SM E115SR EN PDF

Copyright © New Holland
INTRODUCTION
E115SR
E135SR
WORKSHOP MANUAL
ENGLISH
Print No. 604.13.426
Edition: 03/2005
English - Printed in Italy
Printed by Studio ti - 20005
0-1
INTRODUCTION
TO THE READER
• This manual has been written for a skilled technician, - For any question or comment, or in case you
in order to give him the information necessary to notice a mistake in this manual content, please
repair this machine.
contact:
- Read this manual carefully for correct
information about repair procedures. NEW HOLLAND KOBELCO CONSTRUCTION
MACHINERY S.p.A.
Strada di Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCE MANUALS
• In addition to this Workshop Manual, refer also to

the following:
- Operation and maintenance instruction

manual
- Spare parts catalog
DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL
• The complete repair manual consists of two volumes: remove and install procedures, disassembly and
assembly procedures.
- E115SR Workshop Manual "Excavator"
• The complete Workshop Manual for the excavator
• "Excavator" and "Engine" Workshop Manuals model E115SR consists of the following volumes
contain the technical information necessary for identified by print number as shown herebelow:
machine/engine service and repair, service
equipment, information on maintenance standards,
VOLUME MACHINE TYPE PRINT No.

Workshop Manual - "Excavator" E115SR 604.13.426
0-3
INTRODUCTION
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on

the highway, are caused by the failure of some individuals to follow simple and
fundamental safety rules or precautions. For this reason MOST ACCIDENTS
CAN BE PREVENTED by recognising the real cause and doing something
about it before the accident occurs.
Regardless of the care used in the design and construction of any type of
equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient operation.
Carefully read indications, cautions and safety warning quoted in the
“SAFETY RULES” section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many thousand
serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.
S ATTENTION
On machines having hydraulically, mechanically and/or cable controlled
equipment (such as showels, loaders, dozers, scrapers etc.) be certain
the equipment is lowered to the ground before servicing, adjusting and/
or repairing.
If it is necessary to have the equipment partially or fully raised to gain
access to certain items, be sure the equipment is suitably supported by
means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION

MACHINERY S.p.A.
Product Support - Documentation Centre
Strada di Settimo, 323 - 10099 - S. Mauro T.SE (TO) ITALY
All rights reserved. Reproduction of text and illustrations in whole or in part, is

strictly prohibited.
0-4
INDEX
INDEX
SPECIFICATIONS
Section 1 - Outline
Section 2 - Specification
Section 3 - Attachment dimension
MAINTENANCE
Section 11 - Tools
Section 12 - Standard maintenance time schedule
Section 13 - Maintenance standard and test procedure
SYSTEM
Section 21 - Mechatro control system

Section 22 - Hydraulic system
Section 23 - Electric system
Section 24 - Components system
Section 25 - Air-conditioner system
DISASSEMBLING
Section 31 - Disassembling and assembling

Section 32 - Attachment
Section 33 - Upper structure
Section 34 - Travel system
TROUBLESHOOTING
Section 41 - Troubleshooting (mechatro control)

Section 42 - Troubleshooting (Hydraulic)
Section 43 - Troubleshooting (Electric)
Section 44 - Troubleshooting (Engine)
ENGINE
Section 51 - Engine
OPT
Section 63 - Mounting the breaker and nibbler & breaker
0-5
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS 5. Do not work on any machine that is supported

only by lift, jacks or a hoist. Always use blocks or
YY S WARNING YY jack stands, capable of supporting the machine,
before performing any disassembly.
The proper and safe lubrication and maintenance for
this machine, recommended by Distributor, are
outlined in the OPERATOR’S MANUAL for the
machine.
YY S WARNING YY
Improper performance of lubrication or maintenance Do not operate this machine unless you have read
procedures are dangerous and could result in injury and understand the instructions in the OPERATOR’S
or death. Read and understand the MANUAL before MANUAL. Improper machine operation is dangerous
performing any lubrication or maintenance. and could result in injury or death.
The serviceman or mechanic may be unfamiliar with

6. Relieve all pressure in air, oil or water systems
many of the systems on this machine. This makes it before any lines, fittings or related items are
important to use caution when performing service disconnected or removed. Always make sure all
work. A knowledge of the system and or components raised components are blocked correctly and be
is important before the removal or disassembly of any alert for possible pressure when disconnecting
component. any device from a system that utilizes pressure.
7. Lower the bucket, dozer, or other attachments to

Because of the size of some of the machine the ground before performing any work on the
components, the serviceman or mechanic should machine. If this cannot be done, make sure the
check the weights noted in this manual. Use proper bucket, dozer, ripper or other attachment is
lifting procedures when removing any components. blocked correctly to prevent it from dropping
Weight of components table is shown in the section; unexpectedly.
SPECIFICATIONS.
8. Use steps and grab handles when mounting or
dismounting a machine. Clean any mud or debris
The following is a list of basic precautions that must from steps, walkways or work platforms before
always be observed. using. Always face to the machine when using
steps, ladders and walkways. When it is not
1. Read and understand all Warning plates and possible to use the designed access system,
decal on the machine before Operating, provide ladders, scaffolds, or work platforms to
Maintaining or Repairing this machine. perform safe repair operations.
2. Always wear protective glasses and protective 9. To avoid back injury, use a hoist when lifting
shoes when working around machines. In components which weigh 20 kg (45 lbs) or more.
particular, wear protective glasses when using Make sure all chains, hooks, slings, etc., are in
hammers, punches or drifts on any part of the good condition and are the correct capacity. Be
machine or attachments. Use welders gloves, sure hooks are positioned correctly. Lifting eyes
hood/goggles, apron and the protective clothing are not to be side loaded during a lifting operation.
appropriate to the welding job being performed.
Do not wear loose fitting or torn clothing. Remove 10. To avoid burns, be alert for hot parts on machines
all rings from fingers, loose jewelry, confine long which have just been stopped and hot fluids in
hair and loose clothing before working on this lines, tubes and compartments.
machinery.
11. Be careful when removing cover plates. Gradually
3. Disconnect the battery and hang a “Do Not back off the last two capscrews or nuts located at
Operate” tag in the Operators Compartment. opposite ends of the cover or device and carefully
Remove ignition keys. pry cover loose to relieve any spring or other
pressure, before removing the last two capscrews
4. If possible, make all repairs with the machine or nuts completely.
parked on a level, hard surface. Block the machine
so it does not roll while working on or under the 12. Be careful when removing filler caps, breathers
machine. Hang a “Do Not Operate” tag in the and plugs on the machine. Hold a rag over the cap
Operators Compartment. or plug to prevent being sprayed or splashed by
liquids under pressure. The danger is even
0-6
SAFETY PRECAUTIONS
greater if the machine has just been stopped Shields that protect against oil spray onto hot
because fluids can be hot. exhaust components in event of a line, tube or seal
failure must be installed correctly.
13. Always use the proper tools that are in good
condition and that are suited for the job at hand. 21. Do not operate a machine if any rotating part is
Be sure you understand how to use them before damaged or contacts any other part during
performing any service work. operation. Any high speed rotating component
that has been damaged or altered should be
14. Reinstall all fasteners with the same part number. checked for balance before reusing.
Do not use a lesser quality fastener if replacements
are necessary. 22. Be careful when servicing or separating the
tracks (crawlers). Chips can fly when removing or
15. Repairs which require welding should be installing a track (crawlers) pin. Wear safety
performed only with the benefit of the appropriate glasses and long sleeve protective clothing. Tracks
reference information and by personnel (crawlers) can unroll very quickly when separated.
adequately trained and knowledgeable in welding Keep away from front and rear of machine. The
procedures. Determine type of metal being machine can move unexpectedly when both tracks
welded and select correct welding procedure and (crawlers) are disengaged from the sprockets.
electrodes, rods or wire to provide a weld metal Block the machine to prevent it from moving.
strength equivalent at least to that of the parent
metal. Make sure to disconnect 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
containing fluid.
17. Be sure all protective devices including guards

and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution and replace the guard or
shield after repair is completed.
18. The maintenance and repair work while holding

the bucket raised is dangerous due to the possibility
of a falling attachment. Don’t fail to lower the
attachment and place the bucket to the ground
before starting the work.
19. Loose or damaged fuel, lubricant and hydraulic

lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Very small (pinhole) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use 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
installed correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
0-7
SAFETY PRECAUTIONS
NOTE
0-8
E115SR
E135SR
SECTION 1 OUTLINE
TABLE OF CONTENTS
1. General precautions for repairs .............................................................................. 1-1

1.1 Preparation before disassembling ................................................................................................... 1-1
1.2 Safety in disassembling and assembling ......................................................................................... 1-1
1.3 Disassembling and assembling hydraulic equipment ...................................................................... 1-1
1.4 Electrical equipment ....................................................................................................................... 1-2
1.5 Hydraulic parts ................................................................................................................................ 1-3
1.6 Welding repair ................................................................................................................................. 1-3
1.7 Environmental measure ................................................................................................................... 1-3
2. International unit conversion system ...................................................................... 1-4

1. GENERAL PRECAUTIONS FOR REPAIRS
3) Stop the engine before starting inspection and

1.1 PREPARATION BEFORE maintenance to prevent the operator being caught
DISASSEMBLING in machine.
(1) Understanding operating procedure 4) Identify the location of a first-aid kit and a fire
Read OPERATION & MAINTENANCE MANUAL extinguisher, and also where to make contact in a
carefully to understand the operating procedure. state of emergency.
5) Choose a hard, level and safe place, and place
(2) Cleaning machines the attachment on the ground securely.
Remove soil, mud, and dust from the machine 6) Use a lifter such as a crane to remove heavy parts
before carrying it into the service shop to prevent (23 kg [50 lbs] or more) from the machine.
loss of work efficiency, damage of parts, and diffi- 7) Use proper tools, and replace or repair defective
culty in rust prevention and dust protection while tools.
reassembling. 8) Support the machine and attachment with supports
or blocks if the work is performed in the lifted
(3) Inspecting machines condition.
Identify the parts to be disassembled before start-
ing work, determine the disassembling procedure
by yourself considering the workshop situations 1.3 DISASSEMBLING AND
etc., and request procurement of necessary parts ASSEMBLING HYDRAULIC
in advance. EQUIPMENT
(1) Removing hydraulic equipment
(4) Recording 1) Before disconnecting pipes, release the hydraulic
Record the following items for communication and pressure of the system, or open the return side
prevention of recurring malfunction. cover and take out the filter.
1) Inspection date and place 2) Carefully drain oil of the removed pipes into a
2) Model name, applicable machine number, and containers without spilling on the floor.
hour meter read 3) Apply plugs or caps on the pipe ends to avoid oil
3) Trouble condition, place and cause, if any spillage and dust intrusion.
4) Visible oil leakage, water leakage and damage 4) Clean off the external surface of the equipment
5) Clogging of filters, oil level, oil quality, oil contami- before disassembling, and drain hydraulic and gear
nation and loosening of connections oil before placing it on the workbench.
6) Result of consideration if any problem exists based
on the operation rate per month calculated from (2) Disassembling hydraulic equipment
hour meter indication after the last inspection date. 1) Do not disassemble, reassemble or modify the
hydraulic equipment without the permission of the
(5) Arrangement and cleaning in service shop manufacturer, who is not responsible for the
1) Tools required for repair work. performance and function of the product after
2) Prepare space to place the disassembled parts. reassembling.
3) Prepare oil containers for spilling oil etc. 2) When disassembling and reassembling for un-
avoidable reason, refer the work to qualified
personnel who have the specific knowledge or
1.2 SAFETY IN DISASSEMBLING completed the parts service training.
AND ASSEMBLING 3) Provide matching marks to facilitate reassembling
1) Wear appropriate clothes with long sleeves, safety work.
shoes, safety helmet and protective glasses. 4) Before starting the work, read the manual of dis-
2) Suspend warning tag "DO NOT OPERATE" from assembling procedure, if it is provided, and decide
the doorknob or the operating lever, and have a whether the work can be performed by yourself.
preliminary meeting before starting work. 5) Use the special jig and tools without fail if they are
1-1
specified.
6) If it is hard to remove a part according to the WARNING
procedure, do not try it by force but investigate the Operation of the hydraulic equipment without filling
hydraulic oil or lubricant or without performing air bleeding
cause.
will result in damage to the equipment.
7) Place the removed parts in order and attach tags
to facilitate the reassembling.
8) Note the location and quantity of parts commonly 3) Perform air bleeding of the hydraulic pump and
applied to multiple locations. slewing motor after loosening the upper drain plug,
starting the engine and keep it in low idle condi-
(3) Inspecting parts tion. Complete the air bleeding when seeping of
1) Ensure that the disassembled parts are free from hydraulic oil is recognized, and tightly plug.
seizure, interference and uneven contact. 4) Perform air bleeding of the travel motor and the
2) Measure and record wear condition of parts and hydraulic cylinders by running the engine for more
clearance. than 5 minutes at low speed without load.
3) If the problem is found in a part, repair or replace it
with a new one.
WARNING
(4) Reassembling hydraulic equipment Do not allow the hydraulic cylinder to bottom on the
1) Turn ON the ventilation fan or open windows to stroke end just after the maintenance.
maintain good ventilation prior to starting the
cleaning of parts.
2) Perform rough and finish cleaning before assem- 5) Perform air bleeding of pilot line by performing a
bling. series of digging, slewing and travel.
3) Remove washing oil by air and apply clean hydrau- 6) Check hydraulic oil level after placing the attach-
lic or gear oil for assembling. ment to the oil check position, and replenish oil if
4) Always replace the removed O-rings, backup rings necessary.
and oil seals with new ones by applying grease in
Checking hydraulic oil level
advance.
Level gauge Oil level lines
5) Remove dirt and moisture from and perform (Level located
degreasing on the surface where liquid gasket to between the two
lines shows
be applied. appropriate
amount of oil)
6) Remove rust preventive agent from the new parts
before use.
7) Fit bearings, bushings and oil seals using special
jigs.
1.4 ELECTRICAL EQUIPMENT
8) Assemble the parts utilizing matching marks.
9) Ensure all the parts are completely assembled after
the work. (1) Do not disassemble electrical equipment.
(5) Installing hydraulic equipment (2) Handle it carefully not to drop and give a shock.
1) Ensure hydraulic oil and lubricant are properly
supplied. (3) Turn the key OFF prior to connecting and discon-
2) Perform air bleeding when: necting work.
a. Hydraulic oil changed
b. Parts of suction side piping replaced (4) Disconnect the connector by holding it and press-
c. Hydraulic pump installed ing the lock. Do not pull the wire to apply force to
d. Slewing motor installed the caulking portion.
e. Travel motor installed
f. Hydraulic cylinder installed (5) Connect the connector and ensure it is completely
locked.
1-2
(6) Turn the key OFF prior to touching the terminal of used depending on the working pressure even
starter or generator. the size of fitting and the total length of the hose
is same.
(7) Remove the ground (earth) terminal of battery • Tighten the fitting at the specified torque. En-
when handling tools around the battery or its relay. sure no kink, tension, interference nor oil leak-
age is recognized.
(8) Do not splash water on the electrical equipment
and connectors during machine washing. 1.6 WELDING REPAIR
(1) Refer repair welding to qualified personnel accord-
(9) Check for moisture adhesion inside the waterproof ing to the appropriate procedure.
connector after pulling it out, since it is hard to
remove moisture from the connector. If moisture (2) Disconnect the ground (earth) cable of the battery
adhesion is found, dry it completely before the before starting the repair. Failure to do so will cause
connection. damage to the electrical equipment.
(3) Move away the articles in advance that may cause

WARNING fire if exposed to sparks.
Battery electrolyte is hazardous.
Battery electrolyte is dilute sulfuric acid. Exposure of
skin or eyes to this liquid will cause burning or loss of (4) Before starting the repair of the attachment, do not
eyesight. If the exposure occurs, take the following fail to cover the plated surface of the piston rod
emergency measures and seek the advice of a medical with flameproof sheet to prevent it from being
specialist. exposed to sparks.
• When skin exposed: Wash with water and soap
sufficiently.
1.7 ENVIRONMENTAL MEASURE
• When eyes exposed: Immediately wash away with
(1) Run the engine at the place that is sufficiently
city water continuously for more than 10 minutes.
• When a large amount of the liquid flows out: Neutralize ventilated.
with sodium bicarbonate or wash away with city
water. (2) Industrial waste disposal
• When swallowed: Drink a large amount of milk or Dispose of the following parts according to the
water. relevant regulations:
• When clothes exposed: Immediately undress and
Waste oil and waste container
wash.
Battery
(3) Precautions for handling hydraulic oil

1.5 HYDRAULIC PARTS Exposure of eyes to hydraulic oil will cause inflam-
mation. Wear protective glasses before handling
1) O-ring to avoid an accident. If an eye is exposed to the
• O-rings have elasticity and are not damaged oil, take the following emergency measures:
before use. • When an eye exposed: Immediately wash away
• Use the appropriate O-rings. O-rings are made with city water sufficiently till stimulative feeling
of various kinds of materials having different vanishes.
hardness to apply to a variety of parts, such • When swallowed: Do not let vomit, and receive
as the part for moving or fixed portion, sub- medical treatment immediately.
jected to high pressure, and exposed to corro- • When skin exposed: Wash with water and soap
sive fluid, even if the size is same. sufficiently.
• Fit the O-rings without distortion and bend.
• Always handle floating seals as a pair. (4) Others
2) Flexible hose (F hose) Use replacement parts and lubricants authorized
• Use the appropriate parts. Different parts are as the Distributor genuine parts.
1-3
2. INTERNATIONAL UNIT CONVERSION SYSTEM

Introduction (4) Derived Units bearing Peculiar Designations
Although this manual uses the JIS unit system. Table 2-4
If you need SI unit, refer to following QUANTITIES DESIGNATION SIGN DERIVED UNIT
international system of units. Frequency Hertz Hz 1Hz=1s-1
Given hereinunder are an excerpt of the units Force Newton N 1N=1kgfym/s2
that are related to this manual : Pressure, Pascal Pa 1Pa=1N/m2
Stress
1. Etymology of SI Units Energy Joule J 1J=1Nym
French : Le Système International d’ Unitès Work,
English : International System of Units Quantity of
heat
2. Construction of SI Unit System
Power Watt W 1W=1J/s
Motive power,
Electric power
Basic units
Charge, Coulomb C 1C=1A・s
Table 2-1
Quantity of
Supplement- Derived units of
electricity
SI units ary units basic units Potential Volt V 1V=1J/C
SI unit
Table 2-2 Table 2-3 Voltage, (1W/A)
system Electromotive
Derived Derived units force
units bearing peculiar Quantity of Farad F 1F=1C/V
designations static
Table 2-4 electricity
Capacitance
Prefixes of SI Electric Ohm Ω 1Ω=1V/A
(n-th power of 10, where n is an integral) resistance
Table 2- 5
Celcius Celcius degree ℃
temperature or degree
(1) Basic Units Illuminance lux X 1. X=1 m/m2
Table 2-1
QUANTITIES DESIGNATION SIGN (5) Prefixes of SI
Length Meter m Table 2-5
Mass Kilogram kg PREFIX POWER
Time Second s DESIGNATION SIGN
Current Ampere A Giga- G 109
Thermodynamic Kelvin K Mega- M 106
temperature Kilo- k 103
Gram molecule Mol mol Hecto- h 102
Luminous intensity Candela cd Deca- da 10
Deci- d 10－1
(2) Supplementary Units Centi- c 10－2
Table 2-2 Milli- m 10－3
Micro- μ 10－6
QUANTITIES DESIGNATION SIGN
Nano- n 10－9
Plane angle Radian rad Pico- p 10－12
Solid angle Steradian sr
(6) Unit Conversion Table
(3) Derived Units of Basic Units Table 2-6
Table 2-3 QUANTITIES JIS SI REMARKS
QUANTITIES DESIGNATION SIGN Mass kg kg
Area Square meter m2 Force kgf 10N 9.807N
Volume Cubic meter m3 Torque kgfym 10Nym 9.807Nym
Velocity Meter per second m/s Pressure kgf/cm2 0.1MPa 0.098MPa
Acceleration Meter per second / second m/s2 Motive power PS 0.7355kW
Density Kilogram per cubic meter kg/m3 Revolution rpm min－1 r/min ※1
※1 Units that are allowed to use

1-4
E115SR
E135SR
SECTION 2 SPECIFICATIONS
TABLE OF CONTENTS
1. Name of components .............................................................................................. 2-1
2. General dimension .................................................................................................. 2-2

2.1 4.6m (15’1”) boom ........................................................................................................................... 2-2
2.2 4.26m (14’) boom ............................................................................................................................ 2-2
3. Weight of components ............................................................................................ 2-3
4. Transportation dimension and weight ..................................................................... 2-4
5. Specifications and performance ........................................................................... 2-12

5.1 Speed and climbing capability ....................................................................................................... 2-12
5.2 Engine ........................................................................................................................................... 2-12
5.3 Hydraulic components ................................................................................................................... 2-12
5.4 Weight ........................................................................................................................................... 2-12
6. Type of crawler ...................................................................................................... 2-14
7. Type of bucket ....................................................................................................... 2-16
8. Combinations of attachment ................................................................................. 2-17
9. Engine specification .............................................................................................. 2-18

9.1 Specifications ................................................................................................................................ 2-18
9.2 Engine characteristic curve (isuzu BB 4BG1T) .............................................................................. 2-20
1. NAME OF COMPONENTS
2-1
2. GENERAL DIMENSION
2.1 E135SR (LC)
3
4.6m (15′1″) Boom+2.45m (8′) Arm+0.5m (0.65cuyyd) Bucket+600mm (23.6″) Shoe
*Marked dimensions do not include height of shoe lug.
2.2 E135SRL
3
4.6m (15′1″) Boom+2.45m (8′) Arm+0.5m (0.65cuyyd) Bucket+700mm (28″) Shoe
2.3 E115SR
3
4.26m (14′) Boom+2.2m (7′3″) Arm+0.45m (0.59cuyyd) Bucket+600mm (23.6″) Shoe
2-2
3. WEIGHT OF COMPONENTS Unit : kg (lbs)

Model E135SRLC
E135SR E115SR
Item [E135SRL]
Machine complete 13,700(30,200) 13,900(30,640) 11,900(26,230)
[15,700(34,610)]
1. Upper frame assy (including the following :) 7,330(16,160) ← 6,080(13,400)
1.1 Counterweight 3,490(7,690) ← 2,340(5,160)
Counterweight (Add-on) 600(1,320) ← ←
1.2 Cab 210(460) ← ←
1.3 Engine ※ 368(810) ← 363(800)
1.4 Hydraulic oil tank ※ 91(200) ← ←
1.5 Fuel tank ※ 53(116) ← ←
1.6 Slewing motor (including reduction unit) 110(240) ← ←
1.7 Control valve 122(270) ← 114(251)
1.8 Boom cylinder ※ 107(235)×2 ← 84(235)×2
1.9 Pin (2pcs. for mounting boom) 37(82) ← ←
1.10 Pump ※ 95(210) ← ←
1.11 Radiator ※ 77(170) ← 65(143)
2. Lower frame assy (including the following :) 4,450(9,810) 4,650(10,250) 4,140(9,130)
[6,750(14,880)]
2.1 Slewing bearing 149(330) ← ←
2.2 Travel motor (including reduction unit) 144(320)×2 ← ←
2.3 Upper roller 8(18)×2 8(18)×4 8(18)×2
2.4 Lower roller 27(60)×12 27(60)×14 27(60)×12
2.5 Front idler 70(150)×2 ← ←
2.6 Track tension adjuster 57(125)×2 ← ←
2.7 Sprocket 36(79)×2 ← ←
2.8 Swivel joint 30(66) ← ←
2.9 Track link with 700mm (28in) shoes assy ― [1,340 (2,950)]×2 ―
Track link with 600mm (24in) shoes assy 870(1,920)×2 915(2,020)×2 760(1,670)×2
Track link with 500mm (20in) shoes assy 730(1,610)×2 ── 680(1,500)×2
2.9.1 Track link assy 290(640)×2 300(660)×2 270(590)×2
[465(1,040)]×2
2.10 Dozer blade (OPT) 470(1,040) ← ←
2.11 Dozer blade cylinder (OPT) ※ 57(125)×2 ← ←
3. Attachment 1,920(4,230) ← 1,680(3,700)
3.1 Bucket assy 380(840) ← 340(750)
3.2 Arm assy (including the following :) 580(1,280) ← 490(1,080)
3.2.1 Arm 374(820) ← 300(660)
3.2.2 Bucket cylinder ※ 90(198) ← 87(190)
3.2.3 Idler link 12(26)×2 ← ←
3.2.4 Bucket link 43(95) ← 35(77)
3.2.5 Attachement pin 36(79) ← 24(52)
3.3 Boom assy (Including the following :) 940(2,070) ← 850(1,870)
3.3.1 Boom 740(1,630) ← 680(1,500)
3.3.2 Arm cylinder ※ 149(330) ← 128(280)
3.3.3 Pin (Mounting arm・Mounting arm cylinder) 29(64) ← 27(59)
4. Lubricant and water (including the following :) 310(680) ← ←
4.1 Hydraulic oil 138(304) ← ←
4.2 Engine oil 11(24) ← ←
4.3 Fuel + water 139(310) + 18(40) ← ←
NOTE : Numerical values marked ※ indicate the dry weight.
2-3
4. TRANSPORTATION DIMENSION AND WEIGHT

E135SR(LC) E135SRL
● OVERALL DIMENSIONS OF A STD COMPLETE MACHINE ON A TRAILER
Model E135SR E135SRLC E135SRL
Item
Shoe & Width mm(ft-in) 600mm (24″) 2,590 (8′6″) 800mm (32″) 2,790
(9′2″)
Weight kg(lbs) 13,700 (30,200) 13,900 (30,600) 16,000 (35,300)
* LC SPEC.
** L SPEC.
● OVERALL DIMENSIONS OF WITHOUT ARM AND BUCKET

Type A : Shoe width L : Length H : Height W : Width Weight
Combination mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) kg (lbs)
STD 600 (24″) 6,510 (21′4″) 2,740 (8′12″) 2,590 (8′6″) 12,720 (28,000)
Without
LC 600 (24″) 6,590 (21′7″) 2,940 (9′8″) 2,840 (9′4″) 12,920 (28,500)
Arm and Bucket
L 800 (32″) 6,620 (21′9″) ↑ ↑ 14,920 (32,900)
** L SPEC.
● OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

STD 600 (24″) 3,570 (11′9″) 2,740 (8′12″) 2,590 (8′6″) 11,780 (26,000)
Without
LC 600 (24″) 3,740 (12′3″) 2,940 (9′8″) 2,840 (9′4″) 11,980 (26,400)
Arm and Bucket
L 800 (32″) 3,800 (12′6″) ↑ ↑ 13,980 (30,800)
** L SPEC.
2-4
● OVERALL DIMENSIONS OF BOOM

Type
4.6m (15ft-1in) Boom
Item
Length×Height×Width 4.76×1.39×0.57
L×H×W m(ft-in) (15′7″×4′7″×1′10″)
Weight kg (lbs) 940 (2,080)
● OVERALL DIMENSIONS OF ARM+BUCKET

Type 3
2.45m (8ft) Arm+0.5m (0.65cu･yd) Bucket
Item
L×H×W m(ft-in) (14′4″×2′8″×3′3″)
Weight kg (lbs) 970(2,140)
● OVERALL DIMENSIONS OF ARM

Type
2.45m (8ft) Arm
Item
L×H×W m(ft-in) (10′6″×2′×1′3″)
2-5
● OVERALL DIMENSIONS OF BUCKET
Type Hoe bucket

Length× 1.19×1.07×0.70 1.19×1.07×0.70 1.19×1.07×0.80 1.19×1.07×0.90
Height×Width
L×H×W m (ft-in) (3′11×3′6″×2′4″) (3′11×3′6×2′4″) (3′11″×3′6″×2′7″) (3′11″×3′6″×2′11″)
Weight kg
(lbs) 280 (620) 300 (660) 340 (750) 350 (770)
Bucket
capacity 0.24 (0.31) 0.31 (0.41) 0.38 (0.50) 0.45 (0.59)
3
m (cu･yd)
Type Hoe bucket V-bucket Slope finishing bucket

Length× 1.19×1.07×1.00 1.19×1.07×1.10 1.25×0.65×1.79 1.01×0.79×1.80
Height×Width
L×H×W m (ft-in) (3′11″ ×3′ 6″×3′ 3″) (3′11″ ×3′ 6″×3′ 7″) (4′1″×2′2″×5′10″) (3′4″×2′7″×5′11″)
Weight kg
(lbs) 380 (840) 400 (880) 290 (640) 550 (1,210)
Bucket
capacity STD 0.50 (0.65) 0.57 (0.75) 0.46 (0.60) 0.52 (0.68)
3
m (cu･yd)
z Hoe bucket z V-bucket z Slope finishing bucket
2-6
E115SR
● OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER
Type 4.26m
3
(14ft) Boom+2.2m (7ft-3in) Arm+
Item 0.45m (0.59cu･yd) Bucket+600mm (23.6in) Shoes
Width mm(ft-in) 2,590 (8′6″)
Weight kg(lbs) 11,900 (26,230)
● OVERALL DIMENSIONS OF WITHOUT ARM AND BUCKET

Without arm and 600 (24″) 6,030 (19′9″) 2,740 (9′) 2,590 (8′6″) 11,070 (24,400)
bucket 500 (20″) 6,030 (19′9″) 2,740 (9′) 2,490 (8′2″) 10,990 (24,200)
● OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

Without boom, arm 600 (24″) 3,320 (10′11″) 2,740 (9′) 2,590 (8′6″) 10,220 (22,500)
and bucket 500 (20″) 3,320 (10′11″) 2,740 (9′) 2,490 (8′2″) 10,140 (22,400)
2-7
● OVERALL DIMENSIONS OF BOOM

Type
4.26m (14ft) Boom
Item
L×H×W m(ft-in) (14′6″×4′4″×1′10″)
Weight kg (lbs) 790 (1,740)
● OVERALL DIMENSIONS OF ARM+BUCKET

Type 3
2.2m (7ft-3in) Arm+0.45m (0.59cu･yd) Bucket
Item
L×H×W m(ft-in) (13′4″×2′7″×3′1″)
● OVERALL DIMENSIONS OF ARM

Type
2.2m (7ft-3in) Arm
Item
L×H×W m(ft-in) (9′7″×1′11″×1′2″)
2-8
● OVERALL DIMENSIONS OF BUCKET
Type Hoe bucket

Length×
1.35×0.60×0.46 1.19×1.03×0.60 1.19×1.03×0.70 1.19×1.03×0.80
Height×Width
L×H×W m (ft-in)
(4′5″×2′×1′6″) (3′11″×3′5″×2′) (3′11″×3′5″×2′4″) (3′11″×3′5″×2′7″)
Weight kg
(lbs) 210 (460) 260 (570) 280(620) 320 (705)
Bucket
capacity 0.17 (0.22) 0.23 (0.30) 0.30 (0.39) 0.37 (0.48)
3
m (cu･yd)
Type Hoe bucket V-bucket Slope finishing bucket

Length×
1.19×1.03×0.95 1.19×1.03×1.00 1.29×0.64×1.81 0.99×0.73×1.60
Height×Width
L×H×W m (ft-in)
(4′5″×2′×3′1″) (4′5″×2′×3′3″) (4′3″×2′1″×5′11″) (3′3″×2′5″×5′3″)
Weight kg
(lbs) 350 (770) 370 (820) 280(620) 480(1,060)
Bucket
capacity STD 0.45(0.59) 0.51(0.67) 0.46(0.60) 0.40 (0.52)
3
m (cu･yd)
z Hoe bucket z V-bucket z Slope finishing bucket
2-9
E135SR L DOZER
● OVERALL DIMENSIONS OF A COMPLETE MACHINE
● DOZER SPECIFICATIONS
ITEM E135SR L E135SRLC

(From the center of the arm
Length fixing pin to the tip of the blade) R1,630mm (5´4˝ ) R1,730mm (5´8˝ )
Width [600mm (23. 6˝ ) shoe only] 2,590mm (8´6˝ ) 2,590mm (8´6˝ )
Height 570mm (1´10˝ ) 570mm (1´10˝ )
Weight 470kg (1,040 lb) 480kg (1,060 lb)
2 2
Set Pressure of Main Relief Valve 210kgf/cm (2,990psi) 210kgf/cm (2,990psi)
2 2
Set pressure of Overload Relief Valve 280kgf/cm (3,980psi) 280kgf/cm (3,980psi)
2-10
E115SR
● OVERALL DIMENSIONS A COMPLETE MACHINE
● DOZER SPECIFICATIONS
ITEM E115SR
(From the center of the arm
Length fixing pin to the tip of the blade) R1,630mm (5´4˝ )
Width [600mm (23. 6˝ ) shoe only] 2,590mm (8´6˝ )
Height 570mm (1´10˝ )
Weight 455kg (1,000 lb)
2
Set Pressure of Main Relief Valve 210kgf/cm (2,990pis)
2
Set pressure Of Overload Relief Valve 280kgf/cm (3,980pis)
2-11
5. SPECIFICATIONS AND PERFORMANCE

E135SR(LC) E135SRL
5.1 SPEED AND GRADEABILITY
Model
Item E135SR(LC), E135SRL
Swing speed 11.7rpm

km/h
Travel speed (1-speed/2-speed) (mph) 2.8 / 5.1 (1.7 / 3.2)
Gradeability %(degree) 70 (35)
5.2 ENGINE
Engine model ISUZU BB－4BG1T
Type Water-cooled, 4-cycle direct injection, turbo charged engine
Number of cylinders－Bore×Stroke 4－105mm×125mm

(4.13in×4.92in)
Total displacement 4,329cc (264cu･in)
Rated output / Rotation speed 62.5kW (85PS) / 2,050rpm
Maximum torque / Rotation speed 32.4kgf･m (235 lbf･ft) / 1,600rpm
Starter 24V / 4.5kW
Alternator 24V / 50A
5.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston + gear pump
Hydraulic motor (swing) Axial piston motor
Hydraulic motor (travel) 2-speed axial piston motor
Control valve 6-spool control valve

Cylinder
(Boom, Arm, and Bucket) Double action cylinder
Oil cooler Air-cooled type
5.4 WEIGHT Unit : kg (lbs)
E135SR E135SRLC E135SRL
Fully equipped weight 13,700 (30,200) 13,900 (30,640) 15,700 (34,610)
Upper structure 7,330 (16,160) 7,330 (16,160) 7,330 (16,160)
Lower machinery 4,450 (9,810) 4,650 (10,250) 6,750 (14,880)

With 600mm (24in) shoe With 600mm (24in) shoe With 700mm (28in) shoe
Attachment
〔Boom+2.45m(8ft) Arm+0.5m3(0.65cu･yd)Bucket〕 1,920 (4,230) 1,920 (4,230) 1,920 (4,230)
2-12
E115SR
5.5 SPEED AND CLIMBING CAPABILITY
Model
Item E115SR
Swing speed 11.4rpm

km/h
TRAVEL SPEED (1-speed/2-speed) (mph) 3.5 / 6.0 (2.2 / 3.7)
Gradeability %(degree) 70 (35)
5.6 ENGINE
Engine model ISUZU BB－4BG1T
Type Water-cooled 4-cycle direct injection turbo charger engine
Number of cylinders－Bore×Stroke 4－105mm×125mm

(4.13in×4.92in)
Total displacement 4,329cc (264cu･in)
Rated output / Rotation speed 58.8kW (80PS) / 2,050rpm
Maximum torque / Rotation speed 30.0kgf･m (217 lbf･ft) / 1,600rpm
Starter 24V / 4.5kW
Alternator 24V / 30A
5.7 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston + gear pump
Hydraulic motor (swing) Axial piston motor
Hydraulic motor (travel) 2-speed axial piston motor
Control valve 6-spool control valve

Cylinder
(Boom, Arm, and Bucket) Double action cylinder
Oil cooler Air-cooled type
5.8 WEIGHT Unit: kg (lbs)
E115SR
Fully equipped weight 11,900 (26,230)
Upper structure 6,080 (13,400)

Lower machinery 4,140 (9,130)
〔With grouser shoe〕 With 600mm (24in) shoe
Attachment
〔Boom+2.2m(7ft-3in) 1,680 (3,700)
Arm+0.45m3(0.59cu･yd)Bucket〕
2-13
6. TYPE OF CRAWLER
E135SR(LC) E135SRL
Overall width of Ground pressure

Shape Shoe width mm (in) 2
crawler mm (ft-in) kgf /cm (psi)
Grouser shoe
500 (20) 2,490 (8′2″) 0.43 (6.12)
600 (24) 2,590 (8′6″) 0.36 (5.1)
700 (28) 2,690 (9′0″) 0.32 (4.49)
800 (32) 2,790 (9′2″) 0.30 (4.3)

44 links
Rubber pad shoe
500 (20) 2,490 (8′2″) 0.44 (6.26)
44 links
Flat shoe
500 (20) 2,490 (8′2″) 0.43 (6.12)
44 links
Triangle shoe
800 (32) 2,790 (9′2″) 0.28 (3.98)
44 links
NOTE :
Use grouser shoes 500mm (20in) or 600mm (24in) on rough ground (areas covered with rocks and gravel). If
you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track
assembly (link, roller, etc.) damage.
2-14
E115SR
Overall width of Ground pressure

Shape Shoe width mm (in) 2
crawler mm (ft-in) kgf /cm (psi)
Grouser shoe
500 (20) 2,490 (8′2″) 0.41 (5.83)
600 (24) 2,590 (8′6″) 0.34 (4.8)
700 (28) 2,690 (9′0″) 0.31 (4.41)
41 links
Rubber pad shoe
500 (20) 2,490 (8′2″) 0.43 (6.12)
41 links
Flat shoe
500 (20) 2,490 (8′2″) 0.42 (5.97)
41 links
Triangle shoe
800 (32) 2,790 (9′2″) 0.27 (3.84)
41 links
NOTE :
Use grouser shoes 500mm (20in) or 600mm (24in) on rough ground (areas covered with rocks and gravel). If
you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track
assembly (link, roller, etc.) damage.
2-15
7. TYPE OF BUCKET
E135SR L – E135SR LC
Hoe bucket Heaped Outer width mm (ft-in) Availability
Struck Number of W or W/O Weight
capacity With side Without side of face
m3(cu･yd) tooth side cutter shovel kg (lbs)
m3(cu･yd) cutter cutter
0.20 600 500 280
0.24(0.31) 3 W YES
(0.26) (2′) (1′8″) (620)
0.23 700 600 330
0.31(0.41) 3 W YES
(0.3) (2′4″) (2′) (660)
0.28 800 700 340
0.38(0.50) 4 W YES
(0.37) (2′7″) (2′4″) (750)
0.35 900 800 350
0.45(0.59) 4 W YES
(0.46) (2′11″) (2′7″) (770)
STD 0.38 1,000 900 380
5 W YES
0.50(0.65) (0.50) (3′3″) (2′11″) (840)
0.43 1,100 1,000 400
0.57(0.75) 5 W YES
(0.56) (3′7″) (3′3″) (880)
0.50 1,150 400
0.70(0.92) ── 5 W/O YES
(0.65) (3′9″) (880)
E115SR
Hoe bucket Heaped Outer width mm (ft-in) Availability

Struck Number of W or W/O Weight
capacity of face
m3(cu･yd) With side Without side tooth side cutter shovel kg (lbs)
m3(cu･yd) cutter cutter
0.13 450 210
0.17(0.22) ── 3 W/O YES
(0.17) (1′6″) (460)
0.19 600 500 260
0.23(0.30) 3 W YES
(0.25) (2′) (1′8″) (570)
0.22 700 600 280
0.30(0.39) 3 W YES
(0.29) (2′4″) (2′) (620)
0.27 800 700 320
0.37(0.48) 4 W YES
(0.35) (2′7″) (2′4″) (705)
STD 0.39 950 850 350
4 W YES
0.45(0.59) (0.51) (3′1″) (2′9″) (770)
0.35 1,000 900 370
0.51(0.67) 5 W YES
(0.46) (3′3″) (2′11″) (820)
2-16
8. COMBINATIONS OF ATTACHMENT
E135SR L – E135SR LC
Hoe bucket Heaped Struck Applicable Arm
capacity
m3(cu･yd) m3(cu･yd) 2.1m (6′11″) Arm 2.45m (8′) Arm 2.95m (9′8″) Arm
0.20
0.24(0.31) ○ ○ ○
(0.26)
0.23
0.31(0.41) ○ ○ ○
(0.3)
0.28
0.38(0.50) ○ ○ ◎
(0.37)
0.35
0.45(0.59) ○ ○ △
(0.46)
STD 0.38
○ ◎ ×
0.50(0.65) (0.50)
0.43
0.57(0.75) ◎ △ ×
(0.56)
0.50
0.70(0.929 △ × ×
(0.65)
E115SR
Hoe bucket Heaped Struck Applicable Arm

capacity
m3(cu･yd) m3(cu･yd) 1.9m (6′3″) Arm 2.2m (7′3″) Arm 2.7m (8′10″) Arm
0.13
0.17(0.22) ○ ○ ○
(0.17)
0.19
0.23(0.30) ○ ○ ○
(0.25)
0.22
0.30(0.39) ○ ○ ○
(0.29)
0.27
0.37(0.48) ○ ○ ◎
(0.35)
STD 0.39
○ ◎ △
0.45(0.59) (0.51)
0.35
0.51(0.67) ◎ △ ×
(0.46)
NOTE :
◎ Standard combination
○ General operation : Excavation or loading of sand, gravel, and clay
△ Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
× Prohibited combination : There are problems from the view points of strength and stability.
z Use the attachments recommended by the Dealer. Reinforcement of arm allows to use it as
nibbler and breaker.
The trouble due to the use in the condition "Use not allowed" described in the above table is not
included in our responsibility
z When bucket marked by △ has been attached or nibbler has been attached on long arm, the
specified stability may not be obtained. So add weight 600kg (1,320 lbs) in add-on type as
required.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage
to the arm and bucket may occur.
2-17
9. ENGINE SPECIFICATION
9.1 SPECIFICATIONS
Model E135SR E115SR

Engine model ISUZU BB－4BG1T ISUZU BB－4BG1T
Diesel, 4-cycle water-cooled, Diesel, 4-cycle water-cooled,
Type in-line, direct injection, in-line, direct injection,
turbo charger turbo charger
Number of cylinder－
Bore×Stroke mm (in) 4×105(4.13)×125(4.92) ←
Total displacement cc (cu･in) 4,329(264) ←
Compression ratio 18.0 ←
Rated out put kW (PS) at rpm 62.5 (85) at 2,050 58.8 (80) at 2,050
Maximum kgfym (lbfyft) at rpm
torque 32.4 (235) at 1,600 30.0 (217) at 1,600
High idling rpm 2,310±20 ←
Low idling rpm 1,000±20 ←

Injection valve
opening pressure kgf/cm2(psi) 185(2,630) ←
Thermostat action F)
Start/Full open ℃(° 82 / 95(180 / 203) ←
Firing order 1－3－4－2 ←

Compression kgf/cm2 (psi) at rpm
pressure 31(440) at 200 ←
Lubrication oil pressure ── ──
Fuel injection timing 9°±1°before top dead point ←
Valve clearance Open Close

0.4mm (0.016″) 19°before top 47°after bottom
Valve clearance Intake valve in cold condition dead point dead point
0.4mm (0.016″) 57°before bottom 15°after top
Exhaust valve in cold condition dead point dead point
Starter capacity V×kW 24×4.5 ←
Generator capacity
(Alternator) V×A 24×50 24×30
∅550 (21.7in) suction type ∅550 (21.7in) suction type
Cooling fan drive method 8 fans, V-belt drive, pulley 6 fans, V-belt drive, pulley
ratio Crank / Fan= 0.89 ratio Crank / Fan= 0.98
Engine oil quantity
(Oil pan only) (gal) Max. 13(3.4), Min. 11(2.9) ←
Dry weight kg (lbs) 368(811) ←

Fuel consumption
ratio g/kW･h (g/PS･h) 224±7％ (164±7%) ←
Allowable inclination Front / Rear and Right / Left : 35°
Dimension (L×W×H) mm (in) 900×690×865 860×670×850

(34.4in×27.2in×34.1in) (33.9in×26.4in×33.5in)
Rotating direction Counterclockwise seeing from flywheel side
2-18
E135SR E135SRLC E135SRL

9.2 ENGINE CHARACTERISTIC CURVE (ISUZU BB－4BG1T)
Condition to be measured : With fan and generator
Without muffler and air cleaner
1 (Nym) (kgfym)
313±20.0Nym /About1600min－
1 330
(31.9±2.0kgfym /About1600min－ ) (33)
310
SHAFT TORQUE (31) SHAFT
TORQUE
290
(29)
(PS) (kW) 270
80 (27)
1
(100) 62.5±1.8kW/2050min－
1
(85±2.5PS/2050min－ )
SHAFT OUTPUT
(80) 60
SHAFT
(60)
OUTPUT
40
(40)
20
1
2350±20min－
(20)
0
(g/kWyh) (g/PSyh)
280
(210)
260 (190) FUEL
CONSUMPTION
224.0±7%/kW yh /2050min－
1 (170) RATE
240
(150) SFC
220 (130)
FUEL CONSUMPTION RATE
200
1000 1500 2000 2500
ENGINE SPEED (min－1)
Fuel consumption volume Fuel consumption volume
= Fuel consumption rate ×kw×Load factor (α) = Fuel consumption rate ×PS×Load factor
0.835×1000 0.835×1000
or (α)
224g/kw･h 164g/PS･h
= ×62.5kw×α
0.835×1000 0.835×1000
= ×85PS×α
=16.7α･ /h
α：Standard load factor (0.70～0.80)

Fuel consumption in regular operation
(load factor：0.70～0.80)
11.7～13.4 /h
2-19
E115SR
9.3 ENGINE CHARACTERISTIC CURVE (ISUZU BB－4BG1T)
Condition to be measured : With fan and generator
Without muffler and air cleaner
1 (Nym) (kgfym)
300±20.0Nym /About1600min－
1
(30.6±2.0kgfym /About1600min－ ) 330
(33)
310
SHAFT TORQUE (31) SHAFT
TORQUE
290
(29)
(PS) (kW)
270
80 (27)
1
(100) 58.7±1.8kW/2050min－
1
(79.8±2.5PS/2050min－ )
(80) 60
SHAFT OUTPUT
SHAFT
(60)
OUTPUT
40
(40)
20
1
2350±20min－
(20)
0
(g/kWyh) (g/PSyh)
280
1
(210)
224.0±7%/kW yh /2050min－
260 (190) FUEL
CONSUMPTION
(170) RATE
240
(150) SFC
FUEL CONSUMPTION RATE
220 (130)
200
1000 1500 2000 2500
ENGINE SPEED (min－1)
Fuel consumption volume Fuel consumption volume
= Fuel consumption rate ×kw×Load factor (α) = Fuel consumption rate ×PS×Load factor
0.835×1000 0.835×1000
or (α)
224g/kw･h 164g/PS･h
= ×58.7kw×α
0.835×1000 0.835×1000
= ×79.8PS×α
=15.7α･ /h
α：Standard load factor (0.70～0.80)

Fuel consumption in regular operation
(load factor：0.70～0.80)
11.0～12.6 /h
2-20
E115SR
E135SR
SECTION 3 ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
1. Boom ...................................................................................................................... 3-1

1.1 Boom dimensional drawing ............................................................................................................. 3-1
1.2 Boom maintenance standard ........................................................................................................... 3-2
2. Arm ......................................................................................................................... 3-4

2.1 Arm dimensional drawing ................................................................................................................ 3-4
2.2 Arm maintenance standard ............................................................................................................. 3-5
3. Bucket ..................................................................................................................... 3-7

3.1 Hoe bucket ...................................................................................................................................... 3-7
3.2 Special bucket ................................................................................................................................. 3-9
3.3 Detail dimensional drawing of lug section ...................................................................................... 3-11
3.4 Detail dimensional drawing of boss section ................................................................................... 3-13
4. Dozer .................................................................................................................... 3-14

4.1 Dozer dimensional drawing ........................................................................................................... 3-14
4.2 Dozer maintenance standard ........................................................................................................ 3-15
1. BOOM
1.1 BOOM DIMENSIONAL DRAWING
I
d3
B C
C
D
H
G B
d1
F
E
C
B
A
I
J
d4
d2
SECTION BB SECTION CC
Fig. 1-1 Boom dimensional drawing
Table 1-1 Unit : mm (ft-in)

E135SR(LC)
No. NAME E115SR
E135SRL
A Boom length 4,600 (15´1˝ ) 4,260 (13´12˝ )
B Boom foot width 574 (1´10.6˝ ) 574 (1´10.6˝ )
C Boom end inner width 274 (10.8˝ ) 232 (9.13˝ )
D Boom end outer width 386 (1´3.2˝ ) 376 (1´2.8˝ )
E Height of boom cylinder rod pin 961 (3´1.8˝ ) 919 (3´0.2˝ )
F Height of arm cylinder (head side) pin 1,084.5 (3´7˝ ) 1,037.5 (3´5˝ )
G Distance between pins of boss R2,024 (6´8˝ ) R1,960 (6´5˝ )
H Distance between pins of bracket R2,303 (7´7˝ ) R2,129.5 (6´12˝ )
I Arm cylinder (head side) inner width 108 (4.25˝ ) 108 (4.25˝ )
J Outer width of bracket on the arm cylinder (rod side) mounting section 400 (1´3.7˝ ) 400 (1´3.7˝ )
d1 Boom foot pin dia. ∅70 (2.76˝ ) ∅70 (2.76˝ )
d2 Boom cylinder (rod side) pin dia. ∅80 (3.15˝ ) ∅75 (2.95˝ )
d3 Pin dia. of arm end. ∅70 (2.76˝ ) ∅70 (2.76˝ )
d4 Arm cylinder (head side) pin dia. ∅70 (2.76˝ ) ∅70 (2.76˝ )
3-1
1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
on boom section
C B A
Fig. 1-2 Clearance of pin and bushing on boom section
1) E135SR L E135SR LC Table 1-2 (1/2) Unit : mm (in)

Standard value Clearance
Sym
Service Remedy
Item Bushing
-bol Pin Pin dia. i.d. Standard Repairable
dia. tolerance tolerance value level limit
0 +0.231 +0.291
(0) (+0.0091) (+0.0115)
A Boom foot －0.030 +0.160 +0.160
∅70 (－0.0012) (+0.0063) (+0.0063)
(2.7559) +0.030 +0.180
Boom cylinder (+0.0012) (+0.0071)
B 0 +0.070
(Head side) More than Replace
(0) (+0.0028) 2.0
+0.030 +0.180 +0.180
1.2 bushing
(0.08)
Boom cylinder ∅80 (+0.0012) (+0.0071) (+0.0071) (0.05) or pin
C (3.1496) 0 +0.100 +0.070
(Rod side)
(0) (+0.0039) (+0.0028)
+0.030 +0.180
Arm cylinder ∅70 (+0.0012) (+0.0071)
D (2.7559) 0 +0.070
(Head side)
(0) (+0.0028)
2) E115SR Table 1-2 (2/2) Unit : mm (in)

Sym
Service Remedy
Item Bushing
-bol Pin Pin dia. i.d. Standard Repairable
0 +0.231 +0.261
(0) (+0.0091) (+0.0103)
A Boom foot －0.030 +0.160 +0.160
∅70 (－0.0012) (+0.0063) (+0.0063)
(2.7559) +0.030 +0.180
Boom cylinder (+0.0012) (+0.0071)
B 0 +0.070
(Head side) More than Replace
(0) (+0.0028) 2.0
1.2
(0.08)
bushing
+0.030 +0.180 +0.180
Boom cylinder ∅75 (+0.0012) (+0.0071) (+0.0071)
(0.05) or pin
C (2.9528) 0 +0.100 +0.070
(Rod side)
(0) (+0.0039) (+0.0028)
+0.030 +0.180
Arm cylinder ∅70 (+0.0012) (+0.0071)
D (2.7559) 0 +0.070
(Head side)
(0) (+0.0028)
3-2
(2) Clearance in thrust direction on the boom

cylinder installation section A
B A
C
C
D
L3 X L3’ L3
X L4
D
4
※ 3
SECTION DD
SECTION CC
X L2 X L2
X L1
1
2 2
SECTION AA
SECTION BB
Fig. 1-3 Clearance in thrust direction on the boom cylinder installation section
E135SR L EVOLUTION E135SR LC EVOLUTION E115SR EVOLUTION
Table 1-3 Unit : mm (in)
Shim adjusting clearance Length under
Basic size
Sec- (Total of both sides) pin neck
Item Remedy
tion Sym Standard Repairable Service
Size No. Length
-bol value level limit
Boom 574 (22.6) 0.6 (0.02) 1.0 1.5 716
A Boom foot L1 1
Upper frame 581 (22.9) or less (0.04) (0.06) (28.2)
Boom cylinder Boom cylinder 90 (3.54) 0.6～1.0 2.0 2.5 180
B L2 2
(Head side) Upper frame 94 (3.70) (0.02～0.04) (0.08) (0.10) (7.09) Shim
Boom cylinder Boom cylinder L3 80 (3.15)
0.6～2.0 2.5 3.0 ※ 597 adjustment
C
(Rod side) Boom L3’ 400 (15.7) (0.02～0.08) (0.10) (0.12) 3 (23.5)
Arm cylinder Boom cylinder 100 (3.94) 0.6～1.0 2.0 2.5 212
D L4 4
(Head side) Boom 108 (4.25) (0.02～0.04) (0.08) (0.10) (8.35)
However the mark ※ shows the length specified in the figure because it has no neck length.
3-3
2. ARM
2.1 ARM DIMENSIONAL DRAWING
B
G
F
D
H
A A
R
C Ⅰ
B A POINT
D1 D2 B POINT
O
d5
H
D
K
L
J
H
d1 d2
2.95m arm Spec.
SECTION AA P
d3
Q
D4
d4
N
SECTION BB
VEIW Ⅰ
Fig. 2-1 Arm dimensional drawing

E135SR LC E135SR LC
E115SR E115SR
E135SR L E135SR L
No. NAME No. NAME
2.95m 2.95m
(9´8˝ ) Long STD STD (9´8˝ ) Long STD STD
2950 2450 2200 244 210
C Arm length L Arm link section boss width ←
(9´8˝ ) (8´ ) (7´3˝ ) (9.61˝ ) (8.27˝ )
R660 268 226
←
Distance between pins A point (26.2˝ ) R638.5 R626.5 M Boss width (9.37˝ ) (8.90˝ )
D of boss and bracket
R674 (25.1˝ ) (24.7˝ ) 108 108
B point N Bracket inner width ←
(26.5˝ ) (4.25˝ ) (4.25˝ )
∅80 ∅75 98 98
D1 I.D of boss ← O Bracket inner width ←
(3.15˝ ) (2.95˝ ) (3.86˝ ) (3.86˝ )
∅75 501
D2 I.D of boss ← ← P Idler link dimension ← ←
(2.95˝ ) (19.7˝ )
∅150 482 468
D4 I.D of boss ← ← Q Bucket link dimension ←
(5.91˝ ) (19.0˝ ) (18.4˝ )
Distance between of boss and R1820 R1815.5 Height between pins of boss and 20 15
E bracket ← R center ←
(5´12˝ ) (5´11˝ ) (0.79˝ ) (0.59˝ )
R350 ∅65 ∅60
F Distance between of boss and boss ← ← d1 Pin dia. ←
(13.8˝ ) (2.56˝ ) (2.36˝ )
Height between pins of boss and 456.5 442 ∅60
G bracket ← d2 Pin dia. ← ←
(18.0˝ ) (17.4˝ ) (2.36˝ )
258.5 ∅70
← ←
Height between pins A point (10.3˝ ) 246.5 244 d3 Pin dia. (2.76˝ )
H of boss and bracket (9.70˝ ) (9.61˝ )
150 ∅70
B point d4 Pin dia. ← ←
(5.91˝ ) (2.76˝ )
250 216 ∅60
J Arm top end width (with bushing) ← d5 Pin dia. ← ←
(9.84˝ ) (8.50˝ ) (2.36˝ )
232 198
K Boss width ←
(9.13˝ ) (7.80˝ )
3-4
2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing E
B D,D’ F
C G
Fig. 2-2 Clearance of pin and bushing on arm section
1) E135SR L E135SR LC Table 2-2 (1/2) Unit : mm (in)

Sym Item Pin Pin dia. Bushing i.d. Standard Repairable Service Remedy
-bol
＋0.228 ＋0.308
(＋0.0090) (＋0.0121)
A Arm point －0.020 ＋0.168 ＋0.188
∅65 (－0.0008) (＋0.0066) (＋0.0074)
－0.080 ＋0.234 ＋0.314
Bucket link (2.5591) (－0.0031) (＋0.0092) (＋0.1236)
B (Bucket connection) ＋0.171 ＋0.191
(＋0.0067) (＋0.0075)
＋0.246 ＋0.306
Idler link (＋0.0097) (＋0.0120)
C (Arm connection) ＋0.187 ＋0.187
(＋0.0073) (＋0.0073)
0 ＋0.236 ＋0.296
Bucket link (0) (＋0.0093) (＋0.0117)
D (Idler link connection) －0.060 ＋0.180 ＋0.180 Replace
∅60 (－0.0024) (＋0.0071) (＋0.0071) 1.2 2.0
bushing
Bucket cylinder (2.3622)
＋0.240
(0.45) (0.08)
D’ (Rod side)
(＋0.0094)
＋0.100
or pin
(＋0.0039)
＋0.180
Bucket cylinder (＋0.0071)
E (Bottom side) ＋0.030 ＋0.100 ＋0.180
(＋0.0012) (＋0.0039) (＋0.0071)
0 ＋0.070
Arm cylinder (0) (＋0.0028)
F (Rod side)
∅70
＋0.231 ＋0.251
(2.7559) ±0.020 (＋0.0091) (＋0.0099)
G Arm foot (±0.0008) ＋0.160 ＋0.140
(＋0.0063) (＋0.0055)
2) E115SR Table 2-2 (2/2) Unit : mm (in)

Sym Item Pin Pin dia. Bushing i.d. Standard Repairable Service Remedy
-bol
＋0.228 ＋0.288
(＋0.0090) (＋0.0113)
A Arm point －0.020 ＋0.168 ＋0.188
(－0.0008) (＋0.0066) (＋0.0074)
－0.080 ＋0.234 ＋0.294
Bucket link (－0.0031) (＋0.0092) (＋0.0116)
B (Bucket connection) ＋0.171 ＋0.191
(＋0.0067) (＋0.0075)
＋0.246 ＋0.306
Idler link (＋0.0097) (＋0.0120)
C (Arm connection) ＋0.187 ＋0.187
∅60 (＋0.0073) (＋0.0073)
Bucket link (2.3622) 0
(0)
＋0.236
(＋0.0093)
＋0.296
(＋0.0117)
D (Idler link －0.060 ＋0.180 ＋0.180 Replace
connection) (－0.0024) (＋0.0071) (＋0.0071) 1.2 2.0
bushing
Bucket cylinder
＋0.240 (0.45) (0.08)
D’ (Rod side)
(＋0.0094) or pin
＋0.100
(＋0.0039)
＋0.180
Bucket cylinder (＋0.0071)
E (Bottom side) ＋0.030 ＋0.100 ＋0.180
(＋0.0012) (＋0.0039) (＋0.0071)
0 ＋0.070
Arm cylinder (0) (＋0.0028)
F (Rod side)
∅70
＋0.231 ＋0.251
(2.7559) ±0.020 (＋0.0091) (＋0.0099
G Arm foot (±0.0008) ＋0.160 ＋0.140
(＋0.0063) (＋0.0055)
3-5
(2) Clearance of arm and cylinder installing

sections in thrust direction
E
D D’
B C F
E
A B G
D D’
F
C
A
G
X3 L3 5 6
X1 L1
X5 L5 X6 L6
1 3
SECTION AA SECTION CC SECTION EE SECTION FF
X2 L2 X4 L4
X4’ L4’ L7
2 4 X7 7
SECTION BB SECTION DD, D’ D’ SECTION GG

Fig. 2-3 Clearance of arm and cylinder installing sections in thrust direction

Shim adjusting clearance Length under
Remedy
Sec- Basic size (Total of both sides) pin neck
Item
tion Standard Repairable Service
No. E135SR E115SR
value level limit No. E135SR E115SR
250 216
Arm (9.84) (8.50)
A Arm point L1 251 218 0.6～1.0 1
Bucket (9.88) (8.58) 1.2 ※391 ※351
250 216 (0.02～0.0
Link side (0.05) (15.4) (13.8)
(9.84) (8.50) 4)
B Bucket link L2 252 218 2
Bucket (9.92) (8.58)
244 210
Idler link Arm (9.61) (8.27) 0.5 (0.02) 1.0 2.0
C L3 or less (0.04) (0.08) 3
(Arm connection) Link side
Shim adjustment
― ―
2.44 226
Link
Bucket link
Bucket link side (9.61) (8.90) ※328 ※310

L4 0.6～1.0
connection Idler link side ― ―
1.2 (12.9) (12.2)
D Bucket 90 (0.02～0.0
(0.05)
4
Rod side (3.54) ←
4)
cyinder L4’ 98
connection Bucket link side (3.86) ←
Bucket Bottom side
90
(3.54) ← ※196 ※184
E cylinder L5 98 5
Arm 0.6～2.0 (7.72) (7.24)
(Bottom side) (3.86) ←
2.0 2.5
100 (0.02～0.0
(0.08) (0.10)
Arm cylinder Rod side (3.94) ←
8) ※212
F L6 108 6 ←
(Rod side) Arm (4.25) ← (8.35)
268 226
G Arm foot Arm L7 (10.6) (8.90) 0.5 (0.02) 1.0 2.0 ※386
274 232 or less (0.04) (0.08)
7 (15.2)
←
Boom L7’ (10.8) (9.13)
Note : The mark ※ shows the length from the under

head to the center of pin hole.
3-6
3. BUCKET
3.1 HOE BUCKET
(1) Hoe bucket dimensional drawing
G
d2
D
A
d1
I I0 B Bushing out dia.
H
C
F
Fig. 3-1 Hoe bucket dimensional drawing
Table 3-1
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 I0 Pitch between teeth
E Inner width of bracket d1 Outer width of bushing
F Outer width of side cutter d2 Pin dia.
(2) Hoe bucket dimensional table
1) E135SR L E135SR LC Table 3-2 (1/2) Unit : mm (ft-in)
Type Hoe bucket

〔 STD〕
0.24m3 0.31m3 0.38m3 0.45m3 0.57m3 0.70m3
Capacity 0.50m3
(0.31cuyyd) (0.41cuyyd) (0.50cuyyd) (0.59cuyyd) (0.75cuyyd) (0.92cuyyd)
(0.65cuyyd)
A 370 (14.6˝ ) ← ← ← ← ← ←
B R1,225 (4´ ) ← ← ← ← ← ←
C 862 (33.9˝ ) 462 (18.2˝ ) 562 (22.1˝ ) 662 (26.1˝ ) 772 (30.4˝ ) 962 (37.9˝ ) 1,112 (3´8˝ )
D 324 (12.8˝ ) ← ← ← ← ← ←
E 252 (9.92˝ ) ← ← ← ← ← ←
F 1,000 (3´3˝ ) 593 (23.3˝ ) 700 (27.6˝ ) 800 (31.5˝ ) 910 (35.8˝ ) 1,100 (3´7˝ ) ―
G 739 (29.1˝ ) 383 (15.1˝ ) 439 (17.3˝ ) 539 (21.2˝ ) 649 (25.6˝ ) 839 (33.0˝ ) 989 (38.9˝ )
H 900 (35.4˝ ) 500 (19.7˝ ) 600 (23.6˝ ) 700 (27.6˝ ) 810 (31.9˝ ) 1,000 (3´3˝ ) 1,150 (3´9˝ )
I 193.5 (7.62˝ ) 187 (7.36˝ ) 237 (9.33˝ ) 191 (7.52˝ ) 228 (8.98˝ ) 218.5 (8.60˝ ) 256 (10.1˝ )
I0 193.5 (7.62˝ ) 187 (7.36˝ ) 237 (9.33˝ ) 191 (7.52˝ ) 228 (8.98˝ ) 218.5 (8.60˝ ) 256 (10.1˝ )
d1 ∅80 (3.15˝ ) ← ← ← ← ← ←
d2 ∅65 (2.56˝ ) ← ← ← ← ← ←
3-7
2) E115SR Table 3-2 (2/2) Unit : mm (ft-in)
Type Hoe bucket

〔 STD〕
0.17m3 0.23m3 0.30m3 0.37m3 0.51m3
Capacity 0.45m3
(0.22cuyyd) (0.30cuyyd) (0.39cuyyd) (0.48cuyyd) (0.67cuyyd)
(0.59cuyyd)
A 375 (14.8˝ ) ← ← ← ← ←
B R1,201 (3´11˝ ) R1,193 (3´11˝ ) R1,201 (3´11˝ ) ← ← ←
C 812 (32.0˝ ) 420 (16.5˝ ) 462 (18.2˝ ) 562 (22.1˝ ) 662 (26.1˝ ) 872 (34.3˝ )
D 274 (10.8˝ ) ← ← ← ← ←
E 218 (8.58˝ ) ← ← ← ← ←
F 950 (37.4˝ ) ― 600 (23.6˝ ) 700 (27.6˝ ) 800 (31.5˝ ) 1,010 (3´4˝ )
G 685 (27.0˝ ) 354 (13.9˝ ) 335 (13.2˝ ) 435 (17.1˝ ) 535 (21.1˝ ) 745 (29.3˝ )
H 850 (33.5˝ ) 450 (17.7˝ ) 500 (19.7˝ ) 600 (23.6˝ ) 700 (27.6˝ ) 910 (35.8˝ )
I 242 (9.53˝ ) ― ― ― 192 (7.56˝ ) 196 (7.72˝ )
I0 241 (9.49˝ ) 172.5 (6.79˝ ) 187.5 (7.38˝ ) 237 (9.33˝ ) 191 (7.52˝ ) 196 (7.72˝ )
d1 ∅75 (2.95˝ ) ← ← ← ← ←
d2 ∅60 (2.36˝ ) ← ← ← ← ←
3-8
3.2 SPECIAL BUCKET

(1) Special bucket dimensional drawing
C
1) Bucket with ejector
B’ E
H
d1
I0 I0
A
d2
2) Slope finishing bucket

D
E
A
d1
d2
B
J G
3) Dismantle Spec. bucket
d2
D
A
d1
I I0
B
H C
F
Fig. 3-3 Special bucket dimensional drawing
3-9
Table 3-3
No. NAME
A Distance between pin and bracket
B Distance between bucket pin and tooth end
B’ Distance between bucket pin and bucket end
C Inner width of bucket top end
D Inner width of lug
E Inner width of bracket
F Outer width of side cutter
G Outer width of bucket bottom
H Bucket inner width of front side
I Pitch between teeth
I0 Pitch between teeth
J Finishing plate depth
d1 Pin dia.
d2 Pin dia.
(2) Special bucket dimension

Model E135SR L E135SR LC E115SR
Dismantle Bucket Slope Bucket Slope
Type
Spec. bucket with ejector finishing bucket with ejector finishing bucket
1800×900 1600×900
0.50m3 0.21m3 (5´11˝ ×35.4˝ ) 0.21m3 (5´3˝ ×35.4˝ )
Capacity (0.65cuyyd) (0.27cuyyd) 0.52m3 (0.27cuyyd) 0.40m3
(0.68cuyyd) (0.52cuyyd)
A 370 (14.6˝ ) 375 (14.8˝ ) R370 (14.6˝ ) 375 (14.8˝ ) R375 (14.8˝ )
B R1,225 (4´) ― R928 (36.5˝ ) ― R878 (34.6˝ )
B’ ― 1,072 (3´6˝ ) ― 1,073 (3´6˝ ) ―
C 862 (33.9˝ ) 434 (17.1˝ ) ― 434 (17.1˝ ) ―
D 324 (12.8˝ ) ― 324 (12.8˝ ) ― 290 (11.4˝ )
E 250 (9.92˝ ) 266 (10.5˝ ) 252 (9.92˝ ) 230 (9.06˝ ) 218 (8.58˝ )
F 1,000 (3´3˝ ) ― ― ― ―
G 739 (29.1˝ ) 400 (15.7˝ ) 1,800 (5´11˝ ) 400 (15.7˝ ) 1,600 (5´3˝ )
H 900 (35.4˝ ) 419 (16.5˝ ) ― 419 (16.5˝ ) ―
I 193.5 (7.62˝ ) ― ― ― ―
I0 193.5 (7.62˝ ) 172.5 (6.79˝ ) ― 172.5 (6.79˝ ) ―
J ― ― 900 (35.4˝ ) ― 900 (35.4˝ )
d1 ∅80 (3.15˝ ) ∅80 (3.15˝ ) ∅80 (3.15˝ ) ∅75 (2.95˝ ) ∅75 (2.95˝ )
d2 ∅65 (2.56˝ ) ∅65 (2.56˝ ) ∅65 (2.56˝ ) ∅60 (2.36˝ ) ∅60 (2.36˝ )
3-10
3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION

B
∅J
∅A
BOSS (E135SR)
A M BOSS (E115SR)
3-G
∅D
∅F
∅E
SHIM t=1 Insert No.13 pin until the Ⅰ BOSS (E135SR)

surface becomes level. SECTION AA BOSS (E115SR)
DETAIL Ⅰ
Fig. 3-4 Dimension of lug section
1) E135SR L E135SR LC Table 3-5 (1/2) Unit : mm (ft-in)

Lug plate thickness
Screw hole P.C.D

Spring pin dia.
Boss outer dia.
Boss outer dia.
Capacity
Pin hole dia.
Type of
Boss width.
Boss width.
Screw dia.
of bucket
Hole dia.
bucket
m3 (cuyyd)
A B D E F G H J M N
〔STD〕
0.50 (0.65)
0.24 (0.31)
0.31 (0.41)
∅65 22 ∅80 ∅10 ∅146 22 ∅138 36 115
Hoe bucket 0.38 (0.50) M14
(2.56˝ ) (0.866˝ ) (3.15˝ ) (0.394˝ ) (5.75˝ ) (0.866˝ ) (5.43˝ ) (1.42˝ ) (4.53˝ )
0.45 (0.59)
0.57 (0.75)
0.70 (0.92)
Dismantle ∅65 22 ∅80 ∅10 ∅146 22 ∅138 36 115
0.50 (0.65) M14
Spec. bucket (2.56˝ ) (0.866˝ ) (3.15˝ ) (0.394˝ ) (5.75˝ ) (0.866˝ ) (5.43˝ ) (1.42˝ ) (4.53˝ )
Bucket with ∅80
0.21 (0.27)
ejector (3.15˝ )
Slope 1800×900
∅80 115
finishing (5´11˝ ×35.4˝ )
(3.15˝ ) (4.53˝ )
bucket 0.52 (0.68)
3-11
2) E115SR Table 3-5 (2-2) Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Spring pin dia.
Boss outer dia.
Boss outer dia.

