : 147.1N•m (108 lbf•ft)
34-67
34. TRAVEL SYSTEM
34.2.9 MAINTENANCE STANDARD
34.2.9.1 INSPECTION BEFORE ASSEMBLING

(1) Thrust washer
1) Check if there are seizure, abnormal wear or uneven wear.
2) Check if the wear is over the allowable limit.
(2) Gears
1) Check if there are pitting or seizure on the tooth surface.
2) Check if there are clacks on the root of tooth by die check.
(3) Bearings
Rotate by hand to see if there are something unusual such as noise or uneven rotation.
(4) Floating seal
Check flaw or score on sliding surfaces or on O-rings.
34.2.9.2 MAINTENANCE STANDARD OF PARTS

The followings are the general maintenance standards. D E C
However, it is most important to determine which parts
should be replaced, depending on the characteristics
shown before disassembling, damages or discoloration
of exterior view, the purpose of disassembling, the
A
expected remaining service life etc..
Fig. 34-124
Maintenance standards
Mark Items Criteria Allowable limit Disposition
Smooth, without abnormal Replace 3 pieces
A Wear of planetary shaft ←
wear or seizure as a set
Replace (Replace 3
Smooth, without abnormal Not over 1.6mm (0.063") of
B Condition of tooth surface pieces as a set for
wear or seizure pitching nor cracks at root
planetary gears)
Adjust shim
Thrust clearance of angular From -0.08 mm To 0.02 mm
C ← thickness
bearings (2) (-0.0031"~0.0008")
[Refer to 34.2.8(6)]
Thickness of thrust washer 1 From 3.9 mm To 4.1 mm 0.1 mm (0.004")
D Replace
(21) (0.15"~0.16") of wear
Thickness of thrust washer 2 4.4±0.2mm 0.15 mm (0.006")
E Replace
(17) (0.17"~0.18") of wear
4.5±0.16mm 0.15 mm (0.006")
F Thickness of thrust plate (26) Replace
(0.171"~0.183") of wear
G Lubrication oil 2,000 working hours (engine hour meter) Replace
34-68
34. TRAVEL SYSTEM
34.2.9.3 TIGHTENING TORQUE

Use torque wrench when tightening the following Hex. socket head bolts and plugs.
ITEM Description Size Tightening torque

N•m (lbf•ft)
461±44.1 (340±33)
4 Hex. socket head bolt M20× 120
(with applying Loctite#242)
53.9±5.9 (40±4.4)
98.1±9.8 (72.4±7.2)
29 Taper plug G3/4 147±14.7 (108±11)
34.2.9.4 INSPECTION AFTER ASSEMBLED

(1) Quantity of lubrication
After installed the propelling unit, position the drain port at lowest position and check if lubrication oil comes out
when loosen the level plug.
(2) Rotating inspection
Put the unit on the test stand and rotate with no load and check if there are abnormal noise or leak of oil. Take
care not to overspeed the motor. Rotate within specified flow rate.
34-69
34. TRAVEL SYSTEM
[MEMO]
34-70
46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS
46.1 JUDGMENT OF ACTUAL THING AT SITE .....................................................................46-3

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................................46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ....................................................46-4
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-4
46
46-1
46. TROUBLE SHOOTING (BY ERROR CODES)

SK460-8: LS10-02001~ S5LS4611E01
LC–8 : YS10-01501~ (ASIA, OCE)
46-2
Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.
Fig. 46-1 Attending the field to verify actual thing.
46.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
(2) Verify background of trouble occurred
1) Model name and serial number
2) Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
Fig. 46-2 Verifying background of trouble occurred.
additional works.
(3) 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.
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
Fig. 46-3 Confirm the symptoms of the trouble.
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 Fig. 46-4 Diagnosing fail by means
surfaces. troubleshooting.
46-3
46.2 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 code When it is hard to recreate the failure situation, cancel
after self diagnosis is remained in trouble history the data in the history and reproduce the 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 instructions
displayed or is not remained in the history in Chapter 47 "TROUBLESHOOTING BY
TROUBLE".
46.3 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
46.4 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 Code Trouble Described

page
A015 Engine adjustment (A adjustment) is not adjusted yet or is failed. 46-7
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed. 46-7
A215 Written data of ROM adjustment data is incorrect. 46-8
A225 Writing of ROM adjustment data is incorrect. 46-8
A235 Written data of ROM hour meter data is incorrect. 46-9
A245 Writing of ROM hour meter data is incorrect. 46-9
A255 Writing of proportional valve adjustment data is incorrect. 46-10
B012 Incorrect output of boom up pressure sensor 46-10
B013 Disconnection of boom up pressure sensor 46-11
B014 Short-circuit of boom up pressure sensor 46-11
B022 Incorrect output of boom down pressure sensor 46-12
B023 Disconnection of boom down pressure sensor 46-12
B024 Short-circuit of boom down pressure sensor 46-13
B032 Incorrect output of arm out pressure sensor 46-13
B033 Disconnection of arm out pressure sensor 46-14
B034 Short-circuit of arm out pressure sensor 46-14
46-4

page
B042 Incorrect output of arm in pressure sensor 46-15
B043 Disconnection of arm in pressure sensor 46-15
B044 Short-circuit of arm in pressure sensor 46-16
B052 Incorrect output of bucket digging pressure sensor 46-16
B053 Disconnection of bucket digging pressure sensor 46-17
B054 Short-circuit of bucket digging pressure sensor 46-17
B062 Incorrect output of bucket dump pressure sensor 46-18
B063 Disconnection of bucket dump pressure sensor 46-18
B064 Short-circuit of bucket dump pressure sensor 46-19
B072 Incorrect output of swing pressure sensor 46-19
B073 Disconnection of swing pressure sensor 46-20
B074 Short-circuit of swing pressure sensor 46-20
B092 Incorrect output of travel right pressure sensor 46-21
B093 Disconnection of travel right pressure sensor 46-21
B094 Short-circuit of travel right pressure sensor 46-22
B102 Incorrect output of travel left pressure sensor 46-22
B103 Disconnection of travel left pressure sensor 46-23
B104 Short-circuit of travel left pressure sensor 46-23
B113 Disconnection of pressure sensor of optional selector positioning 46-24
B114 Short-circuit of pressure sensor of optional selector positioning 46-24
B162 Incorrect output of P1 optional side pressure sensor 46-25
B163 Disconnection of P1 side optional pressure sensor 46-25
B164 Short-circuit of P1 side optional pressure sensor 46-26
B172 Incorrect output of P2 optional side pressure sensor 46-26
B173 Disconnection of P2 side optional pressure sensor 46-27
B174 Short-circuit of P2 side optional pressure sensor 46-27
C012 Incorrect output of P1 pump pressure sensor 46-28
C013 Disconnection of P1 pump pressure sensor 46-28
C014 Short-circuit of P1 pump pressure sensor 46-29
C022 Incorrect output of P2 pump pressure sensor 46-29
C023 Disconnection of P2 pump pressure sensor 46-30
C024 Short-circuit of P2 pump pressure sensor 46-30
C033 Disconnection of boom head pressure sensor 46-31
C034 Short-circuit of boom head pressure sensor 46-31
C043 Disconnection of boom rod pressure sensor 46-32
C044 Short-circuit of boom rod pressure sensor 46-32
D012 Failure of output transistor ON at P1 bypass cut proportional valve 46-33
D013 Disconnection of P1 bypass cut proportional valve 46-33
D022 Failure of output transistor ON at P2 bypass cut proportional valve 46-34
D023 Disconnection of P2 bypass cut proportional valve 46-34
D032 Failure of output transistor ON at travel straight proportional valve 46-35
D033 Disconnection of travel straight proportional valve 46-35
D062 Failure of output transistor ON at arm in high speed proportional valve 46-36
D063 Disconnection of arm in high speed proportional valve 46-36
D112 failure of output transistor ON at P1 travel-independent proportional valve 46-37
D113 Disconnection of P1 travel-independent proportional valve 46-37
D122 Failure of output transistor ON at P2 travel-independent proportional valve 46-38
D123 Disconnection of P2 travel-independent proportional valve 46-38
46-5

page
E012 Failure of output transistor ON at P1 pump proportional valve 46-39
E013 Disconnection of P1pump proportional valve 46-39
E022 Failure of output transistor ON at P2 pump proportional valve 46-40
E023 Disconnection of P2 pump proportional valve 46-40
F011 Failure of output transistor OFF and GND short of attachment boost SOL valve 46-41
F013 Failure of output transistor ON and disconnection of attachment boost SOL valve 46-41
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46-42
F023 Failure of output transistor ON and disconnection of swing parking SOL valve 46-42
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve 46-43
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve 46-43
F041 Failure of output transistor OFF and GND short of optional selector SOL valve 46-44
F043 Failure of output transistor ON and disconnection of optional selector SOL valve 46-44
G032 Overrun of speed sensor of direct input Mechatro-controller 46-45
G033 Disconnection of speed sensor of direct input Mechatro-controller 46-45
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-46
G043 Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-47
H013 Disconnection of acceleration potentio 46-48
H014 Power short-circuit of acceleration potentio 46-48
H023 Disconnection of boom angle potentio 46-49
H024 Power short-circuit of boom angle potentio 46-49
H033 Disconnection of arm angle potentio 46-50
H034 Power short-circuit of arm angle potentio 46-50
H091 Failure of GND short-circuit of fuel sensor 46-51
H093 Disconnection of fuel sensor 46-51
I111 Received error of CAN1 communication (passive error) 46-52
I113 Received error of CAN1 communication (time-out) 46-52
I313 Received error of cluster communication (time-out error) 46-53
K014 Adhesion of battery relay terminal 46-53
R014 Failure of arc prevention relay of wiper motor 46-54
R024 Failure of normal rotation relay of wiper motor 46-55
R034 Failure of reverse rotation relay of wiper motor 46-56
R044 Failure of washer motor relay 46-57
R134 Failure of swing flasher relay 46-57
R144 Failure of swing flasher relay 46-58
R154 Failure of travel alarm relay 46-58
R164 Failure of auto idling stop relay 2 46-59
R174 Failure of engine forcible stop relay 46-60
R184 Failure of lever lock relay 46-61
R214 Failure of safety relay 46-61
46-6
Table46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" 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
Table46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the 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
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
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"
3
46-7
Table46-3
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
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
Service Screen No.
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
Table46-4
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
normal condition
Service Screen No.
2
3
46-8
Table46-5
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
normal condition
Service Screen No.
2
3
Table46-6
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter 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
Service Screen No.
2
3
46-9
Table46-7
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
normal condition
Service Screen No.
2
3
Table46-8
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
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
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 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.
46-10
Table46-9
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
Control in the
mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 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-101F
Table46-10
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Returned in
normal condition
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
CN-101F
46-11
Table46-11
Error code B022
Trouble Boom down pressure sensor outputs error
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-2 BOOM LOWER
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
Table46-12
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
CN-101F
46-12
Table46-13
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
Table46-14
Error code B032
Trouble Arm-in pressure sensor outputs error
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-3 ARM OUT
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
46-13
Table46-15
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom Shock at stopping of arm-out is great.
Control in the
event of failure
Returned in
normal condition
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
CN-101F
Table46-16
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Control in the
event of failure
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
normal condition
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
46-14
Table46-17
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure 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
Service Screen No. 5 B-4 ARM IN
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
Table46-18
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
normal condition
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
CN-101F
46-15
Table46-19
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
normal condition
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
Table46-20
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-5 BUCKET DIG
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
46-16
Table46-21
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom The bucket digging speed slows down a little.
Control in the
event of failure
Returned in
normal condition
Table46-22
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Control in the
event of failure
Returned in
normal condition
46-17
Table46-23
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-6 BUCKET DUMP
1 • Bucket dump pressure sensor When B062 is cancelled and other error occurs by turning starter switch on
2 • Wiring between bucket dump When B062 is displayed after turning the starter switch on after the connector
CN-125F
and repair it if necessary.
Table46-24
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom The bucket dump speed slows down a little.
Control in the
event of failure
Returned in
normal condition
46-18
Table46-25
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Control in the
event of failure
Returned in
normal condition
Table46-26
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-7 SWING
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
46-19
Table46-27
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
Table46-28
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
46-20
Table46-29
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-9 TRAVEL (R)
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
Table46-30
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom The Travel right operability becomes poor.
Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
normal condition
46-21
Table46-31
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Control in the
event of failure
Returned in
normal condition
Table46-32
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-10 TRAVEL (L)
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
46-22
Table46-33
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom The Travel left operability becomes poor.
Control in the
event of failure
Returned in
normal condition
Table46-34
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Control in the
event of failure
Returned in
normal condition
46-23
Table46-35
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 16 B-11
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
CN-104F
Table46-36
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 16 B-11
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
CN-104F
46-24
Table46-37
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-16 P1 OPT.
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
Table46-38
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
46-25
Table46-39
Error code B164
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
Table46-40
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
46-26
Table46-41
Error code B173
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work.
Control in the
event of failure
Returned in
normal condition
Table46-42
Error code B174
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work.
Control in the
event of failure
Returned in
normal condition
46-27
Table46-43
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 7 C-1 PUMP P1
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
Table46-44
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
normal condition
46-28
Table46-45
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Returned in
normal condition
Table46-46
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
46-29
Table46-47
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Returned in
normal condition
Table46-48
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Returned in
normal condition
46-30
Table46-49
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
Table46-50
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
46-31
Table46-51
Error code C043
Trouble Boom rod pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-4 BOOM-ROD
1 • Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom rod When C043 is displayed after turning the starter switch on after the connector
Table46-52
Error code C044
Trouble Boom rod pressure sensor’s power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-4 BOOM-ROD
1 • Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom rod When C044 is displayed after turning the starter switch on after the connector
46-32
Table46-53
Error code D012
Trouble P1 bypass cut proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 bypass cut proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
1 • P1 bypass cut proportional When D012 is cancelled and other error occurs by turning starter switch on
valve after exchanging the connector with other sensor.
PSV-D Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 bypass cut When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
Table46-54
Error code D013
Trouble P1 bypass cut proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
event of failure
Returned in
normal condition
PSV-D Check sensor unit for possible failure. If failure found, replace it.
46-33
Table46-55
Error code D022
Trouble P2 bypass cut proportional valve and output transistor ON are failure.
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
PSV-B Check sensor unit for possible failure. If failure found, replace it.
Table46-56
Error code D023
Trouble P2 bypass cut proportional valve’s wiring is disconnected.
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
PSV-B Check sensor unit for possible failure. If failure found, replace it.
46-34
Table46-57
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
Table46-58
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
46-35
Table46-59
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
Table46-60
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
46-36
Table 46-61
Error code D112

Trouble P1 independent travel proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 100mA or more.
Combined operations of travel and attachment at travel independent mode, attachment be-
Symptom
comes slow.
Control in the
Normal control.
event of failure
Returned in
normal condition
Screen No. 15 D-11 P1 I-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
1 • P1 independent travel When D112 is cancelled and other error occurs by exchanging the
proportional valve PSV-M connector for other proportional valve. Check proportional valve for
possible failure. If failure found, replace it. When replacing of connector is
executed, turn off the power source once.
2 • Wiring between P1 travel When D112 is displayed after the connector is exchanged with other
independent proportional valve and proportional valve.
controller
Check wiring for possible failure according to the wiring checking procedure
CN-177F
When replacing of connector is executed, turn off the power source once.
Table 46-62
Error code D113
Trouble P1 independent travel proportional valve’s is disconnected.
condition (If output is 100 mA of less, judging is not done).
Combined operations of travel and attachment at travel independent mode, attachment becomes
Symptom
slow.
Control in the
Normal control.
event of failure
Returned in
normal condition
Service Screen No. 15 D-11 P1 I-TRAVEL
proportional valve PSV-M connector for other proportional valve. Check proportional valve for
possible failure. If failure found, replace it. When replacing of connector is
executed, turn off the power source once.
controller
CN-177F
46-37
Table 46-63
Error code D122
Trouble P2 independent travel proportional valve and output transistor ON are failure.
Judging
condition
Symptom
slow.
Control in the
Normal control.
event of failure
Returned in
normal condition
proportional valve PSV-M connector for other proportional valve.
Check proportional valve for possible failure. If failure found, replace it.
When replacing o connector is executed, turn off the power source once.
2 • Wiring between P1 travel When D112 is displayed after the connector is wxchanged with other
controller
CN-105F and repaor it if necessary.
CN-178F
When replacing o connector is executed, turn off the power source once.
Table 46-64
Error code D123
Trouble P2 independent travel proportional valve’s is disconnected..
condition (If output is 100 mA of less, judging is not done).
Symptom
slow.
Control in the
Normal control.
event of failure
Returned in
normal condition
proportional valve PSV-M connector for other proportional valve.
Check proportional valve for
possible failure. If failure found, replace it.
controller
CN-178F
46-38
Table46-65
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
condition
Service Screen No. 9 E-1 PUMP P1
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after 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
Table46-66
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
46-39
Table46-67
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
condition
Table46-68
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
46-40
Table46-69
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
Table46-70
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost 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 not output.
normal condition
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
46-41
Table46-71
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
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.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
Table46-72
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
normal condition
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
46-42
Table46-73
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
Table46-74
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
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
Service Screen No. 3 F-3 1/2-TRAVEL
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
46-43
Table46-75
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
condition
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
Service Screen No. 11 F-4 OPT SELECT
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
Table46-76
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
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
Service Screen No. 11 F-4 OPT SELECT
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
46-44
Table46-77
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller 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.)
Table46-78
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
46-45
Table46-79
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Control in the
Normal control
event of failure
Returned in
normal condition
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
2
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
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
5 • Engine controller Check that the error is corrected after replacement of controller.
46-46
Table46-80
G043
When cranking is executed for 60 seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed after
starting the engine.
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
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
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
5 • Engine controller Check that the error is corrected after replacement of controller.
46-47
Table46-81
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
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 Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
Table46-82
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
CN-402F
CN-102F
46-48
Table46-83
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-2 BOOM
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
CN-702F
CN-103F
Table46-84
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-2 BOOM
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
CN-702F
CN-103F
46-49
Table46-85
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-3 ARM
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
CN-703F
CN-103F
Table46-86
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-3 ARM
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
CN-703F
CN-103F
46-50
Table46-87
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
CN-152F
CN-104F
Table46-88
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
CN-152F
CN-104F
46-51
Table46-89
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
normal condition
Service Screen No.
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
Table46-90
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
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
Service Screen No. 2 G-5 WATER TEMP
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
CN-3F
CN-101F
46-52
Table46-91
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
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
Service Screen No.
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
CN-600F
CN-101F
Table46-92
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
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 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller 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
46-53
Table46-93
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
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
Service Screen No. 25 PREVENT ARC
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for 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 wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V 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.
46-54
Table46-94
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
Symptom Wiper does not move.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 CW MOTOR RLY
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.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
E-1
46-55
Table46-95
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
Symptom Wiper does not move after forward rotation.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 CCW MOTOR RLY
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.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
E-1
46-56
Table46-96
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 MOTOR RELAY
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V 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
E-1 Replace fuse/relay box.
Table46-97
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 22 D13
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
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 24V 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.
46-57
Table46-98
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
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 24V 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.
Table46-99
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
event of failure
Returned in
normal condition
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
46-58
Table46-100
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition 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
Service Screen No. 4 K-1 AIS RELAY 2
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
46-59
Table46-101
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition 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
Service Screen No. 4 K-3 ENG STOP
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
46-60
Table46-98
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-4 LOCK LEVER
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.
2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
Table46-99
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-2 SAFETY RLY
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
2 • Wiring between safety lock When R214 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
46-61
[MEMO]
46-62
47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS
47.1 HYDRAULIC SYSTEM ....................................................................................................47-3

47.2 ELECTRIC SYSTEMS .....................................................................................................47-27
47.2.1 WIRING CHECKING PROCEDURE ......................................................................47-27
47.2.2 TROUBLE...............................................................................................................47-30
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-33
47
47-1
47. TROUBLESHOOTING (BY TROUBLE)

SK460-8: LS10-02001~ S5LS4711E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
47-2
47.1 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 when swing operation is stopped
(15)Slow travel speed/weak
(16)Travel deviation
(17)Travel 1st/2nd speed not changed
(18)Travel parking on a slope is not held
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20)Slow breaker (crusher) operation, weak power
(21)Option selector valve malfunction: not switched to breaker circuit
(22)Option selector valve malfunction: not switched to nibbler circuit
47-3
(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 on
(10A) the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by tester,
switch diagnosis Push down the lever and it turns on, push or check that the power voltage
up and it turns off. is lowered by pushing the lever
down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for possible
switching solenoid is switched connector. 24V by pushing the lever down, failure.
correctly 0V by pushing it up Check harness for possible
failure.
4 Safety lever lock relay Carry out service No.4 K-4 lock lever: Check action of relay by tester
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 position. Check 5V power for controller
All pilot low pressure sensors are 0MPa to
0.1MPa.
6 Solenoid valve for Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve
safety lock lever solenoid A1 port 4MPa 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 primary Check that it is 4MPa or more in high idling Check gear pump and the relief
pressure at gear valve for possible failure
pump
9 Multi control valve (in Change position Since all are blocked due to poor switching
case that travel is performance, check that the lever select
operable) pattern is set to the proper position.
10 Unload solenoid Carry out service •No.21 D-06 Check controller for possible
proportional valve diagnosis •At normal: OFF failure.
(Travel straight
•At pressure release: ON
proportional valve)
11 Secondary pressure of Measure the •At normal: 0MPa Replace solenoid proportional
unload solenoid secondary pressure of •At pressure release: 4MPa or more valve.
proportional valve unload solenoid
(Travel straight proportional valve
proportional valve) directly (A port)
12 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis. E-2 P2 pump largely differed from the actually
pump proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever & proportional valve and controller
idling for possible failure.
Operation No.19 Travel left full lever &
idling
13 Secondary pressure of Measure the pump Check that pump proportional valve Replace proportional valve
pump proportional proportional valve secondary pressure is 2.7MPa or more in
valve secondary pressure right (left) travel full lever and high idling
directly in idling operation
operation. (Ports a6, Right travel: P2 pump proportional valve
a7) Left travel: P1 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 are Reset or replace
28MPa in boom up full lever, high idling
and H mode operation.
47-4

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/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
2 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly (Ports a6, a7) and high idling operation.
3 Pressure sensor of P1, Check pressure •See Service Diagnosis Data List Check pressure sensor and
P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
resistance against sliding
outside surface
Spring free from breakage, damage,
etc.
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.
(3) Move at lever neutral position

1 Pilot pressure sensor Carry out service Check that targeted pilot pressure of Check remote control valve
diagnosis sensor is 0MPa in high idling
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Main spool Check targeted spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage
4 Over load relief valve Check targeted spool Free from dust entered in port relief Replace
visually valve. Seat is free from abnormality
5 Lock valve poppet Check targeted poppet Seat is free from abnormality Replace
(in case of boom and visually
arm)
6 Lock valve selector Exchange lock valve Check that the trouble is reversed Replace
(in case of boom and selector of boom/arm
arm) and boom/arm
47-5

7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace
boom sliding of spool in sleeve sliding Do not pull spool out of sleeve
(in case of boom) forcibly.
8 Holding valve relief Check targeted spool Filter free from abnormal Replace
valve for boom visually contamination
(in case of boom)
9 Cylinder Check targeted cylinder Make sure of no problem of seals by Replace cylinder or seals
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
0.1MPa
proportional valve diagnosis failure.
•At normal: OFF
(Travel straight
proportional valve) •At pressure release: ON
3 Secondary pressure of Measure the secondary •At normal: 0MPa Replace solenoid proportional
unload solenoid pressure of unload •At pressure release: 4MPa or more valve.
proportional valve solenoid proportional
(Travel straight valve directly (A port).
proportional valve)
Operation No. 1 Operation is nil proportional valve and controller
P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5~1.0MPa in control lever neutral
directly. (Ports a6, a7) and high idling operation
6 Slow return check valve Visual check Check that slow return check valve Clean and replace
of pilot line installed on pilot line is free from dust
(in case of boom up or entered
arm out)
47-6
(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 valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
boom up operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
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 pressure
operation. sensor.
proportional valve diagnosis •At boom: OFF failure.
(Travel straight
proportional valve)
5 Secondary pressure of Measure the secondary •At normal: 0MPa Replace solenoid proportional
proportional valve)
Operation No.4 boom up full lever & in proportional valve and controller
operation for possible failure.
proportional valve secondary pressure 2.1 to 3.0MPa in boom up full lever and
directly (Ports a6, a7) high idling operation
breakage
9 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 high. outside surface
10 Holding valve for boom Visual check When removing, free from abnormal Replace
(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.
11 Boom spool Visual check When removing, free from abnormal Replace
Only P1 pressure is Spring is free from breakage. damage)
high.
12 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is low.
47-7

13 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
14 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 low. relief
15 Over load relief valve Visual check (Head Pressure is 28MPa or more in boom up When only relief pressure of
<Trouble> side) full lever and high idling. Free from boom up is low, replace valve
Relief pressure is low. dust entered in over load relief valve.
Seat is free from abnormality
16 Actual measuring Carry out service No.8 Travel straight In case where the reading is
current value of travel diagnosis. •See Service Diagnosis Data List largely differed from the actually
straight proportional Operation No.4 boom up full lever & in measured value, check
valve. operation proportional valve and controller
17 Secondary pressure of Measure the secondary Check that pressure is 1.1MPa to Replace proportional valve.
travel straight pressure of 8-secton 1.6MPa in boom up full lever and high
proportional valve solenoid block a6 port idling operation.
(Travel straight) directly.
(6) Slow boom down/insufficient power for lifting up body

1 Boom down pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control valve Measure remote control Check that pressure is 3.0MPa or more Check remote control valve
pressure pressure of boom down in boom down full lever and high idling When equipped with multi
directly operation control valve, check it while
changing lever pattern.
proportional valve diagnosis •At boom down: OFF failure.
(Travel straight
proportional valve)
4 Secondary pressure of Measure the secondary •At boom down: 0MPa Replace solenoid proportional
proportional valve)
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
pump proportional valve Operation No.5 boom down full lever measured value, check
& in operation proportional valve and controller
6 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures are within the range of 2.3 to
valve secondary pressure 3.0MPa in boom down full lever and
47-8

7 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
8 Travel straight Measure directly the High idling pressure is 0.8MPa or less Replace proportional valve
proportional valve travel straight regardless neutral/operation
secondary pressure proportional valve
secondary pressure.
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
11 Holding valve (poppet) Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding. (Check on the casing side for
Boom down is slow. Free from abnormal damage, etc on damage)
outside 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 and Disassembly and Free from abnormal resistance against Replace spool assembly
Machine can not be
lifted by supporting with
boom.
15 Over load relief valve Visual check Free from dust entered in port relief Replace
<Trouble> valve.
Machine can not be Seat is free from abnormality
lifted by supporting with
boom.
16 Boom spool for 2nd Visual check When removing, free from abnormal Replace (Check on the casing
speed resistance against sliding side for damage.)
outside surface.
17 Boom back-pressure Disassembly and Free from abnormal resistance against Replace
check valve investigation sliding
18 Shuttle valve Visual check Free from internal contamination. Clean or replace
Free from scratching
19 Swing priority release Disassembly and Free from internal contamination Replace
valve investigation Free from scratching
47-9
(7) Slow arm in, insufficient power

1 Arm in pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.6 arm in full lever and sensor
pressure control pressure of arm in arm in full lever and high idling When equipped with multi
in operation control valve, check it while
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 pressure
operation. sensor
proportional valve diagnosis •At arm in: OFF failure.
(Travel straight
proportional valve)
5 Secondary pressure of Measure the secondary •At arm in: 0MPa Replace solenoid directional
proportional valve)
Operation No.7 Arm in full lever & in proportional valve and controller
P1, P2 pump proportional valve valve pressures are 2.7MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a6, a7) operation. (Secondary pressure is
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 in diagnosis Operation No. 1 Operation is nil largely differed from the actually
spool 2 proportional Operation No.6 Arm in full lever & measured value, check
valve relief proportional valve and controller
Operation No.7 Arm in full lever & in for possible failure.
operation
9 Secondary pressure of Measure directly the Check that secondary pressure of Replace proportional valve
arm in spool 2 proportional valve proportional valve secondary
proportional valve secondary pressure at pressures are within the range of
the ports A8 (arm 2 following
spool) of 8 sections Lever neutral: 0MPa
solenoid block. Motion in the air: 1.9 to 2.4MPa
Arm in relief: 2.5MPa or more
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
idling
47-10

11 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 8 sections
solenoid block
breakage
14 Over load relief valve Visual check (Head Pressure is 28MPa or more in arm in When only relief pressure of arm
<Trouble> side) and relief. in is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality
15 Over load relief valve Visual check (Rod side) Pressure is 28MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
relief valve.
Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
P1, P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
P1, P2 pressure is high Free from abnormal damage, etc on damage)
or low. outside surface
18 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
Arm in power is poor.
19 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
20 Swing priority valve Disassembly and Free from abnormal resistance against Replace
investigation sliding
(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
control pressure of arm in arm out full lever and high idling When equipped with multi
out operation control valve, check it while
47-11

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 pressure
operation. sensor
proportional valve diagnosis •At arm out: OFF failure.
(Travel straight
proportional valve)
5 Secondary pressure of Measure the secondary •At arm in: 0MPa Replace solenoid directional
proportional valve)
Operation No.9 Arm out full lever & in proportional valve and controller
proportional valve secondary pressure 1.9 to 3.1MPa in arm out full lever and
(Secondary pressure is affected by oil
temperature and attachment weight)
8 Actual measuring Carry out service No.8 Travel straight In case where the reading is
current value of travel diagnosis •See Service Diagnosis Data List largely differed from the actually
straight proportional Operation No.9 arm out full lever & in measured value, check
valve operation proportional valve and controller
9 Secondary pressure of Measure directly the Check that pressure is 1.1MPa to Replace proportional valve
travel straight proportional valve 1.6MPa in arm out full lever and high
proportional valve secondary pressure at idling operation.
the ports A6 (travel
straight) of 8 sections
solenoid block
breakage
12 Over load relief valve Visual check (Rod side) Pressure is 28MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
relief valve. Seat is free from
abnormality
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
47-12

outside surface
15 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation (spring sliding
<Trouble> side) Spring is free from breakage.
Both P1, P2 pressures
are low.
16 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
17 Shuttle valve Visual check Free from internal contamination Clean or replace
(9) Bucket digging is slow

1 Bucket digging pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
control pressure of in bucket digging full lever and high When equipped with multi
bucket digging idling operation control valve, check it while
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 pressure
operation. sensor
proportional valve diagnosis •At arm out: OFF failure.
(Travel straight
proportional valve)
5 Secondary pressure of Measure the secondary •At arm out: 0MPa Replace solenoid directional
proportional valve)
Operation No.13 Bucket digging full proportional valve and controller
lever & in operation for possible failure.
7 Secondary pressure of Measure the pump Check that secondary pressures of P1/ Replace proportional valve
P1, P2 pump proportional valve P2 pump proportional valve are within
proportional valve secondary pressure the range of following.
directly (Ports a6, a7) P1/P2 pump proportional valve:
2.8MPa or more
8 Attachment boost Carry out service No.3 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF MEAS Replace solenoid valve
OFF
47-13

9 Attachment boost Measure switching Check that pressure is 0MPa in bucket Replace solenoid valve
solenoid secondary valve secondary digging full lever and high idling
pressure pressure operation
current value of P2 diagnosis Operation No.12 Bucket digging full largely differed from the actually
bypass cut proportional lever & relief measured value, check
valve proportional valve and controller
11 Secondary pressure of Measure directly the Check that P2 bypass cut secondary Replace proportional valve
P2 bypass cut proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at digging full lever and high idling
the ports A5 (P2 bypass operation
cut) of 8 sections
solenoid block
12 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston
13 Check stroke limiter Visual check When piston is removed from cover, it Replace
<Trouble> is free from abnormal resistance (Check on the casing side for
Both P1, P2 pressures against sliding damage.)
are high. Free from abnormal damage, etc on
outside surface
breakage
Operation No.3 Boom up full lever and
relief
16 Travel straight spool Visual check When removing, free from abnormal Replace
outside surface
17 Bucket spool Visual check When removing, free from abnormal Replace
18 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
(10)Bucket dump is slow

1 Bucket dump pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.14 Bucket dump full sensor
control pressure of in bucket dump full lever and high When equipped with multi
bucket dump idling operation control valve, check it while
47-14

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 pressure
operation. sensor
directional valve (Travel diagnosis •At bucket dump: OFF failure.
straight proportional
valve)
5 Secondary pressure of Measure the secondary •At bucket dump: 0MPa Replace solenoid directional
directional valve (Travel solenoid proportional
straight proportional valve directly (A port).
valve)
Carry out service Operation No.15 Bucket dump full proportional valve and controller
diagnosis. lever & in operation for possible failure.
P1, P2 pump proportional valve pressures is 1.6MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is
directly (Ports a3, a4) 1.6MPa or more in bucket dump full
lever and high idling operation.
current value of P2 diagnosis Operation No.14 Bucket dump full largely differed from the actually
bypass cut proportional lever & relief measured value, check
valve proportional valve and controller
9 Secondary pressure of Measure directly the Check that P2 bypass cut secondary Replace proportional valve
P2 bypass cut proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at dump full lever and high idling
the ports A5 (P2 bypass operation.
cut) of 8 sections
solenoid block.
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
piston
11 Check stroke limiter Visual check Free from abnormal damage and wear Replace
<Trouble> on outside of piston inside cover (Check on the casing side for
Pilot pressure is low. damage.)
breakage
<Trouble> Operation No.3 Boom up full lever and
outside surface
47-15

15 Bucket spool Visual check When removing, free from abnormal Replace
visually relief valve.
(11)Swing does not move/slow

1 Swing pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
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 Check harness
ON Swing: COMP OFF MEAS OFF
4 Swing parking brake Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid solenoid valve A2 port In operation: 4MPa or more
5 Shuttle valve Visual check No contamination in the shuttle valve. Clean or replace
<Trouble> No damage on shuttle valve.
Pilot pressure is low.
6 Pump pressure sensor Carry out service •See Service Diagnosis Data List Check high pressure sensor
diagnosis for P2 pump Operation No.11 Swing full lever and
pressures in operation in operation
directional valve (Travel diagnosis •At swing: OFF failure.
straight proportional
valve)
8 Secondary pressure of Measure the secondary •At swing full lever: 0MPa Replace solenoid directional
directional valve (Travel solenoid proportional
straight proportional valve directly (A port).
valve)
current value of P2 diagnosis largely differed from the actually
Operation No.11 Swing full lever & in proportional valve and controller
P2 pump proportional proportional valve pressure is 2.7MPa or more in swing
valve secondary pressure full lever and high idling operation
directly (Ports a6, a7)
47-16

(Check this trouble by Operation No.18 Travel right full lever actually measured value, check
only swing operation) & idling proportional valve and
idling
proportional valve secondary pressure at
(Check this trouble by the ports A6 (travel
only swing operation) straight) of 8 sections
solenoid block
breakage
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
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
17 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
outside surface (brake plate etc)
18 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
20 Shuttle valve Visual check Free from internal contamination Clean or replace
(12)Noise occurred at swing operation

solenoid diagnosis Lever neutral: COMP. ON MEAS. ON Check harness
Swing: COMP OFF MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
47-17

3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
4 By-pass check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from abnormal Replace
7 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally worn Replace
and chipped.
(13)Swing drifts on a slope while swing control lever is in neutral position

1 Swing pressure sensor Carry out service •Engine stop & starter key ON Check and replace pressure
diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1MPa.
breakage
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: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake plate/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 is inside of shuttle Clean or replace
<Trouble> valve. No abnormality like damage is
Pilot pressure is low there.
2 Swing pressure sensor Carry out service •Engine stop & starter key ON Replace pressure sensor
diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
3 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
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.
47-18

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
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
proportional valve diagnosis •At travel: OFF failure.
(Travel straight
proportional valve)
4 Secondary pressure of Measure the secondary •At forward (reverse): 0MPa Replace solenoid directional
proportional valve)
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
idling
6 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a6, a7) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
7 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
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, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure
proportional valve secondary pressure
47-19

breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
outside surface
11 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
12 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motor’s
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motor’s
locked crawler belt) and high idling relief valve is failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
14 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
(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
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
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, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure.
47-20

proportional valve secondary pressure
proportional valve diagnosis •At travel: OFF failure.
(Travel straight
proportional valve)
6 Secondary pressure of Measure the secondary •At forward (reverse): 0MPa Replace solenoid directional
proportional valve)
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
idling
8 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a6, a7) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2 Exchange delivery pipe Check the direction of deviation If the direction is changed,
of P1 for P2 inspect a pump. If the direction
is not changed, inspect a valve
and travel unit.
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 targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
13 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motor’s
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motor’s
locked crawler belt) and high idling relief valve is failed.
Replace as necessary
47-21

14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
outside surface
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
outside surface
etc.
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.
(17)Travel 1/2 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: 0MPa Replace solenoid valve
switching solenoid pressure on solenoid In operation: 4MPa or more
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 travel Visual check Free from abnormal wear on piston Replace
motor and seal (Check on the casing side for
damage)
(18)Machine does not stay on a slope in traveling

1 Pilot pressure sensor Carry out service •Engine stop & starter key switch is ON Check pressure sensor and
diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1MPa Check remote control valve
breakage
47-22

3 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
etc.
4 Orifice of passage for Visual check Free from entry of dust Remove dust or replace
parking brake in travel
motor
(19)Machine does not travel straight in simultaneous operation of traveling and attachment

1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be •Check voltage of low pressure
current value of travel diagnosis COMP 565mA and MEAS 535 to sensor other than travel sensor
straight proportional 595mA in both travel full lever and in •In case where the reading is
valve boom up full lever at high idling largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.
2 Secondary pressure of Measure directly the Check secondary pressure is within Replace proportional valve
travel straight proportional valve range of 1.6 to 2.1MPa in both travel
proportional valve secondary pressure full lever and in boom up full lever at
high 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 side bypass valve and pump)

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 senso
control pressure of in optional attachment full lever and
travel right and left high idling operation
3 Unload solenoid Carry out service •In optional operation: OFF Check controller for possible
proportional valve diagnosis •At pressure release: ON failure.
(Travel straight
proportional valve)
4 Secondary pressure of Measure the secondary •In optional operation full lever: 0MPa Replace solenoid directional
proportional valve)
5 Actual measuring Carry out service •See Service Diagnosis Data List •Check voltage of low pressure
current value of travel diagnosis Operation No.16 P2 side OPT full sensor other than sensor for
straight proportional lever & relief optional attachment
valve Check that the current value does not •In case where the reading is
(Check by optional change, regardless of operations. largely differed from the
operation only) actually measured value, check
proportional valve and
controller for possible failure.
47-23

6 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 0.8MPa or less, regardless
proportional valve secondary pressure at of neutral lever position or operation.
(Check by optional the ports A6 (travel
operation only) straight) of 8 sections
solenoid block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
piston (Check it through PBp2 port.)
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
24.5MPa.)
9 Remote control valve Check targeted remote Check sealing ability of shuttle valve Replace
control valve and entry of dust in orifice.
outside surface
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
P1, P2 pressures are outside surface
high. Spring is free from breakage.
visually relief valve
(21)Selector valve for option malfunctions: Breaker circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 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 solenoid Screw for emergency Check that the error indication is Replace solenoid valve
disappeared by turning emergency
screw
3 N&B selector solenoid Carry out service •No.11 F-4 Option selector is B mode Check solenoid valve
diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector pressure Carry out service •No.16 B-11 Check pressure sensor
sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa at A
mode
47-24
(22)Selector valve for option malfunctions: Nibbler circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 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 solenoid Carry out service •No.11 F-4 Option selector is A mode Check solenoid valve
diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB
47-25
Table47-1 Action of optional selector solenoid valve

Optional Selector
Safety lock Safety lock selector valve
Engine Work Spool Failure diagnosis
No. lever SW's lever relay's valve detecting Warning display
condition mode position display
input output COMP. pressure
MEAS. sensor
1 Running ON OFF A OFF Nibbler Normal — —
2 "SELECTOR VALVE [F042] displayed
Running ON OFF A ON Breaker Normal
FAILURE" simultaneously
3 "SELECTOR VALVE
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 — —
6 "SELECTOR VALVE [F043] displayed
Running ON OFF B OFF Nibbler Normal
FAILURE" simultaneously
7 "SELECTOR VALVE
Running ON OFF B ON N&B Normal —
FAILURE"
8 Running ON OFF B OFF Breaker Normal — [F043] displayed
9 "SELECTOR VALVE
Running ON OFF — — — Failure [B113] displayed
FAILURE"
10 Stopping — — — — — — — —
11 — OFF — — — — — — —
12 — — ON — — — — — —
47-26
47.2 ELECTRIC SYSTEMS

47.2.1 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.
WIRE
(1) Checking for disconnection between connectors.
(When both ends measurement is easy because of
TESTER
short distance between connectors,)
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,)
Measure the resistance using tester. JUMPER
Pull out opposite connector first. WIRE
Where the resistance is zero (0), if the terminal on

one side is connected to frame body grounding with TESTER
jumper wire, it is in normal condition. FRAME BODY GROUNDING
The resistance is 1M or more when the 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 1M or more, it is in normal
condition. TESTER
FRAME BODY GROUNDING
(3) Checking for presence or absence of short-circuit

between wirings.
When the resistance is 1M or more, it is in normal
condition. TESTER
47-27
(4) Checking connector terminal for contact

Insert male terminal into female terminal unit, and INSERT
then check that the inserting force is equivalent to
other female terminals. MALE TERMINAL FEMALE TERMINAL
If looseness is there, replace the female terminal
with new one.
Clean the dirt terminal.
Do not insert the male terminal the thickness differs. It

may cause loose connection.
(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
PART
a. Check the terminal crimped condition.
Pull one electric cable with the about 3kg force,
RUBBER
and make sure that the cable does not come out PLUG
RECEPTACLE.
of the terminal. CONTACT
When came out, replace the terminal and crimp PLUG

SEALING
it again. (is housed in plug)
b. Check connector for imperfect insertion DOUBLE LOCK

PLATE FOR PLUG
Check that all top ends form a line on the same DOUBLE LOCK
position as seen from the connector engaged
PLATE FOR CAP
side. CAP
When moved along, push it in further through TAB.CONTACT

wire inserting hole. RUBBER PLUG
c. Check connector for intruding of water.