Capacity
Pin hole dia.
Boss width.
Boss width.
Type of
Screw dia.
of bucket
Hole dia.
bucket
m3 (cuyyd)
A B D E F G H J M N
〔STD〕
0.45 (0.59)
0.17 (0.22)
∅60 22 ∅75 ∅10 ∅140 22 ∅128 28 107
Hoe bucket 0.23 (0.30) M14
(2.36˝ ) (0.866˝ ) (2.95˝ ) (0.394˝ ) (5.51˝ ) (0.866˝ ) (5.04˝ ) (1.10˝ ) (4.21˝ )
0.30 (0.39)
0.37 (0.48)
0.51 (0.67)
Bucket with ∅75 ∅128
0.21 (0.27)
ejector (2.95˝ ) (5.04˝ )
Slope 1600×900
∅10 107
finishing (5´3˝ ×35.4˝ ) M14
bucket (0.394˝ ) (4.21˝ )
0.40 (0.52)
3-12
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION
∅G H 5
∅A ∅B ∅C ∅D
30°
15
DETAIL Ⅰ
E
Fig. 3-4 Dimension of boss section

Capacity
Type of
Model of bucket ∅A ∅B ∅C ∅D E F ∅G H I
bucket m3(cuyyd)
〔STD〕
0.50 (0.65˝ )
0.24 (0.31˝ )
0.31 (0.41˝ )
Hoe bucket ∅101.6 ∅69 ∅94.5±0.2 ∅99.5 19 34 ∅15 13 2.5
0.38 (0.50˝ )
E135SR LC
(4.00˝) (2.72˝) (3.70˝±0.0079˝) (3.92˝) (0.748˝) (1.34˝) (0.591˝) (0.512˝) (0.0984˝)

0.45 (0.59˝ )
0.57 (0.75˝ )
0.70 (0.92˝ )
Dismantle
Spec. 0.50 (0.65˝ )
E135SR L
bucket
Bucket with
0.21 (0.27˝ )
ejector 15 30
Slope 1800×900 ↑ ↑ ↑ ↑ ↑ ↑ ↑
(0.591˝) (1.18˝)
finishing (5´11˝×35. 4˝ )
bucket 0.52 (0.68˝ )
Loader
0.52 (0.68˝ )
bucket
〔STD〕
0.45 (0.59˝ )
∅95 ∅64 ∅88.5±0.2 ∅93.5 30 45 ∅15 13 2.5
0.17 (0.22˝ )
Hoe bucket 0.23 (0.30˝ ) (3.74˝) (2.56˝) (3.48˝±0.0079˝) (3.68˝) (1.18˝) (1.77˝) (0.591˝) (0.512˝) (0.0984˝)
0.30 (0.39˝ )
E115SR
0.37 (0.48˝ )
0.51 (0.67˝ )
Bucket with 25 40
0.21 (0.27˝ )
ejector ↑ ↑ ↑ ↑ ↑ ↑ ↑
(0.984˝) (1.57˝)
Slope 1600×900
finishing (5´3˝ ×35.4˝ )
bucket 0.40 (0.52˝ )
3-13
4. DOZER
4.1 DOZER DIMENSIONAL DRAWING
G E
d2 d1 F
A D
B
G E
C
d2 d1
↑ VIEW Ⅰ
Ⅰ
Fig. 4-1 Dozer dimensional drawing
Unit : mm (ft-in)
Table 4-1 E135SR L E115SR
E135SR LC
No. NAME DIMENSION DIMENSION
A Blade width 2,590 (8´6˝ ) ←
B Blade height 590 (23.2˝ ) ←
C Distance from dozer attaching pin center to R1,729 (5´8˝ ) R1,633 (5´4˝ )
cutting edge end
D Inner width of dozer attaching bracket 672 (26.5˝ ) ←
E Width of dozer attaching bracket 128 (5.04˝ ) ←
Distance from dozer attaching pin center to
F R881 (34.7˝ ) ←
attaching pin on dozer cylinder head side
G Attaching bracket inner width on dozer cylinder 92 (3.62˝ ) ←
head side
d1 Dozer attaching pin dia. ∅60 (2.36˝ ) ←
d2 Attaching pin dia. on dozer cylinder head side ∅60 (2.36˝ ) ←
3-14
4.2 DOZER MAINTENANCE STANDARD

A T=Tightening torque : kgfym (lbfyft)
T=6.7±0.7
(48±5.1)
M12×120
B DOZER CYLINDER C T=11.7±1.2
A (85±8.7)
}
L3 3
M12×120 M12×120
T=11.7±1.2 T=11.7±1.2
(85±8.7) (85±8.7)
VIEW B VIEW A SECTION CC
Fig. 4-2 Dozer maintenance standard
(1) Clearance of pin and bushing

Sym Bushing
Item Pin Pin dia. Repairable Service Remedy
-bol i.d. Clearance
dia. tolerance tolerance level limit
Dozer cylinder －0.06 ＋0.200 ＋0.320
A
(Rod side) (－0.0024) (＋0.0079) (＋0.0125)
Dozer cylinder －0.12 0 ＋0.060
B Replace
(Head side) ∅60 (－0.0047) (0) (＋0.0024) 1.2 (0.05) 2.0
bushing
(2.36) －0.150 ＋0.230 ＋0.440 or more (0.08) or pin
(－0.0059) (＋0.0091) (＋0.0173)
C Dozer foot
－0.210 ＋0.130 ＋0.280
(－0.0083) (＋0.0051) (＋0.0110)
(2) Clearance in thrust direction on the dozer cylinder attaching section

Shim adjusting cleance Length under
Basic size (Total of both sides) pin neck
Sym
Item Remedy
-bol Sym Standard Repairable Service
Size No. Length
-bol value level limit
Dozer cylinder Rod side 90 (3.54)
A (Rod side) L1 1
Lower frame 92 (3.62) 180
Dozer cylinder Head side 90 (3.54) 1.0～2.0 2.0 (0.08) 3.0 (7.09) Shim
B (Head side) L2 2 adjustment
Dozer 92 (3.62) (0.04～0.08) or more (0.12)
Dozer 128 (5.04) 218
C Dozer foot L3 3
Lower frame 150 (5.91) (8.58)
3-15
NOTE
3-16
E115SR
E135SR
SECTION 11 TOOLS
TABLE OF CONTENTS
1. Tightening torques for capscrews and nuts ........................................................... 11-1
2. Screw size ............................................................................................................. 11-2
3. Tightening torques for nuts and sleeves ................................................................ 11-3
4. Plug ....................................................................................................................... 11-4
5. Special spanner for tube ........................................................................................ 11-7
6. Special tools .......................................................................................................... 11-8
7. Application of screw locking compound and sealing compound .......................... 11-10
8. Suction stopper ................................................................................................... 11-11

8.1 Components ................................................................................................................................ 11-11
8.2 Dimension ................................................................................................................................... 11-11
9. Counterweight lifting jig ...................................................................................... 11-12
10. Boom foot pin pulling tools................................................................................ 11-13
11. Upper frame lifting jig ........................................................................................ 11-14
12. Engine mounting ............................................................................................... 11-15
13. Track spring set ................................................................................................. 11-15

1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables 1-1 and 1-2 indicate tightening torques Insufficient tightening may lead to a loosening or
applicable to cases where no special note is given. loss of bolts. Always tighten bolts to proper
Overtightening of bolts may result in a twist-off torques.
and a fracture under load.
Table 1-1 Tightening torque for coarse thread metric screws (not plated) unit : kgfym (lbfyft)
Strength
grade 4.8 T 7T 10.9 T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
0.45±0.05 0.38±0.04 0.98±0.1 0.83±0.08 1.77±0.18 1.5±0.15
M 6 P=1 (3.3±0.4 ) (2.7±0.3) (7.1±0.7) (6.0±0.6) (13±1) (11±1)
1.09±0.11 0.92±0.09 2.4±0.2 2.0±0.2 4.3±0.4 3.6±0.4
M 8 P=1.25 (7.9±0.8) (6.7±0.7) (17±1) (14±1) (32±3) (26±3)
2.2±0.2 1.83±0.18 4.7±0.5 4.0±0.4 8.5±0.9 7.2±0.7
M10 P=1.5 (16±1) (13±1) (34±4) (29±3) (61±7) (52±5)
3.7±0.4 3.2±0.3 8.1±0.8 6.8±0.7 14.6±1.5 12.3±1.2
M12 P=1.75 (27±3) (23±2) (59±6) (49±5) (110±11) (89±9)
5.9±0.6 5.0±0.5 12.8±1.3 10.8±1.1 23±2 19.5±1.9
M14 P=2 (43±4) (36±4) (93±9) (78±8) (170±14) (140±14)
9.0±0.9 7.6±0.7 19.5±2.0 16.4±1.6 35±4 29±3
M16 P=2 (65±7) (55±5) (140±14) (120±12) (250±29) (210±22)
12.4±1.2 10.5±1.0 27±3 23±2 49±5 41±4
M18 P=2.5 (90±9) (76±7) (200±22) (170±14) (350±36) (300±29)
17.5±1.7 14.7±1.4 38±4 32±3 68±7 57±6
M20 P=2.5 (130±12) (110±10) (270±29) (230±22) (490±51) (410±43)
23±2 19.6±2.0 51±5 43±4 92±9 77±8
M22 P=2.5 (170±14) (140±14) (370±36) (310±29) (670±65) (560±58)
30±3 24±3 65±7 53±5 118±12 96±10
M24 P=3 (220±22) (170±22) (470±51) (380±36) (850±87) (690±72)
44±4 36±4 96±10 78±8 173±17 140±14
M27 P=3 (320±29) (260±29) (690±72) (560±58) (1300±120) (1000±100)
60±6 50±5 131±13 110±11 235±24 198±20
M30 P=3.5 (430±43) (360±36) (950±94) (800±80) (1700±170) (1400±140)
81±8 68±7 176±18 148±15 317±32 266±27
M33 P=3.5 (590±58) (490±51) (1300±130) (1100±110) (2300±230) (1900±200)
105±10 88±9 227±23 190±19 409±41 343±34
M36 P=4 (760±72) (640±65) (1600±170) (1400±140) (3000±300) (2500±250)
Table 1-2 Tightening torques for fine threads metric screws (not plated) unit : kgfym (lbfyft)
Strength
grade 4.8 T 7T 10.9 T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
1.15±0.11 0.97±0.1 2.5±0.2 2.1±0.2 4.5±0.4 3.8±0.4
M 8 P=1 (8.3±0.8) (7.0±0.7) (18±1) (15±1) (33±3) (27±3)
2.3±0.2 1.91±0.19 4.9±0.5 4.2±0.4 8.9±0.9 7.5±0.7
M10 P=1.25 (17±1) (14±1) (35±4) (30±3) (64±7) (54±5)
4.0±0.4 3.4±0.3 8.7±0.9 7.3±0.7 15.7±1.6 13.2±1.3
M12 P=1.25 (29±3) (25±2) (63±7) (53±5) (110±12) (95±9)
9.4±0.9 7.9±0.8 20±2 17.2±1.7 37±4 31±3
M16 P=1.5 (68±7) (57±6) (140±14) (120±12) (270±29) (220±22)
19±1.9 15.8±1.6 41±4 34±3 74±7 62±6
M20 P=1.5 (140±14) (110±12) (300±29) (250±22) (540±51) (450±43)
32±3 27±3 70±7 58±6 126±12 105±10
M24 P=2 (230±22) (200±22) (510±51) (420±43) (910±87) (760±72)
65±6 54±5 142±14 118±12 255±26 212±21
M30 P=2 (470±43) (390±36) (1000±100) (850±87) (1800±190) (1500±150)
87±9 72±7 190±19 158±16 341±34 284±28
M33 P=2 (630±65) (520±51) (1400±140) (1100±120) (2500±250) (2100±200)
109±11 91±9 238±23 198±20 428±43 357±36
M36 P=3 (790±80) (660±65) (1700±170) (1400±140) (3100±310) (2600±260)
11-1
2. SCREW SIZE
(1) Capscrew 2) Socket bolt

d d
B
B
Table 2-1 Table 2-2 Table 2-3

Nominal B mm Nominal B mm Nominal B mm
screw size screw size screw size
Tool Unified Tool Tool
(d) size (d) size
size (screw threads)
M6 10 1/4-20UNC 11 M6 5
M8 13 5/16-18UNC 13 M8 6
M10 17 3/8-16UNC 14 M10 8
M12 19 7/16-14UNC 16 M12 10
(M14) (22) 1/2-13UNC 19 M14 12
M16 24 5/8-11UNC 24 M16 14
(M18) (27) 3/4-10UNC 29 (M18) 14
M20 30 7/8-9UNC 33 M20 17
(M22) 32 1-8UNC 38 M24 19
M24 36 1 1/8-7UN 43 M30 22
(M27) (41) 1 1/4-7UN 48 M36 27
M30 46 1 1/2-6UN 57 M42 32
M36 55 M48 36
M42 65
M45 70
M48 75
M56 85
(M60) 90
M64 95
(M68) 100
M72 105
M76 110
M80 115
11-2
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES
Table 3 indicates standard tightening torques sleeves in flareless joint may develop oil leaks
applicable to cases where no particular note is through pipe connections.
given. Always tighten nuts and sleeves to proper
Overtightening or understanding of nuts and torques.
Table 3-1
Working pressure Tube size Opposing Tightening torque
OD×thickness
kgf / cm2 (psi) mm (in) flats (HEX) kgfym (lbfyft)
10×1.5 19 5±1
(0.394×0.059) (36±7)
15×2.0 27 12±1.2
(0.591×0.079) (87±9)
300 18×2.5 15±1.5
32
(4270) (0.709×0.098) (108±11)
22×3.0 36 22±2.2
(0.866×0.118) (159±16)
28×4.0 41 28±2.8
(1.10×0.157) (200±20)
300 35×5.0 45±4.5
55
(4270) (1.38×0.197) (330±33)
Table 3-2
SLEEVE NUT
B
∅d ∅d
Opposing
Tube size Tube size
flats (HEX)
∅d ∅d B
6 6 14
8 8 17
10 10 19
12 12 22
15 15 27
18 18 32
22 22 36
28 28 41
32 32 50
35 35 55
38 38 60
11-3
4. PLUG
(1) Plug for hydraulic pipe joint
Table 4-1
1) Cap nut
Applicable Opposing flat
pipe T screw
O. D : A H1 H
6 M12×1.5 14 14
8 M14×1.5 17 17
10 M16×1.5 17 19
12 M18×1.5 19 22
15 M22×1.5 24 27
18 M26×1.5 27 32
H1 T screw H 22 M30×1.5 32 36
28 M36×1.5 38 41
Table 4-2
2) Plug
Applicable
pipe
O. D : A
6
8
10
12
15
18
Flareless
joint body Nut 22
28
3) Nut Table 4-3

Applicable Opposing
pipe d screw flat
O. D : A
d screw 6 M12×1.5 14
8 M14×1.5 17
10 M16×1.5 19
12 M18×1.5 22
15 M22×1.5 27
18 M26×1.5 32
22 M30×1.5 36
28 M36×1.5 41
32 M42×1.5 50
35 M45×1.5 55
38 M48×1.5 60
11-4
(2) Plug for hydraulic equipment

1) PF screw
B Table 4-4
O ring PF Norminal
screw B mm O ring
PF 1/4 19 1B P11
PF 3/8 22 1B P14
PF 1/2 27 1B P18
PF 3/4 36 1B P24
PF screw PF 1 41 1B P29
2) PT screw
Table 4-5
PT B mm
B screw
PT screw
PT 1/8 5
PT 1/4 6
PT 3/8 8
PT 1/2 10
PT 3/4 14
PT 1 17
PT 1 1/4 22
PT 1 1/2 22
(3) Plug for (F) flare hose

Table 4-6
PF screw
PF B mm
screw
PF 1/4 14
PF 3/8 17
PF 1/2 22
Opposing
flat B PF 3/4 27
PF 1 36
Table 4-7
PF E mm F mm
screw
PF 1/4 14 19
PF PF 3/8 17 22
screw
PF 1/2 23 27
Opposing Opposing PF 3/4 27 36
flat F flat E PF 1 36 41
PF 1 1/4 40 50
11-5
(4) Plug for ORS joints

Male
O RING
Table 4-8
Applicable
Opposing Norminal
Screw size A hose
O.D flats(HEX) O ring
A
A 1-14UNS ∅21.7 27 1B A16
A
1 3/16-12UN ∅27.2 36 1B A18
1 7/16-12UN ∅34.0 41 1B A21
Female Table 4-9

Applicable
Opposing
Screw size A tube
O.D flats(HEX)
A 1-14UNS ∅21.7 32
1 3/16-12UN ∅27.2 36
1 7/16-12UN ∅34.0 41
11-6
5. SPECIAL SPANNER FOR TUBE

Table 5-1
Applicable tube diameter HEX
Drawing of a special spanner mm (in)
mm (in) mm
70 (2.76)
8(0.315)
15 16
27 (0.630) PART-No. 22(0.866)
(0.591)
HEX27 40(1.57)
□
＋0.3
(
12.7 －0.1 0.500 －0.004
＋0.012
)
70 (2.76)
42(1.65)
18 19
32 (0.748) PART-No. 22(0.866)
(0.709)
22(0.866)
HEX32 □ 12.7 ＋0.3 ( ＋0.012
－0.1 0.500 －0.004 )
70 (2.76)
40(1.57)
22 19
30 PART-No. 22(0.866)
(0.748)
(0.866)
22(0.866)
HEX30 □ 12.7 ＋0.3 (
－0.1 0.500 －0.004
＋0.012
)
48 (1.89) 70 (2.76)
11.5 (0.453)
22
36 23
(0.906) PART-No. 22(0.866)
(0.866)
HEX36 □ 12.7 ＋0.3 (

－0.1 0.500 －0.004
＋0.012
)
60 (2.36) 109 (4.29)
14.5 (0.571)
28
41 29 PART-No. 22(0.866)
(1.14)
(1.10)
HEX41 □ (
12.7 ＋0.3
＋0.012
－0.1 0.500 －0.004 )
80 (3.15) 109 (4.29)
28 31
46 (1.22) PART-No. 35(1.38)
(1.10)
HEX46 □
＋0.5
(
19.05 －0.1 0.750 ＋0.020
－0.004 )
109 (4.29)
80 (3.15)
32 50 33 PART-No.
PART-No. 35(1.38)
(1.26) (1.30)
HEX50 □ 19.05 ＋0.5 ( ＋0.020

－0.1 0.750 －0.004 )
11-7
6. SPECIAL TOOLS
Table 6-1
No. Tools name Sketch Applicable
Allen wrench Pump

1
Nominal B : 10 suction
Commercial tool length (L1) － cut length = Required length

40(1.57˝ ) － 10(0.39˝ ) = 30(1.18˝ )
Allen wrench Pump

2
Nominal B : 14 install
Commercial tool length (L1) － cut length = Required length

56(2.20˝ ) － 11(0.43˝ ) = 45(1.77˝ )
Cut
Swing
Spanner
3 motor
Nominal S : 32
A,B port
Commercial tool outer width (D) － cut length = Required length

73(2.87˝ ) － 13(0.51˝ ) = 60(2.36˝ )
Additional M10×22 For

Plug threading slinging
4 for M10 eye bolt
PF3/4 the swing
motor
PF3/4 O ring
For
slinging
Eye bolt the swing
5 M10×18
motor
&
M10 Flare hose
11-8
Table 6-2
No. Tools name Sketch Applicable

M8 Eye bolt
Plug
tube dia. 22 )
(Nominal
Reference nut Flare hose
6 Reference
Eye bolt
Nut M8×18
Additional
threading for
M8 Eye bolt
M8 Eye bolt
M8×18
Plug Additional
Nominal threading
1-14UNS
7 Flare hose
Eye bolt
M8 Eye bolt
M8×18
Plug Additional
threading
Nominal
1 3/16-12UN
8 Flare hose
Eye bolt
Eye bolt For slinging the

M8×15 swing motor
9
&
Flare hose
M8
Plug
PF1/2 Additional M8×20 For slinging the
10
threading for
swivel joint
M8 Eye bolt
O RING
PF1/2
11-9
7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING

COMPOUND
(1) For general
Table 7-1
Manufacturer
Service Features
Loctite Three-bond
#242 1360K Low strength

Screw locking
compound #262 1374 Middle strength
#271 1305 High strength

Sealing
compound #515 1215 Sealing
(2) For specific location

Table 7-2
No. Use Manufacturer Name Equivalent Applicable
(Manufacture ; Loctite)
#1901 Anti-seizure Cylinder
#1215 gray #5699 Swing motor

Three-bond
#1211 white #5301J Swing motor
#1303B #211 Main pump
Sealing (Manufacturer ; Three-bond)

compound
& #222 #1344N Main pump

adhesive Loctite
#277 #1307N Pilot valve
(Manufacture ; Three-bond)
Loctite Parmatex 98D #1121 Hydraulic oil tank : Hose

Sumitomo Locktite #515
Chemical Cyano Bond P0－1 For swing bearing : Seal
Co., Lad. Three-bond #1215
Showa-Shell Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease
petroleum bath
11-10
8. SUCTION STOPPER
8.1 COMPONENTS
No. NAME Q’TY

SUCTION STOPPER ASSY 1 Rod
1 ROD 1
2 NUT 1
3 COVER 1
4 O RING 1
2 Nut
3 Cover
4 O ring
8.2 DIMENSION
50
(1.97″)
Fig. 8-1 Components of suction stopper
∅113 (4.45″)
2
M8 NUT
∅8(0.315″)
M8 ∅100 +0.5
0
(3.94″+0.0197
0 )
∅108
(4.25″)
ROD COVER
fig. 8-2 Dimension of suction stopper
11-11
9. COUNTERWEIGHT LIFTING JIG

(1) Use two eye bolts M36 or commercial
equivalent for the standard counterweight
lifting gear.
M36
(2) Use two commercial eye bolts M20 for the

lifting gear for the additional weight
(knapsack type).
M20
11-12
10. BOOM FOOT PIN PULLING TOOLS
Fig. 10-1 Slide hammer for boom foot pin
Tools accessories assy

Table 10-1
No. Tool name Sketch Applicable
Rod Boom foot

pin pulling
AA
1
M24
M24
Boom foot
2 Hammer
pin pulling
11-13
11. UPPER FRAME LIFTING JIG
SECTION AA
Q'ty : 2set
Material : POK400(SS41)
Fig. 11-1 Upper frame lifting jig
11-14
12. ENGINE MOUNTING

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

Fig. 12-1 Engine stand
13. TRACK SPRING SET

M30
Retainer nut
Retainer plate
Stand
Hydraulic jack
Base
Fig. 13-1 Track spring set jig
11-15
NOTE
11-16
E115SR
E135SR
SECTION 12 STANDARD MAINTENANCE TIME SCHEDULE
TABLE OF CONTENTS
1. Standard maintenance time schedule for excavator .............................................. 12-1
2. Standard working time table for the maintenance of engine .................................. 12-9
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR

(1) Standard maintenance time schedule (2) Classification of working code
1) Units of working time : 6 minutes=0.1 hour
No. Group Remarks
2) Calculating method of standard maintenance
01 Attachment Indicates installing,
time : 02 Cab & Guard
03 Swing frame removing, replacement
Maintenance time=working time×
04 Travel system and overhaul.
the number of workers
06 Electric Indicates the installing,
(working time=Maintenance time÷ equipments removing and
the number of workers) replacement of single
3) When more than one operation is going on : items.
Add each standard service time. 09 E/G relation Indicates overhaul of the
single engine.
A pure time (readily started) is given except (Materials prepared by
covers easily removed by hand. Assy works manufacturer )
include the following works marked with
black dot •. (3) Conditions for standard service time of the
4)O/H : Basically the installing and removing engine
operations are included. 1) Tools designated by E/G maker are used
5) Abbreviations in the table. 2) Genuine parts are changed
A/C ; Air conditioner F hose ; Flexible hose 3) Correct working procedures are observed.
ASSY ; Assembly O/H ; Over haul • The time required for works specified
ATT ; Attachment SOL ; Solenoid in this Chapter shows the total time
BRG ; Bearing SW ; Switch for maintenance.
C/V ; Control valve V ; Valve
Cyl ; Cylinder
E/G ; Engine
Unit : Hour
Work to be
E135SR
E115SR
Group Location done Unit Remark
00 Bucket relation 2. Reference for bucket

01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.5 ←
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1 ←
03 • Bucket attaching pin Detach/attach 1 Include omission of pin. 0.1 ←
04 • Bucket drive pin Detach/attach 1 0.1 ←
05 • Bucket sling and movement Preparation 1 pc. 0.1 ←
06 Bucket (single) O/H 1 pc. Not include attaching and detaching. 2.0 ←
07 • Tooth Replace 1 pc. 0.5 ←
01 Attachment
08 • Side cutter Replace 1 pc. 1.0 ←

09 • Bushing Replace 1 pc. 0.5 ←
10 Arm relation 3. Reference for arm
11 Arm ASSY Detach/attach 1 pc. 1.0 ←
• Bucket cylinder attaching and detaching
12 position and piping Preparation 1 pc. 0.3 ←
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1 ←
14 • Bucket cylinder head pin Detach/attach 1 pc. Include omission of pin. 0.1 ←
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1 ←
16 • Arm cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1 ←
17 • Boom top pin Detach/attach 1 pc. Include detent of pin. 0.1 ←
18 • Arm sling and movement Detach/attach 1 pc. 0.1 ←
30 Boom relation 4. Reference for boom
31 Boom ASSY Detach/attach 1 pc. 1.0 ←
32 • Boom attaching and detaching position Preparation 1 pc. 0.1 ←
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.2 ←
34 • Boom cylinder rod pin Detach/attach 1 Include omission of two pins. 0.2 ←
12-1
Work to be
E135SR
E115SR
53 Cover (3) Detach/attach 1 pc. 0.1 ←

02 Cab & Guard

60 Counter weight relation 5. Reference for counter weight
61 Counter weight ASSY Detach/attach 1 pc. 0.4 ←
62 • Counter weight lifting jig Detach/attach 1 set 0.1 ←
63 • Counter weight temporary slinging Preparation 1 pc. 0.1 ←
64 • Counter weight mounting bolt Detach/attach 1 pc. 0.1 ←
65 • Counter weight slinging Detach/attach 1 pc. 0.1 ←
00 Control relation
01 E/G control ASSY Detach/attach 1 pc. Include adjustment. 0.2 ←
02 • Emergency stop knob (control) cable Replace 1 pc. 0.1 ←
10 Intake relation 8. Reference for Air cleaner
11 Air cleaner ASSY Detach/attach 1 pc. 0.4 ←
12 • Hose (3) Detach/attach 1 0.1 ←
13 • Hose (2) Detach/attach 1 0.1 ←
14 • Element Replace 1 0.1 ←
20 Exhaust relation 9. Reference for muffler
21 Muffler ASSY Detach/attach 1 pc. 0.4 ←
22 • U bolt Detach/attach 1 pc. 0.1 ←
23 • Clamp ASSY Detach/attach 1 pc. 0.1 ←
24 • Gasket Replace 1 pc. 0.1 ←
30 Radiator relation 13. Reference for Radiator
03 Swing frame
31 Radiator ASSY Detach/attach 1 pc. 3.5 ←

32 • Coolant (LLC) Replace 1 pc. 0.2 ←
33 •• Concentration of coolant Measuring 1 pc. 0.2 ←
34 •A/C condenser Detach/attach 1 pc. 0.2 ←
35 • Stay Detach/attach 1 pc. 0.1 ←
36 • Bracket Detach/attach 1 0.2 ←
37 • Sub tank Detach/attach 1 pc. 0.1 ←
38 • Fan guard Detach/attach 1 pc. 0.2 ←
39 • Water hose (radiator → E/G) Detach/attach 1 0.2 ←
40 • Radiator mounting bolts removing Detach/attach 1 pc. 0.2 ←
41 • Under cover Detach/attach 1 pc. 0.1 ←
42 • Hydraulic oil tank・suction stopper Attach/detach 1 pc. 0.2 ←
43 •Hydraulic oil piping coupling Detach/attach 1 pc. 0.8 ←
44 •Hydraulic oil piping Detach/attach 1 pc. 0.2 ←
45 •Water hose (E/G → radiator) Detach/attach 1 0.2 ←
46 •Radiator lifting or hoisting Detach/attach 1 pc. 0.2 ←
50 Fuel relation 10. Reference for fuel tank
51 Fuel tank ASSY Detach/attach 1 pc 1.5 ←
52 •Fuel Replace 1 pc. 0.2 ←
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. 0.2 ←
Note : The numbers in the parentheses like cover(1)
match the guard numbers on the swing frame
12-3
Work to be
E135SR
E115SR
35 • Boom cylinder piping Detach/attach 2 pc. 0.2 ←

36 • Arm & bucket piping Detach/attach 1 pc. 0.2 ←
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1 ←
38 • Boom foot pin Detach/attach 1 Include omission of pin. 0.2 ←
39 • Boom assy slinging Detach/attach 1 pc. 0.1 ←
01 Attachment
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.3 ←

41 • Arm cylinder piping Detach/attach 1 pc. 0.1 ←
42 • Arm cylinder head pin Detach/attach 1 Include omission of pin. 0.1 ←
43 • Arm cylinder slinging Detach/attach 1 pc. 0.1 ←
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.6 ←
51 • Boom cylinder piping Detach/attach 2 0.2 ←
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.2 ←
53 • Boom cylinder slinging Detach/attach 2 0.2 ←
60 Bucket cylinder O/H 1 3.0 ←
61 • Pin bushing Replace 1 Include seal. 1.0 ←
70 Arm cylinder O/H 1 3.0 ←
71 • Pin bushing Replace 1 set Include seal. 1.0 ←
80 Boom cylinder O/H 2 6.0 ←
81 • Pin bushing Replace 1 set Include seal. 1.0 ←
10 Cab relation 1. Reference for cab
11 Cab ASSY Detach/attach 1 pc. 1.2 ←
1 pc.
12 • Front lower glass, floor mat Detach/attach each 0.1 ←
13 • Rear cover mounting bolts Detach/attach 5 places 0.2 ←
14 • Seat rear cover Detach/attach 1 pc. 0.2 ←
15 • Air-con duct Detach/attach 2 0.2 ←
16 • Coupler for gauge cluster (electric) Detach/attach 1 0.1 ←
17 • Cab slinging Detach/attach 3 places 0.4 ←
20 Guard relation 6. Reference for guard
22 • Cover (1) slinging Detach/attach 1 pc. 0.1 ←
02 Cab & Guard
23 Panel assy (2) Detach/attach 1 pc. 0.1 ←

24 Cover assy (6) Detach/attach 1 pc. 0.1 ←
25 Bonnet assy (5) Detach/attach 1 pc. 0.2 ←
26 • Bonnet assy slinging Detach/attach 1 pc. 0.1 ←
27 Guard (3) Detach/attach 1 pc. 0.1 ←
28 Guard assy (4) Detach/attach 1 pc. 0.1 ←
30 Guard (24) Detach/attach 1 pc. 0.2 ←
32 Guard (18)(19) Detach/attach 1 pc. 0.1 ←
33 Guard assy (26)(85) Detach/attach 1 pc. 0.1 ←
34 Guard assy (17) Detach/attach 1 pc. 0.2 ←
35 Bracket assy (16) Detach/attach 1 pc. 0.2 ←
36 Cover assy (73) Detach/attach 1 pc. 0.1 ←
37 Bracket assy (12) Detach/attach 1 pc 0.2. ←
38 Bracket assy (27) Detach/attach 1 pc . 0.2 ←
50 Cover relation 7. Reference for under cover
12-2
Work to be
E135SR
E115SR
58 • Tank slinging Detach/attach 1 pc. 0.2 ←

Other necessary works Detach/attach 1 pc. Removing and installing guard 0.3 ←
Removing and installing battery 0.2 ←
60 Hydraulic oil tank relation 11. Reference for hydraulic oil tank
61 Hydraulic oil tank ASSY Detach/attach 1 pc. After removing fuel tank ; 3.5 ←
62 • Hydraulic oil tank attaching and detaching position Detach/attach 1 pc. 0.1 ←
63 • Return oil pipe on tank upper cover Detach/attach 1 pc. 0.4 ←
64 • Hose on upper cover Detach/attach 1 pc. 0.2 ←
65 • Cover Detach/attach 1 pc. 0.2 ←
66 • Hydraulic oil Replace 1 pc. 0.4 ←
67 • Other necessary works Detach/attach 1 pc. Multi C/V attaching bracket movement 0.2 ←
Multi pilot hose removing and attaching 0.4 ←
68 • Pilot drain hose Detach/attach 1 pc. 0.2 ←
69 • Pump suction hose Detach/attach 1 0.4 ←
70 • Mounting bolt Detach/attach 1 pc. 0.2 ←
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.2 ←
72 • Return filter Replace 1 0.2 ←
73 • Suction filter Cleaning 1 0.2 ←
80 Pump relation After removing counter weight
81 Pump ASSY Detach/attach 1 pc. 2.3 ←
03 Swing frame
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.3 ←

83 • Strainer & stopper Detach/attach 1 pc. 0.3 ←
84 • Piping Detach/attach 1 set 0.8 ←
85 • Guard Detach/attach 2 pcs 0.4 ←
86 • Pump slinging Detach/attach 1 pc. 0.4 ←
87 • Cleaning Cleaning 1 pc. 0.1 ←
88 • Vent air Adjust 1 pc. 0.1 ←
89 Pump ASSY O/H 1 pc. 3.0 ←
Other necessary works Detach/attach 1 set Counter weight 0.4 ←
90 Swing motor unit relation
91 Swing motor ASSY Detach/attach 1 pc. 2.2 ←
93 • Drain hose clamp Detach/attach 1 0.2 ←
95 • Unit slinging Detach/attach 1 pc. 0.4 ←
96 • Cleaning and sealant Cleaning 1 set 0.2 ←
97 • Swing motor O/H 1 pc. 3.0 ←
98 • Swing reduction gear O/H 1 pc. 3.5 ←
100 Swivel joint relation 19. Reference for swivel joint
101 Swivel joint ASSY Detach/attach 1 2.2 ←
102 • Piping (Top part only) Detach/attach 1 set 0.4 ←
103 • Whirl stop bolt Detach/attach 1 0.2 ←
104 • Cover Detach/attach 1 0.3 ←
105 • Joint & elbow Detach/attach 1 set 0.3 ←
106 • Mounting bolt Detach/attach 1 set 0.3 ←
107 • Swivel joint slinging Detach/attach 1 0.3 ←
108 • Cleaning Cleaning 1 set 0.2 ←
109 Swivel joint O/H 1 set Removing and installing guard 3.0 ←
Other necessary works Detach/attach 1 set Lower piping 0.5 ←
12-4
Work to be
E135SR
E115SR
110 Multi control valve 15. Reference for multi C/V

111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.0 ←
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.2 ←
115 • Cleaning Cleaning 1 set 0.2 ←
Other necessary works Detach/attach 1 set Guard 0.3 ←
120 Main control valve 16. Reference for control valve
121 Main control valve ASSY Detach/attach 1 pc. 1.5 ←
122 • Attach tag to port name of pipe Preparation 1 pc. 0.5 ←
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1 ←
125 • Valve slinging Detach/attach 1 pc. 0.1 ←
126 Main control valve ASSY O/H 1 set 5.0 ←
Other necessary works Detach/attach 1 set Guard 0.3 ←
Detach/attach 1 set Battery 0.2 ←
Detach/attach 1 set Fuel tank ASSY 1.5 ←
Detach/attach 1 set Multi C/V movement 0.5 ←
130 Dozer control valve
03 Swing frame
131 Control V ASSY Detach/attach 1 0.5 ―

132 • Write hose name on Control V connecting hose Detach/attach 1 set 0.1 ―
133 • Piping Detach/attach 1 set 0.1 ―
134 • Mounting bolt Detach/attach 1 set 0.1 ―
135 • Cleaning Cleaning 1 set 0.1 ―
136 Control V ASSY O/H 1 set 1.0 ―
140 Engine (E/G) mounting relation 14. Reference for engine
141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.5 ←
142 • Harness connector & grounding & cable connection Detach/attach 1 pc. 0.2 ←
143 • Fuel hose Detach/attach 1 pc. 0.1 ←
144 • Others Detach/attach 1 set 0.4 ←
146 • Engine slinging Detach/attach 1 set 0.2 ←
148 Engine O/H 1 set Reference for engine
Other necessary works Detach/attach 1 set Removing and installing guard 0.5 ←
Detach/attach 1 set Removing and installing counter weight 0.4 ←
Detach/attach 1 set Removing and installing pump 2.3 ←
Detach/attach 1 set Removing and installing air cleaner 0.4 ←
Detach/attach 1 set Removing and installing muffler 0.4 ←
Detach/attach 1 set Removing and installing radiator 2.5 ←
150 Upper frame 20. Reference for upper frame
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.0 ←
153 • Upper frame slinging Detach/attach 1 pc. 0.3 ←
155 • Sealant Apply 1 pc. 0.2 ←
Other necessary works Detach/attach 1 set Cab 1.5 ←
Detach/attach 1 set Guard 0.3 ←
Detach/attach 1 set Counter weight 0.4 ←
Detach/attach 1 set Boom 1.5 ←
12-5
Work to be
E115SR
E115SR
00 Travel relation 1. Reference for crawler

One
01 Track link ASSY Detach/attach side Include adjustment of tension. 1.0 ←
One
02 • Track link attaching and detaching position Preparation side 0.1 ←
One
03 • Master pin Detach/attach side 0.4 ←
One
04 • Track link extending and winding Detach/attach side 0.4 ←
05 Shoe plate Replace 1 pc. 0.4 ←
10 Upper roller relation 2. Reference for upper roller
11 Upper roller ASSY Detach/attach 1 After removing track link 0.2 ←
12 Upper roller O/H 1 1.0 ←
20 Lower roller relation 3. Reference for lower roller
21 Lower roller ASSY Detach/attach 1 0.2 ←
22 Lower roller O/H 1 1.0 ←
30 Front idler relation 4. Reference for front idler
One
31 Front idler ASSY Detach/attach side After removing track link 0.5 ←
One
32 Front idler ASSY slinging Detach/attach side 0.2 ←
One
33 Front idler ASSY Detaching side 0.2 ←
One
34 Idler ASSY O/H side 1.0 ←
One
35 Idler adjuster ASSY O/H side Replace spring 2.0 ←
One
36 • Grease cylinder O/H side 0.5 ←
04 Travel system
40 Sprocket 5. Reference for sprocket

One
41 Sprocket Replace side After removing track link 0.5 ←
50 Travel motor relation 8. Reference for travel motor
One
51 Travel motor ASSY Detach/attach side After removing track link 1.4 ←
One
52 • Motor cover Detach/attach side 0.1 ←
One
53 • Hydraulic piping Detach/attach side 0.7 ←
One
54 • Motor mounting bolt Detach/attach side 0.4 ←
One
55 • Motor slinging Detach/attach side 0.1 ←
One
56 Motor cleaning Cleaning side 0.1 ←
One
57 Travel motor O/H side 3.0 ←
One
58 Travel reduction gear O/H side 3.0 ←
60 Swivel joint relation
Include bonnet assy removing and
61 Pipe on swivel joint travel side Detach/attach 1 pc. installing. 0.5 ←
62 Swivel joint O/H 1 pc. Refer to Upper structure (Group No.100) ―
6. Refer to 6. Swing bearing removing
70 Swing bearing and installing.
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper flame 0.6 ←
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.4 ←
73 Swing bearing slinging Detach/attach 1 pc. 0.2 ←
80 Dozer relation
81 Dozer ASSY Detach/attach 1 pc. 0.6 ―
82 ● Dozer cylinder piping Detach/attach 1 pc. 0.2 ―
83 ● Dozer cylinder slinging Detach/attach 1 0.2 ―
84 Dozer slinging Detach/attach 1 pc. 0.2 ―
85 Dozer Cylinder O/H 1 2.0 ―
Controller
equipments
C-1 Controller (KPSS) Replace 1 0.2 ←

Electric
C-2 Gauge cluster Replace 1 0.2 ←

C-4 Air conditioner Amplifier Replace 1 0.2 ←
C-5 Power window controller (OPT) Replace 1 0.2 ←
06
C-6 IT controller (OPT) Replace 1 1.0 ←
12-6
E135SR(LC)
Work to be
E115SR
Diode
D-1 Diode Replace 1 0.2 ←
Electric equipments
Include C1 controller removing and
E-1 Fuse box Replace 1 installing. 0.3 ←
E-2 Alternator Replace 1 1.0 ←
E-3 Hour meter Replace 1 0.2 ←
E-5 Horn Replace 1 0.2 ←
E-6 Cigar lighter Replace 1 0.2 ←
E-7 Tuner AM & FM(OPT) Replace 1 0.2 ←
E-7 Tuner AM(OPT) Replace 1 0.2 ←
E-8 Speaker left (OPT) Replace 1 0.2 ←
E-9 Speaker right(OPT) Replace 1 0.2 ←
E-10 Receiver dryer Replace 1 Include gas sealing. 0.3 ←
Include counter weight removing and
E-11 Air compressor Replace 1 installing. 0.5 ←
Light
L-1 Boom work light left Replace 1 Bulb 0.2 ←
L-2 Work light right Replace 1 0.2 ←
Electric equipments
L-3 Room light Replace 1 0.2 ←

L-4 CAB work light Replace 1 0.2 ←
L-5 CAB work light (OPT) Replace 1 0.2 ←
Motor
M-1 Starter motor Replace 1 installing. 1.0 ←
M-2 Governor motor Replace 1 installing. 0.5 ←
M-3 Wiper motor (Non rise up) Replace 1 0.2 ←
M-4 Washer motor Replace 1 ←
06
0.2
M-5 Cable assy (P/W motor OPT) Replace 1 0.5 ←
M-6 Power window lock motor (OPT) Replace 1 0.2 ←
M-7 Power window lock motor (OPT) Replace 1 0.2 ←
M-8 Skylight wiper motor (OPT) Replace 1 0.2 ←
Proportional valve
Include proportional valve removing and
PSV-A Arm re-circulation confulx proportional valve Replace 1 installing. 1.0 ←
PSV-B P2 by-pass cut proportional valve Replace 1 installing. 1.0 ←
PSV-C Travel straight proportional valve Replace 1 installing. 1.0 ←
PSV-D P1 bypass cut proportional valve Replace 1 installing. 1.0 ←
PSV-PI P1 pump proportional valve Replace 1 1.0 ←
PSV-P2 P2 pump proportional valve Replace 1 1.0 ←
Relay
R-1 Battery relay Replace 1 0.2 ←
R-3 Glow relay Replace 1 0.2 ←
R-4 Safety relay Replace 1 Include guard removing and installing 0.4 ←
Include C1 controller removing and
R-5 Wiper motor relay Replace 1 installing 0.3 ←
R-6 Washer motor relay Replace 1 0.3 ←
R-7 Horn relay Replace 1 0.3 ←
R-8 Work light relay Replace 1 0.3 ←
R-28 Auto idle stop relay 1 Replace 1 0.3 ←
R-29 Auto idle stop relay 2 Replace 1 0.3 ←
12-7
Work to be
E135SR
E115SR
Sensor
SE-1 Pressure sensor (low pressure ; bucket digging) Replace 1 0.2 ←
SE-2 Pressure sensor (low pressure ; bucket dump) Replace 1 0.2 ←
SE-3 Pressure sensor (low pressure ; boom up) Replace 1 0.2 ←
SE-4 Pressure sensor (low pressure ; boom down) Replace 1 0.2 ←
SE-5 Pressure sensor (low pressure ; swing) Replace 1 0.2 ←
SE-7 Pressure sensor (low pressure ; arm in) Replace 1 0.2 ←
SE-8 Pressure sensor (low pressure ; arm out) Replace 1 0.2 ←
Include removing and installing guard on
SE-9 Pressure sensor (low pressure ; travel right) Replace 1 cab lower side. 0.4 ←
Include removing and installing guard on
SE-10 Pressure sensor (low pressure ; travel left) Replace 1 cab lower side. 0.4 ←
SE-13 Engine speed sensor Replace 1 Include guard removing and installing. 0.5 ←
SE-14 Engine water temperature sensor Replace 1 0.2 ←
SE-15 Fuel sensor Replace 1 Include guard removing and installing. 0.3 ←
SE-16 Accel potentio Replace 1
06 Electric equipments
0.2 ←
SE-22 P1 pump pressure sensor Replace 1 0.2 ←
SE-23 P2 pump pressure sensor Replace 1 0.2 ←
Solenoid
SV-1 Swing parking SOL Replace 1 installing. 2.0 ←
SV-3 2-speed travel SOL Replace 1 installing. 2.0 ←
SV-4 Lever lock SOL Replace 1 installing. 2.0 ←
Switch
SW-1 Key switch Replace 1 0.2 ←
SW-3 2-speed travel switch Replace 1 0.2 ←
SW-4 Swing parking release switch Replace 1 0.2 ←
SW-5 KPSS release switch Replace 1 0.2 ←
SW-6 Engine water temperature switch Replace 1 0.2 ←
SW-7 Engine oil pressure switch Replace 1 0.2 ←
SW-8 Clogged air filter switch Replace 1 0.1 ←
SW-10 Horn switch Replace 1 0.2 ←
SW-11 Lever lock switch Replace 1 0.3 ←
SW-12 Heater switch (OPT) Replace 1 0.2 ←
SW-13 Air conditioner switch Replace 1 0.2 ←
SW-16 Auto accel release switch Replace 1 0.2 ←
SW-21 Work light switch Replace 1 0.2 ←
12-8
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF

ENGINE
Introduction 2. Special equipments not listed in this table
This standard working time table provides time may be used for operation.
required for maintenance (if the work is carefully
carried out) under the following condition : If such operations are performed, fill out reasons
○Tools designated by us are used. in the Claim Application Sheet in detail and
○Genuine parts are prepared. submit it to us.
○Correct working procedures are observed. (Note 1) Unit of maintenance time
○The engine is mounted correctly to the The maintenance time is given in
machine. 6 minutes=0.1 hour in the decimal system.
1. The working hours given in this table can not (Note 2) Applicable models :
be applied because of special machine BB-4BG1T; E135SR LC EVOLUTION
construction. E115SR EVOLUTION
Work Mainte- Work Mainte-

to be nance to be nance
Location of work done time Location of work done time
Engine body Valve timing mechanism

Detach & Detach &
Flywheel assy attach 0.9 Rocker arm & shaft assy attach 0.6
• Including replacing of ring gear, etc. • Incl. overhauling locker arm
Engine cushion rubber (both sides) Replace 0.4 Tappet Replace 5.4
Replace 0.1 Detach &
Drain plug Tappet chamber cover attach 0.4
Detach &
Engine assy attach 21.6 Valve rocker stand Replace 0.4
Detach &
• Incl. overhaul of engine and cylinder body Timing gear casing cover attach 1.2
Sealing plug Replace 0.2 • Incl. replacement of gear
Replace Detach &
Cylinder block drain cock assy 0.1 Cam shaft attach 11.6
Detach &
Piston & conn rod (2 cycle) attach 11.8 • Incl. replacement of bearing and tappet
Incl. replacing parts (4 cycle) 11.4 Intake, exhaust system
Crank shaft rear oil seal Replace 0.2 Air intake hose Replace 0.3
Detach &
Crank shaft pulley attach 0.8 Manifold fastening bolts Retighten 0.3
Detach &
• Incl. replacement of front oil seal Inlet manifold attach 1.1
Retighten Detach &
Oil pan 0.3 Exhaust manifold attach 0.7
Detach & Detach &
Oil pan attach 0.9 Throttle valve assy attach 0.8
• Incl. overhaul of oil pump • Incl. overhaul of throttle valve
Detach &
Crank casing & oil pan attach 2.5 Intake shutter spring Replace 0.1
Incl. overhaul of oil pump and replacement Detach &
of other parts Intake shutter attach 0.5
Oil pan level gauge guide tube Replace 0.1 • Incl. overhaul of intake shutter
Detach &
Cylinder head Turbo charger assy (If equipped) attach 1.8
Valve clearance Adjust 0.5 • Incl. overhaul of turbo charger
Detach & Detach &
Cylinder head cover attach 0.5 Turbo charger oil pipe (1 pc.) attach 0.1
Detach &
• Incl. retightening cylinder head Turbo charger oil pipe (2 pcs.) attach 0.2
Detach & Detach &
• Cylinder head assy attach 9.6 Inlet pipe assy attach 0.2
Detach &
• Overhaul of cylinder head, replacement of valve guide, etc. Exhaust pipe adapt assy attach
Lubricating system
Detach &
Oil filter element cover attach 0.5
• Incl. replacement of relief valve
Oil filter element (cartridge) Replace 0.2
Detach &
Oil filter assy attach 0.6
12-9
Work Mainte- Work Mainte-

to be nance to be nance
Location of work done time Location of work done time
• Incl. overhaul of oil filter Fuel pipe (Filter → injection) Replace 0.4
Detach &
Oil filter oil pipe attach 0.3 Fuel return pipe Replace 0.4
Detach &
Oil cooler assy (incl. replacement of one hose) attach 0.7 Fuel hose Replace 0.2
Detach &
Oil cooler assy (2 hoses) attach 0.9 Cooling system
Oil cooler water hose Replace 0.1 Fan belt Adjust 0.1
Oil relief valve Replace 0.2 Fan belt Replace 0.1
Detach &
Fuel system Cooling fan attach 0.3
Detach &
Injection time Adjust 0.3 Water pump assy attach 1.2
Detach &
Injection pump assy attach 3.8 • Incl. overthaul of pump
Detach &
• Incl. replacement of governor, feed pump, etc. Water pipe and hose attach 1.0
Injection pump overflow valve Replace 0.3 • Incl. replacement of pipe and packings
Detach &
Injection pump diaphragm Replace 0.3 Thermostat attach 0.6
Detach &
Fuel feed pump assy attach 1.2 • Incl. performance test
Incl. overhaul of pump and replacement of
check valve Electrical equipments of engine
Detach & Detach &
Feed pump strainer attach 0.3 Starter assy attach 0.8
• Incl. cleaning strainer Generator pulley Replace 0.6
Detach & Detach &
Injection pipe (2 pcs.) attach 0.1 Generator assy attach 1.3
Injection pipe (4 pcs.) 0.2 Generator drive belt Replace 0.1
Injection pipe clip Replace 0.1 Voltage regulator Adjust 0.5
Nozzle leakoff pipe Replace 0.3 Voltage regulator Replace 0.1
Primimg pump Replace 0.4 Glow plug (2 pcs.) Replace 0.3
Injection pump Vent air 0.1 Glow plug (4 pcs.) Replace 0.4
Fuel cut solenoid Replace 0.1 Glow plug relay Replace 0.1
Detach &
Nozzle holder assy (1 pc.) attach 0.7 Switch, unit, relay
Detach &
• Incl. replacement of nozzel (2 pcs.) attach 1.2 Ignition & starter switch Replace 0.2
Detach &
• Incl. replacement of nozzel (4 pcs.) attach 1.7 Oil pressure unit Replace 0.1
Fuel filter (cartridge) Replace 0.1 Oil pressure switch Replace 0.1
Detach &
Fuel filter element attach 0.2 Thermo unit Replace 0.2
Detach &
Fuel filter assy attach 0.6 Control resistor Replace 0.2
Detach & Detach &
Fuel filter overflow valve attach 0.4 Auto stop motor assy attach 0.2
Fuel pump (feed pump → filter) Replace 0.4
12-10
E115SR
E135SR
SECTION 13 MAINTENANCE STANDARD

AND TEST PROCEDURE
TABLE OF CONTENTS
1. How to use the maintenance standard and cautions to be exercised .................... 13-1
2. Performance inspection standard table ................................................................. 13-2
3. Measurement of engine speed .............................................................................. 13-6

3.1 Measurement of engine speed ...................................................................................................... 13-6
4. Measurement of hydraulic pressure ..................................................................... 13-7

4.1 Preparing to measure hydraulic pressure ...................................................................................... 13-7
4.2 Place to install pressure gauge ..................................................................................................... 13-7
4.3 Pressure adjustment position ........................................................................................................ 13-8
4.4 Procedure for adjusting relief valve ............................................................................................. 13-10
5. Measuring travel performances .......................................................................... 13-11

5.1 Travel speed ................................................................................................................................ 13-11
5.2 Deviation of travel ........................................................................................................................ 13-11
5.3 Performances of parking brake .................................................................................................... 13-12
5.4 Drain rate of travel motor ............................................................................................................. 13-12
6. Measuring swing performances .......................................................................... 13-13

6.1 Swing speed ................................................................................................................................ 13-13
6.2 Performance of swing brake ........................................................................................................ 13-13
6.3 Performance of swing parking brake ........................................................................................... 13-14
6.4 Drain rate of swing motor ............................................................................................................ 13-14
7. Measuring attachment operating performances ................................................. 13-15

7.1 Operating time of cylinders .......................................................................................................... 13-15
7.2 Oil tighteness of cylinders ........................................................................................................... 13-15
8. Measuring performances of swing bearing ......................................................... 13-16
9. Mechatro controller “A” adjustment ..................................................................... 13-17

9.1 Engine control input / output ........................................................................................................ 13-17
9.2 Engine control installation ........................................................................................................... 13-17
9.3 E/g control equipment ................................................................................................................. 13-18
9.4 “A” Adjustment of mechatro control ............................................................................................. 13-19
1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS
TO BE EXERCISED
(1) Application (3) Cautions to be Exercised at Judgment

1) When the machine is new; 1) Evaluation of measured data;
confirm that the performances are in disagreement of measuring conditions,
accordance with standard specifications as variations of data peculiar to a new machine,
compared to the performance standards. and measuring errors are to be evaluated.
Determine generally at what levels measured
2) At specific self inspection; (rule by country) values are located, instead of determining
use the data for the criterion, for the purpose whether or not values fall within or run out
of correction, adjustment and replacement. of the reference values.
3) When performances are deteriorated; 2) Determining correction, adjustment or

determine whether it is caused by a fault or replacement;
end of service life after long hours of machine performances deteriorate with time
operation, to be used for safety and as parts wear and some deteriorated
economical considerations. performances may be restored to new levels.
Therefore, determine correction, adjustment
4) When main components are replaced; or replacement, depending upon the
for example, use data to restore performances operating hours, kind of work and
of pumps and others. circumstances in which the machine is
placed, and condition the machine
(2) Terminology performances to its most desirable levels.
1) Standard values;
values to be used to condition or assemble a (4) Other Cautions to be exercised
new machine. Where special notes are not 1) Parts liable to degrade;
given, these values represent standard rubber products, such as, hydraulic hoses,
specifications (machine with standard O rings, and oil seals deteriorate with time;
attachments and standard shoes). replace them at regular intervals or at
overhauls.
2) Reference values for remedy;
values at which readjustment is required. In 2) Parts requiring regular replacement;
order to ensure performance and safety it is out of critical hoses that are necessary to
strictly prohibited to use the machine over secure safety, we designate Very Important
the specified values. Parts (V.I.P) and recommend that they
should be replaced regularly.
3) Service limit;
this is the limit value at which reconditioning 3) Inspection and replacement of oils and greases;
is impossible without replacement of parts. If in performing maintenance, it is necessary
the value is expected to exceed the service for the user to familiarize himself with how to
limit before next inspection and correction handle the machine safely, cautions to be
are performed, replace the parts exercised and inspection/lubrication
immediately. The operation over the specified procedures. Refer to the operators manuals
values causes increase of damage and as well.
requires the down time of machine, and also
causes safety problems.
13-1
2. PERFORMANCE INSPECTION STANDARD TABLE

Table 1 (1/2)
Note; the mode is already S mode when power is thrown.
E135SR L E135SR LC Unless otherwise specified, measure it on H mode.
Measuring Position Measuring
Inspection Item Standard
Hi Lo Unit Adjusting
Position Size Port value Point condition
Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 ＋1 －1 Class ― Sampling

condition
50 ＋5 －5 Atmospheric temp.
Hydraulic oil temperature Tank surface (122) (41) (23) ℃ ―
75 50℃～－10℃
Water temperature Radiator surface
＋15 －15 (°
F) ― (122°
F～14° F)
(167) (59) (5)
Lo idle 1000 ＋25 －25 LOW throttle
Selector switch on
Engine speed
FULL throttle
Measuring
Hi idle the gauge cluster 2310 ＋30 －30

(H mode)
screen Adjustment
S mode min－1
Standard
2200 ＋30 －30 Perform all

(Injection pipe) not required
measurement with
diti
FC mode 1700 ＋30 －30

the air-conditioner
Decel 1050 ＋30 －30 “OFF”.
50 ＋5
Pilot primary pressure circuit G pump a3 (700) (＋70)
0 PR1 HI idle
Travel L and R
P1,P2 a1,2 350 Simultaneous
Valve pressure
＋5
& (5000) (＋70)
0 MR1
ATT P1,P2 a1,2 Boom up
Main relief
230 ＋5
Ex. & Doz. P4 a4 (3300) (＋70)
0 MR4,5 Dozer up
210 ＋5
Extra P4 a4 (3000) (＋70)
0 MR5 Extra ope.
210 ＋5
Dozer P4 a4 (3000) (＋70)
0 MR4 Dozer up
H 385 －35 OR3 Boom up
Boom a1 (5500)
0
(－500)
R OR4 Boom down
H 385 －35 OR1 Bucket digging
Bucket a1 (5500)
0
(－500)
R OR2 Bucket dump
Forward kgf/cm2 ―
High pressure circuit
RH a1 ― ― ― (Psi) Simultaneous
Travel
Reverse ― Operation of travel

Main pump
RH and LH
Forward ― (without port relief)
LH a2
Port relief valve pressure
PF1/4 ― ― ―
Reverse ―
LH 285 ＋35 ＋5 OR5 Swing LH
Swing a2 (4100) (＋500) (＋70)
RH OR6 Swing RH
H 385 －35 OR7 Arm in
Arm a2 (5500)
0
(－500)
R OR8 Arm out
H 280 －70 OR9 Dozer down
Dozer a4 (4000)
0
(－1000)
R OR10 Dozer up
H 250 ＋10 OR12 Nibbler close
N&B a2 (3600) (＋150)
0
R OR11 Nibbler open
H 230 －20 OR13 Extra ope.
Extra a4 (3300)
0
(－300)
R OR14 Extra ope.
Extra H OR9,13 Ex. & Doz. ope
230 －20
& a4 (3300)
0
(－300)
Dozer R OR10,14 Ex. & Doz. ope
13-2
E135SR L E135 LC Table 1 (2/2)

Measuring Posision Standard Adjusting Measuring
Inspection Item Hi Lo Unit
Position Screen code value Point condition
Operating
valve
Arm variable 665 ＋5 －5
Service diagnosis screen No.

A 23 lever neutral
recirculation
323 ＋5 －5 FULL
indicated current value
P2 by-pass cut 350 ＋5 －5 NEUTRAL

B 21
Gauge cluster
valve
Multi display
700 ＋5 －5 FULL
350 ＋5 －5 NEUTRAL
Proportional
Travel Adjustment
straight valve C 22 532 ＋5 －5 mA FULL
not required
Drain press By switch
700 ＋5 －5 operation
C－2

D 20
valve 700 ＋5 －5 FULL
P1, P2 pump P1or P2 24or25
742 ＋5 －5 FULL
Inspection item E135SR L Unit E135SR LC

Standard value Standard value
1-speed 34.5～31.1 25.1～22.7
H mode
Sprocket revolution 2-speed 57.9～52.3 44.4～40.2
min－1
(RH,LH) S mode 2-speed 57.2～52.2 42.0～38.0
FC mode 2-speed 44.4～40.0 33.9～30.7
Up 2.5～3.1
Boom
Down 2.6～3.2
In 2.9～3.5
Operating speed
Operating time of Arm

Out 2.2～2.8
cylinder sec ←
Digging 3.2～3.8
(At no load) Bucket
Dumping 1.8～2.4
Dozer Down 3.2～4.1
(OPT.) Up 3.0～3.6
Variable speed ―
Swing speed sec/1 rev ←
STD speed 4.8～5.8
― ―
1-speed ←
Iron 20.1～22.1
Travel speed sec/20m
― ―
2-speed ←
Iron 11.8～13.2
Amount of travel 2-speed
deviation 0～0.25 m / 20m ←
Parking brake drift 1 / 5 Gradient 0 mm / 5min ←
Performance of Newtral position after
Swing brake 180°full speed swing 55～75 degree ←
Performance of
Performance
Swing parking brake 1 / 5 Gradient 0 mm (in) ←

Tip of the bucket tooth 90
ATT amount of Boom cylinder 3 mm/5min
←
drift Arm cylinder 4 (At no load)
Dozer cylinder 3
30～50
Amount of horizontal play at the bucket tooth
(1.18～1.97) mm (in) ←
The port relief valves No.OR1～OR8 on the control section are adjusted to the following operation
numbers in advance. ⑧ ④
①Bucket digging ②Bucket dumping ③Boom up
④Boom down ⑤Swing left ⑥Swing right ⑤ ⑥ ① ②
⑦Arm in ⑧Arm out
⑦ ③
LH RH
CONTROL LEVER
13-3
Table 2 (1/2)
Note; the mode is already S mode when power is thrown.
E115SR Unless otherwise specified, measure it on H mode.
Measuring Position Standard
Inspection Item Hi Lo Unit Adjusting Measuring
Position Size Port value Point condition
Hydraulic oil in Sampling
Cleanliness of hydraulic oil NAS 8 ＋1 －1 Class ―
tank
50 ＋5 －5 Ambient temp.
Hydraulic oil temperature Tank surface (122) (41) (23) ℃ ―
75
50℃～－10℃
Water temperature Radiator surface
＋15 －15 (°
F) ― (122°
F～14° F)
(167) (59) (5)
Lo idle Selector switch on LOW throttle
Engine speed
935 ＋25 －25

the gauge cluster FULL throttle
Hi idle 2320 ＋30 －30
(H mode)
screen or
injection pipe min－ Adjustment
S mode 2050 ＋30 －30
1 not required Perform all
measurement with
FC mode 1800 ＋30 －30 the air-conditioner
“OFF”.
Decel 1050 ＋30 －30
50 ＋5
Pilot primary pressure circuit G pump a3 (710) (＋70)
0 PR1 HI idle
Travel P1,P2 a1,2 L&R simultaneous
330
Valve pressure
＋5
& (5000) (＋70)
0 MR1
ATT P1,P2 a1,2 Boom up
Main relief
210 ＋5
Extra P5 a5 (3000) (＋70)
0 MR5 Dozer up
230 ＋5
Ex.&Dozer P4 a4 (3300) (＋70)
0 MR4 Extra ope.
210 ＋5
Dozer P4 a4 (3000) (＋70)
0 MR4 Dozer up
H 365 －35 OR3 Boom up
Boom a1 (5200)
0
(－500)
R OR4 Boom down
H 365 －35 OR1 Bucket digging
Bucket a1 (5200)
0
(－500)
R OR2 Bucket dump
Forward kgf/cm2 ―
RH PF1/4 a1 ― ― ― (Psi) Simultaneous
High pressure circuit
Travel
Reverse ― Operation of travel

RH and LH
Over load relief valve pressure
Main pump
Forward ― (without over load

LH a2 ― ― ― relief)
Reverse ―
LH 265 ＋35 ＋5 OR5 Swing LH
Swing a2 (3800) (＋500) (＋70)
RH OR6 Swing RH
H 365 －35 OR7 Arm in
Arm a2 (5200)
0
(－500)
R OR8 Arm out
H 280 －70 OR9 Dozer down
Dozer a4 (4000) (－1000)
R OR10 Dozer up
H 250 ＋10 OR12 Nibbler close
N&B a2 (3600) (＋150)
0
R OR11 Nibbler open
H 230 －20 OR13 Extra ope.
Extra a4 (3300)
0
(－300)
R OR14 Extra ope.
Extra H OR9,13 Ex. & Doz. ope.
230 －20
& a4 (3300)
0
(－300)
Dozer R OR10,14 Ex. & Doz. ope.
13-4
E115SR Table 2 (2/2)

Measuring Posision Standard Adjusting Measuring
Inspection Item Hi Lo Unit
Position Screen code value Point condition
Operating
valve
Arm variable 665 ＋5 －5
Service diagnosis screen No.

A 23 lever neutral
recirculation
323 ＋5 －5 FULL
indicated current value

B 21
Gauge cluster
valve
Multi display
700 ＋5 －5 FULL
Proportional
Travel Adjustment
straight valve C 22 532 ＋5 －5 mA FULL
not required
Drain press By switch
700 ＋5 －5 operation
C－2

D 20
valve 700 ＋5 －5 FULL
P1, P2 pump P1or P2 24or25
742 ＋5 －5 FULL
Inspection item E115SR Unit E115SR

Standard value Standard value
1-speed 34.5～31.1 24.4～22.0
H mode
Sprocket revolution 2-speed 57.9～52.3 44.1～39.9
min－1
(RH,LH) S mode 2-speed 52.2～47.2 38.9～35.1
FC mode 2-speed 45.8～41.4 34.0～30.8
Up 2.6～3.2
Boom
Down 2.8～3.4
Operating time of
In 2.6～3.2
Operating speed
cylinder Arm sec ←

Out 2.2～2.8
(At no load)
Digging 3.4～4.0
Bucket
Dumping 2.0～2.6
― ―
Swing speed sec/1 rev ←
STD speed 4.8～5.8
― ―
1-speed ←
Iron 20.1～22.1
Travel speed sec/20m
― ―
2-speed ←
Iron 11.8～13.2
Amount of travel 2-speed 0～0.24 m / 20m
deviation ←
Parking brake drift 1 / 5 Gradient 0 mm / 5min ←
Performance of Neutral position after 45～65 degree
Swing brake 180°full speed swing ←
Performance of
Performance
Swing parking brake 1 / 5 Gradient 0 mm (in) ←

Tip of the bucket tooth 90 ←
ATT amount of Boom cylinder 3 mm/5min
drift Arm cylinder 4 (At no load)
Dozer cylinder 3
30～50 mm (in)
Amount of horizontal play at the bucket tooth ←
(1.18～1.97)
The port relief valves No.OR1～OR8 on the control section are adjusted to the following operation
numbers in advance. ⑧ ④
①Bucket digging ②Bucket dumping ③Boom up
④Boom down ⑤Swing left ⑥Swing right ⑤ ⑥ ① ②
⑦Arm in ⑧Arm out
⑦ ③
LH RH
CONTROL LEVER
13-5
3. MEASUREMENT OF ENGINE SPEED

E/G water temp. gauge Screen select switch
3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine
Start engine to raise the coolant temperature
of engine to 40℃ to 80℃. (104° F to 176°
F)
The E/G coolant temperature gauge is used to
measure. The range in white color shows the
temperature of approx. 40℃ to 100℃ (104° F
to 212°F), so confirm that the measured value
indicates the temperature within the range of
OK 2250RPM
white color.
(2) Actual measurement of engine speed by the

256 hr. have passed
screen select switch
after E/G oil was
1) After the engine starts, raise the engine
speed to high idle, press the screen change Fig. 1 Example of E/G revo. by the screen select SW.
switch once, and the engine rpm is displayed
on multi-display. GAUGE CLUSTER
2) Verify the engine rpm by pressing each work
mode switch.
3) Verify the rpm of deceleration speed.
MULTI
4) Change the screen by pressing the screen
DISPLAY
change switch twice. MODE
SELECT SW.
SCREEN
(3) Engine speed measured value through SELECT SW.
service diagnosis
1) Turn "ON" the starter switch with the buzzer BUZZER
stop switch pressed and start the engine. STOP SW.
2) Pull the safety lock lever to the unlocked
position.
2 No.2
3) Press the screen change switch once, and
E/G SET 2205 No load set rpm
display the No. 2 engine rpm screen.
MEAS 2201 Actual rpm
4) Press the work mode select switch on the
gauge cluster, check engine rpm of each E/G PRS. LIVE LIVE/DEAD indication
working mode. MODE SW H H/S/FC indication
5) Verify the rpm of deceleration speed. Fig. 2 Engine speed measuring service diagnosis
6) Turn the starter key switch to "OFF", and the PICK UP
display disappears.
(4) Measuring with diesel engine speed meter

1) Install diesel engine speed meter pickup on
and of injection pipes on which the pickup SPEED METER
can be easily installed. (See Fig. 3.)
2) Check E/G speed shown in Table 1 in idling
speed.
Fig. 3 Measurement of E/G speed

13-6
4. MEASUREMENT OF HYDRAULIC PRESSURE

4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
70kgf/cm2 (1000psi) pressure gauge .........1 unit
400～500kgf/cm2 (5700～7100psi)
pressure gauge ..................................................3 unit
Pressure measuring equipment and
instrument for analysis ................................... 1 set
A3
(2) Measuring cleanliness of hydraulic oil
After releasing air in the hydraulic oil
tank, open the cover and sample oil in
the hydraulic tank, and measure with
the instrument for analysis. If the
measured value is higher than the
reference value, replace the return
filter or change the hydraulic oil.
a2(a1)
Fig. 4 Gauge port on main pump
a3
4.2 PLACE TO INSTALL PRESSURE GAUGE
Preparation
Start the engine before working, and relieve the
oil pressure of hydraulic system by operating the
switches on gauge cluster. Then stop the engine.
(1) Main circuit

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

Replace pilot gauge plug a3 with plug PF1/4
for pressure measurement, and attach
a2
pressure gauge 70kgf/cm2 (1000psi).
a1
(3) Dozer circuit Fig. 5 (1/2) Location of plugs for pressure
Replace dozer pump gauge plug PF1/4 a4 mesurement
with plug for pressure measurement, and a4
attach pressure gauge 500kgf/cm2 (7100psi).
(4) Extra circuit

Replace extra pump gauge plug PF1/4 a4
DOZER
with plug for pressure measurement, and CONTROL VALVE
attach pressure gauge 500kgf/cm2 (7100psi). PUMP
Fig. 5 (2/2) Location of plug for dozer circuit

pressure mesurement
13-7
4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
MAIN RELIEF VALVE

MR1
BUCKET DUMPING
OVERLOAD RELIEF
OR2
ARM IN OVERLOAD
BOOM UP RELIEF
OVERLOAD RELIEF OR7
OR3
NIBBLER CLOSE
OVERLOAD RELIEF
OR12
Fig. 6-1 View from the top of the machine
NIBBLER OPEN
OVERLOAD RELIEF
OR11
ARM OUT
OVERLOAD RELIEF
OR8
BOOM DOWN
OVERLOAD RELIEF
OR4
BUCKET DIGGING
OVERLOAD RELIEF
OR1
Fig. 6-2 View from the bottom of the machine
13-8
(2) Dozer or Extra control valve

MAIN RELIEF VALVE
OVERLOAD
MR4 or 5
RELIEF
T P OR9 or 13
B1 A1
OVERLOAD
RELIEF
OR10 or 14
Fig. 7 Dozer or Extra control valve
(3) Pilot relief valve

Pilot relief valve PR1 is built in main pump.
PR1 ADJUST SCREW

FOR PILOT RELIEF
a2( a1 )
Fig. 8 Pilot relif valve position
(4) Swing port relief Plug PF 1/4 for

pressure
The swing motor is equipped with plugs for measurement
pressure measurement, but the measurement
is carried out using gauge ports a1 and a2 .
(See Fig. 4.)
SWING RIGHT SWING LEFT

OVER LOAD OVER LOAD
RELIEF VALVE OR6 RELIEF VALVE OR5
Fig. 9 Swing port relief position
13-9
4.4 PROCEDURE FOR ADJUSTING RELIEF

VALVE
(1) Pilot relief valve
Adjust it with adjust screw (611).
: 6mm
Table 3
611
Pressure change
No. of turns of adjust screw kgf/cm2(psi)
1 turn Approx. 21 (300)
Fig. 10 Pilot relief valve
(2) Main relief valve
(Travel section, ATT common section)
Loosen lock nut (7) and adjust it with adjust 7
screw (6).
6
: 19mm
: 4mm
Table 4
Pressure change
No. of turns of adjust screw kgf/cm2(psi) Fig. 11 Main relief valve
(Travel section, ATT common section)
(3) Port relief valve (Boom, bucket, arm sections) 8

Loosen lock nut (8) and adjust it with adjust
screw (7). 7
: 19mm
: 4mm
Table 5
Pressure change
No. of turns of adjust screw kgf/cm2(psi) Fig. 12 Port relief valve
(Boom, bucket, arm sections)
(4) Swing port relief valve

When the adjusted pressure is 10kgf/cm2 71
(142psi) or less, loosen nut (71) and adjust it
with cap (90).
: 41mm
: 22mm
When the pressure adjusted value is over 90
10kgf/cm2 (142psi), replace the relief valve Fig. 13 Swing port relief valve
assy.
(5) Travel surge cut valve

Adjustment is done by manufacturer, so don’t
replace parts other than O ring.
Loosen cap (204) and adjust it with shim
(205). 204
: 10mm 205
Fig. 14 Travel surge cut valve
13-10
5. MEASURING TRAVEL PERFORMANCES

5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
Operating oil temperature ; 45～55℃
45～55℃(113～131° F)
Crawler on the right and left sides are Fig. 15 One side lifted position
tensioned evenly.
(3) Preparation
Install the reflection panel with a magnet to REFLECTION
the travel motor cover. PANEL
Swing the swing frame through 90°as shown
in Fig.15 and make the crawler on one side
take off the ground, using the attachment.
(4) Measurement
Engine revolution ; Hi idle
2-speed travel switch ; 1-speed and 2-speed Fig. 16 Adhering position of reflection panel
Measuring points ; Right and left
Method, example 1 ; Sprocket E115SR
revolution E135SR
Table 6-2 Unit : min－1
Measure revolution with a stroboscope.
Measurement Standard Reference value Service
Method, example 2 ; item value for remedy limit
Measure the revolutions per minute H1 34.5～31.1 26.9～24.3 22.0～
visually.
H2 57.9～52.3 45.2～40.8 36.9～
E115SR EV.
Sprocket S2 52.2～47.2 40.7～36.8 33.3～
revolution E135SR LC Table 6-1 Unit : min－1
Measurement Standard Reference value Service FC2 45.8～41.4 35.7～32.3 29.2～

item value for remedy limit H1 25.1～22.7 19.6～17.7 16.0～
RH H1 34.5～31.1 26.9～24.2 22.0～ H2 44.4～40.2 34.6～31.4 28.3～
& E135SR EV.
LH H2 57.9～52.3 45.0～40.8 36.9～ S2 42.0～38.0 32.8～29.6 26.8～
S2 57.2～52.2 44.6～40.7 36.6～ FC2 33.9～30.7 26.4～23.9 21.6～
FC2 44.4～40.0 34.6～31.2 28.3～
5.2 DEVIATION OF TRAVEL
(1) Purpose
Measure the amount of deviation at 20m
(22yard) travel and confirm the horizontal
balance between the hydraulic pump and the
travel motor of the travel drive system. (Approx. 1ft)
(2) Condition 30～40cm
45～55℃(113～131°
Hydraulic oil temperature ; 45～55°C F) Fig. 17 Travel position
RH and LH crawler are tensioned evenly.
Plain, level and solid ground
Engine revolution ; Hi idle
(3) Preparation
1) Straight course more than 30m (33yard) A
2) Travel position in which the bottom of the 20m (66ft)
bucket is lifted by about 30cm (1ft).
(4) Measurement Fig. 18 Measuring method
1) Measure the max. deviation distance of the
circular arc in the 20m (22yard) length, Unit : m/20m
excluding the preliminary run of 3～5m (10～ Travel deviation Table 7 (in/22yard)
Reference
16ft). Measuring
Standard value value Service limit
position for remedy
2) Operate the both of travel levers at the same
time. A 0.24 (10 ) or less 0.48 (20) 0.72 (30)
13-11
5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a no-load
(1ft)
travel position and on a 1/5 gradient slope. 30cm
(2) Condition
A slope with 1/5 (Approx. 12deg) gradient and 1/5 GRADIENT
(Approx. 12deg)
a stopped condition in a no-load travel
position Fig. 19 Parking brake operating position
(3) Preparation
Place an angle meter on the shoe plate and
confirm that it makes an angle more than
12°.
Hang a perpendicular in parallel with the
guide frame rib on the track frame and put a
mark (matching mark) on the shoe plate. C ANGLE METER
GUIDE FRAME
(4) Measurement Fig. 20 Method of measurement
Five minutes after the engine stops, measure
Unit : mm/5 min
the movement distance of the matching
Parking brake Table 8 (in/5min)
mark.
Measuring Reference value Service
position Standard value for remedy
limit
C 0 1 (0.04) 2 (0.08)
∅22 PIPE
FORWARD (0.866˝ )
90 ∅10
5.4 DRAIN RATE OF TRAVEL MOTOR (3.54˝ ) (0.394˝ )
(1) Purpose 40
(1.57˝ )
To measure the drain rate of the travel motor
and to confirm the performances of the travel RIB˝A˝ 130
STOPPER (5.11˝ )
motor. ˝B˝
(2) Conditions 45～55℃(113～131° F)
Hydraulic oil temperature ; 45～55°C
∅70
Engine revolution ; Hi idle (2.76˝ )
ROTARY DIRECTION
(3) Preparation
Fig. 21 Location of stopper applied to travel sprocket
1) Place a stopper under the RH and LH travel
sprockets.
2) Stop the engine and vent pressure from the
hydraulic circuit.
3) Connect a hose with the drain port of the
travel motor and take drain in a container.
(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.
Fig. 22 Method of measuring
1) Start the engine and relieve pressure at the the drain rate of travel motor
full stroke of the travel lever.
Drain rate of Unit : /30sec
2) Measure the drain rate for 30 seconds of Table 9 (gal/30sec)
travel motor
relieving.
Take three measurements in the forward position Standard value for remedy limit
motion on each side at one time and make the
Drain rate 5 (1.3) 13 (3.4) 15 (4.0)
13-12
6. MEASURING SWING PERFORMANCES

6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature ;4 45～55℃(113～131° F) Fig. 23 Swing speed measuring position
Plain, level, and solid ground (at the max. reach)
Engine ;Hi idle
(3) Preparation
Bucket unloaded, arm cylinder min.
retraction (Max. reach), arm cylinder min.
extension (Min. reach)
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make two turns after one turn of
preliminary run and calculate the time
required for one turn. Fig. 24 Swing speed measuring position
(at the min. reach)
6.2 PERFORMANCE OF SWING BRAKE
Swing speed Table 10 Unit : sec / rev
(1) Purpose
Confirm the braking torque performances by position
Standard value
for remedy limit
the swing relief valve.
E135SR 4.8～5.8 6.1～7.4 8.0～
(2) Conditions
45～55℃(113～131°
Hydraulic oil temperature ;45～55°C F) E115SR 4.8～5.8 6.1～7.4 8.0～
Engine ;Hi idle
(3) Preparation
1) A height of 1.5m (5ft) at which the bottom of
the bucket matches the tip of the tooth on
condition that the bucket is empty, the arm
1.5m (5ft)
cylinder is most retracted and the bucket is
used for digging.
2) Put a mark (matching mark) on the outer Fig. 25 Swing brake performance measuring position
circumference of the swing bearing of the Measuring the length of the arc over the
upper frame side and of the track frame side. outer circumference of swing race
Erect two poles (flags ) at the front and back Matching marks
of the extended line of the matching mark. on swing race B
(4) Measurement
1) When operating in regular swing speed, by
shifting lever to neutral position at pole
position the swing operation stops.
2) Calculate the swing drift angle by the
following equation, after the upper swing
Matching marks on track frame
body stops, using the amount of deflection
(m) of the matching marks on the swing race
and the length (m) of the circumference of the Fig. 26 Measuring position of swing brake performances
swing race : Swing brake
performance Table 11 Unit : degree
Amount of deflection of Measuring Reference value Service
Swing drift matching marks [m (ft-in)] Standard value
position for remedy limit
angle (°)= ×360°
Circumferential length of E135SR 75°or less 85° 95°
swing race [m (ft-in)]
E115SR 65°or less 75° 85°
13-13
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 with 1/5 (Approx. 12deg.) gradient 1/5
Stop the machine at right angles with the
slope at the height of 1.5m (5ft) at which the YN-B74
bottom of the bucket matches the tip of the Fig. 27 Swing parking brake
performance measuring position
tooth on condition that the bucket is empty,
the arm cylinder is most retracted and the
Measuring the length of the arc over the
bucket is operated for digging. outer circumference of swing race
(3) Preparation Matching marks
Put the angle meter on the shoe plate and on swing race C
make sure that the angle is more than 12°.
Put a matching mark over the outer
circumference of the swing bearing on the
upper frame side and on the track frame side.
(4) Measurement
When five minutes has passed after the Matching marks on track frame
engine stops, measure the length of the Fig. 28 Measuring position
movement of the matching marks. of swing brake performances
6.4 DRAIN RATE OF SWING MOTOR

Performance of swing Unit : mm/5 min
(1) Purpose parking brake Table 12 (in/5min)
Measure the drain rate of the swing motor Measuring Reference value
position Standard value Service limit
and confirm the performances of the swing for remedy
motor. C 0 1 (0.04) 2 (0.08)

(2) Conditions
Hydraulic oil temperature;45～55° C
45～55℃(113～131° F)
Engine revolution ;Hi idle
(3) Preparation
1) Stop the engine.
2) Vent pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from
its end returning to the hydraulic oil tank
and take oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock
1) Start the engine and put the side faces
against the inside of the right or left shoe
plates.
2) Relieve the swing motor at full stroke of the YN-B74
swing motion. Fig. 29

3) Receive in a container the amount of drain
accumulated in 30 seconds of relieving. Drain rate of Unit : /30sec
swing motor Table 13 (gal/30sec)
Measuring Reference value
item Standard value for remedy Service limit
Drain rate 5.0 (1.3) 8.0 (2.1) 11 (2.9)
13-14
7. MEASURING ATTACHMENT OPERATING PERFORMANCES

7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm
② ①
and bucket and confirm the performances
(1ft)
between the hydraulic pump and the cylinder 30cm
of the attachment drive system. Fig. 30 Measuring position for bucket digging
(2) Condition and dump
45～55℃(113～131°
Hydraulic oil temperature ;45～55°C F)
Engine ;Hi idle
Operating time excluding the cushion stroke
(3) Preparation
Plain ground with the bucket empty ③
(4) Measurement 1 ; Boom up and down ④
With the boom operating lever at full stroke,
measure the required operating time of the Fig. 31 Measuring position for boom up
and down motions
bucket between the ground surface and its
highest position. ⑧
When lowering the boom, allow the

bucket onto a soft ground or cushioning ⑦
(1ft)
such as rubber tires ; never put the 30cm ※⑩
bucket against concrete or other solid ※⑨
material. Fig. 32 Measuring position for arm in
and out motions
Measurement 2 ; Arm in and out, bucket Cylinder Operating time Table 14 Unit : sec
digging and dump Measuring Reference Value Service
Standard value
In a position in which the tooth of the bucket position for remedy limit
rises to a level of about 30cm (1ft) above ① 3.4～4.0 4.4～5.1 5.6～
② 2.0～2.6 2.7～3.3 3.5～
ground, measure the full stroke operating
E135SR
③ 2.7～3.3 3.5～4.2 4.5～

time required with the arm and bucket ④ 2.8～3.4 3.6～4.3 4.7～
operating levers at full stroke. ⑦ 3.1～3.7 4.0～4.7 5.1～
⑧ 2.4～3.0 3.1～3.8 4.1～
⑨ 3.2～4.1 4.2～5.4 5.6～
7.2 OIL TIGHTNESS OF CYLINDERS ⑩ 3.0～3.6 3.8～4.6 5.0～
(1) Purpose ① 3.4～4.0 4.4～5.1 5.6～
② 2.0～2.6 2.7～3.3 3.5～
Confirm that the cylinder oil tight by
E115SR
③ 2.6～3.2 3.3～4.1 4.4～

checking the moving length of the cylinder ④ 2.8～3.4 3.6～4.4 4.7～
rods. ⑦ 2.6～3.2 3.3～4.1 4.4～
⑧ 2.2～2.8 2.9～3.6 3.8～
(2) Condition
⑨ 3.2～4.1 4.2～5.4 5.6～
Hydraulic oil temperature ;45～55°C
45～55℃(113～131° F) ⑩ 3.0～3.6 3.8～4.6 5.0～
B
Immediately after cylinders are replaced,
bleed off air from the cylinders, before C
checking for oil tightness. A
The arm cylinder has moved 30mm (1.2in)
from the stroke end. (Off the cushioning CONDITIONS D
range) 1.5m(5ft)
(3) Preparation Fig. 33
Keep the tip of the bucket at 1.5m (5ft)
height, with the bucket empty and the arm Oil tightness of Unit : mm/5min
cylinder Table 15 (in/5min)
cylinder is most retracted. [Provided the arm
Measuring Reference Value
cylinder is extended by 30mm (1.2in).] position Standard value for remedy Service limit
(4) Measurement A 3 (0.12) 6 (0.24) 9 (0.35)
Measure the items five minutes after the B 4 (0.16) 7 (0.28) 10 (0.39)
engine is turned off. C 3 (0.12) 6 (0.24) 9 (0.35)
D 90 (3.5) 150 (5.9) 180 (7.1)
Dozer 5 (0.20) 8 (0.31) 10 (0.39)
13-15
8. MEASURING PERFORMANCES OF SWING BEARING
LOCATION OF BEARING
(1) Purpose
MOUNTING CAPSCREWS
Measure the gap between the lower frame
and the bottom face of the swing bearing and
SWING BEARING
estimate the degree of wear of the swing
A
bearing.
DIAL INDICATOR
(2) Condition
Plain, level and solid ground LOWER FRAME
The swing bearing mounting bolts are not
loosened. Fig. 34 How to measure the axial play
The swing bearing is lubricated well, not of swing bearing
making abnormal sound during turning.
(3) Preparation
1) Install a dial indicator to the magnetic base 90～110°
and fix it to the lower frame.
2) Direct the upper swing body and the lower (1ft)
frame toward the travel direction, bring the 30cm
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing Fig. 35 Measuring position Ⅰ
body side and set the reading at zero.
(4) Measurement 1 (Measuring positionⅠand Ⅱ)

1) Measure the travel of the outer race in the
axial direction in positionⅠ[The arm at
90°～110°and the crawler front lifted about
30cm (1ft)] and in position Ⅱ, using a dial 1.5m (5ft)
indicator.
Fig. 36 Measuring position Ⅱ
Axial play of
swing bearing Table 16 Unit : mm (in)
Measuring Reference value
position Standard value for remedy Service limit
0.5～1.5 1.9～2.9 3.0～

A (0.02～0.06) (0.07～0.11) (0.12～)
(5) Measurement 2 (Measuring position Ⅲ)

1) With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the
bucket about 10mm (0.4in) and swing the tip
of the bucket to the right and the left by man (0.4in)
10mm
power.
But in this case, the gap of the attachment is
included. Fig. 37 Measuring position Ⅲ
Right and left
movement of
the tip of bucket Table 17 Unit : mm (in)
Measuring Standard Reference value
position value for remedy Service limit
Bucket
tiptoe 50 (1.97) 100 (3.94) 120～(4.72～)
13-16
9. MECHATRO CONTROLLER“A”ADJUSTMENT
9.1 ENGINE CONTROL INPUT/OUTPUT
C-1 MECHATRO CONTROLLER
GAUGE CLUSTER
MULTI DISPLAY
MODE SELECT SW.
GOVERNOR
MOTOR
ENGINE
SCREEN
SELECT SW.
BUZZER PUMP
STOP SW. ACCEL DIAL STARTER SW.
Fig. 38 E/G SPEED SENSOR
9.2 ENGINE CONTROL INSTALLATION
E/G
EMERGENCY STOP KNOB
OPERATOR SEAT
TIGHTENING TORQUE
4.0±0.4 kgfym
(29±2.9 lbfyft)
Apply Loctite ♯262
or equivalent. TIGHTENING TORQUE 1.1±0.1 kgfym(8.0±0.72 lbfyft)
Fasten it with the Apply Loctite ♯262 or equivalent.
TIGHTENING TORQUE
mounting plate for the 2.0±0.2 kgfym
engine lifting hook (14±1.4 lbfyft)
Apply Loctite ♯242
GOVERNOR LEVER or equivalent.
TIGHTENING TORQUE A GOVERNOR MOTOR

1.0±0.1 kgfym
(7.2±0.72 lbfyft)
E/G A TIGHTENING
EMERGENCY TORQUE
STOP CABLE 6.6±0.7 kgfym
(48±5.1 lbfyft)
Apply Loctite
♯242 or equivalent.
SECTION AA
(ADJUST BOLT)
Fasten it with harness
against the frame clip.
VIEWⅠ
Fig. 39
13-17
9.3 E/G CONTROL EQUIPMENT REDUCTION GEAR SECTION

(1) Governor motor and C－1 controller OIL SEAL
MOTOR SECTION
1) By operating accel dial, the input voltage OUTPUT SHAFT
change is sensed by CN11－32 pins of C－1
controller.
2) The C－1 controller computes the input
voltage, and outputs command to governor CAM
motor (M－2), and incline governor lever of
LIMIT
engine to the swing angle corresponding to SWITCH
accel dial set value.
3) The limit switch in governor motor is set to a
angle from motor rotation OFF to ON
position (Starting point).
Fig. 40
(2) Rotation sensor
1) Installing place Opposing flat 19 SIGNAL(Yellow)
M16×1.5 Opposing flat 17
Engine flywheel housing
2) Sensor attaching procedure

① Apply Loctite #262 on pick-up thread section. GND(Black)
② Tighten thread by hand until it contacts Fig. 41
flywheel ring gear, and turn it back one and
half turns.
③ Then tighten the nut to specified torque
2.5～3.5kgym (18～25 lbfyft).
④ After installation, check that the Engine
speed meter measured value corresponds to
the engine speed in service diagnostics while
operating engine.
⑤ Output voltage at 2,310rpm 20V(AC) or more
at 1,000rpm 40V(AC) or less
GAUGE CLUSTER
(3) Work mode selector switch
If the work mode switch [MODE] is pressed,
a signal is transmitted to the C－1 controller.
SCREEN
The controller changes the work modes in the SELECTSW.
order of S→H→FC each time the work mode
switch is pressed. A selected mode is
BUZZER STOP SW.
indicated at the uppermost part of the gage
cluster. MODE SELECT SW.
(4) Buzzer stop switch Fig. 42

When the error is detected by self-diagnosis,
the C－1 controller sends alarm by sounding
buzzer. And press buzzer stop switch to stop
buzzer sounding. Also, when engine coolant
temperature has risen or the engine oil
pressure has lowered, buzzer sounds. But in
this case the buzzer sounding does not stop.
13-18
9.6 “A”
A”ADJUTMENT OF MECHATRO CONTROL
(1) When adjustment of mechatro control is
required; GROMMET
Case “A”adjustment
Replace mechatronic controller. ○
Replace governor motor. ○
CPU ROM DATA FAILURE
on display. ○
CPU ROM DATA FAILURE and C－1 MECHATRO CONTROLLER
CPU MECHATRO SET ERROR ○
are shown by turns. Fig. 43
(2) Preparation
1) Warm up engine.
2) Turn A/C switch OFF.
3) Turn starter switch OFF to stop engine.
4) Pull up the safety lock lever and pull up the
left control box upwards.
MULTI DISPLAY
5) Pull operator seat forward fully and incline
seat back forward.
6) Remove resin cover on the rear side, then
mechatro controller appears. (Remove 5
SCREEN SELECT
atta-ching bolts from resin cover with driver SWITCH
◯,＋).
Note : Check to be sure that the engine
emergency stop lever knob is fully
pressed down. If mechatro controller is
adjusted in the condition where the knob Fig. 44
is pulled out, the engine speed can not be
set properly.
Table 18 (1/2)
(3) Adjustment Procedure Multi display Movement of governor motor
① Remove grommet on upper surface of
FULL
mechatro controller, and switch internal STOP
adjustment JP switch from RUN to
TEST .
LEVER
In normal
RUN position LEVER
During GOVERNOR
TEST adjustment
MOTOR
A (Hi)
② Turn starter switch ON . as accel position
(Lo) A
Turn the accel dial to a certain position.
MONITOR
SYSTEM OK
Stop at the position set by accel dial.

13-19
Table 18 (2/2)
Procedure Multi display on Movement of governor motor
gauge cluster
③ Keep the buzzer stop switch pressed and
when it is let free after 5 to 10 seconds, STEP 1 A
S
STEP 1 is displayed on the multi display.
CPU START
Then let your hand free and wait till the
display changes to STEP 2.
STEP 2 Self-traveled to the engine stop

position (S).
④ After confirming the STEP 2 display,
S
move to the engine room and adjust the STEP 2
rod assy to its standard length CPU GAP (STOP)
135mm(5.31in) so the clearance between
the governor lever and the engine stop set
bolt becomes“A0.1mm”(0.004in).
Then if the governor motor is replaced, Stop at the position
insert the rod assy after the STEP 2 〔Tools〕
● Spanner 13mm×2pcs
indication.
● Spanner 6mm
● Thickness gauge
⑤ Press the buzzer stop switch once, and wait

until the STEP 3 indication is provided. S A
STEP 3
CPU START E/G
Automatically run to the engine

available position(A).
⑥ When STEP 3 comes up, start the engine. A
On that occasion, the accel dial may be in STEP 3
any position.
CPU START E/G
Stop at the A position

⑦ If the buzzer stop switch is pressed onc time,
STEP 4 comes up. The controller reads Lo A Hi
STEP 4
revolution from the A position of governor
CPU MEMORY
motor to LOW IDLE and then to HI IDLE.
(The required time is approx 3 minutes.)
Move from A position to Lo

idling position, and self-travels
from Lo position to high idling
(Hi) position.
⑧ Wait till the indication on the multi Hi
display changes to "FINISH" after reading FINISH
is completed.
CPU 2310 rpm.
When the indication on the display
changes, the engine revolution returns
automatically to an initial position of the
(Approx. A Hi
accel dial.
Note: If "FINISH" is not indicated, it means 5 seconds)
that the adjustment has failed. Then turn
OFF the starter switch and readjust it.
13-20
(4) After completion of adjustment

1) Turn starter switch OFF to stop engine.
2) Return the inner adjust switch to RUN from TEST, attach the grommet, push the screen select
switch on the gauge cluster one time, and get an engine rpm indication.
3) The auto accel release switch located on the right-hand console is a seesaw hold type switch. If it is
pressed on the rear side(bland side) of the machine, the auto accel is released, and the engine is
brough to HIGH IDLE after started up.
4) Make sure that if the work mode on the switch panel is changed, the mode display on the gauge
cluster changes and the engine rpm on the multi display changes.
5) Set accel dial to low idling position, and changes connector after engine stops, and starts engine
after switching to auto accel.
6) Set accel dial to high idling, and check engine speed when running in auto accel position.
7) Get "MONITOR SYSTEM OK" by pushing the screen select switch on the gauge cluster two times.
8) Attach resin cover as it was, and slide operator seat backward to move the seatback backward.
Then, check connector of speaker for disconnection.
9) Turn the left control box forward, bring down the safety lock lever, and start the engine again. Then
make sure that the actual engine revolution under the service diagnosis No.2 matches the measured
value on the diesel revolution meter. This completes the operation.
AUTO ACCEL
RELEASE SW.
Fig. 45 Exchange the auto accel release SW.
13-21
NOTE
13-22
E115SR
E135SR
SECTION 21 MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
1. Summary of mechatro control system ................................................................... 21-1

1.1 Mechatro control system in general ............................................................................................... 21-1
1.2 Boom raise conflux ........................................................................................................................ 21-2
1.3 Swing cut valve control .................................................................................................................. 21-2
1.4 Arm in recirculation and sequence conflux .................................................................................... 21-3
1.5 Arm in anti-cavitation control ......................................................................................................... 21-4
1.6 Arm out conflux ............................................................................................................................. 21-4
1.7 Travel straight ................................................................................................................................ 21-5
1.8 Swing priority control ..................................................................................................................... 21-6
1.9 Pressure draining (releasing) control ............................................................................................. 21-7
1.10 Pump control (positive control and P-Q control) .......................................................................... 21-8
1.11 Standby flow constant control ...................................................................................................... 21-9
1.12 FC mode control ........................................................................................................................ 21-10
1.13 Relief cutoff control .................................................................................................................... 21-11
2. Mechatro controller .............................................................................................. 21-13

2.1 Summary of mechatro controller ................................................................................................. 21-13
2.2 Self diagnosis display function .................................................................................................... 21-13
2.3 Service diagnosis ........................................................................................................................ 21-15
2.4 Trouble history diagnosis ............................................................................................................. 21-13
2.5 How to correct the E/G oil supply cumulative time ........................................................................ 21-13
2.6 Engine starting frequency display function .................................................................................... 21-17
2.7 Mechatro control equipment .......................................................................................................... 21-19
1. SUMMARY OF MECHATRO CONTROL SYSTEM
1.1 MECHATRO CONTROL SYSTEM IN GENERAL
System summary Furtures Purpose

P1, P2 pump is P1 pump is controlled by A) The power curve shall be an
1
controlled by proportional valve. ideal curve.
proportional valve.
P2 pump is controlled by B) Supply an optimum flow for
2
proportional valve. each operation.
Part of the control The travel straight valve is

3 z Make the changeover soft.
valve is controlled controlled by proportional valve.
by the proportional
The bypass cut valve is controlled
valve. 4 z Make the changeover soft.
by proportional valve.
The main spool is
The arm variable recirculation z Control the arm speed as
■ : GOVERNOR MOTOR controlled 5 valve is controlled by proportional
valve. you desire.
hydraulically.
□ : ENGINE SPEED SENSOR The swing action is controlled by
6 P2 bypass cut z Make the controllability soft.
: HIGH PRESSURE SENSOR valve(=proportional valve.)
The open and close actions of the
◎ : LOW PRESSURE SENSOR 7 swing P/B are controlled by
solenoid valve.
◇ : ACCEL DIAL POTENTIOMETER
21-1
1.2 BOOM RAISE CONFLUX 1.3 SWING CUT VALVE CONTROL
(1) Boom raise conflux (1) Swing cut valve control

1) Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom 1) Start swing operation, and the swing pilot secondary pressure switches swing spool, and is input into
conflux spool, and inputs into low pressure sensor. low pressure sensor.
2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes 2) The output voltage of the low pressure sensor is put into the mechatro controller which processes the
the pilot signal and outputs the command corresponding to input voltage to P1,P2 pump and P2 bypass pilot signal. A command value is then put out to the P2 bypass cut proportional valve.
cut valve. 3) The P2 pump and the P2 bypass cut proportional valve put out secondary pilot pressure according to a
3) Each proportional valve puts out the secondary pressure for the pilot proportional valve according to command value of the mechatro controller.
command values from the mechatro controller, changes the delivery rates of the P1, P2 pump and This changes the delivery rate of the P2 pump and switches the P2 bypass cut valve.
switches the P2 bypass cut valve. 4) The pure hydraulic command switches the swing main spool. Then a mechatro command switches the
4) A pure hydraulic command switches the boom main spool and the boom conflux valve. A mechatro P2 pump and the P2 bypass cut valve.
command switches the P1, P2 pumps and the P2 bypass cut valve. This causes the oil discharged by If the amount of change is controlled, the swing motion is controlled softly.
the P1 pump to combine with that by the P2 pump at boom raise operation.
21-2
1.4 ARM IN RECIRCULATION & SEQUENCE CONFLUX (1) Recirculation cut control
2
1) If load increases and the load pressure of the pump rises above 160kgf/cm (2280psi) during arm in
operation, the output voltage of the high pressure sensor (SE-23) is put into the mechatro controller.
The mechatro controller processes pilot signals and puts out a command current that cuts off the
variable recirculation, to the variable recirculation proportional valve.
2) The variable recirculation proportional valve puts out secondary pilot pressure according a command
current of the mechatro controller, brings back the variable recirculation valve to the recirculation cut
position and blocks the recirculation passage.
(2) Sequence conflux control
2
1) If load increases and the load pressure rises above 220kgf/cm (3130psi) during arm in operation, the
mechatro controller processes a pilot signal and puts out a command current to the travel straight
proportional valve and the P1 bypass cut proportional valve according to the secondary operating pilot
pressure.
2) The travel straight proportional valve and the P1 bypass cut proportional valve put out the secondary
pilot pressure according to a command current of the mechatro controller and switches the travel straight
valve and the P1 bypass cut valve.
3) When the travel straight valve is changed over, the parallel passage on the P1 side connects with the
parallel passage on the P2 side.
When the P1 bypass cut valve and the P2 bypass cut valve are changed over, the oil discharged by the
P1 pump is combined with that by the P2 pump by arm operation.
Note: If sequence conflux control operates during slope finishing work, the oil is combined in the parallel
passage. The operability is deteriorated as the oil for the bucket operation is combined together. If a
signal is put into the low pressure sensor on the bucket dump side, the sequence conflux control does
not operate.
(3) Recirculation control
1) Start arm in operation simultaneously, and arm operation pilot secondary pressure switches arm spool,
and is input into low pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro
controller processes the pilot signal and puts out a command current according to the input voltage to
the P2 pump proportional valve, the P2 bypass cut proportional valve and the variable recirculation
proportional valve.
3) Each proportional valve puts out secondary pilot pressure according to a command current from the
mechatro controller and switches the discharge rate of the P2 pump. At the same time it switches the P2
bypass cut valve and the variable recirculation valve of the control valve.
4) The pure hydraulic command switches the arm main spool. Then a command from the mechatro
controller switches the P2 pump, the P2 bypass cut valve and the variable recirculation valve. This
causes the returned oil of the arm cylinder rod side to be recirculated to the oil discharged by the P2
pump.
21-3
1.5 ARM IN ANTI- CAVITATION CONTROL 1.6 ARM OUT CONFLUX
(1) Arm in anti- cavitation control

1) If the arm in is performed, the secondary pilot pressure for arm operation switches the arm spool and is (1) Arm out conflux
put into the low pressure sensor. 1) Start arm out operation simultaneously, and arm operation pilot pressure switches arm spool, arm conflux
2) An engine speed command put out from the acceleration potentiometer is put into he mechatro spool and is input into low pressure sensor.
controller. 2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller
3) The output voltage from the low pressure sensor is put into the mechatro controller, and processes the processes pilot signals and puts out command current according to the input voltage to the P1, P2 pump
pilot signal and puts out a command current according to the input voltage to the P2 pump proportional proportional valves and the P1 cut proportional valve.
valve and the P2 bypass cut proportional valve. 3) Each proportional valve puts out a secondary pilot pressure according to a command current from the
4) Also, the mechatro controller puts out a command current to the variable recirculation proportional valve mechatro controller, changes the discharge rate of the P1 and P2 pumps and switches the P1 bypass cut
according to the input voltage from the accel potentiometer. valve of the control valve.
5) Each proportional valve puts out a secondary pilot pressure according to a command current from the 4) A pure hydraulic command switches the arm main spool. A mechatro command switches the P1, P2
mechatro controller. This controls the variable recirculation valve to provide a spool stroke according to pumps and the P1 bypass cut valve. This causes the oil discharged by the P1 pump to combine with the
the engine speed and changes the recirculation ratio. This holds down cavitation when the engine speed oil discharged by the P2 pump during arm operation.
is low and the discharge rate of the pumps is low.
21-4
1.7 TRAVEL STRAIGHT TRAVEL STRAIGHT
1) Start ATTs work operations (boom, arm, bucket, swing) in travel operation (right and left), and the pilot
pressure switches respective spools, and is input into respective low pressure sensors.
Note: Boom raise operation is explained here.
2) If mechatro controller receives the input satisfying the following combination shown in Table, the
controller determines it as travel straight, and the travel straight signal turns on.
3) After the travel straight signal has turned on, the signal is input to respective proportional valve
corresponding to the following commands.
Travel straight proportional valve command

Outputs switching command corresponding to boom raise pilot pressure
(ATT pilot pressure in high priority in operation)
P1 bypass cut valve command
The P1 bypass cut valve does not operate if the boom raise operation is performed. During the arm and
swing operation, the higher of the remote control pressures is selected to put out a select pressure.
P2 bypass cut valve command
Outputs switching command corresponding to boom raise pilot pressure (Selection of the higher ATT pilot
pressures from C/V on P1 side during operation) and the pressure selected by travel right pilot pressure
as high priority.
(Reference) Operating condition where travel straight signal turns on
Boom Bucket Arm Swing

In travel right operation(P1) ○ ○ ― ―
In travel left operation(P2) ― ― ○ ○
21-5
1.8 SWING PRIORITY CONTROL (1) Swing priority control at Arm in (The forced recirculation position)
1) If swing operation is performed during arm in (or arm in is performed during swing), the secondary pilot
pressure for arm operation switches arm spool and swing spool. Respective pressure is simultaneously
put into each low-pressure sensor (SE-7, SE-5).
2) The output voltage of the low pressure sensor is put into the mechatro controller.
The mechatro controller processes pilot signals. The command currents according to the input voltage
are put out to the ,P1 pump proportional valve(PSV-P1), P2 pump proportional valve (PSV-P2), travel
straight proportional valve (PSV-C), P1 bypass cut proportional valve (PSV-D), P2 bypass cut
proportional valve (PSV-B) and the arm variable recirculation valve (PSV-A).
3) Each proportional valve puts out a secondary pilot pressure according to a command current from the
mechatro controller and switches the delivery rate of the P1&P2 pumps. At the same time, the pressure
moves the P1&P2 bypass cut spool to full stroke position, and switches the arm variable recirculation
valve to the forced recirculation position.
4) If arm in and swing operations are performed simultaneously, the secondary pilot pressure moves sub-
spool of arm spool and consequently passage in arm cylinder head is restricted. The arm variable
recirculation spool is shifted to forced recirculation position, the return oil from rod side is recirculated at
head side while restricton. The operation pressure of arm cylinder is risen by restriction of arm cylinder
circuit.
5) Delivery oil of P2 pump flows into swing and arm sections of P2 side, but it flows preferentially into swing
side because the operation pressure of arm cylinder is higher than swing side pressure.
6) On the other hand, as travel straight spool is shifted to travel straight position and P1 bypass cut spool is
switched, delivery oil of P1 pump flows into parallel circuit of P2 side and confluxes with swing circuit, and
swing priority is available.
7) By this operation the operating pressure of arm cylinder is risen, delivery oil of P2 pump preferentially
flows into swing side which pressure is lower than arm.
Arm working speed keeps minimum loss because recirculation oil is used to arm cylinder, and as P1
pump delivery oil confluxes with swing circuit, swing priority control is more available.
8) If arm in and swing operation are performed, energized signal from mechatro controller to swing parking
brake solenoid valve (SV-1) is cut, and swing parking brake is released.
21-6
1.9 PRESSURE DRAINING (RELEASING) CONTROL (1) Pressure draining (releasing) control
1) If display select switch and buzzer stop switch of gauge cluster are kept pressed for more than five
seconds, the mechatro controller judges it as Pressure Releasing Control.
2) If the mechatro controller judges it pressure releasing control, the mechatro controller performs the
following regardless of input signals (From operation pilot valve, accel potentiometer, etc.):
a. Puts out a minimum tilting angle command to the pump proportional valve.
b. Puts out a command current for pressure releasing control revolution to the governor motor.
c. Puts out a command current for the pressure position switch to the travel straight proportional valve.
d. Puts out a standby command current to the P1 bypass cut valve and the P2 bypass cut proportional
valve.
3) A command current from the mechatro controller causes the following to occur:
a. The pump proportional valve puts out a secondary pilot pressure to the pump to minimize the tilting
angle of the pump.
b. The governor motor controls the engine revolution to a pressure releasing control revolution.
c. The travel straight proportional valve puts out a secondary pilot pressure to switch the travel straight
valve to the pressure releasing position.
d. The P1 bypass cut valve and the P2 bypass cut proportional valve put out a secondary pilot pressure
to hold the P1 bypass cut valve and the P2 bypass cut valve in their standby position.
4) The mechatro controller senses the output voltage of the high pressure sensor of the main pump, judges
it as pump pressure and displays “DRAINING HYD. PRESS” or “FAIL DRAIN HYD. PRESS” on the
gauge cluster.
5) Since the travel straight valve is in the pressure releasing position, the oil discharged by each pump is
unloaded to the tank passage.
If the operating levers are operated and the spools switched, the pressure remaining in the actuators may
be discharged.
21-7
(1) Positive control
1.10 PUMP CONTROL (POSITIVE CONTROL & P_Q CONTROL) 1) If any operation performed, the secondary pilot pressure switches the spools and is put into the low
pressure sensors.
2) The output voltage of the low pressure sensor is put into the mechatro controller which processes pilot
signals and puts out command current to the proportional valve of each pump according to the input
voltage.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
from the mechatro controller, switches the tilting angle of the pump and controls the discharge rate of the
pump.
4) This causes the delivery rate according to a lever stroke to be supplied to the actuator, thus an operating
speed according to a lever stroke is achieved.
(2) P-Q control
1) The output voltage of the high pressure sensor attached to each pump piping is put into the mechatro
controller, which processes pilot signals and computes command current according to input voltage (load
pressure).
2) The lower of the command current computed by positive control and the command value (1) computed by
P-Q control is selected and put out to the proportional valve of each pump as a command current.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
of the mechatro controller, switches the tilting angle of the pump and controls the discharge rate of the
hydraulic pressure.
4) This increases the load of the actuator, enabling the engine to keep running even if the pump is highly
loaded.
21-8
1.11 STANDBY FLOW CONSTANT CONTROL (1) Standby flow constant control
1) An engine rotation command put out of the accel potentiometer is put into the mechatro controller.
2) The mechatro controller processes pilot signals and puts out a command current to the proportional valve of
each pump so as to make the delivery rate of the pump constant when the engine speed is below an
intermediate rpm between the FC mode and the Decel revolutions.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current of
the mechatro controller, changes the tilting angle of the pump till the engine speed arrives at an intermediate
rpm between the FC mode and the Decel revolutions.
4) If the engine speed increases an intermediate rpm between the FC mode and the Decel revolutions, command
current from the mechatro controller become constant, with the result that the delivery rate of each pump rises
linearly as the engine speed increases.
5) The result is that the motion of the lever at the start of each operation becomes the same as that when a
standby flow is available. Also, if the engine revolution is increased, the operating feeling according to each
revolution is available.
21-9
1.12 FC MODE CONTROL (1) FC mode control
1) If the FC mode is selected by the switch on the gauge cluster, FC mode signal is put into the mechatro
controller.
2) Upon receipt of the FC mode signal, the mechatro controller; a. Judges it as FC mode, and
b. Puts out a FC mode rpm command to the governor motor.
3) The governor motor controls the engine speed to a level that matches a command current from the
mechatro controller. During operation it puts out, to each proportional valve, a command current in the FC
mode according to the input voltage from the low pressure sensor.
(2) Peculiar control of proportional valve at FC mode
1) If arm in action is performed at FC mode, the secondary pilot pressure for arm in operation switches the
arm spool and is put into the lower pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller
processes pilot signals and puts out command current according to the input voltage to the P2 pump
proportional valve and the P2 bypass cut proportional valve.
3) In that case, a peculiar control command current at the FC mode is put out to the variable recirculation
proportional valve. (the recirculation ratio higher than normal recirculation operation)
4) This combines the speed drop of the ATTs as the engine speed decreases with the fine arm operation at
the FC mode, in order to improve the delicate controllability of the entire working.
21-10
1.13 RELIEF CUTOFF CONTROL
This page is blank by abolition of this function
21-11
This page is blank for editing convenience
21-12
2. MECHATRO CONTROLLER The functions displayed on the multidisplay are classified roughly into the following 7 types.
※1. CPU error displayDisplay the error of the mechatro controller, etc. (28 items)
2.1 SUMMARY OF MECHATRO CONTROLLER ※ 2. Self-diagnosis displayDisplays the failure of the I/O system of the mechatro controller such as the low and high
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. However, the pressure sensors, governor motor, proportional valve, solenoid valve,
mechatro display and the cumulative engine oil lubrication time may be changed over if the screen change etc.
switch is pressed. 3. Service diagnosis displayDisplays the information output by the mechatro controller such as the pressure sensor
detection, proportional valve, solenoid valve, etc.
RIGHT HAND (22 items)
OPERATOR 4. Trouble history display Stores and displays the contents of the troubles detected through the mechatro self diagnosis.
CONTROL LEVER 5. Mechatro A adjustment displayDisplays it by procedure during the mechatro A adjustment.
6. E/G oil supply cumulative (integrated) time Displays the E/G oil supply cumulative time and E/G speed (rpm) list.
CIGARETTE LIGHTER
7. Warning displays When the machine is normal after self-diagnosis (※) but the actual operation fails, the occurence of
PLUG any of the following items is indicated every time.
(Opt.switch)
DOZER LEVER
(SK115SRDZ SPEC.)
AUTO IDLE STOP

SELECT SWITCH
ACCEL DIAL
STARTER SWITCH
Note 1. The buzzer sounds on display

FUSE BOX No. 2,3,5,6,7,32 and 33.
Note 2. The buzzer does not stop by
MECHATRO the buzzer stop switch,
CONTROLLER except No.7.
SWING PARKING BRAKE RELEASE SWITCH
GAUGE CLUSTER KPSS WORK MODE RELEASE SWITCH
2.2 SELF DIAGNOSIS DISPLAY FUNCTION
(1) Summary
It performs self diagnosis of control inputs and outputs of pressure sensors and proportional valves
while the machine is in operation. Errors coming out of the self diagnosis are displayed on the multi
The work mode selector switch contains the following functions. display of the gauge cluster. Regarding the connector numbers and the pin numbers, refer to the C-1
① Display item roll forwarded in trouble history operation Mechatro Controller which appears later. Wire numbers and colors may be confirmed on the electric
② Time display roll forwarded when correcting E/G oil
circuit diagram or on the harnesses.
supply cumulative time
③Number of engine starting up is increased. (2) I/O configuration
INPUT
Buzzer stop switch contains the following functions. SERIAL COMMUNICATION
Pressure sensor
① Stops the warning sounding
Gauge cluster
② Display item rollbacked in service diagnosis operation Proportional valve
Control
③ Display item rollbacked in trouble history operation (Buzzer alarm)
Selector valve (SOL)
④ Time display rollbacked when correcting E/G oil supply
cumulative time Governor motor
⑤Number of engine starting up is decreased. Battery relay
SCREEN CHANGE MULTI DISPLAY LCD 21-13
SWITCH
(3) Self diagnosis Connector
No. Contents Display of monitor No. Wire No. Wire color
Indication item -Pin No.
Connector Arm variable recirculation CN15－10 757 BrG
No. 19
No. Contents Display of monitor Wire No. Wire color propo-valve fail CN15－11 758 YV
-Pin No.
Mechatro controller Pump P1 CN15－17 760 VR
1 20 Propo-valve fail CN15－18 759 BrG
fail
Pump P2 CN15－19 764 VW
2 ROM data CN14－25 600 R 21
Propo-valve fail CN15－20 763 GY
When the E/G Travel two-speed
speed is not in 22 solenoid valve fail CN15－21 702 LgB
3 Mechatro set error the range from
300rpm~3000rpm
CN11－3 902 WV Swing parking
Boom raising 23 CN15－22 700 VR
4 CN11－2 502 LgY solenoid valve fail
pressure sensor fail CN11－1 952 BR
CN15－1 851 G
CN11－4 903 OB Governor motor CN15－2 852 B
5 Boom lowering 24 current fail
CN11－5 503 LO CN15－15 853 R
pressure sensor fail CN11－6 953 BrW W
CN15－16 854
CN11－9 904 OL Governor motor
6 Arm in
CN11－8 504 PW 25 starting point indexing CN11－34 560 V
pressure sensor fail CN11－7 954 BrY fail
CN11－10 905 OW CN11－33 930 WR
Arm out
7
pressure sensor fail
CN11－11 505 PL 26 Accel potentio meter CN11－32 530 P
CN11－12 955 Gr fail CN11－31 970 BW
CN11－15 900 RB Gauge cluster→Mechatro
8 Bucket digging CN14－26 601 W
CN11－14 500 LgR 27 controller communication
pressure sensor fail CN11－13 950 BrR failure CN14－27 602 B
CN11－16 901 RL
9 Bucket dump
CN11－17 501 LgW 28 Battery relay fail CN15－24 805 WG
pressure sensor fail CN11－18 951 BL
CN11－21 906 YB
10 Swing right CN11－20 506 V 29
Draining
― ― ―
pressure sensor fail CN11－19 956 GrL hyd. pressure
Travel right CN11－27 908 YL
12 CN11－26 508 VY Fail drain
pressure sensor fail 30 hyd. pressure ― ― ―
CN11－25 958 BY
Travel left CN11－28 909 YR
13 CN11－29 509 Sb
pressure sensor fail CN11－30 959 BG
Pump P1 CN12－3 941 YL
14 CN12－2 514 VY
pressure sensor fail CN12－1 964 BrB
Pump P2 CN12－4 915 YR
15 CN12－5 515 Sb
pressure sensor fail CN12－6 965 BrL
P1 bypass cut CN15－4 755 BP
16
propo-valve fail CN15－5 756 PW
P2 bypass cut CN15－6 751 BO