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.
47-28
(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.
47-29
47.2.2 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.
47-30
(1) Engine does not stop.

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

1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro controller and
accel potentiometer operation. replace as necessary
(Use remote control because the auto
accel function is working.)
3 Wiring Transmission circuit line See "WIRING CHECKING Repair wiring
No.770 from mechatro PROCEDURE"
controller to gauge
cluster
4 Gauge cluster Gauge cluster Replace gauge cluster
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).

1 Engine coolant Check engine coolant No.2 G-5 WATER TEMP Replace engine coolant sensor
temperature temperature by carrying Auto accel does not work in the
out service diagnosis. temperature -15°C or less.
Warm up and raise the coolant
temperature to – 15°C or more
2 Gauge cluster Indication of auto accel Mark "Display/not display" for auto Replace gauge cluster
accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is in the range of 0~0.1MPa at
control lever neutral position.
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)

1 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.
47-31
(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

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.19 D125 Check wiper interlock switch
Wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE" and
repair it if necessary
3 Rise up limit switch built- Service diagnosis No.25 Wiper system Check according to "WIRING
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 relay Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
R-30: Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.
47-32
47.3 ENGINE RELATED TROUBLESHOOTING
Checking
Filters Liquid Leak, clogging
Air leak between turbocharger and intake manifold

Factors
Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn
Poor or deteriorated battery

Shortage of fuel level
Improper fuel in use

Air cleaner clogged
Fuel filter clogged
Oil level of oil pan

Oil filter clogged
Muffler clogged
Engine oil leak
Coolant level
Trouble
Poor start ability (Take a long time)

Faulty starting
Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)
Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient
Engine poor run-up (Low follow-up ability)

rotation
Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures
Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration
47-33
Checking Electric equipment

Shovel side Shovel side Engine side
Loose mounting bolts, damage of mounting rubber

Factors
Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator
Loose connection of battery cable terminal

Failure of radiator pressure cap
Failure of hydraulic system

Startup circuit wiring
Starter switch key
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-34
Intake and Lubrication Cooling

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

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged
Leak and crush of hydraulic piping
Failure of thermostat (Not open)

Fuel leak into the head cover
Improper fuel injection time
Failure of regulator valve
Damage of water pump

Damage of EGR cooler
Failure of supply pump
Failure of relief valve

Failure of oil pump
Failure of injector
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-35
Engine body
Factors
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



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-36
51. ENGINE
PREFACE
This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of HINO MOTOR.
51
51-1
51. ENGINE

SK460-8: LS10-02001~ S5LS5111E01
SK480LC–8 : YS10-01501~ (ASIA, OCE)
51-2
GENERAL 1–1
ENGINE
1
1 GENERAL
General information
Outline
Warning................................................................... 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-7
Tightening of engine bolts and nuts ...................... 1-11
Tightening of chassis bolts and nuts..................... 1-13
Tightening of flare nuts and hoses........................ 1-15
Taper thread sealant for piping ............................. 1-16
Assembly of joints and gaskets for piping ............. 1-17
Handling of liquid gasket....................................... 1-19
Failure diagnosis table for each problem .............. 1-20
Failure diagnosis procedures................................ 1-21
Failure diagnosis using HinoDX............................ 1-23
Connection method of HinoDX ............................. 1-26
Chassis number and engine number ................... 1-26
1–2 GENERAL
Warning
JP30001010102001
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical experts. Those who are not
qualified, who are not appropriately trained, who perform service without appropriate tools or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows "Warning" and "Caution" for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with "Warning" or
"Caution" are not absolute for safety.
GENERAL 1–3
How to read this manual

JP30001010102002
1. Scope of repair work

(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly⋅ disassembly and inspection⋅ adjustment" and "Final inspection".
(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement, assembly⋅ disassembly
and inspection⋅ adjustment" in the second process. Explanation of "Final inspection" in the third process is omitted here.
(3) Although the following work is not described in this manual, it should be performed in actual work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual inspection
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually equipped
in general service shop are omitted.
4. How to read sections and titles

(1) Sections are classified according to J2008, SAE standard.
(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(4) Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.)
! CAUTION The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in February, 2007. (Some areas do not show exploded view.
They will be additionally issued when the parts catalog CD is revised.) Be sure to use the
parts catalog for confirmation of illustrations and part numbers and for ordering parts.
5. How to read troubleshooting

(1) Failure diagnosis in this manual describes Step 2 and Step 3 below:
Hear from customers for conditions and environments of

(1) Question "Step 1"
failures and check the fact.
Perform diagnosis inspection, status inspection, function

(2) Pre-inspection inspection and basic inspection. Check the failure status.
"Step 2"
(3) Reproduction method If it is difficult to reproduce the problem with status
inspection, use the reproduction method.
(4) Troubleshooting for each Summarize inspection results obtained from Step 2.
diagnosis code Perform inspection systematically according to
"Step 3"
(5) Troubleshooting for each troubleshooting procedures for each diagnosis code or
failure status failure status.
Check if failure occurs again after repair. If it is difficult to

(6) Confirmation test "Step 4" reproduce a failure, perform the confirmation test under
the conditions and environment of the failure.
1–4 GENERAL
(2) Pre-inspection
• Pre-inspection is performed in the following steps:

Diagnosis inspection →Diagnosis deletion →Failure status check (Use the reproduction
method if not reproduced.) →Diagnosis reconfirmation
• Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
Pre- estimated cause of a failure.
inspection • An error code is displayed if a failure occurs instantaneously. If any specific failure is not
found, perform troubleshooting using the reproduction method.
• Failure status check
If failure is reproduced,perform Step 2 →Step 3 →Step 4.
If failure is not reproduced,use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)
GENERAL 1–5
6. How to read explanation details

(1) Part layout
Example
ENGINE MECHANICAL [J08E] 9–17
Timing Gear Cover and Flywheel Housing

Part layout
JP04117090402003
Part name code
Part catalog Fig. No.
SAPH041170900182
11308 Flywheel housing 11390 End plate

Description of
11309 Oil seal retainer 9828A Front oil seal* part name code
11357 Gasket* 9828B Rear oil seal*
11357A Gasket*
*Parts not to be reused.

Left: Part name code (nut)
Tightening torque
9069H M14 : 171.5 N.m{1, 750 kgf.cm, 126 lbf.ft} 9419A M16 : 196 N.m{2, 000 kgf. cm, 145 lbf.ft}
9069J M12 : 97 N.m{990 kgf.cm, 71 lbf.ft} 9419B M16 : 196 N.m{2, 000 kgf. cm, 145 lbf.ft}
Service procedure
Overhaul item
SAPH300010100001
✩ It is the ID number for parts to prepare electronic data. It is not required for repair work.
1–6 GENERAL
7. Definition of terms
Terms in this manual are defined as follows:
(1) Direction
a. Individual unit
Front/back direction
The power input side is front and the output side is back.
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
Vertical direction
With the unit installed on the upper frame, the upward direction shall be the upper side and the
downward direction the lower side.
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
(2) Standard value ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ Basic dimension excluding tolerance and clearance generated by tolerances
when two parts are joined
(3) Repair limit⋅ ⋅ ⋅ It is the value requiring repair. Symbol of + or - with the value means increase or decrease
to the standard value.
(4) Operation limit⋅ ⋅ ⋅ It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
(5) Warning⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ It is an item that may result in risk of human life or serious injury by incorrect
handling.
(6) Caution⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ It is an item that should not be performed including inhibited work or an item that
require attention in working procedures.
(7) Reference⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ ⋅ It is supplementary explanation in work.
8. Unit
(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
Conventional Conversion value*1(1[Conventional unit] = X

SI unit
unit [SI unit])
Force N kgf 1kgf=9.80665N
Torque*2 N⋅ m kgf⋅ cm 1kgf⋅ cm=0.0980665N⋅ m
kgf/cm2 1kgf/cm2=98.0665kPa=0.0980665MPa
Pressure Pa
mmHg 1mmHg=0.133322kPa
r/min 1rpm=1r/min
Rotational speed rpm
min-1 1rpm=1min-1
Spring constant N/mm kgf/mm 1kgf/mm=980665N/mm
Volume L cc 1cc=1mL
Efficiency W PS 1PS=0.735499kW
Calorific value W⋅ h cal 1kcal=1.13279W⋅ h
Fuel consumption rate g/W⋅ h g/PS⋅ h 1g/PS⋅ h=1.3596g/kW⋅ h
*1
:X means the value when 1 [Conventional unit] is converted to the SI unit. It is used as the
conversion factor from the conventional unit to the SI unit.
GENERAL 1–7
*2:The conversion value of the torque may vary depending on the unit. Observe the standard
values described for each unit.
Safety information
Precautions for work

JP30001010101001
1. General precautions
To ensure safety in work and to prevent accidents, observe the following items:
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V-belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.
f. Since the battery fluid is poisonous and corrosive sulfuric acid, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may
occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
2. Precautions for service work

Pay attention to the following points before service work
(1) Preparation before disassembly
a. Prepare general tools, special tools and gauges before work.
b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
battery before work.
c. Perform inspection according to the procedure in the text before disassembly.
(2) Inspection during disassembly
Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
(3) Arrangement of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
(4) Washing of disassembled parts
Clean and wash parts to be reused well.
(5) Inspection and measurement
Inspect and measure parts to be reused as required.
(6) Assembly
a. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct parts
in the correct order.
b. Be sure to use genuine parts for parts to be replaced.
c. Use new packings, gaskets, O-rings and cotter pins.
d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly.
(7) Check of adjustment
1–8 GENERAL
Make adjustments to the service standard values using a gauge or tester.
3. Precautions for electric system

(1) Removal of battery cable
a. In an electric system, remove the cable from the battery

minus (-) terminal to prevent burnout due to short-
circuit.
b. When the battery cable is removed, the battery terminal
Loosen
may be damaged. Loosen the nut completely and never
pry it for removal.
SAPH300010100002
(2) Handling of electronic parts
a. Do not give impact on electronic parts such as

computer and relay.
b. Do not place electronic parts at a high temperature and
humidity area.
c. Do not expose electronic parts to water in washing of a
vehicle.
SAPH300010100003
(3) Handling of wire harness
a. Mark clamps and clips to prevent interference of a wire

harness with body edge, sharp edge and bolts. Be sure
to reassemble it to the original position.
b. When parts are assembled, be careful not to pinch a
wire harness.
SAPH300010100004
GENERAL 1–9
(4) Handling of connector
a. When a connector is removed, hold the connector (as

shown by the arrow in the left figure) and pull it out. Do
not pull the wire harness.
b. Unlock the locking connector before pulling.
c. Insert the locking connector completely until it clicks.
d. To insert a test lead into the connector, insert it from the
back of the connector.
e. If it is difficult to insert a test lead from the back of the
connector, prepare a harness for inspection.
SAPH300010100005
1–10 GENERAL
4. Precautions for electric welding

Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
welding.
(1) Turn "OFF" the starter switch.
(2) Make sure that switches are "OFF".
(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(4) Disconnect connectors of each computer.
(5) Remove all fuses. (For locations of fuses, refer to "manual".)
(6) Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint of the frame for connection of grounding from the frame.
(7) Other precautions
a. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they may
not be exposed to spatter.
b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
maintain welding quality.
(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color.
(9) After reassembly, check the function if it operates correctly.
General information
GENERAL 1–11
Tightening of engine bolts and nuts

JP30001010102003
1. Tightening torque of general standard bolts

(1) For bolts with seatings
Unit:N⋅ m{kgf⋅ cm}
Screw diameter x Pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5{290} 36{370}
M10 x 1.25 (Fine thread) 60{610} 74.5{760}
M10 x 1.5 (Coarse thread) 55{560} 68.5{700}
M12 x 1.25 (Fine thread) 108{1,100} 136{1,390}
M12 x 1.75 (Coarse thread) 97{990} 125{1,280}
M14 x 1.5 (Fine thread) 171.5{1,750} 216{2,210}
M14 x 2 (Coarse thread) 154{1,570} 199{2,030}
Remark Bolt with number "7"on the head Bolt with number "9"on the head
! CAUTION • 8T bolt is in accordance with 7T bolt.
(2) For bolts with washers

Screw diameter x Pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6{60} 10{100} 13{130}
M8 x 1.25 (Coarse
14{140} 25{250} 31{320}
thread)
M10 x 1.25 (Fine thread) 29{300} 51{520} 64{650}
M10 x 1.5 (Coarse

26{270} 47{480} 59{600}
thread)
M12 x 1.25 (Fine thread) 54{550} 93{950} 118{1,200}
M12 x 1.75 (Coarse

49{500} 83{850} 108{1,100}
thread)
M14 x 1.5 (Fine thread) 83{850} 147{1,500} 186{1,900}
M14 x 2 (Coarse thread) 74{750} 132{1,350} 172{1,750}
Bolt with number "4" on

Bolt with number "7" on
the head Bolt with number "9" on
Remark the head Stud with C
Projection bolt Stud with the head
surface at free end
R surface at free end
! CAUTION • 8T bolt is in accordance with 7T bolt.
R surface (4T) C surface (7T)
SAPH300010100006
1–12 GENERAL
2. Precoated bolt
Precoated bolt is the bolt with application of seal lock
agent at the thread.
(1) When re-application of lock agent is required

a. When precoated bolts are removed
b. When precoated bolts are moved due to tightening
Seal lock agent check (for loosening or tightening)
NOTICE • Check torque with the lower limit of the

SAPH300010100007 tightening torque allowable value. If
movement is found, tighten the bolt according
to the procedure below.
(2) Re-use method of precoated bolt lock

a. Clean bolt and screw holes. (Clean screw holes for
replacement.)
b. Dry completely by blowing air.
c. Apply the specified seal lock agent to the thread of the
bolt.
3. Plastic region tightening method (angle method)

One turn by 90°
(1) Precautions
Some engines are tightened with the plastic region
Tighten it 90°
tightening method.
Since it is different from the conventional method, tighten
it according to the instruction in the text.
SAPH300010100008
(2) Parts tightened

One turn by 90° Tighten it 45°
One turn by 45° (Second time) Cylinder head bolt, crankshaft main bearing cap bolt,
connecting rod bearing cap bolt, etc.
Tighten it 90°
(First time)
! CAUTION • Measure the overall length of the bolt before
assembly and replace the bolt if the length
exceeds the operation limit.
Apply engine oil to bolt seating and bolt
thread in assembly.
SAPH300010100009
(3) Tightening method after tightening to seating torque

Two turns by 90° Tighten it 90°
(Second time) Tightening of 90° , 135° (90° once and 45° once) and
Tighten it 90° 180° (90° twice) is available.
(First time)
SAPH300010100010
GENERAL 1–13
Tightening of chassis bolts and nuts

JP30001010102004
1. Tightening torque of general standard bolts and nuts

(1) Selection method of tightening torque
a. Find the applicable strength zone from the table below and select the bolt tightening torque from the
table described later.
b. Select the nut tightening torque from the mating bolt as described above.
(2) Identification method of bolt strength zone
a. Identification method with product
Hexagonal bolt
Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression and
upset on the head with the symbol in the table.
Strength zone 6T 7T 8T 9T 10T 11T 12T
Identification symbol for part 6 7 8 q*1 10 11 12
(*1): 9 may be misread with 6. It is expressed in q.
Depression Relief Base depression Upset
SAPH300010100011
Hexagonal nut
Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below:
Formula
(3) Types of general standard bolts and nuts
Standard seating Seating A with flange Seating B with flange

1–14 GENERAL
(4) Standard tightening torque table of general standard bolts and nuts
(Representative standard seating is described.)
Strength
zone
Bolt 4T 7T 9T
diameter
(mm)
4.5±1.8{50±20}
(Cab)
M6 9.0±1.8{90±20} 11.5±2.0{117±23}
5.5±1.1{60±10}
(Chassis)
14.0±3.5{140±40}
(Cab)
M8 22.0±4.0{220±40} *2 29.0±5.5{300±60} *2
17.0±3.0{170±30}
(Chassis)
43.0±8.5{440±90} *2 57.0±11.0{580±110} *2
(Cab) (Cab)
M10 27.0±5.0{276±55}
51.5±10.0{530±100} 68.5±13.5{700±140}
(Chassis) (Chassis)
76.0±15.0{776±150} *2 100.0±20.0{1,020±200} *2
(Cab) (Cab)
M12 48.0±9.5{490±98}
91.0±18.0{930±180} 120.0±24.0{1,220±240}
(Chassis) (Chassis)
M14 77.0±15.0{786±157} 120.0±24.0{1,220±240} 160.0±32.0{1,630±326}
M16 120.0±24.0{1,220±244} 190.0±38.0{1,940±390} 250.0±50.0{2,550±510}
M18 165.0±33.0{1,680±336} 260.0±52.0{2,650±530} 345.0±69.0{3,520±704}
M20 235.0±47.0{2,400±480} 370.0±74.0{3,770±750} 490.0±98.0{5,000±1,000}
M22 320.0±64.0{3,270±654} 505.0±100.0{5,150±1,030} 670.0±130.0{6,840±1,370}
M24 405.0±81.0{4,130±826} 640.0±125.0{6,530±1,310} 845.0±165.0{8,620±1,720}
! CAUTION • Use the tightening torque value for seating A with flange except for *2 in the table larger by
10% than the tightening torque value in the table.
• Use the tightening torque value for seating B with flange of *2 in the table larger by 20%
than the tightening torque value in the table.
The tightening torque value of M8 for seating B with flange remains unchanged.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in
pairs. Use the standard seating for the tightening torque value.
GENERAL 1–15
Tightening of flare nuts and hoses

JP30001010102005
1. Tightening torque of pipe flare nut

Pipe outer
diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15
Material
Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80}
2. Tightening torque of hoses

Hose outer diameter

Hose outer diameter Hose outer diameter
φ13,φ20,φ22, fitting at
φ10.5 fitting PF3/8 fitting
packing
21.5±1.5{215±15}
Air hose Only meter gauge 41.5±2.5{425±25} —
10{100}
3. Lock nut tightening torque of brass joint

Screw nominal
M12 M16 M20 M27
size
Tightening
15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}
torque
1–16 GENERAL
Taper thread sealant for piping

JP30001010102006
The taper thread of the air pipe joint has application of sealant
[Loctite #575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.
1. For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
(1) The sealant (#Loctite 575) has strong sealing feature. The
Frame Air pipe (Flare joint) return torque of the taper joint is increased about 1.5
(No application of sealant)
times the initial tightening torque. When the joint is
Since sealant is disconnected, use a long wrench for disconnection.
applied to this area,
remove accessories
(2) When a joint at a poorly accessible area is replaced,
with the joint remove accessories first and disconnect the joint.
attached and remove
Air hose
SAPH300010100016
2. For connection
1/4 turn Amount of application: 0.1 g/piece

(1) For application of sealant (#Loctite 575), wipe the sealing
area completely with a rag or thinner. Apply sealant
directly to about three ridges for quarter round with offset
3 threads
1 thread
of one ridge from the end. Tighten it according to the
tightening torque in the table below.
Remove dirt completely from the mating part (female)
before tightening.
SAPH300010100017 ! CAUTION • If your eye or skin comes in contact with

sealant, wash it off immediately with water.
Tightening torque of taper joint Unit:N⋅ m{kgf⋅ cm}
Screw
diameter 1/4 3/8 1/2
Material
49±10{500±
Steel 64±15{650±150}
100}
Aluminum,
25±5{250±50} 34±5{350±50} 44±5{450±50}
brass
(2) When a sealing tape is replaced with sealant, remove the

tape completely first as in (1).
! CAUTION • Be careful to prevent entry of dirt or foreign

matter in the pipe.
(3) If air leak is found after assembly with application of

sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and
(2).
GENERAL 1–17
Assembly of joints and gaskets for piping

JP30001010102007
1. Tightening torque of joints

Metal sealing method

Sealing method
Gasket sealing method (Flare pipe type, nipple connector type)
Tightening screw (Aluminum + Rubber or Copper)

Type A Type B
size
M8 13{130}
M10 20{200} 11{110}
M12 25{250} 20{200}
M14 25{250} 31{320}
M16 29{300} 39{400}
M18 39{400} 59{600}
M20 *39{400} 64{650} 20{200}
M24 69{700}
M28 *127{1300}
2. Joint assembly procedure and subsequent inspection

(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
gasket, etc.).
(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
pipes finally after temporary tightening to prevent leak.
(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(4) Observe the values above for each tightening torque.
*When assembled soft washer #4840FR-N (aluminum and rubber carbon pressure bonding) is loosened or
removed, be sure to replace it with a new part. This is not necessary for normal retightening.
1–18 GENERAL
3. Examples of joint methods in various pipes
Metal sealing method

Gasket sealing method Type A Type B
(Flare pipe type) (Nipple connector type)
Joint bolt
Flare pipe Sealing surface: 3 places
Gasket Connector
Flare nut Nut
Connector nipple
Joint bolt
Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint Gasket
with sleeve Gasket Sealing surface
Sealing surface: 5 places
Gasket : 5 places
Joint bolt Nut

Lock washer Bracket
Nut
Sealing surface
: 8 places Connector nipple
Sealing surface: 1 place

Sealing surface: 1 place
Flare connector
Nut Lock washer

Box nut
3-way joint
Sealing surface
: 8 places
Joint pipe
Bracket
Sealing surface
: 3 places
One piece eye joint without sleeve
Joint bolt
Joint bolt
Joint pipe

GENERAL 1–19
Handling of liquid gasket

JP30001010102008
1. Application of liquid gasket and part assembly procedure

(1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
deposit of oil, moisture, dirt, etc.
Be sure to overlap parts at the beginning and at the end of application.
(2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
liquid gasket again if offset occurs.
(3) Assemble parts within 20 minutes after application of the liquid gasket.
If 20 minutes has passed, remove the liquid gasket and apply it again.
(4) Start the engine at least 15 minutes or more after assembly of parts.
2. Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.
3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in
a cartridge, use the application gun.
Winding tool
Application gun
Tube: 150 g
Cartridge type: 300 g
For a tube, desired application width may be obtained from the cut position at the nozzle end.
1:Approx. 2 mm at the 1st section cut

2:Approx. 5 mm at the 2nd section cut
Nozzle of tube
General information
Description of function
1–20 GENERAL
Failure diagnosis table for each problem

JP30001010301001
The cause and action for each item are described.

Engine mechanical
JP03Z01020601001
Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (compression Non-synchronous injection timing Adjust injection timing.
pressure) Faulty fuel injection pressure Adjust injection pressure
Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of vavle guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
SAPH300010100031
GENERAL 1–21
Failure diagnosis procedures

JP30001010301002
1. Display of failure code

(1) If the system has an error, the failure code is displayed on the multiple display of gauge cluster.
SAPH300010100032
2. Deletion method of past failure

(1) To delete past failures of the engine ECU, use HinoDX on
the PC. (Refer to "HinoDX manual".)
SAPH300010100033
3. Deletion of cluster gauge past failure

(1) Turn "ON" the starter switch.
(2) When the buzzer stop switch is pressed consecutively 5

times in 10 seconds, the failure history mode is displayed.
(3) Press work mode selecting switch and the buzzer stop
switch at the same time for 10 seconds or more.
(4) When the display shows "No error", deletion is completed.
SAPH300010100034
1–22 GENERAL
4. How to read troubleshooting for each diagnosis monitor code

(1) "Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives
output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be
started from the code list.
ENGINE DIAGNOSIS CODE [Engine Common] 3–15
Failure of main speed sensor (DTC code P0335/diagnosis monitor code 13)
JP03Z01030601004
1 Measurement of resistance between terminals
1. Set the starter key to "LOCK" and connect the signal check
B6 B B7 harness.
2. Remove the ECU side connector of the signal check harness

and meausre the resistance between terminal B6 and terminal
B7. Details of work
Standard value : Approx. 125.5 17 (20 dC)
NG [3] Go to measurement of resistance between sensor terminals.

SAPH03Z010300010
OK
2 Check of diagnosis code
1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, output the diagnosis code again.
Standard : Normal
NG Contact failure of ECU connector, ECU failure,

short-circuit of harness
SAPH03Z010300011
OK
Normal
1. Remove the connector of the main engine speed sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.
Standard value : Approx. 125.5 17 (20 dC)
NG Failure of main engine speed sensor
Indicates replacement of the main

SAPH03Z010300012
engine revolution sensor.
OK
Check the harness of the relevant circuit and repair the faulty area.
Harness disconnection or connector failure
SAPH300010100035
GENERAL 1–23
Failure diagnosis using HinoDX

JP30001010301003
! CAUTION HinoDX is used for inspection and adjustment

of the system in addition to failure diagnosis.
1. HinoDX
(1) With HinoDX, failure of the common rail fuel injection

system can be diagnosed. The interface box (Hino-Bowie)
and the special cable are required for connection to the
unit.
Hino-Bowie
SAPH300010100036
Cable between unit and Hino-Bowie
CD-ROM HinoDX (380140047)
! CAUTION • Install the software of the Hino Diagnostic

eXplorer (Hino DX) in the PC. For the
installation method, refer to the instruction
manual accompanying the CD.
2. List of failure diagnosis tools
Part name Part No. External shape General description and function
PC • Operating system (OS): Windows 95,

(DOS/V standard) Windows 98 (IE5.0 or later), Windows
2000 (SP3, IE5.0 or later), Windows XP
(SP1a, IE6.0 or later)
—
• CPU and memory: Conditions that
assure operation of the above operating
system
• Display: 800 x 600, 256 colors or more
Hino-Bowie • PC interface
(Interface box) Cable between unit • The cable for connection between PC
and Hino-Bowie and Hino-Bowie is enclosed with Hino-
Bowie.
Signal check 380100045 Interrupting installation between unit

harness (for common rail fuel harness and ECU allows inspection with a
injection system) tester rod while the power is supplied.
1–24 GENERAL
3. Connection of signal check harness
(1) To prevent damage to the ECU connector and to improve

accessibility, connect the signal check harness and put a
testing rod on the signal check connector of the signal
check harness for measurement.
a. Disconnect the connector from the ECU.
Unit harness ! CAUTION • Do not break the locking tab of the connector.
Signal check harness
b. Connect the signal check harness to the machine
harness and the ECU.
Test lead
(for common rail fuel injection system)
Part No.
09049-1080
Signal check connector
SAPH300010100040
GENERAL 1–25
(2) Terminal No.

For the signal check harness connector, the ECU terminal number in the text is treated as follows:
ECU unit
Signal check
harness
ECU side Unit side
SAPH300010100041
1–26 GENERAL
Connection method of HinoDX

JP30001010301004
1. Removal of the maintenance cover

(1) Remove the maintenance cover (A) on the rear cover
Maintenance Cover (A)
behind the operator seat by pushing down the tab at the
top (at one location).
NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.
SAPH300010100042
2. Connection of HinoDX
Engine ECU (1) Connect the engine failure diagnosis connector to the PC
which installed HinoDX through the interface box.
Special tool : Hino-Bowie (Interface box)

Connecting cable
Engine failure
diagnosis CD-ROM HinoDX (380140047)
connector
(2) Set the starter key to "ON" and start HinoDX.
SAPH300010100043
Failure diagnosis connector
Hino-Bowie
Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH300010100044
Setup layout
Layout
Chassis number and engine number

JP30001010401001
1. Engine type and engine number

Engine type and engine number are
stamped on the left side

of the cylinder block.
When ordering parts, report this number for smooth
processing.
Stamp position Example: P11C TB10001
SAPH300010100045
STANDARD VALUE 2–1
ENGINE
2 STANDARD VALUE 2
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Engine Body................................................................ 2-2

Standard value........................................................ 2-2
Fuel System ................................................................ 2-2
Tightening torque.................................................... 2-2
Emission control ........................................................ 2-2
Electrical...................................................................... 2-3
Standard value........................................................ 2-3
Intake ........................................................................... 2-3
Engine Mechanical ..................................................... 2-4
Standard value........................................................ 2-4
Tightening torque.................................................. 2-12
Exhaust...................................................................... 2-13
Cooling ...................................................................... 2-13
Standard value...................................................... 2-13
Lubrication ................................................................ 2-14
Standard value...................................................... 2-14
Starting and Charging.............................................. 2-16
Standard value (alternator 60A)............................ 2-16
Tightening torque (alternator 60A)........................ 2-16
Standard value (starter) ........................................ 2-17
Tightening torque (starter) .................................... 2-18
Turbocharger............................................................. 2-18
Standard value...................................................... 2-18
2–2 STANDARD VALUE
Engine Body
Standard value
JP30109020205001
Unit: MPa {kgf/cm2, lbf/in.2}
Operation
Inspection item Standard value Repair limit Action
limit
Compression pressure
2.9{30, 720} — 2.5{26, 362} Overhaul
(Engine revolution per cylinder: 200 r/min)
Fuel System
Tightening torque
JP30109020205002
Unit:N⋅ m{kgf⋅ cm,lbf⋅ ft}
Tightening area Tightening torque Remark
Injector clamp mounting bolt 26{270, 19}
Injector union bolt 20{200, 15}
Leakage pipe - cylinder head

20{200, 15}
(Union bolt)
Injection pipe (M14) 44{450, 32}
Injection pipe (M16) 54{550, 40}
Supply pump cotter bolt 91{930, 67}
Supply pump coupling bolt 61{620, 45}
Supply pump mounting bolt 28{290, 20}
Supply pump drive gear mounting nut 245{2,500, 180}
Emission control
Tightening torque
JP04118010701002
EGR cooler mounting bolt 55{560,40}
EGR valve mounting bolt 72{730,53}
EGR pipe mounting bolt and nut 72{730,53}

Electrical
Standard value
JP31199020205003
Inspection item item item Standard value Remark
14 - 16mm {0.5512 - 0.6299in.} Compression

Deflection (Reference push force 98N gauge (09444-
{10kgf, 22lbf}) 1210) is used.
When installing Belt tension
a new belt gauge (95506-
600 - 690N
Tension 00090 Denso
{65 - 70kgf,135 - 155lbf}
part No.) is
V–belt tension used.
adjustment 15 - 17mm {0.5906 - 0.6693in.} Compression
Deflection (Reference push force 98N gauge (09444-
{10kgf, 22lbf}) 1210) is used.
At the time of Belt tension
inspection gauge (95506-
590 - 640N
Tension 00090 Denso
{60 - 65kgf,133 - 144lbf}
part No.) is
used.
Intake
Tightening torque
JP30109020205003
Intake manifold mounting bolt 55{560, 40}
Intake air heater mounting nut and intake pipe

55{560, 40}
mounting nut
Engine Mechanical
Standard value
JP30109020205004
Unit:mm{in.}
Standard Operation
Inspection item Repair limit Action
value limit
Cylinder liner protrusion 0.04 - 0.10

{0.0016 - — —
0.0039}
Cylinder liner flange width 8{0.315} — —
Cylinder block flange width 8{0.315} — 7.97{0.3138} Replacement
Cylinder block inner A 127 -

diameter 127.0085
— —
{5.000 -
5.003}
B 127.0085 -
127.0165
— —
{5.003 -
5.0007}
C 127.0165 -
127.0250
— —
{5.0007 -
5.0010}
Cylinder liner outer A 126.9795 -

diameter 126.9875
— —
{4.9992 -
4.9995}
B 126.9875 -
126.9960
— —
{4.9995 -
4.9998}
C 126.9960 -
127.0045
— —
{4.9998 -
5.0002}
Standard Operation
value limit
Clearance between A 0.0120 -

cylinder liner and 0.029
— —
cylinder block {0.0005 -
0.0011}
B 0.0120 -
0.029
— —
{0.0005 -
0.0011}
C 0.0125 -
0.029
— —
{0.0005 -
0.0011}
Cylinder liner inner diameter 122.15 Replacement

122{4.803} —
{4.8090}
Piston outer diameter (Pin hole 25 mm

121.95
above the lower end of the skirt square — —
{4.8012}
direction)
Piston clearance 0.060 - 0.080 Replace liner or

{0.0024 - — 0.15{0.0059} piston.
0.0031}
Standard Operation
value limit
Piston Free joint Top Approx. 12.7 — —

ring clearance
Second Approx. 14.6 — —
Third Approx. 15 — —
Oil Approx. 11 — —
Cylinder Top 0.30 - 0.50 Replace piston ring.

liner Joint {0.0118 - — 1.5{0.0590}
for assembly 0.0196}
Clearance
Second 0.50 - 0.70
{0.0197 - — 1.2{0.0472}
0.0275}
Third 0.35 - 0.50

{0.0138 - — 1.2{0.0472}
0.0196}
Oil 0.30 - 0.50

{0.0118 - — 1.0{0.0393}
0.00196}
Piston ring Top 3.312

— (Taper)
thickness {0.1304}
Second 2.306
— (Taper)
{0.0908}
Third 2.0{0.0787} — 1.80{0.0708}
Oil 4.0{0.1575} — 3.90{0.1535}
Piston Piston ring Top (Taper) — — Replace piston.

ring and groove
Second (Taper) — —
ring
groove Third 2.0{0.0787} — —
Oil 4.0{0.1575} — —
Clearance Top — — — Replace piston ring

between or piston.
Second — — —
piston ring
and ring Third 0.065 - 0.105
groove {0.0026 - — 0.20{0.0078}

0.0041}
Oil 0.025 - 0.065

{0.0010 - — 0.10{0.0039}
0.0025}
Piston pin Piston pin outer diameter 47{1.850} — — Replace piston pin.
Piston boss inner diameter 47{1.850} — —
Clearance between piston 0.041 - 0.059 Replace piston or

pin and piston boss {0.0017 - — 0.05{0.019} piston pin.
0.0023}
Standard Operation
value limit
Connecti Small end bushing inner

47{1.850} — —
ng rod diameter
Small end bushing oil 0.025 - 0.043 Replace piston pin or

clearance {0.0394 - — 0.10{0.0039} connecting rod.
0.0016}
Large end width 42.85

— —
{1.6800}
End play 0.15 - 0.32 Replace connecting

{0.0059 - — 0.6{0.0236} rod or crankshaft.
0.0125}
Connecting rod bolt length 102.5 Replacement

— 105.0{4.1338}
{4.0354}
Cranksha Journal outer diameter 90{3.543} — 88.8{3.4960} Replace crankshaft

ft journal bearing or
Journal bearing thickness 3{0.118} — —
crankshaft.
Journal crankshaft oil 0.044 - 0.097
clearance {0.0018 - — 0.3{0.0118}
0.0038}
Pin outer diameter 80{3.150} 79.8{3.1417} 78.8{3.1023}
Journal bearing thickness 2.5{0.0984} — —
Pin connecting rod oil 0.025 - 0.084

clearance {0.0010 - — 0.30{0.0118}
0.0033}
Thickness of thrust bearing 3{0.118} — —
Crankshaft end play 0.110 - 0.240 Replace thrust

{0.0044 - — 0.5{0.0196} bearing.
0.0094}
Crankshaft runout — — 0.07{0.0027} Replace crankshaft.
Crank pin width 43{1.693} — —

Standard Operation
value limit
Camshaft Camshaft No.1 65.0{2.5590} — — Replace camshaft.

journal outer
No.2 64.6{2.5433} — —
diameter
No.3 64.2{2.5275} — —
No.4 63.8{2.5118} — —
No.5 63.4{2.4960} — —
No.6 63.0{2.4803} — —
No.7 62.6{2.4645} — —
Bearing oil clearance 0.030 - 0.120 Replace camshaft or

{0.0012 - — 0.3{0.0118} bearing.
0.0047}
Cam height IN 56.03 55.23 Replace camshaft.