17 propo-valve fail CN15－7 752 GrR
18 Travel priority CN15－8 753 BG

propo-valve fail CN15－9 754 GrB
21-14
2.3 SERVICE DIAGNOSIS No. DISPLAY REMARKS No. DISPLAY REMARKS
No.12 No.22
The result of the service diagnosis at the present time is displayed in 22 categories depending on the PRESS. SENSOR PROPO-VALVE
data output by the mechatro controller. B－7 SWING (R) Sensor voltage / D－3 S-TRAVEL Command current /
12 3.5V 38k Pressure converted value 22 COMP. 600mA 45k Pressure converted value
How to display B－8 SWING (L) Sensor voltage / MEAS. 600mA 45k Feedback current /
1) Turn the starter key switch on, keeping the buzzer stop switch depressed, and place the attachment 3.5V 38k Pressure converted value Pressure converted value
to the travel position while operating in the low idling condition after the engine starts. No.13 No.23
2) The mechatro controller P/NO and the program version in the 1st item are displayed. PRESS. SENSOR PROPO-VALVE
B－9 TRAVEL (R) Sensor voltage / D－6 A-RECIRCULAT Command current /
E115SR E135SR LC GAUGE CLUSTER B－10 TRAVEL (L) Sensor voltage / MEAS. 600mA 45k Feedback current /
3.5V 39k Pressure converted value Pressure converted value
No.1 No.1
MAIN CONTROLLER P/No. No.14 No.24
MAIN CONTROLLER P/No.
PRESS. SENSOR PROPO-VALVE
PROGRAM VERSION PROGRAM VERSION C－1 PUMP P1 Sensor voltage / E－1 P1 PUMP Command current /
VER 5.70 Screen select switch Buzzer stop switch 14 3.5V 350k Pressure converted value 24 COMP. 600mA 45k Pressure converted value
VER 5.70
Advances the screen Returns the screen C－2 PUMP P2 Sensor voltage / MEAS. 600mA 45k Feedback current /
3.5V 350k Pressure converted value POWER SHIFT 100mA Pressure converted value
No.15 No.25
3) By pressing screen select switch, goes to No.2,No.3… in order. PRESS. SENSOR PROPO-VALVE
4) By pressing the buzzer stop switch, returns from No.13, No.12… in order. B－16 P1 OPT. Sensor voltage / E－2 P2 PUMP Command current /
5) Turn the starter switch off, and the display also goes off. B－17 P2 OPT. Sensor voltage / MEAS. 600mA 45k Feedback current /
3.5V 36k Pressure converted value POWER SHIFT 100mA Pressure converted value
No.20 No.39
PROPO-VALVE MECHATRO ADJT.
No. DISPLAY REMARKS No. DISPLAY REMARKS D－1 P1 BYPASS Command current / CONT. SW TEST RUN/TEST indication
No.1 No.6 20 COMP. 600mA 45k Pressure converted value 39 CONT. VOL 100% Inner trimmer
Service diagnosis
MAIN display
CONT.P/No. SK115SR or SOL. VALVE MEAS. 600mA 45k Feedback current / PROG. SW OFF ON/OFF indication
YV22E00008F1 SK135SR F－3 1/2-TRAVEL Pressure converted value
1 YY22E00022F1 P/No. indication 6 COMP. OFF ON/OFF indication
PROGRAM VER Version indication MEAS. OFF ON/OFF indication No.21 No.40
VER 5.30 SWITCH OFF ON/OFF indication PROPO-VALVE RELEASE SW
D－2 P2 BYPASS Command current / KPSS TEST ON/OFF indication
No.2 No.8 21 COMP. 600mA 45k Pressure converted value 40 SWING BRAKE OFF ON/OFF indication
E/G SET 2310 No load set rpm RELAY MEAS. 600mA 45k Feedback current /
MEAS 2310 Actual rpm I－2 BAT. RELAY Pressure converted value
2 E/G PRS. LIVE LIVE/DEAD indication 8 COMP. OFF ON/OFF indication
KPSS SW H H / S / FC indication MEAS. OFF ON/OFF indication
KEY SWITCH OFF ON/OFF indication
No.3 No.9
H－1 PRESS. SENSOR Note:
ACCEL VOLT. 4.2V Potentio voltage B－1 BOOM RAISE Sensor voltage /
3 POS. 100% Voltage position 9 3.5V 35k Pressure converted value Service diagnosis and trouble history can be displyed with the screen select switch and the buzzer stop
MOTOR STEP 440 No of motor steps B－2 BOOM LOWER Sensor voltage / switch. Note that the displays do not come out in some cases if the switches are pressed too quickly.
POS. 100% Step position 3.5V 35k Pressure converted value
(This is not a fault.) Give one second or more before pressing next switch.
No.4 No.10
GOVERNOR MOTOR PRESS. SENSOR
G－1 COIL A 1.0A A phase current B－3 ARM OUT Sensor voltage /
4 G－1 COIL B 1.0A B phase current 10 3.5V 36k Pressure converted value
G－2 LIMIT OFF ON/OFF indication B－4 ARM IN Sensor voltage /
3.5V 36k Pressure converted value
No.5 No.11
SOL. VALVE PRESS. SENSOR
F－2 SWING-BRAKE B－5 BUCKET DIG Sensor voltage /
5 COMP. OFF ON/OFF indication 11 3.5V 37k Pressure converted value
MEAS. OFF ON/OFF indication B－6 BUCKET DUNP Sensor voltage /
RELEASE SW OFF ON/OFF indication 3.5V 37k Pressure converted value
21-15
2.4 TROUBLE HISTORY DIAGNOSIS 4) To scroll the page, use the work mode select 2.5 HOW TO CORRECT THE E/G OIL SUPPLY CUMULATIVE TIME
The error item detected by the self-diagnosis is switch and the buzzer stop switch. (1) LCD display
stored in the mechatro controller as a history and z Press the work mode select switch, page up.
LCD display Operating procedure Buzzer sound
is displayed on the multidisplay. z Press the buzzer stop switch, page down.
Note :
(1) How to display All the error items are stored by hour meter, when
1) Turn the starter switch on. the hour meter is differed, press the work mode
O K 1515 RPM
2) Press the buzzer stop switch 5 times in select switch and the buzzer stop switch, and
sequence for 10 seconds. displays all items and make sure that they are Normal
(Example) right. 256Hr. have passed None
display after E/G oil was
CONTENTS DISPLAY
5) Turn the starter switch off, and the display is
No errors NO ERROR Supplementary explanation :
disappeared.
00025H If the screen change switch is pressed, the above three
Error detected in the B-1 BOOM RAISE (2) How to cancel the contents of the trouble screen may be changed over.
past D-1 P1 BYPASS CUT history
F-3 TRAVEL 1.2-SPEED 1) Display the trouble history mode.
2) Press the work mode select switch and the
3) Transmits the error data (one or many) and buzzer stop switch for 10 seconds or more
hour meter to the gauge cluster. concurrently.
z Hour meter and 3 error data are displayed 3) When the deletion is completed, the “NO
on the screen. ERROR” is displayed.
z If three error data or more exist, display the 4) Turn the starter switch off.
data three by three in order for every 5 (2) How to correct
seconds. Proce-
Note :
dure
Operating procedure Display on multidisplay
All the stored items are erased. (Normal)
It is impossible to erase data partially. MONITOR
A Turn the starter switch “ON”. is displayed.
SYSTEM OK
E/G speed is displayed
Press the gauge cluster screen change switch Press once
B MONITOR
2250RPM
once, and the E/G speed (rpm) is displayed. SYSTEM OK
(3) Contents of the trouble history
Symbol Display Symbol Display Press once more, and the engine oil supply E/G speed is displayed 100Hr AFT
C Press once more
cumulative time screen is displayed. 2250RPM E/G OIL CH
A－1 ROM DATA FAILURE D－1 P1 BYPASS CUT
A Controller relation
A－2 MECHATRO SET ERROR Proportional valve D－2 P2 BYPASS CUT
D D－3 TRAVEL PRIORITY Press the screen change switch for 3 to 10
(Control valve)
B－1 BOOM RAISING D－6 ARM VALEABLE D seconds and release the hand, it returns to 100Hr AFT MONITOR
100Hr AFT
B－2 BOOM LOWERING RECULATION E/G OIL CH SYSTEM OK E/G OIL CH
Portional valve E－1 the correction mode.
B－3 ARM OUT E
PUMP P1 PORPO- VALV
B－4 ARM IN (Hydraulic pump) E－2 PUMP P2 PORPO- VALV
Press the work mode selector switch “H”, and 100Hr AFT Cumulative time 101Hr AFT
Low pressure B－5 BUCKET DIGGING F－2 SWING PARKING E
B F Solenoid valve the cumulative time increases. (once 1Hr) E/G OIL CH increases E/G OIL CH
sensor B－6 BUCKET DUMP F－3 TRAVEL 1,2-SPEED
B－7 SWING RIGHT G－1 STEP MOTOR
CURRENT-NG Press the buzzer stop switch, the cumulative 100Hr AFT The cumulative 99Hr AFT
B－8 SWING LEFT G E/G Accessory G－2 STEP MOTOR S/PT. F
ERROR time decreases. (once 1Hr) E/G OIL CH time decreases E/G OIL CH
B－9 TRAVEL RIGHT
B－10 TRAVEL LEFT G－3 E/G REV. SENSOR
H Potentio relation H－1 ACCELERATR Press the gauge cluster screen change switch (Normal)
High pressure POTENTIO
C－1 PUMP P1 once the correcting time is stored, and exits 99Hr AFT Complete the MONITOR
C sensor I－1 RECEIVE ERROR G
(Hydraulic pump)
C－2 PUMP P1 I from the correction mode and OK symbol is E/G OIL CH correction SYSTEM OK
I－2 BAT. RELAY
MONITOR SYSTEM OK displayed to complete the correction.
Note :
Press the screen change switch once after the procedure D, and the condition is stored and the correction is
completed.
21-16
2.6 ENGINE STARTING FREQUENCY DISPLAY FUNCTION

Since it is supposed that the engine starting frequency increases because of adoption of auto idling stop
function, the engine starting frequency can be indicated on multidisplay as a guide for maintenance of
starter motor.
(1) How to display engine-starting frequency
1) Switch auto idling stop selector switch on.
2) While keeping buzzer stop switch pressed, switch engine key on.
(Display service diagnosis.)
3) Press screen change switch in the condition the initial main controller parts number is displayed,
and the following screen is displayed.
(Ex.)
No.1
Starting frequency 12345 times
MAIN CONT. P/N
START 12345
Replacing reminder frequency 30,000 times
PROGRAM VER
(Differ with machine model)
VER 3.00
(2) How to correct the value of engine starting frequency

Set starting frequency to zero when starter was replaced, and reset starter frequency to the value
set before replacing controller.
In the engine condition shown in Item (1)-3).

4) Press screen change switch for 5 seconds or more and release it, and "Reset" mode is displayed.
5) Press work mode selector switch, and starting frequency increases. (By 100 times. By 1000 times
while keeping it pressed)
6) Press buzzer stop switch, and starting frequency decreases. (By 100 times. By 1000 times while
keeping it pressed)
7) Press screen change switch after setting starting frequency to the desired value, and the desired
value is memorized (stored).
(3) Warning contents when starting frequency was reached to the replacing reminder frequency.
Each time starter switch is switched on; the following screen is displayed and flickers on cluster
gauge for 10 seconds.
In this case, overhaul or replace the starter.
(Ex.)
No.1
MAIN CONT. P/N
STARTER CHG
Replacing reminder frequency 30,000 times
PROGRAM VER
(Differ with machine model)
VER 3.00
21-17
This page is blank for editing convnience.
21-18
2.7 MECHATRO CONTROL EQUIPMENT
(1) C－1 Mechatro controller Connec- Pin Port In/out Connec- Pin Port In/out
Specification Signal level No. name Specification put Signal level
10 2 1 6 2 1 4 2 18 2 1 tor No. No. name put tor No.
1) General view Engine coolant high temp. LS 1 D7
1 B8 IN GND / OPEN
16 High/Normal
Engine oil pressure low LS 2 D7´
26 2 B9 Without/With IN GND / OPEN
3 D8
Air filter clogged LS
34 3 B10 Clogged/Normal IN GND / OPEN 4 D8´
4 B11 Double single select SW. opt IN GND / OPEN 5 D9
WINDOW
27 22 18 16 12 28 22 5 B12 Over load SW. (KCME) IN GND / OPEN 6 D9´
FOR CN11 CN12 CN13 CN14 7 D10
6 B13 JIB pressure SW. (KCME OPT) IN GND / OPEN
ADJUST
13 2 18 2 1 11 2 1 7 B14 Extra pressure SW. (KCME OPT) IN GND / OPEN 8 D10´
CN16
Fuel level thermistor 9 D11
ROM REWRITE COUPLER 8 B15 Low/Normal IN 670Ω/1140Ω
10 D11´
9 B16
11 D12
10 B17
12 D12´
11 B18 Connector for flat control IN 13 H1
26 24 14 16 9 22 13 12 12 C1
CN15 CN16 CN17 ADJUSTMENT SWITCH 14 H1´
13 C2 Wiper interlock SW. OUT GND / OPEN 15 B26
CN14
Connec- Pin Port In/out 14 C3 16 C22
tor No. No. name Specification put Signal level 15 C4 Washer motor relay Out/Stop OUT GND / OPEN
1 C15
1 G 16 C5 Front working light relay ON/OFF OUT GND / OPEN
2 C16
2 A12 P1 pump pressure sensor IN 0.5～4.5V 17 C6
2) List of connectors 3 C17 Swing flasher & working light unit OUT GND / OPEN
3 +5V 18 +5V
4 C18 Swing flasher & working light unit OUT GND / OPEN
Connec- Pin Port In/out 4 +5V
tor No. No. name Specification put Signal level 19 B19
5 C19 IT controller source
5 A13 P2 pump pressure sensor IN 0.5～4.5V 20 C7
1 G 6 C20
6 G 21 C8
2 A1 Boom raise pressure sensor IN 0.5～4.5V 7 C21
7 G 22 C9
3 +5V Opt. P1 side pressure 8 B20 Auto accel release switch ON/OFF IN GND / OPEN
8 A14 sensor IN 0.5～4.5V 23 C10
4 +5V 9 B21
Boom lower pressure 9 +5V 24 G
5 A2 sensor IN 0.5～4.5V 10 B22 (Swing flasher select switch) IN GND / OPEN
10 +5V 25 TXD1 IN/OUT
6 G 11 B23 Lock lever SW. IN +24V / OPEN
11 A15 26 RXD1 Gauge cluster IN/OUT CN17
7 G 12 B24
CN12 12 G 27 G
8 A3 Arm in pressure senor IN 0.5～4.5V 13 B25 Auto idle stop select SW. IN GND / OPEN
13 A16 Alternator voltage IN 0～36V 28 SHG Shield earth
9 +5V 14 TXD2 OUT
1 F1 IT controller
10 +5V 14 A17 15 RXD2 IN
Accel motor A phase
11 A4 Arm out pressure sensor IN 0.5～4.5V 15 B2 Key switch(ON) ON/OFF IN +24V / OPEN 2 F1´ 16 G
12 G 16 B3 Key switch(GLOW) ON/OFF IN +24V / OPEN 3 SHG Shield earth 17 SHG
13 G 17 B4 Travel 1.2 speed switch ON/OFF IN GND / OPEN 4 D1 P1 bypass cut OUT 0～800mA 18 +5V
Bucket digging pressure Swing parking release switch 5 D1´ proportional valve C OUT 0～800mA
14 A5 sensor IN 0.5～4.5V 18 B5 Release/Normal IN 17Ω/ OPEN 19 A23
6 D2 P2 bypass cut OUT 0～800mA 20 A24
15 +5V KPSS rerease switch
19 B6 Release/Normal IN ～12V / 12V～ 7 D2´ proportional valve A OUT 0～800mA
16 +5V 21 A25
Bucket extend pressure 20 E1 IN 3.0～20Vp-p 8 D3 Travel straight OUT 0～800mA
17 A6 sensor IN 0.5～4.5V Engine revolution sensor 22 G
CN11 21 E1´ 9 D3´ proportional valve B OUT 0～800mA
18 G 1 DL IN/OUT
22 SHG Shield earth 10 D4 Arm variable recirculation OUT 0～800mA
19 G proportional valve D
2 TXD3 IN/OUT
1 G 11 D4´ OUT 0～800mA CN18 Handy checker
20 A7 Swing pressure sensor IN 0.5～4.5V Opt. P2 side pressure 3 RXD3 IN/OUT
2 A18 sensor IN 0.5～4.5V 12 +24V
21 +5V Power supply + 24V 4 G
3 +5V 13 +24V
22 +5V
4 +5V CN15 14 +24V Battery back up
23 A8
5 A19 15 F2
24 G Accel motor B phase
25 G
6 G 16 F2´
Travel right pressure 7 G 17 D5 P1 pump proportional OUT 0～800mA
26 A9 sensor IN 0.5～4.5V
8 A20 18 D5´ valve E OUT 0～800mA
27 +5V CN13
9 +5V 19 D6 P2 pump proportional OUT 0～800mA
28 +5V
10 +5V 20 D6´ valve F OUT 0～800mA
29 A10 Travel left pressure sensor IN 0.5～4.5V
11 A21 Travel 1,2-speed selector valve
OUT +24V / OPEN
30 G 21 C11 2 speed/1 speed
12 G Swing parking selector valve
31 G 22 C12 OUT +24V / OPEN
13 G ◯,P /Release
32 A11 Accel potentio IN 0～5.0V
14 A22 23 C13
33 +5V 24 C14 Auto idle stop relay OUT +24V / OPEN
Accel motor starting point detection 15 +5V
34 B1 LS starting Point/Reguler
IN GND / OPEN 25 G
16 B7 Power supply (earth)
26 G
21-19
(2) Gauge cluster (symbol C-2) (3) Governor motor(Symbol M－2)
1) General view NAME PLATE
Gauge and
Display lamp
Multi display LCD MATED SIDE

(Liquid crystal display) AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
Screen select VIEW Ⅰ
switch etc.
CONNECTION DIAGRAM MOTOR CONNECTOR

No. Item name No. Item name LIMIT SWITCH CONNETOR
BROWN RED
1 Fuel sensor 5 GND
(A) (B) LIMIT SWITCH MOTION RANGE
2 Engine water temp. sensor 6 Sourse (+24V)
3 RXD (Serial communication) 7 GND
ORANGE YELLOW
4 TXD (Serial communication) 8 (None) (A) (B)
LIMIT SWITCH CONNECTOR WIRE TABLE MOTOR CONNECTOR WIRE TABLE
6 1 2 No. Lead color Connection

No. Lead color Connection 1 Brown A
5 5 White COM 2 Orange A
7 6 Red NO 3 Red B
3 4
3) Function 7 Yellow NC 4 Yellow B
① It processes signals by communication between the gauge cluster and the mechatro controller, displays HOUSING : 174359-2 (AMP) HOUSING : 174259-2 (AMP)
them in lamps, displays them in LCDs and actuates the buzzer. TERMINAL : 171661-1 (AMP) TERMINAL : 171661-1 (AMP)
RETAINER : 1-174360-1 (AMP) RETAINER : 1-174260-1 (AMP)
② It puts out coolant temperature signals, fuel level signals and panel switch signals to the mechatro
WATER RESISTANCE : 172888-2 (AMP) WATER RESISTANCE : 172888-2 (AMP)
controller through the communication port.
③ Screen Select SW: Scroll forward (See Page 15.), and displays of the E/G revolution and the cumulative
hours after changing engine oil (See Page 16.).
④ Other functions
• MODE SW. : The display changes S, H, FC, S, in that order each time the switch is pressed.
After the key is turned OFF, the display begins with ‘S’.
• Adjusting the engine : Perform mechatronic adjustment in a conventional way, using the Buzzer
Stop SW.
(See the Maintenance)
• Service diagnosis : This is displayed if the key is turned ON with the Buzzer Stop SW pressed.
This is the same as before.
• Trouble history : Turn ON the key and press the Buzzer Stop SW five times
continuously in ten seconds. (See Page 16.)
• Pressure release control : Press both the Screen Select SW and the Buzzer Stop SW. at the same
time and hold it for more than five seconds.
21-20
E115SR
E135SR
SECTION 22 HYDRAULIC SYSTEM
TABLE OF CONTENTS
1. Summary .............................................................................................................. 22-1
2. Hydraulic circuits and components ....................................................................... 22-2

2.1 EU Standard .................................................................................................................................. 22-2
2.2 Dozer specification ........................................................................................................................ 22-4
2.3 Boom and arm safety specification ................................................................................................ 22-5
2.4 Extra specification ......................................................................................................................... 22-6
2.5 N & B specification ........................................................................................................................ 22-7
3. Color coding standard for hydraulic circuits .......................................................... 22-8
4. Neutral circuit ........................................................................................................ 22-8

4.1 Safety loock lever and pilot circuit .................................................................................................. 22-8
4.2 Pump control ................................................................................................................................. 22-8
4.3 P-Q curve control action pumps .................................................................................................... 22-8
5. Travel circuit ........................................................................................................ 22-10

5.1 Travel forward pilot simultaneous operation circuit ....................................................................... 22-10
5.2 2 speed travel solenoid command circuit and auto 1st speed return function ............................. 22-10
5.3 Travel main circuit ........................................................................................................................ 22-10
5.4 Travel motor function ................................................................................................................... 22-10
6. Bucket circuit ...................................................................................................... 22-12

6.1 Bucket digging pilot circuit ........................................................................................................... 22-12
6.2 Auto accel operation .................................................................................................................... 22-12
6.3 Constant flow control for standby ................................................................................................ 22-12
6.4 Bucket digging main circuit .......................................................................................................... 22-12
7. Boom circuit ........................................................................................................ 22-14

7.1 Boom up pilot circuit .................................................................................................................... 22-14
7.2 Boom up 2 pumps conflux main circuit in C/V ............................................................................. 22-14
7.3 Boom down pilot circuit ................................................................................................................ 22-16
7.4 Prevention of neutral fall by lock valve and boom down ............................................................... 22-16
7.5 Fixed recirculation function of boom down main circuit ............................................................... 22-16
8. Swing circuit ....................................................................................................... 22-18

8.1 Swing left pilot circuit ................................................................................................................... 22-18
INDEX
8.2 Swing out parking brake .............................................................................................................. 22-18

8.3 Swing main circuit ....................................................................................................................... 22-18
8.4 Swing motor function ................................................................................................................... 22-18
9. Arm circuit .......................................................................................................... 22-20

9.1 Arm in, light-duty operation pilot circuit ........................................................................................ 22-20
9.2 Arm in, light-duty variable normal recirculation main circuit ......................................................... 22-20
9.3 Arm in, heavy-duty operating pilot circuit ..................................................................................... 22-22
9.4 Sequence conflux circuit at heavy-duty arm in ............................................................................ 22-22
9.5 Arm out pilot circuit ...................................................................................................................... 22-24
9.6 Arm out 2 pumps conflux main circuit .......................................................................................... 22-24
9.7 Neutral drop protection with arm lock valve ................................................................................. 22-24
10. Combined circuit (with multiple C/V circuit) ...................................................... 22-26

10.1 Boom up/travel, pilot circuit ........................................................................................................ 22-26
10.2 Boom up/travel, main circuit ...................................................................................................... 22-26
10.3 Swing/arm in, pilot circuit ........................................................................................................... 22-28
10.4 Swing/arm in, swing priority main circuit .................................................................................... 22-28
11. Pressure draining (releasing) circuit ................................................................. 22-30

11.1 Pressure release pilot circuit ..................................................................................................... 22-30
11.2 Pressure release main circuit .................................................................................................... 22-30
12. Hydraulic lines .................................................................................................. 22-32

12.1 Hydraulic lines list ...................................................................................................................... 22-32
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy
operability, safety, mass volume handling and low fuel consumption.
Table 1
Perfor-
mance Device Function Features
Travel straight Travel straight at combined operation.
2 speed travel changeover 2 speed changeover of travel speed.
Auto parking brake Automatic braking when parking.
Travel
Motor overrun protection Prevents overrunning of travel motor

on the 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
Swing priority circuit Easy operation of stable swing speed,

Easy operability and safety
(simultaneous operation of arm arm slanted leveling, swing press

digging and swing motions) digging.
Automatic swing parking brake Protect it from swing drift on the slope.
Hydraulic pilot control system Delicate operability.
Attachment
Pilot safety lock system Cut out of hydraulic pilot circuit by

safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected
drop.
Pressurized hydraulic oil tank To prevent hydraulic oil from being
contaminated and to promote self
suction ability of pump.
Suction strainer Remove dust on suction side.
Others
Line filter ; pilot circuit To prevent pilot operating circuit from

malfunctioning.
Return filter ; return circuit Hydraulic oil contamination.
Cooling hydraulic oil by oil cooler To prevent hydraulic oil from fouling
Pressure release circuit To prevent hydraulic oil from being
deteriorated.
Variable displacement pump of electric Use engine power effectively with 2
flow control type. variable pumps (2delivery sides).
Mass handling capability
Pump
Boom raise conflux circuit Speed up of boom raise operation.

Attachment
Arm conflux circuit Speed up of arm operation.

Dozer blade (OPT.) Dozing operation.
Auto accel Reduce fuel consumption and noise by

Micro computer
consumption
lowering engine speed when control

lever is in neutral position.
Low fuel
22-1
2. HYDRAULIC CIRCUITS AND COMPONENTS

Standard spec. E135SR(LC) E135SRL
No. NAME MODEL No.
1 PUMP ASSY (WITH GEAR PUMP) K3V63DTP100R
2 CONTROL VALVE (MAIN) KMX13YB
3 SWING MOTOR UNIT M2X63CHB-13A
4 TRAVEL MOTOR UNIT GM18VL2
5 LH
BOOM CYLINDER CA100X1038B38F
6 RH
7 ARM CYLINDER CA115X1135B38F
8 BUCKET CYLINDER CA95X885B38F
9 SWIVEL JOINT
10 PILOT VALVE (ATT) PV48K2005
11 PILOT VALVE (TRAVEL) 07291-00000
13 INLINE FILTER YTD9257
14 SUCTION STRAINER Y-672300
15 SOLENOID VALVE ASSY 7KWE5G
16 RETURN FILTER FZ1F183S011A
18 BREATHER ASSY AB0210, GA001B
19 BOOST CHECK VALVE Y-443600
20 BY-PASS CHECK VALVE Y-479600
21 SLOW RETURN VALVE 07579-00000
23 CONTROL VALVE (Ex.&N&B) KADV22Y/S10102
Standard spec. E115SR
No. NAME MODEL No.
1 PUMP ASSY (WITH GEAR PUMP) K3V63DTP100R
2 CONTROL VALVE (MAIN) KMX13YC
3 SWING MOTOR UNIT M2X63CHB-13A
4 TRAVEL MOTOR UNIT GM18VL2
5 LH
BOOM CYLINDER CA95X995B36F
6 RH
7 ARM CYLINDER CA110X1075B36F
8 BUCKET CYLINDER CA95X885B38F
9 SWIVEL JOINT
10 PILOT VALVE (ATT) PV48K2005
11 PILOT VALVE (TRAVEL) 07291-00000
13 INLINE FILTER YTD9257
14 SUCTION STRAINER Y-672300
15 SOLENOID VALVE ASSY 7KWE5G
16 RETURN FILTER FZ1F183S011A
18 BREATHER ASSY AB0210, GA001B
19 BOOST CHECK VALVE Y-443600
20 BY-PASS CHECK VALVE Y-479600
23 CONTROL VALVE (Ex.&N&B) KADV22Y / S10102
22-2
HYDRAULIC CIRCUITS AND COMPONENT MODEL
1 SE-22
P
SE-23
P
D2 P D1
PSV1 PH1 A1 a1 Dr1 a2 A2 PH2 PSV2 SWING

a3 a4 PG
DB
B A
3
A B
M
※3 ※3
PB PA
M A3 D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
※4 Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
14 MAIN CONTROL VALVE 20
P
P2
CMR1
P1 T
SE-8 22
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
TRAVEL SWING Pss SE-5
SWING LH
BOOM UP
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
P
CRb
※2
CAr
CRa ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR E135SR(LC)
CUT B 23 ※2 ※2
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2 ※1 ※1
BOOM(LH) R
Ao2 365kgf/cm (5190psi) 385kgf/cm (5480psi)
2 2
H ※2 ※2
VARIABLE Po
RECIRCULATION A
2 2
※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-3
2.2 DOZER SPEC.
E115SR
Applicable machines; same as STD E135SR
Dozer spec.
No. NAME MODEL NO.
50 HYD PUMP ASSY SGP1A25F2H9
51 SWIVEL ASSY
52 DOZER CYL. (LH) CA110X220B21G
53 DOZER CYL. (RH) CA110X220B21G
54 CONTROL VALVE KVS-65-1
NOTES : 1. This hydraulic circuit is used to add

to following circuit.
REMARKS
E115SR STD
E135SR STD
2. Item 50 and 51 are different from STD.
M
B4
51
FG
A4
PUMP
50
MAIN CONTROL VALVE P2 P1 T
HYD. TANK
BLADE 54 DOWN
UP
VALVE
A1 B1
210 kgf/cm2 280 kgf/cm2 52

(2990psi) (3970psi)
BLADE(LH)
P T
BLADE(RH)
53
22-4
2.3 BOOM & ARM SAFETY SPEC.
Applicable machines; same as STD
E115SR EVOLUTION
NOTES : 1. This hydraulic circuit is used to BOOM&ARM SAFETY SPEC. E135SR EVOLUTION
add to following circuit. No. NAME MODEL NO.
REMARKS 60 HOLDING VALVE KHCV20P010
E135SR EVOLUTION 61 HOLDING VALVE KHCV20P010
E115SR EVOLUTION E115SR EVOLUTION
BOOM SAFETY SPEC. E135SR EVOLUTION
No. NAME MODEL NO.
60 HOLDING VALVE KHCV20P010
61 HOLDING VALVE KHCV20P010
M
PUMP
HYD. TANK
BOOM(LH)
R
A B1
DR
61
PL C B
385 kgf/cm2
(5480psi)
PLc2 P
Drd PL C B
OUT PBa
PBb DOWN Pisc
Drc BOOM ARM
PAb UP IN PAa
Bb DOWN
PLc 1
DR
A B1
60
IN Aa
P
BOOM(RH) R
Ab UP ARM H
OUT Ba A B1
DR
60
PL C B
385 kgf/cm2
(5500psi)
22-5
2.4 EXTRA SPEC.
Applicable machines ; Same as STD
E115SR
NOTES : 1. This hydraulic circuit is used to EXTRA SPEC. E135SR(LC)
add to following circuit. No. NAME MODEL NO.
REMARKS 50 HYD PUMP ASSY SGP1A25F2H9
E135SR(LC) 81 PILOT VALVE 16041-0000
E115SR 82 CONTROL VALVE KVS-65-1
83 HYD. VALVE ASSY
2. This symbol means attachable 84 SOLENOID VALUE 16084-0000
port coupler for pressure detector.
PUMP ASSY
50
HYD. TANK
EXTRA 82 TO EXTRA HYD.

VALVE
A1 B1
81 EXTRA
230 kgf/cm2 PILOT VALVE
(3300psi)
PB1 PA1
210 kgf/cm2 T
(3000psi) P
B A
P T
T
83
B
84
A
P SE-24
A
NOTES 2
P T
SOL/V BLOCK
T
SAFETY
LOCK
4 LEVER
P1
22-6
E115SR
NOTES : 1. This hydraulic circuit is used to add to following circuit. N & B spec. SE135SR(LC)
Applicable machines ; Same as STD REMARKS No. NAME MODEL NO.
2.5 N & B SPEC. E115SR 70 PILOT VALVE 16030-00000
E135SR(LC) 71 SELECTOR VALVE
72 STOP VALVE
2. MARK OF SELECTOR VALVE (ITEM 71)
75 CONTROL VALVE KADV22Y/S10102
N : NIBBLER
B : BREAKER
3. FOR USING OF NIBBLER CONFLUENCE/SINGLE FLOW OR BREAKER, OPERATING CONDITION
SELECTION COMMAND OF PROPOTIONAL SOLENOID VALVE
CONFLUENCE/SINGLE FLOW POSITION OF
P1 PUMP P2 PUMP TRAVEL STRAIGHT P1 BYPASS CUT P2 BYPASS CUT
CHANGEOVER SWITCH SELECTOR VALVE (ITEM 71)
CONFLUENCE FLOW OF NIBBLER CONFLUENCE "ON" N
SINGLE FLOW OF NIBBLER CONFLUENCE "OFF" N
BREAKER CONFLUENCE "OFF" B
Note : ON = , OFF =
M 4. ADJUST OVERLOAD RELIEF VALVE OF OPT. PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.
PUMP
HYD. TANK PTb
TRAVEL
STRAIGHT
70 NIBBLER & BREAKER

PILOT VALVE
72
T
71 P
NOTES 3 N NIBBLER
B C1 C2 A
B P SE-11
BREAKER
SOL/V BLOCK PCb

T P1 BYPASS CUT P2 BYPASS CUT
PCa
SAFETY
LOCK
4 LEVER
ROD
LCo2 N&B PBo2
HEAD
PAo2
75 250 kgf/cm2
(3550psi)
NOTES 4 Bo2
Ao2
Po
P1
22-7
3. COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS 4. NEUTRAL CIRCUIT
This section describes the following. diameter of it and increases the tilting angle
Blue ................... Feed, drain circuit, less than 1) Safety lock lever and pilot circuit (α). The servo piston and the sleeve are linked
4.5kgf/cm2 (64psi) 2) Pump control together by the feedback lever (611). A pin is
Green ................. Return, make up circuit, 3) P-Q curve control action of pumps provided at point A of the feedback lever. Since
4.5～6kgf/cm2 (64～85psi) the feedback lever runs on the fulcrum, the
Purple ................ Secondary pilot pressure, 4.1 SAFETY LOCK LEVER AND PILOT CIRCUIT servo piston and the sleeve (651) move in the
6～50kgf/cm2 (85～710psi) Purpose: opposite directions and stop where the spool-
Red ..................... Primary pilot pressure, To protect attachment from unexpected sleeve opening is closed.
35～50kgf/cm2 (500～710psi) operation for safety, however, dozer is outside 2) Flow reducing action
Orange ............... Main pump drive pressure, of adaptation. If the command current I of the mechatro
50～350kgf/cm2 (710～4980psi) Principle: controller decreases, the secondary pressure
Blue tone ........... At valve selection Cut pressure source of pilot valve for of the solenoid proportional valve decreases.
Red valve ........... When proportional valve operation. This causes the pilot spring (646) to move the
(reducing) is operating Operation: spool (652) to the left. If the spool is shifted,
Red solenoid ...... In active and exciting After engine starts, push down the safty lock the discharge pressure P1 is admitted to the
Displaying the flow circuit and standby circuit lever (red), and the limit switch (SW-11) is larger diameter chamber of the servo piston
when operating. turned on, the pilot operation circuit is by way of the spool.
Regarding the electrical symbols in this manual, changed to standby condition. The discharge pressure P1 is there at the
refer to the electric circuit diagram. smaller diameter of the servo piston at all
4.2 PUMP CONTROL times, but because of the difference in the area
Type: causes the servo piston to move to the right and
Variable displacement pump of electric flow to decrease the tilting angle. If the servo piston
control type. moves to the right the same way as above, the
Principle: sleeve moves to the left by the feedback lever,
Controls the tilting angle of the pump till the opening of the spool-sleeve is closed.
(delivery rate) by changing the command
current I to the solenoid proportional 4.3 P-Q CURVE CONTROL ACTION OF PUMPS
reducing valve. Type:
Operation: Electrically flow controlled variable-
1) Flow increase function (for example; P1 displacement pump
pump): Principle:
This is a positive control type that increases Outputs of the high pressure sensor for the
the command current I of the mechatro pump are converted to P-Q curve control values
controller. If the attachment other than the by the mechatronic controller to give commands
dozer is operated, the secondary pilot to the pump’s solenoid proportional valve.
operating pressure is put in each low Operation:
pressure sensor. The output voltage of the The high-pressure sensor of the pump
low pressure sensor is put into the mechatro converts the discharge pressure of the pump
controller. The mechatro controller to voltage outputs.
processes pilot signals and put out a current The mechatronic controller converts the
command according to the input voltage. If voltage outputs from the high-pressure
the secondary pressure of the solenoid sensor to command current as it makes P-Q
proportional valve increases, the spool (652) curve control.
is pushed to the right via the pilot piston In the meantime, the mechatronic controller
(643) and stops where it balances the action selects the lower of the command current and
of the pilot spring (646). the positive control command current from
The larger diameter of the servo piston (532) the low-pressure sensor and sends out a
opens to the tank port, moves to the left by current command to each proportional valve
the discharge pressure P1 of the of the pump.
22-8
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
646
B A
3
A B
643 M
652
651
532 A PB PA
611
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
265kgf/cm (3770psi) 285kgf/cm (4060psi)
2 2
SWING 51kgf/cm (725psi) 51kgf/cm (725psi)
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-9
NEUTRAL CIRCUIT ; SAFETY LOCK LEVER ON
5. TRAVEL CIRCUIT
This section describes the following. pressure.
1) Travel forward pilot simultaneous operation Provided if the main circuit pressure exceeds
circuit 290 kgf/cm2, the self pressure pushes back
2) 2 speed travel solenoid command circuit and the 2 speed select piston to select 1st speed.
auto 1-speed return function
3) Travel main circuit 5.3 TRAVEL MAIN CIRCUIT
4) Travel motor function Operation:
If the travel spool is changed by the travel
5.1 TRAVEL FORWARD PILOT SIMULTANEOUS pilot action, the oil discharged from port A1,
OPERATION CIRCUIT A2 of the main pump enters ports B, A of the
Purpose: travel motor by way of the BL-, Br port of C/V
Light operating force and shockless operation and the C, D ports of the swivel joint (8) and
Operation: performs the following functions in the travel
1) If the travel lever with damping mechanism motor.
is operated for travel right, left and forward
motions, the secondary pilot proportional 5.4 TRAVEL MOTOR FUNCTION
pressure comes out of the 2,4 ports of P/V Function:
(11). The higher of the pressures is selected, 1) Prevents overrunning of travel motor on
comes out of the 5, 6 ports and acts upon the downhill slope.
low pressure sensors (SE9), (SE10). 2) Hydraulic motor cavitation protective check
2) Pilot proportional secondary pressure flows valve.
into PBL, PBr ports of control valve, acts on 3) Shockless relief valve and anticavitation
travel spool, and switches main circuit. valve when stopping it with the force of
3) The output voltage of the low pressure sensor inertia.
is put into the mechatro controller. The 4) High/Low 2 step change mechanism and auto
mechatro controller processes signals and 1st speed return at high load.
puts out a flow increase current to the P1 5) Travel parking brake.
pump proportional valve (PSV-1) and the P2
pump proportional valve (PSV-2).
5.2 2 SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION
Purpose:
Change travel motor speed with switch.
Principle:
If the switch is turned, an electric signal is
issued. It excites the 2-speed travel solenoid
which in turn converts the primary pilot
pressure and the self pressure to a tilting
angle of the variable displacement motor.
Operation:
Press switches with rabbit and turtle marks
on travel lever grips, and the solenoid (SV-3)
of proportional valve block (15) is excited and
is switched, and solenoid command is output
by port 3 and sends to P port of travel motor
(4), opens oil passage to 2 speed piton, and
switches it to 2 speed tiling rotation with self
22-10
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-11
TRAVEL CIRCUIT ; TRAVEL 2nd SPEED OPERATION
6. BUCKET CIRCUIT
This section describes the following. 6.3 CONSTANT FLOW CONTROL FOR STANDBY
1) Bucket digging pilot circuit Principle:
2) Auto accel operation At pressures below the intermediate
3) Constant flow control for standby revolution between the decel and the FC
4) Bucket digging main circuit mode, a command current is put out so as to
make the delivery rate of the pump constant.
6.1 BUCKET DIGGING PILOT CIRCUIT Operation:
Operation: Even if the engine revolution of the accel
1) If bucket digging action is performed, the potentiometer is set in Lo rpm, the pump
secondary proportional pilot pressure comes delivers a discharge rate equal to the
out of port ① of the right pilot valve (10), intermediate revolution between the above
enters port PBc of C/V (2) and acts upon the decel and the FC mode. For this reason, the
low pressure sensor (SE-1). At the same time, actuator operates faster than the moving of
the pressure changes the bucket spool. the operating lever when load is light.
2) The output voltage of the low pressure sensor
is put into the mechatro controller. The 6.4 BUCKET DIGGING MAIN CIRCUIT
controller processes signals and puts out a Operation:
command current for pump flow increase to With pilot operation, the pressure oil
the solenoid proportional valve (PSV-1) on switches bucket spool, and is fed into bucket
the P1 pump. The relation between the low cylinder H side through C/V (2) BC port. And
pressure sensor and the pump flow increase the return oil from cylinder R side flows into
is the same as above; the explanation of it is tank circuit while being restricted by bucket
deleted hereafter. spool through C/V (2) AC port.
6.2 AUTO ACCEL OPERATION

Principle:
Start operating with signal output by low
pressure sensor.
Operation: <Lever in neutral position>
When the signal is not input to low pressure
sensor for 4 seconds or more after turning
accel dial to Max. position, become engine
speed to 1050rpm automatically.
<Lever in operation position>
When the pressure of 5.7kgf/cm2 (81psi) or
more is input to low pressure sensor in STD
specification (travel, bucket, boom, swing and
arm), the proportional voltage received from
low pressure sensor is output to mechatro
controller, and restores the E/G speed to the
speed set by accel dial with control lever
operation.
22-12
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
Dra ATT.
LCc BOOM PB1 PILOT
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-13
BUCKET CIRCUIT ; BUCKET DIGGING OPERATION
7. BOOM CIRCUIT
This section describes the boom raise conflux 3) Then the oil passes through boom spool,
operation. opens lock valve of boom lock valve, and is led
1) Boom up pilot circuit into H side of boom cylinder through C/V (2)
2) Boom up 2 pumps conflux main circuit in C/V Ab port.
4) The return oil from boom cylinder R side
7.1 BOOM UP PILOT CIRCUIT flows into tank circuit through boom spool
Operation: from C/V (2) Bb port.
1) If the boom up action is performed, the
secondary pilot proportional pressure from
the right pilot valve (10) comes out of port ③
and acts upon the low pressure sensor (SE3).
At the same time, the pressure acts upon the
PAb port and the PB1 port of C/V (2).
2) The voltage output by low pressure sensor is
processed by mechatro controller and outputs
command current to P2 bypass cut valve
(PSV-B) and solenoid valve outputs
proportional secondary pressure and the
pressure acts on C/V (2) PCa port.
3) Then, the secondary pressure fed into C/V (2)
PAb port switches boom conflux spool. And
the solenoid proportional secondary pressure
fed into PCa port switches P2 bypass cut
valve.
7.2 BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT

IN C/V
Purpose: Boom up speed increase
Principle: Confluxing oil from 2 pumps
Operation:
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. However
since the boom spool is moved and bypass
circuit is closed, the oil opens load check
valve LCb through parallel circuit and flows
into boom spool.
2) Meanwhile, the oil discharged from the A2
port of the P2 pump enters the P2 port of C/V
(2) and is branched to the bypass circuit and
the parallel circuit. If the P2 bypass cut valve
is changed over, the center bypass circuit is
closed. The oil then passes through the
parallel circuit and via the restrictor on the
circumference of the boom conflux spool,
pushes the load check valve CCb open from
the boom conflux circuit, and combines the oil
discharged by the P1 pump internally.
22-14
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-15
BOOM CIRCUIT ; BOOM UP OPERATION, CONFLUX FUNCTION
This section describes boom down operation. 7.5 FIXED RECIRCULATION FUNCTION OF
1) Boom down pilot circuit. BOOM DOWN MAIN CIRCUIT
2) Prevention of natural fall by lock valve and Purpose:
actuation at lowering. Prevention of cavitation during boom
3) Fixed recirculation function of boom down lowering motion.
main circuit. Principle:
The oil returning from the boom cylinder
7.3 BOOM DOWN PILOT CIRCUIT head (H) is recirculated to the rod (R).
Operation: Operation:
1) Start boom down operation, and the pilot When the oil is supplied to the boom cylinder
proportionl secondary pressure is output rod (R) side during boom down operation,
through port (4) of pilot valve, and acts on the boom moves faster than it should do in
low pressure sensor (SE4), at the same time some cases by the self weight of the
branches into two circuits, then scts C/V(2) attachment. On that occasion, the circuit
PBb and PLC1 ports. pressure on the rod (R) side is on the negative
2) The voltage output by low pressure sensor side. The oil supplied to the boom cylinder
(SE4) is input into mechatro controller. rod (R) flows into the A1 port of the P1 pump
3) Then, the proportionl secondary pressure fed and the P1 port of C/V. The oil then passes
into C/V(2) PBb port switches boom spool. through the boom spool and goes out of the
And the proportional secondary pressure Bb port. On that occasion, the oil returning
flown into C/V (2) PLC1 port releases boom from the head (H) goes through the
lock valve. recirculation path in the boom spool, pushes
the check valve (C) in the spool open, is
7.4 PREVENTION OF NATURAL FALL BY LOCK recirculated to the Bb port and is supplied to
VALVE AND BOOM DOWN the rod (R). When the (R) pressure is larger
Purpose: than the (H) pressure, the check valve (C)
Prevention of natural fall when the lever is closes. Thereupon, the recirculation is
neutral. stopped.
Principle:
The oil is prevented from returning to the
boom spool by the poppet seat of the boom
lock valve.
Operation:
During the boom lowering, the boom spool
shifts by secondary proportional pressure of
PLC1 port to change the selector valve of the
lock valve located at the end of the spool.
Then the poppet spring chamber of the lock
valve connects with the drain line (drc), with
the result that the lock valve poppet is moved
to an open state. When the boom spool is
neutral, the drain line on the lock valve
poppet spring chamber side is closed. since
the poppet is closed, the oil returning to the
boom spool from the boom cylinder head (h) is
held. this prevents oil leaks from the boom
spool, thereby preventing the boom cylinder
from making a natural fall.
22-16
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-17
BOOM CIRCUIT ; BOOM DOWN OPERATION
8. SWING CIRCUIT
This section describes the following operations. 3) The swing parking solenoid (SV-1) is excited
1) Swing left pilot circuit five seconds after the pressure of the swing
2) Swing auto parking brake low pressure sensor (SE-5) disappears. In the
3) Swing main circuit case of arm in, the swing parking solenoid
4) Swing motor function (SV-1) is excited to operate the mechanical
brake the moment the pressure of the low
8.1 SWING LEFT PILOT CIRCUIT pressure sensor (SE-7) for arm in disappears.
Operation:
1) If the swing left action is performed, the 8.3 SWING MAIN CIRCUIT
secondary pilot proportional pressure goes out of Operation:
port ⑤ of left pilot valve (10) and acts upon the The delivery oil through A2 port of P2 pump
low pressure sensor (SE-5). At the same time, flows into P2 port of the C/V (2) and is branched
the pressure acts upon the PAS port of C/V (2). into the bypass circuit and parallel circuit, but
2) The low pressure sensor output voltage the bypass circuit is closed with the movement
enters in the mechatro controller, and after of the swing spool, the pressure opens load
signal processing the mechatro controller check valve (LCS) through the parallel circuit
outputs the command current to P2 bypass flows into B port of the swing motor through AS
cut solenoid proportional valve (PSV-B), and port of the C/V (2) and rotates the swing motor
the proportionl valve secondary pressure is counterclockwise. However, when starting
discharged from this the solenoid valve and swing operation, the oil flows out in the tank
acts on PCa port of the C/V (2). circuit through P2 bypass cut valve from the
3) Then, the secondary pressure entered into bleed off passage of the swing spool. The P2
PAS port of the C/V (2) switches the slewing bypass cut valve closes in late and
spool. And the solenoid proportionl valve consequently the swing hunting due to the
secondary pressure entered in PCa port control of the swing flow rate is prevented.
switches the P2 bypass cut spool.
8.4 SWING MOTOR FUNCTION
8.2 SWING AUTO PARKING BRAKE 1) Anticavitation circuit when reducing swing
Purpose: speed.
Swing lock and parking brake in neutral 2) Shockless relief to protect it from reverse
position rotation.
Principle:
Release mechanical brake only when required
to operate swing and arm in
Operation:
1) The swing parking function operates usually
when the key switch is ON condition and the
mechanical brake spring is actuated.
2) If the swing parking solenoid is de-excited, the
mechanical brake is released only when the
secondary operating pressure that is built up
during swing action or arm in action acts upon
either of the low pressure sensors (SE-5.7).
22-18
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-19
SWING CIRCUIT ; SWING LEFT OPERATION
9. ARM CIRCUIT
This section describes the following operations. 9.2 ARM IN, LIGHT－DUTY VARIABLE NORMAL
1) Arm in, light-duty operating pilot circuit RECIRCULATION MAIN CIRCUIT
2) Arm in, light-duty variable normal Operation:
recirculation main circuit 1) The oil returning from the arm cylinder (R)
opens the arm lock valve and flows into the
9.1 ARM IN, LIGHT－DUTY OPERATING PILOT arm variable recirculate spool through the
CIRCUIT arm spool.
Purpose: 2) Since the passage to the tank is throttled by
Speed-up and Anticavitation when the arm is the arm variable recirculation spool, the oil
at light duty. returning from the arm cylinder (R) flows
Principle: into the load check valve CAr.
The oil returning from the arm cylinder rod 3) Since the R side pressure of the cylinder is
(R) is recirculated variably to the head of C/V. higher than the H side pressure of it when
Operation: working load is light, the pressure pushes the
1) If arm in is performed, the secondary pilot load check valve CAr open and is recirculated
proportional pressure is generated from to the H side so as to speed up the light-duty
port⑦ of left pilot valve (10) and acts upon digging operation.
the low pressure sensor (SE-7). At the same 4) If the FC mode is selected, the command
time, the pressurized oil is branched to two current to the arm variable recirculation
circuits acts upon the PAa port and the PLC2 solenoid proportional valve decreases. This
port of C/V (2), changes the arm spool, and reduces the secondary pressure of the
releases the arm lock valve. solenoid proportional valve. The result is that
2) The output voltage of the low pressure sensor the arm variable recirculation valve is turned
is put into the mechatro controller and to the normal recirculation, thereby causing
processes pilot signals. It is then put out to the arm variable recirculation function to
the P2 pump proportional valve (PSV-2), the prevent cavitation.
proportional valve (PSV-B) of the P2 bypass
cut valve and the arm variable recirculation
proportional valve (PSV-A).
3) The pressure from the P2 pump proportional
valve (PSV-2) and the P2 bypass cut
proportional valve (PSV-B) is created in
proportion to the pilot operating pressure
and acts upon the P2 pump and the PCa port
of the bypass cut valve of C/V (2). In the
case of the arm variable recirculation
proportional valve, the secondary pressure of
the solenoid proportional valve is controlled
so it is put out in reversely proportional to
the pilot operating pressure. Therefore, in the
light-duty arm digging, the secondary
pressure of the solenoid proportional valve
decreases which changes from forcible
recirculation to normal recirculation.
22-20
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-21
ARM CIRCUIT ; ARM IN LIGHT LOAD OPERATION, VARIABLE RECIRCULATION FUNCTION
This section describer the following operations. 3) Then, the confluxed oil is fed into arm
3) Arm in, heavy duty operating pilot circuit cylinder H side through C/V (2) Aa port from
(recirculation cut) arm spool.
4) Arm in, heavy-duty sequence conflux main 4) In addition, the return oil from arm cylinder
circuit R side flows into arm lock valve through Ba
port, but since the arm lock valve CRa is
9.3 ARM IN, HEAVY DUTY OPERATING PILOT open, it flows into arm spool.
CIRCUIT 5) Then, the oil passes though orifices on arm
Operation: spool and returns into tank while restricting.
1) If the arm is at heavy duty (more than 160
kgf/cm2) of the pump pressure during arm in
operation, the current of the arm variable
recirculation solenoid proportional valve is
reduced to a minimum, and the arm variable
recirculation function is cut off.
2) The moment the command current for the
arm variable recycle solenoid proportional
valve is minimized, the travel straight
solenoid proportional valve(PSV-C) and the
P1 bypass cut solenoid proportional
valve(PSV-D) are energized. The secondary
pressures of those solenoid valves act upon
the PTb port and the PCb port of the C/V(2)
and changes over the travel straight valve
and the P1 bypass cut valve. This makes up
an arm sequence conflux flow configuration.
3) The action of the left pilot valve in an arm in
motion is the same as in a light-duty
operation.
9.4 SEQUENCE CONFLUX CIRCUIT AT HEAVY-

DUTY ARM IN
Purpose: Arm in speed up.
Principle: Confluxing oil from 2 pumps in C/V (2).
Operation:
1) Since the bypass cut valve is shifted, the oil
discharged by the P2 pump flows into the
travel left section from the P2 port of C/V (2).
The oil is then branched to the bypass circuit
and the parallel circuit. The pressure then
pushes the load check valve CP2 via the
parallel circuit and flows into the arm spool.
2) Meantime, the oil discharged by the P1 pump
flows into the P1 port of C/V (2), flows into
the travel straight section and the oil
pressure pushes the load check valve CT2
open through the parallel circuit, combines
with the oil from the load check valve LCa of
the P2 parallel circuit, and flows into the arm
spool.
22-22
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-23
ARM CIRCUIT ; ARM IN HEAVY LOAD OPERATION, CONFLUX FUNCTION
This section describes the following operations. 9.7 NATURAL DROP PROTECTION WITH ARM
5) Arm out pilot circuit LOCK VALVE
6) Arm out 2 pumps conflux main circuit Purpose:
7) Natural drop protection with arm lock valve To prevent the arm from falling naturally by
the weight of the arm & bucket.
9.5 ARM OUT PILOT CIRCUIT Principle:
Operation: Complete seat of the return circuit against
1) If arm out operation is performed, the the arm spool of the arm cylinder R side
secondary proportional pilot pressure comes circuit.
out of port ⑧ of the left pilot valve (10) and Operation:
acts upon the low pressure sensor (SE-8). At 1) If the secondary pressure for arm operation
the same time, the pressure is branched to disappears and the arm cylinder stops, the
two circuits and acts upon the PA1, PBa pressure on the rod (R) side passes through
ports of C/V (2). the selector of the lock valve from the Ba port
2) Then, the pilot secondary pressure fed into of C/V, acts the back pressure on the lock
C/V (2) PBa port switches arm spool and fed valve and seats the lock valve.
into PAL port switches arm conflux valve. 2) Since the oil flow from the lock valve to the
3) The output voltage of the low pressure sensor arm spool is blocked completely, the arm is
(SE-8) puts in the mechatro controller which prevented from falling naturally due to oil
processes signals. The controller puts out a leaks through the arm spool.
current command to the P1 bypass cut
solenoid proportional valve (PSV-D). The
secondary pressure comes out of the solenoid
valve, acts upon the PCb port of C/V (2) and
switches the spool of P1 bypass cut valve.
9.6 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
Purpose: Arm out operation speed up.
Principle:
The oil discharged by the P1 pump is
combined with that discharged by the P2
pump in C/V (2).
Operation:
1) The oil discharged by the P1 pump switches
the spool of arm conflux valve. Then the oil
discharged by the P1 pump is combined with
that on the R side of the arm cylinder
through the arm conflux valve and road
check valve CCa.
2) The oil delivered by P2 pumps flows in the
same way until the oil reaches to arm spool.
Then, the oil passes through arm spool opens
arm lock valve CRa with free flow and flows
into arm cylinder R side through C/V (2) Ba
port.
3) And, the return oil from arm cylinder H side
flows into Aa port, passes through arm spool,
and returns into tank circuit.
22-24
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-25
ARM CIRCUIT ; ARM OUT OPERATION, CONFLUX FUNCTION
10. COMBINED CIRCUIT 4) Next, the travel motion is performed by the
oil discharged by the P2 pump.
(WITH MULTIPLE C/V CIRCUIT)
5) Before entering the travel valve, the oil
This section describles only the difference in discharged by the P2 pump is branched off
combined operation. into the P1 and P2 bypass lines. The oil then
1) Boom up/travel, pilot circuit passes through the right and left travel
2) Boom up/travel, main circit spools and is supplied to the travel motor via
the Br and BL ports of the C/V (2).
10.1 BOOM UP/TRAVEL, PILOT CIRCUIT 6) However, part of the oil gets through by way
Opreation: of the notched throttle in the travel straight
<Points which are differed from the independent valve spool. The throttled passage controls
operation> the speed of the attachments such as travel
1) With signal processing of mechatro controller, and boom motions.
the controller outputs command current to
travel straight valve (PSV-C) and P2 bypass
cut valve (PSV-B) and this solenoid valve
outputs secondary pressure, then acts on C/V
(2) PTb and PCa ports.
2) Next, the PTb port pressure changes the
travel straight valve by one step. The
solenoid proportional secondary pressure
which flows into the PCa port of C/V (2)
changes over the P2 bypass cut valve.
10.2 BOOM UP/TRAVEL, MAIN CIRCUIT

Purpose:
Trevel straight operation is available even if
the attachment is operated during travel
operation.
Principle:
The travel motion and attachment operations
are performed by respective pump.
Operation:
1) The boom and other attachments operate on
the P1 pump circuit.
2) The oil discharged by the P1 pump runs into
the travel straight section.
3) Since the travel straight valve spool has
moved, the oil discharged by the P1 pump
passes the travel straight valve, pushes the
load check valves (CT1 and CT2) open and
branches off into the P1 and P2 parallel lines.
The oil from the load check valve (CT1) which
has run into the P1 parallel line attempts to
get out of the Ab port of the C/V (2) past the
load check valve (LCb) and the boom spool.
However, since the back pressure of the boom
lock valve (CRb) is raised and closed, the oil
enters the P2 parallel line, passes through
the boom conflux valve and the load check
valve(Ccb) and is supplied to the boom
cylinder(H) via the Ab port of the C/V (2).
22-26
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-27
COMBINED OPERATION ; BOOM UP / TRAVEL FORWARD, 1st-SPEED
This section describes difference in combined And swing pilot pressure is led from "Pisc"
operation. port to sub-spool in arm spool, the pressure of
3) Swing/Arm in, pilot circuit arm cylinder head (H) rises higher by
4) Swing/Arm in, swing priority main circuit restricting opening of arm spool circuit
according to swing pilot pressure, as a result
10.3 SWING/ARM IN, PILOT CIRCUIT the oil P2 pump flows preferentially into
Opreation: swing circuit.
1) When swing and arm in operations are This is so-called swing priority control.
concurrently carried out, with signal
processing of mechatro controller, the
controller outputs commands current to
travel straight valve (PSV-C) & P1 bypass cut
valve (PSV-D) & P2 bypass cut valve (PSV-
B) and this solenoid valve outputs secondary
pressure, then acts on C/V (2) PTb & PCb &
Pca ports.
(These operations are the same as that of the
combined respective independent operation.)
2) The arm variable recirculation valve
operates, the same as usual, but the spool
moves toward the forcible recirculation side
according to the pilot pressure for the arm in
action.
10.4 SWING/ARM IN, SWING PRIORITY MAIN

CIRCUIT
Purpose: Stable swing speed.
Principle:
Control the oil flow rate to arm cylinder, and
give a priority of the delivery of P2 pump to
swing operation.
Operation:
Swing main circuit is actuated by P2 pump
flow, but when the operation of swing and
arm in are operated simultaneously, the
secondary pressure of travel straight valve
switches it's spool and the secondary pressure
of P1 cut proportional valve closes P1 cut
valve and oil of P1 pump confluxes
consequently with P2 pump circuit. The oil
flows into swing and arm circuits in the same
time because both circuits are paralleled.
Return oil pressure rises and also arm
cylinder head (H) pressure rises because of
following two reason.
Arm variable recirculation spool returns to
forced recirculation side according to swing
pilot pressure. Return oil from arm cylinder
rod (R) side is restricted in arm variable
recirculation valve.
22-28
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
SOL/V BLOCK TRAVEL L. REV.
P1 P1
BYPASS T P2 VARIABLE PCa
BYPASS CUT CCa BYPASS
CUT D RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-29
COMBINED OPERATION ; SWING / ARM IN LIGHT LOAD, SWING PRIORITY FUNCTION
11. PRESSURE DRAINING
(RELEASING) CIRCUIT
This section describes the following operations. to five times to their full stroke, pressure may
1) Pressure drain (releasing) pilot circuit be relieved. After draining pressure is
2) Pressure drain (releasing) main circuit completed, turn off the starter key and
buzzer sound stops. If the pump pressure is
11.1 PRESSURE RELEASE PILOT CIRCUIT determined to be more than 9.8 kgf/cm2
Purpose: (140psi) by the output value of the high
To release the main circuit pressure for pressure sensor or the high pressure sensors
piping repair work. (SE-22,23) are broken, the buzzer sounds
Principle: continuously. In that case, also the buzzer is
When press screen change switch of gauge not stopped unless the engine key is turned
cluster and buzzer stop switch at the same to OFF. Repeat the pressure releasing
time for more than 5 seconds, mechatro procedure once again.
controller recognizes this is pressure release Operation:
control and out puts the following command. If the travel straight valve is turned to the
1) Puts out the minimum tilting command value pressure release position, the oil delivered by
to the pump proportional valve (PSV-1, PSV- each pump is unloaded to the tank passage. If
2). the spools are switched by pilot operation, the
2) Puts out a pressure release control revolution remaining pressure from the actuators may
command value to the governor motor. be relieved to the tank circuit, i.e. the main
(electric system). circuit pressure may be released.
3) Travel straight solenoid proportional valve
(PSV-C) is input the command value to
change the pressure release position.
4) Puts out a standby command value to the P1,
P2 bypass cut proportional valves. (a
command that does not put out the secondary
pressure of the P1, P2 bypass proportional
valves).
Operation:
1) The pump proportional valve minimizes the
delivery rates of the P1, P2 pumps.
2) The secondary pilot pressure for the travel
straight valve pressure release position
selection comes out of the travel straight
proportional valve (PSV-C), flows into the
PTb port of C/V (2) and switches the travel
straight valve to its pressure release position.
11.2 PRESSURE RELEASE MAIN CIRCUIT