—
{2.2059} {2.1744}
EX 53.72 52.92
—
{2.1150} {2.0835}
Cam lift IN 6.63{0.2610} — 6.48{0.2551}
EX 8.72{0.3433} — 8.57{0.3374}
Thrust plate thickness 8{0.315} — —
End play 0.10 - 0.23 Replace thrust plate.

{0.0039 - — 0.3{0.0118}
0.0091}
Camshaft runout — — 0.05{0.0019} Replace camshaft.
Valve Tappet Tappet outer

28{1.102} — —
system diameter
Tappet guide
inner 28{1.102} — —
diameter
Oil clearance 0.020 - 0.066 Replace tappet.

{0.0008 - — 0.10{0.0039}
0.0260}
Rocker arm Shaft outer 27.92 Replace shaft.

28{1.102} —
diameter {1.0992}
Bushing Replace bushing.

28.08
inner 28{1.102} —
{1.1055}
diameter
Oil clearance 0.044 - 0.120 Replace shaft or

{0.0018 - — — bushing.
0.0393}
Standard Operation
value limit
Valve Valve stem IN 8{0.315} — 7.88{0.3102} Replace valve.

system outer
EX
8{0.315} — 7.88{0.3102}
diameter
Valve guide IN 8{0.315} — Refer to the

inner diameter Replace valve guide.
EX 8{0.315} — main text.
Oil clearance IN 0.040 - 0.077 Replace valve or

between {0.0016 - — 0.12{0.0047} valve guide
valve system 0.0030}
and valve
EX 0.057 - 0.094
guide
{0.0023 - — 0.14{0.0055}
0.0037}
Valve sink IN -0.05 - 0.35 Replace valve or

{-0.0020 - — 0.7{0.0275} valve seat.
0.0137}
EX 0.55 - 0.95
{0.0217 - — 1.3{0.0511}
0.0374}
Valve seat IN 30° 30° - 30° 35’ — Correction

angle
EX 45° 45° - 45° 30’ —
Valve spring Set length

54.1{2.130} — —
inner (IN)

54.7{2.1535} — —
inner (EX)
Valve spring Set load 166.7N 153.0N Replacement

inner (IN) {17.0kgf, — {15.6kgf,34.4
37.5lbf} lbf}
Valve spring Set load 160.8N 147.1N

inner (EX) {16.4kgf, — {15.0kgf,
36.2lbf} 33.0lbf}
Valve spring Free length

72.0{2.8346} — 70.0{2.7559}
inner

58.1{2.2874} — —
outer (IN)

58.7{2.3110} — —
outer (EX)
Standard Operation
value limit
Valve Valve spring Set load 389.3N 357.9N Replacement

system outer (IN) {39.7kgf, — {36.5kgf,
87.5lbf} 80.5lbf}
Valve spring Set load 351.1N

382.5N{39.0k
outer (EX) — {35.8kgf,78.9
gf86.0lbf}
lbf}
Valve spring Free length

93.0{3.6614} — 91.0{3.5826}
outer
Push rod bend — — 0.5{0.0197}
Timing Supply pump drive gear - 0.05 - 0.19 Replace each gear.
gear Main idle gear(No.2) {0.0020- — 0.30{0.0118}
backlash 0.0075}
Camshaft gear - Main idle 0.07 - 0.19

gear(No.2) {0.0028 - — 0.30{0.0118}
0.0074}
Main idle gear(NO.1) - 0.07 - 0.19

Crankshaft gear {0.0028 - — 0.30{0.0118}
0.0074}
Oil pump drive gear and oil 0.06 - 0.30

pump driven gear {0.0024 - — 0.40{0.0157}
0.0118}
Camshaft gear - Idle gear 0.06 - 0.19

{0.024 - — 0.30{0.0118}
0.0074}
Main idle Shaft outer diameter 64{2.520} — —
Bushing inner diameter 64{2.520} — —

{0.0012 - — 0.20{0.0028} bushing.
0.0035}
End play 0.065 - 0.149

{0.0026 - — 0.30{0.0118}
0.0058}
Idle gear Shaft outer diameter 52{2.047} — —

{0.0012 - — 0.20{0.0028} bushing.
0.0035}
End play 0.070 - 0.125

{0.0028 - — 0.30{0.0118}
0.0049}
Head bolt length (long) 250{9.843} — 252{9.921} Replacement

Standard Operation
value limit
Head bolt length (short) 158{6.220} — 161{6.338} Replacement
Injector protrusion 2.9{0.1142} — —
Flatness under cylinder head 0.05{0.0019} Grind for correction

0.15{0.0059} —
or less
Flatness above cylinder block 0.05{0.0019} Grind for correction

0.15{0.0059} —
or less
Clearance between engine speed 1.0 - 1.5

sensor and flywheel ring gear {0.0394- — — Adjustment
0.0591}
Flywheel Plane run- Correction

0.2{0.0078}
out — —
or less
Axial run-out Replacement
Valve clearance IN 0.45{0.0177} — — Adjustment

(Cold engine)
EX 0.60{0.0236} — —
Valve Exhaust valve open

59° — —
timing (before BDC)
Exhaust valve close

13° — —
(after TDC)
Intake valve open

11° — —
(before TDC)
Intake valve close

22° — —
(after BDC)
Supply pump drive bearing rolling 0.39 - Shim adjustment

torque 1.17N⋅ m
{4 -
— —
12kgf⋅ cm,
3.5 -
10.4lbf⋅ in.}
Tightening torque
JP30109020205005
Head cover mounting bolt (upper) 25{250, 18}
Head cover mounting bolt (lower) 54{550, 40}
Head bolt 118{1,200, 87}+90° +90° Angle method
Additional head bolt 69{700, 51}
Rocker support bolt 52{530, 38}
Rocker arm adjusting screw lock nut

44{450, 32}
(M10)
Rocker arm adjusting screw lock nut Exhaust side

(M12) 69{700, 51} with engine
retarder
Cross head adjusting screw lock nut

28{290, 20}
(M10)
Cross head adjusting screw lock nut

28{290, 20}
(M12)
Idle gear shaft mounting bolt 108{1,100, 80}
Idle gear shaft mounting bolt

44{450, 32}
(main idle)
Supply pump drive gear mounting nut 245{2,500, 180}
Supply pump drive bearing case retainer mounting

25{250, 18}
bolt
Flywheel mounting bolt 270{2,750, 200}
Flywheel housing mounting bolt (M8) 25{250, 18}
Flywheel housing mounting bolt (M14) 113{1,150, 83}
Flywheel housing stay mounting bolt (M14) 113{1,150, 83}
Flywheel housing stay mounting bolt (M16) 211{2,150, 156}
Connecting rod mounting nut 69{700, 51}+90° +90° Angle method
Cooling jet mounting bolt 23{230, 17}
Main bearing cap mounting bolt 274{2,800, 200}
Camshaft gear mounting bolt 137{1,400, 100} Warm fitting
Crankshaft damper - crank pulley mounting bolt 108{1,100, 80}
Crank pulley - crankshaft 245{2,500, 180}
Timing gear case cover mounting bolt 44{450, 32}
Engine mounting bracket mounting bolt 76{770, 56}
Engine speed sensor (B) At the unit side

49±4.9{500±50, 36±4} Engine speed
sensor
Exhaust
Tightening torque
JP30109020205006
Exhaust manifold mounting nut 59{600, 44}
Exhaust manifold mounting stud bolt 30{300, 22}
Exhaust manifold bracket mounting bolt 68.5{700, 51}
Cooling
Standard value
JP30109020205007
Unit:mm{in.}
Standard Operation
value limit
Thermostat valve open temperature 74.5 - 78.5° C Replacement

— —
{176 - 183° F}
Thermostat valve lift 10{0.394} Replacement

— —
(Set temperature 90 ° C{194 ° F}) or more
Inspection item item Belt position Standard value Remark
9 - 11mm
Compression
{0.3543 - 0.4331in.}
Deflection gauge (09444-
(Reference push force 98N
1210) is used.
{10kgf, 22lbf})
When installing
Belt tension
a new belt
gauge (95506-
520 - 610N
Tension 00090 Denso
{53 - 62kgf,117 - 137lbf}
part No.) is
Fan belt tension used.
adjustment 12 - 14mm
Compression
{0.4724 - 0.5512in.}
Deflection gauge (09444-
(Reference push force 98N
1210) is used.
{10kgf, 22lbf})
At the time of
Belt tension
inspection
gauge (95506-
340 - 440N
Tension 00090 Denso
{35 - 45kgf,76 - 99lbf}
part No.) is
used.
Tightening torque
JP30109020205008
Tension pulley bracket - timing gear case cover 55{560, 40} M10
211{2,150, 156} M16
Fan drive ASSY - timing gear case cover 47{480, 35}
Tension pulley fixing nut 108{1,100, 80}
Fan drive pulley - fan spacer 60{610, 44}
Cooling fan - fan spacer 47{480, 35}
Thermostat case mounting bolt 55{560, 40}
Cooling fan mounting nut 66±7{673±71,487±5}
Lubrication
Standard value
JP30109020205009
Unit:mm{in.}
Standard Operation
value limit
Oil pump End play 0.045 - 0.105 Replacement

drive gear {0.0018 - — 0.15{0.0059}
0.0041}
Tip clearance 0.038 - 0.115 Replacement

{0.0015 - — 0.17{0.0066}
0.0045}
Shaft outer diameter 20{0.787} — —
Case cover inner diameter 20{0.787} — —
Oil clearance 0.040 - 0.074 Replacement

{0.0016 - — 0.17{0.0066}
0.0029}
Oil pump Shaft outer diameter 20{0.787} — —

driven
gear
Oil clearance 0.040 - 0.074 Replacement
{0.0016 - — 0.17{0.0066}
0.0029}
Drive gear and driven gear backlash 0.072 - 0.208 Replacement

{0.0029 - — 0.4{0.0157}
0.0081}
Tightening torque
JP30109020205010
Oil pan mounting bolt 31{320, 23} M8
51{520, 38} M10
Oil pan drain cock 69{703, 51}
Oil pump mounting bolt (M10) 47{480, 35}
Oil pump mounting bolt (M14) 113{1,150, 83}
Oil pump feed pipe mounting bolt (M8) 21{210, 15}
Oil pump feed pipe mounting bolt (M10) 23{230, 17}
Oil strainer mounting bolt 23{230, 17}
Oil pump case assembly bolt A 22.6±2.9{230±30,17±2}
Oil pump case assembly bolt B 44.0±4.9{449±50,32±3.6}
Oil cooler element mounting nut 19.6±4.9{200±50,14±4}
Oil cooler with oil filter mounting bolt (M8) 25{250, 18}
Oil cooler with oil filter mounting bolt (M10) 47{480, 35}
Oil pressure switch 19{190, 14}
Oil filter warning switch 29.4±4.9{300±50,22±4}

Starting and Charging

Standard value (alternator 60A)
JP30002020205012
Standard Operation
value limit
Resistance between stator coil

0.15 - 0.17 Ω — — Replacement
terminals (U—V, V—W, W—U)
Resistance between stator coil core and Replacement

1MΩ or more — —
coil
Resistance of field coil 6.4 - 7.0 Ω — — Replacement
Resistance between field coil core and Replacement

1MΩ or more — —
coil
Ball bearing Replacement

25mm{0.984i 24.98mm{0.9
insertion —
n.} 834in.}
area
Shaft outer diameter of
Roller
rotor assembly
bearing 17mm{0.669i 16.98mm{0.6
—
insertion n.} 685in.}
area
Resistance between diode and Forward Replacement

Approx. 10 Ω — —
rectifier holder resistance value
Reverse
Infinite — —
resistance value
Resistance between Forward Replacement

Approx. 10 Ω — —
regulator terminals F -E resistance value
Reverse
Infinite — —
resistance value
Tightening torque (alternator 60A)

JP30002020205013
Unit:N⋅ m{kgf⋅ cm, lbf⋅ ft}
Bearing cover mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}
Pulley mounting nut 127 - 157{1,300 - 1,600, 94 - 115}
Field coil - Rear bracket 2.9 - 3.9{30 - 39, 2.1 -2.5}
Heat sink mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}
Regulator mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}
Inside B terminal mounting nut 4.9 - 5.9{50 - 60, 3.7 - 4.3}
Front side - Rear side mounting bolt 7.8 - 9.8{80 - 99, 6 - 7}
Coupler holder mounting bolt 1.9 - 2.5{20 - 25, 1.4 - 1.8}
Cover mounting bolt 3.3 - 4.4{34 - 44, 2.5 - 3.2}

Standard value (starter)

JP30109020205013
Unit:mm{in.}
Standard Operation
value limit
Yoke Resistance between coil Replace yoke

— — 1 kΩ or less
assembly lead wire and yoke assembly.
Brush length 13{0.512} Replace brush.

18{0.709} —
or less
Armature Resistance between Replace armature

1 MΩ or more — 1 kΩ or less
assembly commutator and core assembly.
Commutator outer diameter 34{1.339}

36{1.417} —
or less
Shaft outer diameter A 11.98

12{0.472} — {0.4717}
or less
Shaft outer diameter B 8.98

9{0.354} — {0.3535}
or less
Undercut depth 0.5 - 0.8 Correction

0.2{0.0079}
{0.0197 - —
or less
0.0314}
Holder Resistance between holder Replace holder

— — 1 kΩ or less
assembly and plate assembly.
Brush length 13{0.512} or Replace brush.

18{0.709} —
less
Shaft A 25.90
assembly 26{1.024} — {1.0197}
outer or less Replace shaft
diameter assembly.
B 14.04
14.1{0.5552} — {0.55258}
or less
Clutch assembly inner sleeve outer 27.90

diameter 28{1.102} — {1.0984} Replacement
or less
Metal bushing inner diameter of pinion 28.2 Replace pinion

case 28{1.102} — {1.1102} case.
or more
Metal bushing inner diameter of center Replace center

26{1.024} — 26.2{1.0315}
bracket bracket.
Metal bushing inner diameter of shaft Replace shaft

9{0.354} — 9.2{0.3622}
assembly assembly.
Bearing housing inner diameter of rear 28.1{1.1062} Replace rear

28{1.102} —
bracket or more bracket.
Standard Operation
value limit
Start Between C terminal and M Replace start

0.12 - 0.14 Ω — —
magnet terminal (P coil) magnet switch
switch assembly.
Between C terminal and
assembly 1.13 - 1.25 Ω — —
body (H coil)
Tightening torque (starter)

JP30109020205014
Starter mounting nut 127{1,300, 114}
M lead wire mounting nut 12.3 - 15.2{126 - 154, 9.1 - 11.0}
Rear bracket mounting through bolt 15.7 - 17.6{160 - 179, 11.6 - 12.9}
Brush holder fixing bolt of rear bracket 3.6 - 4.9{37 - 49, 2.6 - 3.6}
Start magnet switch assembly mounting bolt at

3.6 - 4.9{37 - 49, 2.6 - 3.6}
pinion case
Battery cable mounting nut 16 - 22{165 - 225, 12 - 16}
Turbocharger
Standard value
JP30109020205015
Unit:mm{in.}
Inspection item Standard value Operation limit Action
Shaft axial play 0.06 - 0.09 Replacement

{0.0023 - 0.110{0.0043}
0.0035}
Shaft radial play 0.10 - 0.17 Replacement

{0.0039 - 0.205{0.0081}
0.0067}
Tightening torque
JP30109020205016
Turbocharger mounting nut 59{600, 44}

PARTS TO BE PREPARED 3–1
ENGINE
3 PARTS TO BE PREPARED
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ì¡éÍçHãÔÅiSST)
3
Engine Body................................................................ 3-2
Special tools ........................................................... 3-2
Fuel System ................................................................ 3-2
Special tools ........................................................... 3-2
Electrical...................................................................... 3-2
Special tools ........................................................... 3-2
Engine Mechanical ..................................................... 3-2
Special tools ........................................................... 3-2
Instruments ............................................................. 3-3
Lubricant, etc. ........................................................ 3-3
Cooling ........................................................................ 3-3
Special tools ........................................................... 3-3
Lubrication .................................................................. 3-3
Instruments ............................................................. 3-3
Starting and Charging................................................ 3-4
Jig(reference dimensionaldrawing
for manufacture)...................................................... 3-4
Common tools......................................................... 3-4
Instruments ............................................................. 3-4
Lubricant, etc. ........................................................ 3-5
Turbocharger............................................................... 3-5
Special tools ........................................................... 3-5
Instruments ............................................................. 3-5
3–2 PARTS TO BE PREPARED
Engine Body
Special tools
JP30109030901003
Shape Part No. Name Remark
09552–1080 Compression gauge adapter
Engine Mechanical
Special tools
JP30109030901004
Shape Part No. Name Remark
For crankshaft front oil seal

380100066 Puller
removal

380100065 Press
mounting
For crankshaft rear oil seal

380100067 Puller
removal

380100068 Press
mounting
Instruments
JP30109030901005
Name Remark
Micrometer For measurement of parts
Cylinder gauge For measurement of parts
Thickness gauge For measurement of parts
Dial gauge For measurement of parts
Square For measurement of valve spring squareness
Calipers For measurement of parts
Straight edge Valve sink
Spring tester For measurement of valve spring set load
Lubricant, etc.
JP30109030901006
Name Remark
Liquid gasket (Threebond TB1207C or equivalent : Red) Push rod cover and flywheel housing
Liquid gasket (Threebond TB1211 or equivalent : White) Lower part of nozzle seat and oil pan
Red lead For inspection of valve contact
Lapping compound For valve adjustment
Dye penetrant For inspection of crack and damage
Lubrication
Instruments
JP30109030901008
Name Remark
Micrometer For measurement of part outer diameter
Cylinder gauge For measurement of part inner diameter
Thickness gauge For measurement of each clearance

3–4 PARTS TO BE PREPARED
Starting and Charging
Jig (reference dimensional drawing for manufacture)

JP30109030901009
Alternator
This is used for assembly of bearing. Reference dimensions are shown in the figures below:
Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
φ23{20.827} φ25{0.984}
1C{0.039}
35{1.378}
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 φ50{1.969}
+0.5{0.0196} {0.394 - 0.787}
φ19{0.748}
0
φ30{1.181}
Jig C Jig D
φ34{1.339} φ41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
φ54{2.126} φ64{2.520}
φ60{2.362} φ70{2.756}
SAPH301090300036
Common tools
JP30109030901010
Alternator
Name Remark
Soldering bit 80 - 100 W
Instruments
JP30109030901011
Alternator
Name Remark
Circuit tester For measurement of parts
Megger tester For inspection of insulation
Micrometer For measurement of parts
Regulator checker (G&M Machinery ICD-101D or

For inspection of regulator
equivalent)
Starter
Name Remark
Circuit tester For measurement of parts
Micrometer For measurement of part outer diameter
Growler tester For inspection of armature
Cylinder gauge For measurement of part inner diameter
For measurement of brush length and commutator

Calipers
outer diameter
Dial gauge For measurement of shaft runout
Magnet stand For measurement of shaft runout
Lubricant, etc.
JP30109030901012
Starter
Name Remark
Kyodo Yushi Multemp AC-N For lubrication of parts
Nisseki Mitsubishi Pyroknock #2 For lubrication of parts
For pouring grease into the metal (center bearing)

Grease syringe
grease reservoir
Turbocharger
Instruments
JP30109030901014
Name Remark
Dial gauge For measurement of turbine shaft bend

ENGINE ASSEMBLY/DISASSEMBLY 4–1
ENGINE
4 ENGINE ASSEMBLY/DISASSEMBLY
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Inspection Before Service ......................................... 4-2

Measurement of compression pressure ................. 4-2 4
Engine Body................................................................ 4-3
Removal.................................................................. 4-3
Installation............................................................... 4-5
Work after installation ............................................. 4-5
4–2 ENGINE ASSEMBLY/DISASSEMBLY
Inspection Before Service

Measurement of compression pressure
JP30109040702001
NOTICE • Measure the compression pressure before

disassembly of the engine and record the
result. Regular measurement of the
compression pressure can tell the engine
status.
1. Preparation before measurement

(1) Charge the battery completely.
(2) Check the valve clearance and adjust it when exceeding
the standard value.
(3) Warm the engine and set the water temperature to 80
° C{176 ° F}.
(4) Remove the air cleaner.
(5) Remove the head cover.
(6) Remove all injectors.
(7) To prevent spread of engine oil, attach a jig which cuts a
head cover in half. (Cut it so that the camshaft may be
covered.
2. Measurement
(1) Attach a special tool to the nozzle sheet of the cylinder

where the compression pressure is measured.
Special tool : 380100069 Compression gauge
adapter
(2) Turn the starter and measure the compression pressure.
! CAUTION • Do not operate the starter for 15 seconds or

more.
SAPH301090400001
• Since the air cleaner is removed, prevent

entry of dirt.
(3) Measure the compression pressure of each cylinder

continuously.
Engine revolution 200r/min {rpm}

Unit : MPa {kgf/cm2,lbf/in.2}
Compression pressure
Standard value 2.9 {30, 421}
Operation limit 2.5 {26, 362}
(4) If the compression pressure is below the operation limit,

overhaul the engine.
(5) After measurement, reassemble the removed parts.
Engine Body
Removal
JP30109040702002
1. Preliminary work before removal of engine

(1) Place the vehicle on a level ground.
(2) Block tires with scotch.
(3) Remove the battery cable from the battery minus terminal.
2. Drain of coolant and engine oil

Right side of engine
(1) Drain coolant from the radiator drain cock and the oil
cooler drain plug.
NOTICE • Removal of the filler cap facilitates quick

drain.
• Connection of an appropriate hose to the oil
cooler drain pipe facilitates drain of coolant
Oil cooler drain plug
without spread.
SAPH301090400002
! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• To dispose coolant, observe the specified
method (waste disposal) or the method with
attention to the environment.
(2) Drain engine oil from the oil pan drain plug as required.
! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• Dispose coolant according to the specified
method (waste treatment) or with a method
considering the environment.
Drain cock
SAPH301090400003
3. Removal of intake hose, intercooler hose and exhaust pipe
(1) Loosen the clamp and remove the intake hose.

(2) Remove nuts and remove the exhaust pipe.
Intake manifold
! CAUTION • Close the opening of the intake manifold with
a packing tape to prevent entry of dirt inside
the engine.
Cylinder head
cover
SAPH301090400004
4–4 ENGINE ASSEMBLY/DISASSEMBLY
4. Disconnection of fuel hose

Feed
(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with its end facing
Return
upward to prevent spill of fuel.
! CAUTION • Wipe spilled fuel with a rag.
SAPH301090400005
5. Disconnection of water, engine oil pipes, etc.

(1) Disconnect the hose between the radiator and the engine.
(2) Disconnect the car heater pipe.
(3) Disconnect the oil filter pipe.
! CAUTION • Wipe off spilled water and engine oil with a

rag.
6. Engine lifting
(1) Place a hook on the hole in the engine hanger.

(2) Keep a little slack of the wire rope.
(3) When the wire is completely tense, make sure that the
wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.
Reference: "Lubrication, oil filter"
! CAUTION • Work carefully so that the engine may not

come in contact with the frame and others.
SAPH301090400006
Installation
JP30109040702003
1. Connection of fuel hose

(1) Insert a fuel hose and fix it with a hose band.
Work after installation

JP30109040702004
1. Inspection of engine oil
(1) Make sure that the drain cock is closed.

(2) Pour engine oil.
Engine oil amount (L{us gal})
Oil pan Oil filter and Remote hose
Approx. 35{9.25} Approx. 7.5{1.98}
Filler cap
! CAUTION • Please use Hino genuine engine oil
SAPH301090400007
• Check the amount of oil with an oil level
gauge.
Multi grade SAE #10W-30
Single grade SAE #30
2. Air bleeding of fuel system
(1) Prepare a rag to receive fuel at the end of the drain hose.
(2) Loosen the air bleeding bolt of the fuel filter.
(3) Turn the knob of the priming pump to the left to let it float
up, and then operate it.
(4) Move the knob until fuel without bubble comes out from
the drain hose.
(5) Tighten the air bleeding plug.
Tighening torque : 7N⋅ m{70kgf⋅ cm,7 lbf⋅ ft}
SAPH301090400008
! CAUTION • Do not tighten the air venting plug while

operating the knob of the priming pump.
(6) Turn the knob of the priming pump again five or six turns.
(7) Press the priming pump and tighten it fully to the right.
! CAUTION • After work, wipe off spilled fuel. After start of

the engine, make sure that there is no fuel
leak.
FUEL SYSTEM 5–1
ENGINE
5 FUEL SYSTEM
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Fuel System ................................................................ 5-2

Fuel system diagram............................................... 5-2
Part layout (typical example)................................... 5-3
Replacement of the fuel filter .................................. 5-7
Replacement of supply pump ................................. 5-9
5
Replacement of injector ........................................ 5-11
Inspection of injector ............................................. 5-15
Inspection of common rail function parts
(evaluation) ........................................................... 5-16
Overhaul of
supply pump drive bearing case ........................... 5-17
5–2 FUEL SYSTEM
Fuel System
Fuel system diagram
JP30109050402001
Injection pipe
Common rail
Feed pump
Overflow Overflow pipe

valve Flow damper
Injector
Leakage pipe
Pressure limiter
Return Through feed pipe
pipe
Fuel
Filter
Priming pump
Supply pump
Feed pipe Fuel tank

Feed pipe
Feed pipe
Feed pump
Through feed valve
SAPH301090500001
FUEL SYSTEM 5–3
Part layout (typical example)

JP30109050402002
Fuel pipe
SAPH301090500002
23081 Leakage pipe 23811 Feed pipe

23300 Fuel filter 23811A Feed pipe
23391 Leakage pipe 23812 Feed pipe
23701 Injection pipe 23815 Feed pipe
23702 Injection pipe 23816 Overflow pipe
23703 Injection pipe 23816A Through feed pipe
23704 Injection pipe 23871 Pressure feed pipe
23705 Injection pipe 9655-10100 Gasket*
23706 Injection pipe 9655-14140 Gasket*
23766A Fuel pipe SZ209 Gasket*
23766B Overflow pipe

Tightening torque
23081 20N⋅ m{200kgf⋅ cm,15 lbf⋅ ft} 23705 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft}
23701 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft} 23706 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft}
23702 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft} 23871 Common rail side:54N⋅ m{550kgf⋅ cm,40
lbf⋅ ft}
23703 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft} 23871 Supply pump side:44N⋅ m{450kgf⋅ cm,32
lbf⋅ ft}
23704 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft}
5–4 FUEL SYSTEM
Supply pump,Common rail,Injector
SAPH301090500003
11195 Injector clamp 22760 Common rail assembly

11491B Common rail bracket 29611 Oil pipe
13610 Supply pump drive case assembly 9645A O-ring*
13611 Supply pump drive shaft 9655-12100 Gasket*
13691 Bearing holder case 9655-15104 Oil seal*
13693 Bearing retainer 9851A O-ring*
15773 Oil pipe 9851B O-ring*
15774 Fuel pipe 900111 Shim
22730 Supply pump 993-302080 Bearing
23670 Injector 993-322070 Bearing

Tightening torque
22730 Cotter bolt:91N⋅ m{930kgf⋅ cm,67 lbf⋅ ft} 9181-08400 25N⋅ m{250kgf⋅ cm,18 lbf⋅ ft}
22730 Coupling bolt:61N⋅ m{620kgf⋅ cm,45 9191-08901 28N⋅ m{290kgf⋅ cm,21 lbf⋅ ft}
lbf⋅ ft}
900124 26N⋅ m{270kgf⋅ cm,19 lbf⋅ ft} 9219A 245N⋅ m{2,500kgf⋅ cm,181 lbf⋅ ft}
FUEL SYSTEM 5–5
Fuel filter
SAPH301090500004
23300 Fuel filter assembly 23401 Fuel filter

23316 Air bleeding plug
Tightening torque
23316 7N⋅ m{70kgf⋅ cm,5 lbf⋅ ft}
5–6 FUEL SYSTEM
Priming pump
SAPH301090500005
22509 Knob 22570 Priming pump assembly

FUEL SYSTEM 5–7
åšä²óvóÃçÄñ⁄
êÆî óvóÃ
Replacement of the fuel filter

JP30109050704001
1. Fuel filter removal

(1) Remove the fuel filter.
• Prepare a tray because the filter contains
diesel fuel
• For disposal of fuel, observe the local
disposal procedure.
SAPH301090500006
2. Fuel filter installation

(1) Remove dirt and foreign matter from the installation
surface.
(2) Apply a thin coating of diesel oil to the gasket of the new
fuel filter.
(3) Turn the fuel filter clockwise by hand until the gasket
comes into contact with the body seal face.
• Confirm that the gasket is in positive contact
with the seal surface.
Element
Gasket
Scale
Element
SAPH301090500007
5–8 FUEL SYSTEM
(4) Use the special tool and tighten for approximately another
2/3 turns.
• At the time of installation, take care that the
gasket is not damaged by twisting.
• Replace the gasket by the new one in the
element kit.
• Do not reuse an element.
• After work, wipe off spilled fuel. After start of
leak.
• Do not use a commercial chain-type filter
wrench or similar to install the filter. This can
cause scratches or deformation for the outer
circumference, which can lead to fuel leakage
and fire.
• The scale markings are in the order of
1→2→3→4→5→6→1→2..., and one gradation
corresponds to 60° .
• The above 2/3 turns corresponds to 4
gradations (240° ), and element and body
should be marked before turning.
3. Fuel system air venting
(1) Prepare a shop towel or similar at the time of the drain

hose to receive fuel.
(2) Loosen the fuel filter air venting plug.
(3) Turn the knob of the priming pump to the left to let it float
up, and then operate it.
(4) Operate the knob until fuel without air bubbles flows from
the hose.
(5) Tighten the air venting plug.
SAPH301090500008
Tightening torque: 7 N⋅ m {70 kgf⋅ cm,5 lbf⋅ ft}
• Do not tighten the air venting plug while
operating the knob of the priming pump.
(6) Turn the knob of the priming pump again five or six turns.
(7) Press the priming pump and tighten it fully to the right.
• After work, wipe off spilled fuel. After start of
leak.
FUEL SYSTEM 5–9
Replacement of supply pump

JP30109050704004
1. Removal of supply pump

• The supply pump does not have to be
adjusted.
• If insufficient discharge rate or a faulty sub-
engine speed sensor occurs, contact the
Denso service shop.
(1) Remove the fuel pipe and oil pipe connected to the supply
pump.
Supply pump
SAPH301090500009
(2) Align the No. 1 cylinder to the compression top dead

center and align the stamp lines of the supply pump.
stamp lines.
Align
Coupling (3) Remove the coupling bolt.
SAPH301090500010
(4) Remove four bolts and remove the supply pump.
(5) Loosen the cotter bolt and ensure shaft play for
reinstallation.
Loosen the cotter bolt.

SAPH301090500011
2. Installation of supply pump

(1) Turn the crankshaft in the engine rotating direction
Flywheel housing (clockwise as viewed from the cooling fan side), align the
Inspection window
"16" stamp line of the crankshaft damper with the pointer,
and align the No. 1 cylinder to the compression top dead
center.
16 • If the pointer is matched with "16", but the
supply pump bearing case shaft key or cotter
bolt faces down, No. 6 is at the compression
top dead center. Turn the crankshaft one turn
SAPH301090500012
and set the No. 1 cylinder at the compression
top dead center.
5–10 FUEL SYSTEM
(2) Make sure that the cotter bolt is loose and install the
supply pump on the bracket.
Tightening torque : 28 N⋅ m {290 kgf⋅ cm, 20 lbf⋅ ft}

Install the supply
pump with a loose
cotter bolt.
SAPH301090500013
(3) Install two bolts at the coupling and tighten the coupling
Stamp line bolt by aligning the stamp line of the supply pump.
Coupling bolt
• Make sure that there is no clearance between
laminate plates. Make sure that there is no
flange deformation due to crashing of
laminate plates.
(4) Tighten the cotter bolt.

Cotter bolt
SAPH301090500014 • Make sure that laminate plates are not
deformed or there is no undue force on them.
(5) Replace the gasket with a new one and connect the fuel
Injector pipe and oil pipe to the supply pump.
Common rail Tightening torque :

44 N⋅ m {450 kgf⋅ cm, 32 lbf⋅ ft} (Fuel pipe M14)
54 N⋅ m {550 kgf⋅ cm, 40 lbf⋅ ft} (Fuel pipe M16)
㧹
㧹
Supply
Pump
SAPH301090500015
FUEL SYSTEM 5–11
Replacement of injector
JP30109050704005
1. Removal of injector harness

Injector harness (1) Remove each connector and bolt and remove the injector
harness.
• Since the injector harness bracket is
susceptible to distortion, be careful for
handling.
• Refer to the following for installation of the
engine retarder. "Reference: Engine
mechanical, Engine retarder, Removal"
SAPH301090500016
2. Removal of leakage pipe
(1) Remove the injector and cylinder head union bolts.

(2) Remove bolts and remove the leakage pipe.
• Since the leakage pipe is susceptible to
distortion, be careful for handling.
SAPH301090500017
3. Removal of injector
(1) Remove the injection pipe seal.
(2) Remove the injector clamp mounting bolt and remove the
injector and injector clamp.
• It is difficult to pull it out, pull it out with an
A injector puller.
(3) Remove the O-ring from the cylinder head.
A)INJECTOR PULLER
B)INJECTOR
BS07K644
5–12 FUEL SYSTEM
4. Installation of injector
O-ring
(1) Install a new O-ring on the cylinder head groove and
insert the injector.
• Apply engine oil to the O-ring and be careful
to prevent pinching of the O-ring.
SAPH301090500019
(2) Put a new injection pipe oil seal on the injector and install
it with bolts and nuts.
• Do not fix the injector clamp until the injection
pipe is tack welded temporarily.
• Install the injection pipe seal to prevent undue
force to the injector. (Offset position between
the injection pipe oil seal and the injector may
cause oil leak or poor assembly of the
injection pipe.)
SAPH301090500020
(3) Replace the gasket with a new one and tack weld the
leakage pipe to the injector and cylinder head temporarily.
• Install the gasket in a direction in which it
does not interfere with the valve spring.
• Since the injector top union bolt and the
cylinder head joint union bolt are different in
screw thread pitch, be careful for handling.
Injector top union bolt (M10 x 1.0)

Cylinder head joint union bolt (M10 x 1.5)
SAPH301090500017
(4) Tack weld the injection pipe through the injection pipe seal
Injection pipe seal until it comes in contact with the seat.
Injection pipe
• Tack weld it by adjusting so that the injector is
aligned with the injection pipe.
• Make sure that the seal spring is installed
correctly.
Seal spring
SAPH301090500021
FUEL SYSTEM 5–13
(5) Tighten the injector clamp mounting bolts to fix the

Injector clamp injector.

• After tightening, make sure that the rocker
arm moves smoothly.
Make sure that there is no undue force on the
injection pipe oil seal. (Otherwise, oil leak or
Injection pipe
poor assembly of injection pipe may occur.)
(6) Tighten the injection pipe.

SAPH301090500022
(7) Tighten the leakage pipe.

• Assemble so that the gasket connection may
not come in contact with the rocker arm.
SAPH301090500017
5. Installation of injector harness

Injector harness (1) Connect each connector and install the injector harness.
SAPH301090500023
5–14 FUEL SYSTEM
6. Entry of injector correction value to the engine ECU (entry

using HinoDX and QR code reader)
• When the injector is replaced, it is necessary
to enter the injector correction value (QR
code) described on the new injector to the
engine ECU. Incorrect entry of the correction
value may result in faulty engine.
• Available entry methods of the injector
correction value are the PC tool and the QR
SAPH301090500024
code reader.
• The work flow is described below. For detailed
procedures, refer to the operation manual of
the HinoDX.
(1) Read the injector QR code with the scanner of the QR

code reader and prepare the correction data file.
(2) Enter the injector correction value directly from the
HinoDX to the engine ECU.
PC
QR code reader
Hino-Bowie
(Special interface)
Connector
New injector
ECU
SAPH301090500025
FUEL SYSTEM 5–15
Inspection of injector
JP30109050704006
1. Inspection of injector insulation

(1) Remove the injector plastic terminal cap (upper).
<Cross-section view of injector head>
(2) Measure the insulation resistance between the injector
upper body and one terminal (no polarity) of two terminals
for the injector harness.
Terminal (harness Terminal cap (upper)
tightening area) Standard value
Terminal cap 1000 MΩ or more
(normal temperature)
(lower)
(3) Measure the resistance value between two terminals

above.
Injector harness
and rubber seal
Standard value
0.45 Ω ± 0.1
(at 20 ° C{68 ° F})
(4) If the resistance value in (2) and (3) exceeds the standard
value, replace the injector assembly.
Upper body
2. Cleaning of injector
(1) Remove sludge at or around the terminal, if any.
• In removing sludge, do not use a cleaning
SAPH301090500026
agent. Wipe it off with a rag. Use of a cleaning
agent may result in electric failure due to
penetration of the agent.
nomatch
5–16 FUEL SYSTEM
Inspection of common rail function parts

(evaluation)
JP30109059999001
1. Inspection of pressure sensor

(1) If the check engine lamp illuminates and it applies to
"Pressure sensor disconnection", "Pressure sensor short-
circuit" or "Pressure sensor output does not change" in
inspection of failure diagnosis system, replace the
pressure sensor.
2. Inspection of pressure limiter
(1) Remove the hollow screw of the pressure limiter.

(2) Install a blank plug on the pipe side using a bolt to prevent
Install a blank plug
on the pipe. fuel discharge.
Remove the hollow screw
SAPH301090500027
(3) Install the union on the pressure limiter and connect the
plastic hose to the tip of the union.
(4) Prepare a fuel container at the tip of the plastic hose.

(5) If the engine is started and fuel discharge is recognized
Union continuously, replace the pressure limiter.
Plastic hose
Container
SAPH301090500028
3. Inspection of flow damper

(1) Start the engine, run it from idling to full throttle and check
the diagnosis code of "flow damper operation".
(2) If the diagnosis code of "flow damper operation" is
detected, replace the applicable injector and inspect
again.
(3) If the failure is reproduced after the injector is replaced,
replace the flow damper with the common rail assembly.
êÆî óvóÃ
FUEL SYSTEM 5–17
Overhaul of supply pump drive bearing case

JP30109050702001
1. Removal of timing gear case cover

"Reference: Engine mechanical, timing gear cover and
flywheel housing, timing gear case cover replacement"
2. Removal of supply pump drive gear
(1) Remove the drive gear mounting nut.

(2) Remove the oil pipe connected to the supply pump drive
bearing case.
SAPH301090500029
(3) Pull out the gear using a puller or install a box nut on the
shaft, hit the shaft with a copper hammer, loosen and
Box nut
remove the gear with impact.
(4) Remove the supply pump drive bearing case.
SAPH301090500030
3. Disassembly of supply pump drive bearing case

(1) Remove the bolt and disassemble the supply pump drive
bearing case.
SAPH301090500031
5–18 FUEL SYSTEM
4. Assembly and adjustment of supply pump drive bearing

case
(1) Insert the bearing and shaft applied with engine oil into
the case, replace the O-ring with a new one applied with
engine oil and assemble the supply pump bearing case as
shown in the figure.

• Adjust temporarily with a shim so that the
drive shaft is turned manually and there is no
SAPH301090500032 axial backlash.
• Assemble so that the bearing retainer

protrusion (oil return groove) is lower.
SAPH301090500033
(2) Measure the rolling torque using a torque wrench and

adjust it so that it satisfies the standard value.
Standard value (N⋅ m 0.39 - 1.17

{kgf⋅ cm, lbf⋅ in.}) {4 - 12, 3.5 - 10.4}
(3) Apply engine oil to the lip of a new oil seal.
SAPH301090500034
(4) Press fit the oil seal using a suitable driver so that the oil
seal is flush with the bearing retainer.
SAPH301090500035
FUEL SYSTEM 5–19
5. Installation of supply pump drive bearing case
(1) Replace the O-ring with a new one and install the supply
pump bearing case with adjusted preload from the back.
(2) Fix the drive shaft, align the gear stamp, install the drive
gear and tighten the nut.
Tightening torque : 245 N⋅ m {2,500 kgf⋅ cm, 180
lbf⋅ ft}
6. Installation of timing gear cover

SAPH301090500036
"Reference: Engine mechanical, timing gear cover and
flywheel housing, timing gear case cover replacement"
ELECTRICAL 7–1
ENGINE
7 ELECTRICAL
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Electrical System........................................................ 7-2

Layout of components............................................. 7-5
Inspection of components ....................................... 7-7
Installation of components ...................................... 7-9
Installation of starter ............................................... 7-9
Installation of alternator ........................................ 7-10
7
INTAKE 8–1
ENGINE
8 INTAKE
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Intake Manifold ........................................................... 8-2

Replacement........................................................... 8-3
8
8–2 INTAKE
Intake Manifold
JP30109080402001
SAPH301090800001
17031 Intake pipe 17171 Gasket*

17101 Intake manifold 17171A Gasket*
17113A Intake pipe 17171B Gasket*
17113B Intake pipe 900239 Hose
17113C Intake pipe 9769A Clamp
17138 Bracket

Tightening torque
9068-10450 55N⋅ m {560 kgf⋅ cm,40 lbf⋅ ft} 9241-10107 55N⋅ m {560 kgf⋅ cm,40 lbf⋅ ft}
9068-60050 55N⋅ m {560 kgf⋅ cm,40 lbf⋅ ft}
êÆî
óvóÃ
INTAKE 8–3
Replacement
JP30109080704001
1. Removal of wiring harness

(1) Remove each connector and remove the wiring harness.
2. Removal of injection pipe

(1) Remove the injection pipe in front of the intake manifold.
3. Removal of intake manifold
(1) Remove the injection pipe.
SAPH301090800002
(2) Remove the intake manifold.
! CAUTION • Close the opening for installation of the

engine with a packing tape, etc. to prevent
entry of dust.
SAPH301090800003
4. Installation of intake manifold

(1) Clean inside of the intake manifold and the cylinder head.
(2) Replace the gasket with a new one and install the intake
manifold.
5. Installation of injection pipe

(1) Install the injection pipe using the part layout of the fuel
system.
SAPH301090800004
8–4 INTAKE
6. Installation of intake pipe

(1) Replace the gasket with a new one and install the intake
pipe.
SAPH301090800002
ENGINE MECHANICAL 9–1
ENGINE
9 ENGINE MECHANICAL
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Cylinder Head ............................................................. 9-2

Replacement........................................................... 9-5
Overhaul ............................................................... 9-10
Cylinder Block .......................................................... 9-14
Part layout............................................................. 9-14
Overhaul ............................................................... 9-15
Timing Gear Cover and Flywheel Housing............. 9-18
Part layout............................................................. 9-18
Replacement of flywheel housing ......................... 9-19
Replacement of crankshaft front oil seal............... 9-20
Replacement of crankshaft rear oil seal................ 9-21
Replacement of timing gear case cover................ 9-23
9
Main Moving Parts.................................................... 9-24
Part layout............................................................. 9-24
Replacement of piston and connecting rod .......... 9-25
Inspection of piston and connecting rod ............... 9-29
Replacement of crankshaft ................................... 9-33
Inspection of crankshaft ........................................ 9-34
Replacement of crankshaft pulley......................... 9-35
Replacement of flywheel....................................... 9-36
Inspection of flywheel ........................................... 9-39
Camshaft and Idle Gear ........................................... 9-41
Part layout............................................................. 9-41
Gear train layout ................................................... 9-42
Removal of camshaft ............................................ 9-43
Disassembly of camshaft ...................................... 9-43
Inspection of camshaft .......................................... 9-44
Assembly of camshaft........................................... 9-45
Installation of camshaft ......................................... 9-46
Removal of timing gear ......................................... 9-47
Inspection of timing gear....................................... 9-48
Installation of timing gear...................................... 9-48
Inspection of installation status for each gear....... 9-50
Valve System............................................................. 9-51
Part layout............................................................. 9-51
Overhaul of valve system...................................... 9-52
Adjustment of valve clearance .............................. 9-59
9–2 ENGINE MECHANICAL
Cylinder Head
JP30109090402001
SAPH301090900001
11101 Cylinder head assembly 12210A Ventilator

11115 Head gasket* 12203 Ventilation pipe
11185 Head bolt (additional) 12261 Ventilator hose
11185A Head bolt 12261A Oil hose
11185B Head bolt 12505 Silent block
11201 Head cover (lower) 13719 Valve stem oil seal*
11211 Head cover (upper) 18109 Terminal
11213 Gasket* 23745 Injection pipe oil seal
11213A Gasket 9349A Stud bolt (for exhaust manifold
installation)
11455 Plate 9851A O-ring*
12108 Oil filler cap 9851C O-ring*
12210 Ventilator

Tightening torque
11185 69N⋅ m{700kgf⋅ cm,51 lbf⋅ ft} 9191-08401 25N⋅ m{250kgf⋅ cm,18 lbf⋅ ft}
11185A 118N⋅ m{1,200kgf⋅ cm,87 9349A 30N⋅ m{300kgf⋅ cm,22 lbf⋅ ft}
lbf⋅ ft}+90° +90°
11185B 118N⋅ m{1,200kgf⋅ cm,87 9412-10301 54N⋅ m{550kgf⋅ cm,40 lbf⋅ ft}
lbf⋅ ft}+90° +90°
9068-10250 68.5N⋅ m{700kgf⋅ cm,51 lbf⋅ ft} 9412-10551 54N⋅ m{550kgf⋅ cm,40 lbf⋅ ft}
9068-10350 68.5N⋅ m{700kgf⋅ cm,51 lbf⋅ ft} 9412-10851 54N⋅ m{550kgf⋅ cm,40 lbf⋅ ft}
9068-10600 68.5N⋅ m{700kgf⋅ cm,51 lbf⋅ ft} SZ109 25N⋅ m{250kgf⋅ cm,18 lbf⋅ ft}
SAPH301090900002
11101 Cylinder head 11135 Valve seat

11122 Valve guide 11176 Nozzle seat
11131 Valve seat
êÆî óvóÃ
Replacement
JP30109090704001
1. Removal of head cover (upper)

Bolt Head cover (1) Remove the ventilator hose and the bolt and remove the
(upper)
head cover (upper).
! CAUTION • Be careful for fall of the silent block.
Silent block Ventilator hose
SAPH301090900003
2. Removal of injector
Reference: "Replacement of fuel system, injector"
3. Removal of rocker arm assembly

Referenc:" Engine mechanical, Overhaul of valve system"
4. Removal of head cover (lower)
(1) Pull out the push rod.
! CAUTION • Do not pull out the tappet together with the

push rod.
SAPH301090900004
(2) Remove one fuel pipe at the rear of the head cover
(lower).
! CAUTION • Wipe off spilled fuel.
SAPH301090900005
(3) Remove bolts and remove the head cover (lower).
SAPH301090900006
5. Removal of cylinder head

(1) Loosen the head bolts from outside to inside gradually (1/
4 turn for each) as shown in the order of the figure and
remove them.

SAPH301090900007
(2) Remove the cylinder head using an eye bolt and hoist.
NOTICE • If it is difficult to remove the cylinder head,

insert a chisel between the cylinder head and
the cylinder block, and move the chisel
vertically so that the contact surface may not
be damaged. Then, separate the cylinder
head.
SAPH301090900008
6. Inspection of head bolt length
(1) Measure the under head length of the head bolt using a
vernier calipers. If it is out of the operation limit, replace it
with a new one.
Standard value Operation limit

(mm{in.}) (mm{in.})
Long 250{9.843} 252{9.921}
SAPH301090900009 Short 158{6.220} 161{6.338}

7. Compression upper dead center setting of No.1 cylinder

Key
(1) Turn the crankshaft in the engine rotating direction
Flywheel housing
inspection window (clockwise as viewed from the cooling fan side), align the
"16" stamp line of the crankshaft damper with the pointer,
and set the No. 1 cylinder to the compression top dead
center.
! CAUTION • If the pointer is matched with "16", but the

supply pump bearing case shaft key or the
SAPH301090900010 coupling cotter bolt faces down, No. 6 is at
the compression top dead center. Turn the
crankshaft one turn and set the No. 1 cylinder
at the compression top dead center.
Coupling bolt
Stamp line
Cotter bolt
SAPH301090900011
8. Installation of head gasket
(1) Place a new head gasket on the cylinder block.
! CAUTION • Remove dirt, water or oil from the mounting

surfaces of the cylinder head and the cylinder
block before work.
• Never reuse the gasket. Otherwise, it may
damage the engine.
• Before installation of the head gasket, make sure
SAPH301090900012
that there is no fall of or damage to the seal ring.
• Do not apply liquid gasket to each seal.
9. Installation of cylinder head
(1) Clean the head bolt seating at the cylinder head upper
surface and the cylinder head lower surface.
(2) Align the dowel pins of the cylinder block using an eye bolt
and hoist and mount the cylinder head.
! CAUTION • Before mounting the cylinder head, make sure

that there is no foreign matter in the cylinder.
SAPH301090900008
(3) Apply engine oil to the bolt seating and thread and tighten
19 head bolts in the order shown in the figure.
Seating torque : 118 N⋅ m {1,200 kgf⋅ cm, 87 lbf⋅ ft}
SAPH301090900013
(4) Install the armature assembly.

(5) Install 7 rocker support bolts (head bolts) in the order
Seating torque : 118 N⋅ m {1,200 kgf⋅ cm, 87 lbf⋅ ft}
SAPH301090900014
(6) Make sure the 26 head bolts are tightened to a torque

value of 118N⋅ m {1,200kgf⋅ cm, 87lbf⋅ ft} and finally
tighten the additional bolt.
Additional bolt
SAPH301090900015
(7) Mark the heads of the 26 head bolts in the above figure in
Paint
the same direction using paint.
q q
(8) Tighten 26 head bolts at rotation angle 90° in the same
order as above using a special tool and make sure that all
paint marks are in the same direction. Tighten them
further at rotation angle 90° and make sure that all paint
marks are in the same direction.
Paint ! CAUTION • If a bolt is turned excessively in retightening,

SAPH301090900016 do not loosen it.
SAPH301090900017
10. Installation of head cover (lower)
(1) Replace the gasket with a new one and install the head
cover (lower).
SAPH301090900018
(2) Replace the gasket with a new one and install one fuel
pipe.
SAPH301090900019
11. Installation of injector

Reference: "Fuel system, Replacement of injector"
12. Installation of head cover (upper)

Bolt Head cover
(upper) (1) Wipe dirt and oil on the joint surfaces of the head cover
(upper) and head cover (lower) and on the groove of the
gasket and install the head cover (upper) and gasket.
! CAUTION • Since the head covers are floating mount, do

not overtighten the bolts.
Silent block Ventilator hose
(2) Connect the ventilator hose.
SAPH301090900003
Overhaul
JP30109090702001
1. Cleaning of cylinder head
(1) Remove carbon or other deposit using a scraper.

(2) Clean the cylinder head.
! CAUTION • To remove carbon or other deposit, do not

damage the lower surface of the cylinder
head.
SAPH301090900020
2. Replacement of valve guide

Valve guide
(1) Remove the valve stem seal.
(2) Remove the valve guide using a brass bar or press.
(3) If a new valve guide is assembled, press-fit carefully,
being careful not to pry the end.
! CAUTION • In press fit, be careful not to damage the valve

stem at the upper/lower ends of the guide.
• In press fit, be sure to apply engine oil to the
SAPH301090900021 circumference of the valve guide.
3. Replacement of valve seat
Backing Valve seat ! CAUTION • The valve seat replacement procedure below
metal may damage the cylinder head depending on
the case. It is recommended that a request for
replacement be made to a machining vendor.
Electric
Valve welding
(1) If the valve seat is replaced, use an out-of-use valve. After
Cut these 3 parts.
cutting three pieces from the valve circumference, weld
them to the valve seat.
SAPH301090900022
! CAUTION • Apply grease to protect the cylinder head

lower surface from welding spatter before
work.
(2) Put a backup metal (e.g. brass bar) at the valve stem head
and pull out the valve seat using a press.
(3) Remove welding spatter or dirt on the valve seat surface.
ࠑ ࠑ
ࠑ ࠑ
Intake Exhaust
SAPH301090900023
(4) Heat the cylinder head to approx. 80 ° C{176 ° F} to 100

° C {212 ° F} and strike the cooled valve seat into the
mounting area of the cylinder head.
! CAUTION • Be careful not to break it because it is a

sintered part.
SAPH301090900024
(5) Apply small amount of lapping compound to the contact

surface between the valve and the valve seat.
(6) Strike gently while turning the valve using a lapping tool
for adjustment.
SAPH301090900025
4. Replacement of nozzle seat
(1) Tap the nozzle seat from the cylinder head lower part.
Then, put a bolt in the nozzle seat tap.
(2) Hit the bolt head using a hammer and pull out the nozzle
seat toward the cylinder head upper part.
(3) Remove the O-ring from the cylinder head.
! CAUTION • After pulling out the nozzle seat, be sure to

remove deposit such as remaining liquid
SAPH301090900026 gasket or dirt.
(4) After attaching a new O-ring applied with engine oil into
Nozzle seat O-ring the nozzle seat hole in the cylinder head, apply the liquid
gasket [Threebond TB1211 (white) or equivalent] to the
lower part of a new nozzle seat and assemble it on the
cylinder head.
! CAUTION • Be sure to replace the O-ring with a new part.

Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
SAPH301090900027
head.
• Install it within 20 minutes after application of
the liquid gasket.
(5) Clamp the nozzle seat using a 0.375 steel ball and a
Push rod pneumatic hammer.
Pressing tool
Nozzle seat
! CAUTION • Do not strike out with a normal hammer.

Conical surface A must be in close contact on
㧭 the circumference after clamping.
Steel ball
SAPH301090900028
5. Inspection of cylinder head
(1) Check for crack or damage using dye penetrant. If a faulty

condition is found, replace the cylinder head.
SAPH301090900029
(2) Measure distortion of cylinder head lower surface using a

ruler. If the measurement value is beyond the repair limit,
grind and correct it.
Standard value (mm{in.}) Repair limit (mm{in.})
0.05{0.0019} 0.15{0.0059}
SAPH301090900030
Cylinder Block
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Part layout
JP30109090402002
SAPH301090900031
11408 Cooling jet 11841 Camshaft bearing

11467 Cylinder liner 11851 Camshaft bearing
11811 Camshaft bearing 11861 Camshaft bearing
11821 Camshaft bearing 11871 Camshaft bearing
11831 Camshaft bearing 15605 Bolt
Tightening torque
11521 274N⋅ m{2,800kgf⋅ cm,203lbf⋅ ft} 15605 23N⋅ m{230kgf⋅ cm,17lbf⋅ ft}
êÆî óvóÃ
Overhaul
JP30109090702002
1. Removal of cylinder liner
(1) Put match marks on the flange surfaces of the cylinder

block and the cylinder liner using a oil based marker.
! CAUTION • Store removed cylinder liners for each

cylinder number.
• Never provide match marks with a punch.
SAPH301090900032
(2) Pull out the cylinder liner toward the cylinder block upper
part using a puller.
! CAUTION • Be careful for handling of the cylinder liner.

Do not reuse the cylinder liner which has
been dropped.
• Do not touch the cooling jet during work.
SAPH301090900033
2. Installation of cylinder liner

(1) Apply engine oil to the inner bore of the cylinder block.
(2) Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a guide.
! CAUTION • When a new cylinder liner is installed, install

the cylinder liner with the same identification
mark (A, B, C) stamped on the cylinder block.
SAPH301090900034
3. Inspection of protrusion at cylinder liner flange
(1) Measure protrusion of the flange using a dial gauge.
0.04 - 0.10
Standard value (mm{in.})
{0.0016 - 0.0039}
SAPH301090900035
4. Inspection of cooling jet
(1) Remove the standard oil check valve and install the
cooling jet on the cylinder block.
Check bolt
SAPH301090900036
(2) Connect the injection test oil hose from the lower part of
the cylinder block to the tool check bolt.
! CAUTION • Use new engine oil for injection of oil.
Check bolt
Oil hose
SAPH301090900037
(3) Set a tool on the cylinder block.
(4) Inject oil from the nozzle of the cooling jet at the hydraulic
Special tool
test kit
pressure of 196 kPa{2 kgf/cm2, 28 psi}.
NOTICE • Refer to the drawing for the oil injection unit.

Cylinder
Liner
Cooling jet
SAPH301090900038
Oil injection unit (example)

Pressure
regulator
Oil hose
Air tank
(oil tank)
Air
Air gauge compression
Air hose
To cooling jet
Valve
SAPH301090900039
(5) When the injection center hits within the specified line of
the gauge, it is considered normal.
Injection Gauge target circle
! CAUTION • Oil is susceptible to combustion due to
spread. Do not use fire near around.
• Work at well ventilated place.
Faulty Faulty Normal Normal (6) Make sure that the jet position check gauge hole at the
tool assembly end may not interfere with the cooling jet
pipe.
SAPH301090900040
(7) If injection does not hit the target circle, correct it with a
special tool.
! CAUTION • If the injection position of the cooling jet is

incorrect, replace parts with new ones instead
of correction.
(8) Remove the check bolt and install the cooling jet on the
cylinder block using the genuine oil check valve.
(9) After assembly of the piston, make sure that the cooling
jet does not interfere with the piston at the piston bottom
dead center.
5. Inspection of cylinder block
(1) Check for crack or damage using dye penetrant. If a faulty

condition is found, replace the crankshaft.
(2) Measure distortion on the cylinder block using a ruler. If
the measurement value is beyond the operation limit,
replace it.
0.05{0.0019} 0.15{0.0059}
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SAPH301090900041
Timing Gear Cover and Flywheel Housing

Part layout
JP30109090402003
SAPH301090900042
11306 Dust cover 11356 Flywheel housing stay

11311 Timing gear case assembly 11356A Flywheel housing stay
11321 Timing gear case cover assembly 12281 Engine hanger
11351 Flywheel housing assembly 9828A Crankshaft rear oil seal*
11328 Gasket* 9828B Crankshaft front oil seal*
11329 Gasket*

Tightening torque
11185 211N⋅ m{2,150kgf⋅ cm,156 lbf⋅ ft} 9411-10502 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft}
900125 211N⋅ m{2,150kgf⋅ cm,156 lbf⋅ ft} 9411-10602 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft}
9409A 172N⋅ m{1,750kgf⋅ cm,127 lbf⋅ ft} 9411-10952 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft}
9411-10252 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft} 9412-14652 113N⋅ m{1,150kgf⋅ cm,83 lbf⋅ ft}
9411-10352 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft}
êÆî óvóÃ
Replacement of flywheel housing

JP30109090702003
1. Removal of flywheel housing
(1) Remove the housing stay.

Flywheel (2) Remove 8 M8 bolts and then remove the flywheel
housing
stay housing.
Flywheel
housing
stay
SAPH301090900043
2. Installation of flywheel housing

Application width
3.5 - 4.5mm (1) Remove contamination from the joint surfaces of the
{0.1378 - 0.1771in.}
flywheel housing and the cylinder block using a scraper.
(2) Apply the liquid gasket [Threebond TB1207D (red) or
equivalent] to the flywheel housing as shown in the figure.
(3) Install the guide bolts at several mounting threads and
align the flywheel housing with the cylinder block without
shifting the liquid gasket.
SAPH301090900044 ! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of
4±0.5mm{0.1575 ± 0.0197in.}.
the liquid gasket.
(4) Tighten the flywheel housing stay and flywheel housing

bolts.
Flywheel Tightening torque :

housing
stay Flywheel housing: M14
113 N⋅ m{1,150 kgf⋅ cm, 83 lbf⋅ ft}
Flywheel housing stay: M16
211 N⋅ m{2,150 kgf⋅ cm, 156 lbf⋅ ft}
Flywheel åšä²óvóÃçÄñ⁄
housing
stay
SAPH301090900043
Replacement of crankshaft front oil seal

JP30109090704002
1. Removal of crankshaft front oil seal

(1) Align the special tool with the convex in the crankshaft
rear oil seal, insert the special tool sleeve and fix it.
Special tool : 380100066 Puller
! CAUTION • Install the special tool so that the dowel pin of

the crankshaft may not come in contact with
it.
SAPH301090900045
(2) Tighten the center bolt of the special tool gradually and
pull out the crankshaft front oil seal.
! CAUTION • Check the engagement of the special tool and

oil seal during work and pull it out so that the
special tool is not removed.
SAPH301090900046
2. Installation of crankshaft front oil seal
(1) Make sure that there is no impact mark or dirt on the oil
seal insertion of the timing gear case cover and
crankshaft.
(2) Remove contamination from the special tool press.
(3) Apply a small amount of engine oil to the lip of a new oil
seal.
(4) Insert the oil seal into the crankshaft manually until it
stops paying attention to the direction of the oil seal.
SAPH301090900047
! CAUTION • Install the oil seal so that the felt surface is

outside and the slinger (steel plate) surface is
inside.
• Install the oil seal so that it is not tilted.
(5) Install the plate on the end of the crankshaft with 2 bolts.
Special tool : 380100065 Press
SAPH301090900048
(6) Align the press with the guide bolt, tighten the center bolt
and press-fit the oil seal.
! CAUTION • Press-fit uniformly on the circumference.
(7) Tighten until the press hits and make sure the oil seal is
press-fit uniformly on the circumference.
SAPH301090900049
Replacement of crankshaft rear oil seal

JP30109090704003
1. Removal of crankshaft rear oil seal

(1) Align the special tool with the convex in the crankshaft
rear oil seal, insert the special tool sleeve and fix it.
Special tool : 380100067 Puller
SAPH301090900050
! CAUTION • Since the special tool can be used for K13C

and P11C, align "K" and "P" with the
positions shown in the figure and install it on
the oil seal.
SAPH301090900051
(2) Tighten the center bolt of the special tool gradually and
pull out the crankshaft rear oil seal.
! CAUTION • Check the engagement of the special tool and

oil seal during work and pull it out so that the
special tool is not removed.
SAPH301090900052
2. Installation of crankshaft rear oil seal

Oil seal guide
(1) Make sure that there is no impact mark or dirt on the oil
seal insertion of the flywheel housing and crankshaft.
Oil seal
(2) Remove contamination from the special tool press.
(3) Apply a small amount of engine oil to the lip of a new oil
seal.
(4) Insert it into the oil seal guide of the special tool press,
paying attention to the direction of the new oil seal.
Special tool : 380100068 Press
SAPH301090900053
! CAUTION • Install the oil seal so that the felt surface is

outside and the slinger (steel plate) surface is
inside of the engine.
• Install the oil seal so that it is not tilted.
(5) Install the oil seal guide assembled with the oil seal on the
end surface of the crankshaft with 2 bolts.
! CAUTION • Make sure that the step of the crankshaft and

the oil seal guide is uniform on the
circumference after tightening the guide bolt.
SAPH301090900054
(6) Align the press with the oil seal guide and tighten it with
the center bolt.
! CAUTION • Press-fit uniformly on the circumference.
(7) Tighten until the press hits and make sure that the oil seal
is press-fit uniformly on the circumference.
SAPH301090900055
Replacement of timing gear case cover

JP30109090704004
1. Removal of crankshaft front oil seal

Reference: "Engine mechanical, Timing gear cover and
flywheel housing, Replacement of crankshaft front oil
seal"
2. Removal of timing gear case cover

(1) Remove bolts and remove the timing gear cover.
3. Installation of timing gear cover

(1) Replace the gasket and O–ring with new ones and install
the timing gear cover.
(2) Cut the gasket projecting to the engine lower surface so
that it becomes a flat surface.
4. Installation of crankshaft front oil seal

Reference: "Engine mechanical, Timing gear cover and
flywheel housing, Replacement of crankshaft front oil"
Main Moving Parts

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ç\ê¨îzíuê}
Part layout
JP30109090402004
SAPH301090900056
04132 Piston pin 13453 Ring gear

11011 Thrust bearing 13470 Crankshaft pulley assembly
11701 Crankshaft bearing 13471 Crankshaft pulley
13201 Connecting rod bearing 13521 Crankshaft gear
13260 Connecting rod assembly 13531 Oil pump drive gear
13265 Connecting rod bolt 9532-07220 Key
13272 Connecting rod bushing 9819A Retainer ring*
13400 Crankshaft assembly S1304 Piston ring
13407 Crankshaft damper S130B Piston assembly

Tightening torque
13266 69N⋅ m{700kgf⋅ cm,51 lbf⋅ ft}+90° +90° 900124 108N⋅ m{1,100kgf⋅ cm,80 lbf⋅ ft}
13455 270N⋅ m{2,750kgf⋅ cm,200 900124A 245N⋅ m{2,500kgf⋅ cm,180 lbf⋅ ft}
lbf⋅ ft}(Standard)
13455 225N⋅ m{2,290kgf⋅ cm,166 9068-10300 55N⋅ m{560kgf⋅ cm,41 lbf⋅ ft}
lbf⋅ ft}(Vehicle with PTO)
êÆî
óvóÃ
Replacement of piston and connecting rod

JP30109090704005
1. Removal of piston
(1) Remove nuts and remove the connecting rod cap.
! CAUTION • Fix the cylinder liner on the block.

• Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.
• Store removed connecting rod cap for each
SAPH301090900057
cylinder number so that combinations of the
connecting rod and the connecting rod cap
may not be changed.
(2) Remove carbon on the cylinder liner inner surface with a

scraper or a sand paper (No. 150 or so) in the
circumferential direction.
! CAUTION • Do not damage parts lower than the carbon

deposit area.
(3) Fix the cylinder liner with bolts and a plate.
SAPH301090900058
(4) Hit the connecting rod from underneath the engine using
the handle of a hammer. Remove the piston together with
the connecting rod.
SAPH301090900059
NOTICE • In removing the piston, rotate the connecting

Cooling jet
rod as shown in the figure. Do not bend the
cooling jet.
! CAUTION • Store removed pistons and connecting rods

for each cylinder number.
• Be careful not to touch the cooling jet.

SAPH301090900060
2. Disassembly of piston and connecting rod
(1) Remove the retainer ring using snap ring pliers.

(2) Warm the piston to 50 ° C{122 ° F} or more.
(3) Remove the piston pin using the brass bar and disconnect
the piston from the connecting rod.
SAPH301090900061
(4) Remove the piston ring using a ring expander.
! CAUTION • Since the piston ring is susceptible to

damage, be careful for handling.
• Store piston rings for each cylinder number.
• Store the piston rings so that the upper and
lower surfaces may be identified.
SAPH301090900062
3. Assembly of piston and connecting rod

Piston "0" mark position
(1) Warm the piston to 50 ° C{122 ° F} or more.
(2) Install the piston on the connecting rod so that the "0"
Ex-haust side In-take side
mark on the piston may be opposite to the match mark
stamp on the connecting rod.
Oil hole
! CAUTION • Make sure that the oil hole offset is as shown
Match mark stamp
in the figure.
(3) Install a new retainer ring using snap ring pliers.

SAPH301090900063
! CAUTION • Make sure that there is no backlash in the

retainer ring.
(4) Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
and top ring using a ring expander.
(5) Connect the joint of the coil expander and fit the oil ring
inside the ring. Offset the coil expander joint with the ring
Upper surface
Oil joint by 180 deg for installation.
Top Second Third
(6) Allocate the joints of the piston ring with uniform intervals
as shown in the figure.
Lower surface Oil ring
Clearance
Joint
Coil expander Second
Oil Third
Top
SAPH301090900064
4. Installation of piston and connecting rod

Second ring (1) Apply engine oil to the inner diameter surface of the
connecting rod.
(2) Allocate the joints of the piston ring with uniform intervals
Oil ring Third ring as shown in the figure.
Top ring
SAPH301090900065
(3) Measure the overall length of the connecting rod bolt

using a vernier calipers. If it is out of the operation limit,
replace it with a new one.
Overall length
of the bolt
Standard value (mm{in.}) Operation limit (mm{in.})
102.5{4.0354} 105.0{4.1338}
(4) Apply engine oil to the connecting rod bolt thread and the
nut seat and install the piston on the connecting rod.
SAPH301090900066
(5) Install the connecting rod bearing to suit concave shape of
the connecting rod.
! CAUTION • Make sure that the oil hole of the connecting

rod bearing is aligned with the oil hole of the
connecting rod.
(6) Apply engine oil to the piston, cylinder liner and

connecting rod bearing and compress the piston ring
using a ring compressor.
! CAUTION • Make sure that there is no deformation or

damage to the piston ring holder.
(7) Insert the piston carefully so that the connecting rod may
not come in contact with the cooling jet.
! CAUTION • Face the "0" mark on the piston toward the

exhaust side for insertion.
• Set the crankshaft of the cylinder as the top
Cooling jet dead center for assembly.
• Do not damage the cylinder liner, crankshaft
and cooling jet during work.
SAPH301090900067
• After assembly, make sure that the oil hole of
the connecting rod is at the air intake side.
(8) Install the connecting rod bearing to suit concave shape of

the connecting rod cap.
Match mark
stamp (9) Apply engine oil to the bolt thread and seating, align the
connecting rod cap and connecting rod match mark
directions and numbers and tighten nuts temporarily.

• Do not change the combination between the

! CAUTION
connecting rod and the connecting rod cap.
SAPH301090900068
(10) Tighten the connecting rod nut and mark the nut head in
Paint mark the same direction with paint.
Seating torque : 69 N⋅ m {700 kgf⋅ cm, 51 lbf⋅ ft}

ࠑ

(11) 90Retighten the 90 deg connecting rod nut.

(12) Retighten the 90 deg connecting rod nut.
(13) Make sure that all marks are in the same direction.
Paint mark ! CAUTION • If a bolt is turned excessively in retightening,

do not loosen it.
SAPH301090900069
(14) Make sure that the end play is the standard value after
installation.
0.15 - 0.32
0.6{0.0236}
{0.0059 - 0.0125}
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Inspection of piston and connecting rod

JP30109090703001
1. Inspection of piston clearance
(1) Measure the inner diameter of the cylinder liner sliding

surface using a cylinder gauge.
122{4.803} 122.15{4.8090}
SAPH301090900070
(2) Measure the piston outer diameter using a micrometer.
! CAUTION • The measuring position is 25 mm{0.984 in.}

above the piston lower end and square to the pin
hole.
Standard value (mm{in.}) 121.95{4.8012}
(3) Calculate the difference between the inner diameter of the

cylinder liner and the outer diameter of the piston. If it is beyond
SAPH301090900071
the standard value, replace the cylinder liner and the piston.
0.060 - 0.080
0.15{0.0059}
{0.0024 - 0.0031}
2. Inspection of clearance between piston ring and ring groove
(1) Measure the piston ring width using a micrometer. If it is

beyond the operation limit, replace the piston ring.

(mm{in.}) (mm{in.})
Top ring 3.312{0.1304} (Taper)
Second
2.306{0.0908} (Taper)
SAPH301090900072 ring
Third ring 2.0{0.0787} 1.80{0.0708}
Oil ring 4.0{0.1575} 3.90{0.1535}

(2) Measure the piston ring groove using a thickness gauge.