Operation:
If the operating lever is shifted to neutral
during engine running and the pressure
release switch is kept pressed for more than
five seconds,“FAIL DRAIN HYD.
PRESS”is displayed on the gauge cluster
and the intermittent buzzer sounds
22-30
contineously. If the operating levers of the
right and left four
1 SE-22
P
SE-23
P
D2 P D1

a3 a4 PG
DB
B A
3
A B
M
PB PA
M A3 D1
P D2
B1 a5
4 B D EE F F A C
4
PUMP ASSY
Dr3 13 9 B A
B3
18
16 TOWER BLOCK
4.5kgf/cm
2
2 2.0kgf/cm P
2
(64psi)
(28psi) 19 SE-1
P
P2
CMR1
P1 T
SE-8 22
PL1
CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
STRAIGHT
CT2 REV. AL
CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
CT1
SWING RH
SWING LH
BOOM UP
ARM OUT
ARM IN
Br FOR. LEFT AS
ATT.
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
CCb P 10
Ac DUMP PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc
PAb UP
BOOM
LCa ARM
Pisc
21
IN PAa
P
SE-3 ATT. T P
PLc1 VALVE
P
CRb
CAr
CRa ARM R 7 11
SE-4
Ab UP OUT Ba
2 5 1 4 6 3
TRAVEL R. FOR.
P P
ARM SE-9 SE-10
P1 SOL/V BLOCK
P1 P2 VARIABLE
21 TRAVEL L. REV.
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
P2
CUT B 23
5 330kgf/cm (4700psi)
2
350kgf/cm (4970psi)
2
Bo2
BOOM(LH) R
2 2
H
VARIABLE Po
RECIRCULATION A
2 2
2 2
H
P1
1 PARKING BRAKE
BOOM(RH) R 6
15 R 8
H
BUCKET
22-31
PRESSURE DRAIN (RELEASING) CIRCUIT
12. HYD. LINES
12.1 HYD. LINES LIST (1/2)
DIVISION
Gr. ITEM NAME
1 －1 PUMP CONTROL LINES

－2
2 SOL. VALVE CONTROL LINES
3 ATT REMOTE CONTROL LINES

REMOTE CONTROL LINES
4 TERMINAL BLOCK CONTROL LINES
5 －1 P-T BLOCK CONTROL LINES

－2
－1
－2 KCME
－3 MAIN C/V
6 －4 CONTROL LINES With BOOM SAFETY
－5
－6 With B/A SAFETY
7 TRAVEL CONTROL LINES

－1 H/V CONTROL BOOM SAFETY
8
－2 LINES B/A SAFETY
9 EX.&N&B REMOTE CONTROL L.
10 VALVE CONTROL LINES
11 －1 PUMP HYD. LINES

－2
12 －1 UPPER HYD. LINES

－2
13 －1 RETURN HYD. LINES

－2
14 Add UPPER HYD. LINES (DOZER)

MAIN HYD. LINES UPPER
15 Add RETURN HYD. LINES (DOZER)
16 －1 UPPER HYD. LINES (Ex.&N&B)

－2
17 －1 SWIVEL HYD. LINES (For upper)

－2
－1
－2
－3 LOWER HYD. LINES
18 －4
－5
－6 LOWER HYD. LINES (DOZER)
－1
19 －2 SWIVEL HYD. LINES (For lower)
－3
20 －1 TRAVEL HYD. LINES
－2
22-32
NOTE : C/V : Control valve B/A : Boom/Arm
H/V : Holding valve
12.1 HYD. LINES LIST (2/2)
DIVISION
Gr. ITEM NAME

－1
－2 BOOM HYD. LINES
－3
21 －4 BOOM HYD. LINES (Ex.&N&B)
－5
－6 BOOM HYD. LINES (ARM SAFETY)
－1
－2 ARM HYD. LINES
－3
22 －4 ARM HYD. LINES (Ex.&N&B)
ATTACHMENT
－5 CONNECTOR ASSY
－1
－2 BOOM CYL.
－3
－4 BOOM CYL. with H/V
－5
－6 CYLINDER ARM CYL.
23
－7 HYD. LINES
－8 ARM CYL. with H/V
－9
－10 BUCKET CYL.
－11 DOZER CYL.
22-33
ITEM PART NAME REMARKS or PART No. ITEM PART NAME REMARKS or PART No. ITEM PART NAME MARKS or PART No. ITEM PART NAME MARKS or PART No.
Q’TY Q’TY Q’TY Q’TY
(1-1) STD 13 HOSE ; PF1/4 L=3150 1 Arm variable recirculation 32 GROMMET 1 (6-1) STD
(1-2) PUMP CONTROL LINES With dozer 14 HOSE ; PF1/4 L=3200 1 P1 bypass cut changeover 33 CLIP 1 (6-2) EXTRA & N&B
1 INLINE FILTER 1 ← 15 HOSE ; PF3/8 L=550 1 Safety lock changeover 35 TUBE 1 L=1200 (6-3) STD
2 CONNECTOR 3 ← PF3/8 16 HOSE ; PF3/8 L=3000 1 SOL. block prim. press. 36 CLIP 1 (6-4) MAIN C/V CONTROL EXTRA & N&B
3 TEE 1 ← PF1/4 17 HOSE ; PF3/8 L=3400 1 Drain 37 BUSHING 1 (6-5) STD
4 ELBOW 2 ← PF3/8 18 TUBE 1 L=600 (6-6) EXTRA & N&B
5 ELBOW 1 ← PF3/4 19 CLIP 2 (4) T. BLOCK CONTROL 2 CONNECTOR 3 ← ← ← ← 4 PF3/8
6 ELBOW 1 ← PF3/4 20 CAPSCREW 2 M10×70 1 BRACKET 1 3 CONNECTOR 3 ← ← ← ← ← PF1/4 L=23
8 ELBOW 1 ← PF1/4 with filter 21 WASHER 2 M10 2 TERMINAL BLOCK 1 4 CONNECTOR 2 ← ← ← ← ← PF3/8 L=23
9 CONNECTOR 1 ← PF1/4-PF3/8 22 RUBBER 1 L=700 3 PRESS. SENSOR 2 5 CONNECTOR 1 ← ← ← ← ← PF1/4-PF3/8 L=23
10 HOSE ; PF1/4 L=400 1 ← P2 Pump SOL. prim. press. 23 CLIP 3 4 ELBOW 5 PF3/8 6 CONNECTOR 3 ← ← ← ← ← PF3/8 L=46
11 HOSE ; PF3/8 L=1000 1 ← Pilot pump delively 24 CLIP 3 5 PLUG 1 PF1/4 7 CONNECTOR 1 ← ← ← ← ← PF3/8 ∅0.8 throtlling
12 HOSE ; PF1/4 L=900 1 ← P1 Pump SOL. prim. press. 25 GUIDE 1 6 ELBOW 1 PF3/8 8 CONNECTOR 2 ← 3 ← ← ← PF1/4-PF3/8
13 HOSE ; PF3/4 L=480 1 ← Suction 26 RUBBER 1 L=125 9 HOSE ; PF3/8 L=700 2 ⑥ Swing left, ⑧ Arm out 9 ELBOW 4 ← ← ← ← ← PF1/4
14 TEE 2 ← PF3/8 28 TUBE 1 L=1200 10 HOSE ; PF3/8 L=800 1 ① Bucket digging 10 ELBOW 9 ← 8 ← ← ← PF3/8
15 CAPSCREW 3 ← M10×20 29 CLIP 1 11 CAPSCREW 2 M8×25 11 ELBOW 7 8 6 7 6 7 PF1/4-PF3/8
16 WASHER 3 5 M10 30 RUBBER 1 12 WASHER 4 M8 12 TEE 1 ← ← ← ← ← PF1/4
17 CONNECTOR 1 ← PF1/4 L=23 with filter 13 NUT 2 M8 13 TEE 1 ← ← ← ← ← PF1/4
18 PLUG 2 ← PF1/4 (3) ATT REMOTE CONTROL 14 CAPSCREW 2 M12×25 14 PRESSURE SENSOR 5 ← ← ← ← ←
19 ELBOW 1 ← PF1/4-PF3/8 1 PILOT VALVE 2 15 WASHER 2 M12 15 ELBOW 1 ← ← ← ← ← PF3/8
20 ELBOW 1 ← PF3/8 2 CONNECTOR 2 PF1/4 with filter 16 CHECK VALVE 1 16 TEE 7 ← 8 ← 9 ← PF3/8
21 HOSE ; PF3/8 L=700 1 ← Drain 3 BOOT 2 17 CONNECTOR 1 ← ← ← ← ← PF3/8 L=28
22 HOSE GUARD － 1 L=600 4 CONNECTOR 10 PF3/8 (5-1) P-T BLOCK CONTROL 18 HOSE ; PF1/4 L=650 1 ← ← ← ← ← Drain
24 TUBE 1 ← L=790 5 ELBOW 1 PF3/8 1 P-T BLOCK 1 19 HOSE ; PF1/4 L=450 1 ← ← ← ← ← Drain
25 CLIP 1 ← 6 HOSE ; PF3/8 L=1400 1 Drain 2 CONNECTOR 1 PF3/8 20 HOSE ; PF1/4 L=500 1 ← ← ← ← ← Drain
26 PLUG 1 ← PF1/4 7 HOSE ; PF3/8 L=1950 1 Drain 3 ELBOW 3 PF3/8 21 ELBOW 2 ← ← ← ← ← PF1/4
28 TUBE 1 ← L=1000 8 HOSE ; PF1/4 L=1450 1 Prim. press. for P/V 4 ELBOW 3 PF1/4 22 TUBE 2 ← ← ← ← ← L=600
29 CLIP 2 ← 9 HOSE ; PF1/4 L=2000 1 Prim. press. for P/T 5 CAPSCREW 2 M8×40 23 TUBE 1 2 1 2 1 2 PF1/4-PF3/8
30 CONNECTOR 1 ← PF3/8 L=23 10 HOSE ; L=4300 GRAY 1 ⑤ Swing left 6 WASHER 2 M8 24 CONNECTOR 1 ← ← ← ← ← PF3/8 ∅1.2 throtlling
31 TUBE 1 ← L=300 11 HOSE ; L=4050 RED 1 ⑥ Swing right 9 PLUG 1 PF3/8 25 HOSE ; PF1/4 L=400 2 ← ← ← ← ← Arm conflux com.
32 TEE 1 ← PF3/8 12 HOSE ; L=4200 BLUE 1 ⑦ Arm in 10 ELBOW 1 PF3/8 26 HOSE ; PF1/4 L=760 2 ← ← ← ← ← RAb ; Boom up,
PLC1 ; Boom lock changeover
33 ELBOW － 2 PF1 13 HOSE ; L=4050 GREEN 1 ⑧ Arm out 12 CONNECTOR 1 PF1/4 L=23 27 ELBOW 3 ← ← ← ← ← PF1/4
34 HOSE ; PF1 L=760 － 1 Suction 14 HOSE ; L=3800 RED 1 ① Bucket digging 13 PLUG 1 PF1/4 28 TEE －－ 1 1 1 1 PF3/8
35 SOCKET BOLT － 2 M10×30 15 HOSE ; L=3800 BLUE 1 ② Bucket dump 16 CONNECTOR 1 PF3/8 29 CONNECTOR 2 ← ← ← ← ← PF1/4
36 TUBE 1 ← L=600 16 HOSE ; L=3400 GREEN 1 ③ Boom up & boom conflux 30 TUBE 3 ← ← ← ← ← L=650
37 ELBOW 1 ← PF3/8 17 HOSE ; L=3400 GRAY 1 ④ Boom down (5-2) P-T BLOCK CONTROL 31 TUBE 1 ← ← ← ← ← L=650
18 HOSE ; L=2600 1 Drain 1 BLOCK 1 32 TUBE 1 ← ← ← ← ← L=350
(2) SOL. VALVE CONTROL 19 HOSE ; L=470 2 2 CAPSCREW 2 M8×40 33 CHECK VALVE 2 ← ← ← ← ←
1 CAPSCREW 1 M10×20 20 CLIP 4 3 WASHER 2 34 TEE 2 ← ← ← ← ← 2-PF1/4-PF3/8
2 SOLENOID VALVE 1 21 RUBBER 1 L=220 4 ELBOW 3 PF3/8 35 HOSE ; PF3/8 L=760 1 ← ← ← ← ← Swing press. SW. com.
3 CONNECTOR 1 PF1/4 22 RUBBER 1 L=520 5 CONNECTOR 1 PF3/8 L=23 37 HOSE ; PF1/4 L=700 1 ← ← ← ← ← Arm lock changeover
4 CONNECTOR 1 PF3/8 L=23 with filter 23 RUBBER 1 L=300 6 CONNECTOR 1 PF1/4 L=23 38 CONNECTOR －－ 1 1 1 1 PF1/2-PF3/8
5 ELBOW 7 PF1/4 24 RUBBER 1 L=390 7 CONNECTOR 2 PF1/4 40 TEE 2 ← ← ← ← ← PF1/4
6 ELBOW 2 PF3/8 25 GROMMET 1 8 ELBOW 4 PF1/4 41 HOSE ; PF1/4 L=650 1 ← ← ← ← ← Drain
7 ELBOW 1 PF3/8 26 CLIP 2 9 ELBOW 3 PF3/8-PF1/4
8 WASHER 1 M10 27 CLIP 1 10 ELBOW 1 PF3/8
9 HOSE ; PF1/4 L=1600 1 Travel 2 speed changeover 28 SOCKET BOLT 8 M6×25 11 CONNECTOR 1 PF3/8
10 HOSE ; PF1/4 L=2200 1 Swing P/B prim. press. 29 WASHER 8 M6 12 TEE 2 PF1/4
11 HOSE ; PF1/4 L=2650 1 Travel straight changeover 30 CAPSCREW 3 M10×20 13 TEE 2 PF3/8
12 HOSE ; PF1/4 L=3250 1 P2 bypass cut changeover 31 WASHER 4 M10 14 ELBOW 1 PF3/8
22-34
ITEM PART NAME Q’TY REMARKS or PART No. ITEM PART NAME Q’TY REMARKS or PART No. ITEM PART NAME Q’TY MARKS or PART No. ITEM PART NAME Q’TY MARKS or PART No.
(7) TRAVEL CONTROL (9) Ex.&N&B REMOTE (11-1) EXTRA & N&B 29 HOSE 1 ← 1-14UNS L=1120
PUMP HYD. LINES
1 PILOT VALVE 1 1 HOSE ; PF1/4 L=3200 1 Boom ; N/B close (11-2) With dozer 30 HOSE 1 ← 1-14UNS L=1600
2 PRESSURE SENSOR 2 2 HOSE ; PF1/4 L=2900 1 Arm ; N/B open 1 TUBE 1 － Suction 31 TUBE 2 ← ∅21.7 L=16.5
3 CONNECTOR 1 PF3/8 3 HOSE ; PF1/4 L=400 2 P/V prim. press. 2 O RING 1 ← 32 HOSE 2 ← 1-14UNS L=1950
4 WASHER 4 M10 4 HOSE ; PF1/4 L=500 1 Drain 3 RUBBER 2 ← L=200 33 RUBBER 1 ← L=95
5 CONNECTOR 1 PF1/4 with filter 5 NUT 2 M8 4 HOSE 1 ← Suction 34 O RING 19 ← 1B A16
6 ELBOW 4 PF3/8 6 PIN 2 5 HOSE 1 ← 1-3/16-12UN L=900 35 O RING 1 ← 1B A18
7 HOSE ; PF1/4 L=400 1 Prime. press. for P/V 7 WASHER 6 M8 6 HOSE 1 ← 1-3/16-12UN L=1050 36 CLAMP 2 ← ∅21.7
8 HOSE ; PF3/8 L=450 1 Drain 8 SOCKET BOLT 4 M10×20 7 O RING 2 ← 37 GROMMET 1 ←
9 HOSE ; PF3/8 L=3000 2

□,1 RH Reverse, □,3 LH
9 LOCK WASHER 4 M10 8 O RING 2 ← 1B P26 38 CAPSCREW 4 ← M10×25
Reverse
10 SOCKET BOLT 4 M10×30 10 CAPSCREW 4 M10×25 9 ELBOW 1 ← 1-3/16-12UN, PF3/4 39 CAPSCREW 2 ← M10×45
11 HOSE ; PF3/8 L=2600 2

□,2 RH Forward, □,4 LH 11 WASHER 8 M10 10 CONNECTOR 1 ← 1-3/16-12UN, PF3/4 40 CAPSCREW 3 ← M12×45
Forward
12 CLIP 1 12 CONNECTOR 2 PF1/4 L=23 11 HALF CLAMP 4 ← 41 CAPSCREW 1 2 M12×90

13 TUBE 1 L=400 13 ELBOW 7 PF1/4 12 CAPSCREW 8 ← M10×35 44 RUBBER 1 ← L=125
H/V CONTROL LINES 14 ELBOW 2 PF1/4 with filter 13 SOCKET BOLT 4 ← M12×30 45 BRACKET 1 －
(8-1) STD 15 PILOT VALVE 1 14 LOCK WASHER 8 ← M10 46 CLAMP 1 －
(8-2) STD 16 CONNECTOR 1 PF1/4 15 LOCK WASHER 4 ← M12 47 TUBE 1 ←
1 BRACKET 1 ← 17 CAPSCREW 4 M8×20 16 CLIP 4 ← 49 PLUG 1 ← PF3/8
2 CONNECTOR 1 2 PF3/8 18 LOCK ASSY 1 RH. 17 PRESSURE SENSOR 2 ← LC52S00012P1 RETURN HYD. LINES
3 ELBOW 1 ← PF3/8 19 PEDAL 2 18 TUBE － 1 Suction (13-1) STD
4 ELBOW － 1 PF3/8 20 RUBBER 2 19 RUBBER 2 ← L=170 (13-2) With dozer
5 ELBOW 1 ← PF1/2 21 LOCK ASSY 1 LH. UPPER HYD. LINES 1 TUBE 1 ←
6 PLUG 5 2 PF3/8 22 PRESSURE SENSOR 1 (12-1) STD 2 TUBE 1 ←
7 BLOCK 1 ← 23 PLUG 1 PF1/4 (12-2) EXTRA & N&B 3 PLUG 1 － PF3/4
8 TUBE 1 ← L=1800 24 ELBOW 1 PF1/4 1 BRACKET － 1 4 CONNECTOR 1 ← PF3/4 L=140
9 TUBE － 1 L=400 25 HOSE ; PF1/4 L=2100 1 Arm ; Extra. 2 BUSHING 1 ← 2-∅26.5 5 CONNECTOR 2 ← PF1
10 TUBE 1 ← L=1900 26 HOSE ; PF1/4 L=420 1 Drain 3 BUSHING 1 ← ∅26.5-∅30.4 6 ELBOW 1 ← PF1/2
11 HOSE ; PF1/2 L=1700 1 ← Drain 27 HOSE ; PF1/4 L=2500 1 Boom ; Extra. 4 CLAMP － 1 7 ELBOW 2 ← PF3/4
12 HOSE ; PF1/2 L=2000 1 ← Drain 28 PILOT VALVE 1 7 SUPPORT 1 ← 8 ELBOW 2 ← PF1
13 HOSE ; PF3/8 L=2000 1 ← Boom down command 8 SUPPORT 1 ← 9 TUBE 1 ← L=1600
14 HOSE ; PF3/8 L=1750 1 ← Boom down command (10) HYD. VALVE CONTROL 9 CONNECTOR 7 ← 1-14UNS, PF3/4 10 HOSE 1 ← PF3/4 L=1600
15 HOSE ; PF3/8 L=2300 － 1 Arm in command 1 HOSE ; PF1/4 L=2700 1 10 CONNECTOR 1 ← 1-3/16-12UN, PF3/4 11 HOSE 1 ← PF1 L=3600
16 HOSE ; PF3/8 L=680 － 1 Arm in command 2 HOSE ; PF1/4 L=500 1 Prime pressure 11 CONNECTOR 4 ← 1-14UNS, PF3/4 12 HOSE 1 ← PF1 L=1600
17 HOSE ; PF1/2 L=660 － 1 Drain 3 HOSE ; PF1/4 L=600 1 Drain 12 CLIP 3 ← 13 COUPLING 2 ← ∅42.7
18 CAPSCREW 2 ← M8×20 4 CONNECTOR 1 PF1/4 13 ELBOW 1 ← 1-14UNS, PF1/2 14 CHECK VALVE 1 ←
19 TUBE － 1 L=600 5 ELBOW 1 PF1/4 14 ELBOW 1 ← 1-14UNS, PF1/2 15 CHECK VALVE 1 ←
20 TUBE － 1 L=600 6 SOLENOID VALVE 1 15 RUBBER 1 ← L=100 16 CONNECTOR 1 ← PF3/8 L=68
21 WASHER 2 ← M8 7 BRACKET 1 16 HOSE 1 ← 1-14UNS L=1070 17 ELBOW 1 ← PF1/2
22 WASHER 2 ← M10 8 CAPSCREW 2 17 TUBE 1 ← 18 TEE 1 ← PF3/8, 2-PF1/2
23 TUBE 1 ← L=1500 9 CAPSCREW 2 18 HOSE 1 ← 1-14UNS L=920 19 TEE 1 ← PF1/2
24 CAPSCREW 2 ← M10×25 10 WASHER 2 19 HOSE 1 ← 1 3/16-12UN L=2930 20 HOSE 1 ← PF1/2 L=1200
25 TUBE 1 － L=400 11 WASHER 2 20 HOSE 1 ← 1-14UNS L=2970 21 HOSE 1 ← PF1/2 L=700
26 CLIP 1 ← 12 ELBOW 1 21 HOSE 1 ← 1-14UNS L=2620 22 HOSE 1 ← PF1/2 L=1850
27 CLIP 1 ← 22 HOSE 1 ← 1-14UNS L=2570 23 WASHER 4 ← M10
30 ELBOW 2 ← PF1/2-PF3/8 23 WASHER 6 ← M10 24 CAPSCREW 4 ← M10×75
31 ELBOW － 1 PF1/2-PF3/8 24 WASHER 4 5 M12 25 O RING 1 ← 1A G45
25 GROMMET 1 ← 2-∅29 26 U BOLT 1 ←
26 CLIP 1 ← 27 WASHER 4 ← M8
27 HOSE 1 ← 1-14UNS L=1680 28 NUT 5 ← M8
28 HOSE 1 ← 1-14UNS L=1200 29 TUBE 1 ← L=1000
22-35
30 CLIP 5 ← 25 GROMMET 1 2-∅29 31 O RING 3 1-14UNS 13 HOSE ※ 2 ←←
31 CONNECTOR 1 ← PF1/2-PF3/4 L=70 26 CLIP 1 32 O RING 1 1 3/16-12UN 14 CLAMP 2 ←←
32 RUBBER 2 ← 27 HOSE 1 1-14UNS L=1680 33 HOSE 1 1-14UNS L=3050 15 CONNECTOR 4 ←←
33 CAPSCREW 1 ← M8×50 28 HOSE 1 1-14UNS L=1200 35 HOSE 1 1 3/16-12UN L=1950 16 CONNECTOR 2 ←←
34 BUSHING 5 ← 29 HOSE 1 1-14UNS L=1120 36 HOSE 1 PF1 L=850 17 CLAMP 2 ←←
35 SPACER 1 ← 30 HOSE 1 1-14UNS L=1600 37 CAPSCREW 4 M8×25 18 SPACER 4 ←←
36 RUBBER 1 ← L=200 31 TUBE 2 ∅21.7 L=16.5 38 WASHER 4 M8 19 WASHER 4 ← ← M8
37 CLIP 1 ← 32 HOSE 2 1-14UNS L=1950 40 ELBOW 1 PF3/8 20 LOCK WASHER 4 ← ← M8
33 RUBBER 1 41 BUSHING 1 21 CAPSCREW 4 ← ← M8×40
(14) UPPER HYD. LINES 34 O RING 19 1-14UNS 42 CLIP 1 22 HOSE 4 ← ← L=300
1 ELBOW 2 PF1/2-∅18 35 O RING 1 1-3/16-12UN 43 CAPSCREW 1 M12×20 23 CLIP 10 ← ←
2 TEE 1 2-PF1/2 PF1/4 36 CLAMP 2 ∅21.7 44 LABEL 1
3 ELBOW 1 PF1/2 37 GROMMET 1 45 HOSE 1 1-14UN L=1540 (18-4) LOWER HYD. E115SR With dozer
4 HOSE 1 ∅18 L=1300 38 CAPSCREW 4 M10×25 46 CONNECTOR 1 PF1 (18-5) LINES (DZ) E135SRLC With dozer
5 HOSE 1 ∅18 L=1200 39 CAPSCREW 2 M10×45 49 CAPSCREW 1 M12×35 1 TUBE 1 ← ∅22
6 HOSE 1 PF1/2 L=680 40 CAPSCREW 3 M12×45 50 TEE 2 PF1/2 2 TUBE 1 ← ∅22
7 O RING 2 1B P18 41 CAPSCREW 2 M12×90 51 TEE 1 2-PF1/2-PF3/8 3 TUBE 1 ← ∅22
8 PLUG 1 PF1/4 44 RUBBER 1 L=125 52 TEE 1 PF1/2 4 TUBE 1 ← ∅22
9 CONNECTOR 1 PF1/2 L=32 47 TUBE 1 53 CONNECTOR 1 PF1/2 5 TUBE 1 ← ∅18
10 HOSE GUARD 1 L=600 49 PLUG 1 PF3/8 54 CONNECTOR 1 PF1/2-PF1/4 L=20 6 TUBE 1 ← ∅18
55 PRESSURE SENSOR 1 7 TUBE ※ 1 ← ∅22
(15) RETURN HYD. LINES (16-2) UPPER HYD. LINES 56 HYD. VALVE ASSY 1 8 TUBE ※ 1 ← ∅22
1 CONNECTOR 1 PF1/2-PF3/4 1 HOSE 1 PF1/2 L=2150 57 TUBE 1 ∅18 9 TUBE ※ 1 ← ∅22
2 ELBOW 1 PF3/4 2 HOSE 1 PF1/2 L=2100 58 CONNECTOR 2 PF1/2-∅18 10 TUBE ※ 1 ← ∅22
3 HOSE 1 PF3/4 L=450 3 HOSE 1 PF1/2 L=600 59 O RING 2 1B P18 11 TUBE ※ 1 ← ∅18
4 HOSE GUARD 1 L=600 5 TUBE 1 L=1300 12 TUBE ※ 1 ← ∅18
7 CONNECTOR 1 PF1/2 L=41 (17-1) STD 13 TUBE 1 ← ∅15
SWIVEL HYD. LINES
(16-1) UPPER HYD. LINES 8 HOSE 1 PF1/2 L=520 (17-2) STD 14 TUBE 1 ← ∅15
1 BRACKET 1 9 CLIP 2 1 ELBOW 2 ← PF1 1-14UNS 15 TUBE 1 ← ∅15
2 BUSHING 1 2-∅26.5 10 BUSHING 1 2-∅23.5 2 ELBOW 2 ← PF1 1-14UNS 16 TUBE 1 ← ∅15
3 BUSHING 1 ∅26.5-∅30.4 11 CONNECTOR 1 PF1/2 3 CONNECTOR 1 ← PF1/2 L=130 17 TUBE 1 ← ∅15
4 CLAMP 1 12 CONNECTOR 2 PF1/2 L=32 4 O RING 4 ← 1-14UNS 18 TUBE 1 ← ∅15
7 SUPPORT 1 13 CAPSCREW 4 M12×30 5 ELBOW － 2 PF1/2-∅18 19 TUBE ※ 2 ←
8 SUPPORT 1 14 HOSE 1 PF1/2 L=1400 6 O RING － 2 1B P18 20 TUBE 4 ←
9 CONNECTOR 7 1-14UNS PF3/4 15 ELBOW 5 PF1/2 21 CLAMP 2 ←
10 CONNECTOR 1 1-3/16-12UN PF3/4 16 BRACKET 1 2-PF1/2 (18-1) E115SR STD 22 CONNECTOR 4 ←
LOWER
11 CONNECTOR 4 1-14UNS PF3/4 17 WASHER 6 M12 (18-2) HYD. E135SR STD 23 CONNECTOR 2 ←
LINES
12 CLIP 3 18 CONNECTOR 3 PF1/2 (18-3) E135SRLC STD 24 TEE 2 ←
13 ELBOW 1 1-14UNS PF1/2 19 ELBOW 1 PF1/2 1 TUBE 1 ← ← ∅22 25 CLAMP 4 ←
14 ELBOW 1 1-14UNS PF1/2 20 ELBOW 1 PF1/4-PF3/8 2 TUBE 1 ← ← ∅22 26 CLAMP 2 ←
15 RUBBER 1 L=100 21 PLUG 1 PF1/4 3 TUBE 1 ← ← ∅22 27 SPACER 4 ←
16 HOSE 1 1-14UNS L=1070 22 BRACKET 1 4 TUBE 1 ← ← ∅22 28 WASHER 4 ←
17 TUBE 1 23 SELECTOR VALVE 1 2400P1005F3 5 TUBE 1 ← ← ∅18 29 LOCK WASHER 6 ←
18 HOSE 1 1-14UNS L=920 24 BUSHING 1 ∅26.5-∅30.5 6 TUBE 1 ← ← ∅18 30 CAPSCREW 4 ←
19 HOSE 1 1 3/16-12UN L=2930 25 CONNECTOR 1 PF1-PF3/4 7 TUBE ※ 1 ← ← ∅22 31 CAPSCREW 2 ←
20 HOSE 1 1-14UNS L=2970 26 CONNECTOR 1 1-14UNS-PF3/4 8 TUBE ※ 1 ← ← ∅22 32 NUT 2 ←
21 HOSE 1 1-14UNS L=2620 27 CONNECTOR 1 1-14UNS-PF3/4 9 TUBE ※ 1 ← ← ∅22 33 HOSE 4 ← L=300
22 HOSE 1 1-14UNS L=2570 28 ELBOW 1 PF1 10 TUBE ※ 1 ← ← ∅22 34 CLIP 10 ←
23 WASHER 6 29 ELBOW 1 1-14UNS-PF3/4 11 TUBE ※ 1 ← ← ∅18
24 WASHER 5 30 ELBOW 1 1 3/16-12UN-PF3/4 12 TUBE ※ 1 ← ← ∅18
22-36 NOTE ; The parts with mark ※ are having different part numbers.
(18-6) LOWER HYD. LINES (20-1) TRAVEL HYD. LINES (21-3) EXTRA & N&B (22-3) ARM HYD. LINES EXTRA & N&B
BOOM HYD. LINES (Ex.+ N&B)
1 TUBE 1 1 CONNECTOR 4 PF3/4 (21-4) EXTRA & N&B (22-4) (Ex. + N&B)
2 TUBE 1 2 CONNECTOR 2 PF1/2 1 TUBE ※ 1 ← ∅34.0×t4.0 1 TUBE ※ 1 ← ∅34.0×t4.0
3 TUBE 1 3 CONNECTOR 2 PF1/4 2 TUBE ※ 1 ← ∅21.7×t2.8 2 TUBE ※ 1 ← ∅27.2×t3.2
4 TUBE 1 4 O RING 4 1B P24 3 TUBE ※ 1 ← ∅34.0×t4.0 3 TUBE ※ 1 ← ∅18×t2.5
5 TUBE ※ 1 5 O RING 2 1B P18 4 TUBE ※ 1 ← ∅21.7×t2.8 4 TUBE ※ 1 ← ∅18×t2.5
6 TUBE ※ 1 5 TUBE ※ 1 ← ∅18×t2.5 5 TUBE ※ 1 ← ∅18×t2.5
7 TUBE 1 (20-2) TRAVEL HYD. LINES 6 TUBE ※ 1 ← ∅18×t2.5 6 TUBE ※ 1 ← ∅18×t2.5
8 TUBE 1 1 CONNECTOR 4 PF3/4-∅22 7 TUBE ※ 1 ← ∅18×t2.5 7 HOSE ※ 1 (←) L=1200 (L=1300)
9 TUBE 1 2 CONNECTOR 2 PF1/2-∅22 8 TUBE ※ 1 ← ∅18×t2.5 8 HOSE ※ 1 (←) L=1450 (L=1400)
10 TUBE 1 3 CONNECTOR 2 PF1/4 9 CONNECTOR 2 ← ∅18-∅18 9 HOSE ※ 2 (←) L=1050 (L=1100)
11 TUBE 1 4 O RING 4 1B P24 10 CONNECTOR 2 ← ∅18-PF1/2 10 STOP VALVE 2 ← 24100P1006F1
12 TUBE 1 5 O RING 2 1B P18 11 O RING 1 ← 11 CONNECTOR 2 ←
13 HOSE 2 L=300 12 O RING 3 4 12 TEE 2 ← 3-M26×P1.5
14 HOSE 2 (21-1) 13 O RING 1 ← 13 PLUG 2 ← M26×P1.5
BOOM HYD. LINES (STD)
15 CLIP 12 (21-2) 14 O RING 1 ← 14 PLUG 2 ←
16 CONNECTOR 6 1 TUBE ※ 1 ← ∅27.2×3.2 15 PLUG 2 ← PF1 15 NUT 2 ←
17 CLAMP 2 2 TUBE ※ 1 ← ∅21.7×2.8 16 CLAMP 2 ← ∅18 16 CLAMP 1 ←
18 CLAMP 2 3 TUBE ※ 1 ← ∅21.7×2.8 7 CLAMP 3 ← ∅22 17 CLAMP 1 ←
19 CAPSCREW 4 M10×40 4 TUBE ※ 1 ← ∅21.7×2.8 18 CLAMP 3 ← ∅35 18 CLAMP 1 ←
20 LOCK WASHER 4 M10 5 CLAMP 4 ← 19 CLAMP 1 ← ∅18-∅18 19 BRACKET 2 ←
6 CLAMP 2 ← 20 CLAMP 4 ← ∅18-∅22 20 O RING 3 ←
(19-1) SWIVEL HYD. LINES (STD LOWER) 7 CLAMP 2 ← 21 CLAMP 4 ← ∅18-∅22 21 O RING 1 ←
1 CONNECTOR 4 PF1-∅22 8 CAPSCREW 1 ← M10×40 22 CLAMP 1 ← ∅22-∅35 22 CAPSCREW 8 ← M8×25
2 CONNECTOR 2 PF1/4 9 CAPSCREW 5 ← M10×45 23 CAPSCREW 10 ← M10×45 23 CAPSCREW 1 ← M10×45
3A TEE － PF1/2-∅18 10 CAPSCREW 2 ← M12×45 24 CAPSCREW 1 ← M12×65 24 CAPSCREW 1 ← M10×55
3B CONNECTOR 2 PF1/2-∅18 11 LOCK WASHER 6 ← M10 25 CAPSCREW 3 ← M14×60 25 CAPSCREW 4 ← M12×45
4 O RING 4 1B P29 12 LOCK WASHER 2 ← M12 26 LOCK WASHER 10 ← M10 26 CAPSCREW 1 ← M14×65
5 O RING 1 1B P18 13 O RING 6 ← 1B A16 27 LOCK WASHER 1 ← M12 27 WASHER 8 ← M8
14 O RING 2 ← 1B A18 28 LOCK WASHER 3 ← M14 28 WASHER 4 ←
(19-2) SWIVEL HYD. LINES (DZ LOWER) 29 LOCK WASHER 2 ← M10
1 CONNECTOR 4 PF1-∅22 (21-5) BOOM HYD. LINES STD 30 LOCK WASHER 4 ← M12
2 CONNECTOR 2 PF1/4 (21-6) (Boom / Arm safety) STD 31 LOCK WASHER 1 ← M14
3 TEE 1 PF1/2-∅18 1 HOSE ※ 1 (←) PF1/2 L=3900 (4100)
4 O RING 4 1B P29 2 HOSE ※ 1 (←) PF3/8 L=3800 (4000) (22-5) CONNECTOR ASSY
5 O RING 3 1B P18 3 HOSE GUARD 1 ← L=500 1 CONNECTOR 1
6 CONNECTOR 2 PF1/2 4 BRACKET 1 ← 2 PLUG 1
5 CONNECTOR 2 ← PF1/2-PF3/8 3 O RING 1 1B P24
(19-3) SWIVEL HYD. LINES (L LOWER) 6 CONNECTOR 2 ← 2-PF3/8
1 CONNECTOR 4 PF1-∅22 7 CAPSCREW 2 ← M10×20
2 CONNECTOR 2 PF1/4 8 CAPSCREW 1 ← M10×16
3A TEE － PF1/2-∅22 9 LOCK WASHER 2 ← M10
3B CONNECTOR 2 10 WASHER 1 ← M10
4 O RING 4 1B P29 11 CLIP 1 ←
5 O RING 1 1B P18 12 CLIP 20 ←
(22-1) STD
ARM HYD. LINES (STD)
(22-2) STD
1 HOSE ※ 2 (←) L=1050 (L=1100)
22-37
(23-1) STD 33 PLATE 1 ← 17 LOCK WASHER 1 ← M10
BOOM CYL. HYD. LINES
(23-2) STD 34 CLAMP 1 ← 18 LOCK WASHER 4 ← M10
1 TUBE ※ 1 ← 35 CONNECTOR 1 ← 2-PF1/2 19 O RING 2 ← 1B A16
2 TUBE ※ 1 ← 36 CONNECTOR 1 ← PF1/4-9/16-18UNF 20 O RING 2 ← 1B P26
3 TUBE 1 ← 37 ELBOW 1 ← PF1/4-9/16-18UNF 21 CLIP 20 ←
4 TUBE 1 ← 38 TEE 1 ← PF1/2-PF1/4-1-14UNS
5 HOSE 4 ← L=740 39 CAPSCREW 2 ← M5×40 (23-9) STD
BUCKET CYL. HYD.
6 CLAMP 2 ← 40 CAPSCREW 2 ← M8×25 (23-10) STD
7 CAPSCREW 2 ← M10×45 41 CAPSCREW 2 ← M10×65 1 TUBE ※ 1 ←
8 CAPSCREW 16 ← M10×30 42 NUT 2 ← M10×8 2 HOSE ※ 1 ←
9 LOCK WASHER 2 ← M10 43 WASHER 2 ← M8 3 CLAMP 1 ←
10 CONNECTOR 2 ← 44 WASHER 2 ← M10 4 CAPSCREW 1 ← M10×50
11 GREASE NIPPLE 2 ← 45 LOCK WASHER 2 ← M5 5 SOCKET BOLT 4 8 M10×30
12 O RING 4 ← 1B A16 46 O RING 1 ← 6 O RING 2 ← 1B A16
13 O RING 4 ← 1B P26 7 O RING 2 ← 1B P26
(23-5) STD 8 GREASE NIPPLE 1 ←
ARM CYL. HYD. LINES
(23-3) BOOM CYL. HYD. STD (23-6) STD 9 GREASE NIPPLE 1 ←
(23-4) (Boom safety) STD 1 TUBE ※ 1 ← 10 LOCK WASHER 1 ← M10
1 TUBE ※ 1 ← ∅21.7×t2.8 2 HOSE ※ 1 (←) L=870 (L=870) 11 SOCKET SCREW 4 － M10×35
2 TUBE ※ 1 ← ∅21.7×t2.8 3 HOSE ※ 1 (←) L=830 (L=800)
3 TUBE 2 ← ∅21.7×t2.8 4 CLAMP 1 ← (23-11) DOZER CYL. HYD.
4 HOSE 4 ← 1-14UNS L=740 5 HALF CLAMP 2 ← 1 CONNECTOR 4 PF1/2
5 HOSE 1 ← 1-14UNS L=1250 6 CONNECTOR 1 ← 2 O RING 4 1B P18
6 HOSE 1 ← 3/8 L=1400 7 SOCKET BOLT 4 ← M10×30
7 HOSE 1 ← 1/2 L=1400 8 CAPSCREW 1 ← M10×45
8 HOLDING VALVE ※ 1 ← 9 SOCKET BOLT 4 ← M10×35
9 HOLDING VALVE ※ 1 ← 10 GREASE NIPPLE 1 ←
10 CONNECTOR 1 ← 2-PF3/8 11 O RING 1 ← 1B A16
11 CONNECTOR 2 ← 2-PF3/8 12 O RING 2 ← 1B P26
12 CONNECTOR 1 ← PF1/2-1-14UNS 13 LOCK WASHER 1 ← M10
13 CONNECTOR 2 ← PT1/4-PF1/4 14 LOCK WASHER 4 ← M10
14 CONNECTOR 1 ← PF1/2-PF3/8
15 ELBOW 1 ← 2-PF3/8 (23-7) ARM CYL. HYD. STD
16 ELBOW 1 ← 2-PF3/8 (23-8) (Arm safety) STD
17 ELBOW 2 ← PF3/4-1-14UNS 1 TUBE ※ 1 ←
18 ELBOW 1 ← PF1/2-PF3/8 2 HOSE ※ 1 (←) L=870 (L=870)
19 ELBOW 1 ← 2-PF1/2 3 HOSE ※ 1 (←) L=830 (L=800)
20 TEE 1 ← 3-PF3/8 4 HOLDING VALVE 1 ←
21 TEE 1 ← 3-PF1/2 5 CONNECTOR 1 ← 2-PF3/8
22 GREASE NIPPLE 2 ← PT1/8 6 CONNECTOR 1 ← 2-PF3/8
23 CLAMP 2 ← 7 CONNECTOR 1 ← PT1/4-PF1/4
24 CAPSCREW 2 ← M10×45 8 ELBOW 1 ← PF1/2-PF3/8
25 CAPSCREW 8 ← M10×30 9 ELBOW 1 ←
26 CAPSCREW 8 ← M10×60 10 PLUG 1 ←
27 LOCK WASHER 4 ← M10 11 GREASE NIPPEL 1 ← PT1/8
28 O RING 8 ← 12 CLAMP 1 ←
29 O RING 4 ← 1B P26 13 HALF CLAMP 2 ←
30 CLIP 10 ← 14 CAPSCREW 1 ← M10×45
31 OIL PRESS. SWITCH 1 ← 15 SOCKET SCREW 4 ← M10×35
32 PLATE 1 ← 16 SOCKET SCREW 4 ← M10×60
22-38 NOTE ; The parts with mark ※ are having different part numbers.
This page is left blank for editing convenience
22-39
PILOT PIPNG
(1-1) Pump control lines STD
(1-2) Pump control lines For DOZER
22-40
(2) SOL. valve control lines
22-41
(3) ATT remote control lines
22-42
(4) Terminal block control lines (5-1) P-T block control lines STD
(5-2) P-T block control lines EXTRA & N & B
22-43
(6-1) Main C/V control lines (1/2) KCME
(6-2) Main C/V control lines (1/2) KCME N&B
(6-3) Main C/V control lines (1/2) KCME With BOOM SAFETY
(6-4) Main C/V control lines (1/2) KCME N & B with BOOM SAFETY
(6-5) Main C/V control lines (1/2) KCME With BOOM・ARM SAFETY
(6-6) Main C/V control lines (1/2) KCME N & B with BOOM・ARM SAFETY
22-44
Main C/V control lines (2/2)
22-45
(7) Travel control lines
22-46
(8-1) Holding valve control lines BOOM SAFETY
(8-2) Holding valve control lines BOOM・ARM SAFETY
22-47
(9) Extra & N & B remote control lines
22-48
(10) Hyd. valve control lines
22-49
(11-1) Pump hyd. lines STD
(11-2) Pump hyd. lines DOZER
22-50
(12-1) Upper hyd. lines (1/2)
(12-2) Upper hyd. lines (1/2) EXTRA & N & B
22-51
(12-1) Upper hyd. lines (2/2)
(12-2) Upper hyd. lines (2/2) EXTRA & N & B
22-52
(13-1) Return hyd. lines (1/2) STD
(13-2) Return hyd. lines (1/2) For DOZER
22-53
(13-1) Return hyd. lines (2/2) STD
(13-2) Return hyd. lines (2/2) DOZER
22-54
(14) Add upper hyd. lines DOZER (15) Add return hyd. lines DOZER
22-55
(16-1) Upper hyd. lines (1/2) EXTRA & N&B
22-56
Upper hyd. lines (2/2) EXTRA & N&B
22-57
(16-2) Upper hyd. lines (1/2) EXTRA & N&B & DOZER
22-58
Upper hyd. lines (2/2) EXTRA & N & B & DOZER
22-59
(17-1) Swivel hyd. lines STD (17-2) Swivel hyd. lines DOZER
22-60
(18-1) Lower hyd. lines E1115SR
(18-2) Lower hyd. lines E135SR
(18-3) Lower hyd. lines E135SRLC
(19-1 ) S/J hyd. lines
(20-1) Travel hyd. lines ; YV12H00003F1
22-61
(18-4) Lower hyd. lines DOZER E115SR
(18-5) Lower hyd. lines DOZER E135SRLC
(19-2) S/J hyd. lines
22-62
(18-6) Lower hyd. lines E135SRL
(19-3) S/J hyd. lines
(20-2) Travel hyd. lines
※ ※
22-63
(21-1) Boom (4.25M) hyd. lines E115SR
(21-2) Boom (4.6M) hyd. lines E135SR(LC)
22-64
(21-3) Boom hyd. lines EXTRA & N & B, E115SR
(21-4) Boom hyd. lines EXTRA & N & B, E135SR(LC E135SR (LC)
E135SR (LC)
E115SR
E115SR (LC)
E135SR (LC)
E115SR
22-65
(21-5) Boom hyd. lines Boom / Arm SAFETY E115SR
(21-6) Boom hyd. lines Boom / Arm SAFETY E135SR(LC)
22-66
(22-1) Arm hyd. lines STD, E115SR
(22-2) Arm hyd. lines STD, E135SR(LC)
22-67
(22-3) Arm hyd. lines Ex. + N&B E115SR
(22-4) Arm hyd. lines Ex. + N&B E135SR(LC)
22-68
(22-5) Connector assy N&B (23-1) Boom cylinder hyd. lines STD E115SR
(23-2) Boom cylinder hyd. lines STD E135SR(LC)
22-69
(23-3) Boom cylinder hyd. lines
(23-4) Boom cylinder hyd. lines
22-70
(23-5) Arm cylinder hyd. lines STD E115SR (23-9) Bucket cylinder hyd. lines E115SR
(23-6) Arm cylinder hyd. lines STD E135SR(LC) (23-10) Bucket cylinder hyd. lines E135SR(LC)
(23-11) Dozer cylinder hyd. lines
(23-7) Arm cylinder hyd. lines With HOLDING VALVE E115SR

(23-8) Arm cylinder hyd. lines With HOLDING VALVE E135SR(LC)
22-71
NOTE
22-72
E115SR
E135SR
SECTION 23 ELECTRICAL SYSTEM
TABLE OF CONTENTS
1. Electric circuit diagram .......................................................................................... 23-1
2. Electrical equipment list ........................................................................................ 23-4
3. Harness ................................................................................................................ 23-5

3.1 Harness list ................................................................................................................................... 23-5
3.2 Harness connection drawing ......................................................................................................... 23-6
3.3 Operators controls ......................................................................................................................... 23-7
3.4 Controller assy .............................................................................................................................. 23-8
3.5 Instrument panel assy ................................................................................................................. 23-12
3.6 Upper electric assy ...................................................................................................................... 23-13
3.7 Upper harness assy .................................................................................................................... 23-14
3.8 Engine harness assy ................................................................................................................... 23-20
3.9 Floor harness assy ...................................................................................................................... 23-23
3.10 Cab harness assy ...................................................................................................................... 23-25
3.11 Cab assy ................................................................................................................................... 23-29
3.12 Battery install and battery .......................................................................................................... 23-31
3.13 Llight install ................................................................................................................................ 23-31
3.14 Boom harness assy ................................................................................................................... 23-33
3.15 Fuel pump assy ......................................................................................................................... 23-34
Fig. 1 (1/3) Electric circuit diagram
23-1
23-2
23-3
2. ELECTRICAL EQUIPMENT LIST
Group Code NAME Group Code NAME Group Code NAME

C－1 Mechatro controller (E115SR) M－1 Starter motor (24V×4.5kW) SV－1 Swing parking sol.
C－1 Mechatro controller (E135SR(LC)) M－2 Governor motor SV－3 2-speed travel sol.
CONTROLLER
C－2 Gauge cluster (KCME Spec.) M－3 Wiper motor SV－4 Lever lock sol.
MOTOR
SOLENOID
M－4 Washer motor (tank assy) SV－6 Clockwise rotate sol
C－4 Air conditioner controller (A/C Acc.) M－9 Fuel pump SV－7 Counterclockwise rotate sol.
M－11 Fuel supply pump SV－24 Extra depressure sol.
D－1 Diode R－1 Battery relay

D－2 Diode R－3 Glow relay PSV－A Arm variable recirculation proportional valve
PROPORTIONAL VALVE
D－3 Diode R－4 Safety relay PSV－B P2 bypass cut proportional valve
DIODE
D－4 Diode R－5 Wiper motor relay PSV－C Travel straight proportional valve
SOLENOID
D－5 Diode R－6 Washer motor relay PSV－D P1 bypass cut proportional valve
D－6,7,8,9 Diode R－7 Horn relay PSV－P1 P1 pump proportional valve
R－8 Work light relay PSV－P2 P2 pump proportional valve
R－9 Extra depressure relay
RELAY
E－1 Fuse box R－10 Cab work light relay 1
E－1 Alternator (E115SR) R－11 Cab work light relay 2
E－2 Alternator (E135SR(LC)) R－19 Flasher relay
E－3 Hour meter R－20 Timer relay SW－1 Key switch
E－4 Horn (Low) R－22 Clockwise rotate relay
E－5 Horn (High) R－23 Counterclockwise rotate relay SW－3 2-speed travel switch
ELECTRIC FITTINGS
E－6 Cigarette lighter R－28 Auto idle stop relay 1 SW－4 Swing parking release switch
E－7 Tuner AM & FM R－29 Auto idle stop relay 2 SW－5 KPSS release switch
E－8 Speaker (Left) SW－6 E/G water temperature switch [105℃(221°F)]
E－9 Speaker (Right) SE－1 Pressure sensor (low pressure) bucket digging SW－7 E/G oil pressure switch
E－10 Receiver drier (A/C Accessory) SE－2 Pressure sensor (low pressure) bucket dump SW－8 Air filter clogging switch
E－11 A/C compressor (A/C Accessory) SE－3 Pressure sensor (low pressure) boom up SW－10 Horn switch left
E－14 Resistor (P1, P2 pump proportional valve) SE－4 Pressure sensor (low pressure) boom down SW－11 Lever lock switch (Limit SW.)
E－16 DC－DC converter SE－5 Pressure sensor (low pressure) swing SW－13 Air conditioner switch (Panel assy)
E－17 Power socket 12V SE－7 Pressure sensor (low pressure) arm in SW－16 Auto accel release switch (Decel)
E－25 Battery (95E41R) SE－8 Pressure sensor (low pressure) arm out SW－17 Swing flasher select switch
SE－9 Pressure sensor (low pressure) travel right SW－20 Horn switch right (Handle assy)
SWITCH
SE－10 Pressure sensor (low pressure) travel left SW－21 Work light switch
L－1 Boom work light left SE－11 Pressure sensor (low pressure) ; P2 option SW－22 Single/Conflux flow select switch
L－2 Work light right SE－11 Pressure sensor (low pressure) ; N&B (Opt.) SW－23 Wiper inter lock switch
SENSOR
L－3 Room light (Cab) SE－12 Pressure sensor (low pressure) ; Offset left opt. SW－30 Rotary light switch
L－4,5,78 Cab work light (front) SE－12 Pressure sensor (low pressure) ; Offset right opt. SW－32 Overload indicate switch
LIGHT
L－8 Engine room light SE－13 E/G speed sensor SW－39 Overload pressure switch
L－9 Boom work light (right, left) SE－14 E/G water temperature sensor SW－42 Engine room light switch
L－10 Cab work light (rear) SE－15 Fuel sensor SW－43 Jib press switch : option
L－11,1 Swing flasher (right, left) SE－16 Accel potentiometer SW－44 Extra press switch : option
2
L－15 Rotary light SE－20 Pressure sensor (low pressure) ; P1 option SW－46 Clockwise rotate sw.
SE－20 Pressure sensor (low pressure) ; Jib extend / retract opt. SW－47 Counterclockwise rotate sw.
SE－22 Pressure sensor (high pressure) ; P1 pump SW－50 Door SW.
SE－23 Pressure sensor (high pressure) ; P2 pump SW－52 Auto idle stop select SW.
SE－26 Pressure sensor (low) ; Revolution R/L Opt.
23-4
3. HARNESS
3.1 HARNESS LIST
DIVISION DWG. No. HARNESS
GROUP ITEM NAME SPEC. NAME ITEM ITEM

3.3 OPERATORS CONTROLS
DZ
3.4 CONTROLLER ASSY Cab harness assy 3
Instrument panel harness 3-4
3.5 INSTRUMENT PANEL ASSY ――
3.6 UPPER ELEC ASSY Harness ; E/G room light 13
UPPER 3.7 UPPER HARNESS ASSY Cable ; Starter 1

FRAME Cable ; Battery relay 2
Cable ; Battery 3
Cable ; Ground 4
Cable ; Frame ground 6
Harness ; Overload SW. 24
Harness ; Main 25
3.8A E/G HARNESS ASSY Harness ; E/G sub 1A
3.8B 1B
3.9 FLOOR HARNESS ASSY Cable ; Ground 3
Harness ; Under floor 10
3.10 CAB HARNESS ASSY Harness ; Instrument panel LH 1
Harness ; Instrument panel RH 2
Harness ; Cab front 3
CAB 3.11 CAB ASSY Harness ; Wiper 2-37
Harness ; Curl code 61
CAB INSTALL Harness ; Manual window wiper 64
Antena 65
Harness ; Room lamp 189
BATTERY 3.12 BATTERY INSTALL
BATTERY
LIGHT 3.13 3.13.1 DECK
INSTALL 3.13.2 CAB Harness ; 5 Work light 2-18
3.13.3 BOOM
BOOM 3.14 BOOM HARNESS ASSY Harness 2
1
FUEL 3.15 FUEL PUMP ASSY
23-5
3.2 HARNESS CONNECTION DRAWING
Fig. 2 Harness connection drawing

23-6
3.3 OPERATORS CONTROLS
E115SR STD
OPERATORS CONTROLS
E115SR DOZER
ITEM PART NAME Q’TY REMARKS
6 GRIP ASSY 1 ← Travel
6-2 SWITCH 1 ← 1-2 Speed
35 CONTROL BOX ASSY 1 ← LH
35-21 LIMIT SWITCH 1 ←
35-39 GRIP ASSY 1 ← LH
35-39-2 HANDLE ASSY 1 ←
36 CONTROL BOX ASSY 1 ← RH
36-12 GRIP ASSY 1 ← 3 switch
36-12-2 HANDLE ASSY 1 ←
Fig. 3 Operators controls

23-7
3.4 CONTROLLER ASSY
E115SR
CONTROLLER ASSY
E135SR(LC)
3 CAB HARNESS ASSY 1 ← Not shown
3-4 HARNESS 1 ← Instrument panel
5 RESISTOR 1 ←
6 SWITCH ASSY 1 ← Swing parking
7 SWITCH ASSY 1 ← KPSS
8 RELAY 8 ←
20 TIMER RELAY 1 ←
24 CONTROLLER － 1
26 CONTROLLER 1 －
31 RELAY 1 ←
Fig. 4 Controller assy
23-8
3.4.3-4 INSTRUMENT PANEL HARNESS (1/2)
Fig. 5 (1/3) Instrument panel harness

23-9
3.4.3-4 INSTRUMENT PANEL HARNESS (2/2)

23-10
23-11
3.5 INSTRUMENT PANEL ASSY
INSTRUMENT PANEL E115SR
ASSY E135SR
2 GAUGE CLUSTER － 1
11 SPEAKER 2 －
21 SWITCH 1 － Decel
26 CONVERTER 1 － DC-DC
38 SOCKET 1 － 12V
40 SWITCH 1 － Over load indicate
41 SWITCH 1 － Rotary light
46 HOUR METER 1 －
61 PANEL ASSY － 1 RH
61-2 POTENTIOMETER － 1
61-3 KEY SWITCH － 1
NAME PLATE INSTALL

1 SWITCH 1 Auto idle stop select
Fig. 6 Instrument panel assy

23-12
3.6 UPPER ELEC ASSY 3.6.13 E/G ROOM HARNESS
E115SR (L)
UPPER ELEC ASSY
E135SR (LC)
1 BATTERY RELAY 1
2 HORN 1 High
3 HORN 1 Low
13 HARNESS 1 E/G room light
14 ROOM LIGHT 1 E/G
16 SWITCH 1 E/G room light
Fig. 7 Upper elec assy

23-13
3.7 UPPER HARNESS ASSY
UPPER HARNESS ASSY

1 CABLE 1 Starter
2 CABLE 1 Battery relay
3 CABLE 1 Battery
4 CABLE 1 Earth
6 HARNESS 1 Frame earth
24 HARNESS 1 Over load SW.
25 HARNESS 1 Main
Fig. 8 (1/3) Upper harness assy

23-14
23-15
23-16
3.7.1 STARTER CABLE 3.7.4 BATTERY GROUND CABLE
INSTALL TERMINAL
TERMINAL CORRUGATE TERMINAL BOLT DOUBLE- 60-8L
NUT
60-8 60sq TUBE BA710 WOUND TAPING
60sq
INSTALL
TERMINAL VIEW Ⅰ
WHITE TAPING CORRUGATE CAP BC816
YAZAKI : 7034-1283
CAP
1PAF-58Y
A Ⅰ
YAZAKI : 7034-1283 TAPING
AVX5sq
TERMINAL Fig. 12
LA310
Wind two connectors back to back 3.7.6 FRAME GROUND CABLE : LE13E01006P1
with vinyl tape and put a cap.
DETAIL OF A
CONNECTORS SELECTION TABLE

CONNECTOR PART NO.
NAME MAKER LA308 5B 5B
(PIN NUM.) HOUSING TERMINAL
1PAM
1PAF-58Y YAZAKI 7123-4210-40 7116-3250 Fig. 13 YAZAKI : 7122-3010
Fig. 9
3.7.2 BATTERY RELAY CABLE
TERMINAL TERMINAL
60-8 BC818
CAP AV60B CAP
YAZAKI : 7034-1283 BTC-135-R (RED)
Fig. 10
3.7.3 BATTERY CABLE
CODE AV60B CODE

CAP TERMINAL TERMINAL CAP
Fig. 11
23-17
3.7.25 MAIN HARNESS
Fig. 14 (1/2) Main harness

23-18
3.7.24 OVER LOAD SWITCH HARNESS ; YY13E01072P1
Fig. 14A
Fig. 14 (2/2) Main harness
23-19
p
3.8 ENGINE HARNESS ASSY BY USING EXISTING CAPSCREW

E/G SUB HARNESS TIGHTEN LIFTING LUG FOR
ENGINE HARNESS ASSY E115SR ENGINE AND CLIP TOGETHER.
CONNECTOR (GRAY) TIGHTENING TORQUE
ITEM PART NAME Q’TY REMARKS :
STARTER TERMINAL
1 HARNESS 1 E/G sub
E115SR
CLIP
CLIP TERMINAL AND STARTER CABLE
CONNECTOR WITH
RUBBER CAB
TO BATTERY RELAY
VIEW Ⅰ
MAIN HARNESS
DETAIL OF STARTER MOTOR
GND (E/G ACCESSORY)
TIGHTEN GND.CABLE CONNECTOR OF ENGINE SPEED SENSOR
STARTER MOTOR (M-1) TIGHTENING TORQUE :
8.5kgfym {61 lbfyft}
GOVERNOR MOTOR (M-2)

INSTALL CLIP AS
CLIP CONNECTOR DIRECTION SHOWN BELOW.
OF HARNESS
SAFETY RELAY (R-4)
A
DIS-
AIR HEATER E/G WATER HIGH CHARGE
TEMP. LIMIT SW. (SW-7)

SUCTION
E/G WATER
NOT TO PASS TEMP SW. (SW-6)
B OVER HEAD
UNDER SUPPLIED
C NUT
COVER. WITH E/G.
E/G COOLANT THERMO VIEW Ⅱ
SENSOR (SE-14)
E/G COOLANT THERMO ALTERNATOR (E-2)
SENSOR (SE-14)
TIGHTEN ITEM CLIP AND HARNESS
GND TERMINAL OF ITEM 1. WASHER
TIGHTENING TORQUE :
5.1kgfym {37 lbfyft}
E/G SUB HARNESS DETAIL D
TIGHTENING TORQUE :
0.5～0.7kgfym {3.6～5.1 lbfyft}
TIGHTENING
D TORQUE :
AIR HEATER 0.2～0.5kgfym FIX HARNESS AT
{1.4～3.6 lbfyft} WHITE TAPING
POSITION
WIRING HARNESS OUT CLIP
OF TOUCH ENGINE
CLIP
BY USING EXISTING FIX CONNECTOR CLIP
CAPSCREW TIGHTEN WITH BRACKET FIX THE HARNESS
LIFTING LUG FOR AS DRAWING
MAIN HARNESS
ENGINE AND CLIP
TOGETHER.
DETAIL A NOT TOUCH THE

HARNESS
DETAIL OF ENGINE SPEED SENSOR DETAIL OF GOVERNOR MOTOR BRACKET
AIR COMPRESSOR SIDE HARNESS
DETAIL OF ALTERNATOR
DETAIL B DETAIL C
Fig. 15 (1/2) Engine harness assy
23-20
BY USING EXISTING CAPSCREW
3.8 ENGINE HARNESS ASSY TIGHTEN LIFTING LUG FOR
E/G SUB HARNESS
ENGINE HARNESS ASSY E135SR ENGINE AND CLIP TOGETHER.
TIGHTENING TORQUE :
CONNECTOR (GRAY)
ITEM PART NAME Q’TY REMARKS 6.6kgfym {48 lbfyft}
STARTER TERMINAL
1 HARNESS 1 E/G sub
E135SR
CLIP
CLIP TERMINAL AND STARTER CABLE
CONNECTOR WITH VIEW Ⅰ
RUBBER CAB
TO BATTERY RELAY
MAIN HARNESS DETAIL OF STARTER MOTOR CONNECTOR OF ENGINE

SPEED SENSOR
GND (E/G ACCESSORY)

STARTER MOTOR (M-1) TIGHTEN GND.CABLE
GOVERNOR MOTOR (M-2)