If it is out of the operation limit, replace the piston.
Top ring groove (Taper)
Second ring groove (Taper)
Third ring groove 2.0{0.0787}
Oil ring groove 4.0{0.1575}

SAPH301090900073
(3) Calculate the difference between the piston ring thickness

and ring groove. If it is beyond the operation limit, replace
the piston ring or the piston.
Standard value Operation

(mm{in.}) limit (mm{in.})
Top ring clearance — —
Second ring clearance — —
0.065 - 0.105
Third ring clearance 0.20{0.0078}
{0.0026 - 0.0041}
0.025 - 0.065
Oil ring clearance 0.10{0.0039}
{0.0010 - 0.0025}
3. Inspection of piston ring joint clearance

Cylinder liner
(1) Insert the piston ring into the cylinder liner by
80mm{3.150in.} horizontally using piston.
(2) Measure the piston ring joint clearance using a thickness
gauge. If it is out of the operation limit, replace the piston ring.
Piston ring
Operation limit
(mm{ni.})
Top ring 0.30 - 0.50{0.0118 - 0.0196} 1.5{0.0590}

SAPH301090900074
Second ring 0.50 - 0.70{0.0197 - 0.0275} 1.2{0.0472}
Third ring 0.35 - 0.50{0.0138 - 0.0196} 1.2{0.0472}
Oil ring 0.30 - 0.50{0.0118 - 0.0196} 1.0{0.0393}
4. Inspection of piston pin
(1) Measure the outer diameter of the contact area of the

piston pin with the piston boss using a micrometer.
Standard value (mm{in.}) 47{1.850}
SAPH301090900075
(2) Measure the piston boss inner diameter using a cylinder

gauge.
(3) Calculate the difference between the outer diameter of the piston
pin contact area with the piston boss and the inner diameter of the
piston boss. If it is out of the operation limit, replace the piston pin.
SAPH301090900076
0.041 - 0.059{0.0017 - 0.0023} 0.05{0.0019}
5. Inspection of connecting rod bushing oil clearance
(1) Measure the outer diameter of the center of the piston pin
using a micrometer.
SAPH301090900077
(2) Measure the connecting rod bushing inner diameter using

a cylinder gauge.
(3) Calculate the difference between the outer diameter of the

center of the piston pin and the inner diameter of the
connecting rod bushing. If it is beyond the operation limit,
replace the piston pin and connecting rod.
SAPH301090900078
0.025 - 0.043{0.0394 - 0.0016} 0.10{0.0039}
6. Inspection of connecting rod
(1) Check for crack or damage to the connecting rod using

dye penetrant. If a faulty condition is found, replace the
crankshaft.
SAPH301090900079
(2) Insert a rod with the diameter of 6 mm{0.236 in.} from the
oil hole at the connecting rod large end and make sure
that it goes through the oil hole at the small end. If the rod
with the diameter of 6 mm{0.236 in.} does not through due
to clogging of the oil hole, replace the connecting rod.
SAPH301090900080
7. Inspection of connecting rod oil clearance
(1) Measure the outer diameter of the crankshaft crank pin

using a micrometer.
Measure 2 parts.
Standard value Repair limit Operation limit

(mm{in.}) (mm{in.}) (mm{in.})
80{3.150} 79.8{3.1417} 78.8{3.1023}
SAPH301090900081
(2) Assemble the bearing on the connecting rod large end,

install the cap and tighten the nut of the connecting rod
bolt.
(3) Measure the bearing inner diameter of the connecting rod

large end using a cylinder gauge.
crank pin of the crankshaft and the inner diameter of the
connecting rod bearing. If it is beyond the operation limit,
replace the connecting rod bearing and the crankshaft.
SAPH301090900082
NOTICE • The crankshaft can be ground and corrected.
0.025 - 0.084
0.30{0.0118}
{0.0010 - 0.0033}
Replacement of crankshaft
JP30109090704006
1. Removal of crankshaft
(1) Remove the main bearing cap and the crankshaft bearing.
Remove the crankshaft using a hoist.
! CAUTION • Since the part is heavy, be careful for

handling.
• Store removed main bearing caps and
crankshaft bearings for each cylinder number.
SAPH301090900083
2. Installation of crankshaft
(1) Place the bearing with oil hole on the cylinder block and
apply engine oil.
(2) Place the crankshaft.
(3) Align the bearing with no hole with the bearing cap and
apply engine oil.
(4) Insert the thrust bearing applied with engine oil between
the crankshaft and the cylinder block so that the dented
surface faces outside.
(5) Apply engine oil to the thrust bearing at the cap side in the
same way and install the cap with the dented surface
facing outside.
Dent
SAPH301090900084
(6) Install it so that the triangular mark on the main bearing

Front of engine
cap faces the front of the engine.
Stamp number
! CAUTION • Check the stamp number of each main

bearing cap with the stamp number of the

cylinder block.
(7) Apply engine oil to the bolt seating and the bolt thread of
the main bearing cap bolt and tighten the bolts three times
Stamp number
from the center to outside.
SAPH301090900085
! CAUTION • Loosen the No. 4 cap bolt, tap the front/rear ends of
the crankshaft with a plastic hammer for initial fit and
tighten it while sometimes turning the crankshaft.
Tightening order : 4—3—5—2—6—1—7

lbf⋅ ft}
(8) Make sure that the crankshaft turns smoothly.
Inspection of crankshaft
JP30109090703002
1. Inspection of end play

(1) Measure the end play of the crankshaft using a dial
gauge. If it is beyond the operation limit, replace the thrust
bearing.
0.110 - 0.240
0.5{0.0196}
{0.0044 - 0.0094}
2. Inspection of rotation runout
(1) Hold the No. 1 and No. 7 journals with the V–block,
measure the rotation runout of the crankshaft, and if it
exceeds the operation limit, replace the crankshaft.
Operation limit (mm{in.}) 0.07{0.0027}
SAPH301090900086
3. Inspection of crankshaft oil clearance
(1) Measure the outer diameter of the crankshaft journal

Measure 2 using a micrometer.
parts.
ࠑ
90{3.543} 88.8{3.4960}
SAPH301090900087
(2) Do not install the crankshaft. Install the crankshaft bearing

and the main bearing cap on the cylinder block.
(3) Measure the crankshaft bearing inner diameter using a

cylinder gauge.
crankshaft journal and the inner diameter of the
crankshaft bearing. If it is beyond the standard value,
replace the crankshaft or crankshaft bearing.
SAPH301090900088
0.044 - 0.097
0.30{0.0118}
{0.0018 - 0.0038}
4. Inspection of crack and damage to crankshaft and of oil

hole
(1) Check for crack or damage to the crankshaft using dye

penetrant. If a faulty condition is found, replace the
crankshaft.
SAPH301090900089
(2) Check for clogging of the crankshaft oil hole. If faulty

condition is found, replace the crankshaft.
SAPH301090900090
Replacement of crankshaft pulley

JP30109090704007
1. Removal of crankshaft pulley
(1) Remove the 1 crankshaft pulley mounting bolt and install

the guide bolt to prevent fall.
(2) Remove the remaining bolts while supporting the
crankshaft pulley, and remove the crankshaft pulley
assembly.
! CAUTION • When the bolt is removed, the crankshaft

pulley may fall. It must be firmly supported
SAPH301090900091 during removal.
NOTICE • Insert a large flat tip screwdriver into the

inspection hole to prevent turning of the
crankshaft.
2. Installation of crankshaft pulley

(1) Assemble the crankshaft pulley and crankshaft damper.
Tightening torque : 108 N⋅ m {1,100 kgf⋅ cm, 80 lbf⋅ ft}
(2) Apply engine oil to the bolt seat and the bolt thread of the
crankshaft pulley mounting bolt.
(3) Install the crankshaft pulley on the crankshaft and tighten

it according to the figure.
lbf⋅ ft}

NOTICE • Insert a large flat tip screwdriver into the
SAPH301090900092 inspection hole to prevent turning of the
crankshaft.
Replacement of flywheel
JP30109090704008
1. Removal of flywheel
㧔㧭㧕
(1) Remove the engine revolution sensor on the flywheel
housing.
Engine ! CAUTION • If the engine revolution sensor is not removed

revolution before removing the flywheel, the engine
sensor
revolution sensor is damaged.
㧔㧮㧕
SAPH301090900093
(2) Remove the 2 flywheel mounting bolts and install the

guide bolt to prevent fall.
(3) Remove the remaining bolts while supporting the

flywheel, and remove the flywheel.
! CAUTION • Since the part is heavy, be careful for

handling.
SAPH301090900094
2. Removal of ring gear

(1) Heat the entire ring gear circumference with a burner until
it is about 200 ° C{392 ° F}.
! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.
SAPH301090900095
(2) Hit the circumference of the ring gear gently using a

backing rod to remove the ring gear from the flywheel.

SAPH301090900096
3. Installation of ring gear
(1) Heat the entire ring gear circumference with a burner until
it is about 200 ° C{392 ° F}.

SAPH301090900097
(2) Face the chamfered side toward the flywheel and install it
on the flywheel quickly.

SAPH301090900098
4. Installation of flywheel
(1) Make sure that there is no burr or dirt on the joint surface
of the crankshaft and the flywheel and the screw hole.
(2) Align the flywheel with the crankshaft with 2 guide bolts,
apply engine oil to the bolt seating and thread and install
the bolts.
Tightening torque :
Standard
270 N⋅ m{2,750 kgf⋅ cm, 200 lbf⋅ ft}
Vehicle with PTO
225 N⋅ m{2,290 kgf⋅ cm, 166 lbf⋅ ft}
SAPH301090900094 ! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Since the bolts for vehicles with PTO cannot
be reused, replace them with new ones.
(3) Install the engine revolution sensor on the flywheel

housing.
5. Installation of the engine rotation sensor

(1) Install engine revolution sensor (A).
㧔㧭㧕
(2) Screw in engine revolution sensor (B) by hand, until its tip
comes into contact with the ring gear, and then turn it one
turn back.
Engine
revolution ! CAUTION • When a tool is used to screw in the engine
sensor
rotation sensor, the sensor may become
damaged.
㧔㧮㧕
SAPH301090900093
(3) Match the gap between engine revolution sensor (B) and
ring gear to the reference value and secure with the lock
}
91
-0 m
Engine revolution sensor(B)

94 1.5 m
.05
nut.
{0. 1.0 -
Tightening torque: 49 ± 4.9 N⋅ m {500 ± 50

03
kgf⋅ cm,36±4 lbf⋅ ft}
Ring gear
Standard value (mm{in.}) 1.0 - 1.5{0.0394 - 0.0591}
SAPH301090900099
Inspection of flywheel
JP30109090703003
! CAUTION • When flywheel plane run-out and axial run-out

are not within the standard values, troubles
like coupling damage or shaft damage may be
caused at the time of connection with the
machine.
1. Inspection of flywheel plane run-out and axial run-out

(1) Hoist the flywheel side of the engine, so that no load acts
onto the flywheel housing.
Raise (2) Push the crankshaft to the front of the engine and stabilize
it.
! CAUTION • Take care not to include the end play of the

crankshaft in the measurement.
SAPH301090900100
(3) Use a dial gauge to measure plane run-out (A) and axial
run-out (B) of the flywheel.
Repair limit (mm{in.}) 0.2{0.0078}
! CAUTION • Measure in engine rotation direction

(counterclockwise as seen from the flywheel)
at eight positions in intervals of 45° .
SAPH301090900101
SAPH301090900102
(4) If the plane run-out of the flywheel is outside the reference

values, clean the mounting surface for the flywheel on the
crankshaft and reassemble after using an oil stone to
remove burr.
If the value is still outside the reference values, replace
the flywheel.
(5) If the axial run-out of the flywheel is outside the reference
values, replace the flywheel.
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Camshaft and Idle Gear

Part layout
JP30109090402005
SAPH301090900103
13505 Idle gear assembly 13580 Idle gear shaft assembly

13505A Main idle gear assembly 13581 Idle gear shaft
13511 Camshaft 13613 Supply pump drive gear
13523 Camshaft gear 900116 Spacer
13571 Thrust plate 900116Ç` Spacer
13572 Thrust plate 9532-07150 Key
13572A Thrust plate 9851A O-ring*
13572B Thrust plate

Tightening torque
900124A 44N⋅ m{450kgf⋅ cm,32 lbf⋅ ft} 9019A 137N⋅ m{1,400kgf⋅ cm,100 lbf⋅ ft}
900124 108N⋅ m{1,100kgf⋅ cm,80 lbf⋅ ft}
Gear train layout

JP30109090402006
Air compressor idle gear

Main idle gear (No.1)
Main idle gear (No.2)
Supply pump drive gear
Camshaft gear
Oil pump drive gear

Crankshaft gear
Oil pump driven gear
Details of parts A, B and C

SAPH301090900104
êÆî óvóÃ
Removal of camshaft
JP30109090702004
1. Removal of push rod cover
(1) Remove the push rod cover on the side of the engine.
(2) Hold the roller tappet so that it does not fall.
SAPH301090900105
2. Removal of camshaft
(1) Turn the camshaft gear, align the camshaft gear hole with
the thrust plate mounting bolt position, remove the bolt
and remove the shaft.
! CAUTION • Pull out the cam bearing so that it is not

damaged.
NOTICE • Refer to the following for installation of the

camshaft.
SAPH301090900106
Reference: "Engine mechanical, Camshaft
and idle gear, Installation of camshaft"
Disassembly of camshaft
JP30109090702005
1. Removal of camshaft
(1) Fix the camshaft through an aluminum plate, etc. with a

vice and remove the camshaft gear bolt.
! CAUTION • Prevent faulty conditions on the gear such as

deformation, impact, scratch, etc.
(2) Pull out the main bearing from the crankshaft using a
puller.
SAPH301090900107
NOTICE • Refer to the following for inspection and
disassembly of the camshaft.
and idle gear, Inspection of camshaft"
and idle gear, Assembly of camshaft"
Inspection of camshaft
JP30109090703004
1. Inspection of cam height on camshaft
(1) Measure the cam height using a micrometer. If it is

beyond the operation limit, replace the camshaft.

(mm{in.}) (mm{in.})
Cam IN 56.03{2.2059} 55.23{2.1744}

height EX 53.72{2.1150} 52.92{2.0835}
SAPH301090900108
Cam IN 6.63{0.2610} 6.48{0.2551}
lift EX 8.72{0.3433} 8.57{0.3374}
2. Inspection of camshaft bearing oil clearance
(1) Measure the outer diameter of the camshaft journal using

a micrometer.
Journal No. 1 65.0{2.5590}
Journal No. 2 64.6{2.5433}
Journal No. 3 64.2{2.5275}

SAPH301090900109
Journal No. 4 63.8{2.5118}
Journal No. 5 63.4{2.4960}
Journal No. 6 63.0{2.4803}
Journal No. 7 62.6{2.4645}
(2) Measure the camshaft bearing inner diameter using a

cylinder gauge.
camshaft journal and the inner diameter of the camshaft
bearing. If it is beyond the operation limit, replace the
camshaft or camshaft bearing.
0.030 - 0.120{0.0012 - 0.0047} 0.30{0.0118}
3. Inspection of camshaft runout
(1) Hold the camshaft with the V–block, measure the rotation
runout of the camshaft using a dial gauge. If it is beyond
the operation limit, replace the camshaft.
SAPH301090900110
Assembly of camshaft
JP30109090702006
1. Installation of ring gear

(1) Insert the spacer and thrust plate into the camshaft.
(2) Warm the cam gear to approx. 180 ° C{356 ° F} using a
heater (piston heater, etc.).
! CAUTION • Do not touch parts with bare hand because

they are hot.
(3) Apply engine oil to the bolt seating and thread, fix the cam
gear using a vice with the part number stamp surface
facing outside, and tighten the bolt.
lbf⋅ ft}
! CAUTION • Prevent faulty conditions on the gear such as

deformation, impact, scratch, etc.
(4) Tighten the bolt again to the specified torque after the
cam gear decreases to room temperature.
SAPH301090900111
2. Inspection of camshaft end play
Thrust plate thickness (1) Measure the camshaft end play using a thickness gauge
and measure the thrust plate thickness using calipers. If it
is beyond the operation limit, replace the thrust plate.

(mm{in.}) (mm{in.})
End play
0.10 - 0.23
End play 0.3{0.0118}
{0.0040 - 0.0090}
SAPH301090900112
Thrust plate
8{0.315} —
thickness
Installation of camshaft
End play JP30109090702007
SAPH301090900113
1. Tappet installation
(1) Insert the tappet coated with engine oil.
! CAUTION • Check the tappet visually for absence of

eccentric wear, cracks, scratches, etc.
SAPH301090900114
2. Installation of camshaft
(1) Apply engine oil to the camshaft journal and insert it into
the cylinder block while turning the camshaft.
! CAUTION • Do not damage the camshaft bearing.
(2) Install the camshaft using 4 bolts.

(3) Make sure that the camshaft end play is the standard
value.
SAPH301090900106 Standard value (mm{in.}) 0.10 - 0.23

{0.0040 - 0.0090}
(4) Apply the liquid gasket [Threebond TB1207C (red) or

equivalent] and install the push rod cover.
! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 - 0.0984 in.}.
the liquid gasket.
SAPH301090900105
Removal of timing gear

JP30109090702008
1. Removal of supply pump drive gear

Reference: "Fuel system, Overhaul of supply pump drive
bearing case"
2. Removal of idle gear and main idle gear
(1) Remove the idle gear shaft mounting bolts of the idle gear
and main idle gear.
(2) Remove the thrust plate and main idle gear at the main
idle gear side.
SAPH301090900115
3. Removal of idle gear shaft

Example of use of special tool
! CAUTION • Do not remove the idle gear shaft unless
necessary.
(1) Pull out each idle gear shaft using a slide puller.
! CAUTION • Refer to the following for installation of the

timing gear.
and idle gear, Assembly of timing gear"
SAPH301090900116
Inspection of timing gear

JP30109090703005
1. Inspection of idle gear oil clearance
(1) Measure the idle gear shaft outer diameter using a

micrometer and measure the idle gear bushing inner
diameter using a cylinder gauge.
Standard value
(mm{in.})
Main Shaft outer diameter 64{2.520}

idle gear Bushing inner diameter 64{2.520}
Shaft outer diameter 52{2.047}

Idle gear
Bushing inner diameter 52{2.047}
(2) Calculate the difference between the idle gear shaft outer
diameter and the idle gear bushing inner diameter. If it is
beyond the operation limit, replace the idle gear shaft and
the idle gear bushing.

SAPH301090900117 (mm{in.}) (mm{in.})
0.030 - 0.090
Main idle gear 0.20{0.0078}
{0.0012 - 0.0035}
0.030 - 0.090
Idle gear 0.20{0.0078}
{0.0012 - 0.0035}
Installation of timing gear

JP30109090702009
1. Temporary tightening of air compressor idle gear shaft
(1) Apply engine oil to the idle gear shaft.

(2) Direct the identification hole of the idle gear shaft to the
lower part of the engine and fix the idle gear shaft, gear
and thrust plate temporarily.
! CAUTION • Press-fit vertically so that the idle gear shaft

does not hit the timing gear case.
Identification hole
(3) Apply engine oil to the bolt seating and the bolt thread and
SAPH301090900118
fix it temporarily.
2. Installation of idle gear
(1) Align the gear mark and install each idle gear.
Tightening torque :
Main idle gear
44 N⋅ m {450 kgf⋅ cm, 32 lbf⋅ ft}
Idle gear
108 N⋅ m {1,100 kgf⋅ cm, 80 lbf⋅ ft}
(2) Make sure that each backlash and end play are within the
standard value after installation.
"Reference: Engine mechanical, Camshaft and idle gear,
Inspection of timing gear installation status"
SAPH301090900119
Inspection of installation status for each

gear
JP30109090703006
1. Inspection of backlash
(1) Measure backlash between gears using a dial gauge. If it
is beyond the operation limit, replace the gear.
Standard
Operation
value
limit (mm{in.})
(mm{in.})
Between supply
SAPH301090900120
0.05 - 0.19
pump drive gear
{0.0020 - 0.30{0.0118}
and main idle
0.0074}
gear(No.2)
Between camshaft 0.07 - 0.19

gear and main idle {0.0028 - 0.30{0.0118}
gear(No.2) 0.0074}
0.06 - 0.19
Between camshaft
{0.0024 - 0.30{0.0118}
gear and idle gear
0.0074}
Between main idle 0.07 - 0.19

gear(NO.2) and {0.0028 - 0.30{0.0118}
crankshaft gear 0.0074}
Between oil pump 0.06 - 0.30

drive gear and oil {0.0024 - 0.40{0.0157}
pump driven gear 0.0118}
2. Inspection of idle gear end play
(1) Measure the end play of the main idle gear and idle gear
using a thickness gauge. If it is beyond the operation limit,
replace the gear and shaft.
Standard value Operation

(mm{in.}) limit (mm{in.})
0.065 - 0.149
Main idle gear 0.30{0.0118}
{0.0028 -0.0049}
SAPH301090900121
0.070 - 0.125
Idle gear 0.30{0.0118}
{0.0026 -0.0058}
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Valve System
Part layout
JP30109090402007
SAPH301090900122
13706 Crosshead 13840 Rocker arm assembly

13707 Tappet 13901 Rocker shaft
13711 Intake valve 13951 Rocker arm support
13715 Exhaust valve 13951B Rocker arm support
13731 Outer valve spring 13951C Rocker arm support
13732 Inner valve spring 900126 Valve spring retainer
13734 Lower spring seat 900129 Collar
13735 Upper spring seat S1306 Push rod
13830 Rocker arm assembly
Tightening torque
900125 52N⋅ m{530kgf⋅ cm,38 lbf⋅ ft} 9219A Rocker arm:44N⋅ m{450kgf⋅ cm,
32lbf⋅ ft}
9219A Crosshead:28N⋅ m{290kgf⋅ cm,20 lbf⋅ ft}
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Overhaul of valve system

JP30109090702010
1. Removal of rocker arm assembly
(1) Loosen the lock nut and turn the adjusting screw
completely.
! CAUTION • Removal without turning the adjusting screw

may bend the rocker shaft.
SAPH301090900123
(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm shaft.

SAPH301090900124
(3) Pull out the push rod.
! CAUTION • Do not pull out the tappet together with the

push rod.
SAPH301090900125
2. Inspection of rocker arm oil clearance
(1) Measure the outer diameter of the rocker shaft using a

micrometer.
28{1.102} 27.92{1.0992}
SAPH301090900126
(2) Measure the rocker arm bushing inner diameter using a

cylinder gauge.
28{1.102} 28.08{1.1055}

rocker shaft and the inner diameter of the rocker arm
bushing. If it is beyond the standard value, replace the
SAPH301090900127 rocker shaft or the rocker arm bushing.
0.044 - 0.120
{0.0018 - 0.0393}
3. Removal of valve spring
(1) Compress the valve spring from the cylinder head using a
spring tool and remove the valve spring retainer.
SAPH301090900128
(2) Remove the intake and exhaust valves.
! CAUTION • Attach a tag with the applicable cylinder

number to the valve so that combinations of
the valve and the cylinder head may not be
mixed.
SAPH301090900129
4. Replacement of valve stem seal
(1) After removing the valve stem seal, assemble the valve
2 spring lower seat. Apply engine oil to the lip and the inner
1 surface of the stem seal. Strike the valve stem seal using
3 a suitable driver until the driver comes in contact with the
valve spring lower seat.
! CAUTION • After assembly of the stem seal, make sure

that there is no deformation, crack or
4 6 inclination of the rubber, or disconnection of
5
the spring.
7 1)Driver
2)Stern seal
3)Valve spring lower seat
4)Spring
5)Rubber
6)Oil application
7)stern seal
BS07K645
5. Inspection of valve spring

Clearance A
(1) Measure squareness of the valve spring using a square or
a thickness gauge. If it is beyond the operation limit
(clearance A), replace the valve spring.
Clearance A (mm{in.}) 2.0{0.0787}
SAPH301090900131
(2) Measure the set load of the valve spring using a spring
tester. If it is out of the operation limit, replace the valve
spring.

(mm{in.}) (mm{in.})
Set length Intake 54.1{2.1299} —

(mm{in.}) Exhaust 54.7{2.1535} —
Inner
SAPH301090900132
Set load Intake 166.7{17, 37.5} 153{15.6, 34.4}
(N{kgf,lbf}) Exhaust 160.8{16.4, 36.2} 147.1{15.0, 33.0}
Set length Intake 58.1{2.2874} —

(mm{in.}) Exhaust 58.7{2.3110} —
Outer
Set load Intake 389.3{39.7, 87.5} 357.9{36.5, 80.5}
(N{kgf,lbf}) Exhaust 382.5{39.0, 86.0} 351.1{35.8, 78.9}
(3) Measure the free length of the valve spring using a vernier
calipers. If it is out of the operation limit, replace the valve
spring.

(mm{in.}) (mm{in.})
Inner valve spring 72.0{2.8346} 70.0{2.7559}
Outer valve spring 93.0{3.6614} 91.0{3.5826}

SAPH301090900133
6. Inspection of spring seat
(1) Check for wear and damage of the spring seats (upper
and lower). If a faulty condition is found, replace the seats.
SAPH301090900134
7. Inspection of oil clearance between valve guide and valve

stem
(1) Measure the outer diameter of the valve stem using a

micrometer.
Standard
Operation
value
limit (mm{in.})
(mm{in.})
Intake valve stem 8{0.315} 7.88{0.3102}

SAPH301090900135
Exhaust valve stem 8{0.315} 7.88{0.3102}
(2) Measure the valve guide inner diameter using a cylinder

gauge.
Standard value
(mm{in.})
Intake valve guide 8{0.315}
Exhaust valve guide 8{0.315}
SAPH301090900136
(3) Calculate the difference between the valve stem outer

diameter and the valve guide inner diameter. If it is beyond
the operation limit, replace the valve stem or the valve

guide.

#

$ Standard Standard Operation
value clearance limit
(mm{ni.}) (mm{in.}) (mm{in.})
%
Stem outer 0.12
SAPH301090900137 8{0.315} 0.040 - 0.077
diameter {0.0047}
Intake {0.0016 -
Guide inner
8{0.315} 0.0030} Following
diameter
Stem outer 0.14

8{0.315} 0.057 - 0.094
diameter {0.0055}
Exhaust {0.0023 -
Guide inner
8{0.315} 0.0037} Following
diameter
Guide inner Part A Part B Part C

diameter (mm{in.}) (mm{in.}) (mm{in.})
Intake 7.88{0.3102} 7.88{0.3102} 7.82{0.3079}
Exhaust 7.86{0.3094} 7.86{0.3094} 7.80{0.3071}
8. Inspection of valve sink

Valve sink
(1) Measure valve sink using a straight edge, thickness
gauge or dial gauge. If it is beyond the operation limit,
replace the valve or the valve seat.

(mm{in.}) (mm{in.})
Intake -0.05 - 0.35

0.7{0.0275}
valve sink {-0.0020 - 0.0137}
SAPH301090900138
Exhaust 0.55 - 0.95

1.3{0.0511}
valve sink {0.0217 - 0.0374}
9. Inspection of tappet oil clearance
(1) Measure the tappet guide inner diameter using a

micrometer and measure the tappet guide inner diameter
using a cylinder gauge.
Standard value
(mm{in.})
Tappet outer diameter 28{1.102}
SAPH301090900139 Tappet guide inner

28{1.102}
diameter
(2) Calculate the difference between the tappet outer

diameter and the tappet guide inner diameter. If it is
beyond the operation limit, replace each part.
0.020 - 0.066
0.10{0.0039}
{0.0008 - 0.0260}
SAPH301090900140
10. Installation of valve and valve spring
(1) Place the lower seat, valve spring and upper seat on the
cylinder head in the order listed.
(2) Compress the valve spring using a spring tool and install
the valve spring retainer.
! CAUTION • Apply engine oil to the contact surface of

each part before assembly.
• Be sure to assemble each valve at the original
SAPH301090900128 cylinder position.
• When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
valve stem seal.
• Since the valve spring has equal spacing,
vertical direction is not specified for
assembly.
• Check for scratch on the valve stem seal
when the valve is reused.
11. Installation of rocker arm assembly
(1) Apply engine oil to both ends of the push rod and insert it
into the cylinder block.
SAPH301090900141
(2) Apply engine oil to the valve stem head.
(3) Apply engine oil to the crosshead mounting area.

(4) Attach the crosshead.
! CAUTION • Make sure that the crosshead is correctly

placed on the valve.
Correct Wrong
SAPH301090900142
(5) Place the rocker arm assembly on the cylinder head and
temporarily tighten the 12 support bolts until it comes in
contact with the cylinder head upper surface in the order
! CAUTION • If an engine retarder is equipped, long bolts

for tightening the engine retarder are used for
the 4, 6, 10, 12 areas in the figure. Use
substitute bolts (9001-24352). (Remove this
SAPH301090900143
bolt when installing the engine retarder.)
• Turn all adjusting screws and place the rocker
arm assembly.
(6) Tighten 12 support bolts in the order shown in the figure.

(7) If an engine retarder is equipped, remove the substitute
bolts 4, 6, 10, 12 that tighten the rocker arm support.
NOTICE • Install the engine retarder on the area where

the substitute bolt is used.
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Adjustment of valve clearance

JP30109090706001
! CAUTION • Make sure that the bolts around head bolts

are tightened to the specified tightening
torque before adjustment.
• When an engine retarder is installed, remove
the engine retarder, use substitute bolts to
tighten the rocker arm support to the
specified tightening torque, and then adjust
the valve clearance.
• Make sure that there is no dirt on the
crosshead, the valve stem and the push rod.
1. Adjustment of valve clearance

Coupling bolt
(1) Turn the crankshaft and check that the timing mark at the
Stamp line Flywheel housing flywheel inspection window is at "1/6" and that the key on
inspection window
the shaft of the supply pump bearing case is pointing up
to confirm that the No. 1 cylinder is at the compression top
16 dead center.
! CAUTION • If the timing mark is at "1/6", but the shaft key

Half coupling bolt Pointer
is pointing down, the No. 6 cylinder is at the
SAPH301090900144
compression top dead center. In this case,
turn the crankshaft another turn to set the No.
1 cylinder to the compression top dead
center.
(2) When the No. 1 cylinder is at the compression top dead

center, the valves marked by { in the following table can
be adjusted, and when the No. 6 cylinder is at the
compression top dead center, the valves marked by ●
can be adjusted.
At the time of No. 1 At the time of No. 6

Cylinder Valve cylinder at the cylinder at the
No. layout compression top compression top
dead center dead center
Suction {
1
Exhaust {
Suction ●
2
Exhaust {
Suction {
3
Exhaust ●
Suction ●
4
Exhaust {
Suction {
5
Exhaust ●
Suction ●
6
Exhaust ●
(3) Loosen the adjusting screw and the lock nut of the
crosshead completely.
14 mm{0.5512in.}
or more
! CAUTION • Provide the adjusting screw protrusion of 14
mm{0.5512 in.} or more from the top surface
of the crosshead. If the adjusting screw is not
completely separated from the valve stem,
Clearance correct adjustment is not allowed.
SAPH301090900145
(4) Insert a thickness gauge between the rocker arm and the
Thickness gauge
crosshead and adjust the clearance with the adjusting
Adjustment screw of the rocker arm. Tighten the lock nut.
Standard value IN 0.45{0.0177}

There is a (cold engine)
clearance. EX 0.60{0.0236}
(mm{in.})
Contact

SAPH301090900146
(5) Loosen the adjusting screw of the crosshead with the

Start thickness gauge inserted. Make sure that feel on the
Feel of thickness gauge thickness gauge is not lighter.
(Do not move.) Nut fixing position
! CAUTION • If it becomes lighter, make adjustments again

(Correct contact) from the beginning.
Feel does not change.

Adjusting screen loosening amount Large
SAPH301090900147
(6) Tighten the adjusting screw of the crosshead until the

Thickness gauge thickness gauge does not move.
Adjustment
Contact Contact
SAPH301090900148
(7) While loosening the adjusting screw of the crosshead

Start gradually, tighten the lock nut of the crosshead at the
Feel of thickness gauge
position where feel on the thickness gauge is appropriate.

(Do not move.) Nut fixing position
(Correct contact)
! CAUTION • Do not over-loosen the adjusting screw. Over-
loosening of the adjusting screw reproduces
Feel does not change. the original status. Although feel on the
Adjusting screen loosening amount Large thickness gauge is appropriate, there is a
SAPH301090900149 clearance between the adjusting screw and
the valve of the crosshead. Correct
adjustment is not allowed.
EXHAUST 10–1
ENGINE
10 EXHAUST
Setup layout
Layout
Exhaust Manifold...................................................... 10-2

Part layout (typical example)................................. 10-2
Replacement......................................................... 10-3
10
10–2 EXHAUST
Exhaust Manifold
JP30109100402001
SAPH301091000001
17044 Insulator 17105 Exhaust manifold

17044A Insulator 17118 Exhaust manifold bracket
17104 Gasket* 17271 Insulator
17104D Gasket*

Tightening torque
9209A 59⋅ m{600kgf⋅ cm, 44 lbf⋅ ft} 9029B 68.5⋅ m{700kgf⋅ cm, 50 lbf⋅ ft}
9068-10700 68.5⋅ m{700kgf⋅ cm, 50 lbf⋅ ft}
Service procedure
Replacement procedure item
EXHAUST 10–3
Replacement
JP30109100704001
1. Removal of exhaust manifold
(1) Remove the turbocharger.

(2) Remove the insulator.
(3) Remove the exhaust manifold bracket.
(4) Remove the exhaust manifold.
2. Replacement of stud bolt

(1) Remove dirt (e.g. sealant) at the female thread of the
cylinder head and clean the thread again with tap (M10 x
SAPH301091000002
1.5).
(2) Tighten the new stud bolt.
! CAUTION • Excessive tightening with overtorque may

cause crack in the cylinder head.
3. Installation of exhaust manifold

(1) Install a new gasket and align the exhaust manifold with
the cylinder head.
22 20 18 16 14 12 10 8 6 4 2 (2) Tighten the nuts from the top to the bottom and from the
1 right to the left.
23 21 19 17 15 13 11 9 7 5 3 Tightening torque : 44 N⋅ m {450 kgf⋅ cm, 32 lbf⋅ ft}
SAPH301091000003
(3) Tighten the nuts again from the top to the bottom and from
the right to the left.

1 3 5 7 9 11 13 15 17 19 21
23 ! CAUTION • Be sure to retighten it.
2 4 6 8 10 12 14 16 18 20 22
SAPH301091000004
10–4 EXHAUST
(4) For the exhaust manifold bracket, fix the eight bolts
Exhaust
manifold temporarily, push the bracket against the cylinder block,
Bracket center tighten the bolt at the manifold side and then tighten the
Spacer
bolt at the cylinder block side.
Bolt Cylinder head
Tightening torque : 68.5 N⋅ m {700 kgf⋅ cm, 50 lbf⋅ ft}
Cylinder block
Bolt
(5) Connect the insulator.
Fix bracket and (8) bolts temporarily. (6) Install the turbocharger.
Push the
bracket.
Tighten bolt.
(Manifold side)
Tighten bolt.
(Block side)
SAPH301091000005
COOLING 11–1
ENGINE
11 COOLING
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Cooling System ........................................................ 11-2

Cooling system drawing........................................ 11-2
Part layout............................................................. 11-3
Replacement of coolant pump .............................. 11-5
Replacement of thermostat case .......................... 11-5
Inspection of thermostat ....................................... 11-6
Replacement of fan drive, tension pulley .............. 11-7
Replacement of cooling fan, fan spacer................ 11-9
11
11–2 COOLING
Cooling System
Cooling system drawing
jp30109110804001
Reservoir
Coolant temperature gauge
Radiator cap
Thermostat case
Cylinder head
Thermostat
Radiator
Cylinder block
Car heater
Coolant pump Oil cooler
Drain cock
Drain cock
SAPH301091100001
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COOLING 11–3
Part layout
jp30109110402001
Water pump, Thermostat
SAPH301091100002
16100 Coolant pump 16332 Coolant pump outlet pipe

16173 Coolant pump pulley 900234 Coolant hose
16303 Thermostat case 9644A O-ring*
16308 Coolant pump pulley 9645A O-ring*
16323 Thermostat case cover 9655-14140 O-ring*
16325 Gasket* 9778-04620 Clamp
16325A Gasket* 9851A O-ring*

Tightening torque
9068-10800 55N⋅ m {560 kgf⋅ cm.40 lbf⋅ ft} 9068-10950 55N⋅ m {560 kgf⋅ cm,40 lbf⋅ ft}
11–4 COOLING
Fan drive system
SAPH301091100003
16365 Fan spacer 9201-14110 Pulley lock nut

16371 Fan drive pulley 9644C O-ring*
16384 Tension pulley 9645B O-ring*
16390 Fan drive assembly 9851C O-ring*
16630 Tension pulley assembly 9851D O-ring*
88444 Tension pulley bracket S1637 Fan drive
9189A Adjusting bolt SZ910 Fan belt

Tightening torque
9068-10750 55 N⋅ m {560 kgf⋅ cm,40 lbf⋅ ft} 9201-14110 108 N⋅ m {1,100 kgf⋅ cm,80 lbf⋅ ft}
9201-10080 60 N⋅ m {610 kgf⋅ cm,44 lbf⋅ ft} 9419A 47 N⋅ m {480 kgf⋅ cm,35 lbf⋅ ft}
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COOLING 11–5
Replacement of coolant pump

jp30109110704004
1. Removal of coolant pump

Coolant
pump Hose (1) Loosen the coolant hose clamp, remove bolts and remove
the coolant pump.
2. Installation of coolant pump

(1) Insert the coolant hose into the coolant pump and install
the coolant pump on the timing gear case.
(2) Tighten the coolant hose clamp.
SAPH301091100004
Replacement of thermostat case

jp30109110704003
1. Removal of thermostat case

Hose Thermostat case
(1) Remove the coolant pump.
(2) Remove the coolant hose clamp, remove bolts and
remove the thermostat case.
2. Installation of thermostat case

(1) Insert the coolant hose into the thermostat case, replace
the gasket with a new one and install the thermostat case
on the cylinder head.
SAPH301091100005
(2) Tighten the coolant hose clamp.
(3) Replace the gasket with a new one and install the coolant
pipe.
(4) Replace the coolant pump.
11–6 COOLING
Inspection of thermostat
jp30109110703001
1. Individual inspection of thermostat

Wire Thermometer (1) Put the thermostat in water as shown in the figure and
heat it.
! CAUTION • Support the thermostat in the center to

prevent approach to the heat source.
Thermostat Valve lift • Stir the water well so that water temperature
in the container may be uniform.
Heat source
SAPH301091100006
(2) Measure the temperature (valve opening temperature)

T1 : Valve opening temperature (start of valve opening) that opens the thermostat valve.
T2: Full open lift inspection temperature
10mm Thermostat valve

{0.394in.}
opening temperature
74.5 - 78.5{166.1 - 173.3}
Valve lift
standard value :
T1(° C{° F})
0°C{32°F} 10°C Temperature
T1°C{°F} T2°C{°F}
{50°F}
NOTICE • The thermostat valve opening temperature
SAPH301091100007
(T1) is stamped on the thermostat seat.
(3) Increase the water temperature to 90 ° C and measure the

lift of the thermostat valve.
Thermostat valve full

open lift inspection Valve lift : L (mm{in.})
L1 At cold open
L2 : (T2) °C {°F} temperature : T2 (° C{° F})
L : Valve lift
L 90{194} 10{0.394} or more
L 1
L 2
(4) Put the full open thermostat valve in water at normal
SAPH301091100008
temperature. Make sure that the thermostat valve closes
completely within 5 minutes.
(5) If faulty item is found with the inspection above, replace
the thermostat.
COOLING 11–7
Replacement of fan drive, tension pulley

jp30109110704001
1. Removal of fan drive, tension pulley

(1) Remove the cooling fan.
(2) The pulley fixing nut of the tension pulley, loosen the
adjusting bolt and remove the V belt.
V belt
Fixing nut
Tension pulley
Adjusting bolt
SAPH301091100009
(3) Loosen the four fan drive mounting bolts and remove the
(a) fan drive(a) from the timing gear case cover.
(4) Remove the tension pulley(b).
View A (b)
SAPH301091100010
2. Installation of fan drive, tension pulley

(1) Install the tension pulley assembly on the timing gear
case cover with the tension pulley bracket.
Install the pulley fixing nut temporarily.
Tension pulley
SAPH301091100011
(2) Install two new O–rings on the O–ring groove at the timing
case cover side and install the fan drive assembly on the
timing gear case cover.
O-ring
SAPH301091100012
11–8 COOLING
(3) Fix the V belt temporarily.

(4) Install the cooling fan.
Tightening torque : 66±7 N⋅ m {673±71 kgf⋅ cm, 487±
5lbf⋅ ft}
3. Adjustment of fan belt

(1) Loosen the tension pulley fixing nut to the degree that the
pulley moves freely.
(2) Adjust it with adjusting bolt B so that the fan belt tension
between the tension pulley and the fan drive pulley is the
standard value.
Tension pulley
Fan drive fixing nut
pulley When a new belt
Item In inspection
is installed
9 - 11mm 12 - 14mm
Tension pulley
Adjusting bolt Deflection {0.3543 - {0.4724 -
SAPH301091100013 0.4331in.} 0.5512in.}
520 - 610 N 340 - 440 N
Tension {53 - 62 kgf, 117 {35 - 45 kgf,76 -
- 137 lbf} 90 lbf}
! CAUTION • If the fan belt is replaced with a new one, it

becomes loose due to initial fitting. Run the
engine for three to five minutes and adjust the
tension of the belt again.
NOTICE • At the time of inspection, the new fan belt has

reached the value after complete initial
stretching. A new fan belt completes initial
stretching after running the engine for
approximately two hours.
(3) After adjustment, tighten the tension pulley fixing nut and
fix the pulley.
Tightening torque : 108 N⋅ m {1,100 kgf⋅ cm, 80 lbf⋅ ft}
COOLING 11–9
Replacement of cooling fan, fan spacer

jp30109110704002
1. Removal of cooling fan

(1) Remove the cooling fan from fan spacer.
Fan spacer
Cooling fan
SAPH301091100014
(2) Remove nuts and remove the fan spacer from the fan
drive pulley.
Fan spacer Fan drive pulley
SAPH301091100015
2. Installation of fan spacer

(1) Install the fan spacer on the fan drive pulley.
3. Installation of cooling fan

(1) Install the fan spacer on the cooling fan.
Tightening torque : 66±7 N⋅ m {673±71 kgf⋅ cm,49±5
lbf⋅ ft}
(2) Fix the fan belt temporarily.
LUBRICATION 12–1
ENGINE
12 LUBRICATION
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Lubrication System .................................................. 12-2

System drawing .................................................... 12-2
Oil Pump.................................................................... 12-3
Part layout............................................................. 12-3
Replacement......................................................... 12-5
Overhaul ............................................................... 12-7
Oil Filter ................................................................... 12-10
Part layout........................................................... 12-10
Replacement....................................................... 12-12
Oil cooler ................................................................. 12-16
Part layout........................................................... 12-16
Replacement....................................................... 12-20
Overhaul ............................................................. 12-23
Oil pan ..................................................................... 12-26
Part layout........................................................... 12-26
Replacement....................................................... 12-27
12
12–2 LUBRICATION
Lubrication System
System drawing
JP30109120804001
Rocker arm
Sub oil hole Crosshead

Liner circumference cooling
Check valve
To oil pan
Cam bearing circumference groove
Main oil hole

Sub oil hole for liner cooling
Piston
Cooling jet Bushing rod
Check valve (each cylinder)
Crankshaft Check Tappet

valve
Main oil hole
Camshaft
To idle gear No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Camshaft
Air compressor
To idle shaft
To valve system
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Supply pump
Filter warning switch To supply pump drive unit
Safety valve
Oil cooler Safety valve Pressure gauge

Air compressor
Relief valve
Oil filter
To oil pan
To oil pan
Bypass
Oil pump
Safety valve
Oil strainer To oil pan Turbocharger
Turbocharger check valve
Air compressor idle gear
SAPH301091200001
LUBRICATION 12–3
Oil Pump
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Part layout
JP30109120402001
SAPH301091200002
15110 Oil pump 9644E O-ring*

15104 Oil strainer 9851A O-ring*
15431 Oil feed pipe

Tightening torque
9181-08200 21N⋅ m{210kgf⋅ cm,15 lbf⋅ ft} 9411-10451 47N⋅ m{480kgf⋅ cm,35 lbf⋅ ft}
9181-08500 23N⋅ m{230kgf⋅ cm,17 lbf⋅ ft} 9411-14902 113N⋅ m{1,150kgf⋅ cm,83 lbf⋅ ft}
9181-08550 21N⋅ m{210kgf⋅ cm,15 lbf⋅ ft}
12–4 LUBRICATION
SAPH301091200003
15101 Oil pump body assembly 15132 Relief valve spring

15107 Driven gear 15133 Plug
15110 Oil pump 900700 Bolt A
15115 Cover 9061-10350 Bolt B
15131 Relief valve
Tightening torque
15133 83.4±4.9N⋅ m{850±50kgf⋅ cm,62±4lbf⋅ ft} 9061-10350 44.0±4.9N⋅ m{449±50kgf⋅ cm,32±4lbf⋅ ft}
900700 22.6±2.9N⋅ m{230±30kgf⋅ cm,17±2lbf⋅ ft}
LUBRICATION 12–5
êÆî óvóÃ
Replacement
JP30109120704002
1. Removal of oil pump

(1) Remove bolts and remove the oil pan.
SAPH301091200004
(2) Remove bolts and remove the oil strainer.
SAPH301091200005
(3) Remove bolts and remove the oil feed pipe and the oil
pump.
SAPH301091200006
2. Installation of oil pump

(1) Replace the O-ring with a new one and install the oil pump
and oil feed pipe.
Tightening torque :
47 N⋅ m {480 kgf⋅ cm, 35 lbf⋅ ft} (Oil pump: M10)
113 N⋅ m {1,150 kgf⋅ cm, 83 lbf⋅ ft} (Oil pump: M14)
21 N⋅ m {210 kgf⋅ cm, 15 lbf⋅ ft} (Oil feed pipe: M8)
! CAUTION • In installation, be careful that the O-ring may

not be caught.
SAPH301091200006
12–6 LUBRICATION
(2) Replace the O-ring with a new one and install the oil
strainer.

not be caught.
SAPH301091200005
3. Installation of oil pan

"Reference: Lubrication, Oil pan, Replacement"
LUBRICATION 12–7
êÆî óvóÃ
Overhaul
JP30109120702001
1. Disassembly of oil pump

Plug
(1) Remove the plug and remove the spring and relief valve.
Spring
Relief valve ! CAUTION • When the plug is removed, the spring and the
relief valve may eject out.
SAPH301091200007
(2) Remove bolts and remove the oil pump case cover.
(3) Remove the driven gear.
! CAUTION • Do not damage the joint surface during work.
Driven gear
SAPH301091200008
2. Inspection of oil pump

(1) Inspection of clearance between drive gear and oil pump
case (tip clearance)
a. Measure the clearance between the drive gear and the

oil pump case using a thickness gauge. If it is beyond
the operation limit, replace the oil pump assembly.

Drive gear
0.038 - 0.115
0.17{0.0066}
SAPH301091200009 {0.0015 - 0.0045}
(2) Inspection of side clearance between drive gear and oil

pump case (end play)
Drive gear
a. Place the straight edge on the case and measure the
drive gear width and the oil pump case depth using a
depth gauge.
b. Calculate the difference between the width of the drive
gear and the oil pump case depth. If it is beyond the
operation limit, replace the oil pump assembly.
SAPH301091200010 Standard value (mm{in.}) Operation limit (mm{in.})

0.045 - 0.105
0.15{0.0059}
{0.0018 - 0.0041}
12–8 LUBRICATION
(3) Inspection of clearance of drive gear shaft outer diameter

and drive gear side hole inner diameter of oil pump case
cover
a. Measure the outer diameter of the drive gear shaft

using a micrometer and measure the drive gear side
hole inner diameter of the oil pump case cover using a
micrometer.
Drive gear shaft Standard value

Measuring area
SAPH301091200011 (mm{in.})
Outer diameter of drive gear shaft 20{0.787}
Drive gear side hole inner
20{0.787}
diameter of oil pump case cover
b. Calculate the difference between the outer diameter of

the drive gear shaft and the drive gear side hole inner
Oil pump
case cover diameter of the oil pump case cover. If it is beyond the
operation limit, replace the oil pump case cover.

0.040 - 0.074
0.17{0.0066}
{0.0016 - 0.0029}
SAPH301091200012
(4) Inspection of oil clearance between outer diameter of

driven gear shaft and inner diameter of driven gear
bushing
a. Measure the outer diameter of the driven gear shaft

using a micrometer and measure the inner diameter of
Driven gear shaft
the driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
SAPH301091200013 Outer diameter of driven gear
20{0.787}
shaft
Inner diameter of driven gear
20{0.787}
bushing
b. Calculate the difference between the outer diameter of

the driven gear shaft and the inner diameter of the
driven gear bushing. If it is beyond the operation limit,
replace the oil pump or the driven gear.

0.040 - 0.074
0.17{0.0066}
{0.0016 - 0.0029}
SAPH301091200014
LUBRICATION 12–9
(5) Inspection of drive gear backlash
a. Fix the oil pump with a vice.

b. Measure backlash between the drive gear and the
driven gear using a dial gauge. If it is beyond the
operation limit, replace the oil pump.

0.072 - 0.208
Drive gear 0.4{0.0157}
{0.0029 - 0.0081}
SAPH301091200015
Plug
3. Assembly of oil pump
(1) Install the relief valve, spring and plug on the oil pump
Spring
case cover.
Relief valve
Tightening torque : 83.4 ± 4.9 N⋅ m {850 ± 50 kgf⋅ cm,
62 ± 48 lbf⋅ ft}
SAPH301091200016
(2) Apply engine oil to the gear inner surface and the shaft,
align the oil pump body dowel pin and assemble the oil
pump.
Tightening torque :
22.6 ± 2.9 N⋅ m {230 ± 30 kgf⋅ cm, 17 ± 2 lbf⋅ ft}(Bolt A)
44.0 ± 4.9 N⋅ m {449 ± 50 kgf⋅ cm, 32 ± 4 lbf⋅ ft}(Bolt B)
ç\ê¨ê}
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#
$
SAPH301091200017
12–10 LUBRICATION
Oil Filter
Part layout
JP30109120402003
SAPH301091200018
15600 Oil filter assembly 9655-12100 Gasket*

15671 Oil filter bracket 9644A O-ring*
23201 Oil hose(Bypass) 9644B O-ring*
23201A Oil hose 9739A Joint
23201B Oil hose

Tightening torque
23301A 196N⋅ m{2,000kgf⋅ cm,145 lbf⋅ ft} 9411A-10002 47N⋅ m{480kgf⋅ cm,35 lbf⋅ ft}
23301B 196N⋅ m{2,000kgf⋅ cm,145 lbf⋅ ft} 9419A 47N⋅ m{480kgf⋅ cm,35 lbf⋅ ft}
9019A 25N⋅ m{255kgf⋅ cm,18 lbf⋅ ft}
LUBRICATION 12–11
SAPH301091200019
15600 Oil filter assembly 15643 Drain plug

15604 Safety valve 15651 Center bolt
15607 Oil filter element 15651A Center bolt
15607A Oil filter element 15660 Oil filter warning switch
15612 Oil filter element cover 15691 O-ring*
15614 Cover 15691A O-ring*
15614A Cover 9851C O-ring*
15615 Spring 9851D O-ring*
15629 Gasket* 9851E O-ring*
15629A Gasket*

Tightening torque
15643 17.2±2.5N⋅ m{175±25kgf⋅ cm,13±2lbf⋅ ft} 15651A 44±4.9N⋅ m{450±50kgf⋅ cm,32±4lbf⋅ ft}
15651 44±4.9N⋅ m{450±50kgf⋅ cm,32±4lbf⋅ ft}
12–12 LUBRICATION
êÆî
óvóÃ
Replacement
JP30109120704001
NOTICE • The shape of brackets and hose joints in the

illustrations and the hose routing differ
according to the model.
1. Engine oil draining
(1) Prepare a tray or another container to receive engine oil,

loosen the drain plug at the lower end of the oil filter, and
drain the engine oil.
! CAUTION • When draining the engine oil, follow the

Center
bolt specified method (waste processing) or an
environment-friendly method.
Center
bolt Drain plug
SAPH301091200020
2. Removal of oil filter element
(1) Loosen the center bolt and remove the cover.
SAPH301091200021
(2) Remove the oil filter element.

O-ring
Cover
O-ring
! CAUTION • Make sure that there is no O-ring left at the oil
Cover cooler case.
Oil filter element
Center bolt Center bolt

SAPH301091200043
3. Disconnecting the oil hose

Union bolt
! CAUTION • When disconnecting the oil hose, receive the

Joint oil remaining in the hose in a container and
(Fix) plug the end of the hose with a shop towel or
similar.
(1) Secure the joint securely with a hand vise or similar,

loosen the nut of the oil hose, and disconnect the oil hose
Oil hose from the oil filter assembly. (Inlet and outlet)
SAPH301091200022
LUBRICATION 12–13
! CAUTION • When working with two spanners, use

spanners with the same length for the
moment arm to make spanner control easier.
NOTICE • Install the joint on the oil filter bracket.
(2) Loosen the union bolt and disconnect the oil hose
(bypass) from the oil filter assembly. Remove the two
gaskets.
4. Removal of the oil filter element cover (when required)

Bolt (two)
Oil filter element cover (1) Disconnect the oil filter warning (clogging alarm)
connector.
(2) Loosen the bolt and remove the oil filter element cover
from the oil filter bracket.
(3) Remove the three O-rings from the oil filter element cover
or the oil filter bracket.
Bolt
Oil filter warning switch
SAPH301091200023
5. Removal of the oil filter bracket (when required)
(1) Loosen the bolt and remove the oil filter bracket.
Bolt
Oil filter bracket.

SAPH301091200024
6. Installation of the oil filter bracket (when it has been

removed)
(1) Install the oil filter bracket with a bolt on the oil filter
bracket.
Bolt
Oil filter bracket.

SAPH301091200024
12–14 LUBRICATION
7. Installation of the oil filter element cover (when it has been

Bolt (two)
Oil filter element cover
removed)
(1) Replace the O-ring by a new one and install the oil filter
element cover with a bolt on the oil filter bracket.
(2) Connect the oil filter warning (clogging alarm) connector.
Bolt
SAPH301091200023
8. Connecting the oil hose

Union bolt
tighten the nut of the oil hose, and connect the oil hose to
Joint
(Fix) the oil filter assembly. (Inlet and outlet)
lbf⋅ ft} (PF1)

Oil hose spanners with the same length for the
SAPH301091200025 moment arm to make spanner control easier.
• If the joint part has been loosened, replace
the O-ring by a new one.
(2) Replace the gasket by a new one and connect the oil
hose(bypass) with a union bolt to the oil filter assembly.
Tightening torque : 26.5 N⋅ m {270 kgf⋅ cm, 20 lbf⋅ ft}
9. Installation of oil filter element

O-ring
(1) Remove contamination or foreign matter on the mounting
O-ring Cover
surface of the oil filter element cover.
Cover
(2) Apply engine oil thinly to the O-ring (large⋅ small) of a new
oil filter element.
(3) Install the oil filter element.
Oil filter element

(4) Tighten the center bolt.
Tightening
Center bolt Center bolt
torque:44±4.9N⋅ m{450±50kgf⋅ cm,32±4lbf⋅ ft}
SAPH301091200026
LUBRICATION 12–15
(5) Replace the O–ring of the drain plug with a new one for
installation.
Tightening
torque:17.2±2.5N⋅ m{175±25kgf⋅ cm,13±2lbf⋅ ft}

not be damaged by distortion.
• Do not reuse the O-ring.
NOTICE • Assemble the full flow side oil filter element

so that the top and the bottom are identified
correctly.
• The oil filter element on the bypass side can

be installed in either orientation, as it has the
Bypass side Full flow side same shape at top and bottom.
SAPH301091200027
10. Engine oil filling

(1) Confirm that the drain plug at the lower end of the oil filter
has been tightened, and then fill in engine oil while looking
at the oil level gauge.
Reference: "Engine removal/installation, work after
installation, engine oil inspection"
12–16 LUBRICATION
Oil cooler
ç\ê¨ê}
ç\ê¨îzíuê}
Part layout
JP30109120402005
SAPH301091200028
15431A Coolant pipe 9644E O-ring*

15710 Oil cooler assembly 9659A Gasket*
9644A O-ring* 9659B Gasket*
9644D O-ring*

Tightening torque
900124A 39N⋅ m{400kgf⋅ cm,29 lbf⋅ ft} 9411-10501 55N⋅ m{560kgf⋅ cm,40 lbf⋅ ft}
9191-08002 25N⋅ m{250kgf⋅ cm,18 lbf⋅ ft} 9419A 47N⋅ m{480kgf⋅ cm,35 lbf⋅ ft}
LUBRICATION 12–17
SAPH301091200029
23201 Oil hose(Bypass) 9644A O-ring*

23201A Oil hose 9655-12100 Gasket*
23201B Oil hose 9739A Joint
90404A Joint

Tightening torque
23301A 196N⋅ m{2,000kgf⋅ cm,145 lbf⋅ ft} 9019A 25N⋅ m{255kgf⋅ cm,18 lbf⋅ ft}
23301B 196N⋅ m{2,000kgf⋅ cm,145 lbf⋅ ft}
12–18 LUBRICATION
SAPH301091200030
24106 Oil pipe 9655-14140 Gasket*

Tightening torque
9019D 25N⋅ m{255kgf⋅ cm,18 lbf⋅ ft} 9068-10180 55N⋅ m{560kgf⋅ cm,40 lbf⋅ ft}
LUBRICATION 12–19
SAPH301091200031
15612 Oil cooler cap 9851B O-ring*

15621 Gasket* 9851C O-ring*
15643 Drain plug 9851D O-ring*
15662 Valve cap 9851E O-ring*
15675 Relief valve 9851F O-ring*
15710 Oil cooler assembly 9851G O-ring*
15712 Oil cooler element 9851H O-ring*
15714 Safety valve 9851J O-ring*
15715 Gasket* 9851K O-ring*
15716 Valve cap 9851L O-ring*
15717 Gasket* 9851M O-ring*
15717A Gasket* 9851N O-ring*
15721 Cover 9851P O-ring*
15726 Valve cap 9851Q O-ring*
15726A Valve cap S1148 Drain plug
15726B Plug S1565 Center bolt
15726C Plug S1571 Plug
23314 Plug S1572 Plug
23322 Plug S1572A Oil cooler cover
9851A O-ring* S1572B Oil cooler cover

Tightening torque
9191-08301 19.6±4.9N⋅ m{200±50kgf⋅ cm,14±4lbf⋅ ft} 9191-08401 19.6±4.9N⋅ m{200±50kgf⋅ cm,14±4lbf⋅ ft}
12–20 LUBRICATION
êÆî óvóÃ
Replacement
JP30109120702003
NOTICE • The shape of brackets and hose joints in the

illustrations and the hose routing differ
according to the model.
1. Removal of pipes
(1) Disconnect all pipes connected to the oil cooler.
! CAUTION • Loosen the bolts after preparing containers to

receive cooling water or engine oil
respectively.
(2) Remove O-rings and gaskets.
SAPH301091200032
2. Disconnecting the oil hoses
! CAUTION • When disconnecting the oil hose, receive the

oil remaining in the hose in a container and
plug the end of the hose with a shop towel or
similar.

loosen the nut of the oil hose, and disconnect the oil hose
from the oil filter assembly. (Inlet and outlet)
Oil hose
(Bypass)
moment arm to make spanner control easier.
NOTICE • Install the joint on the oil filter bracket.
(2) Loosen the union bolt and disconnect the oil hose
(Bypass) from the oil filter assembly.Remove two gaskets.
Lock 3. Oil cooler removal

(1) Remove the bolts and take off the oil cooler.
SAPH301091200033
LUBRICATION 12–21
4. Installation of oil cooler
(1) Use a scraper to remove any dirt from the connection

surfaces of oil cooler and cylinder block.
(2) Install new O-rings in the O-ring installation grooves of the
oil cooler.
! CAUTION • At the time of installation, take care that the

O-ring is not damaged by twisting.
• Install O-rings on the oil cooler side.
SAPH301091200034
(3) Insert positioning stud bolts in the cylinder block mounting

holes and install the oil cooler.
(4) After temporary tightening of the bolts, remove the

positioning stud bolts and tighten the bolts securely.
Tightening torque
: 25 N⋅ m {250 kgf⋅ cm, 18 lbf⋅ ft}(M8)
: 47 N⋅ m {480 kgf⋅ cm, 35 lbf⋅ ft}(M10)
SAPH301091200035
12–22 LUBRICATION
5. Connecting the oil hoses

tighten the nut of the oil hose, and connect the oil hose to
the oil filter assembly. (Inlet and outlet)
Tightening torque : 196 N⋅ m
{2,000 kgf⋅ cm, 145 lbf⋅ ft}(PF1)

Oil hose moment arm to make spanner control easier.
(Bypass)
• If the joint part has been loosened, replace
the O-ring by a new one.
(2) Replace the gasket by a new one and connect the oil
hose(Bypass) with a union bolt to the oil filter assembly.
6. Pipe installation
Lock (1) Replace O-rings and gaskets by new ones and connect
the pipes to the oil cooler.
SAPH301091200033 Unit : N⋅ m{kgf⋅ cm,lbf⋅ ft}
Tighten-
Position M radius Quantity ing
torque
55
Coolant pipe IN M10 2
{560,40}
39
M24 1
{400,29}
Union
25
Oil pipe M14 1
{250,18}
55
Clip M10 1
{560,40}
LUBRICATION 12–23
êÆî óvóÃ
Overhaul
JP30109120702002
1. Removal of oil cooler element
Bolt (1) Remove the bolts and take off the cover of the oil cooler.
(2) Remove the nuts and remove the oil cooler element from
Cover the oil cooler.
Gasket
Oil cooler element
O-ring
Gasket
O-ring
Gasket
Nut
SAPH301091200036
2. Disassembly oil cooler cap.
! CAUTION • Do not remove the plug unless necessary.
(1) Remove the safety valve.

Safety valve (2) Remove the relief valve.
(3) Remove the oil filter warning switch.
Relief valve
SAPH301091200037
12–24 LUBRICATION
3. Safety valve wear and tear inspection
(1) Inspect the safety valve visually and replace it in case of

wear or damage.
Safety valve
SAPH301091200038
4. Relief valve wear and tear inspection
(1) Inspect the relief valve visually and replace it in case of

wear or damage.
Relief valve
SAPH301091200039
5. Assembly of oil cooler case
(1) Replace the O-ring with a new one and install each valve.
Tightening torque :
19 N⋅ m {190 kgf⋅ cm, 141 lbf⋅ ft}(Oil pressure
warning switch)
24.5±4.9 N⋅ m {250±50 kgf⋅ cm, 18±4 lbf⋅ ft}(Valve
cap: M14)
cap: M26)
cap: M20)
SAPH301091200040
LUBRICATION 12–25
6. Installation of oil cooler element
Bolt (1) Replace the gasket and O-ring with new ones and install
the oil cooler element.
Cover Tightening torque :
19.6±4.9N⋅ m{200±50kgf⋅ cm,14±4lbf⋅ ft}
(2) Replace the gasket of the cover with a new one and install
it.
Gasket
Oil cooler element
O-ring
Gasket
O-ring
Gasket
Nut
SAPH301091200036
12–26 LUBRICATION
Oil pan
ç\ê¨ê}
ç\ê¨îzíuê}
Part layout
JP30109120402004
SAPH301091200041
12111 Oil pan 12151 Gasket*

12149 Drain cock 9659C Gasket*

Tightening torque
9191-08452 31N⋅ m{320kgf⋅ cm, 23 lbf⋅ ft}
LUBRICATION 12–27
êÆî óvóÃ
Replacement
JP30109120704004
1. Removal of oil pan

(1) Remove bolts and remove the oil pan.
! CAUTION • If the gasket is sticking, remove it using a

scraper, etc.
2. Installation of oil pan

Liquid gasket
applying position (1) Apply a small amount of liquid gasket [Threebond TB1211
(white)] to the step of the joint surface between the timing
gear case and the cylinder block and between the
flywheel housing and the cylinder block.
(2) Replace the gasket with a new one and install the oil pan.
! CAUTION • Wipe off oil on the oil pan and cylinder block
SAPH301091200042 before installation.
STARTING AND CHARGING 13–1
ENGINE
13 STARTING AND CHARGING

ç\ê¨ê}
ç\ê¨îzíuê}
Starter........................................................................ 13-2
Part layout (typical example)................................. 13-2
Disassembly.......................................................... 13-3
Inspection of components ..................................... 13-9
Assembly ............................................................ 13-14
Alternator (60A) ...................................................... 13-16
Part layout (typical example of 60A) ................... 13-16
Circuit drawing (60A) .......................................... 13-17
Disassembly (60A).............................................. 13-18
Inspection of components (60A) ......................... 13-21
Assembly (60A)................................................... 13-24
Inspection after assembly (60A) ......................... 13-28
13
13–2 STARTING AND CHARGING
Starter
JP30109130402001
SAPH301091300001
28011 Clutch subassembly 28138 Packing*

28100 Starter assembly 28140 Brush holder assembly
28111 Bushing 28142 Brush
28113 Lever assembly 28142A Brush
28115 Pinion case 28143 Spring
28117 Packing* 28150 Center bracket
28117A Packing* 28160 Armature assembly
28118 Plate 28168 Retainer clip*
28118A Plate 28199 Dust protector
28118B Plate 28251 Pinion
28118C Plate 28252 Bearing
28118D Cover 28255 Shaft assembly
28120 Yoke assembly 28253 Planetary gear
28133 Rear bracket 28253A Internal gear

Tightening torque
28112 14 - 16N⋅ m{140 - 160kgf⋅ cm,10 - 28112E 15.7 - 17.6N⋅ m{160 - 179kgf⋅ cm,12 -
12lbf⋅ ft} 13lbf⋅ ft}
28112A 3.6 - 4.9N⋅ m{37 - 49kgf⋅ cm,3 - 4lbf⋅ ft}
êÆî óvóÃ
Disassembly
JP30109130702001
M lead wire NOTICE • Fix the starter on the working table to ease
accessibility.
M terminal
1. Removal of M lead wire

(1) Remove the cap of the M terminal.
(2) Remove nuts and remove the M lead wire.
SAPH301091300002
2. Removal of rear bracket

Through bolt (1) Loosen and remove two through bolts.
Rear bracket
SAPH301091300003
(2) Remove two set bolts and remove the rear bracket.
Set bolt ! CAUTION • Hold the M lead wire and remove the rear
bracket by lifting.
SAPH301091300004
3. Removal of brush holder assembly

Brush holder
assembly (1) Lift the spring using a flat tip screwdriver, long-nose pliers
or pliers. Remove four brushes from the brush holder
assembly.
! CAUTION • Do not cut the brush lead fixing clamp.
(2) Remove the brush holder assembly from the armature

Spring
assembly.
Brush
Brush lead
Clamp
SAPH301091300005
4. Removal of yoke assembly

M lead wire (1) Remove the yoke assembly from the center bracket
Yoke assembly
assembly.
! CAUTION • Do not hold the M lead wire and hold the yoke
assembly outer diameter for removal.
Center bracket
assembly
SAPH301091300006
5. Removal of packing
Yoke assembly
(1) Remove the packing from the centering parts at both ends
of the yoke assembly.
! CAUTION • The packing must not be reused. Replace it

with a new one.
Packing Packing
SAPH301091300007
6. Removal of armature assembly

(1) Remove the armature assembly by lifting.
Armature
assembly
! CAUTION • When the armature assembly is removed, the
washer at the end of the gear may be dropped
Center and lost. Be careful for handling.
bracket
assembly
SAPH301091300008
7. Removal of rear bearing

(1) Pull out the bearing of the armature assembly using a
Rear bearing puller or press.
! CAUTION • Removed bearing must not be reused.

Replace it with a new one.
Puller
SAPH301091300009
8. Removal of cover
Packing Cover
(1) Remove the cover from the center bracket assembly.
(2) Remove the packing.
! CAUTION • Damaged packing must not be reused.

Replace it with a new part.
SAPH301091300010
9. Removal of planetary gear

(1) Remove the planetary gear from the carrier pin.
Planetary gear ! CAUTION • Make sure that the gear is not damaged or
chipped.
Carrier pin
SAPH301091300011
10. Removal of internal gear

(1) Remove the internal gear from the center bracket.
! CAUTION • Make sure that the gear is not damaged or

chipped.
Internal gear
Center case
SAPH301091300012
11. Removal of shim washer

(1) Remove the internal gear from the center bracket.
Shim
SAPH301091300013
12. Removal of pinion

(1) Remove the retainer clip using a tool such as snap ring
pliers.
Retainer clip ! CAUTION • Retainer clip must not be reused. Replace it

with a new one.
Pinion stopper
NOTICE • Push upward or pull out the chipped part of
the clip mouth.
Pinion
SAPH301091300014
(2) Remove the pinion stopper.

(3) Remove the pinion.
Pinion stopper
! CAUTION • Make sure that the gear is not damaged or
chipped.
Pinion
SAPH301091300015
13. Removal of pinion case

Pinion case
(1) Remove two set bolts at the switch using a box
screwdriver or offset wrench.
(2) Lift and remove the pinion case.
Clutch
assembly
SAPH301091300017
14. Removal of lever

(1) Hold the lever holder and press the entire lever to the
Plunger clutch. Remove the link with the plunger.
Holder
Lever assembly
SAPH301091300018
(2) Turn and pull out the lever assembly using the clutch as
the axis.
Lever assembly
SAPH301091300019
15. Removal of brake plate

(1) Hold the clutch case outer diameter and slide the clutch
assembly upward. Pinch the clip end fixing the brake plate
with pliers and remove it by bending.
SAPH301091300020
(2) Remove the brake plate.
Brake plate
SAPH301091300021
16. Removal of clutch assembly

(1) While pressing the clutch assembly to the center bracket
Clutch assembly
assembly, offset the helical spline by one tooth.
Pull out the clutch assembly upward from the offset
Center bracket position and remove it.
assembly
SAPH301091300022
17. Removal of shaft assembly

Washer (1) Turn the center bracket assembly upside down. Hold the
carrier plate and pull out the shaft assembly.
! CAUTION • Washers are available at the upper and lower

parts of the carrier plate. Be careful for loss of
the washers.
Shaft assembly
SAPH301091300023
18. Removal of packing

(1) Turn the center bracket assembly upside down again and
remove the packing.
! CAUTION • Packing must not be reused.
Packing
SAPH301091300024
Inspection of components
JP30109130703001
1. Inspection of yoke assembly

(1) Make sure that the coil lead wire has electric continuity
using a circuit tester.
SAPH301091300025
(2) Measure the resistance between the coil lead wire and the
Tester rod yoke with a circuit tester and check insulation. When the
value is below the operation limit, replace it.
Field coil
Operation limit 1 kΩ or less
! CAUTION • After cleaning and drying, take

Yoke assembly
measurements.
SAPH301091300026
(3) Measure the brush length using vernier calipers.
18{0.709} 13{0.512} or less
SAPH301091300027
2. Inspection of armature assembly

(1) Turn the armature assembly using a commercially
available growler tester and put a piece of steel on the
armature assembly. Make sure that the steel piece is not
vibrating on the core circumference.
SAPH301091300028
(2) Make sure that adjacent segments of the commutator

have electric continuity using a circuit tester.
(3) Make sure that there is no discoloration at the coil.
SAPH301091300029
(4) Measure the resistance between the commutator and the

core using a circuit tester and check insulation.
1 MΩ or more 1 kΩ or less

measurements.
SAPH301091300030
(5) Measure the commutator outer diameter using vernier

calipers.
! CAUTION • After removing roughness on the surface

(after polishing), take measurements.
Commutator outer diameter
36{1.417} 34{1.338} or less

SAPH301091300031
(6) Measure the undercut depth between segments. If the

undercut depth is beyond the operation limit, repair it.
0.5 - 0.8{0.0197 - 0.0314} 0.2{0.0078} or less
! CAUTION • In repair, do not leave insulation material at

the end of the segment.
SAPH301091300032
(7) Measure the shaft outer diameter using a micrometer. If it

is beyond the operation limit, replace the armature
assembly.
㧭
Measuring area
㧮 (mm{in.}) (mm{in.})
11.98{0.4717}
Part A 12{0.472}
or less
SAPH301091300033 8.98{0.3535}
Part B 9{0.354}
or less
3. Inspection of brush holder assembly

(1) Measure the resistance between the holder (plus) and the
plate using a circuit tester and check insulation. When the
value is below the operation limit, replace it.
Operation limit 1 kΩ or less

measurements.
SAPH301091300034
(2) Measure the brush length using vernier calipers.
18{0.709} 13{0.512} or less
(3) Make sure that the spring has pressure.
SAPH301091300035
4. Inspection of shaft assembly

(1) Measure the outer diameter of the shaft using a
micrometer
If it is beyond the operation limit, replace the shaft.
㧮㧭
Measuring area
(mm{in.}) (mm{in.})
25.90{1.0197}
Part A 26{1.024}
or less
SAPH301091300036
14.04{0.5528}
Part B 14.1{0.5552}
or less
5. Inspection of clutch assembly

(1) Measure the outer diameter of the inner sleeve using a
micrometer.
28{1.102} 27.90{1.0984} or less
SAPH301091300037
6. Inspection of bearing
(1) Measure the inner diameter (1 in the figure) of the pinion
case bearing metal part using a cylinder gauge.
28{1.102} 28.2{1.1102} or more
SAPH301091300038
(2) Measure the inner diameter (2 in the figure) of the center

bracket bearing metal part using a cylinder gauge.
26{1.024} 26.2{1.0315}

SAPH301091300039
(3) Measure the inner diameter (3 in the figure) of the shaft

assembly bearing metal part using a cylinder gauge.
9{0.354} 9.2{0.3622}
(4) Measure the inner diameter (4 in the figure) of the rear

bracket bearing housing using a cylinder gauge.
SAPH301091300040 Standard value (mm{in.}) Operation limit (mm{in.})
28{1.1024} 28.1{1.1062} or more

7. Inspection of start magnet switch assembly (resistance of

C terminal
P coil)
M terminal
(1) Measure the P coil resistance between the C terminal and
the M terminal using a circuit tester.
Standard value (Ω) 0.12 - 0.14
SAPH301091300041
8. Inspection of start magnet switch assembly (resistance of

H coil)
(1) Measure the H coil resistance between the C terminal and
C terminal the body using a circuit tester.
Standard value(Ω) 1.13 - 1.25

Body
SAPH301091300042
9. Inspection of start magnet switch assembly (electric

continuity inspection)
M terminal (1) Check electric continuity between the B terminal and the
M terminal using a circuit tester, and make sure that there
is no electric continuity.
B terminal
SAPH301091300043
(2) Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
using a circuit tester.
SAPH301091300044
Assembly
JP30109130702002
1. Assembly procedure
Perform assembly procedure in the reverse order
disassembly.
2. Tightening torque
For the bolt tightening torque, refer to the parts layout.
3. Lubrication
Refer to the following figure and table for lubricant to be
applied.
! CAUTION • There shall be no lubricant on the

commutator surface, brush and contact.
SAPH301091300045
Table of lubricant
Lubricant Lubricant
Code Lubricating point Amount (g{oz}) Remark
used manufacturer
Pinion case metal 0.8 - 1.5{0.0282 -

1 Multemp AC-N Kyodo Yushi
and grease reservoir 0.0529}
Bracket center metal 0.8 - 1.5{0.0282 -

and grease reservoir 0.0529}
0.2 - 0.5{0.0070 - Applied to both sides

3 Shim washer Multemp AC-N Kyodo Yushi
0.0176} of washer.
0.5 - 1{0.0176 -
4 Armature front metal Multemp AC-N Kyodo Yushi
0.035}
0.2 - 0.5{0.0070 - Applied to both sides

5 Shim washer Multemp AC-N Kyodo Yushi
0.0176} of washer.
Internal gear
7 - 11{0.247 -
6 Armature gear Multemp AC-N Kyodo Yushi
0.388}
Planetary gear
Pinion straight 0.5 - 1{0.0176 -

Spline 0.035}
0.3 - 0.6{0.0106 -
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
0.0211}
0.5 - 1{0.0176 -
9 Helical spline Multemp AC-N Kyodo Yushi
0.035}
Clutch case lever Pyroknock 1 - 2{0.0070 - Nisseki

10
shifter No.2 0.0176} Mitsubishi
Bracket rear bearing Pyroknock 0.2 - 0.5{0.0070 - Nisseki

11
housing No.2 0.0176} Mitsubishi
1 - 2{0.0070 -
12 Planetary gear metal Multemp AC-N Kyodo Yushi
0.0176}
0.4 - 0.8{0.0141 -
13 Lever holder Multemp AC-N Kyodo Yushi
0.0282}
Assemble the roller

after application of
Pyroknock 0.2 - 0.5{0.0070 -
14 Lever roller rod grease to prevent fall Kyodo Yushi
No.2 0.0176}
of the roller in
assembly.
Alternator (60A)
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Part layout (typical example of 60A)

JP30002130402002
SAPH301091300046
27017 Field coil 27392 Cover

27060 Armature assembly 27410 Stator coil
27311 Front bracket 27412 Collar
27312 Bearing cover 27431 Pulley
27330 Rotor assembly 27441 Fan
27353 Heat sink minus 27445A Coupler holder
27356 Heat sink plus 27700 Regulator
27359 Rear bracket 28252 Ball bearing
27364 B terminal 28252A Roller bearing
Tightening torque
27317 7.8 - 9.8N⋅ m{80 - 99kgf⋅ cm,6 - 7lbf⋅ ft} 27317C 1.9 - 2.5N⋅ m{20 - 25kgf⋅ cm,1.4 -
1.8lbf⋅ ft}
27317A 1.9 - 2.5N⋅ m{20 - 25kgf⋅ cm,1.4 - 27391 127 - 157N⋅ m{1,300 - 1,600kgf⋅ cm,94 -
1.8lbf⋅ ft} 115lbf⋅ ft}
27317B 2.9 - 3.9N⋅ m{30 - 39kgf⋅ cm,2.1 - 27391A Internal nut :
2.5lbf⋅ ft} 4.9 - 5.9N⋅ m{50 - 60kgf⋅ cm,3.7 -
4.3lbf⋅ ft}
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Circuit drawing (60A)

JP30002130803001
Capacitor
Diode
Fuse Load
. Lamp (1.4 to 3W)
4
Starter switch
2
Field coil
0
Regulator
Stator coil Battery 24V
'
Alternator
SAPH301091300047
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Disassembly (60A)
JP30002130702003
! CAUTION • Place a rubber mat and perform work on the

mat.
1. Disconnection of front from rear
(1) Remove fixing bolts and remove the cover.
! CAUTION • Press the tabs of the cover for removal. Be

careful not to break the tabs with excessive
force.
SAPH301091300048
(2) Remove bolts with a screwdriver and remove the coupler

holder.
SAPH301091300049
(3) Remove three through bolts and disconnect the front from
the rear.
SAPH301091300050
2. Disassembly of front
(1) Remove nuts and remove the pulley, fan and collar.
! CAUTION • Tie around a general V–belt in the pulley

groove and fix the pulley with a vice.
SAPH301091300051
(2) Remove the rotor assembly using a press.
! CAUTION • Do not damage the end of the thread.