INSTALL CLIP AS
CLIP CONNECTOR
DIRECTION SHOWN BELOW.
OF HARNESS
SAFETY RELAY (R-4)
D DIS-
CHARGE
GLOW
E/G WATER HIGH
SUCTION
TEMP. LIMIT SW. (SW-7)
UNDER
E/G WATER VIEW Ⅱ SUPPLIED
TEMP SW. (SW-6) AIR CONPRESSOR CLUTCH NUT
A B WITH E/G.
E/G COOLANT THERMO
SENSOR (SE-14) TIGHTEN EARTH
NOT TO PASS OVER
ALTERNATOR (E-2) TERMINAL TO
HEAD COVER.
COMPRESSOR HARNESS
BRACKET
WASHER
E/G SUB HARNESS DETAIL C

TIGHTENING TORQUE :
0.5～0.7kgfym {3.6～5.1 lbfyft}
FIX HARNESS AT
C E/G SUB HARNESS WHITE TAPING
POSITION
GLOW
CLIP
WIRING HARNESS OUT

OF TOUCH ENGINE.
BY USING EXISTING FIX CONNECTOR FIX THE HARNESS

CAPSCREW TIGHTEN WITH BRACKET MAIN HARNESS AS DRAWING
CLIP
LIFTING LUG FOR ENGINE
TIGHTENING
AND CLIP TOGETHER.
TORQUE :
TIGHTENING TORQUE : CLIP 0.2～0.5kgfym
HARNESS FOR 6.6kgfym {48 lbfyft} {1.4～3.6 lbfyft} DETAIL D NOT TOUCH THE
ENGINE WATER HARNESS
TEMP. SENSOR
TO E/G WATER TO E/G WATER
DETAIL OF ENGINE SPEED SENSOR DETAIL OF GOVERNOR MOTOR BRACKET
TO BE FIXED
TEMP. SENSOR TEMP. SENSOR
WITH MAIN LINE
USING THIS CLIP. DETAIL OF ALTERNATOR
DETAIL A DETAIL B
Fig. 15 (2/2) Engine harness assy
23-21
3.8.1A E/G SUB HARNESS
E115SR
3.8.1B E/G SUB HARNESS

E135SR(LC)
Fig.16 Engine sub harness

23-22
3.9 FLOOR HARNESS ASSY 3.9.3 GROUND CABLE
FLOOR HARNESS ASSY
3 CABLE 1 Ground
10 HARNESS 1 Under floor
Fig. 18 Ground cable
EXTRA DEPRESSURE SOL. (SV-24)
Fig. 17 Floor harness assy
23-23
3.9.10 UNDER FLOOR HARNESS
SEALING PLUG TO BE
INSERTED IN TO ALL
TERMINAL
SV-24 :
EXTRA DEPRESSURE SOL.
PSV-A :
ARM VARIABLE
RECIRCULATION
PROPORTIONAL SOL.
Fig. 19 Under floor harness
23-24
3.10 CAB HARNESS ASSY
CAB HARNESS ASSY
1 HARNESS 1 Instrument panel LH
2 HARNESS 1 Instrument panel RH
3 HARNESS 1 Cab front
PASS HARNESS OF LOWER

THROUGH THIS GROMMET
Fig. 20 Cab harness assy

23-25
3.10.1 INSTRUMENT PANEL HARNESS LH
Fig. 21 Instrument panel harness LH

23-26
3.10.2 INSTRUMENT PANEL HARNESS RH
Fig. 22 Instrument panel harness RH
23-27
3.10.3 CAB FRONT HARNESS
Fig. 23 Cab front harness

23-28
3.11 CAB ASSY
E115SR EV.
CAB ASSY (With M/W)
E135SR LC EV.
ITEM NAME Q’TY REMARKS 68
2 FRONT WINDOW ASSY 1 61 CN-3M～4PAF-HM 25 CONNECT WITH DOOR SWITCH 2
CONNECT CURL CODE HARNESS
2-8 WIPER ASSY 1 CN-2F
2-37 HARNESS 1 For M/W
25 DOOR SWITCH 1 195
64
61 CURL CODE HARNESS 1
64 HARNESS 1
65 ANTENNA 1
68 ROOM LAMP 1
189 ROOM LAMP HARNESS 1
195 STOPPER ASSY 1 Wipper control
195-3 INTER ROCK SWITCH 1 65
CAB INSTALL
E115SR EV.
CAB INSTALL
E135SR LC EV.
CONNECT WITH
ITEM NAME Q’TY REMARKS HARNESS.
4 WASHER TANK ASSY 1
CONNECT WITH
4-1 ELECK MOTOR ASSY 1 INSTRUMENT
PANEL HARNESS
2PAM
189
CONNECT TO TUNER
CLIP
HARNESS 2-37 4PAM-HM
CURL
CODE
2-8
4PAF
CAB 4
GLASS MARK
Fig. 25 Cab install F1 : MANUAL WINDOW
Fig. 24 Cab assy
23-29
3.11.2-37 WIPER HARNESS 3.11.61 CURL CORD HARNESS 3.11.64 CAB WIPER MOTOR HARNESS
Fig. 26 Fig. 27
Fig. 28
3.11.65 ANTENNA 3.11.189 ROOM LAMP HARNESS WINDOW WASHER TANK & MOTOR
Fig. 29 Antenna
Fig. 31
Fig.30 Room lamp harness
23-30
3.12 BATTERY INSTALL & BATTERY 3.13 LIGHT INSTALL
E115S 3.13.1 DECK LIGHT INSTALL
BATTERY INSTALL E115SR
E135SR
DECK LIGHT INSTALL
ITEM PART NAME Q’TY REMARKS E135SR
1 PLATE 1 ITEM PART NAME Q’TY REMARKS
2 CAPSCREW 2 1 LIGHT 1
3 LOCK WASHER 2 M10
BATTERY
NUT (SUPPLIED WITH WORKING LIGHT)

TIGHTENING TORQUE :
1.75 kgfym (13 lbfyft).
BRACKET
Mounting procedure of rightside deck light
Fig. 33 Deck light install
Fig. 32 Battery instll & battery
23-31
3.13.2 CAB LIGHT INSTALL
E115SR
CAB LIGHT INSTALL
E135SR(LC)
6 SWITCH 1
18 HARNESS 1 For 5 light
3.13.2.18 5 LIGHT HARNESS ; YT80E01002P1
Fig. 35 5 light harness

Fig. 34 Cab light instal
23-32
3.13.3 BOOM LIGHT INSTALL 3.14 BOOM HARNESS ASSY
E115SR E115SR
BOOM LIGHT INSTALL BOOM HARNESS ASSY
E135SR(LC) E135SR(LC)
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
1 LIGHT 2 1 HARNESS 1 －
2 HARNESS － 1
Fig. 37 Boom harness assy
3.14.1 BOOM HARNESS : YY15E01002P2 E135SR(LC)
Fig. 38 Boom harness
3.14.2 BOOM HARNESS : YV15E01001P1 E115SR
Fig. 36 Boom light install
Fig. 39 Boom harness
23-33
3.15 FUEL PUMP ASSY
FUEL PUMP ASSY

2 FUEL PUMP ASSY 1
2-7 FUEL PUMP 1
Fig. 40 Fuel pump assy
23-34
E115SR
E135SR
SECTION 24 COMPONENTS SYSTEM
TABLE OF CONTENTS
Part I: Hydraulic equipment

1. Hydraulic pump - regulator ................................................................................... 24-1
1.1 Summary ....................................................................................................................................... 24-1
1.2 Hydraulice pump ........................................................................................................................... 24-4
1.3 Regulator ..................................................................................................................................... 24-10
1.4 Control curve of pump ................................................................................................................. 24-15
2. Pilot valve (ATT) .................................................................................................. 24-19

2.1 Outline ......................................................................................................................................... 24-19
2.2 Construction, function and operation ........................................................................................... 24-20
3. Pilot valve (travel) ............................................................................................... 24-24

3.1 Outline ......................................................................................................................................... 24-24
3.2 Construction and operation ......................................................................................................... 24-25
3.3 Operation ..................................................................................................................................... 24-26
4. Control valve ....................................................................................................... 24-29

4.1 Specification ................................................................................................................................ 24-29
4.2 Construction ................................................................................................................................ 24-30
4.3 Hydraulic circuit ........................................................................................................................... 24-35
4.4 Operation ..................................................................................................................................... 24-36
5. Swing motor unit ................................................................................................. 24-55

5.1 Specification ................................................................................................................................ 24-55
5.2 Construction ................................................................................................................................ 24-57
5.3 Operation ..................................................................................................................................... 24-60
6. Travel motor ........................................................................................................ 24-64

6.1 Specification ................................................................................................................................. 24-64
6.2 Construction .................................................................................................................................. 24-65
6.3 Explanation of function .................................................................................................................. 24-69
6A. Travel motor (for L type) ................................................................................... 24-76

6A.1 Specifications ............................................................................................................................. 24-76
6A.2 Construction ............................................................................................................................... 24-77
6A.3 Explanation of function ............................................................................................................... 24-79
INDEX
7. Swivel joint ......................................................................................................... 24-76

7.1 Dozer specification ........................................................................................................................ 24-86
7.2 Standard specification ................................................................................................................... 24-88
8. Cylinder .............................................................................................................. 24-90

8.1 Specification ................................................................................................................................. 24-90
8.2 Construction .................................................................................................................................. 24-90
9. Control valve (for dozer or extra) ......................................................................... 24-97

9.1 Outline .......................................................................................................................................... 24-97
Part II: Electric equipment

1. List of electric equipments ................................................................................... 24-99
2. Specification of electric equipments .................................................................. 24-100

Part I: HYDRAULIC EQUIPMENT

1. HYDRAULIC PUMP・REGULATOR
1.1 SUMMARY
(1) Outside view and hydraulic port
4 a3 PSV1 5 a5,Dr3
A3
A4,B4 3 No. NAME
1 MAIN PUMP ASSY
B3 2 REGULATOR ASSY
Dr1
3 GEAR PUMP ASSY(FOR PILOT)
GEAR PUMP ASSY FOR DOZER
4 (OPT)
5 PTO GEAR CASE ASSY
SOLENOID PROPORTIONAL
6 REDUCING VALVE
PSV2 a4
6 a3 6
a4 2
2 A3
a5
Dr3
B3
Dr1 A1 A2 B1 PH2 a2 A2
Table 1-1 Hydraulic ports
Code Ports name Size

A1,2 Delivery port 3/4″
B1 Suction port 2 1/2″
Dr1 Drain port PF1/2
PSV1,2 Serro assist port PF1/4
PH1,2 Pressure sensor port PF3/8
a1～5 Gauge port PF1/4
A3 Delivery port of gear pump(for pilot) PF3/8
B3 Suction port of gear pump(for pilot) PF3/4
Dr3 Drain port of gear pump(for pilot) PF3/8
A4 Dozer gear pump derivery port(OPT) PF1/2
B4 Dozer gear pump suction port(OPT) PF1
Fig. 1-1 Hydraulic pump y regulator

24-1
(2) Hydraulic circuit diagram
Standard spec.
Solenoid Solenoid
proportional proportional
reducing valve reducing valve
Regulator
Regulator
Main pump
Extra spec. PTO Gear case Gear pump for pilot
Dozer spec.
Solenoid Solenoid
proportional proportional
reducing valve reducing valve
Regulator
Regulator
Main pump
Gear pump PTO Gear case Gear pump for pilot

for dozer or extra
24-2
(3) Specification
Table 1-2
Item Main pump Gear pump for pilot

Pump model K3V63DTP100R－0E02A ZX10LPRZ2－07D
Max.displacement capacity cm3 /rev 51.2×2 (at travel : 57.6) 10
Rated revolution rpm 2,050 (clockwise as seen from shaft end)
Working pressure kgf/cm2(psi) 350(4980) 51(725)
Max. flow /min(gal/min) 105(28)×2 [at travel : 118(31)] 20.5(5.4)
Max. input horse power PS 85(Gear pump only : 4.3)
Max. input torque kgfym (lbfyft) 29.7(210) [Gear pump only : 1.5(11)]
Model KR36－0E02A
Regulator Control function Positive electric flow control
With solenoid proportional reducing
Others valve(KDRDE5K)
Relief set pressure kgf/cm2(psi) 350(4,980) 51(725)
24－3
1.2 HYDRAULIC PUMP

1.2.1 CONSTRUCTION
(1) Main pump
535 789 732 212 156 532 214 531,548 534 702 792 954 124 124 901 116 711 312 719 151 152 113 252
953
808
251
886
406
261 717
406
111 123
824
774
127
710
262
401
490
271 211 153 462,728 157 313 466,725 885 886 314 141 468,728
Fig. 1-2 Construction of main
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
111 SHAFT(F) 1 262 SEAL COVER(R) 1 711 O RING: 1B G95 1

113 SHAFT(R) 1 271 PUMP CASING 2 717 O RING: 1B G120 2
116 1st GEAR 1 312 VALVE BLOCK 1 719 O RING: 1B G115 2
123 ROLLER BEARING 2 313 VALVE PLATE (For clockwise) 1 724 O RING: 1B P8 18
VALVE PLATE
124 NEEDLE BEARING 2 314 (For counter clockwise) 1 725 O RING: 1B P11 2
127 BEARING SPACER 4 401 SOCKET BOLT: M16×175 8 728 O RING: 1B P18 4
141 CYLINDER BLOCK 2 406 SOCKET BOLT: M6×16 8 732 O RING: 1B P16 2
151 PISTON 18 466 VP PLUG: PF1/4 2 774 OIL SEAL 1
152 SHOE 18 467 VP PLUG: PF1/2 3 789 BACKUP RING 2
153 RETAINER PLATE 2 468 VP PLUG: PF1/2 1 792 BACKUP RING 2
156 SPHERICAL BUSHING 2 490 PLUG: NPTF1/16 15 808 HEX. NUT : M16 4
157 CYLINDER SPRING 18 531 TILTING PIN 2 824 SNAP RING 2
211 SHOE PLATE 2 532 SERVO PISTON 2 885 VALVE PLATE PIN 2
212 SWASH PLATE 2 534 STOPPER: L 2 886 SPRING PIN 4
214 TILTING BUSHING 2 535 STOPPER: S 2 901 EYE BOLT: M10 2
251 SWASH PLATE SUPPORT(F) 1 548 FEED BACK PIN 2 953 SET SCREW: M16 2
252 SWASH PLATE SUPPORT(R) 1 702 O RING: 1B G30 2 954 SET SCREW: M16 2
261 SEAL COVER(F) 1 710 O RING: 1B G85 2
24-4
(2) Gear pump(for pilot)
433
700 354 351
434
728
435
312
311
732 850 467
710 361 353 307 310 308 309 434 466 355
725
Fig.1-3 Construction of gear pump(for pilot)
Table 1-4
No. NAME Q’TY No. NAME Q’TY

307 POPPET 1 433 FLANGE SOCKET : M8×40 2
308 SEAT 1 434 FLANGE SOCKET : M8×55 2
309 SPRING SEAT 1 435 FLANGE SOCKET : M10×35 2
310 SPRING 1 466 VP PLUG : PF1/4 1
311 ADJUST SCREW 1 467 ADAPTER : PF1/2-PF3/8 1
312 LOCK NUT : M14 1 700 RING 1
351 GEAR CASE 1 710 O RING : 1B G80 1
353 DRIVE GEAR 1 725 O RING : 1B P11 1
354 DRIVEN GEAR 1 728 O RING : 1B P18 1
355 FILTER 1 732 O RING : 1B P16 1
361 FRONT CASE 1 850 SNAP RING 1
24－5
(3) PTO gear case
GEAR PUMP
326 118 125 825 (for pilot) 728 468
117
126
128
435
886
GEAR PUMP FOR

DOZER(OPTION)
827
115
826
FRONT SIDE REAR SIDE
Fig.1-4 Construction of PTO gear
Table 1-5

115 IDLE SHAFT 1 435 FLANGE SOCKET: M10×20 4
117 2nd GEAR 1 468 VP PLUG: PF3/4 1
118 3rd GEAR 1 728 O RING: 1B P24 1
125 BALL BEARING 2 825 SNAP RING 1
126 ROLLER BEARING 1 826 SNAP RING 1
128 BEARING SPACER 2 827 SNAP RING 1
326 GEAR CASE 1 886 PIN 2
24-6
(4) Gear pump for dozer or extra
55 54 51 6 3 53 52
4 1 7 5 50 2
Fig. 1-5 Construction of gear pump(for dozer)
Specification
Gear pump for dozer
Item
Model SGP1A25F2H9－L389
Displacement capacity cm3/rev 24.9
Working pressure kgf/cm2(psi) 210 (3,000)
Max. flow /min(gal/min) 51 (13)
Relief set pressure kgf/cm2(psi) 210 (3,000)
Table 1-6
1 FRONT COVER 1 50 GASKET(SHAPED LIKE LETTER 3) 2
2 REAR COVER 1 51 GASKET 2
3 BODY 1 52 SOCKET BOLT 4
4 DRIVE GEAR 1 53 WASHER 4
5 DRIVEN GEAR 1 54 OIL SEAL 1
6 SIDE PLATE 2 55 SNAP RING 1
7 BUSHING 4
24-7
1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear (116) and distribute the rotating power REGULATOR
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft (111)
that drives the two pumps and, at the same time,
drives the pilot gear pump and the dozer gear
116
pump(option) arranged on a different axis.
The pump assy consists largely of the rotary
111
group, the main part of the pump that makes
rotary on; the swash plate group that changes the
delivery rate; the valve block group that selects
between oil suction and delivery ; and the PTO
group that transmits the drive power to the gear GEAR PUMP
pump. PTO FOR DOZER
(OR EXTRA)
GEAR
(1) Rotary group GEAR PUMP CASE
(FOR PILOT)
The rotary group consists of shaft (111),
cylinder block (141), piston (151), shoe (152),
plate (153), spherical bushing (156), and
cylinder spring (157).
The shaft is supported by bearings (123) and Fig. 1-6 (1/2) Construction of hydraulic pump
(124) at its both ends. The shoe, which is
caulked to the piston, forms a spherical joint
and relieves it of thrust force that is
generated by load pressure.
Further, the piston is provided with a pocket
so it moves lightly on shoe plate (211), taking
hydraulic balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring,
via the retainer plate and the spherical
bushing, so that it moves smoothly over the
shoe plate. The cylinder block (141) is also
pressed against valve plate (314) by the
action of cylinder spring (157). 313
124
312
111
116
314124
141
157
151 156
・ 153
152
211
Fig. 1-6 (2/2) Rotary group
24-8
(2) Swash plate group 532

The swash plate group consists of swash
plate (212), shoe plate (211),swash plate
support (251), tilting bushing (214), tilting 531 214
pin (531),and servo piston (532). The swash 211
plate is the cylindrical part that is formed on 212
the opposite side of the shoe sliding surface
and is supported by the swash plate
support. 251
The hydraulic force controlled by the
regulator flows into the hydraulic chamber
that is provided on both sides of the servo
piston. This moves the servo piston to the
right and left. The result is that the swash
plate swings on the swash plate support via
the spherical part of the tilting pin and
changes the tilting angle(α). Fig. 1-7 Swash plate group
(3) Valve block group

The valve block group consists of valve block 313
(312), valve plates (313), (314), and valve plate 312
pin (885). The valve plates having two
crescent-shaped ports are installed to valve
block (312) to feed oil and recycle it from 116
cylinder block (141). The oil switched over by 111
the valve plate is connected with the 141 314
885
external pipe by way of the valve block.
(4) PTO group

The PTO group is composed of 1st gear (116),
2nd gear (117) and 3rd gear (118). The 2nd
and the 3rd gear are supported by bearings Fig. 1-8 Valve block group
(125) and (126) respectively and installed to
the valve block. 117
Now, if the shaft is driven by the engine, the
cylinder block rotates together by the spline 126
linkage. If the swash plate is inclined, the
pistons arranged in the cylinder block make
reciprocating motion with respect to the
cylinder while rotating with the cylinder
block. If we keep an eye on a single piston,
it makes a motion away from the valve
plate(oil suction process)in the first 180° and
118
a motion toward the valve plate(oil delivery
125
process) in the remaining 180° . If the swash
plate is not inclined(zero tilting angle), the
piston does not stroke i.e. delivers no oil.
At the same time, the shaft rotation is taken 125
up by the 1st gear (116) and transmitted to
the 2nd gear (117) and the 3rd gear (118), in
that order, to drive the gear pump that is Fig. 1-9 PTO group
linked to the 3rd gear.
24-9
1.3 REGULATOR Table1-7

1.3.1 CONSTRUCTION
No. NAME Q’TY
079 SOLENOID PROPORTIONAL 1

418 REDUCING VALVE
325 VALVE CASING 1
402 SOCKET BOLT: M6×16 4
415 415 SOCKET BOLT: M8×45 6
601 466 VP PLUG: PF1/4 1
897
496 PLUG 9
496 541 SEAT 2
755
543 STOPPER 2
543 614 545 BALL 2
601 CASING 1
545 611 FEED BACK LEVER 1
614 FULCRUM PLUG: PF1/4 1
541 624 SPRING SEAT 1
708 627 PLUNGER 1
756
631 SLEEVE 1
643 PISTON 1
611 646 SPRING 1
651 SLEEVE 1
652 SPOOL 1
656 COVER 1
SECTION AA 658 PLUG: NPTF1/16 1
708 O RING: 1B G75 1
724 O RING: 1B P8 5
731 O RING: 1B P25 1
733 O RING: 1B P18 2
755 O RING: 1B P11 2
756 O RING: 1B P12.5 2
801 HEX NUT: M8 1
887 PIN 1
897 PIN 1
325 496 079 924 SET SCREW 1
624 646 627 733 656 402
643 A 801
466 924
・
755
407
724
A
631 887
731 Fig. 1-10 Construction of regulator

651 733 652 658
24-10
1.3.2 OPERATION
(1) Summary
Regulator KR36-0E01 for the inline axial
piston pump K3V series is of electric flow
control type that regulates the tilting angle
(delivery rate) of the pump as the command
currentⅠto the solenoid proportional
reducing valve is varied.
This regulator is of positive flow control type
that increases the delivery flow Q as the
command current I increases.
If an electric current is put in by this control
according to the flow needed for the
operation, the pump delivers at a flow rate
that is only required by the pump,
consequently holding down unwanted power
consumption.
(2) Positive control.
As shown in the figure on the right, the
regulator regulates the delivery rate of the
pump by command current I.
DELIVERY RATE Q
1) Flow increasing action
As the command current I rises, the
secondary pressure of solenoid proportional
reducing valve (079) increases. This causes
spool (652) to move via pilot piston (643) and
stops where the hydraulic pressure pushing
the spool rightwards balances with the action COMMAND CURRENT Ⅰ
of pilot spring (646).
If the spool (652) moves, port C opens to the
Fig.1-11 Positive flow control
tank port. This causes the pressure of the
large diameter part of servo piston (532) to go
away. This causes the servo piston (532) to
the left by delivery pressure P1 of the small
diameter part, resulting in an increase in the
tilting angle α.
643 652 651 611 624 627 646 801 924
532
808
808
954 953
A
TILTING MAX. TILTING MIN.

Fig. 1-12 Functions of regulator
24-11
Feedback lever(611) is linked with the servo

piston and sleeve(651). As the servo piston
moves to the left, the feedback lever rotates
on point A which causes the sleeve to the
right. As the servo piston moves to the right,
the feedback lever rotates on point A to move SOLENOID PROPORTIONAL
the sleeve to the right. The result is that the REDUCING VALVE REGULATOR
opening of the spool sleeve begins to close
gradually and the servo piston settles down
when the opening of the spool sleeve closes
completely.
646
(2) Flow decrease function
As the command current Ⅰ decreases, the 652
secondary pressure of the solenoid
611
proportional valve decreases. This causes the
spool to move to the left.
When the spool(652) has moved, delivery MAIN
pressure P1 reaches port C via spool and is PUMP
admitted to the large diameter chamber of
643
the servo piston. Delivery pressure P1 is
admitted to the small diameter part of the
servo piston at all times. The servo piston 651
moves rightward by areal difference to C PORT 532 POINT
A
decrease tilting angle (α). As the servo
piston moves to the right, the feedback lever Fig. 1-13 Regulator hydraulic circuit
rotates on point A to move the sleeve to the
left. The sleeve keeps moving till the opening
of the spool sleeve closes and settles down
when the spool sleeve closes completely.
24－12
1.3.3 ADJUSTING REGULATOR

The maximum flow, minimum flow and flow
control characteristics of the regulator may be
controlled by the adjust screw of the regulator.
(Amounts of adjustment are shown in table 1-8.)
However, the adjustment may change

the flow characteristics. Therefore, do
not tamper with the adjust screws
unless there is special reason.
Table1-8 Amounts of change by the adjustment of regulator

Solenoid proportional valve model KR36－0E01
Pump revolution 2050rpm
Adjust screw(954)1/4turn
Max. flow /min (gal/min)
Flow rate△Q=3.3(0.87)
Min. flow /min (gal/min)
Flow control characteristics Current△I=23.3mA
(1) Adjusting the maximum flow

DELIVERY RATE Q
For adjustment, loosen the hex nut (808) and

tighten (or loosen) the set screw (954) on the
large diameter part of the servo piston.
Tightening it decreases the flow and
loosening it increases the flow.
Only the maximum flow changes with other
control characteristics unchanged.
COMMAND CURRENT Ⅰ
Fig. 1-14 Adjusting the max. delivery rate

(2) Adjusting the minimum flow
For adjustment, loosen hex nut (808) and
tighten (or loosen) the set screw (953) on the
small diameter part of the servo piston.
Tightening it increases the flow and
DELIVERY RATE Q
loosening it decreases the flow.

Other characteristics do not change the same
way as the adjustment of the maximum flow.
Note that if the set screw is tightened too
much, the power requirement at the
maximum delivery pressure (at relieving)
increases in some cases.
COMMAND CURRENT Ⅰ
Fig. 1-15 Adjusting the min. delivery rate
24-13
(3) Adjusting the flow control characteristics

For adjustment, loosen hex nut (801) and
tighten (loosen) the set screw (924). If the set
screw is tightened, the control curve moves
DELIVERY RATE Q
rightwards, as shown in Fig.1-16.
COMMAND CURRENT Ⅰ
1.3.4 CAUSES OF FAULT RESULTING FROM Fig. 1-16 Flow control characteristics
REGULATOR
(1) Engine is overloaded
Load each of the pumps and check which of
the pumps, front or rear is faulty. In case
both are faulty, check the following ① and ②:
If only one of the pumps is faulty, start with
③.
① Check that the command current Ⅰ of the
solenoid proportional reducing valve is
normal.
② The secondary pressure Check amplifier

of solenoid proportional dither.
reducing valve is high. Replace solenoid
proportional
reducing valve.
③ Spool (652) and Disassemble and

Sleeve (651) are clean.
stuck.
④ Pilot piston (643) Disassemble and

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

① Confirm that the secondary pressure of the
solenoid proportional reducing valve is
normal.
② Pilot piston (643) Disassemble and clean.

is stuck.
③ Spool (652) and Disassemble and clean.

sleeve (651) are
stuck.
24-14
1.4 CONTROL CURVE OF PUMP E115SR

(1) At H mode
(2) At S mode
24－15
(3) At FC mode
24－16
E135SR(LC) E135SRL
(1) At H mode
(2) At S mode
24－17
(3) At FC mode
24－18
2. PILOT VALVE (ATT)

2.1 OUTLINE
(1) Outside view (2) Specifications
SINGLE SINGLE
Table 2-1
OPERATION OPERATION
ANGLE ANGLE Item Specification
The adjust nut (PORT 2,4) (PORT 1,3)
(opposing flats : 22) :
Fix adjust nut Model PV48K2005
(opposing flats : 22) Operating torque Refer to the curve below
when the lever is installed by
means of spanner or the like. Max. primary pressure 70kgf/cm2 (995psi)
Then tighten the mating lock
Primary pressure 51kgf/cm2 (725psi)
nut to 4.2±0.3kgfym
(30±2.2 lbfyft). Rated flow 20 /min (5.3gal/min)
Weight Approx. 1.9kg (4.2 lbs)
(3) Performance characteristics
5-PF3/8
T=5±0.5(36±3.6)
PF1/4
T=3±0.2(22±1.4)
T=Tightening torque : kgfym (lbfyft)
Hydraulic symbol
Fig. 2-1
24－19
2.2 CONSTRUCTION, FUNCTION AND

OPERATION
(1) Cross section view 312
302
Apply grease
on rotating and
501 sliding sections.
301 Be careful the
assembling
direction
Apply grease on
top section
212 213
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 (0.016˝ ),
1 pc.
PORT 2,4 PORT 1,3

Fig. 2-2 Pilot valve (ATT)
Apply Loctite #277 to areas marked ☆.

Tightening torque Tightening torque
kgfym (lbfyft) No. NAME Q’TY kgfym (lbfyft) 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 4.8 (35) 301 JOINT : M14 1
214 O RING : 1B P20 4 302 CIRCULAR PLATE 1
216-1 SPRING SEAT 1 2 7 (51)☆ 312 ADJUST NUT : M14 1
216-2 SPRING SEAT 1 2 501 BOOTS 1
217 WASHER 2 (SHIM) 4
Note) The parts marked ※ may not be equipped depending on valve type.
24－20
(2) Construction
The pilot valve is constructed as shown in
the cross-sectional view (Fig.2-2). The casing
has a vertical shaft hole in which a reducing
valve is assembled.
The reducing valve consists of spool (201),
spring (241) (for secondary pressure setting),
spring (221) (for return), spring seat (216),
and washer (217). The spring (241) (for
secondary pressure setting) is so set as to
achieve the secondary pressure conversion
5~10 kgf/cm2 (71~140 psi) (varies with the
model.). The spool (201) is pressed against
push rod (212) by spring (221) (for return).
If push rod (212) is pushed down by tilting
the control part of the handle, the spring seat
(216) falls at the same time and changes a set
pressure of spring (241) (for secondary
pressure setting).
The casing (101) is provided with an oil inlet
(primary pressure) port P and an outlet
(tank) port T. They are further provided with
ports 1, 2, 3, 4 from which secondary pressure
is discharged.
(3) Function
1) Basic functions 2) Main functions
The pilot valve controls the stroke and the The function of spool (201) is to receive the
direction of the control valve spool. This is supply pressure of the hydraulic pump by
achieved by applying the output pressure of port P and admit the hydraulic pressure at
the pilot valve to the end of the control valve port P to output ports (1, 2, 3, 4) or admit the
spool. hydraulic pressure at the output ports to port
In order to satisfy the functions, the pilot T. Spring (241) (for secondary pressure
valve is constructed with the following setting) acts upon spool (201) and determines
elements : the output pressure.
1. Inlet port (P) to which the oil of the Push rod (212) that changes the deflection of
hydraulic pump is supplied. spring (241) (for secondary pressure setting)
2. Multiple output ports (1, 2, 3, 4) that exert is inserted in plug (211) so as to enable
the supply pressure from the input port smooth movement.
upon the end of the spool of the control Spring (221) (for return) acts upon casing
valve. (101) and spring seat (216) and brings push
3. Tank port (T) to control the above rod (212) toward zero displacement
mentioned output pressure. regardless of output pressure, in order to
4. Spool that connects the output port with positively bring spool (201) back to neutral.
the inlet port or the tank port. The spring also acts as a reactive force that
5. The mechanical means including springs gives the operator a proper operating feeling.
that act upon the above- mentioned spool,
in order to control the output pressure.
24－21
(4) Function
Now, let us explain the function of the pilot
valve, using the hydraulic diagram (the
figure on the right) and the functional
explanation drawing (Fig. 2-3 to 2-5).
1 3
P T
①Pilot valve ②Pilot pump
1) Lever in neutral (See Fig. 2-3.)

The action of spring (241) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201). Therefore, spool (201) (for return)
is pushed up by spring (221) [spring seat 1
(216)]. The output ports (2, 4) connect with
the T port. The result is that the output
pressure is equal to the tank pressure.
216
241
221
201
PORT(2,4)
Fig. 2-3 Lever in neutral
24－22
2) When the pilot lever is tilted (See Fig. 2-4 )

When the lever is tilted and the push rod
(212) strokes, the spool (201) spring seat
(216) moves down-ward to make the port P to
connect with the port 2, 4, with the result
that the oil of the pilot pump flows to the port 212
2 ,4 to produce a pressure.
216
201
PORT(2,4)
3) Handle held (See Fig.2-5.) Fig. 2-4 When the lever is tilted
When the pressure at ports (2,4) rises to a
level equivalent to the action of spring (241)
that is set by tilting the handle, the hydraulic
pressure balances the spring action. When
the pressure of ports (2,4) rises above a set
value, ports (2,4) and the P port close while
ports (2,4) and the T port open. When the
pressure at ports (2,4) falls below a set value,
ports (2,4) and the P port open while ports
(2,4) and the T port close. Thus the secondary
pressure is kept constant.
241
T PORT
P PORT
PORT (2,4)
Fig. 2-5 When the handle is held
(When the secondary pressure is higher than a set value)
4) Operation in the area where the tilting angle the bottom of the bore of the push rod
of the handle is large. (varies with the model) contacts the spring if the handle is turned
If the handle is inclined beyond a certain beyond a certain angle. This causes the
angle on certain models, the top end of the secondary pressure gradient to change by the
spool contacts the bottom of the bore of the spring action. Thereafter, the bottom of the
push rod. This keeps the output pressure bore of the push rod contacts the top end of
connected with the P port pressure. the spring seat, keeping the output pressure
Furthermore, on a model in which a spring connected with the P port.
seat and a spring are built in the push rod,
24-23
3. PILOT VALVE (TRAVEL)

3.1 OUTLINE
(1) Outside view
VIEW FROM MACHINE FRONT SIDE
Tightening
Port torque Port 4-∅11
size kgfym (lbfyft) name Function
Through
1 LH travel forward port
2 LH travel reverse port
7.5±0.5
PF3/8 3 RH travel forward port
(54±3.6)
4 RH travel reverse port
T Tank port
5 Travel pressure sensor
6 port
3.7±0.2
PF1/4 P Travel pressure sensor
(27±1.4) Fig. 3-1 Out side view of travel pilot valve
port
Pilot primary pressure port
(3) Performance characteristics
(2) Specification
Item Specification
Type 07291-00000
Primary pressure 50kgf/cm2 (710psi)
Secondary pressure 5.5～24kgf/cm2 (78～340psi)
Rated flow 10 /min (2.6gal/min)
Weight Approx. 11kg (24 lbs)
LEFT RIGHT
Hydraulic simbol Control diagram
24-24
3.2 CONSTRUCTION AND OPERATION

Z
33 2 36 33
13 12 28 RORT5
36 14
PORT
5
42
19
37 26 25
1,3 30
20
34 25
22 15
20 21 42
20
39 PORT
PORT66
32 17
44,16 33 36 33
40
6 7 SECTION AA
18 8
24 25,42
41
27
4 10,11 35
9 31 5 29
T=TIGHTENING TORQUE: kgfym(lbfyft)
38
4-M10
T=4.3±0.4(31±29)
SECTION BB
24,41 VIEW Z Fig. 3-2 Construction of travel pilot valve
Apply Loctite #262 to areas marked ☆.
Tightening Tightening
torque No. NAME Q’TY torque No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
1 ORIFICE(SHIM) 4 22 SPRING 4
☆1.5(11) 2 SEAT 2 1.0(7.2) 24 PLUG: PF1/8 3
3 ORIFICE(SHIM) 4 2.5(18) 25 PLUG: PF1/4 3
4 SPOOL 4 6.0(43) 26 SOCKET BOLT: M10×60 2
5 BODY 1 0.5(3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5(11) 28 SETSCREW : M8 4
7 SPRING 4 29 WASHER 4
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN: ∅5 4
11 SHIM t=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING: 1A P5 4
17 GUIDE 4 39 O RING: 1A P24 4
18 SLEEVE 4 40 O RING: 1A P26 4
19 HOLDER 4 41 O RING: 1B P8 3
20 RING 12 42 O RING: 1B P11 3
21 ORIFICE(SHIM) 4 44 PISTON ASSY 4
24-25
3.3 OPERATION
(1) Construction z If the cam operates during travel operation, the oil
The valve consists of the following parts in in the damper chamber is kept from flowing back
terms of hydraulic function: by the check valve. Thus the oil flows to part (E)
only from the orifice. Damper action operates by
A: Damper section
the resistance that is built up as the oil passes
B: Reducing valve section
through the orifice.
C: Shuttle section Let us explain the profile of the piston (See Fig. 3-4).
(2) Operation The upper part of the piston has a diameter of
1) Damper section 12mm (0.472in), while the lower part of it has a
z If the primary pressure is supplied by P, it is diameter of 11mm (0.433in). This results in an
flowed to the damper chamber by way of areal difference, with the result that the piston is
circuits (D) and (E). constantly subject to a vertical force.
The pressure is then filled up in the damper For this reason, the orifice rises by the pressure
caused by the areal difference between the
chamber via the orifice and the check valve.
operating part of the cam and the piston on the
In that case, the air present in the damper
opposite side i.e. the piston follows the cam.
chamber is pushed out to the T port from That is to say, constant damper action
circuits (F) and (G), in order to prevent the operates wherever the cam is located.
damper characteristics from fluctuating by Since the larger diameter of the piston, the cover,
air mixture. the 11mm diameter part of the piston and the
guide are manufactured with minimal clearance,
only a little leakage occurs. Consequently, the
CAM
damper performance is not affected at all.
(F)
PISTON (G)
COVER
(E) CHECK
VALVE
GUIDE
ORIFICE
DAMPER
SPRING FOR CHAMBER
T
SECONDARY (D)
PRESSURE
T
(I)
SPOOL P P
(H)
SECONDARY PRESSURE PORT

BODY
Fig. 3-3
24-26
2) Reducing valve section If the pressure at the secondary pressure port

z At neutral rises above the action of the secondary
The primary pressure supplied by P is shut off pressure spring, the spool is pushed up by the
by the seal between the circumference of the pressure. The result is that the notch (J)
spool and the body hole. enters the hole of the body, shuts off the
The secondary pressure port is connected circuit from the primary pressure port to the
with the T port through the vertical hole (H) secondary pressure port, and causes the
and the horizontal hole (I) in the center of the horizontal hole (I) to connect with the T port
spool. This causes the pressure to be reduced to let the pressure of the secondary pressure
to zero. port out to the T port.
z At operation If the above-mentioned action is repeated, the
If the cam tilts toward the operating pressure at the secondary pressure port
direction, the piston goes down. The spool sub becomes a level that balances the
assy moves down. compressive load of the secondary pressure
If the notch (J) on the circumference of the spring proportional to the cam stroke.
spool connects with the secondary pressure The return spring provides proper repulsive
port, the primary pressure supplied by P force and positively brings the spool of the
enters the secondary pressure port. reducing valve back to its neutral position.
In that case, the horizontal hole (I) enters the
hole of the body and seals it. As the result,
the circuit from the secondary pressure port
to the T port is shut off.
∅12
(0.472˝ )
∅11
(0.433˝ )
RETURN
SPRING
T T
(I)
(J)
P P
(J)
(H)
SECONDARY Fig. 3-4
PRESSURE PORT
24-27
3) Shuttle section
z If pressure is built up at port 1 or 3, the ball
is pressed against the seat by the pressure.
The pressure goes through from port 1 to port
5 (or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4
as the ball is sealed metallically by the seat.
If pressure occurs at port 2 or 4, the ball is
pressed against the body by the pressure. The
result is that the pressure connects with port
5 from port 2 (with port 6 from port 4).
Only a little leakage occurs at port 1 or 3 as
the ball is sealed metallically against the
body.
PORT 5
PORT 2 PORT 1
SEAT BALL
BODY
PORT 4 PORT 3
PORT 6
Fig. 3-5 Shuttle section
24-28
4. CONTROL VALVE Table 4-1
2-M10-20/27 (FOR LIFTING) Tightening
Port torque Port
4-M10 SCREW DEPTH 13 size name Description
4.1 SPECIFICATION kgfym (lbfyft)
(1) General view and hydraulic ports P1 Pump P1 port
P2 Pump P2 port
Ab Boom up port
Bb Boom down port
Ac Bucket dump port
Bc Bucket digging port
Ar Travel right port (forward)
15.3～18.4 Br Travel right port (reverse)
PF3/4 (110～133) AL Travel left port (forward)
BL Travel left port (reverse)
Aa Arm in port
Ba Arm out port
As Swing port (right)
Bs Swing port (left)
Ao2 Option 2 port (A)
Bo2 Option 2 port (B)
10～12.2 (P3) Option port
PF1/2 (72～89) (P4) Option port
MAIN C/V PAa Arm in pilot port
3-M10-20/27 (FOR LIFTING) P1(P2) T PBa Arm out pilot port
PAb Boom up pilot port
PBb Boom down pilot port
TRAVEL TRAVEL PAc Bucket dump pilot port
PTb TRAVEL PAL PBL
STRAIGHT STRAIGHT TRAVEL LEFT LEFT PBc Bucket digging pilot port
PBs2
Dra,Drb PAr Travel right pilot port (forward)
TRAVEL SWING PBs PBr Travel right pilot port (reverse)
PBr PAr SWING PAs
LEFT TRAVEL PAL Travel left pilot port (forward)
BUCKET RIGHT Pss
BOOM PBL Travel left pilot port (reverse)
BOOM PB1 7.0～8.0
PBc PAc BUCKET CONFLUX PF3/8 PAs Swing left pilot port
B CONFLUX PLc2 (51～58)
ARM PBs1 Swing right pilot port
BOOM PAa PBs2 Swing right pilot port
PBb PAb ARM Drd
BOOM Pis Arm recirculation port
ARM PA1 Arm conflux pilot port
P1 CUT Pis RECIRCU- P2
ARM LATION CUT PCa PB1 Boom conflux pilot port
PA1 PCb P1 CUT ARM PTb Travel straight pilot port
CONFLUX
RECIRCULATION
PCa P2 bypass pilot port
PAo2 PBo2 PCb P1 bypass pilot port
PAo2 Option 2 pilot port (A)
(P4) PBo2 Option 2 pilot port (B)
(P3)
Dra Drain port
Drb Drain port
A OPTION C/V Drc Drain port
3.5～3.9 Drd Drain port
PF1/4 (25～28) Pss Swing low pressure sensor port
Pisc Swing priority pilt port
PLc1 Boom lock valve release pilot port
ARM PLc2 Arm lock valve release pilot port
CONFLUX CUT 3-M10-18/22 (FOR LIFTING) 5～6.6
M10 T Tank port
(CUT) (36～48)
(2) Machine specification
BOOM ARM Table 4-2
Item E115SR E135SR
BUCKET BOOM CONFLUX
Main C/V
TRAVEL RIGHT
Model KMX13YC/B33016 KM13YC/B33006
SWING
Max. flow /min (gal/min) 118 (31)×2 118 (31)×2
TRAVEL Max. pressure kgf/cm (psi)
2 385 (5470) 385 (5470)
STRAIGHT TRAVEL LEFT
Main relief valve set pressure kgf/cm2 (psi) 330 (4690) at 60 /min (16gal/min) 350 (4980)at 60 /min (16gal/min)
Port relief valve set pressure kgf/cm2 (psi) 365 (5120) at 30 /min (7.9gal/min) 385 (5470) at 30 /min (7.9gal/min)
P2(P1) Option C/V ←

VIEW B VIEW A Type KADV22Y/S10102 ←
Port releafe sett presure kgf/cm2 (psi) 385 (5470) ←
Fig. 4-1 Control valve outside view and hydraulic port
24-29
4.2 CONSTRUCTION 155 164 101
T
B A
273
PBL PAL
H H PAs
’
TRAVEL TRAVEL
STRAIGHT PBs1 PBs2
C LEFT C
Pss
TRAVEL
RIGHT SWING PB1
D D
BOOM
BUCKET PAa
CONFLUX PBa
E E
BOOM ARM
PCa Pis
F F
ARM
RECIRCULATION
CUT
G (ARM G
CONFLUX) PBo2 PAo2
(CUT)
OPTION 2
H H 162
B
SECTION A－A
A
166 156 102
974 973
P2 P1
973
(974) PTb
162 973
562 562
PBr PAr
552 552
973
CT1 CT2 PAc
PBc
522 522
PBb
515 512 973 PAb
162 168 158
(973)
SECTION J－J PA1 PCb
973 973
SECTION H’－H’
162 164 155 162
SECTION B－B
Fig. 4-2 (1/3) Construction of control valve
24-30
201 166 156 201
156 166 201
201
333 333 333
332 333
332 PAc 332
PAL 332
337
337 337
326 338
328 326
325 327
602 325
332 325 329 332
262 332 332
157 262
262 262 512
167 162 162 Ac CCB
601 AL 512 (ROD SIDE)
522
513 522 512 552
LCc 562
522 CP2
CMR1
522
552 552 552
552
562 562 Bc 562
BL 562
562 CMR2
163 162 (HEAD
552 SIDE)
522 306 162

513 265 304
162 206 265 305
307 PTb
602 PBc PB1 265
PBL
265 (TRAVEL (TRAVEL 206 (BUCKET) (BOOM CONFLUX) 206
STRAIGHT) LEFT)
206
SECTION C－C SECTION E－E
PBs2 201 201
201 333 333
202 332 Drc
333 332 PLc1
Pss 337 (PLc2) (Drd)
333 337
332 PAr 328 PAb PAa
PAs
332 324
329 329
338 337
332 602
327
324 262 332
325 SECTION K－K
211 262
332 329 162
Drb 332 562 162
262 262 556 (HEAD 512
163 SIDE)
512 Ar As 512 524 CRb Aa 522
522 522 514 552
562 LCb LCa 562
CP1 LCs 552
552 552 562
562 522 556
562 Bb
Br Bs CRa
512
163 303
(ROD SIDE)
524
162
(Pisc) 514
Dra
265
301
302
306 206 265
211
265 PBr PBs 602 PBb PBa
265
(BOOM) (ARM)
206 (TRAVEL RIGHT) (SWING) 206
206
SECTION D－D Fig. 4-2 (2/3) Construction of control SECTION F－F
24-31
204 204 Table 4-3 Apply Locktite #262 to areas marked ☆.
333 333
(CUT) (ARM RECIRCULATION) Tightening torque Q'TY Tightening torque Q'TY
332 332
PCb Pis kgfym (lbfyft) No. NAME kgfym (lbfyft) No. NAME
337 337
326 PAL 101 CASING A 1 322 SPRING (TRAVEL STRAIGHT OUTER) ―
326
325 102 CASING B 1 323 SPRING (TRAVEL STRAIGHT INNER) ―
325
332 11.2～13.3 (81～96) 155 PLUG; PF1/2 2 324 SPRING (ARM,SWING INNER) 2
332
262 262 7～8 (51～58) 156 PLUG; PF3/8 3 325 SPRING (TRAVEL, CUT, ARM CONFLUX, 8
602 3.5～4.0 (25～29) 157 PLUG; PF1/4 1 BOOM CONFLUX,TRAVEL STRAIGHT OUTER)
512
309
562 1.3～1.7 (9.6～13) 158 PLUG; PF1/8 1 325 SPRING (TRAVEL, CUT, ARM CONFLUX, ―
Ab
552 162 O RING; 1B G30 17 BOOM CONFLUX)
CAa
(HEAD SIDE)
163 O RING; 1B P15 3 326 SPRING (CUT, ARM CONFLUX, 6
308 164 O RING; 1B P18 2 BOOM CONFLUX, TRAVEL STRAIGHT INNER)
310
512
166 O RING; 1B P14 3 326 SPRING (CUT,ARM CONFLUX, BOOM CONFLUX) ―
522 162
167 O RING; 1B P11 1 327 SPRING (TRAVEL INNER) 2
552 CCa (ROD SIDE)
Ba 309 168 O RING; 1B P8 1 328 SPRING (BOOM,BUCKET INNER) 2
562
262 201 SPRING COVER 7 329 SPRING (ARM,BOOM, BUCKET,SWING OUTER) 4
262
332 202 SPRING COVER 1 332 SPRING SEAT 24
332
325 204 SPRING COVER 4 ☆1.6～1.8 (12～13) 333 SPACER BOLT ; M8 12
325
326 326 206 SPOOL COVER 8 337 STOPPER (OTHER THAN TRAVEL) 10
602 211 LOCK VALVE SELECTOR SUB ASSY 2 337 STOPPER ―
337 337 214 PLATE 2 (OTHER THAN TRAVEL,TRAVEL STRAIGHT)
332 332 262 O RING 12 338 STOPPER (TRAVEL) 2
333 PA1 PCa 333 265 O RING; 1B G35 8 339 STOPPER (TRAVEL STRAIGHT) ―
(ARM CONFLUX) (CUT) 204
204 10～12.2 (72～89) 271 SOCKET BOLT M12×25 8 512 POPPET D=20 11
SECTION G－G 2.6～3.5 (18～25) 273 SOCKET BOLT M8×25 40 513 POPPET (CMR1, CMR2) 2
301 BOOM SPOOL ASSY 1 514 POPPET (LOCK VALVE) 2
PAo2
302 ARM SPOOL ASSY 1 522 SPRING 13
272 303 SWING SPOOL 1 524 SPRING (LOCK VALVE POPPET) 2
304 BUCKET SPOOL 1 13.3～15.2 (96～110) 552 PLUG M22 14
271
305 BOOM CONFLUX SPOOL 1 13.3～15.2 (96～110) 556 PLUG M22 2
306 TRAVEL SPOOL 2 562 O RING; 1B P20 16
307 TRAVEL STRAIGHT SPOOL 1 7～8 (51～58) 601 RELIEF VALVE (MAIN) 1
308 ARM CONFLUX SPOOL 1 7～8 (51～58) 602 RELIEF VALVE (PORT) 6
309 BYPASS CUT SPOOL 2 14.3～18.4 (103～133) 973 SOCKET BOLT M14×110 7
Ao2
310 ARM RECIRCULATION SPOOL ASSY 1 14.3～18.4 (103～133) 974 SOCKET BOLT M14×75 1
214 213
Bo2
PBo2
271 272
SECTION H－H
Fig. 4-2 (3/3) Construction of control valve
24-32
(2) Main relief valve (601) (3) Port relief valve (602)
301 564 563 521 124 561 611 621 661 612
512 541 521 123 124 125 561 562 121 122 611 621 103 163 661 612 651 671 123 125 562
511 522 161 541 101 162 102 651 671

Fig. 4-5
Fig. 4-3
Tightening Tightening Tightening Tightening

torque No. NAME Q'TY torque No. NAME Q'TY torque No. NAME Q'TY torque No. NAME Q'TY
kgfym (lbfyft) kgfym (lbfyft) kgfym (lbfyft) kgfym (lbfyft)
7～8 (51～58) 103 PLUG M27 (HEX 30) 1 541 SEAT 1 7～8 (51～58) 101 BODY M27 (HEX 32) 1 541 SEAT 1
121 SNAP RING 1 561 O RING; 1A, P16 1 7～8 (51～58) 102 PLUG M27 (HEX 30) 1 561 O RING; 1A, P16 1
122 SPACER 1 562 BACKUP RING 1 123 SNAP RING 1 562 BACKUP RING 1
123 SNAP RING 1 611 POPPET 1 124 FILTER STOPPER 1 563 O RING; 1A, P10 1
124 FILTER STOPPER 1 612 SPRING SEAT 1 125 FILTER 1 564 BACKUP RING 1
125 FILTER 1 621 SPRING 1 161 O RING; 1B, P24 1 611 POPPET 1
163 O RING; 1B, P25 1 651 ADJUST SCREW 1 162 O RING; 1B, P22.4 1 612 SPRING SEAT 1
512 PLUNGER 1 661 O RING; 1B, P8 1 301 PISTON 1 621 SPRING 1
521 SPRING 1 2.8～3.2 (20～23) 671 LOCK NUT M14 (HEX 22) 1 511 PLUNGER 1 651 ADJUST SCREW 1
521 SPRING 1 661 O RING; 1B, P8 1
522 SPRING 1 2.8～3.2 (20～23) 671 LOCK NUT M14 (HEX 22) 1
(4) Arm spool (302)
(5) Boom spool (301)
353 315 316 301 317 340 352
358 313 302 312 329 357
Fig. 4-4 320 330
Fig. 4-6
Tightening
torque No. NAME Q'TY
kgfym (lbfyft) Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
302 SPOOL 1 kgfym (lbfyft) kgfym (lbfyft)
312 SUB SPOOL 1 301 SPOOL 1 330 SPRING B2 1
313 PISTON 1 315 PLUNGER 1 1 340 SPRING B3 1
329 SPRING 1 316 PLUNGER 2 1 5～6 (36～44) 352 PLUG 1 M16 1
5～6 (36～44) 357 PLUG (1) 1 317 PLUNGER 3 1 5～6 (36～44) 353 PLUG 2 M16 1
5～6 (36～44) 358 PLUG (2) 1 320 SPRING B1 1
24-33
(6) Control valve for option (213) (7) Lock valve selector sub assy (211)
S202 A
PAo S334 PAo PAo
S337
S333
S323
S603 L101
S324
991 L541
S271
S161
S337 992 L162
TA TA’ S261 S512 L163
S101 Ao S522 Ao
TA’
S161 S301 S561
Po’
Po Po’ S551
C L171
B B L511
S161
TB’ Bo
Bo L512
TB TB’
L161
L201
S262
PBo PBo S603 PBo

S204
A
SECTION A－A VIEW C Fig. 4-8
Po’
L101 CASING 1 7～8 (51～58) L201 PLUG (M27; HEX 22) 1
Po L161 O RING 1 L511 SPOOL 1
SECTION B－B L162 O RING 3 L512 SPRING 1
L163 O RING 2 L541 BUSHING 1
Fig. 4-7 1～1.4 (7.4～10) L171 CAPSCREW; M6×45 4
Apply Locktite #262 to areas marked ☆.