• Support the rotor assembly to prevent fall of
the rotor assembly.
SAPH301091300052
(3) Remove three bolts with a screwdriver and remove the

bearing cover.
SAPH301091300053
(4) Remove the ball bearing from the front bracket using a
press and jig C.
! CAUTION • Place jig C at the inner race of the front

bearing.
• Removed bearing must not be reused.
SAPH301091300054
3. Disassembly of rear
(1) Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
solder suction device
! CAUTION • At solder of the stator coil and the diode, the

end of the diode is clamped. Do not damage
the diode by prying. Deformed diode must not
be reused.
SAPH301091300055 • Perform soldering in a short time (within 5
seconds).
(2) Remove the stator coil from the rear bracket.
! CAUTION • Do not damage the stator coil.
SAPH301091300056
(3) Remove solder of the lead wire connecting the regulator

and the field coil using a soldering bit.
! CAUTION • Remove the lead wire of the field coil by

raising the terminal of the regulator.
• Perform soldering in a short time (within 5
seconds).
SAPH301091300057
Terminal
Lead wire
Regulator assembly
SAPH301091300058
(4) Loosen the nut at the B terminal.
! CAUTION • Loosen the nut to some extent and do not

remove it from the B terminal.
SAPH301091300059
(5) Remove five bolts using a screwdriver and remove the

heat sink assembly (plus), heat sink assembly (minus)
and regulator all together.
! CAUTION • Screw lock is used. Since torque is high until

bolt is removed, be careful not to damage the
groove of the bolt head.
• When the rear bracket is reused, clean the
screw hole.
SAPH301091300060
(6) Remove the capacitor.

(7) Remove three bolts with a screwdriver and remove the
field coil from the rear bracket.
SAPH301091300061
(8) Remove the roller bearing from the rear bracket using a
press, jig A and jig B.
! CAUTION • Removed bearing must not be reused.
SAPH301091300062
Inspection of components (60A)

JP30002130703002

mat.
1. Inspection of stator coil and field coil
(1) Measure the resistance between U-V, V-W and W-U

terminals of the stator coil using a circuit tester.
SAPH301091300063
(2) Measure the resistance between the stator coil core and
each terminal using a megger tester.
Standard value (MΩ) 1 or more
SAPH301091300064
(3) Measure the resistance of the field coil using a circuit

tester.
! CAUTION • Do not damage the circumferential surface of

the coil.
• Damaged coil circumference must not be
reused.
SAPH301091300065
(4) Measure the resistance between the core and the coil
using a megger tester.
Standard value (MΩ) 1 or more
SAPH301091300066
2. Inspection of rotor assembly
(1) Measure the outer diameter of the shaft at the ball bearing
insertion area of the rotor assembly using a micrometer.
SAPH301091300067
(2) Measure the outer diameter of the shaft at the roller

bearing insertion area of the rotor assembly using a
micrometer.
SAPH301091300068
3. Inspection of diode and regulator
(1) Measure the resistance between the minus diode and the
heat sink holder using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
SAPH301091300069
(2) Measure the resistance between the capacitor terminal

and the body using a circuit tester. Make sure that it
indicates 800 kΩ and then immediately indicates infinite
value.
SAPH301091300070
(3) Inspection of regulator

Measure the resistance between regulator terminals F
and E using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
SAPH301091300071
Assembly (60A)
JP30002130702004

mat.
1. Assembly of front
(1) Press fit a new ball bearing into the front bracket using a
press and jig C.
! CAUTION • Place jig C at the outer race of the ball

bearing.
SAPH301091300072 • Removed bearing must not be reused.
(2) Install the bearing cover with bolts.

Tightening torque : 1.9 - 2.5 N⋅ m {20 - 25 kgf⋅ cm, 1.4
- 1.8 lbf⋅ ft}
SAPH301091300073
(3) Install the rotor assembly using a press.
! CAUTION • Be sure to support the inner race of the

bearing for press fit of the rotor.
• Do not damage the shaft.
SAPH301091300074
(4) Install the space collar, fan and pulley on the shaft of the
rotor assembly.
Tightening torque : 127 - 157 N⋅ m {1,300 - 1,600

kgf⋅ cm, 94 - 115 lbf⋅ ft}
! CAUTION • Tie around a general V–belt in the pulley

groove and fix the pulley with a vice.
SAPH301091300075
2. Assembly of rear
(1) Press fit a new roller bearing into the rear bracket using a
press, jig A and jig B.
! CAUTION • Press fit until jig A comes in contact with the

rear bracket.
SAPH301091300076
(2) Install the field coil on the rear bracket.
Tightening torque : 2.9 - 3.9 N⋅ m {30 -39 kgf⋅ cm, 2.1 -

2.5 lbf⋅ ft}
! CAUTION • Tighten bolts finally after temporary

tightening. Tighten them evenly.
SAPH301091300077
(3) Assemble the stator coil on the rear bracket temporarily.
! CAUTION • Do not damage the stator coil.
SAPH301091300078
(4) Install parts referring to the part layout.

- 1.8 lbf⋅ ft}
! CAUTION • Apply screw lock to the ends of the heat sink

mounting bolt and the regulator mounting
bolt.
SAPH301091300079
(5) Solder the lead wire connecting the regulator and the field
coil, and connecting the stator coil and the diode using a
soldering bit.
! CAUTION • Perform soldering after tightening of bolts.

• Bend and fix the regulator terminal before
soldering the lead wire of the field coil.
• Clamp the end of the diode of the stator coil
before soldering.
SAPH301091300080 • Perform soldering in a short time (within 5
seconds).
terminal
Lead wire
Regulator assembly
SAPH301091300081
(6) Tighten the nut inside the B terminal.

- 4.3 lbf⋅ ft}
NOTICE • After installation of the alternator, connect the

wire and tighten the outside nut
SAPH301091300082
3. Joint of front and rear

(1) Joint the front with the rear with bolts.
Tightening torque : 7.8 - 9.8 N⋅ m {80 - 99 kgf⋅ cm, 6 - 7
lbf⋅ ft}
! CAUTION • Tighten bolts evenly.
SAPH301091300083
(2) Install the coupler holder and tighten bolts.

-1.8 lbf⋅ ft}
SAPH301091300084
(3) Align the tab and install the cover. Fix it with bolts.

- 3.2 lbf⋅ ft}
! CAUTION • Do not hit the cover because the tab may be

broken.
SAPH301091300085
Inspection after assembly (60A)

JP30002130703003

mat.
1. Inspection of rotation
(1) Turn the pulley with hand to check if there is no
interference with internal parts and if rotation is smooth.
SAPH301091300086
(2) Measure the resistance between B and E terminals and

between P and E terminals using a circuit tester. If it is
beyond the standard value (e.g. 0 Ω), disassemble it again
and reassemble the unit correctly.
Circuit tester lead

Standard value
(+) (–)
B E Approx. 20 Ω
SAPH301091300087
E B Infinite
P E Approx. 7 Ω
E P Infinite
㧾㧸
㧺㧼
'
Connector details
SAPH301091300088
TURBOCHARGER 14–1
ENGINE
14 TURBOCHARGER
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Turbocharger Assembly........................................... 14-2

Assembly/disassembly layout ............................... 14-2
Removal................................................................ 14-3
Installation............................................................. 14-4
14
14–2 TURBOCHARGER
Turbocharger Assembly
Assembly/disassembly layout
JP30109140402001
SAPH301091400001
15474 Oil outlet pipe 24135 Gasket*

17159 Exhaust manifold connector 9655-12100 Gasket*
24106 Oil inlet pipe 9655-14140 Gasket*
24109 Gasket* 9851A O-ring*
24109A Gasket* S1760 Turbocharger assembly

Tightening torque
9209A 59N⋅ m{600kgf⋅ cm,44lbf⋅ ft}
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TURBOCHARGER 14–3
Removal
JP30109140702001
1. Disconnect the boost pipe and the air pipe.
2. Remove the insulator.

Insulator
SAPH301091400014
3. Disconnect all pipes connected to the turbocharger.

Turbocharger
! CAUTION • Loosen the union bolt of the coolant pipe,

remove it after water draining, separate in the
same way also at the bottom, and then
remove the oil pipe.
• After removal of each pipe, seal the water hole
and the holes on the cylinder block side to
Oil pipe prevent entry of dirt etc.
SAPH301091400015
4. Remove the nuts and take off the turbocharger.

Turbocharger
! CAUTION • After removal, seal the opening on the
exhaust manifold side and on the exhaust
pipe side to prevent entry of foreign objects.
• If the stud bolts should be difficult to remove,
use a commercial stud remover to remove
them and then replace them.
Nut
SAPH301091400016
14–4 TURBOCHARGER
Installation
JP30109140702002
1. Before installation on the engine, pour new engine oil from

the oil inlet and turn the turbocharger with hand to
lubricate the journal bearing and the thrust bearing.
2. Replace the gasket by a new one, install exhaust pipe and

Turbocharger
turbocharger, and install the turbocharger to the engine.

(Turbocharger to exhaust manifold)
! CAUTION • Make sure that there is no dirt or foreign

matter in the exhaust piping system.
• Since heat resistant steel is used for bolts and
Nut nuts, do not mix them with normal bolts for
SAPH301091400016 installation.
3. Replace the gasket with a new one and connect the

Turbocharger coolant pipe and oil pipe to the turbocharger.
! CAUTION • Clean the pipe and make sure that there is no

pipe deformation or no dirt or foreign matter
in the pipe.
• Do not use sealant at the installation surface
of the oil pipe and the coolant pipe or joint
Oil pipe between the coolant hose and the coolant
SAPH301091400015 pipe to prevent failures such as damage due
to clogging or loosening of tightened areas.
4. Install the insulator on the turbocharger.

Insulator
SAPH301091400014
5. Install the boost pipe and U-turn pipe.
! CAUTION • Make sure that there is no dirt or foreign

matter in the air intake system. Do not use
sealant at the inlet/outlet of air to prevent
failures such as damage due to clogging or
loosening of tightened areas.
• Be sure to install the air feed pipe and the air
hose correctly to prevent air leak from
connections.
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–1
ENGINE
16 FAILURE DIAGNOSIS FOR EACH ENGINE

STATUS
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Engine mechanical ............................................... 16-2

Alternator .............................................................. 16-5
Starter ................................................................... 16-6
Turbocharger......................................................... 16-7
16
16–2 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Engine mechanical
JP03Z01020601001
Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Water leak from EGR cooler Replace EGR cooler.
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Clogging of flyscreen (vehicle with Cleaning of flyscreen
flyscreen)
Clogging of intercooler core front Cleaning of intercooler core
part
Engine overheat (compression Non-synchronous injection timing Inspection of supply pump timing
pressure) Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of valve guide Replace valve guide.
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Faulty ventilator Replace ventilator.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Status Cause Action

Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
Insufficient engine power (air Clogging of air cleaner element Clean or replace air cleaner
cleaner) element
Insufficient engine power Overheat Refer to overheat section.
Insufficient engine power (fuel Faulty injection of injector Replace injector
unit) Faulty injector due to deposit of Replace injector
carbon
Entry of air into fuel system Air bleeding of fuel system
Faulty fuel filter Replace element
Faulty fuel Replace with correct fuel
Insufficient engine power Abnormal compression pressure Refer to overheat section.
Insufficient engine power Piston, cylinder liner and piston ring Refer to overheat section.
Faulty engine start (electric unit) Faulty battery Check battery
Faulty wiring of starter Replace starter wiring
Loose battery cable Tighten battery terminal connection
or replace cable
Faulty operation of starter Replace starter assembly
Faulty start assist unit Replace start assist unit
Faulty engine start (air cleaner) Clogging of air cleaner element Clean or replace air cleaner
element
Faulty engine start (fuel unit) Insufficient fuel Replenish fuel and bleed air from
fuel system
Clogging of fuel system Clean fuel system.
Air intake from connection of fuel Tighten connections
system
Clogging of fuel filter Replace fuel filter
Loose connection of injection pipe Tighten connecting nut of injection
pump
Faulty engine start (injector) Injector seizure Replace injector
Faulty engine start (lubrication Excessive viscosity of engine oil Replace with engine oil with correct
unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and
cylinder liner
Bearing seizure Replace bearing and crankshaft
Low compression pressure Overhaul engine
Damage to ring gear Replace ring gear and replace
starter pinion gear.
Status Cause Action

Faulty idling (injector) Faulty injection pressure Adjust injection pressure.
Faulty injection status Adjust or replace injector.
Faulty idling (nozzle) Faulty injection pressure Adjust injection pressure.
Faulty spray status Adjust or replace nozzle
Carbon deposit at nozzle end Remove carbon
Seizure of needle valve Replace nozzle
Faulty idling (engine) Faulty valve clearance Adjustment of valve clearance
Faulty contact of valve seat Adjust or replace valve and valve
seat.
Low coolant temperature Perform warm-up.
Large variation of compression Overhaul engine
pressure between cylinders
Gas leak (head gasket) Reuse Replace gasket.
Damage Replace gasket.
Poor assembly Replace gasket.
Gas leak (head bolt) Loose head bolt Tighten bolt.
Incorrect tightening sequence or Tighten bolt to correct torque
incorrect tightening torque according to the correct tightening
sequence.
Gas leak (cylinder block) Crack Replace cylinder block.
Distortion of cylinder block upper Repair or replace cylinder block.
surface
Depression of cylinder liner Replace cylinder liner or block.
insertion (insufficient protrusion of
cylinder liner)
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Distortion of cylinder head lower Repair or replace cylinder head.
surface
Gas leak (cylinder liner) Crack of cylinder liner Replace cylinder liner.
Corrosion of cylinder liner Replace cylinder liner.
Insufficient protrusion of cylinder Replace cylinder liner or block.
liner
Gas leak (others) Incorrect injection timing Adjust injection timing.
Alternator
JP03Z01020601002
Status Cause Action

Lamp is ON. →Charge current Faulty regulator (open PTr) Replace regulator.
does not run (alternator). Faulty stator coil (disconnection, Replace stator coil.
rare shorting)
Fault feed coil (disconnection, rare Replace feed coil.
shorting)
Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is ON. →Charge current Disconnection of wire (fuse) Replace wire (fuse).
does not run (wiring).
Lamp is ON. →Voltmeter Faulty regulator (shorting of PTr) Replace regulator.
indicates 29V or more Faulty tightening of voltage Repair, replace voltage detection
(alternator). detection circuit (e.g. support) circuit or replace regulator.
Lamp is ON. →Charge current is Faulty regulator (open Tr) Replace regulator.
correctly running (alternator).
Lamp is OFF. →Charge current is Faulty stator coil (disconnection of 1 Replace stator coil.
always limited. →Battery goes phase, rare shorting)
flat (alternator). Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is OFF. →Charge current is Operation load is large (Load Reduce load
always limited. →Battery goes balance is poor).
flat (operation load).
Lamp is OFF. →Charge current is Faulty regulator (shorting of PTr) Replace regulator.
always large. →Battery fluid runs Faulty tightening of voltage Repair or replace voltage detection
short in a short period of time detection circuit (e.g. support) circuit.
(alternator).
Lamp is OFF. →Charge current is Battery is close to the service life. Replace battery.
always large. →Battery fluid runs
short in a short period of time
(battery).
Others →Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
Contact of inner surface (faulty Repair or replace bearing.
bearing, wear of bracket)
Others →Abnormal noise (V belt) Faulty tension of V belt (belt slip) Correction
Starter
JP03Z01020601003
Status Cause Action

Starter does not turn. Turning is Faulty connection of starter key Repair connecting area.
low. Flat battery Charge or replace.
Disconnection, loosening or After cleaning, tighten.
corrosion of battery terminal
Grounding wire is disconnected. Be sure to connect it.
Use of incorrect engine oil Replace with correct oil.
Faulty contact of start magnet Replace start magnet switch
switch assembly. assembly.
Faulty contact or failure of starter Replace starter relay.
relay
Wear of starter brush Replace brush.
Seizure of commutator Repair commutator.
Wear of commutator Undercut
Shorting of armature Replace armature assembly.
Insufficient tension of brush spring Replace brush spring.
Faulty operation of clutch Clean or replace.
Turbocharger
JP03Z01020601005
Status Cause Action

Exhaust smoke is black Clogging of air cleaner element Clean or replace air cleaner
(insufficient intake air). element.
Air intake inlet is closed. Recover normal status.
Leak from connection of air intake Check and repair.
system
Revolution of blower impeller and Replacement
turbine shaft is heavy
Defective waste gate operation Check and replace.
Exhaust smoke is black Oil impurities are deposited at the Replace engine oil and
(Turbocharger is not operating). sealing part of the turbine and disassemble the turbocharger for
revolution of the turbine shaft is cleaning.
heavy.
Seizure of bearing Replace turbocharger.
Seizure of bearing (insufficient Check the oil system of the engine
lubrication or clogging of oil pipe) and repair faulty areas. Also,
replace engine oil.
Seizure of bearing (Oil temperature Check the oil system of the engine
is too high.) and repair faulty areas. Also,
replace engine oil.
Seizure of bearing (Balance of Replace turbocharger.
revolving body is poor.)
Seizure of bearing (insufficient Observe the precautions strictly in
warm-up or sudden stop from the operation manual.
loaded operation: Unloaded
operation)
Contact of or damage to turbine Check and repair engine parts.
shaft and blower impeller
(excessive operation)
Contact of or damage to turbine Check and repair engine parts.
shaft and blower impeller
(excessive increase of exhaust gas
temperature)
Contact of or damage to turbine Inspect the air cleaner and the
shaft and blower impeller (entry of engine parts and repair or replace
foreign matter) the turbocharger.
Contact of or damage to turbine Replace turbocharger.
shaft and blower impeller (wear of
bearing)
Contact of or damage to turbine Replacement
shaft and blower impeller (faulty
assembly)
Status Cause Action

Exhaust smoke is black (due to Exhaust gas is leaking before the Check and repair mounting area.
exhaust gas resistance). turbocharger. Revolution is not
increased.
Since pipe of the exhaust system is Recover normal status.
deformed or clogged, revolution of
the turbocharger is not increased.
Exhaust smoke is white. Engine oil runs out to the blower or Repair or replace pipe.
the turbine due to clogging or
deformation of the oil return pipe.
Negative pressure at the back of Check and replace the pipe.
the blower impeller is increased and Replace or clean the air cleaner
engine oil runs out to the blower. element.
Seal ring is excessively worn or Replace turbocharger.
damaged due to excessive wear of
the bearing.
Water leakage from the EGR cooler EGR cooler replacement.
to the intake system.
Oil is quickly reduced. Seal ring is excessively worn or Replace turbocharger.
damaged due to excessive wear of
the bearing.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Low engine output Gas leak from exhaust system Check and repair faulty areas.
parts
Air leak from blower outlet Check and repair faulty areas.
Clogging of air cleaner element Clean or replace air cleaner
element
Contamination of or damage to Replace turbocharger.
turbocharger
Faulty operation of turbocharger Check and replace.
Acceleration (follow-up of Carbon deposit at the turbine (disc Replace the engine oil and the
turbocharger) is poor (slow). sealing area) makes revolution of turbocharger.
the turbine heavy.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Combustion is faulty. Check the engine fuel system and
recover correct combustion status.
Faulty operation of turbocharger Replace turbocharger.
Status Cause Action

Abnormal noise If the gas passage is extremely Replace turbocharger.
narrowed due to clogging at the
turbine case nozzle or if
acceleration is performed, reverse
flow (usually called surging) occurs
due to clogging of blower discharge
air.
Revolving part is in contact. Replace turbocharger.
Faulty operation of turbocharger Check and replace.
system
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Vibration Loosening between turbocharger Check the turbocharger mounting
and intake/exhaust pipe and status and repair faulty areas.
between oil pipe and mounting area
Failure of metal, contact between Replace turbocharger.
revolving part and peripheral parts,
or damage to the blower impeller of
the turbine rotor due to entry of
foreign matter is found.
Balance of revolving body is poor. Replace turbocharger.
ENGINE DIAGNOSIS CODE 17–1
ENGINE
17 ENGINE DIAGNOSIS CODE

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Engine ECU ............................................................... 17-3 Accelerator sensor 1 and 2 malfunction

Precautions........................................................... 17-3 (DTC code P2120) .............................................. 17-41
System block diagram........................................... 17-4 Emergency accelerator sensor malfunction
Inspection ............................................................. 17-5 (DTC code P1133) ............................................. 17-42
Connection method of HinoDX ............................. 17-6 Atmospheric pressure sensor malfunction
Table of failure code .............................................. 17-7 (DTC code P2228, P2229)................................. 17-44
Signal check harness.......................................... 17-11 Injector common 1 short to GND
Computer pin arrangement ................................. 17-13 (DTC code P1211),
Check the ECU power supply voltage................. 17-14 Injector common 2 short to GND
Check the ground................................................ 17-14 (DTC code P1214) .............................................. 17-45
Engine speed main sensor circuit malfunction Injector common 1 short to BATT
(DTC code P0335) .............................................. 17-15 (DTC code P1212),
Abnormal engine main rotation sensor pulse count Injector common 2 short to BATT
(DTC code P0336) .............................................. 17-16 (DTC code P1215) .............................................. 17-47
Engine speed sub sensor circuit malfunction Injector circuit malfunction
(DTC code P0340) .............................................. 17-18 (DTC code P0201 to P0206)............................... 17-49
Abnormal engine auxiliary rotation sensor pulse count Cylinder contribution/balance fault
(DTC code P0341) .............................................. 17-20 (DTC codes P0263, P0266, P0269, P0272, P0275,
Engine speed main and sub sensor circuit malfunction P0278) ................................................................ 17-52
(DTC code P0335) .............................................. 17-22 PCV1 malfunction
Coolant temperature sensor malfunction (DTC code P0628) .............................................. 17-54
(DTC code P0117, P0118) ................................. 17-23 PCV1 malfunction
Engine overheat (DTC code P0628) .............................................. 17-57
(DTC code P0217) .............................................. 17-24 PCV1 out put short to GND
Engine overrun (DTC code P0629) .............................................. 17-58
(DTC code P0219) .............................................. 17-25 PCV1 malfunction
Fuel temperature sensor malfunction (DTC code P0629) .............................................. 17-60
(DTC code P0187, P0188) ................................. 17-26 PCV2 malfunction
Boost pressure sensor malfunction (DTC code P2633) .............................................. 17-61
(DTC code P0108, P0237) ................................ 17-27 PCV2 out put short to GND
Turbocharger over boost (DTC code P2634) .............................................. 17-64
(DTC code P0234) .............................................. 17-29 Supply pump over-feed
EGR cooler coolant temperature sensor malfunction (DTC code P1229) .............................................. 17-66 17
(DTC code P1417, P1418) ................................. 17-30 Supply pump over-feed
Excessive common rail pressure (DTC code P1266) .............................................. 17-67
(DTC code P0088) .............................................. 17-31 EGR actuator fault
Excessive common rail pressure, supply pump excess (DTC code P1458,P1459)................................... 17-68
forced feed EGR valve sticking 1
Common rail pressure sensor malfunction EGR cooler overheat
Common rail pressure sensor failure Preheat circuit malfunction
(DTC code P0192, P0193) ................................. 17-34 (DTC code P0540) .............................................. 17-71
Fuel leakage Injector correction data conformily error
(DTC code P0093) .............................................. 17-36 (DTC code P1601) ............................................. 17-72
Accelerator sensor 1 malfunction ECU internal error
(DTC code P2122, P2123) ................................. 17-37 (DTC code P0605, P0606, P0607) ..................... 17-73
Accelerator sensor 1 malfunction ECU charge circuit malfunction
(DTC code P2127, P2128) ................................. 17-39 (DTC code P0200, P0611).................................. 17-74
17–2 ENGINE DIAGNOSIS CODE
Main relay malfunction

(DTC code P0686) ..............................................17-75
Starter signal malfunction
(DTC code P0617) ..............................................17-76
CAN communication loss EGR actuator
(DTC code U1122) ..............................................17-77
CAN1 communication error (Engine)
(DTC code U0073)
CAN2 communication error (Unit)
(DTC code U1001) ..............................................17-78
17
Engine ECU
Precautions
JP31Z01170102001
! CAUTION • Make sure that each connector is connected

before inspection.
• Do not place a tester rod on the connecting
surface of the connector. Otherwise,
terminals are damaged or short-circuited.
• Delete the past failure memory after
recording. Perform failure diagnosis again to
check current failure.
• After failure analysis, delete the past failure
memory. If the past failure memory is not
deleted, the failure indicator lamp remains
ON.
• All connector drawings are viewed from the
connecting surface. Place the tester rod from
SAPH31Z011700001
the back.
NOTICE • The mounting position of each sensor is

described in HinoDX with illustrations.
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SAPH31Z011700002
System block diagram

JP31Z01170803001
PCV relay
Fuse 20A
main relay
PCV power Fuse 15A
supply
- +
Battery
Shovel controller
Main relay number Failure diagnosis tool
Accelerator signal 1, 2
KWP2000 Hino-Bowie PC failure
Neutral switch diagnosis
CAN signal
Key switch signal
OUTPUT
Starter signal
INPUT
Air heater relay

Emergency accelerator
sensor
Neutral switch Injector drive signal

Supply pump
(Normal input)
Supply pump control valve drive signal
CAN communication
Others
Main engine speed sensor
Sub-engine speed sensor
Fuel temperature sensor (leakage)

Boost pressure sensor
PC sensor 1
PC sensor 2
Water temperature
sensor
EGR gas temperature sensor
Coolant temperature
EGR cooler exit
sensor
P
P Common rail T T T T
G
Engine
N
EGR
Turbo charger
DC motor
Waste gate
SAPH31Z011700003
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Inspection
JP31Z01170703001
1. Pre-inspection
(1) If the system has an error, the failure code(DTC code) is
displayed on the multiple display of gauge cluster.
SAPH31Z011700004
2. Deletion method of past failure
(1) To delete past failures of the engine ECU, use HinoDX on

the PC. (Refer to "HinoDX operation manual".)
SAPH31Z011700005
3. Deletion of cluster gauge past failure

(1) Turn "ON" the starter switch.
(2) When the buzzer stop switch is pressed consecutively 5

times in 10 seconds, the failure history mode is displayed.
(3) Press work mode selecting switch and the buzzer stop
switch at the same time for 10 seconds or more.
(4) When the display shows "No error", deletion is completed.
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SAPH31Z011700006
Connection method of HinoDX

JP31Z01170301001
1. Removal of the maintenance cover

Maintenance Cover (A)
(1) Remove the maintenance cover (A) on the rear cover
behind the operator seat by pushing down the tab at the
top (at one location).
NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.
SAPH31Z011700007
2. Connection of HinoDX
Engine ECU (1) Connect the system to the engine failure diagnosis
connector through the interface box.
Special tool : Hino-Bowie (Interface box)

Connecting cable
Engine failure
diagnosis CD-ROM HinoDX (380140047)
connector
(2) Set the starter key to "ON" and start HinoDX.
SAPH31Z011700008
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Failure diagnosis connector
Hino-Bowie
Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH31Z011700009
Table of failure code

JP31Z01170601001
NOTICE • For the system status by check engine lamp ON in the table, refer to "Inspection - Pre-
inspection".
"Reference: Engine diagnosis code, Inspection"
[a] Failure diagnosis and

DTC code Estimated failure cause Page
[b] Alarm display (alarm status)
a. Engine does not start. P0606 CPU malfunction (Hard detection) 17-73
Engine stopped. P0335 Engine speed main sensor circuit 17-15
malfunction
b. DTC code display on the (Failure of both NE & G sensors)
multiple display of the P0628 PCV1 malfunction 17-57
gauge cluster. (Failure of both PCV1 & 2)
P0629 PCV1 malfunction 17-60

(Both PCV1 & 2 failure)
P0093 Fuel leakage 17-36
a. Low output (limp form) P2120 Accelerator sensor 1 and 2 malfunction 17-41
b. DTC code display on the

multiple display of the
gauge cluster.
a. Low output P0217 Engine overheat 17-24
P0234 Turbocharger over boost 17-29

b. DTC code display on the P0605 Flash ROM error 17-73
multiple display of the
P0607 Monitoring IC malfunction in CPU 17-73
gauge cluster.
U0073 CAN1 communication error 17-78
(Engine)
U1001 CAN2 communication error 17-78

(Unit)
U1122 CAN communication loss 17-77

(EGR actuator)
P0108 Boost pressure sensor circuit high input 17-27
P0237 Boost pressure sensor circuit low input 17-27
P0201 Injector circuit malfunction -cylinder 1 17-49


a. Low output P1211 Injector common 1 short to GND 17-45

(GND short-circuit)
b. DTC code display on the P1212 Injector common 1 short to BATT 17-47
multiple display of the (VB short-circuit)
gauge cluster. P1212 Injector common 1 short to BATT (Open) 17-47
P1214 Injector common 2 short to GND 17-45

(GND short-circuit)
P1215 Injector common 2 short to BATT 17-47

(VB short-circuit)
P1215 Injector common 2 short to BATT (Open) 17-47
P0200 ECU charge circuit high input 17-74
P0611 ECU charge circuit malfunction 17-74
P0191 Common rail pressure sensor malfunction 17-33
P0192 Common rail pressure sensor circuit low 17-34

input
P0193 Common rail pressure sensor circuit high 17-34

input
P0088 Excessive common rail pressure 17-31

(1st step)
P0088 Excessive common rail pressure 17-31

(2nd step)

(GND short-circuit)
P0629 PCV1 out put short to GND 17-60

(VB short-circuit)
P2634 PCV2 out put short to GND 17-64
P0088 Excessive common rail pressure, supply 17-32

pump excess forced feed
P1229 Supply pump over-feed 17-66
P1266 Supply pump over-feed 17-67
P1458 EGR actuator fault 17-68
P1459 EGR actuator fault 17-68
P0404 EGR valve sticking 1 17-69


a. Other problems P1601 Injector correction data conformity error 17-72
P0686 Main relay malfunction 17-75

b. DTC code display on the P0117 Coolant temperature sensor circuit low 17-23
multiple display of the input
gauge cluster.
P0118 Coolant temperature sensor circuit high 17-23
input
P0340 Engine speed sub sensor circuit 17-18

malfunction
P0335 Engine speed main sensor circuit 17-22

malfunction
P0187 Fuel temperature sensor circuit low input 17-26
P0188 Fuel temperature sensor circuit high input 17-26
P2228 Atmospheric pressure sensor circuit low 17-44

input
P2229 Atmospheric pressure sensor circuit high 17-44

input
P0336 Abnormal engine main rotation sensor 17-16

pulse count
P0341 Abnormal engine auxiliary rotation sensor 17-20

pulse count
P2122 Accelerator sensor circuit 1 low voltage 17-37
P2123 Accelerator sensor circuit 1 high voltage 17-37
P2127 Accelerator sensor circuit 2 low voltage 17-39
P2128 Accelerator sensor circuit 2 high voltage 17-39
P1133 Emergency accelerator sensor malfunction 17-42

high input
P0540 Preheat circuit malfunction 17-71

(Open/ground short-circuit)
P0540 Preheat circuit malfunction 17-71

(VB short-circuit)

a. Other problems P0219 Engine over-run 17-25
P1417 EGR cooler coolant temperature sensor 17-30

b. DTC code display on the malfunction
multiple display of the P1418 EGR cooler coolant temperature sensor 17-30
gauge cluster. malfunction
P0617 Starter signal malfunction 17-76
P0263 Cylinder 1 contribution/balance fault 17-52
P1416 EGR cooler overheat 17-70

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JP31Z01170301002
1. Signal check harness
! CAUTION • When measuring terminal of the engine ECU,

connect the signal check harness to prevent
damage to the connector. Place the tester rod
on the contact box of the signal check
harness for measurement.
NOTICE • Terminal numbers in the text and the

illustrations correspond as shown below in
the "Computer pin arrangement".
ECU terminal name
[Example] For terminal A8 ECU terminal number

(Contact box)
SAPH31Z011700010
2. Connection of signal check harness

(1) Set the starter key to "OFF" and disconnect the connector
from the engine ECU.
(2) Connect the signal check harness to the engine ECU and
the unit harness.
Signal check harness : 380100045
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unit harness
Test lead
Signal check connector
SAPH31Z011700011
Computer pin arrangement

JP31Z01170201001
SAPH31Z011700012
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Check the ECU power supply voltage

JP31Z01170601002
1 Measurement of voltage between terminals
1. Set the starter key to "OFF" and connect the signal check
A5 㧭 A6 D1 㧰 E4 㧱 E5 harness
A7
2. Turn the starter key "ON" and measure voltage between
terminals A5, A6, A7 and terminals D1, E4, E5.
Standard value : 20 V or more
NG • 0V: Blown fuse, harness failure, ground failure, etc.

• 20V or less: Battery deterioration, ground failure,
SAPH31Z011700013
etc.
OK
Normal
Check the ground

JP31Z01170601003
D1 㧰 E4 㧱 E5 harness.
2. Disconnect the ECU side connector of the signal check

Frame harness and measure the resistance between terminals D1,
E4, E5 and the terminal (-) of the battery.
Standard value : 1 Ω or less
NG Disconnection of ground harness, contact failure,

SAPH31Z011700014 etc.
OK
Normal
Engine speed main sensor circuit malfunction

(DTC code P0335)
JP31Z01170601004
B6 B B7 harness.

harness and measure the resistance between terminal B6 and
terminal B7.
Standard value : Approx. 125.5 ± 17 Ω (20 ° C{68 ° F})
NG [3] Go to measurement of resistance between sensor

SAPH31Z011700015 terminals.
OK
1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, Start the engine and confirm that
START no diagnostic code is put out.
Standard : No diagnostic code
OFF NG Contact failure of ECU connector, ECU failure, short-

circuit of harness
SAPH31Z011700016
OK
Normal
1. Disconnect the connector of the main engine speed sensor and

the sensor.
Standard value : Approx. 125.5 ± 17 Ω (20 ° C{68 ° F})
NG Failure of main engine speed sensor
SAPH31Z011700017
OK
Harness disconnection or connector failure

Abnormal engine main rotation sensor pulse count

(DTC code P0336)
JP31Z01170601013
1 Measuring the input waveform on the engine ECU side
B6 㧮 B7
harness.
2. Start the engine.
3. Measure the waveform between terminals B6 and B7 of the

signal check harness.
Standard : 56 pulses from missing tooth to missing

tooth
SAPH31Z011700018
4. Stop the engine after measuring.
NG Go to [2] Measuring the resistance between

terminals.
OK
Defective ECU, defective ECU connector
2 Measuring the resistance between terminals
1. Leave the connector of the engine main rotation sensor

connected.
B7
2. Measure the resistance between terminal No. 1 of the engine

main rotation sensor connector (unit harness side) and
terminal B7 of the signal check harness.
! CAUTION • The connector of the engine main rotation

sensor is shown from the engagement side.
SAPH31Z011700019
3. Measure the resistance between terminal No. 2 of the engine

B6
terminal B6 of the signal check harness.

Standard value : 2Ω or less
NG Defective harness
SAPH31Z011700020
OK
Go to [3] Measuring the output waveform on the sensor side

3 Measuring the output waveform on the sensor side
1. Leave the connector of the engine main rotation sensor

connected.
3. Measure the waveform between terminal No. 1 of the engine

terminal No. 2.

SAPH31Z011700021
Standard : 56 pulses from missing tooth to missing

tooth
NG Defective engine main rotary sensor or defective

flywheel pulser
OK
Defective connector contact

Engine speed sub sensor circuit malfunction

(DTC code P0340)
JP31Z01170601005
1 Measurement of voltage between sensor terminals
harness.
GND +5V
2. Disconnect the connector of the sub-speed sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the sub-speed sensor
connector (at unit harness side).
Standard value : 5.0 ± 0.5 V

SAPH31Z011700022
NG [2] Go to measurement of voltage between terminals.
OK
[3] Go to measurement of voltage between terminals.
1. Measure voltage between terminal D32 and terminal D30 of

D the signal check harness.
D32 D30
Standard value : 5.0 ± 0.5V
NG Engine ECU failure, connector failure
SAPH31Z011700023
OK
Harness failure
1. Set the starter key to "OFF" and connect the connector of the
D D19
sub-speed sensor.
D30
2. Start the engine and keep idling status.
3. Measure voltage between terminal D19 and terminal D30 of

the signal check harness.
4. After measurement, stop the engine.
SAPH31Z011700024 Standard : Pulse waveform of 0 ↔ 5 V
NG [4] Go to measurement of resistance between

terminals.
OK
Engine ECU failure, ECU connector failure
1. Leave the connector of the sub-speed sensor connected.

SIG
D19 2. Measure resistance between the No. 1 terminal at the unit
harness of the sub-speed sensor connector and terminal D19
of the signal check harness.
! CAUTION • The connector of the sub-speed sensor in the

figure is viewed from the fitting surface.
SAPH31Z011700025
NG Harness failure
OK
Failure of sub-speed sensor

Abnormal engine auxiliary rotation sensor pulse count

(DTC code P0341)
JP31Z01170601039
1 Measuring the voltage between the sensor terminals
harness.
GND +5V
2. Disconnect the connector of the engine auxiliary rotation
sensor.
3. Set the starter key to "ON" and measure the voltage between
the +5 V terminal of the engine auxiliary sensor connector (unit
harness side) and the GND terminal.
SAPH31Z011700026 Standard value : 5.0 ± 0.5 V
NG Go to [2] Resistance between terminals.
OK
Go to [3] Measuring the input waveform on the engine ECU side.
2 Measuring the resistance between terminals
SIG engine auxiliary rotation sensor.
D19
2. Measure the resistance between terminal SIG of the engine
auxiliary rotation sensor connector (unit harness side) and
terminal D19 of the signal check harness.
! CAUTION • The connector of the engine auxiliary rotation

SAPH31Z011700027 Standard value : 2 Ω or less
NG Defective harness
OK
Go to [3] Measuring the input waveform on the engine ECU side.