S101 CASING 1 S333 STOPPER 1
S161 O RING G30 3 ☆1.6～1.8 (12～13) S334 BOLT M8 1
S202 SPRING COVER 1 S337 SPRING SEAT 2
S204 SPOOL COVER 1 S512 POPPET 1
S261 O RING 1 S522 SPRING 1
S262 O RING 1 12.2～14.3 (89～103) S551 PLUG (M24 ; HEX 12) 1
2.6～3.5 (18～25) S271 SOCKET BOLT ; M8×25 4 S561 O RING 1
S301 SPOOL 1 7～8 (51～58) S603 RELIEF VALVE (PORT) 2
S323 SPRING (INNER) 1 S991 NAME PLATE 1
S324 SPRING (OUTER) 1 S992 RIVET 2
24-34
4.3 HYDRAULIC CIRCUIT
Table 4-4
601 513 307 54 306
No. NAME
51 Main passage (P1 side)
52 Bypass circuit (P1 side)

TRAVEL
53 Parallel circuit (P1 side)
STRAIGHT 512
TRAVEL LEFT
306 54 Main passage (P2 side)
51 303
55 Bypass circuit (P2 side)
512 56 Parallel circuit (P2 side)
TRAVEL RIGHT SWING 211 Lock valve selector

56
53 55 301 Boom spool
304 52 512 302 Arm spool
BOOM CONFLUX
303 Swing spool
305
BUCKET 512
304 Bucket spool
302
301 305 Boom conflux spool
306 Travel spool

602 512 602
307 Travel straight spool
BOOM ARM
308 Arm conflux spool
602 309 P1,P2 bypass cut valve
(P2 BYPASS CUT)

310 Arm recirculation spool
ARM (VARIABLE)
P1 BYPASS CUT RECIRCULATION 512 Poppet D=20
(ARM CONFLUX)
513 Poppet
514
514 Lock valve poppet
601 Main relief valve

310
OPTION 602 Port relief valve
211 309 514 308 211
S301 Spool for option valve
309 S603 S603 Port relief valve for option valve
512 S603 S301
Fig. 4-9 Hydraulic circuit diagram
24-35
4.4 OPERATION
(1) Control valve in neutral
The oil delivered by hydraulic pump P1 The oil delivered by hydraulic pump P2 also
enters port P1 of the control valve and passes goes past the main passage (54), passes
through the travel straight spool (307) and through the bypass circuit (55) that goes
the main passage (51). It then passes through through the left travel, swing, boom conflux
the bypass circuit (52) that passes the right and arm circuits and then the P2 bypass cut
travel bucket and boom circuits and then the spool (309) and is brought back to the
P1 bypass cut spool (309) and is brought back hydraulic tank via the tank port (T).
to the hydraulic tank via the tank port (T).
309
P1
P2
(54) (55) 309 (51) (52)
Flow of hydraulic oil from hydraulic pump P2 Flow of hydraulic oil from hydraulic pump P1
Fig. 4-10 Functions at neutral
24-36
(2) Functions for travel action

1) At independent travel
If travel operation (forward) is performed, the Meanwhile, the oil which has returned from
secondary pilot pressure from ports (2) and the right travel A side and the left travel A
(4) of the travel pilot valve acts upon ports side passes between the outer circumference
PBr and PBL of the control valve and moves of the left travel spool (306) and the casing
the right and left travel spools (306). and returns to the hydraulic tank via the
The pressurized oil delivered by pump (P1) tank port (T) of the low pressure circuit (D).
flows to the main passage (51) past the travel At backward travel action (when the
straight spool (307), passes between the outer secondary pilot pressure acts upon ports PAr
circumference of the right travel spool (306) and PAL of the control valve), the pressurized
and the casing and is supplied to the right oil works the same way as in the forward
travel motor B by way of port Br. travel action.
In the meantime, the pressurized oil
delivered by pump (P2) passes between the
outer circumference of the left travel straight
spool (306) and the casing, runs to port BL
and is supplied to the left travel motor A side,
the same way as the pressure oil by pump
(P1).
RIGHT TRAVEL MOTOR
B A
Br Ar
306
PILOT PORT
PBr PAr
51 52 51
SECTION D－D (Travel right)
Fig. 4-11 At right travel forward (when PBr is pressurized)
24-37
2) At travel straight motion

If an actuator except the one for travel action is The pressure oil delivered by pump P2 flows,
actuated with the travel system in in most amount of oil, in the C→D direction
position [Ⅰ], the secondary pressure of the and the main passage (54), becomes the oil
electromagnetic proportional valve [C] acts pressure for the right travel and the left
upon port PTb of the control valve and moves travel motions and realizes simultaneous
the travel straight spool (307) right in order operation of the actuator and travel action.
to take position [Ⅱ]. (travel straight function)
The result is that the pressurized oil The secondary pressure of the solenoid
delivered by pump P1 flows from A to B in proportional valve [C] is applied additionally
most amount of oil and becomes the pressure and shifts the travel straight spool (307) to
for the actuators except one for travel action. the right to take the position Ⅲ. All of A to D
ports connect with the T-port in order to
P1
unload the pressure of the circuits as a whole.
P2 CMR2 CMR1 (unload function)
CA
T
PTb
DB
T C D A B T Position [Ⅰ]
CA
T
DB
At travel straight action

Position [Ⅱ]
CA
T
DB
At unload action
SECTION C－C Position [Ⅲ]
Fig. 4-12 Functions at travel straight action
24-38
(3) Bucket
1) When the bucket is digging
When the bucket is digging, secondary pilot the bucket spool (304) and the casing by way
pressure coming from port (1) of the pilot of the U-shaped passage and is supplied to
valve enters port PBc of the control valve and the bucket cylinder head (H) via port (Bc).
moves the bucket spool (304) to the left. In the meantime, the oil which has returned
The pressure oil delivered by pump (P1) flows from the bucket cylinder rod side goes
to the bypass circuit (52) past the main between the outer circumference of the
passage (51), but since it is blocked by the bucket spool (304) and the casing through the
bucket spool (304) that has shifted, it pushes port (Ac) and returns to the hydraulic oil
the check valve open, enters the parallel tank by way of the low pressure circuit (D)
circuit (53), pushes the load check valve (512) and the tank port (T).
open, goes between the outer circumference of
D (52) 304
PILOT PORT
PAC PBC
AC BC
(53)
U-SHAPED PASSAGE
512(LCc)
R H
BUCKET CYLINDER
SECTION E－E (Bucket)
Fig. 4-13 When bucket is digging
24-39
2) When the bucket is dumped

When the bucket is dumped, secondary pilot outer circumference of the bucket spool (304)
pressure from port (2) of the pilot valve and the casing via the U-shaped passage and
enters port PAC of the control valve and supplied to the bucket cylinder rod (R) via
moves the bucket spool (304) to the right. port (AC).
The pressure oil delivered by the pump P1 In the meantime, the oil which has returned
flows to the bypass circuit (52) through the from the bucket cylinder head goes between the
main passage (51), but since it is blocked by outer circumference of the bucket spool (304)
the bucket spool (304), it pushes the check and the casing through the port (Bc) and is
valve open, enters the parallel circuit (53) the supplied to the hydraulic oil tank by way of the
load check valve (512) open, goes between the low pressure circuit (D) and the tank port (T).
(52) (53) D 304
PAC
PBC
AC BC
U-SHAPED PASSAGE
512 (LCc)
R H
BUCKET CYLINDER
SECTION E－E (Bucket)
Fig. 4-14 When bucket is dumped
24-40
(4) Boom
1) When the boom is up
When the boom is up, secondary pilot The pressure oil then passes through the U-
pressure from port (3) of the pilot valve shaped passage, Pushes the boost check valve
enters port PAb of the control valve and open via chamber E of the boom spool (301),
moves the boom spool (301) to the right. It enters chamber BH.
also acts upon port PB1 (Refer to next page) Or the pressure oil enters chamber BH,
and change over the boom conflux spool (305). passing between the outer circumference of
At the same time the secondary pressure of the boom spool (301) and the casing, pushes
the electromagnetic valve [B] acts upon port the lock valve poppet (514) open, flows into
PCa of the control valve and change over the the port (Ab) and is supplied to the boom
P2 bypass cut spool (309). cylinder head (H).
The pressurized oil delivered by the pump P1 Meanwhile, the oil port (Bb) which returns
flows into the bypass circuit (52) through the from the boom cylinder rod (R) goes between
main passage (51), but since it is blocked by the outer circumference of the boom spool
the boom spool (301), it pushes the check (301) and the casing, flows into the tank port
valve open, enters the parallel circuit (53) (T) via the low pressure circuit (D) and
and pushes the load check valve (512) open. returns to the hydraulic tank.
BOOST CHECK INSIDE CONFLUX E (53) 301 D

PASSAGE
PAb PBb
(CRb) Ab Bb U-SHAPED PASSAGE

CHAMBER BH 514 512
(LCb)
R R
SECTION F－F(Boom)
H H
BOOM CYLINDER
Fig. 4-15 When boom is up (Boom spool)
24-41
2) Conflux for boom up

The oil delivered by the pump P2 flows into The oil then pushes the load check valve
the main passage (54), but since the bypass (512) open, passes between the outer
circuit (55) and the parallel circuit (56) are circumference of the boom conflux spool (305)
closed by the P2 bypass cut spool (309) which and the casing via the A side of the U-shaped
has shifted as explained in 1) above (Refer to passage, enters port Ab through the conflux
Fig. 4-16), the oil enters the parallel circuit passage in the casing and combines with the
(56) from travel spool. (Refer to Fig. 4-17) pressure on the pump P1 side.
PCa
P2 BYPASS CUT SPOOL (309)
SECTION G－G (Cut)
Fig. 4-16 P2 cut valve
CONFLUX CHECK VALVE (512) (56)

(CCb)
U-SHAPED PASSAGE
BOOM CONFLUX
PB1
305 TO PORT AB THROUGH THE CONFLUX PASSAGE IN CASING
SECTION E－E (Boom conflux)
Fig. 4-17 When boom is up (Boom conflux spool)
24-42
3) When the boom is down (in H or S mode)

When the work mode selector switch on the conjunction of the boom spool whereupon the
gauge cluster is set to the H (heavy digging) back pressure of lock valve poppet (514)
mode or S (save energy) mode, operation is as connects with DrC.
follows. The returned oil then enters chamber BH and
If the boom down action is performed, the runs into the boom spool (301) through the
secondary pilot pressure from port (4) of the circular notch of the boom spool (301). Since
pilot valve acts upon port PBb of the control the returned oil has sufficient pressure by the
valve and lock valve selector port PLC1 and weight of the boom, arm, etc. , it pushes the
shifts the boom spool (301) to the left, it also poppet C on the right of the illustration
change over the lock valve. through in the spool, passes through its outer
The pressure oil delivered by the pump (P1) circumference and is supplied to the boom
flows into the bypass circuit (52) through the cylinder rod side as the hydraulic oil for boom
main passage (51), but since it is blocked by down motion. (Boom fixed recirculation
the boom spool (301), it pushes the check function).
valve open, enters the parallel circuit (53), Some of the return oil from the head end of the
pushes the load check valve (512) open, boom cylinders forces open the boost check
enters the U-shaped passage, goes between valve, and flows through the low pressure
the outer circumference of the boom spool circuit D to the tank port T, and back to the
(301) and the casing and is supplied to the hydraulic oil tank. The purpose is to allow
boom cylinder rod side via port (Bb). excess return oil to escape to the tank. This
In the meantime, the oil which returns from excess oil is caused by the fact that the area of
the boom cylinder head enters the control the piston at the head end is larger than the
valve by way of port (Ab). Lock valve poppet area of the piston at the rod end.
(514) is located in front of boom spool (301), The boost check valve acts on oil flowing to
but the lock valve is pushed open as the the tank to secure an adequate amount of
lock valve selector spool is changed over in recirculating oil.
CONFLUX
LOCK VALVE PASSAGE
SELECTOR SPOOL BOOST CHECK IN CASING 301 (52) (53) POPPET C
D
PBb
PAb
PLC1
Drc
LOCK VALVE
SELECTOR
211
(CRb) Ab 512 Bb
CHAMBER BH 514 (LCb)
U-SHAPED PASSAGE
R R
SECTION F－F (Boom)
H H
BOOM CYLINDER
Fig. 4-18 When boom is down (in H or S mode)
24-43
(5) Arm
1) Arm out operation
If arm out operation is performed, the spool (302), it pushes the check valve open,
secondary pilot pressure from port (8) of the flows into the parallel circuit (56), pushes the
pilot valve acts upon ports PBa and PA1 of load check valve (512) open, goes between the
the control valve. (refer to next page) outer circumference of the arm spool and the
The pressure oil which enters port PBa shifts casing by way of the U-shaped passage, runs
the arm spool (302) leftwards. The pressure into chamber AR, pushes the lock valve
oil which enters port PA1 changes over the poppet (514) open and is supplied to the arm
arm conflux valve. cylinder rod side via port (Ba).
The secondary pressure of the electromagnetic In the meantime, the oil which returns from
proportional valve [D] acts upon port PCb of the arm cylinder bottom side passes between
the control valve and changes over the P1 the outer circumference of the arm spool
bypass cut valve (309). (302) and the casing, or chamber F in the arm
The pressure oil delivered by pump P2 flows spool (302) by way of the port (Aa), flows into
into the bypass circuit (55) by way of the main the tank port (T) from the low pressure
passage (54), but since it is blocked by the arm circuit (D) and returns to the hydraulic oil
tank.
ARM CYLINDER
H R
512 (LCa) 514 (CRa) CHAMBER AR

(Aa) (Ba)
PBa
PAa
D (55)
302 CHAMBER F (56) U-SHAPED PASSAGE
Fig. 4-19 At arm out operation (Arm spool)
24-44
2) Arm out conflux

In operation 1), the oil delivered by pump P1 Part of the delivered oil passes through the
flows into the bypass circuit (52) through the parallel circuit (53) and the restrictor,
main passage (51), but since the bypass combines with the pressure oil of the bypass
circuit (52) and the low pressure circuit (D) circuit (52), pushes the conflux check poppet
are blocked by the bypass cut spool (309), it (511) open, enters port Ba by way of the
does not run into the low pressure circuit (D). conflux circuit in the casing and finally
Meanwhile, since the arm conflux spool (308) combines with the pressure oil on the pump
has now been changed over, the pressure oil P2 side.
of the bypass circuit (52) goes between the
outer circumference of the arm conflux spool
(308) and the casing.
To port Ba through the conflux

P1 BYPASS CUT SPOOL passage in the casing
309 D (52) 308
PCb PA1
(53) 512 (CCa)
ORIFICE
SECTION G－G (Arm conflux) SECTION
(X1)
Fig. 4-20 At arm out operation (Bypass cut spool and arm conflux spool)
24-45
3) When the arm in is operated the arm cylinder rod (R) enters the control
(under light load) valve through the port (Ba).
If the arm in operation is performed, the Lock valve poppet (514) is located before arm
secondary pilot pressure coming out of port(7) spool (302). Since the lock valve selector spool
of the pilot valve acts upon the PAa port of is changed over, the lock valve poppet (514) is
the control valve and the PLc2 port of the pushed open and the oil enters the AR
lock valve selector. This causes the arm chamber. Since the return oil has sufficient
spool(302) to move to the right and changes pressure by the weight of the arm, it flows
the lock valve. The secondary pressure of the into the arm spool, passes through the inside
solenoid proportional valve [A] acts on the Pis of the arm spool, the notch of the arm spool
port of the control valve and changes the arm and the recirculation passage (60), and flows
recirculation spool (310) to position [Ⅱ]. into arm recirculation spool (310).
The pressure oil delivered by the pump P2 Since the arm recirculation spool is at
flows into the bypass circuit (55) past the position [Ⅱ], the pressurized oil thus flowed
main passage (54), but since the bypass enters passage (61) through the inside of arm
circuit (55) is blocked by the arm spool (302), recirculation spool (310), pushes arm
the oil pressure pushes the check valve CP2 recirculation check valve poppet (512) open,
open, flows into the parallel circuit (56), and is supplied again to the arm cylinder
pushes the load check valve (512) open, goes head (H) as the hydraulic oil for arm digging.
between the outer circumference of the arm (arm recirculation function)
spool (302) and the casing, or chamber F in Part of the hydraulic oil admitted to arm
the arm spool (302) through the U-shaped recirculation spool (310) flows into tank port
passage and is supplied to the arm cylinder (T) from low pressure circuit (D) and returns
head (H) side via port (Aa). to the hydraulic oil tank.
Meanwhile, the oil which has returned from
(61) (60) ARM CYLINDER
LOCK VALVE
SELECTOR SPOOL
H R LOCK VALVE
D SELECTOR PLc2
512 (CRa)
211 Drd
(LCa) 514
CHAMBER AR
ARM VARIABLE (Aa) (Ba)
RECIRCULATION
POSITION [Ⅱ]
PAa
302 (55)
CHAMBER SECTION F－F (ARM)
512(CAr) F (56)
310 (61) (60) Ba
Pis
D SECTION G－G
Fig. 4-21 When arm in is operated (under light load)
24-46
4) When the arm in is operated Then, the hydraulic oil flowed into arm
(under heavy load) recirculation spool (310) does not flow to the
The arm oil recirculation function is effective arm cylinder head [H] that is heavily loaded,
when operating the arm cylinder quickly but flows to tank port (T) from low pressure
under a light load, but under a heavy load circuit(D) and returns to the hydraulic oil
(when heavy duty is required), this function tank. (recirculation cut)
wastes power.
The control valve switches automatically Sequenced conflux :
between oil recirculation under light load If the arm cylinder head (H) is loaded
conditions and no recirculation under heavy heavily, the solenoid proportional valves [C],
load conditions by detecting pump pressure. [D] operate in addition to the above-mentioned
This is called the variable recirculation recirculation cut action. As the result, each
function. When the arm is under a heavy secondary pressure acts upon the PTb and
load, that is, when no recirculation occurs, PCb ports of the control valve, changes the
the oil supply passage to the arm cylinder is travel straight spool (307) to position [Ⅱ]
the same as during recirculation described [Refer to the above 4.4.(2).2).] and changes
above, but the return oil passage is different. the P1 bypass cut spool (309).
The system detects the pump pressure at As the result, the oil flow from the pumps P1
heavy load condition [more than 200kgf/cm2 open check poppet CT2 because P1 bypass cut
(2840psi) of pump pressure]. This causes the spool (309) is shifted, and hydraulic oil of
secondary pressure of solenoid proportional pump P2 is confluxed in the parallel circuit
valve [A] to operate and changes the arm (56) of the control valve and are supplied to
recirculation spool (310) to position [I]. the arm cylinder head (H).
ARM CYLINDER
(61) (60) LOCK VALVE
SELECTOR SPOOL
H R PLc2
LOCK VALVE
Drd
D 514 CHAMBERSELECTOR
AR
Aa Ba Pisc
ARM VARIABLE
RECIRCULATION
POSITION [Ⅰ]
PAa
302 CHAMBER F (55) 312

512(CAr) (61) (56) SECTION F－F (Arm)
310 (60) Ba
Pis
D SECTION G－G (Cut)

Fig. 4-22 When arm in is operated (under heavy duty)
24-47
(5) Swing action

If swing action is performed, the secondary valve (CP2) open and enters the parallel
pilot pressure from port (5) or (6) of the pilot circuit (56).
valve acts upon port PAS1 or PBS2 of the Then the pressure oil pushes open the load
control valve and shifts the swing spool (303) check valve (512) for swing action, flow into
rightward or leftward. U-shaped passage of the swing spool (303).
If the secondary pilot pressure is acting on Then the pressurized oil which has entered
the PBS1 port, it is also acting upon the the U-shaped passage of the swing spool
PBS2 port by way of the external pipe. In the (303) passes between the outer circumference
swing motion, the secondary pilot pressure is of the swing spool (303) and the casing and is
admitted to the Pss port past the shuttle supplied to the A or B side of the swing motor
valve in the cover. through port AS or BS.
Since the Pss port is connected with the Pisc In the meantime, the oil which has returned
port by way of the external pipe, the pressure from the B or A side of the swing motor
acts as swing priority signal. passes between the outer circumference of
The pressurized oil delivered by the pump P2 the swing spool (303) and the casing through
enters the bypass circuit (55) through the the port (BS) or (AS), flows from the low
main passage (54), but since it is blocked by pressure circuit (D) to the tank port (T) and
the swing spool (303), it pushes the check returns to the hydraulic oil tank.
valve
A B
U-SHAPED PASSAGE
SWING MOTOR PARALLEL CIRCUIT (56) P2 SIDE
FOR SWING MOTION (LCs)
303 512
AS BS
Pss PAS
PBS2
PBS1
(55)
SECTION D－D
Fig. 4-23 Swing left action (When PBS is pressurized)
(6) Simultaneous operation of swing and arm in.

When swing and arm in operations are (These operations are the same as that of the
concurrently carried out, with signal combined respective independent operation.)
processing of mechatro controller, the controller The arm variable recirculation valve operates
outputs commands current to travel straight the same as usual, but the spool moves
valve (PSV-C) & P1 bypass cut valve (PSV- toward the forcible recirculation side [Ⅲ]
D) & P2 bypass cut valve (PSV- B) and this according to the pilot pressure for the arm in
solenoid valve outputs secondary pressure, action.
then acts on C/V (2) PTb & PCb & Pca ports.
24-48
Swing main circuit is actuated by P2 pump Arm variable recirculation spool returns to
flow, but when the operation of swing and forced recirculation side according to swing
arm in are operated simultaneously, the pilot pressure. Return oil from arm cylinder
secondary pressure of travel straight valve rod (R) side is restricted in arm variable
switches it's spool and the secondary pressure recirculation valve.
of P1 cut proportional valve closes P1 cut And swing pilot pressure is led from “Pisc”
valve and oil of P1 pump confluxes port to sub-spool in arm spool, the pressure of
consequently with P2 pump circuit. The oil arm cylinder head (H) rises higher by
flows into swing and arm circuits in the same restricting opening of arm spool circuit
time because both circuits are paralleled. according to swing pilot pressure, as a result
Return oil pressure rises and also arm the oil P2 pump flows preferentially into
cylinder head (H) pressure rises because of swing circuit.
following two reasons. This is so-called swing priority control.
ARM CYLINDER
(61) (60) LOCK VALVE
SELECTOR SPOOL
Pisc
H R LOCK VALVE PLc2
CHAMBER AR SELECTOR Drd
D
514
Aa
ARM VARIABLE
RECIRCULATION
POSITION [Ⅲ]
PAa
302 SUBSPOOL SECTION F－F (Arm)

CHAMBER
512(CAr) F (56) (312)
310 (61) (60) (55)
Ba
Pis PCa
D SECTION G－G (Cut) 309
Fig. 4-24 Simultaneous operation of swing and arm digging
24-49
(7) Action of option valve (for P2 pump) :

If such an attachment as the N&B that uses pushes the check valve (CP2) open, flows into
an option valve, the secondary pilot pressure parallel circuit (56), pushes the load check
from port (P) of the pilot valve acts upon the valve (LCo2) open, passes through the
PAo2 or PBo2 port of the control valve and clearance between the outer circumference of
shifts the option spool to the right or the left. the option spool (S301) and the casing and is
At the same time, the secondary pressure of supplied to each attachment from port (Ao2)
solenoid proportional valve [B] acts upon the or (Bo2).
PCa port of the control valve and changes the In the meantime, the oil returned from the
P2 bypass cut spool (309). attachment enters the control valve from port
The hydraulic oil delivered by pump P2 runs (Bo2) or (Ao2), passes through the clearance
into bypass circuit (55) through the main between the outer circumference of the option
passage (54), but since it is cut off by P2 spool (S301) and the casing and returns to
bypass cut spool (309) that has shifted, the oil the hydraulic oil tank from the low pressure
circuit (D) and the tank port (T).
LOAD CHECK VALVE (LCo2)

Ao2 Bo2
PAo2
PBo2
S301
(56) D
Sectional view of option valve
PCa
(55) 309
SECTION G－G (Cut)
Fig. 4-25 Action of option valve
24－50
(8) Functions of lock valve

Lock valve (514) is located between arm That is to say, lock valve selector sub spool
cylinder rod side(R) and arm spool(302) of the (L511) is pressed against bushing (L541) by
control valve to decrease the leakage due to the action of spring (L512).
the holding pressure from the cylinder. In this position, the holding pressure from
Similarly, lock valve(514) is located between boom cylinder head (H) side passes through
arm cylinder head side(H) and boom passage Sa, passage (a) of bushing (L541) and
spool(301) of the control valve to decrease the around spool(L511), and connects to (b), then
leakage due to the holding pressure from the flows through passage Sb, consequently
cylinder. poppet (514) of the lock valve is pressed down
maintaining the seated condition, and the
1) When the main spool is neutral; leakage results in minimal quantity.
The boom spool (301) will be explained
hereinunder. The arm spool (302) will be
explained also.
When boom spool (301) is in neutral position,
it is held in the position shown in Fig. 4-26.
BOOM CYLINDER L511 L512

HEAD (H) SIDE CHAMBER 514
RH PLc1 Drc
Sb
Sa
(a) (b) L541
(301)
Fig. 4-26 Functions of lock valve (when the main spool is neutral)
24-51
2) At boom lower action:

The secondary pilot pressure from port (4) of This causes the orifice (b) of the bushing
the pilot valve acts upon the PBb port of the (L541) to connect with the passage Sb, the
control valve and the PLc1 port of the lock spring chamber of the lock valve poppet (514)
valve selector and shifts the boom spool (301) and the low pressure circuit. The lock valve
to the right. At the same time, the pressure poppet (514) is received by the ring-shaped
shifts the spool (L511) of the lock valve pressure bearing area that consists of the
selector to the right. guide diameter and the seat diameter of the
As the spool (L511) is shifted, the orifice (a) lock valve poppet (514), so that the lock valve
in the bushing (L541) closes. This shuts off poppet is pushed open upwards to release the
the continuity from passage Sa to passage Sb lock function.
in the lock valve selector B sub (212) and the
hold pressure received from the boom Note: The action in the above takes place
cylinder head (H) side ceases to act upon the before the opening (meter-out opening) that
spring chamber (RH) of the lock valve poppet brings the oil returning from the boom
(514). cylinder head (H) of the boom spool (301)
As the spool (L511) moves, continuity is during boom lower action, back to the
established from the orifice (b) of the bushing hydraulic oil tank; the action operates before
(L541) to the drain port (Drc) through the the boom spool strokes from its neutral
inside of the bushing (L541). position. Therefore, the action does not affect
the controllability of the boom lower motion.
L511 L512
CHAMBER
BOOM CYLINDER RH 514 PLc1 Drc
HEAD (H) SIDE
Sb
Sa
Pressurized part (a) (b) L541

of poppet (514)
PBb
PAa
301
Fig. 4-27 Functions of lock valve (at boom lower)
24-52
(9) Operation of main relief valve

The main relief valve is built in casing and
operates as follows:
1) The pressure oil is filled up in chamber A B A

through the orifice (B) of the plunger (512)
and seats the plunger (512) securely against
the body (541).
541 512
Fig. 4-28
2) When the hydraulic pressure of (P) reaches a

set pressure of the spring (621), it pushes B D
open the poppet (611) through the orifice (B)
and flows through the hole (D) to (R).
611 621
Fig. 4-29
3) When the poppet (611) opens, the pressure in

A
chamber A falls, which causes the plunger
(512) to open and the pressure oil of port (P)
to flow directly to (R).
R
512 611
Fig. 4-30
z The numbers of the parts of the

main relief valve in this section
correspond to those in Fig.4-3.
24-53
(10) Operation of port relief valve

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

1. The pressurized oil enters the hole A through P
the clearance between piston (301) and
plunger (511) and fills up chamber B. Thus
R
plunger (511) is seated tightly against seat
(541).
511 541 Fig. 4-31
2. When the hydraulic pressure of the port (P) C
arrives at a set pressure of the spring (621), it
pushes the poppet (611) open, flows on the
circumference of the poppet (611) and passes
through the hole (C) to (R).
P
611 621
Fig. 4-32
511 B
3. When the poppet (611) opens, the hydraulic
pressure in chamber B falls which causes the
plunger (511) to open and allows the
hydraulic pressure of port (P) to flow directly
to (R). P
611
Fig. 4-33
2. Operation of anti cavitation check valve

The check valve supplies oil from port (R)
when a negative pressure is built up at port
(P). When the pressure at (R) gets higher P
than that of port (P), the push-up force of
circuit (R) gets stronger than the pressing
force of chamber B. R
This causes seat (541) to move to the right.
Then the oil passes through the clearance of 541 Fig. 4-34
seat (541) and enters port (P) in sufficient
quantity to fill up the vacancy.
z The numbers of the parts of the

main relief valve in this section
correspond to those in Fig.4-5.
24-54
5. SWING MOTOR UNIT
5.1 SPECIFICATION
(1) Appearance THREAD FOR EYE BOLT
AN PB L 2-M10
Symbol Port name Port

size
DP
A Main port PF1/2
RELIFE VALVE
B B Main port PF1/2
C Make-up port PF3/4

A
DB Drain port PF3/8
Parking brake release
PG port (PG) PF1/4
GN
PA,PB Gauge port PF1/4
C PG L Level gauge PT1/2
IP Gear oil lubrication PT1/4

port
DB
DP Gear oil drain port PT1/2
PA IP
DP2 Gear oil drain port PF1/2
L REDUCTION UNIT
OIL LEVEL GAUGE GN Grease lubrication port PT1/4
A,B C DB The air bleed port when
AN PT1/4
grease is filled up.
PG
DP2
SWING
SHOCKLESS
VALVE BLOCK REDUCTION
UNIT DRAIN HOSE
RELIFE
VALVE
DP
AN
GN
Hydraulic diagram
Fig. 5 -1 Appearance of swing motor unit
24-55
(2) Specification
MODEL E135SR(LC) E115SR
Swing motor unit
Type M2X63CHB－13A－12/285－60 M2X63CHB－13A－11/265－60
Displacement cm3 (in3) 60.0 (3.7) ←

Hydraulic motor
Working pressure kgf/cm2 (psi) 285 (4050) 265 (3800)
Braking torque kgfym (lbfyft) 32 (230) ←

Release pressure
(Stroke end) kgf/cm2 (psi) 23 (330) ←
Relief set pressure kgf/cm2 (psi) 285 (4050) 265 (3800)
Weight kg (lbs) 29 (64) ←
Type RG06D19G3 ←
SAE#90~#140
Lubicate oil API Service Grade GL3 to 4 equivalent
Reduction unit
(Shell spirax 90EP at shipment)

Lubicate oil volume (gal) 1.7 (0.45) ←
Grease EP type grease (Shell Alvania EP2)
Grease volume cm3 (in3) 500 (31) ←
Weight kg (lbs) 75 (165) ←
Total capacity cm3 (in3) 1,152 (70.3) ←

Total
Total weight kg (lbs) 109 (240) ←
24－56
5.2 CONSTRUCTION
(1) Swing motor
992
351
355
051
401 488 469 051-1 051-2
303 468,487 106 981 438

712 451 131 444 433 980
V101
472
V161
707
V171
706
052 V151
982
V401-1
V401-2
114
V401
117
121
702
111 113
743 123
742 993
464
485
116 117 432 471 443 106 101 491 304 437 124 122 301
Fig. 5-2 Swing motor
24-57
Tightning Tightning
torque No. NAME QTY torque No. NAME QTY
101 DRIVE SHAFT 1 471 O RING; 1B G80 1
106 SPACER 3 472 O RING 1
111 CYLINDER 1 485 O RING; 1B P11 1
RETAINER
113 (SPHERICAL BUSHING) 1 487 O RING; 1B P11 2
114 CYLINDER SPRING 1 488 O RING; 1B P20 2
116 PUSH ROD 12 491 OIL SEAL 1
117 SPACER 2 702 BRAKE PISTON 1
121 PISTON 9 706 O RING 1
122 SHOE 9 707 O RING 1
123 PLATE 1 712 BRAKE SPRING 20
124 SHOE PLATE 1 742 FRICTION PLATE 3
131 VALVE PLATE 1 743 SEPARATOR PLATE 4
301 CASING 1 0.17(1.2) 980 PLUG; PF3/8 1
303 VALVE CASING 1 0.45(3.3) 981 PLUG; PF3/4 1
304 FRONT COVER 1 0.09(0.65) 982 PLUG; PF1/4 1
351 PLUNGER 2 6.6(48) 992 PLUG; PT1/2 1
355 SPRING 2 2.2(16) 993 PLUG; PT1/4 1
24(170) 401 SOCKET BOLT; M16×75 4 18(130) 051 RELIEF VALVE ; M33 2
432 SNAP RING 2 051-1 O RING; 1B G30 2
433 RING 1 051-2 BACKUP RING 2
SWING SHOCKLESS VALVE
437 SNAP RING 1 052 BLOCK 1
438 SNAP RING 1 V101 CASING 1
443 ROLLER BEARING 1 0.9(6.5) V151 PLUG; NPTF1/16 4
444 ROLLER BEARING 1 V161 O RING; 1B P22 2
451 PIN 2 3(22) V171 SOCKET BOLT; M8×70 8
SWING SHOCKLESS VALVE;
3.7(27) 464 VP PLUG; PF1/4 1 7(51) V401 M22 2
3.7(27) 468 VP PLUG; PF1/4 2 V401-1 O RING; 1B P20 2
11(80) 469 RO PLUG; M22 2 V401-2 BACKUP RING 2
24-58
2) Swing reduction unit

602 230 231 204 286 211 912 285 287 911 283 403 210
922
282
※ 921
202
203
311
285
※
312
913
402 910
801
925
920
926
102
401
915
z Coat the part marked ※ 201

with Three-Bond #1104B
Fig. 5-3 Swing reduction
TIGHTENING TIGHTENING
TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
102 CASING 1 401 ROLLER BEARING 1
201 DRIVE SHAFT 1 402 ROLLER BEARING 1
202 RING GEAR 1 403 NEEDLE BEARING 3
203 No.2 PLANETARY GEAR 4 10 (72) 602 SOCKET BOLT ; M12×100 10
204 No.2 SUN GEAR 1 801 OIL SEAL 1
210 No.1 PLANETARY GEAR 3 910 SPRING PIN 4
211 No.1 SUN GEAR 1 911 SNAP RING 3
230 No.2 CARRIER 1 912 SNAP RING 1
282 No.2 PIN 4 915 SEAL 1
283 No.1 PIN 3 6.6 (48) 920 ADAPTER ; PT1/2 1
285 SIDE PLATE t=1 7 11 (80) 921 HOSE ; PF1/2 1
286 THRUST WASHER t=2 1 11 (80) 922 PLUG ; PF1/2 1
287 SIDE PLATE t=2 3 2.2 (16) 925 RELIEF FITTING 1s
311 LEVEL BAR 1 2.2 (16) 926 GREESE NIPPLE 1s
312 PIPE 1
24-59
5.3 OPERATION
5.3.1 OPERATION OF HYDRAULIC MOTOR CYLINDER BLOCK(111)
If the high pressure oil flows into the cilynder F2

through the inlet port (a) of valve plate (131), as F1
shown on the figure on the right, the hydraulic

F
pressure acts upon piston (121) and creates force
F in the axial direction.
The force F may be divided into force F1 vertical
DRIVE SHAFT(101)
to shoe plate (124) via shoe (122) and force F2 at
right angles with the shaft.
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment.
VALVE
The cylinder block (111) has nine pistons equally
PLATE
arranged. Rotating torque is transmitted to drive (131)
shaft by turns by pistons connected to inlet port of SHOE SHOE PISTON
PLATE (122) (121)
high pressure oil.
(124)
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite (LOW PRESSURE OIL) (HIGH PRESSURE OIL)
direction.
Theoretical output torque T can be given by the

OUT IN (a)
following equation. PORT PORT
p×q
T=
2×π
p : Effective differential pressure kgf/cm2
q : Displacement per revolution c.c. /rev
Fig. 5-4 Operation of hydraulic motor
5.3.2 VALVE CASING SECTION 351

(1) Operation of anti-cavitation check plunger
Since the system using this type of motor is
not equipped with a valve having a
counterbalance function, the motor is rotated
beyond the oil feed rate in some cases.
The system has check plunger (351) and
sucks in dificient oil, in order to prevent
cavitation from occurring due to oil
deficiency.
Fig. 5-5 Operation of anti-cavitation check plunger
24-60
(2) Operation of relief valve ORIFICE m PISTON (303)

DAMPING
1) Operation at boosted pressure AREA A1 SPRING (321) AREA A2 CHAMBER
1. Consider where the P port is pressurized CHAMBER g
h
from the tank pressure.
The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in
Fig.5-6-(1). P
R
2. Condition shown in Fig.5-6-(2)
If the P port is pressurized, pressure is built PLUNGER (301) AREA A3 SPRING (322)
up in the g chamber via the orifice(m) in PISTON (302) SPRING CHAMBER
plunger (301). This pressure acts upon the
pressure receiving area (A2-A3) of piston
(303). Fig. 5-6-(1)
The force pushing the piston to the right
DAMPING
balances the action of spring (322), piston CHAMBER
m SPRING (321) PISTON AREA A2
(303) begins to shift to the right. Let the h
CHAMBER
pressure at this time be Pg1. The pressure in
the g chamber is held constant (Pg1) while
piston (303) is moving to the right.
The relief pressure (P1) at this time is P
expressed as below:
P1×A1=FSP1+Pg1×A2 ....... (1)
R
FSP1: Force of spring (321) AREA A3 SPRING (322)
PLUNGER (301) SPRING CHAMBER

3. Condition shown in Fig.5-6-(2)
While piston (303) is moving to the right, the
oil in damping chamber (h) is discharged to Fig. 5-6-(2)
the R port through the slit on the
circumference of piston (303). The slit on the
circumference of piston (303) is reduced
halfway. The damping action increases while
the rightward movement is under way, and
the pressure in the g chamber rises PISTON (303) DUMPING
gradually. As seen from equation (1), the m SPRING (321)
CHAMBER
AREA A2
relief pressure (P1) rises as the Pg1 pressure h
CHAMBER g
rises.
4. Condition in Fig.5-6-(3)
When piston (303) arrives at its stroke end, P
the pressure of the g chamber becomes equal
R
to that of the P port. On that occasion, the
relief pressure (Ps) is as below: SPRING (322)
PLUNGER (301) SPRING CHAMBER
AREA A3
FSP1
Ps = ....... (2) Fig. 5-6-(3)
A1－A2
After going through the sequences 1 to 4
above, the relief pressure changes as
shown in Fig.5-6-(4).
2) Operation as pressure falls:
If the pressure against the P port disappears,
plunger (301) is pressed by spring (321) and
lands on the seat.
In the meantime, piston (303) is pushed by
spring (322) and moves to the left. On that
occasion, the oil to damping chamber (h) is Fig. 5-6-(4)
refilled swiftly from the outer circumference
of the piston and the R port, and shifts piston Fig. Operation of relief valve
(303) quickly till it comes back to its initial
condition.
24-61
(3) Operation of swing reactionless valve
Fig. 5-7 Hydraulic circuit diagram for

1) Neutral condition :
swing shockless valve.
Fig.5-7 illustrates the relationship between
the neutral condition of the swing shockless
valve and the hydraulic circuits. Now, let us
consider a braking condition in which brake
pressure generates on the AM port side.
2) When brake pressure occurs :
If pressure(P) generates at the AM port, it k
passes through the passage l, the hole on 322 313 321 311
the shaft of seat(313) and the passage m of
plunger(311) and is admitted to the n Fig. 5-8(1) Neutral condition
chamber. m n
When the pressure P rises above a value(Ps)
set by spring(321), plunger(311) compresses
P=PS
spring(321) and shifts it to the left.
Seat(313) compresses weak spring(322) as
pushed by plunger(311) and moves to the left.
3) At swing shockless action
When inertia load stops moving(point Y, 322 313 321 311
Fig.5-9), brake pressure(P) tries to fall. Fig. 5-8(2) When brake pressure occurs
When P<Ps, plunger(311) moves toward the p t
right return side by the action of spring(321).
Seat(313) tries to move to the right by the
action of spring(322), but since chamber p P<PS
provides damping action by orifice g, the
return of the seat makes a time delay with
regard to the return of the plunger.
Consequently, seat t opens. This makes a k
passage connecting the AM port and BM 322 313 g r 321 311
ports or both ports of the hydraulic motor by Fig. 5-8(3) At swing shockless action
way of Fig. 5-8 Operation of swing reactionless valve
→t→r→k. The result is that the pressures
at the AM and BM ports become equal(PB),
falling into the condition at point Z in Fig.5-9.
This prevents the hydraulic motor from swing
shock by the closing pressure of the AM
port.
Fig. 5-9 Pressure change diagram of swing

reactionless operation
24－62
5.3.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101)
and a spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves FORCE BY
HYDRAULIC
provided in casing (301). PRESSURE
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against
casing (301) via separat or plate (743) and brake FORCE BY
SPRING
piston (702) by the action of brake spring (712), ACTION
frictional force is created between friction plate
(742) and casing (301) and between separator 712
plate (743) and brake piston (702). The frictional 702
force bounds the drive shaft to brake the motor.
OIL 743
In the meantime, when brake release pressure CHAMBER
742
applied to the oil chamber formed between brake
301
piston (702) and casing (301) overcomes the
101 111
spring force, the brake is released as brake piston
(702) moves till friction plate (742) is detached
from casing (301). Fig. 5-9 Operation of swing brake
5.3.4 SWING REDUCTION UNIT

The power of the swing motor drive shaft is
transmitted to sun gear No.2 (204) on the 2nd SWING MOTOR
stage through sun gear No.1 (211) on the 1st
211
stage and carrier No.1 (231).
204
Similarly, the power is transmitted to drive shaft
(201) through sun gear No.2 (204) on the 2nd
stage and carrier No.2 (230). The pinion shaft is 231
supported by two shaft bearing (401),(402) in 202
casing (102). 230
In addition, oil seal (801) is installed at the center
of casing (102) to protect the bearing on the drive
shaft side of which the load condition is difficult
from the gear frictional abrasion powder, and the
102 CHAMBER A
A chamber side is lubricated by oil in the ring
gear (202) and the B chamber is lubricated by the 402
grease sealed inside.
801 CHAMBER B
201
401
Fig. 5-10 Operation of reducting unit
24-63
6. TRAVEL MOTOR
6.1 SPECIFICATION
(1) Appearance
OIL LEVEL CHECK &
15-M16×P2.0 20-M16×P2.0
LUBRICATION PORT
(PT1/2)
A PF3/4
3-∅14 DRAIN PORT D1
PF1/2
TRAVEL
2-SPEED CHANGE
PORT P PF1/4
X ←
Z
DRAIN PORT D2
PF1/2 B PF3/4
Rotation direction Oil inlet Oil outlet OIL LEVEL CHECK &
LUBRICATION PORT
(Viewed from X side) port port (PT1/2)
Clockwise A B
Counterclockwise B A
DRAIN PORT (PT1/2)

VIEW Z
Fig. 6-1 Travel motor ( With reduction unit and brake valve )
(2) Specification
Table 6-1
Item Type GM18VL2－K－33/56－10
Revolution rpm 52.5/31.4

Reduction unit Lube oil Gear oil SAE #90 GL4
Oil level (gal) 2.5 (0.66)
Max. displacement cc / rev (cuyin/rev) 32.7/55.8(2.0/3.4)

Hydraulic Max revolution rpm 3464/2072(2nd-speed/1st-speed)
motor System. pressure kgf/cm2 (psi) 350 (5000)
2-speed change-over pressure kgf/cm2 (psi) 51(725)
Braking torque kgfym 18.2 (130)
Parking brake
Release pressure kgf/cm2 (psi) 8.0 (114)
Total weight kg (lbs) 144 (320)
24-64
6.2 CONSTRUCTION
(1) Outline
Hydralic circuit diagram
2-SPEED
CHANGE
PISTON
PARKING
BRAKE
2-SPEED
CHANGE
VALVE
LOAD CHECK
VALVE
&
ANTI- SHOCKLESS
CAVITATION RELIEF
VALVE VALVE KIT
BRAKE
VALVE
Fig. 6-2
24-65
(2) Hydraulic motor
135
126 139
137 112 171
130 113 167
127 109 103
138
124 141 106
136 121 117 105
128 154 115
107
116
125 111
104
110
142 150 114
166 179 110
164 127 145 132
163 130
138 137 149
202 126 108
199 201 126 102
168 146 190 195 151
140 143
202 194 123 169
193 125
128
138 136
124 191
162
161
Fig. 6-3
No. NAME QTY No. NAME QTY No. NAME QTY
102 (DRIVE) SHAFT 1 127 ANTICAVITATION VALVE 2 162 SHOE 1

103 (SWASH) PLATE 1 128 SPRING 2 163 SPOOL 1
104 CYLINDER BLOCK 1 130 SPRING 2 164 OIL STOPPER 1
105 PISTON 9 132 OIL SEAL 1 166 SPRING 1
106 SHOE 9 135 O RING 1 167 PILOT 2
107 RETAINER PLATE 1 136 O RING 2 168 BALL 2
108 THRUST BALL 1 137 O RING 2 169 COLLAR 1
109 TIMNG PLATE 1 138 O RING 4 170 SOCKET BOLT; M8×65 4
110 WASHER 2 139 O RING 1 171 PARALLEL PIN 2
111 WASHER 1 140 O RING 2 174 SUPER LOCK WASHER 4
112 PISTON 1 141 PARALLEL PIN 1 179 FILTER 1
113 SPRING 8 142 PARALLEL PIN 2 190 ORIFICE 1
114 SPRING 3 143 SOCKET BOLT; M10×30 8 191 SPRING 1
115 PLATE (FRICTION PLATE) 3 144 PLUG 1 193 O RING 2
116 PLATE (SEPARATOR PLATE) 3 145 SNAP RING 1 194 BALL 2
121 PLUG 1 149 BEARING 1 195 ORIFICE 2
123 SPOOL 1 150 BEARING 1 199 NAME PLATE 1
124 PLUG 2 151 NEEDLE ROLLER 3 201 REAR FLANGE 1
125 SPRING RETAINER 2 154 SOCKET PLUG (1/16) 9 202 PLUG 2
126 PLUG 2 161 PISTON 1
24-66
(3) SRV (Shockless relief valve)
202
209
211
208 215
211
217 209 224
217
212 216
204
210
205 217
203
209
206 217
201 222 211
221 208
211
222 209 202
220 213
214
222 211
201
206
203
205
210
204
Fig. 6-4
No. NAME QTY No. NAME QTY

201 VALVE 2 212 BODY 1
202 SLEEVE 2 213 PISTON 1
203 SPRING RETAINER 2 214 PLUG 1
204 PLUG 2 215 PLUG 2
205 SHIM 2 216 BALL 2
206 SPRING 2 217 BACKUP RING 4
208 O RING 2 220 O RING 1
209 O RING 4 221 PISTON SEAL 2
210 O RING 2 221 SOCKET PLUG 6
211 BACKUP RING 4 224 O RING 2
24-67
(4) Reduction unit
21
31
22
2 21
5
30
23
9
23
4
33
1
29
27 27
17 25
7
14
20
22 35
3
36 8
6
15
19
Fig. 6-5
No. NAME QTY No. NAME QTY
1 HUB 1 20 SNAP RING 3

2 SPINDLE 1 21 BEARING 2
3 HOLD FLANGE 1 22 BEARING 6
4 RV GEAR A 1 23 BEARING 6
5 RV GEAR B 1 25 SNAP RING 3
6 INPUT GEAR 1 27 O RING; 1B P7 2
7 SPUR GEAR 3 29 O RING 1
8 COVER 1 30 O RING 1
9 CRANK SHAFT 3 31 FLOATING SEAL 2
14 DISTANCE PIECE 3 33 PLUG 2
15 COUPLING 1 35 SOCKET BOLT 16
17 PIN 24 36 BALL 1
19 REAMER BOLT 3
24-68
6.3 EXPLANATION OF FUNCTION

6.3.1 REDUCTION UNIT
(1) Function
This reduction unit is equipped with spur
gears (Hereinafter referred as 1st reduction
gear section) and differential gears
(Hereinafter referred as 2nd reduction gear
section), reduces the high rotation speed from
the Hydraulic motor, coverts it to low speed
large torque and rotates hub (1) (Casing).
(2) Explanation of function

1) 1st reduction gear section SPUR GEAR (7)
The rotation of hydraulic motor shaft is
CRANK SHAFT (9)
transmitted to input gear (6) which is linked
with shaft (102) in spline.
Then, the rotation speed of three spur gears
(7) which are engaged with input gear is
reduced.
Also, the reduction rate of 1st reduction gear
section is as follows.
Zi SHAFT (102)
i1=－ Zs
i1 = Reduction rate of 1st reduction

gear section
Zi = Number of teeth of input gear
INPUT GEAR (6)
Zs = Number of teeth of spur gear
Fig. 6-6
2) 2nd reduction gear section
a) Three spur gears are engaged with
crankshaft respectively to transmit the power SPUR GEAR
from the 1st reduction gear section to 2nd
NEEDLE BEARING ROTATION
reduction gear section.
The eccentric bodies of crankshaft a and b ECCENTRIC
revolve eccentrically (revolution) while REVOLUING
rotating on its axis by rotating crankshaft. CRANK SHAFT (9)
Also, these eccentric bodies a and b and RV ROTATION
B
gears “A” (4) and “B” (5) transmit only A
the eccentric revolution.
And RV gears A and B revolve in the same
direction and number of revolutions as spur
gear and crankshaft.
b) Teeth number ZR of RV gears A and B is
always engaged with ZP pins (17) rotating
and changing the mesh part in order, by ECCENTRIC
RV GEAR B (5)
eccentrically revolving RV gears A and B. MOTION
By eccentrically revolving RV gears A and B RV GEAR A (4)
one turn, the pin revolves in the same Fig. 6-7
direction of eccentrical revolution in the
portion of difference between number
24-69
of teeth ZR and number of pins ZP

【(ZP－ZR) / ZP】.
This revolution of pin is transmitted to hub, HUB
producing output rotation of reduction unit. 23 24 1 2
22 3
At this point, the speed ratio of 2nd reduction 4 PIN (17)
gear section is as follows.
i2= (ZP－ZR)
ZP
RV GEAR A
i2 = Speed ratio of 2nd reduction AND B
gear section
ZR= Number of RV gears A and B teeth
ZP= Number of pins CRANK SHAFT
360° 360°
REVOLVING
2×24 24
BODY SECTION
Then, the output revolution is as follows,
when the hydraulic motor shaft rotates one
23 24 1 2 22
23 24 1
time. 22
3 2
4 3
4
i= i1×i2
i1 = Speed ratio of 1st reduction
gear section
i2 = Speed ratio of 2nd reduction
gear section
Zi (ZP－ZR) At half rotation (180°

) At one rotation
i= － ×
Zs ZP
6.3.2 HYDRAULIC MOTOR SECTION Fig. 6-8

(BRAKE VALVE, HIGH AND LOW SPEED
CHANGE MECHANISM)
(1) Function
1) Hydraulic motor is referred to as a swash
plate type axial piston motor which converts
the pressure oil power fed by pump into
rotary motion.
2) Brake valve
a) Travel motor controls the force of rotational
inertia of the body to brake and stop the
rotation smoothly.
b) Check valve function to prevent hydraulic
motor from cavitation.
c) Surge cut valve function to control braking
power of hydraulic motor, and anti-cavitation
valve function to prevent cavitation.
3) High and low speed change mechanism
The function of selector valve and control
piston switches the tilting angle of swash
plate. As a result of the switching, travel
motor has high speed low torque motion and
low speed high torque motion.
24-70
4) Parking brake
101
The parking brake is used to the prevent
machine from running away or slipping while 109 104 103
parking on a slope using the friction plate
type brake mechanism, and is installed on
102
the hydraulic motor.
(2) Operation
1) Hydraulic oil fed by pump enters rear flange
(101) of travel motor, and is led from timing
plate (109) to cylinder block (104) through
brake mechanism. This pressure oil is led to
only the one side of Y1－Y2 tied between top 105
dead point and bottom dead point of piston
stroke (105). And the pressure led to one side
of cylinder block pushes 4 or 5 pistons (105),
generating the power (F1kgf= Pkgf / cm2× Y1 F3
Acm2). This power enters on swash plate F3
(103), but swash plate (103) is fixed having
an angle (α) against axis of drive shaft (102), ri
and divided into component of force (F2, F3).
And the radial component of force (F3) F3
generates various torque (T=F3×ri) against
line Y1－Y2. The total torque [T=∑(F3×ri)] is
connected to turning effort, and rotates
Y2
cylinder block (104) through piston (105).
This cylinder block (104) is connected with
drive shaft (102) with spline, and rotates
CYLINDER BLOCK
drive shaft (102) to transmit torque.
PISTON
α
F1
A P
F3
F2
24-71
2) braking
a) Operation (Brake released)
The pressure oil is led to through port (A), 112
opens valve (127), and led to port (C) on the
section side of hydraulic motor to rotate
hydraulic motor.
At the same time, the pressure oil enters
chamber (b) through passage (a) from the
D C
small hole of spool (123), and exerts on the
end of spool to generate the force.
Then the force of spring (128) slides the spool P,S a b
placed on the neutral position leftward. 128 123
The sliding of spool forms the space (passage)
between spool and rear flange with spool
groove. This passage is connected to port (D)
and port (B) of the return circuit of the
hydraulic motor, and the return oil returns to
tank side, enabling hydraulic motor to rotate.
Then, the sliding of spool (123) leads pressure
oil to port (P) and port (S). The pressure oil
B A
led to port (P) moves piston (112) of parking DRAIN 127
brake, and releases parking braking force.
(For details, refer to item“Parking brake”). Fig. 6-12
If pressurized oil is supplied from port (B) the
movements of spool (123) and valve (127) are
reversed so that the hydraulic motor is
rotated reversely.
b) Self-traveling
While machine is being operated, as the
112
travel speed is increased due to steep slope,
the oil flow rate of the hydraulic motor is
higher than the supply flow rate of the
hydraulic oil pump. The rotation of the
hydraulic motor in this case is called a self-
traveling (Overrun). D C
While self-traveling, the oil pressure is
lowered similar to the stopping condition. P,S a b
Then brake valve is moved similar to the
stopping condition, throttles passage in the 128 123
return side of hydraulic motor, and generate
back pressure.
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution
having a balance with the supply flow rate of
pump.
B A
DRAIN 127
Fig. 6-13
24-72
c) At stop and at loss of speed (braking action)

If the pressurized oil which has been supplied Accordingly, the hydraulic oil of chamber (D)
from port (A) during travel action is flows to the chamber (C) at relatively low
suspended the hydeaulic force pressing the pressure and controls the pressure at
spool disappears. Then spool (123) which has chamber (D). At the same time, the hydraulic
been moving to the left tries to return to the pressure prevents cavitation of chamber (C).
right (neutral condition) by the action of When the piston (213) arrives at the stroke
spring (128) via spring retainer (125). At the end, the pressure in chambers (g), (f)
same time, the hydraulic motor tries to turn increases. The right-hand valve (210) is
by inertia, though the hydraulic oil supply closed again. When the right-hand valve
from port (A) is suspended. The oil (201) is closed, the oil at port (D) rises
discharged from the hydraulic motor has no further. If the left-hand valve (201) opens, the
way to escape, with the result that the oil in port (D) acts upon port (C) and opens
hydraulic oil in port (D) is boosted. The the relief valve at a much higher pressure
hydraulic oil thus boosted passes through the than a set value of it. In this way, the
right-hand valve (201) and enters the hydraulic motor is braked smoothly by
chambers (f) and (g), in that order. The piston controlling the pressure in port (D) in two
(213) moves to the right as shown in the steps.
figure so that the pressure does not rise. In
that period, the valve (201) on the right is
pushed open by the pressure of the chamber
(D).
127 128 123
E
B
A
C
f
201
a
g
213
b
Fig. 6-14
24-73
3) Parking brake
a) The pressure oil led through brake valve
actuates on spool (123) of brake valve on the
112 116 115 104
hydraulic motor section, opens passage to
parking brake, and is led to cylinder chamber
(a) compressed of spindle (2) and piston (112)
on the reduction gear section.
If the pressure of oil which is 8kgf/cm2
(110psi) or higher it exceeds the force of
spring moving piston (112) toward rear flange
(101) side.
This movement of piston (112) reduces the
push power to separator plate (116), (117)
and friction plate (115), and makes the
movement of friction plate (115) which is
installed to cylinder block (104) on hydraulic
motor section free releasing the brake power
to cylinder block (104).
113 a 117
Fig. 6-15
b) Stopping
If pressure oil from brake valve is cut, and
the pressure in cylinder chamber (a) lowers
8kgf/cm2 (110psi) or less, the piston (112)
goes to rightward by the force of spring (113).
Also, the force of the spring pushes separator 112 116 115 104
plate (116), (117) and friction plate (115),
which is in a free state because piston (112) is
pushed, against spindle (2) on the reduction
gear section. The frictional force produced by
the push power stops the rotation of cylinder
block (104), and transmits braking torque
18.2 kgfym (132ftylbs) to hydraulic motor
shaft. And since oil is controlled through the
proper oil passage, it results in smooth
operation.
113 a 117
Fig. 6-16
24-74
4) High and low speed change mechanism

a) At low speed
In case the travel 2-speed select pilot
pressure is not supplied from port (D), valve
(163) is pushed up by the action of spring THE TRAVEL
2-SPEED SELECT
(166) and the hydraulic pressure from port PILOT PRESSURE
(A) or (B). This shuts off the pressure of (C) 163
103
and the oil in the P chamber is released to
the drain (motor casing) via the valve. The θ1 SURFACE Y
result is that the swash plate(103) takes the 166 161
max. tilting angle θ1 which in turn
CHAMBER P
maximizes the piston stroke volume,
making the hydraulic motor run at low speed.
b) At high speed
In case the travel 2-speed select pilot
DRAIN
pressure 51kgf/cm2 (725psi) is supplied from
por t(D), valve (163) is pushed down, Fig. 6-17
overcoming the action of spring(166) and the
pressure from port (A) or (B). The
pressurized oil at port (C) is admitted to
chamber P via valve (163). THE TRAVEL
2-SPEED SELECT
Piston (161) is pushed till swash plate (103)
PILOT PRESSURE
hits the surface X and is held. 163
On that occasion, the swash plate (103) takes 103
the min. tilting angle θ2 which in turn θ2 SURFACE X
minimizes the piston stroke volume to make 161
166
the hydraulic motor run at high speed.
CHAMBER P
b) Automatic selection of low speed during high
speed operation :
The pressure at port (A) or (B) increases as
the load of the hydraulic motor increase
DRAIN
during high speed operation, and when the
pressure arrives at 290kgf/cm2 (4120psi), it Fig. 6-18
overcomes the pilot pressure [51kgf/cm2
(725psi)] at port (D).
Valve (163) is then pushed upward. The oil in
the P chamber is released to the drain (motor
casing) via valve (163). THE TRAVEL
2-SPEED SELECT
On that occasion, swash plate (103) hits the PILOT PRESSURE
surface Y of the spindle and takes the max. 163
tilting angle θ1. The angle is held to make 103
the hydraulic motor run at low speed. θ1
SURFACE Y
166 161
CHAMBER P
DRAIN
Fig. 6-19
24-75
6A. TRAVEL MOTOR (FOR L TYPE)
6A.1 SPECIFICATIONS
(1) General view
C1
FEED OIL PORT PT 1/2
D
X
OIL CHECK
B PORT PT 1/2
C2
OIL DRAIN PORT PT 1/2
Fig. 1 Outside View of Travel Motor (with Reduction unit & Brake Valve)
Rotating direction
Oil inlet Oil outlet Port name Port size
(As seen from X side)
CW A B A,B Oil inlet or Oil outlet PF 3 / 4
CCW B A C1 , Drain port PF 1 / 2

C2
D Two speed changeover signal port PF 1 / 4
(2) Specifications
Table 1
Model GM24V-A-58/105-1
Item
Reduction Unit Reduction ratio 48
Output torque kgfym 1470 / 2640
(ftylbs) (10,700 / 19,100)
Revolution H /L rpm 42.1 / 23.5
Recommended gear oil A.P.I. Classification
GL-4, SAE #90
Oil capacity (gal) 3.0 (0.793)
Motor Stroke displacement H /L cc /rev 58.4 / 104.7
(cuin /rev) (3.56 / 6.39)
Working pressure kgf /cm2 (psi) 330 (4,690)
2-speed changeover pressure kgf /cm2 (psi) 40 (570)
Parking Brake Braking torque kgfym (ftylbs) 27 (195)
Brake release pressure kgf /cm2 (psi) 11 (156)
Surge cut valve Cracking pressure kgf /cm2 (psi) 210 (2,990)
Total weight kg (lbs) 240 (529)
24－76
6A.2 CONSTRUCTION
109 113 143 147 139 112 135 148 116 115 114 110 151 107 105 106 153 108 103 17 5 167 102 4 33
A 32
187
6
154
25
145
14
B
186 34
189
9
138
13
121
C 20
198
190 36
141
150
30
199
119 7
120
19
118
3
140
B
132
178
A
149
138
176 191
177 172 175 173 174 133122 101 39 29 2 37 10 40 23 31 1 104 24 12 15 8 35 162 161 27
127130156 126 121 138
168
142
155
192 124
193
125
128
SECTION C－C 194
123
156
SECTION A－A SECTION B－B

136 158 155 124
170 137 159 157
Fig. 2
24－77
No. PART NAME Q’TY No. PART NAME Q’TY No. PART NAME Q’TY
REDUCTION GEARS HYDRAULIC MOTOR 142 PARALLEL PIN 2

1 HUB 1 101 REAR FLANGE 1 143 SOCKET BOLT 9
2 SPINDLE 1 102 SHAFT : DRIVE 1 145 SNAP RING 1
3 CARRIER 1 103 SWASH PLATE 1 147 BACK UP RING 1
4 RING GEAR (A) 1 104 CYLINDER BLOCK 1 148 BACK UP RING 1
5 RING GEAR (B) 1 105 PISTON 9 149 ROLLER BEARING 1
6 CLUSTER GEAR 3 106 SHOE 9 150 BALL BEARING 1
7 SUN GEAR (A) 1 107 RETAINER PLATE 1 151 ROLLER 6
8 COUPLING GEAR 1 108 THRUST BALL 1 153 THRUST PLATE 1
9 SHAFT (G) 3 109 TIMING PLATE 1 154 EXPANDER 5
10 DISTANCE PIECE 1 110 WASHER 2 155 O RING 3
12 DISTANCE PIECE 1 112 PISTON 1 156 O RING 4
13 COVER 1 113 SPRING 12 157 STOPPER 1
14 THRUST COLLAR 6 114 SPRING 1 158 SPRING 1
15 RING 1 115 FRICTION PLATE 2 159 SPRING 1
17 PIN 10 116 SEPARATOR PLATE 2 161 PISTON 1
19 COUPLING 1 118 VALVE SEAT 1 162 SHOE 1
VALVE : PARKING
20 THRUST BEARING 2 119 1 167 STEEL BALL 2
BRAKE
23 SEAL RING 1 120 SPRING 1 168 STEEL BALL 2
24 BALL BEARING 2 121 PLUG 2 170 SOCKET BOLT 4
25 NEEDLE BEARING 6 122 RING 1 172 SPRING PIN 1
27 PARALLEL PIN 10 123 SPOOL:BRAKE VALVE 1 173 VALVE 1
29 O RING 1 124 PLUG 3 174 SPRING 1
30 SOCKET PLUG 3 125 STOPPER 2 175 STEEL BALL 2
31 FLOATING SEAL 1 126 PLUG 2 176 EXPANDER 2
32 CAPSCREW 20 127 VALVE 2 177 SPRING 1
SUPER LOCK
33 20 128 SPRING 2 178 PLUG 1
WASHER
SPOOL : TWO SPEED
34 PARALLEL PIN 3 130 SPRING 2 186 1
CHANGEOVER
35 SOCKET BOLT 10 132 OIL SEAL 1 187 OIL STOPPER 1
36 STEEL BALL 1 133 O RING 1 189 SPRING 1
37 O RING 1 135 O RING 1 190 ORIFICE 1
39 O RING 2 136 BODY 1 191 SPRING 1
40 O RING 1 137 SPOOL : SURGE CUT 1 192 PLUG 2
139 O RING 1 194 ORIFICE 2
141 PARALLEL PIN 2 199 NAME PLATE 1
24－78
6A.3 EXPLANATION OF FUNCTION

6A.3.1 REDUCTION UNIT 1 5 4
The reduction unit reduces the revolution
transmitted via the hydraulic motor and converts
it to high rotating force.
The reduction unit employs a 2-step planetary 6
reduction method.
The planetary mechanism consists of a cluster
gear, a sun gear and a ring gear.
Hydraulic
Motor
7
Fig. 3
1 HUB 5 RING GEAR B

2 SPINDLE 6 CLUSTER GEAR
3 CARRIER 7 SUN GEAR
4 RING GEAR A
In the figure on the right, if the sun gear (7) on Functional explanation drawing
the input side is rotated, three cluster gears (6)
6
rotate. These cluster gears are integrated into a
2-stage gearing system and mesh with the ring 7
gear A (4) and the ring gear B (5). 4
Since the ring gear B (5) is fixed to the crawler
frame, the cluster gears (6) transmit power to the
ring gear A (4), causing it to rotate. 5
Fig. 4
24－79
6A.3.2 HYDRAULIC MOTOR SECTION (BRAKE

VALVE, PARKING BRAKE, AND AUTO 2－
SPEED CHANGEOVER MECHANISM )
〔OPERATING PRINCIPLE〕
(1) Function
1) Hydraulic Motor
The hydraulic motor is what is called a swash
plate type axial piston motor that converts
the force of the hydraulic pressure delivered
by the pump to rotary motion.
2) Brake Valve
The brake valve is built in the hydraulic
motor and performs the following four
functions :
a) It smoothly brakes the hydraulic motor to
101 104 105
a stop by controlling the inertia force
produced as the hydraulic motor attempts
to turn the moment it stops.
b) It serves as a check valve that prevents
cavitation of the hydraulic motor.
c) It serves as a surge cut valve controlling
the braking pressure of the hydraulic
motor and also acts as an anti－cavitation
valve that prevents cavitation.
d) It opens the parking brake releasing port
when the hydraulic motor is run and 109 103 102
closes it when the hydraulic motor is Fig. 5
stopped.
3) Auto 2－Speed Changeover Mechanism
Y1
The action of the changeover valve and the F3
control piston changes the tilting angle of the F3
swash plate to two steps ; high－speed, low
torque rotation and low－speed, high torque ri
rotation.
(2) Functional Description
1) Hydraulic Motor F3
The hydraulic pressure delivered by the
pump enters rear flange (101) of the
hydraulic motor and is admitted into cylinder Y2
block(104) by way of the brake mechanism Fig. 6
and timing plate (109). CYLINDER BLOCK
It is so designed that the hydraulic pressure
is introduced only to one side of a line Y1－Y2 PISTON
connecting the top and bottom dead points of
the process of piston (105). The hydraulic
pressure entering one side of the inside of
cylinder block (104) pushes each of pistons a
(105) (four or five pcs ) and produces a force F1
(F1kgf=Pkgf/cm2 × Acm2). This force which A P
F3
acts upon swash plate (103) is divided into F2
components (F2,F3) as the swash plate
(103)is fixed at an angle (a) with regard to
the axis line of drive shaft (102). Fig. 7
24－80
Out of the components, the radial component (F3) return side of the motor (which has been closed by
produces torques (T= F3×ri) with regard to the the groove of the spool when the motor stops) is
line Y1－Y2. connected with port (B) on the tank side. This
The resultant of these torques(T=Σ (F3×ri) ) causes the return oil from the motor to connect
turns the cylinder block (104) via pistons (105). with the tank to turn the motor.
The cylinder block (104) which is connected with Also, if spool(123) slides, hydraulic pressure
the spline of drive shaft (102) turns drive shaft enters port (P) and port (s). The hydraulic
(102), thereby transmitting torque. pressure entering port (P) actuates piston (112) of
the parking brake and releases the parking brake
force. (For details, refer to para. Parking Brake.)
2) Brake Valve The hydraulic pressure entering port (s) enters
a) At Neutral chamber (t), presses stopper (157) against the
When the control valve is in neutral, ports inside surface of body (136) and prevents spool
(A,B) are connected with the hydraulic
tank. Since spool (123) in the brake valve d
closes the path (A→C, B→D) by springs 112
(128) the paths from the motor to port (C) 113
and the path from the motor to port (D) 123 101
which leads to both ends of the motor are D E C
confined. Consequently, the motor holds 128
its stop position without rotating, even if
external force acts upon it.
If external force acts upon the motor,
pressure builds up on either port (C) or (b)
(D), but since high pressure oil escapes
due to internal leakage of the motor, the
(a)
motor makes a minimal turn. On that 127
occasion, the low pressure side becomes B A
negative which opens the check valve
(127) on the low pressure side contained Fig. 8
in flange (101) and feeds the leakage to
the low pressure side through the
hydraulic tank to prevent rotation of the
motor.
When the spool position is neutral, port 112
136
(E) connects with the hydraulic tank line,
so the oil in chamber (d) returns to the 137
hydraulic tank. This causes spring (113) 157
(D)
to press piston (112) upward and makes (t) (E) (C)
(p)
the parking brake in an operating (s)
condition. 123 (a)
b) During Operation (Brake Release) 125 (b)
If hydraulic pressure is supplied from port
(A), it opens check valve (127) and
attempts to turn the motor by way of port
(C) on the suction side of the motor. At 128
127
the same time the hydraulic pressure
enters chamber (b) through path (a), acts
upon the end face of spool (123) and
causes spool (123) in a neutral position to (B) (A)
be moved leftwards by the action of spring Fig. 9
24－81
(137) from being moved by the hydraulic In this way the valve (127) is actuated by
pressure so that motor port (C) will not a minimal negative pressure which opens
be connected when the motor is in the oil passage from port (A) to the
motion. When hydraulic pressure is suction port (C) of the motor, thereby
supplied from the suction side of the preventing cavitation of the motor.
motor and port (B) on the return side, the
motions of spool (123) and valve (127) are
reversed with regard to the right and left
direction to reverse the rotation of the
motor.
c) At stop and stall (when the brake operates)
If hydraulic pressure from port (A) is
112
shut off, the spool (123) which has moved
to the left attempts to return to the right
via stopper (125) by the action of spring 136
(128). On that occasion, the oil in 137
chamber (b) tends to go out of port (A) (D)
157 (C)
past path (a) in spool (123), but the speed (E)
(P)
of spool (123) returning to the right is
(s)
controlled by the effect of the restrictor in
123 (a)
path (a).
125 (b)
Then, the motor attempts to rotate by its
inertia even after pressure is shut off.
Accordingly, the return oil tends to go
back to port (B) side through port (D) and
128
past a path which is formed in the
127
clearance between the groove of spool
(123) and rear flange (101). When spool
(123) returns to neutral completely, the
path formed in the clearance is closed (B) (A)
completely to stop the motor. Thus the
motor is braked smoothly to a stop as the Fig. 10
oil returning from the motor is gradually
controlled by the return speed of spool
(123) and the spool function.
However, the motor changes its motor
action to pumping action by inertia
moment and tries to suck oil.But oil can
not be fed to the motor as pressurized oil
supply is shut off , with the result that
the motor develops cavitation that has
adverse effect on it. Concurrently, since
the path is closed by spool (123), the
return oil from the motor is confined on
port (D) side which results in a rise in
the pressure. This pressure moves spool
(137) leftwards till port (D) and port (C)
are shortcircuited. These are a surge cut
valve function and an anti－ cavitation
valve function that prevent pressure rise
and cavitation.
24－82
3) Parking Brake
113 112
a) At Running
If hydraulic pressure is supplied from the 116
brake valve, it operates the spool of the
motor brake valve. It opens the path to the
115
parking brake and the pressure is
admitted to cylinder chamber (a) that
consists of the inside surface of the spindle
and piston (112) in the reduction unit. 104
When the hydraulic pressure reaches
10kgf/cm2 (142 psi ) or over, it overcomes
the force of spring (113) and moves piston
(112). The transfer of piston (112) removes
the force that presses piston (112) against
separator plate (116) and friction plate
(115), frees the movement of friction plate
(115) fixed into cylinder block (104) of the
motor, finally releasing the braking force
(a)
against cylinder block (104) of the motor.
Fig. 11
b) At Stop
When hydraulic pressure from the brake
valve is shut off, the pressure in cylinder 113 112
chamber (a) is let free and when it goes 116
down below 10kgf/cm2 (142 psi), piston
(112) tends to return by the action of
115
spring (113). The spring action pushes the
piston which in turn presses now freed
separator plate (116) and friction plate
(115) against the spindle of the reduction 104
unit. A frictional force produced by this
pressing stops the rotary force of cylinder
block (104) and provides the motor shaft
with a braking torque 27 kgfym (195
ftylbs). Smooth action is attained as oil is
controlled through a proper oil passage in
valve (119).
119 (a)
Fig. 12
24－83
4) Auto 2－Speed Changeover Mechanism

a) At Low Speed
When no pilot pressure is supplied from Consequently, swash plate (103) takes the
port (D), spool (186) is pushed upward by maximum tilting angle of θ1 that maximizes
the action of spring (189) and the the displacement of the pistons of the
hydraulic pressure from port (A) or (B) to hydraulic motor to run it at low speed.
shut off the pressure at port (C). As the
result the oil chamber (P) is released into
the motor casing via spool (186).
Pilot pressure
D
A B
189
C 186 θ1
103
A Surface Y
B P Chamber
DRAIN
Fig. 13
b) At High Speed
When pilot pressure〔50kgf/cm2 (711 psi ) spindle (2) and is held on that surface. On
or over 〕 is supplied from port (D), it that occasion, swash plate (103) takes the
overcomes the action of spring (189) and minimum tilting angle θ2 that minimizes the
the pressure through port (A) or (B) and displacement of the pistons of the hydraulic
presses spool (186) down. The pressure at motor to run it at high speed.
port (C) enters chamber (P) via spool
(186). Piston (161) then is pushed up till
swash plate (103) hits surface X of
Pilot pressure
D
A B
189
Surface X
C 186 θ2
A 103
161
B P Chamber
DRAIN
Fig. 14
24－84
c) Functional Description of Automatic

Changeover to Low Speed During High
Speed Motion
If load increases during high speed
motion, the pressure from port (A) or (B)
increases also. When the pressure arrives
at 300kgf/cm2 (4270 psi ), it overcomes
the pilot pressure〔50kgf/cm2 (711 psi)〕
from port (D), so that spool (186) is
pushed upward. Then the pressure of
port (C) is shut off, so that the oil in
chamber (P) is released into the motor
casing via spool (186). As the result, the
swash plate hits surface Y of the spindle
and is held on that surface. On that
occasion, swash plate (103) takes the
minimum tilting angle θ1 which
maximizes the displacement of the
hydraulic motor pistons to run the motor
at low speed.
Pilot pressure
D
A B
189
C 186 θ1
Surface Y
A 103
161
B
P Chamber
DRAIN
Fig. 15
24－85
7. SWIVEL JOINT
7.1 DOZER SPECIFICATION
7.1.1 GENERAL VIEW (SPEC.1)
Y
↓
H
H F
C
A E D
B
G
I
D
C VIEW Y
F E
↑
Z Fig. 7-1 General view of swivel joint
VIEW Z
7.1.2 SPECIFICATION
Table 7-1
Item Spec.1
Working pressure 350kgf/cm2(4980psi)
High pressure ports
Max. impact pressure 525kgf/cm2(7470psi)
A,B,C,D
Rated flow 315 /min(83gal/min)
Working pressure 210kgf/cm2(2990psi)
High pressure ports
Max. impact pressure 525kgf/cm2(7470psi)
F,G
Low pressure ports Working pressure 5kgf/cm2(71psi)
E Rated flow 50 /min(13gal/min)
Low pressure ports Working pressure 50kgf/cm2(710psi)
H,I Rated flow 15 /min(4gal/min)
Revolution 15rpm
A,B,C,D PF1
Ports size E,F,G PF1/2
H,I PF1/4
Length: L 420mm(16.5″)
Weight 63kg(139 lbs)
24-86
7.1.3 CONSTRUCTION
T= Tightening torque: kgfym (lbfyft)
Y
↓
E
2 Note) Be sure to apply grease 12 2 places

on O rings(6),(7) when T=6(43)
assembling.
2 places
6 F
D
C E B
1
D A
H
G
C
H I
B 13
T=1(7.2) VIEW Y
G Note) Fit seal(5) in the completely

degreased seal groove without
application of grease.
F
7 places
5 T=3.1(Loctite#290)
7
3 E
4 8 9
2 places 4 places
Fig. 7-2 Construction
Table 7-2
1 BODY 1 7 O RING; 1A G125 1
2 STEM 1 8 SOCKET BOLT; M8×20 2
3 THRUST PLATE 1 9 SOCKET BOLT; M8×30 4
4 COVER 1 12 PLUG; PT1/2 2
5 SEAL ASSY 7 13 PLUG; PT1/8 1
6 O RING 2
24-87
7.2 STANDARD SPECIFICATION

7.2.1 GENERAL VIEW (SPEC.2)
VIEW Z
Fig. 7-3 General view of swivel joint
7.2.2 SPECIFICATIONS
Table 7-3
Item Spec. 2
Assy
Working pressure 350kgf/cm2 (4980psi)
High pressure ports
Max. impact pressure 525kgf/cm2 (7470psi)
A,B,C,D
Rated flow 255 /min (67gal/min)
Low pressure ports Working pressure 5kgf/cm2 (71psi)
E Rated flow 50 /min(13gal/min)
Low pressure ports Working pressure 51kgf/cm2 (725psi)
F Rated flow 30 /min (8gal/min)
Revolution 15rpm
A,B,C,D PF1
Ports size E PF1/2
F PF1/4
Length (height) 320mm(12.6″)
Weight 27kg(60 lbs)
24－88
7.2.3 CONSTRUCTION
2
6
VIEW Y
12
5
7
SECTION XX
3
9
4 Tightening torque
3.1 kgfym (22.4 lbfyft)
8
Tightening torque
3.1 kgfym (22.4 lbfyft)
Fig. 7-4 Construction

1 BODY 1 6 SEAL ASSY 2
2 STEM 1 7 O RING ; 1A G95 1
3 THRUST PLATE 1 8 SOCKET BOLT ; M8×20 2
4 COVER 1 9 SOCKET BOLT ; M8×30 4
5 SEAL ASSY 5 12 PLUG 1
7.2.4 OPERATION The body (1) and the stem (2) rotate mutually.
The swivel joint consists mainly of body (1) and The oil flowing in from body (1) or stem (2) keeps
stem(2) that rotate mutually, thrust plate (3) on flowing to stem (2) or body (1) past the
preventing both components from falling off, circumferential groove between body (1) and stem
cover(4) closing one side of body(1), seal(5) that (2); the oil flow is never shut off because of
partitions off the circuits and seal assy (6) and O rotation. Further, an oil groove for lubrication
ring (7) that prevent external leaks. that connects with the drain port is provided, in
Four ports for the travel main circuits are order to prevent the body (1) from seizure with
provided on body (1) and stem (2). Further, four the stem (2).
oil passing grooves are arranged in the inner This construction keeps on connecting the circuits
surface of body (1), with seal (5) fixed above and between the swing bodies by means of a swivel joint.
below the circumferential groove.
24－89
8. CYLINDER
8.1 SPECIFICATIONS
(1) General view
Part No. and Manufacturing No.