3 Measuring the input waveform on the engine ECU side
D19 2. Measure the waveform between terminals D19 and D30 of the
D30
signal check harness.
Standard : Seven pulses from excess tooth to excess

tooth
SAPH31Z011700028 NG Go to [4] Measuring the output waveform on the

sensor side.
OK
Defective engine ECU, defective ECU connector
4 Measuring the output waveform on the sensor side.
1. Leave the connector of the engine auxiliary rotation sensor

SIG GND connected.
3. Measure the waveform between terminal SIG of the engine

auxiliary rotation sensor connector (unit harness side) and
terminal GND.
! CAUTION • The connector of the engine auxiliary rotation

SAPH31Z011700029
Standard : Seven pulses from excess tooth to excess

tooth
NG Defective engine auxiliary rotations sensor or

defective pulser
OK
Defective connector contact

Engine speed main and sub sensor circuit malfunction

(DTC code P0335)
JP31Z01170601006
1 Inspection item
1. Take actions of (DTC code P0335) and (DTC code P0340).

"Reference : Engine speed main sensor circuit malfunction
(DTC code P0335), Engine ECU, Engine diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction
(DTC code P0340), Engine ECU, Engine diagnosis code"
Coolant temperature sensor malfunction

(DTC code P0117, P0118)
JP31Z01170601007
DTC P0117 Coolant temperature sensor circuit low input
DTC P0118 Coolant temperature sensor circuit high input
1. Set the starter key to "OFF" and connect the signal check harness.
D E
E19 2. Disconnect the ECU side connector of the signal check
D34 harness and measure the resistance between terminal E19
and terminal D34.
Standard value (Measure either one point of the following.)

Characteristics table of temperature—resistance value
20 ° C{68 ° F} 2.45 kΩ
SAPH31Z011700030
40 ° C{104 ° F} 1.15 kΩ
60 ° C{140 ° F} 0.584 kΩ
80 ° C{176 ° F} 0.318 kΩ
NG [2] Go to measurement of resistance between sensor

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
1. Disconnect the connector of the coolant temperature sensor

and measure the resistance between No. 1 and No. 2 terminals
at the sensor.

20 ° C{68 ° F} 2.45 kΩ
40 ° C{104 ° F} 1.15 kΩ
SAPH31Z011700031 60 ° C{140 ° F} 0.584 kΩ
80 ° C{176 ° F} 0.318 kΩ
NG Failure of coolant temperature sensor
OK
Harness disconnection, connector failure

Engine overheat
(DTC code P0217)
JP31Z01170601008
1. Set the starter key to "OFF", disconnect the connector of the

coolant temperature sensor and measure the resistance
between No. 1 and No. 2 terminals at the sensor.

20 ° C{68 ° F} 2.45 kΩ
40 ° C{104 ° F} 1.15 kΩ
SAPH31Z011700031 60 ° C{140 ° F} 0.584 kΩ
80 ° C{176 ° F} 0.318 kΩ
NG Failure of coolant temperature sensor
OK
Failure of engine cooling system
NOTICE • This code is displayed when the coolant temperature sensor is normal and the coolant
temperature is 105 ° C{221 ° F} or more.
• While this failure code is detected, the maximum injection volume is restricted. When the
coolant temperature is 80 ° C{176° F} or less, normal control is resumed.
Engine overrun
(DTC code P0219)
JP31Z01170601009
1 This failure code is displayed when the engine speed of 2,560 r/min or more is detected. While this
failure code is detected, fuel injection is stopped. When the engine speed is lower than 2,460 r/min,
fuel injection is resumed.
NOTICE • The objective of this failure code is not to

detect overrun due to failure of this system,
but to memorize high revolution of the engine.
• Engine speed may be incorrectly recognized
with noise on the speed sensor signal due to
harness failure or modification, resulting in
detection of overrun.
Fuel temperature sensor malfunction (DTC code P0187, P0188)

JP31Z01170601010
DTC P0187 Fuel temperature sensor circuit low input
DTC P0188 Fuel temperature sensor circuit high input
D E harness.
D34 E26
harness and measure the resistance between terminal E26
and terminal D34.

SAPH31Z011700032 20 ° C{68 ° F} 2.45 kΩ
40 ° C{104 ° F} 1.15 kΩ
60 ° C{140 ° F} 0.584 kΩ
80 ° C{176 ° F} 0.318 kΩ

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
2 Measurement of sensor resistance
1. Disconnect the connector of the fuel temperature sensor and

the sensor.

20 ° C{68 ° F} 2.45 kΩ
40 ° C{104 ° F} 1.15 kΩ
SAPH31Z011700033 60 ° C{140 ° F} 0.584 kΩ
80 ° C{176 ° F} 0.318 kΩ
NG Failure of fuel temperature sensor
OK
Harness disconnection, connector failure

Boost pressure sensor malfunction

(DTC code P0108, P0237)
JP31Z01170601011
DTC P0108 Boost pressure sensor circuit high input
DTC P0237 Boost pressure sensor circuit low input
harness.
GND +5V
2. Disconnect the connector of the boost pressure sensor.
+5V terminal and the GND terminal of the boost pressure
sensor connector (at unit harness side).
Standard value : 5 ± 0.5 V

SAPH31Z011700034
OK
1. Measure the voltage between terminal D25 and terminal D33

D of the signal check harness.
D25
D33 NG Engine ECU failure, ECU connector failure
SAPH31Z011700035
OK
Harness failure
D boost pressure sensor.
D27
D33
terminal D27 and terminal D33 of the signal check harness.
Standard value : 0.2 to 4.8 V
SAPH31Z011700036
OK
1. Leave the connector of the boost pressure sensor connected.

GND SIG
2. Measure the voltage between the SIG terminal and the GND
terminal of the boost pressure sensor connector (at unit
harness side).
NG Boost pressure sensor failure
SAPH31Z011700037
OK
Harness failure
Turbocharger over boost

(DTC code P0234)
JP31Z01170601012
1 Inspection with failure diagnosis tool
1. After failure, perform failure diagnosis with a failure diagnosis

tool (HinoDX) using PC.
㪦㪥 2. Connect the failure diagnosis tool (HinoDX) using PC and set

the starter key to "ON".
㪦㪝㪝
SAPH31Z011700083
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
EGR cooler coolant temperature sensor malfunction

(DTC code P1417, P1418)
JP31Z01170601014
1. Disconnect all ECU connectors and measure the resistance

A D between terminal A34 and terminal D34 of the check harness.

A34 D34
20 ° C{68 ° F} 2.45 kΩ
40 ° C{104 ° F} 1.15 kΩ
60 ° C{140 ° F} 0.584 kΩ
SAPH31Z011700038
80 ° C{176 ° F} 0.318 kΩ
NG [2] Measurement of sensor resistance
OK
ECU, ECU connector failure, harness failure (short-circuit)
2 Measurement of sensor resistance
1. Disconnect the sensor connector and measure the resistance

of the sensor.

20 ° C{68 ° F} 2.45 kΩ
40 ° C{104 ° F} 1.15 kΩ
60 ° C{140 ° F} 0.584 kΩ
SAPH31Z011700039
80 ° C{176 ° F} 0.318 kΩ
NG Sensor failure
OK
Harness failure (disconnection), connector failure

Excessive common rail pressure

(DTC code P0088)
JP31Z01170601015
DTC P0088 Excessive common rail pressure (1st step)
DTC P0088 Excessive common rail pressure (2nd step)
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33 of the signal check
harness.
NG Engine ECU failure or harness/connector contact

SAPH31Z011700040 failure
OK
Failure of common rail pressure sensor

Excessive common rail pressure, supply pump excess forced feed

(DTC code P0088)
JP31Z01170601016
D D20 harness.
D31 2. Start and warm-up the engine until the coolant gauge moves
D33 (failure code P0088 or 76 is displayed).
3. Set the engine speed to idling. PFIN = Approx. 25 MPa

(approx. 1.5 V)
4. Measure the voltage between terminal D20/D31 and terminal

SAPH31Z011700041
D33 of the signal check harness.
Standard value:1.56 V or less
NG Common rail pressure sensor failure or engine ECU

failure
OK
2 Check of failure code
1. Make sure that other failure code is not output.

If other failure code is output, repair the failure code and make
sure again that failure code P0088 or 76 is output. In particular,
if a failure code of the main and sub-engine speed sensor
systems is output, make necessary repairs to prevent output of
the code.
2. Check the fuel injection timing of the supply pump. If the timing
is not set 0° for the top dead center, set it correctly.
3. When there is no error after the check above, delete the past
failure and operate the engine.
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with HinoDX.
SAPH31Z011700042
Common rail pressure sensor malfunction

(DTC code P0191)
JP31Z01170601017
D D20 harness.
D33 terminals D20/D31 and terminal D33.
NG Engine ECU failure or harness/connector contact

failure
SAPH31Z011700043
OK

㧰 D20
2. While measuring the voltage between terminals D20/D31 and
D31 terminal D33 of the signal check harness, repeat full opening/
D33 closing of the accelerator.
Standard : Voltage must change. (1.0 to 3.2 V)
NG Common rail pressure sensor failure or harness/

connector contact failure
SAPH31Z011700044
OK
Engine ECU failure, connector contact failure

Common rail pressure sensor failure

(DTC code P0192, P0193)
JP31Z01170601018
DTC P0192 Common rail pressure sensor circuit low input
DTC P0193 Common rail pressure sensor circuit high input
D33 D harness.
D20
terminals D20/D31 and terminal D33 of the signal check
harness.

SAPH31Z011700045
OK
1. Set the starter key to "OFF" and disconnect the connector of

the common rail pressure sensor.
GND +5V
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at unit harness side).

SAPH31Z011700046 terminals.
OK
Go to [3] measurement of resistance between terminals

1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
D
D20
D31 2. Measure the resistance between terminals D20/D31 of the
signal check harness and the SIG terminal of the common rail
SIG
NG Harness failure
SAPH31Z011700047
OK
Connector contact failure
1. Set the starter key to "OFF" and disconnect the ECU side
2. Measure the resistance between terminals D23/D33 of the

㧮 +5V
B23 signal check harness and the +5 V terminal of the common rail
Standard value:2 Ω or less

B33
NG Harness failure
SAPH31Z011700048
OK

Fuel leakage
(DTC code P0093)
JP31Z01170601019
1 Inspection item
1. For evaluation conditions for this failure diagnosis, if there is no

failure of failure code P0628, P0629, P2633, P2634, P0191,
P192, P0193 or 77, engine revolution is 400 r/min or more and
engine coolant temperature is 60 ° C{140° F} or more, and the
following status (a, b or c) is detected, it is diagnosed as an
error.
a. If the common rail actual pressure (NPC) is 5MPa {51kgf/
cm2, 725lbf/in.2} lower than the target pressure (PFIN) for a
certain time although the supply pump is the maximum
discharge status (failure code P1266 or 77 is detected).
b. If the discharge amount of the supply pump is greater than
during normal idling for a certain period of time when it is
within 5 MPa{51 kgf/cm2, 725 lbf/in.2}, the deviation of NPC
and PFIN during idling control.
c. If the discharge amount of the supply pump is large for a
certain period of time when it is within 5 MPa{51 kgf/cm2,
725 lbf/in.2}, the deviation of NPC and PFIN when the
injection volume is zero.
Since the injection volume and injection pressure are limited
during detection of this failure, the engine output is reduced.
Check clogging of fuel supply system. If the high pressure pipe
does not have a failure, the supply pump may have a failure.
2. Perform more detailed diagnosis with HinoDX.
SAPH31Z011700042
Accelerator sensor 1 malfunction

(DTC code P2122, P2123)
JP31Z01170601020
DTC P2122 Accelerator sensor circuit 1 low voltage
DTC P2123 Accelerator sensor circuit 1 high voltage
harness.
terminal A21 and terminal B20 of the signal check harness.
B20
A21 Standard value : 1.0 - 1.5V (idle status)
NG [3] Voltage measuring at the output port of the

mechatronic controller
SAPH31Z011700049
OK
1. While increasing the throttle, measure the voltage between

Standard value
B20 Engine
A21 Measuring item Voltage(V)
revolution(r/min)
Low idle 800 Approx. 1.0
High idle 1,850 Approx. 2.9
SAPH31Z011700049
NG Defective mechatronic controller
OK
Harness failure
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronic controller and B20 of the signal check
harness.
When an abnormal value is detected, the mechatronic
controller becomes defective.
Abnormal value
: 0.6 V or less
: 4.85 V or more
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller

Accelerator sensor 1 malfunction

(DTC code P2127, P2128)
JP31Z01170601021
DTC P2127 Accelerator sensor circuit 2 low voltage
DTC P2128 Accelerator sensor circuit 2 high voltage
㧭㧮 harness.
A22
B21
Standard value : 1.0 - 1.5V (idle status)
NG [3] Voltage measuring at the output port of the

mechatronic controller
SAPH31Z011700050
OK
1. While increasing the throttle, measure the voltage between

㧭㧮 terminal A22 and terminal B21 of the signal check harness.
A22
B21
Standard value
Engine
Measuring item Voltage(V)
revolution(r/min)
Low idle 800 Approx. 1.0
High idle 1,850 Approx. 2.9
SAPH31Z011700050
NG Defective mechatronic controller
OK
Harness failure
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 27 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.6 V or less
: 4.85 V or more
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller

Accelerator sensor 1 and 2 malfunction

(DTC code P2120)
JP31Z01170601022
1 Inspection item
1. Take action of failure code P2120 or 22.

"Reference: Accelerator sensor 1 malfunction (DTC code
P2121)
"Reference: Accelerator sensor 2 malfunction (DTC code
P2126)"
Emergency accelerator sensor malfunction

(DTC code P1133)
JP31Z01170601023
1 Power supply voltage measuring
1. With the ECU connector connected, disconnect the sensor

connector and measure the voltage between the power
+5V terminal (+5 V) and the GND terminal.
! CAUTION • The connector in the figure is seen from the

fitting surface.
GND Standard value : 5.0 ± 0.5 V

SAPH31Z011700051
OK
1. Measure the voltage between terminals B20 and B23 of the

㧮 signal check harness.
B23 B20
Standard value : 5.0 ± 0.5 V
NG Engine ECU, engine ECU connector failure
SAPH31Z011700052
OK
Harness failure
1. Connect the sensor connector and measure the voltage

between terminals A23 and B20 of the signal check harness.
Standard value : Approx. 0.0 to 2.6±0.3 V (at the time

of 1,700 - 1,850 r/min)
B20
A23 NG [4] Go to measurement of voltage between terminals.
SAPH31Z011700053
OK
Engine ECU failure, engine ECU connector failure
1. Leave the emergency accelerator sensor connected.
2. Connect the sensor connector and measure the voltage

GND between the terminals SIG and GND of the sensor.
! CAUTION • The connector in the figure is seen from the

SIG
fitting surface.
Standard value : Approx. 0.0 to 2.6±0.3 V (at the time

of 1,700 - 1,850 r/min)
SAPH31Z011700054
NG Emergency accelerator sensor failure
OK
Harness failure
Atmospheric pressure sensor malfunction

(DTC code P2228, P2229)
JP31Z01170601024
DTC P2228 Atmospheric pressure sensor circuit low input
DTC P2229 Atmospheric pressure sensor circuit high input
1. After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229) is output.
㪪㪫㪘㪩㪫㪦㪥
Standard : Normal
NG Engine ECU failure

㪦㪝㪝
SAPH31Z011700084
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
Injector common 1 short to GND

(DTC code P1211),
Injector common 2 short to GND
(DTC code P1214)
JP31Z01170601025
harness.

harness.
3. Measure the resistance between each terminal of the signal
D5 D D6 check harness and the ECU case ground.
ECU case ground
(ECU mounting bolt)
DTC code Terminal to measure resistance
ECU case
E6 E E7 P1211 D5, D6
ground
ECU case
P1214 E6, E7
ground
SAPH31Z011700055 Standard value: ∞ Ω

injector terminals.
OK
1. Set the starter key to "OFF" and connect the ECU side
START 2. Start the engine and delete the past failure.
3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
OFF
temporary error has occurred.
SAPH31Z011700016
3 Measurement of resistance between injector terminals
1. Set the starter key to "OFF".
2. Tilt the cab and disconnect the injector clustered connector at

the front of the cam housing.
1 2 3 4
5 6 7 8 3. Measure the resistance between terminals of the injector
9 10 11 12 clustered connector (at unit harness side).
Terminal to measure voltage

DTC code
SAPH31Z011700056
+ side – side
1, 2
ECU case
P1211 9, 10
ground
8, 6
5, 7
ECU case
P1214 12, 11
ground
4, 3
Standard value: ∞ Ω
NG Harness failure (failure including pinching of harness

which has not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
Injector common 1 short to BATT

(DTC code P1212),
Injector common 2 short to BATT
(DTC code P1215)
JP31Z01170601026
D5 D D6 harness.
ECU case ground
(ECU mounting bolt)
harness and set the starter key to "ON".
E6 E E7
3. Measure the voltage between each terminal of the signal check
harness and the ECU case ground.
! CAUTION • Never start the engine because it may cause

SAPH31Z011700057
failure of the unit or electric shock.

DTC code
+ side – side
ECU case
P1212 D5, D6
ground
ECU case
P1215 E6, E7
ground
Standard value: 14V or less
NG [3] Go to measurement of voltage between injector

terminals.
OK
START 2. Start the engine and delete the past failure.
3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
OFF
SAPH31Z011700016
3 Measurement of voltage between injector terminals
2. Tilt the cab and disconnect the injector clustered connector at

the front of the cam housing. Set the starter key to "ON".
1 2 3 4
5 6 7 8 3. Measure the voltage between terminals of the injector
9 10 11 12 clustered connector (at unit harness side).
! CAUTION • Never start the engine because it may cause

failure of the unit or electric shock.
SAPH31Z011700056

DTC code
+ side – side
1
ECU case
P1212 9
ground
8
5
ECU case
P1215 12
ground
4
Standard value: 14V or less
NG Harness failure (harness failure of terminal that has

not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
Injector circuit malfunction

(DTC code P0201 to P0206)
JP31Z01170601027
DTC P0201 Injector circuit malfunction -cylinder 1
harness.
D3
D2 D6 2. Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminals.
D4 D5 Terminal to
Failure area
DTC code measure
(injector)
resistance
P0201 #1 D2 ↔ D5
P0202 #2 D3 ↔ D5
P0203 #3 D4 ↔ D6
E3 E6
E2
E7 P0204 #4 E1 ↔ E6
E1 P0205 #5 E3 ↔ E6
P0206 #6 E2 ↔ E7

injector terminals.
SAPH31Z011700058
OK
START 2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
3. If the same failure code is output again, replace the common

OFF
rail ECU. If the normal code is output, it is considered that a
SAPH31Z011700016
1. Disconnect the injector clustered connector at the front of the

cam housing.
2. Measure the resistance between terminals of the injector

clustered connector (male) at the cam housing.
Terminal to measure
DTC code
resistance
P0201 1↔2
SAPH31Z011700059 P0202 9 ↔ 10
P0203 8↔6
P0204 5↔7
P0205 12 ↔ 11
P0206 4↔3

injector terminals.
OK
Unit harness disconnection (Check the harness between the ECU and the injector clustered connector.)
1. Remove the head cover and disconnect the injector connector

(injector side) of the cylinder indicated by the failure code.
Measure the resistance between the No. 1 terminal and the No.
2 terminal.
Standard value : 0.45 ± 0.1 Ω

injector terminals.
SAPH31Z011700060
OK
Contact failure of harness or connector inside the head cover

1. Remove the terminal cap of the injector of the cylinder

indicated by the failure code and measure the insulation
resistance between the terminal and the upper body.
Standard value : 1, 000 MΩ or more
NG Injector TWV coil disconnection (Replace the injector

assembly.)
SAPH31Z011700061
OK
Injector harness disconnection (Replace the injector harness.)

Cylinder contribution/balance fault

(DTC codes P0263, P0266, P0269, P0272, P0275, P0278)
JP31Z01170601028
DTC P0263 Cylinder 1 contribution/balance fault
1 Inspection of flow damper
1. Set the starter key to "OFF" and stop the engine.
2. Wait for approx. 30 seconds and start the engine.

START
3. Warm up the engine until coolant is 60 ° C{140 ° F} or more and
delete the past failure.
OFF
SAPH31Z011700016
4. If the same failure code is displayed as the current failure after

deleting the past failure, check the flow damper of the cylinder
indicated by the failure code.
Failure area
DTC code
(Flow damper)
P0263 #1
P0266 #2
P0269 #3
SAPH31Z011700062
P0272 #4
P0275 #5
P0278 #6
Inspection details
: Remove the flow damper from the common rail and
run air from one side of the flow damper. Check if the
damper is not blocked by release of air to the
opposite side.
! CAUTION • When air is run, be careful so that dirt, water,

etc. may not enter the flow damper.
The flow damper is activated (air is not run).

: Replace the flow damper.
The flow damper is not activated (air is run).
: [2] Go to check of failure code.
1. Make sure that other failure code is not output. If other failure
code is output, repair the failure first and delete the past failure
with the failure diagnosis tool (HinoDX) using PC. Then, if this
failure code is output again, the following failures may be
estimated.
• Excessive fuel flow due to leak from broken pipe, crack in
pipe or pipe connection between the flow damper and the
injector pipe
→Check for leak
• Too large or too small fuel flow due to increase of leak inside
the injector
→Check for leak on the individual injector with a nozzle tester
• Excessive fuel flow due to failure of injection nozzle and seat
→Check for seat failure on the individual injector with a
nozzle tester
• Too large or too small fuel flow due to malfunction of the
injector
→Check with replacement of injector
• Too small fuel flow due to clogging in the fuel supply system
→Inspection of fuel filter
2. Check the compensation between cylinders and stop an

injector with HinoDX. Then, perform diagnosis while viewing
the engine data.
SAPH31Z011700042
PCV1 malfunction
(DTC code P0628)
JP31Z01170601029
E5 E16
D1 D E4 E E17
harness.

3. Measure voltage between terminal E16/E17 and terminal D1/

E4/E5.
Standard value: 19 V or more

SAPH31Z011700063
NG [3] Go to measurement of resistance of the supply

pump solenoid valve.
OK
connector of the signal check harness. After deleting the past
failure, output the diagnosis code again.
START
Standard: Normal

OFF
SAPH31Z011700016
OK
Normal
3 Measurement of resistance of supply pump solenoid valve 1
1. Set the starter key to "OFF" and remove the harness

connected to supply pump solenoid valve 1.
NOTICE • Supply pump solenoid valve 2 has an

identification tag (rear) on the harness
connected to the supply pump identification
tag.
2. Measure resistance between the No.1 terminal and No.2

terminal of the connector (at parts side) of supply pump
SAPH31Z011700064
solenoid valve 1.
Standard value: 3.2 ± 0.3 Ω
NG Failure of supply pump solenoid valve 1 (Replace the

supply pump.)
OK
4 Measurement of voltage between terminals of supply pump solenoid valve 1
1. Turn "ON" the starter key.

Engine ground,
chassis ground, etc. 2. Measure the voltage between the No. 1 terminal and the GND
terminal of the connector (at unit harness side) of supply pump
solenoid valve 1.
Standard value: 19 V or more
NG [7] Go to measurement of relay power.
SAPH31Z011700065
OK

Supply pump solenoid valve 1 E16
E E17 2. Measure the resistance between terminals E16/E17 of the
signal check harness and the supply pump solenoid valve 1
solenoid valve 1.
Standard value: 2 Ω or less
NG Failure of harness between supply pump solenoid 1

and ECU
SAPH31Z011700066
OK
[6] Go to check of failure code.

1. Connect all connectors, delete the past failure and output the
failure code again.
START NOTICE • If the past failure is deleted and the same

code is displayed again, check it again from
the beginning since it may be a connector
OFF
contact failure.
• Measure resistance between the battery
minus terminal and the same part, such as
SAPH31Z011700016 supply pump solenoid valve 1 and engine
ground, and make sure that it is insulated.
7 Inspection of supply pump solenoid valve relay
1. Set the starter key to "OFF", remove the supply pump solenoid
valve relay and measure the resistance between terminals.
Standard value
: 282 to 369 Ω between terminals in Fig. "1"
: ∞ Ω between terminals in Fig. "2"
NG Failure of supply pump solenoid valve relay
1 2
SAPH31Z011700067
OK
Power circuit harness failure or blown PCV1 fuse

PCV1 malfunction
(DTC code P0628)
JP31Z01170601030
1 Inspection item
1. Take action of failure code P0628 or 71 and P2633 or 72.

"Reference: PCV1 malfunction (DTC code P0628)"
"Reference: PCV2 malfunction (DTC code P2633)"
PCV1 out put short to GND

(DTC code P0629)
JP31Z01170601031
harness.
2. Remove the harness connected to supply pump solenoid valve

1 of the supply pump.

connected to the supply pump, and supply
pump solenoid valve 1 does not have an
SAPH31Z011700064
identification tag.
3. Measure resistance between the No. 1 terminal and No. 2

solenoid valve 1.

supply pump.)
OK

E4, E5 E E16, E17 D harness.
D1
terminals E16, E17 and terminals D1, E4, E5.
Standard value: Approx. 1.0 V or less
NG Failure of harness between supply pump solenoid

valve 1 and ECU (Check short-circuit of supply pump
SAPH31Z011700068 solenoid valve 1 harness and +24 V system.)
OK
Go to [3] Check of failure code

1. Set the starter key to "OFF" and connect all connectors. After
deleting the past failure, output the diagnosis code again.
Standard: Normal
START
OFF
SAPH31Z011700016
OK
Normal
PCV1 malfunction
(DTC code P0629)
JP31Z01170601032
1 Inspection item
1. Take action of failure code P0629 and P2634 or 72.

"Reference: PCV1 out put short to GND (DTC code P0629)"
"Reference: PCV2 out put short to GND (DTC code P2634)"
PCV2 malfunction
(DTC code P2633)
JP31Z01170601033
E5
D1 D E4 E harness.

E14
E15
3. Measure voltage between terminal E14/E15 and terminal E4/
E5/D1.
Standard value: 19V or more

SAPH31Z011700069
NG [3] Go to supply pump solenoid valve 2.
OK
connector of the signal check harness. After deleting the past
failure, output the diagnosis code again.
START
Standard: Normal
NG ECU failure
OFF
SAPH31Z011700016
OK
Normal
1. Set the starter key to "OFF" and remove the harness

connected to supply pump solenoid valve 2 of the supply pump.

connected to the supply pump solenoid valve,
and supply pump solenoid valve 1 does not
have an identification tag.
SAPH31Z011700064 2. Measure resistance between the No. 1 terminal and No. 2

solenoid valve 2.

supply pump.)
OK
4 Measurement of voltage between terminals of supply pump solenoid valve 2
1. Turn "ON" the starter key.

Engine ground,
chassis ground, etc. 2. Measure the voltage between the No. 1 terminal and the GND
solenoid valve 2.
Standard value: 19V or more
NG [7] Go to measurement of relay power.
SAPH31Z011700065
OK

Supply pump
solenoid valve 2 E14 E E15
2. Measure the resistance between terminals E14/E15 of the
signal check harness and the supply pump solenoid valve 2
solenoid valve 2.
Standard value: 2 Ω or less

SAPH31Z011700070 valve 2 and ECU
OK
[6] Go to check of failure code.

1. Connect all connectors, delete the past failure and output the
failure code again.
START NOTICE • If the past failure is deleted and the same

code is displayed again, check it again from
the beginning since it may be a connector
OFF
contact failure.
• Measure resistance between the battery
minus terminal and the same part, such as
SAPH31Z011700016 supply pump solenoid valve 1 and engine
ground, and make sure that it is insulated.
7 Inspection of supply pump solenoid valve relay
1. Set the starter key to "OFF", remove the supply pump solenoid
valve relay and measure the resistance between terminals.
Standard value
: 282 to 369 Ω between terminals in Fig. "1"
: ∞ Ω between terminals in Fig. "2"
NG Failure of supply pump solenoid valve relay
1 2
SAPH31Z011700067
OK
Power circuit harness failure or blown PCV2 fuse

PCV2 out put short to GND

(DTC code P2634)
JP31Z01170601034
harness.

connected to the supply pump solenoid valve,
and supply pump solenoid valve 1 does not
have an identification tag.
2. Measure resistance between the No. 1 terminal and No. 2

SAPH31Z011700064
solenoid valve 2.

supply pump.)
OK

E5
D1 D E4 E harness.

terminals E14, E15 and terminals D1, E4, E5.
E14
E15
Standard value: Approx. 1.0V or less

valve 2 and ECU (Check short-circuit of supply pump
SAPH31Z011700071 solenoid valve 2 harness and +24 V system.)
OK
Go to [3] check of failure code.

1. Set the starter key to "OFF" and connect all connectors. After
deleting the past failure, output the diagnosis code again.
Standard: Normal
START
OFF
SAPH31Z011700016
OK
Normal
Supply pump over-feed

(DTC code P1229)
JP31Z01170601035
1 Inspection item
For evaluation conditions for this failure diagnosis, if the supply

pump discharge volume is the maximum for a certain period of time,
it is diagnosed as an error.
If this failure is output, replace the pressure limiter. If the system
does not recover normal operation, the supply pump may have a
failure.
Perform more detailed diagnosis with HinoDX.
SAPH31Z011700042
Supply pump over-feed

(DTC code P1266)
JP31Z01170601036
1 Inspection item
1. For evaluation conditions for this failure diagnosis, if there is no

failure of failure code P0628, P0629, P2633, P2634, P0191,
P0192, P0193 or 73, 71, 72, 76, engine revolution is 400 r/min
or more and engine coolant temperature is 60° C{140° F} or
more, and the supply pump discharge volume is the maximum
for a certain period of time, it is diagnosed as an error.
If this failure is output, replace the pressure limiter. If the
system does not recover normal operation, the supply pump
may have a failure.
SAPH31Z011700042
2. Perform more detailed diagnosis with HinoDX.

EGR actuator fault

(DTC code P1458,P1459)
JP31Z01170601037
1 EGR inspection
1. Perform warm-up until the engine water temperature becomes

60° or more.
2. Check EGR with the failure diagnosis tool (HinoDX) using PC.
SAPH31Z011700072
EGR valve sticking 1

(DTC code P0404)
JP31Z01170601038
1 EGR inspection
1. Perform warm-up until the engine water temperature becomes

60° or more.
2. Inspect the EGR with a fault diagnosis tool (HinoDX) using a

personal computer.
3. Check that the EGR actuator is operating when the engine is

stopped. (Wiping operation)
SAPH31Z011700073
EGR cooler overheat

(DTC code P1416)
JP31Z01170601041
1 Make sure that P0217 is not displayed.
1. Make sure that there is no P0217 or 6 coolant temperature

overheat.
Standard value: Approx. Water temperature overheat,

no defect
NG Overheat due to cooling system error

Check cooling system (Is there coolant, Coolant
leak)
SAPH31Z011700042
OK
Replace the EGR cooler.

Preheat circuit malfunction

(DTC code P0540)
JP31Z01170601042
C2 harness.
C1 C D1 D E4 E E5

harness and measure the resistance between terminals HRY1,
HRY2 and terminals PGD1, PGD2, PGD3.
Standard value: 25 ± 2.5 Ω
NG [2] Go to measurement of relay resistance.

SAPH31Z011700074
OK
2 Measurement of relay resistance
1. Remove the heater relay and measure the resistance between

terminals.
NG Heater relay failure
SAPH31Z011700075
OK
Harness failure, connector failure

Injector correction data conformily error

(DTC code P1601)
JP31Z01170601043
1 Inspection of QR code
1. Read QR code data with the failure diagnosis tool (HinoDX)

using PC.
Standard value: The code shall conform to the QR

code registered in the service server.
NG Write the QR code again.
SAPH31Z011700042
OK
Replace ECU.
ECU internal error

(DTC code P0605, P0606, P0607)
JP31Z01170601044
DTC P0605 Flash ROM error
DTC P0606 CPU malfunction (Hard detection)
DTC P0607 Monitoring IC malfunction in CPU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check if the same code (DTC
㪪㪫㪘㪩㪫㪦㪥 code P0605, P0606, P0607) is output again.
Standard: Normal
㪦㪝㪝 NG Engine ECU failure
SAPH31Z011700076
OK
normal operation.
ECU charge circuit malfunction

(DTC code P0200, P0611)
JP31Z01170601045
DTC P0200 ECU charge circuit high input
DTC P0611 ECU charge circuit malfunction
1 Check of ECU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check again if the same code
㪪㪫㪘㪩㪫㪦㪥 (P0611, P0200 or 59) is output.
Standard: Normal
㪦㪝㪝 NG Engine ECU failure
SAPH31Z011700076
OK
normal operation.
Main relay malfunction

(DTC code P0686)
JP31Z01170601046
A6
A5 A A7 harness.
2. Disconnect the ECU side connector of the signal check side

Frame harness and set the starter key to "ON".
3. Measure the voltage between terminals A5, A6, A7 and the

chassis GND.
Standard value: 0 V
SAPH31Z011700077
terminals.
OK
ECU failure, ECU connector failure
2 Measurement of resistance between relay terminals
1. Set the starter key to "OFF", remove the battery relay and
measure the resistance between terminals.
NG Faulty battery relay
OK
Harness failure
Starter signal malfunction

(DTC code P0617)
JP31Z01170601047
B B14 C C4 harness.
C3 2. Disconnect the ECU side connector of the signal check

3. Measure voltage between terminal B14 and terminals C3/C4.
! CAUTION • Pay attention to the gear position and

periphery.
SAPH31Z011700078
Standard value
: 0 V (when starter key is at "OFF")
: 24 V (when starter key is at "START")
NG Harness failure
OK

CAN communication loss EGR actuator

(DTC code U1122)
JP31Z01170601048
1 Measurement of the EGR actuator voltage
1. Set the starter key to "OFF" and disconnect the connector of

No.3 the EGR actuator.
No.6 terminals 3 and 6 of the connector of the EGR actuator (on the
side of the unit harness).
Standard:19 V or more
NG Harness defective
SAPH31Z011700079
OK
2 Measurement of the voltage between the CAN communication terminals
harness with the connector of the EGR actuator.
terminals E21 and E22 of the signal check harness.
E21 E22
Standard:Pulse waveform between 0 and 5 V
NG • Wire break, short-circuit (GND short-circuit, 24 V

short-circuit)
SAPH31Z011700080
• Bad harness and/or connector contact
OK
EGR actuator fault

CAN1 Communication error (Engine)

(DTC code U0073)
CAN2 Communication error (Unit)
(DTC code U1001)
JP31Z01170601049
1 Measurement of conductivity of the CANH terminal
No.1 harness.
2. Disconnect the connector of the EGR actuator.
E21
3. Disconnect the connector of the signal check harness on the
ECU side and measure for conductivity between terminal E21
and terminal 1 of the connector of the EGR actuator (on the
side of the unit harness).
SAPH31Z011700081 Standard:Conductivity
OK
2 Measurement of conductivity of the CANL terminal
1. Measure the conductivity between terminal E22 of the signal

check harness and terminal 4 of the connector of the EGR
No.4 actuator (on the side of the unit harness).
Standard:Conductivity
E22
SAPH31Z011700082
OK
Replace the engine ECU

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SHOP MANUAL

Bur • Issued 01July 08

Book Code No.87694078

2) WARNING- Indicates a potentially hazardous

The proper and safe lubrication and maintenance

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3

Book Code No. 87694078

Issue Date of Issue Applicable Machines Remarks

prepare for accidents and fire.

5) For parts which are required to use jig and

(6) Unit Conversion Table

QUANTITIES JIS SI REMARKS

2.1 NAME OF COMPONENTS................................................................................................2-3

Book Code No. 87694078

Issue Date of Issue Applicable Machines Remarks

2.1 NAME OF COMPONENTS

SHOE AND TRACK LINK

IDLER ADJUST ENGINE

UPPER ROLLER COUNTER WEIGHT

TRACK GUIDE RADIATOR AND OIL COOLER

2.2 GENERAL DIMENSIONS

Dimensions marked * do not include the height of the shoe lug.

Dimensions marked * do not include the height of the shoe lug.

2.3 WEIGHT OF COMPONENTS

Marks * show dry weight.

2.4 SPECIFICATIONS AND PERFORMANCE

Area & Model

Engine model HINO P11C-UP

2.4.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

2.5 TYPE OF CRAWLER

900 (35.4) LC 3,350 (10'12") 58 (8.26)

2.6 TYPE OF BUCKET

2.7 COMBINATIONS OF ATTACHMENT

• Use the attachments recommended by KOBELCO.

2.8 ENGINE SPECIFICATIONS

Applicable machine SK485-8

2.8.2 ENGINE CHARACTERISTIC CURVE (HINO P11C-UP)

FUEL CONSUMPTION RATE

ENGINE SPEED (min-1)

Fuel consumption volume

3.1 BOOM ................................................................................................................................3-3

Book Code No. 87694078

Issue Date of Issue Applicable Machines Remarks

Fig. 3-1 Boom dimensional drawing

3.1.2 BOOM MAINTENANCE STANDARD

Fig. 3-2 Clearance of pin and bushing on boom section

(2) Clearance in thrust direction on the boom cylinder installation section

Fig. 3-4 ARM DIMENSIONAL DRAWING

3.45m (11ft-4in) ARM LS12B00242F1 Unit : mm (ft-in)

3.2.2 ARM MAINTENANCE STANDARD

Fig. 3-5 Clearance of pin and bushing on arm section

(2) Clearance of arm and cylinder installing sections in thrust direction

PL1 PL3 PL6

Fig. 3-7 Bucket dimensional drawing

No. NAME No. NAME

3.3.2 BUCKET DIMENSIONAL TABLE

3.3.3 LUG SECTION DIMENSIONAL DRAWING

Insert this pin flush with surface

Screw hole P.C.D

Boss outer dia.

Type of Part No. of

3.3.4 BOSS SECTION DIMENSIONAL DRAWING

Tightening torque N•m (lbf•ft)

%!