Stamp position
Fig. 8-1 Outside view of cylinder
(2) Specifications
Center distance
Cylinder bore / Dry
of mounting pins
Use Stroke Full extend B / Cushion weight
Rod Dia.
Full retract A kg (lb)
∅100 / ∅70
1,038 2,526 / 1,488 With cushion
Boom (3.94″/ 2.76″ (3′5″) (8′3 / 4′11″) 94 (210)
″ on rod side
E135SR(LC)
)
E135SRL
∅115 / ∅80
Arm (4.53″/ 3.15″ 1,135 2,865 / 1,730 With cushion
) (3′9″) (9′5″/ 5′8″) on both sides 140 (309)
∅95 / ∅ 65 995 2,445 / 1,450 With cushion

Boom (3.74″/ 2.56″) (3′3″) (8′0″/ 4′9″) 84 (185)
on rod side
E115SR
∅110 / ∅75
Arm (4.33″/ 3.15″ 1,075 2,655 / 1,580 With cushion
)
(3′6″) (8′8″/ 5′2″) on both sides 114 (251)
∅95 / ∅ 65 885 2,250 / 1,365

Bucket (3.74″/ 2.56″) (2′11 ″) (7′5″/ 4′6″) With cushion 81 (180)
E135SR(LC)
on rod side
E115SR
∅110 / ∅65 220 880 / 660

Dozer (4.33″/ 2.56″) (8.66″) (2′11″/ 2′2″) Without 57 (130)
24－90
8.2 CONSTRUCTION
(1) Boom cylinder T=Tightening torque ; kgfym (lbfyft)
E135SR (LC)
3 B 6
E115SR
Z
→
T=1.8～2.2(13～16)
M10×1.5
28,29 27
26
DETAIL 22 DETAIL B DETAIL C

VIEW Z
T=1.5(11) T=190(1370) T=100(720)
2 14 13 9 8 10 11 12 7 15 4 1 19 20 21 16 18 17 22 23 24 5
PT1/8
C
∅1.2 PT1/4
(0.047″)
25 T=21～22(150～160)
Fig. 8-2 Construction of boom cylinder
(The figure shows the right-hand cylinder.)

1 CYLINDER TUBE 1 11 WEAR RING 2 21 O RING; 1B G100 1
2 BUSHING 2 12 DUST RING 1 22 BUFFER SEAL 1
3 DUST SEAL 2 13 PISTON NUT 1 23 ROD PACKING 1
4 PISTON ROD 1 14 SET SCREW; M8 1 24 DUST SEAL 1
5 PIN BUSHING 1 15 CUSHION RING 1 25 SOCKET BOLT; M14×65 8
6 DUST SEAL 2 16 ROD COVER 1 26 BAND 1
7 PISTON 1 17 BUSHING 1 27 BAND 1
8 O RING 1 18 SURCLIP 1 28 CAPSCREW; M10×30 2
9 BACKUP RING 2 19 O RING; 1B G95 1 29 LOCK WASHER 2
10 PISTON SEAL 1 20 BACKUP RING 1
24-91
(2) Arm cylinder E135SR LC, E115SR

T=Tightening torque; kgfym (lbfyft)
B M10×1.5
B
Z
→
31 32 29
T=1.8～2.2
(13～16)
30 VIEW Z DETAIL 20 DETAIL B DETAIL C
T=1.5 (11) T=190 (1370) T=100 (720)
2,3 12 11 7 6 8 9 10 5 13 4 1 17 18 19 14 16 15 20 21 22 2,3
C
PT1/4
PT1/8
A 23 T=35～37
(250～410)
24
25
26
27 T=5 (36)
28
DETAIL A Fig. 8-3 Construction of arm cylinder

1 CYLINDER TUBE 1 12 SET SCREW; M8 1 23 SOCKET BOLT; M16×70 10
2 BUSHING 4 13 CUSHION RING 1 24 RESTRICTOR 1
3 DUST SEAL 4 14 ROD COVER 1 25 SPRING 1
4 PISTON ROD 1 15 BUSHING 1 26 SPRING SEAT 1
5 PISTON 1 16 SURCLIP 1 27 PLUG; PF3/8 1
6 O RING 1 17 O RING; 1B G110 1 28 O RING; 1B P14 1
7 BACKUP RING 2 18 BACKUP RING 1 29 BAND 1
8 PISTON SEAL 1 19 O RING; 1B G115 1 30 BAND 1
9 WEAR RING 2 20 BUFFER SEAL 1 31 CAPSCREW; M10×30 2
10 DUST RING 2 21 ROD PACKING 1 32 LOCK WASHER 2
11 PISTON NUT 1 22 DUST SEAL 1
24-92
(3) Bucket cylinder E135SR LC, E115SR
T=Tightening torque ; kgfym (lbfyft)

PT1/8
PT1/8
25 26,27 T=1.8～2.2(13～16)

24
VIEW Z
T=1.5 (11)
T=190(1370) T=100(720)
2 3 12 11 7 6 8 9 10 5 13 4 1 17 18 19 14 16 15 20 21 22 2,3
B
C
23 T=21～22
(150～160)
Fig. 8-4 Construction of bucket cylinder

1 CYLINDER TUBE 1 11 PISTON NUT 1 21 ROD PACKING 1
2 BUSHING 2 12 SET SCREW; M8 1 22 DUST SEAL 1
3 DUST SEAL 4 13 CUSHION RING 1 23 SOCKET BOLT; M14×65 8
4 PISTON ROD 1 14 ROD COVER 1 24 BAND 1
6 O RING 1 16 SURCLIP 1 26 CAPSCREW; M10×30 2
7 BACKUP RING 2 17 O RING; 1B G90 1 27 LOCK WASHER 2
8 PISTON SEAL 1 18 BACKUP RING 1
9 WEAR RING 2 19 O RING; 1B G95 1
10 DUST RING 2 20 BUFFER SEAL 1
24-93
(4) Dozer cylinder

T=Tightening torque; kgfym (lbfyft)
B
2 3 3 2
DETAIL B
T=70(510)
T=1.5(11) T=50(360) T=50～70(510～360)
10 11 9 7,8 12 23 5 1 4 18 6 15 16 17 21 14
2-PT1/8
(Grease nipple hole)
19,20 22 24
Fig. 8-5 Construction of dozer cylinder

1 CYLINDER TUBE 1 9 WEAR RING 2 18 SURCLIP 1
2 BUSHING 2 10 PISTON NUT 1 19 O RING 1
3 DUST SEAL 4 11 SET SCREW 1 20 ROD SEAL 1
4 PISTON ROD 1 12 O RING; 1B G65 1 21 ROD PACKING 1
5 PISTON 1 14 ROD COVER 1 22 DUST SEAL 1
6 BUSHING 1 15 O RING; 1B P110 1 23 BACKUP RING 2
7 O RING 1 16 BACKUP RING 1 24 CLIP 1
8 PISTON SEAL 1 17 O RING; 1B G115 1
24-94
Hydraulic cylinder construction

(See Fig. 8-2, 8-3, 8-4, 8-5)
By construction the hydraulic cylinder consists
mainly of cylinder tube assy (1), piston rod assy
(4) that takes out the motion of pistons
reciprocating in the cylinder tube assy, and rod
cover (14) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a piston
mount (crevice) that connects piston rod assy (4)
with other parts.
In addition to these main components, piston seal
(8) and wear ring (9) are located between cylinder
tube assy (1) and piston rod assy (4); buffer seal
(20), rod packing (21) and dust seal (22) are
located between piston rod assy (4) and rod cover
(14); and an O ring and a backup ring are placed
between cylinder tube assy (1) and rod cover (14). CUSHION RING(13) CHAMBER “A”
TANK PATH “B”
8.2.2 OPERATION PISTON(5)
If pressurized oil is fed alternatively to the oil ROD(4)
inlet and outlet provided in the cylinder, force
acts on the piston which in turn causes the piston BOTTOM ROD SIDE
rod (4) to extend and retract. SIDE
(1) Operation of cylinder with cushion (14)

CUSHION STROKE ROD COVER
(Cushion on rod side)
The piston (5) in motion gives rise to shocks if Fig. 8-6 Cushion mechanism on the rod side
it hits the rod cover (14) without reduction of
speed. The cushion mechanism as shown in
Fig. 8-6 is provided to damp them.
RESTRICTED PATH “C”
An oil in chamber “A” returns to the tank by
TANK
passing through paths “B” and “C” at a fixed CLEARANCE “D”
flow rate in a intermediate stroke state (Fig. 8-6)
of pressing bottom side. Next, in a state of
just before stroke end (Fig. 8-7), cushion ring
(13) plunges into path “B”.
At this time, an oil in chamber “A” passes
clearance “D” and restricted path “C”, an oil
flow volume returning to tank suddenly drops
and the piston part movement slows down. Fig. 8-7 Cushioning action on the rod side
CUSHION RING RESTRICTED PATH
Fig. 8-8 Cushioning action on the rod side
24-95
(Cushion on head side) PLUNGER

This construction is similar to the one of cushion TANK CHAMBER “A”
on rod side. In a state of intermediate stroke
pressing rod side, an oil in chamber “A” returns
to tank by passing through paths “B” 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 “C”, an oil flow volume PATH “B” E CLEARANCE “D”
returning to tank suddenly drops and the RESTRICTED PATH “C”
piston part movement slows down.
RESTRICTOR VALVE
SPRING
SPRING SEAT
PLUG
O RING
DETAIL E
Fig. 8-9 Cushioning action on the head side
24-96
9. CONTROL VALVE (FOR DOZER OR EXTRA)
9.1 OUTLINE Tightening

Port torque Port
size Name Function
(1) Outside view kgfym (lbfyft)
A1 Dozer cylinder head side port

11±1.0 B1 Dozer cylinder rod side port
PF1/2
(80±7.2) P Pump port
T Tank port
M8 Return spring force

Neutral; 9.8kgf
Stroke
Full stroke; 13kgf
B1
T
P
A1
4-∅10.5Drill
Fig. 9-1 Outside view of control valve

(2) Specification
Item Specification.
Model KVS-65-1
Main relief pressure 210kgf/cm2(2990psi)
at 50 /min(13gal/min)
A1,B1 port relief 280kgf/cm2(3980psi)
pressure at 30 /min(7.9gal/min)
Max. pressure 250kgf/cm2(3550psi)
Acceptable back
pressure(working) 3.5kgf/cm2(50psi)
Weight Approx. 5kg(11 lbs)

Circuit diagram
24-97
(3) Construction
9 B1 side
Dozer blade up side
8
B1
3
3
A1
6
9
A1 side
Dozer blade 7
down side
Fig. 9-2 Construction of control valve
Tightening
torque No. NAME Q’TY
kgfym (lbfyft)
1.9(14) 1 NUT 4
2 TIE ROD 2
4.7(34) 3 NUT 2
4 TIE ROD 1
5 INLET SECTION ASSY 1
6 OUTLET SECTION ASSY 1
7 SPOOL SECTION ASSY 1
8 MAIN RELIEF VALVE ASSY 1
9 OVER LOAD RELIEF VALVE ASSY 2
24-98
© New Holland
2. ELECTRICAL EQUIPMENT
1 LIST OF ELECTRIC EQUIPMENTS
Group Code NAME Group Code NAME Group Code NAME

C－1 Mechatro controller (SK115SR-1ES) M－1 Starter motor (24V×4.5kW) SV－1 Swing parking sol.
C－1 Mechatro controller (SK135SR(LC)-1ES) M－2 Governor motor SV－3 2-speed travel sol.
CONTROLLER
C－2 Gauge cluster (KCME Spec.) M－3 Wiper motor SV－4 Lever lock sol.
SOLENOID
MOTOR
M－4 Washer motor (tank assy) SV－6 Clockwise rotate sol
C－4 Air conditioner controller (A/C Acc.) M－9 Fuel pump SV－7 Counterclockwise rotate sol.
M－11 Fuel supply pump SV－24 Extra depressure sol.
D－1 Diode R－1 Battery relay

D－2 Diode R－3 Glow relay PSV－A Arm variable recirculation proportional valve
PROPORTIONAL VALVE
D－3 Diode R－4 Safety relay PSV－B P2 bypass cut proportional valve
DIODE
D－4 Diode R－5 Wiper motor relay PSV－C Travel straight proportional valve
SOLENOID
D－5 Diode R－6 Washer motor relay PSV－D P1 bypass cut proportional valve
D－6,7,8,9 Diode R－7 Horn relay PSV－P1 P1 pump proportional valve
R－8 Work light relay PSV－P2 P2 pump proportional valve
R－9 Extra depressure relay
RELAY
E－1 Fuse box R－10 Cab work light relay 1
E－1 Alternator (SK115SR-1ES) R－11 Cab work light relay 2
E－2 Alternator (SK135SR(LC)-1ES) R－19 Flasher relay
E－3 Hour meter R－20 Timer relay SW－1 Key switch
E－4 Horn (Low) R－22 Clockwise rotate relay
E－5 Horn (High) R－23 Counterclockwise rotate relay SW－3 2-speed travel switch
ELECTRIC FITTINGS
E－6 Cigarette lighter R－28 Auto idle stop relay 1 SW－4 Swing parking release switch
E－7 Tuner AM & FM R－29 Auto idle stop relay 2 SW－5 KPSS release switch
E－8 Speaker (Left) SW－6 E/G water temperature switch [105℃(221°F)]
E－9 Speaker (Right) SE－1 Pressure sensor (low pressure) bucket digging SW－7 E/G oil pressure switch
E－10 Receiver drier (A/C Accessory) SE－2 Pressure sensor (low pressure) bucket dump SW－8 Air filter clogging switch
E－11 A/C compressor (A/C Accessory) SE－3 Pressure sensor (low pressure) boom up SW－10 Horn switch left
E－14 Resistor (P1, P2 pump proportional valve) SE－4 Pressure sensor (low pressure) boom down SW－11 Lever lock switch (Limit SW.)
E－16 DC－DC converter SE－5 Pressure sensor (low pressure) swing SW－13 Air conditioner switch (Panel assy)
E－17 Power socket 12V SE－7 Pressure sensor (low pressure) arm in SW－16 Auto accel release switch (Decel)
E－25 Battery (95E41R) SE－8 Pressure sensor (low pressure) arm out SW－17 Swing flasher select switch
SE－9 Pressure sensor (low pressure) travel right SW－20 Horn switch right (Handle assy)
SWITCH
SE－10 Pressure sensor (low pressure) travel left SW－21 Work light switch
L－1 Boom work light left SE－11 Pressure sensor (low pressure) ; P2 option SW－22 Single/Conflux flow select switch
L－2 Work light right SE－11 Pressure sensor (low pressure) ; N&B (Opt.) SW－23 Wiper inter lock switch
SENSOR
L－3 Room light (Cab) SE－12 Pressure sensor (low pressure) ; Offset left opt. SW－30 Rotary light switch
L－4,5,78 Cab work light (front) SE－12 Pressure sensor (low pressure) ; Offset right opt. SW－32 Overload indicate switch
LIGHT
L－8 Engine room light SE－13 E/G speed sensor SW－39 Overload pressure switch
L－9 Boom work light (RL) SE－14 E/G water temperature sensor SW－42 Engine room light switch
L－10 Cab work light (Re) SE－15 Fuel sensor SW－43 Jib press switch : option
L－ Swing flasher (right, left) SE－16 Accel potentiometer SW－44 Extra press switch : option
11,12
L－15 Rotary light SE－20 Pressure sensor (low pressure) ; P1 option SW－46 Clockwise rotate sw.
SE－20 Pressure sensor (low pressure) ; Jib extend / retract opt. SW－47 Counterclockwise rotate sw.
SE－22 Pressure sensor (high pressure) ; P1 pump SW－50 Door SW.
SE－23 Pressure sensor (high pressure) ; P2 pump SW－52 Auto idle stop select SW.
SE－26 Pressure sensor (low) ; Revolution R/L Opt.
24-99
© New Holland
2. SPECIFICATION OF ELECTRIC EQIUPMENTS
File No.
Name of part Specification Description
Use
C－1 Maker SHINKO DENKI

Connector makers P/No.
Rated voltage DC24V CN-11～CN-14 : 1-178203-6 (AMP)
Controller CN-15～CN-17 : 2-178764-6 (AMP)
For details, refer to
Mechatro System. CN-18 : 5045-04A (Molex)
Mechatro controller
CN-18
Window for adjust

4-∅7 Attaching hole
CALSONIC KANSEI
C－2 Maker CO. LTD,
Rated voltage DC24V
Controller More than 3MΩ at
Insulation resistance 500Vmegger
LCD
Gauge cluster
LCD
24-100
File No.
Use
C－4 Rated voltage DC 20～30V

CONTROLLER
Controller
Air conditioner
controller
24-101
File No.
Use
D－1,2,3,5,6,7,8,9 Repetitive peak voltage 400V
Forward current 3A
Diode
Key switch relay Surge current 200A
Battery relay
Gauge cluster
D－4 Rated current 2.5A
Repetitive peak voltage 600V

Diode
Diode HITACHI U05G
Glow relay
Color Green
E－1
Fuse box No. Capacity Name of circuit

① 20A Mechatro controller
② 10A Relay
Fuse 18PAF-HD
③ 10A Cigarette lighter
SUMITOMO
④ 10A DC-DC Converter HOUSING : 6098-0257
TERMINAL : 8240-4422
⑤ 10A Horn
⑥ Blank
⑦ 10A Mechatro controller back-up
⑧ 20A Fuel suppy pump
⑨ 10A Room lamp
⑩ 20A Key switch 7PAM-HD
⑪ 20A Cab work light
⑫ 20A Swing flasher
⑬ 10A Gauge cluster
⑭ 20A Wiper, Washer
⑮ 10A Solenoid valve 18PAF-HD
⑯ 20A Work light
⑰ 10A Resistor 7PAM-HD
⑱ 20A Air conditioner SUMITOMO
HOUSING : 6950-0346
⑲ 10A Air conditioner controller TERMINAL : 8332-4220
⑳ 20A Spare (24V) 8232-4238
24-102
File No.
Name of part
Use Specification Description
E－2 Rated output 24×30A

M5 BATTERY TERMINAL
Alternator
Generator
HEX 24
R TERMINAL ROTATING
DIRECTION M5
E TERMINAL
R TERMINAL
YAZAKI 7322-1424-40
CIRCUIT
24－103
File No.
Use
E－2 Rated output 24×30A
M6 B TERMINAL
Alternator M5 E TERMINAL
PULLY A TYPE
Generator
YAZAKI
7322-1424-40
M5
E TERMINAL
CIRCUIT
E－3 Maker Hobbs corp.
Rated voltage DC10～32V

Hour meter
Service meter
24-104
File No.
Name of part
LOWER
E－4,5 Type
STAMP
Rated voltage DC24V
Horn
Operating voltage
range DC 20～30V
Warning sound
Sound level 113±5 dB
420±20 Hz high sound
Basic frequency 350±20 Hz low sound
More than 3MΩ /
Insulation resistance DC500V
∅8.5
E－6 Model 409112-0000
Rated voltage DC 24V

Cigar lighter
PLUG COMPLETE
Max. current 5A KNOB
Return time Less than 18sec

More than 3MΩ /
Insulation 500V megger
resistance JIS CA104
CASE
180℃～250℃ SOCKET COMPLETE
Fusing temp. (356°F～482°F)
E－7 Rated voltage DC 24V
Tuner
1 L SPEAKER(+)
Radio (AM & FM)
2 R SPEAKER(+)
3 ACC(+B)
4 OPEN
5 L SPEAKER(－)
6 R SPEAKER(－)
7 GND(－)
8 BACK UP(+)
9 OPEN
24－105
File No.
Name of part
E－8,9 Model SX-M1028K
Rated input 8W
Speaker
Impedance 8Ω
Radio
Frequency 33.3Hz
E－10 Maker’s part No. 56640－A0450
Receiver drier
Air conditioner CAULK
2-M6×1.0
E－11 Maker’s part No. 7351－6000

Air compressor
Max. revolution 4000rpm
Air conditioner V belt B type
Cooling R－134a
Oil SP－20 : 135cc
Cover (clutch)
CP3.96MA
YAZAKI 7120-8019
AVX1.25(BLACK)
AVX1.25(GREEN)
24－106
File No.
Use
CONNECTOR YAZAKI 2PAM

Rated power
E－14 consumption 40W HOUSING 7122-2128
TERMINAL 7114-2020
Resistance value 16Ω

Resistor
DC500V /
Insulation resistance More than 20MΩ
SILICON GLASS FURUKAWA DENKO
P1,P2 pump Braided wire Viewmex ER400 or equivalent
(NISSEI DENKI) heat resistant tube
proportional valve NS-GE 1.25sq ∅5×20mm (0.197″×0.787″)
Hot soldering treatment

[melting point 240℃ (464°
F)]
Sumi-tube K
－55℃～+175℃
(－67° F～+347° F)
20mm (0.787″)
∅4.7±0.3
(0.185″±0.012
E－15 Rated voltage DC12V～36V Fasten earth cord directly to band by eye-let
t i l
Rated current 0.2A at 24V
Alarm
Frequency 2200±100Hz
Travel
AMPLIFICATION
CIRCUIT BACK SWITCH
SERVICE
VOLTAGE
DC12V～36V
CONSTANT
VOLTAGE GND POWER
CIRCUIT AV0.5 SOURCE
BLACK AV0.5 R/G ↑
A
VIEW A
BLOCK CIRCUIT DIAGRAM
E－16 Input voltage 24V NOM. HOUSING

YAZAKI 7122-2262
TERMINAL
Output voltage 12V NOM. YAZAKI 7114-2020
Converter
Output current 2.5A MAX.
DC-DC converter YV
WG YB
OL
Fix the wire B
with tape
VIEW A
24-107
File No.
Name of part
E－17 Power supply For 12V
Socket
Power socket
E－25 Type 95E41R-N100
Voltage 12V
Battery
Capacity 5HR 80Ah
Power (Ah) 20HR 100Ah
Weight 26kg (57 lbs)
407L×175W×250H
E－A Electrostatic capacity 80pF

More than 100MΩ
Insulation resistance
Antenna (DC 500V megger)
Radio
24－108
File No.
Use
L－1,9 Type BL84-130
Bulb 24V,70W
Light (halogen)
Boom work light

(left)
CA104
M14×1.5
L－2 Type BL84－200
Bulb DC 24V,70W
Light (halogen)
Effective area of lens 71cm2
Work light (right)
BRACKET
DRAIN HOLE (Turnable)
M12×1.25×25
CA104 CB104
(POWER SUPPLY) (EARTH)
L－3 Bulb 24V,5W BODY

LENS A
Light
Room (Dome) light
BULB
OFF ON
A
SECTION DOOR
SWITCH
24-109
File No.
Use
L－8 Bulb 12V,10W

A
Light
E/G Room light
A
SECTION A
L－11,12 Bulb 24V,6W

VINYL TUBE
(BLACK)
Light
Swing flasher
(Right, left)
DRAIN HOLE
YAZAKI
AV0.5B AV0.5B
M－1 Rated output DC 24V,4.5kW
ISUZU 897225-1991
Motor
Starter motor
CIRCUIT
M5 C TERMINAL M10 B TERMINAL

TO L TERMINAL
M8
M TERMINAL TO S TERMINAL
SEFETY
RELAY
DRAIN PIPE
24-110
File No.
Name of part
M－2 Drive voltage DC 24V
Rated voltage DC 8.5V

Motor REDUCTION GEAR SECTION
Rated current 1.5A / phase OUTPUT OIL SEAL
MOTOR SECTION
Governor motor SHAFT
Number of phases 2 phase (INVOLUTE)
Excitation method 2 Excitation

Z→
Step angle 1.8°
More than 100MΩ
Insulation resistance (500V megger) CAM
LIMIT
Excitation sequence SWITCH
Brown(A) Red(B)
Step
1 2 3 4
Lead
A － + + －
Orange(A) Yellow(B)
B －－ + +
A + －－ +
B + + －－
MOTOR LIMIT SWITCH
CONNECTOR CONNECTOR
Limit switch connector Motor connector
Lead Connec- Lead Connec-
6 No. color tion 1 2
No. color tion
5 White COM 1 Blown A
5 6 Red NO 2 Orange A
7 7 Yellow NC 3 Red B
3 4
4 Yellow B
HOUSING : 6181-0072(SUMITOMO DENSO) HOUSING : 6181-0073(SUMITOMO DENSO)
TERMINAL : 1500-0134(SUMITOMO DENSO) TERMINAL : 1500-0105(SUMITOMO DENSO)
LIMIT
RETAINER : 6918-0327(SUMITOMO DENSO) RETAINER : 6918-0329(SUMITOMO DENSO)
SWITCH
WATER WATER
MOTION
RESISTANCE : 7165-0118(SUMITOMO DENSO) RESISTANCE : 7165-0118(SUMITOMO DENSO) RANGE
VIEW Z
M－3 Rated voltage 24V
Motor Wipe-out angle 106°
Wiper
24－111
File No.
Name of part
(＋) (－)
M－4 Rated voltage DC 24V
Injection pressure More than 118kPa

Motor(tank)
Tank capacity 1.5 (0.4gal)
Window washer
Time rated (with water) Max. continuous 60sec
Injection nozzle ∅1×2 pcs.
MOTOR PUMP
M－9 Rated voltage DC24V

HEX24
Current Less than 1.5A
Motor (pump)
Operating fluid Light oil
Fuel pump Discharge rate OUT
(open circuit) More than 200cc/min →Z
IN
GROMMET M6×1
◯,＋BLACK /
WATERPROOF
CONNECTOR (MALE)
VINYL TUBE (WHITE) YAZAKI 7322-9021
L=100 (3.94″
)
◯,－
VIEW Z
M－11 Voltage 24V

7A
Motor (pump) Supply current [24V at 3m (9ft-10in) head]
35 /min (9.2gal/min)
Flow [at 3m (9ft-10in) head]
Fuel supply pump
Q-H CURVE
HEAD H (m)
FLOW Q ( /min)
24－112
File No.
Use
At start 24V2000A
R－1 Rated voltage / (0.1sec.)
current At charge 28V100A
(continuous)
Relay
Exciting current Less than 0.4A / 24V TERMINAL A
TERMINAL FLW2.0
Battery relay More than B
FLW2.0
Contact force 3.5kgf (7.7 lbs)
F HOUSING :
Closed circuit voltage Less than 16V SUMITOMO
7123-4220-30
F TERMINAL :
Open circuit voltage Less than 7V SUMITOMO
7116-3251
More than 3MΩ / REAR HOLDER :
Insulation resistance 500V megger SUMITOMO
7157-6801-30
MODEL WATER
RESISTANCE :
NUMBER STAMPING L SUMITOMO
POSITION IN A TER- B 7157-3580-60
MINAL
FLOWING DIRECTION OF PRODUCTION PROCESS TERMINAL ←Z
MAIN CURRENT
AVS1.25L
AVS1.25B AVS1.25G
TERMINAL A TERMINAL B EARTH
A1→ ←B1 TERMINAL
EARTH TERMINAL
B
TERMINAL A1 LOCK SECTION
HOUSING AMP
174359-2
RETAINER AMP L TERMINAL
1-174360-1 or 7
TERMINAL AMP
TERMINAL B1 171661-1
WIRE SEAL AMP
VIEW Ⅰ 172888-2 or 172886-2
BLACK
CIRCUIT DIAGRAM
EARTH VIEW Z
R－3 Rated voltage DC 24V

In-rush current 130A
Rated load
Relay Breaking current 30A
Operating voltage Less than DC16V

Glow relay
Release voltage More than DC2V
Exciting current Less than 1A
↑
Z
1 3
1 2
3 4
2 4
CONNECTOR ON CONNECTOR ON
INTERNAL CONNECTION DIAGRAM MATED SIDE. MATED SIDE.
YAZAKI 7323-3010 YAZAKI 7323-2228
VIEW Z
24-113
File No.
Name of part
Relay
Safety relay
CIRCUIT
M5 C TERMINAL M10 B TERMINAL

TO L TERMINAL
M8
M TERMINAL TO S TERMINAL
SEFETY
RELAY
DRAIN PIPE
R－ 5,6,7,8,9,10,11,
22,23,28
More than 1MΩ
Insulation resistance (500V megger)
Relay
Wiper motor, Washer motor,
Horn relay, Work light relay,
Travel alarm, Ex. depress
Hand control extra
Auto idle stop 1
CIRCUIT
R－29 Rated voltage DC24V

(500V megger)
Relay
Maker MITSUBA
Auto idle stop relay 2

Note) This relay is removed only bracket from
the relay EN24S00008P1
CIRCUIT DIAGRAM
24－114
File No.
Name of part
R－19
UPPER
Relay SW ING FLASHER & REAR W ORK LIGHT UNIT

FLASHER DRIVER
H
Flasher relay CONTROL SIGNAL REAR W ORK LIGHT

A D
FLASHER L
B E
DRIVE CIRCUIT
FLASHER R
C F
DRIVE CIRCUIT
Dalay time 1 sec.

Relay
Operation ON : 10 sec, OFF : 5 sec
Timer relay Er EMPTY
UPPER
Er
EMPTY Er EMPTY
24－115
File No.
Use
SE－1～12,20,21,26 Pressure range 0～30kgf/cm2(0～430psi)
Pressure sensor Rated voltage 5±0.5V DC

(low pressure) More than 100MΩ /
Bucket digging, dump, Insulation resistance DC50V megger
Boom up, down, AMP MQS type connector
Swing R, L 3 pole (B type)
Arm in, out
Travel R, L Mating connector (Female)
Option P1, P2 TERMINAL NO. CONNECTION HEX 19 HOUSING：2-967642-1
Rotation R, L TERMINAL：965906-5
1 COM
(Gold plating)
2 OUTPUT (＋)
HARNESS SEAL：967067-1
3 POWER (＋)
PF1/4
O RING TIGHTENING TORQUE
1B P11 3.5kgfym (25 lbfyft)
SE－13 Rated
Output voltage More than 2.5V

Revolution sensor
Clearance 1.0mm (0.04in)
E/G speed sensor CONNECTOR
YAZAKI 7322-1424
M16×1.5
TORQUE2.5～3.5kgfym HEX19 HEX17 SIGNAL(YELLOW)
(18～25 lbfyft)
GND(BLACK)
Z↓
SE－14 Resistance characteristics
50℃ 80Ω
Sensor
60℃ 56.3Ω
E/G Water (Coolant) M16×1.5
temperature 80℃ 29.5Ω TORQUE
2.5 kgfym
100℃ 16.5Ω (18 lbfyft)
106℃ 14.3Ω
VIEW Z
120℃ 10Ω
24-116
File No.
Use
FLOAT
SE－15 FULL
Float level Resistance value Ω

Fuel sensor
FULL
＋0.1
10－0.5 3/4
Fuel sending
3/4 (19)
110°
1/2 A
1/2 32±3
1/4 (49.5)
＋12 1/4
EMPTY 80＋2 FUEL LEVEL
WARNING LAMP "ON" POSITION
EMPTY
FUEL METER SENSOR SWITCH
Er
Er
24V3W FLU
Er
DC
24V
FLOAT AMP CONNECTOR
3MA-JMⅡ＋
HOUSING：174359-2
TERMINAL：171661-1
RETAINER：1-174360-1
VIEW A
SE－16 Total resistance value 2KΩ
Effective electric angle 120°

Potentio meter 3MA-JMⅡ+ AMP
HOUSING：174359-2
Number of notches 10 in range of 90°
TERMINAL：171661-1
Accel dial
Source voltage 5V RETAINER：1-174360-1
NOTCH PART HARNESS SEAL：172888-2
DIAL
POTENTIO
BRACKET
CIRCUIT
24-117
File No.
Use
SE－22,23 Pressure range 0～500kgf/cm2(0～7110psi)
Pressure sensor Max. allowable 750kgf/cm2(10700psi)

(High pressure)
press.
P1 pump
P2 pump Operating source AMP MQS type connector
voltage 5±0.5V DC
3 pole (B type)
Mating connector (Female)
HEX 22 HOUSING：2-967642-1
TERMINAL NO. CONNECTION TERMINAL：965906-5
1 COM (Gold plating)
2 OUTPUT (＋)
3 POWER (＋) PF3/8
O RING
TIGHTENING TORQUE
1B P14 7.5kgfym (54 lbfyft)
SV－1,3,4 Operating pressure 50kgf/cm2 (710psi)

P2 P1
ARM VARIABLE BYPASS TRAVEL BYPASS
Solenoid valve assy Solenoid selector RECIRCULATION CUT STRAIGHT CUT
valve
Coil resistance 34±2Ω(at20℃)
Refer to hydraulic
symbol Dither current 100Hz,300mA P-P
Solenoid
proportional valve
Coil resistance 17.5±1Ω(at20℃)
AMP ECONO SEAL J

Connector MARKⅡ(＋)
specification HOUSING : 174354-2
TERMINAL : 173706-1
P1, T, 4 Port : PF3/8

A, B, C, D, 1, 3 Port : PF1/4 SWING TRAVEL SAFETY
PARKING 1,2-SPEED LOCK
LEVER
PSV－A,B,C,D HYDRAULIC SYMBOL
4-∅11
Solenoid valve assy
Refer to hydraulic
symbol
SOCKET BOLT M5
PLUG
PT 1/16
SECTION A－01－02－A
24-118
File No.
Name of part
PSV－P1,P2 Type KDRDE－5K
No.
Solenoid
Rated feed press 50kgf/cm2 (710psi)
Proportional valve
for pumps P1,P2 Allowable back press 10kgf/cm2 (140psi)
Control pressure range 0～30kgf/cm2 (0～430psi)
Rated current 700mA
Rated voltage DC24V AMP ECONO SEAL J MARKⅡ(＋)

HOUSING : 174352-2
TERMINAL : 173705-1
Tightening torque
0.5kgfym (3.6 lbfyft)
O RING HEX 32
1B P20
SV－24 Rated voltage DC 24V
Solenoid Power consumption 12W
Working pressure 50kgf/cm2 (710psi)

Extra drain press
Max. flow 16/ min (4.2/gal min)
3-PF1/4
(O RING SEAL)
－SIDE GROUND ＋SIDE POWER
COLOR OF CODE : COLOR OF CODE :
BLACK RED
AMP MARK Ⅱ 2P
HOUSING 174354－2 or equivalent
TERMINAL 173706－1 or equivalent
24－119
File No.
Name of part. Specification Description
Use
SW－1
Connection table
Switch T B G1 G2 ACC M ST
P
H
Starter switch
OFF
ACC
ON
START
AUTO RETURN
AUTO RETURN
VIEW A
“K250” STAMPED
A
→
TERMINAL
ARRANGEMENT
SW－3 Type Buried in right travel lever
Switch
MARKS ON SWITCH PORTION

Travel 1,2-speed
CA103
24-120
File No.
Use
Single-pole double-throw
SW－4 Type (alternate) INSULATION TAPE
R B W
Rated DC 30V,10A
Switch
Insulation resistance
Swing parking
release VINYL TUBE
YAZAKI
RED(2) 7122-2237
Contact T No.
1 2 3 7114-2020
construction : position
Swing parking release ON① ○ ○

Normal ON② ○ ○
WHITE(3) BLUE(1)
M12P1
SW－5 Type ST-425N
CIRCUIT DIAGRAM
Switch
KPSS release KEYWAY
12PAM-HD
SUMITOMO 6098-0252
TERMINAL 8230-4282
M4×0.7
SW－6 Rated voltage DC 24V, DC 12V ↓Z
Operating ON 105±2℃
Switch temperature (221±35.6°F)
Contact type A
E/G water (Coolant)
temperature switch Insulation resistance
More than 100MΩ
[105℃(221° F)] (500V megger) HEX 21
VIEW Z
PT3/8
24-121
File No.
Name of part
SW－7 Rated voltage DC24V

More than 0.3 +0.2
0 kgf/cm
2 HEX
Engine oil Operating pressure 27
(4 +2.8
0 psi)
pressure switch
Contact type Normally closed
Engine oil pressure
PT1/8 M4×0.7
SW－8 Over load current 1A / 30V (DC) CA104 RED BLACK
2A / 125V (AC)
Switch
Voltage 600V
Air filter Insulation resistance 1MΩ
clogging switch
CB104
PT1/8
Torque 0.15 kgfym
(1 lbfyft)
SW－10,20,46,47 Voltage DC30V
Current 3A
Switch
Horn, Clockwise,
Counterclockwise
LEAD WIRE : AVFF 0.75ft

PROTECTION
TUBE
VIEW B
24－122
File No.
Use
SW－11 Type Roller plunger type

D4MC－5020
Switch HEX17
CONNECTION TABLE
Safety lock lever
1
NO 2PAM
○
2 ○
COM ○
NC YAZAKI HOUSING 7122-2228
TERMINAL 7114-2020
①
②
SW－13 Operating voltage DC 20V～30V

range (℃ ←→ °
F)
Switch
Air conditioner
operation panel
Single-pole single-throw
SW－16 Type (Alternate)

Switch
CONNECTOR (WITH LOCK) (R)
More than 1MΩ /
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
Auto accel switch
TERMINAL CONNETION
RED /
Terminal R RW
Position WHITE
OFF
ON
SW－17 Single-pole single-throw

Type (Alternate)

Switch
More than 1MΩ / CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger
Swing flasher select EQUIVALENT YAZAKI 7122-2228 RED
switch
TERMINAL CONNECTION
Terminal R RW
Position RED /
WHITE
OFF
ON
24-123
File No.
Name of part

Type (Alternate)

Switch
Insulation resistance 500V megger RED
Work light (switch) EQUIVALENT YAZAKI 7122-2228
TERMINAL CONNECTION
Terminal R RW
Position RED / WHITE
(RW)
OFF
ON

Type (Alternate)
Switch Rated voltage DC 24V

Single / Conflux Insulation resistance 500V megger EQUIVALENT YAZAKI 7122-2228 RED
select switch
TERMINAL CONNECTION
Terminal R RW
(RW)
OFF
ON
24－124
File No.
Name of part
SW－23 Contact arrangement ON-(OFF)
momentary
Switch More than 100MΩ 8.7□
Insulation resistance (500V megger)
14□
Wiper inter lock
switch
BLACK CB104
RED
CA104

Maker's type (Alternate)

Switch
CONNECTOR (WITH LOCK) (R)
More than 1MΩ /
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
Rotary light switch
TERMINAL CONNECTION
Terminal RED / WHITE
Position
R RW (RW)
OFF
ON

Type (Alternate)

Switch
More than 1MΩ / (R)
Insulation resistance DC500V megger
CONNECTOR (WITH LOCK)
Overload display EQUIVALENT YAZAKI 7122-2228 RED
TERMINAL CONNECTION
Terminal R RW
(RW)
OFF
ON
24－125
File No.
Name of part
AMP ECONO SEAL J

SW－39 0.5～408kgf/cm2 MARKⅡ(＋) 174354-2
Pressure range (7.1～5800psi)
Rated voltage DC24V, 2A SET PRESSURE SCREW

Switch
Overload pressure
switch
2-5.5 ∅BORE
NC COMMON
CIRCUIT
＋－
G1/4
SW－42 Maker’s item TS－11

Type
Switch (Alternate)
Engine room light M3

switch
LA103
WIRE COLOR:BLACK
WIRE COLOR:RED
CA104 CB104
TERMINAL:YAZAKI TERMINAL:YAZAKI
:7113-1020-02 :7115-1050-02
CAP:YAZAKI CAP:YAZAKI
:7120-8012 :7120-1010
24－126
File No.
Name of part
SW－43,44 Type Normal open

ON : 6±0.6kgf/cm2
Switch (85±8.5pis)
Specification OFF : 4±0.4kgf/cm2
(57±5.7pis)
Jib press. switch 100MΩ or more
Extra press. switch Insulation resistance (500V megger) AMP ECONO SEAL J
MARKⅡ(M)
PT1/8 HOUSING : 174354-2
Tightening torque TERMINAL : 17166-1
1.7kgfym (12.3 lbfyft)
Apply seal tape to thread
SW－A Rated voltage DC 12V,24V

(0.236″ )
±0.008″
More than 5MΩ
Insulation resistance (500V megger) 2-φ6±0.2
Switch CASE
SCREW
Max. stroke 7.1mm (0.28″)
Cab door
(0.315″)
φ8
BUTTON SPRING TERMINAL

Type (Alternate)
Switch Rated voltage DC 24V

More than 5MΩ CONNECTOR (WITH LOCK) (R)
Insulation resistance (500V megger) RED
EQUIVALENT YAZAKI 7122-2228
Auto idle stop select
TERMINAL CONNECTION
Terminal R RW
Position RED /
WHITE
OFF
ON
24－127
NOTE
24-128
E115SR
E135SR
SECTION 25 AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
1. Construction and piping ........................................................................................ 25-1

1.1 Construction (air-conditioner group) .............................................................................................. 25-1
1.2 Air conditioner piping ..................................................................................................................... 25-2
2. Construction of main components ........................................................................ 25-4

2.1 Air-conditioner ............................................................................................................................... 25-4
2.2 Receiver dryer ............................................................................................................................... 25-6
3. Function ................................................................................................................ 25-7

3.1 Mechanism of cooling circuit ......................................................................................................... 25-7
3.2 Cooling circuit ................................................................................................................................ 25-8
3.3 Component parts ........................................................................................................................... 25-9
4. Disassembly and assembly ................................................................................ 25-13

4.1 Precautions to be exercised in operation ..................................................................................... 25-13
4.2 Removal and installation of the unit ............................................................................................. 25-14
5. Charging refrigerant ............................................................................................ 25-18

5.1 Precautions to be exercised in operation ..................................................................................... 25-18
5.2 Operating procedure ................................................................................................................... 25-19
5.3 Charging procedure ..................................................................................................................... 25-20
6. Electric circuit ..................................................................................................... 25-24

6.1 Wiring diagram and connectors ................................................................................................... 25-24
6.2 Inspecting functional parts ........................................................................................................... 25-25
7. Troubleshooting .................................................................................................. 25-27

1. CONSTRUCTION AND PIPING

1.1 CONSTRUCTION (AIR-CONDITIONER GROUP) 1
1-7
3 5
1-1
5-1 1-3
3-3
5-2
1-4
3-1 1-5
4
8
9
8-10 8-9 8-7
8-3
8-10
8-4
8-9
8-8
8-6
8-10 8-5
8-11
8-1
8-12
Fig. 1 Air-conditioner group
AIR-CONDITIONER GROUP
1 AIR-CONDITIONER ASSY 1 8 AIR DRYER ASSY 1
1-1 AIR-CONDITIONER 1 8-1 RECEIVER 1
1-3 SENSOR 1 8-3 L TUBE 1
1-4 PLATE 1 8-4 D HOSE 1
1-5 MACHINE SCREW 1 8-5 S HOSE 1
1-7 CAP 1 8-6 L HOSE 1
3 COMPRESSOR ASSY 1 8-7 D TUBE 1
3-1 AIR-COMPRESSOR 1 8-8 S TUBE 1
3-3 PULLEY ASSY 1 8-9 CAPSCREW 2
4 PANEL ASSY 1 8-10 CAPSCREW 3
5 AIR FILTER ASSY 1 8-11 CAPSCREW 1
5-1 COVER 1 8-12 BRACKET 1
5-2 FILTER 1 9 CONDENSER 1
25-1
1.2 AIR-CONDITIONER PIPING T=Tightening torque : kgfym (lbfyft)

Nut for tension pully
T=4.6 (33)
32
26
19
32 22
31 16
8 35 1
28 6
27
10
4
11
4 11
11
6
27
2
13 11
19 11
7
15
12
8
21
12 38
24
10 21
24 21
13 11 12
20
23
17 3
11
20 20
18
23
17
Fig. 2 A/C piping
25-2
E135SR
Air-conditioner piping
E115SR
Tightening torque Tightening torque
kgfym (lbfyft)
No. NAME Q’TY kgfym (lbfyft)
No. NAME Q’TY
1 BRACKET 1 ← 0.45 (3.3) 17 CAPSCREW；M6×45 6 ←
2 SUPPORT 1 ← 18 CAPSCREW；M6×20 2 ←
3 SUPPORT 1 ← 19 WASHER；M8 6 ←
4 HOSE；L=3300 2 ─ 20 WASHER；M6 8 ←
HOSE；L=3200 ─ 2 21 WASHER；M10 3 ←
5 SPACER 2 ← 22 LOCK WASHER；M8 4 ←
6 TUBE；L=3000 2 ← 23 LOCK WASHER；M6 6 ←
7 TUBE；L=1900 1 ← 24 NUT；M10 2 ←
8 TUBE；L=1900 1 ← 6.6 (48) 26 CAPSCREW；M10×60 2 ←
10 TUBE；L=1600 1 ← 27 CLIP 4 ←
11 CLIP 8 ← 28 GROMMET 1 ←
12 CLIP 3 ← 6.6 (48) 31 CAPSCREW；M10×50 2 ←
4.0 (29) 13 SEMS BOLT；M8×20 4 ← 32 WASHER；M10 4 ←
4.0 (29) 15 CAPSCREW；M8×16 2 ← 35 V -BELT 1 ←
CAPSCREW；M8×10
0.45 (3.3) 16 4 ← 38 CAPSCREW；M10×25 1 ←
0
25-3
2. CONSTRUCTION OF MAIN COMPONENTS

2.1 AIR-CONDITIONER
(1) Intake unit
51 64
1 62
61 50
64 61
62
52 62
61 61
48
53
62 62
43
49
62
62
62
57
61
45 62
61 44
45
47
42
61 46
55 (2.1.3)
63
63 60
63
Fig. 3 Intake unit
25-4
(2) AIR-CONDITIONER UNIT
39
36
40
61 27
7 5
37 61 20
64
9 62 21
64
1
62 62 65 26 22
31
14 62
36 60 62
60 4
19
30 62
29 18 17 62
10 32
24 4
23 34
25 67 35
24
67 62
33 11 62
24 23
62 16
12 15
67
67
8 56
23 2
59
58 62 64
20
28 62
1 62
3 41
6 64
5
6
13
56 (2.1.5)
54 (2.1.4)
Fig. 4 Air-conditioner unit
25-5
No. NAME QTY No. NAME QTY No. NAME QTY

1 ACTUATOR 3 24 LEVER 3 47 BLOWER MOTOR 1
2 VALVE 1 25 CAM 1 48 CASING 1
3 THERMISTOR 1 26 ROD 1 49 CASING 1
4 CLAMP 2 27 ROD 1 50 FILTER 1
5 ROD HOLDER 2 28 ROD 1 51 LEVER 1
6 SENSOR HOLDER 2 29 DAMPER 1 52 LEVER 1
7 CLAMP 1 30 DAMPER 1 53 DAMPER 1
8 EVAPORATOR 1 31 DAMPER 1 54 FLANGE PLATE 1
9 CASING 1 32 DAMPER 1 55 SENSOR 1
10 CASING 1 33 DAMPER 1 56 SEMS BOLT 1
11 CASING 1 34 DAMPER 1 57 GASKET 1
12 THERMAL INSULATION MATERIAL 1 35 HEATER CORE 1 58 O RING 1
13 THERMAL INSULATION MATERIAL 1 36 CONTROLLER 1 59 O RING 1
14 PACKING 1 37 RELAY 1 60 TAPPING SCREW 6
15 PACKING 1 38 CLAMP 1 61 TAPPING SCREW 13
16 PACKING 1 39 BAND 1 62 SCREW 30
17 BRACKET 1 40 DUCT CAP 1 63 SEMS BOLT 3
18 CLAMP 1 41 HARNESS 1 64 TAPPING SCREW 9
19 PLATE 1 42 RESISTER 1 65 SCREW 1
20 LEVER 2 43 CASING 1 66 CAPSCREW 2
21 LEVER 1 44 CASING 1 67 TAPPING SCREW 4
22 LEVER 1 45 BRACKET 2
23 LEVER 3 46 HOSE 1
2.2 RECEIVER DRYER

2
REFRIGERANT
INLET REFRIGERANT
OUTLET
2-M6 No. NAME QTY

1 1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
3 DESICCANT 1
4 SUCTION PIPE 1
5 FILTER 1
3
6 RECEIVER TANK 1
4
Fig. 5 Receiver dryer

25-6
3. FUNCTION
3.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that Table 1
flows through the cooling circuit changes its
phases from liquid to gas and vice versa Item HFC-134a (R134a)
during which process heat is transferred from Chemical formula CH2FCF3
the low temperature part (compartment) to Molecular weight 102.03
the high temperature part (outside of the
Boiling point -26.19℃ (-15.14°F)
vehicle).
1) Kind of Refrigerant Critical temperature 101.14℃ (214.05° F)
Many kinds of refrigerants that change in Critical pressure 4.065MPa (41.45kgf/cm2
that way are available, but the following *1)
requirements are needed for use in such
Critical density 511kg/m3 (31.9 lb/ft3)
applications:
o Latent heat of vaporization (heat of Density of saturated 1206kg/m3 (75.3 lb/ft3)
vaporization) is large. liquid [25℃ (77.0°F)]
o It is easy to liquefy (condense). (It dose not Specific volume of 0.0310m3/kg (0.496ft3/lb)
require very high pressure for condensation.) saturated vapor
o It is easy to gasify (evaporate). (It evaporates [25℃ (77° F)]
sufficiently at not too low pressure, i.e. cools Latent heat of 197.5KJ/kg {47.19kcal/kg}
down an object.) vaporization
o It has small specific heat. (Since the [0℃ (32° F )]
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held Flammability Nonflammable
down to a minimum.) Ozone destruction 0
o It has a high critical temperature and a low coefficient
solidification point.
o It is stable chemically and does not corrode *1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
and permeate into the circuit parts. (145psi)
o It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
o It has small specific volume.
o It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used, sufficient
refrigeration will not be performed or the
equipment in which the refrigerant is used
may be broken. Therefore, always use a PRESSURE
designated refrigerant for the cooling unit. MPa(kgf/cm2)
Table 1 shows the principal characteristics of R134a
the R134a refrigerant that is used in this 4 (40.8)
machine.
3 (30.6)
(2) Characteristics of Refrigerant (See Fig.6.) LIQUID
In general, the fluid (general term of gas and
liquid) has the following qualities: 2 (20.4)
1) As a gas under certain pressure is cooled
down, it begins to condensate at a certain
1 (10.2) GAS
temperature to take a liquid state. The
temperature at which condensation begins is (5.2)
TEMPERATURE
unique to each substance (fluid) at a given
pressure. The temperature determined by a 0 0 15 18 35 50 100 [℃ (°
F)]
(32) (59)(64) (95) (122) (212.0)
given pressure is called saturation
Fig. 6 Pressure-temperature characteristics of R134a
temperature.
25-7
2) Inversely to 1) above, the pressure at which a

gas condenses for a temperature is
determined. This pressure is called
saturation pressure.
Fig.6 illustrates the relationships between
the saturation temperature and the
saturation pressure in the case of refrigerant
R134a used in the sir-conditioner. At the
temperature and the pressure on the lower
righthand side of the curve in Fig.6, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper
lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-
conditioner is operated in the midst of
summer. As the refrigerant evaporates, it
absorbs evaporation heat from the air of the
compartment. In order to cool the inside of
the compartment down to 25℃ (77° F), the
refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower
temperature. It can be seen from Fig.6 that
R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the
circuits, thereby deteriorating the
performance of the cooling unit.) In the
process in which gaseous refrigerant is
brought back to a liquid state, the refrigerant
is cooled and condensed by the outer air
exceeding 35℃ (95° F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding
10.2kgf/cm2 (145psi), as seen from Fig.6.
3.2 COOLING CIRCUIT
Fig.7 illustrates the cooling circuit of the car
air-conditioner.
In this circuit diagram, the portion that cools
the air of the compartment is the evaporator.
The object air is cooled off by utilizing the INSIDE OF COMPARTMENT
fact that the refrigerant takes heat off the
surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant
takes place is the evaporator, cooled air is EVAPORATOR EXPANSION
constantly delivered to the circumference of BLOWER
VALVE
the evaporator by the blower fan. In the

meantime, liquid refrigerant (slightly wet
vaporized refrigerant) is fed into the INSIDE OF ENGINE
evaporator, when “cooling” effect is attained. S D ROOM
For instance, in order to cool the air to 15℃
(59°F), the refrigerant can not absorb COMPRESSOR COOLING FAN
evaporation heat from the air unless it
evaporates at a temperature lower that 15℃
(59°F). For that purpose, it can be seen from
Fig.6 that the pressure of the refrigerant in RECEIVER
the evaporator must be less than 5.2kgf/cm2 DRYER
(74psi).
Furthermore, the cooling effect deteriorates CONDENSER
unless the feed rate of the refrigerant is
controlled so that all of the refrigerant Fig. 7 Construction of cooling circuit
supplied to the evaporator vaporizes and
turns into dry vapor.
25-8
Consequently, the cooling circuit is so

constructed that the evaporator can cool
down an object (air in this case) sufficiently
(i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of
refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled
by the expansion valve, but the pressure in
the evaporator is held low by the throttling
action of the expansion valve and the suction
action of the compressor. The compressor acts
as a pump that allows the refrigerant to
circulate. The compressive action of the
compressor and the heat exchange (heat
radiation) action of the condenser transform
the refrigerant in a dry vapor state back to a
liquid state.
3.3 COMPONENT PARTS

(1) Evaporator (See Fig.8.)
The evaporator is an important heat
exchanger that absorbs the heat of the
compartment air (object) by the utilization of
the latent vaporization heat of the low-
temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that EVAPORATOR
satisfactory heat transfer between the object
and the refrigerant take place in the
evaporator.
To that end, the evaporator is equipped with O RING
fins on the air side in order to increase the EXPANSION
heat transfer area of the air side and thereby VALVE
perform excellent thermal transfer between
the refrigerant and the air. SOCKET
The humidity in the air condenses as the air BOLT
cools down and adheres to the outside of the M5×40
evaporator as water drops. The cooling effect EVAPORATION (2 PCS.)
deteriorates if the water drops freeze. SENSOR
Therefore, how to discharge water is an
important point. Fig. 8 Evaporator
The amount of refrigerant supplied to the
evaporator is controlled by the expansion
valve which is described in the following. In
order to attain proper control, it is necessary
to reduce the pressure drop of the refrigerant
of the evaporator. Accordingly, reducing the
pressure drop is one element that makes the
evaporator attain its full performances.
(2) Expansion Valve
In order for the evaporator to fulfill its
performances, a proper amount of low-
pressure low-temperature liquid refrigerant
must be fed to the evaporator.
If the feed rate is too low, the refrigerant
completes vaporization early in the
evaporator which results in deterioration of
the cooling effect. If the feed rate is too high,
unvaporized liquid refrigerant returns to the
compressor (liquid back). This not only
deteriorates the cooling effect, but also
damages the compressor valves.
25-9
The expansion valve feeds the flowing high-

pressure high-temperature liquid refrigerant
to the evaporator as low-pressure low-
temperature liquid refrigerant (damp vapor DIAPHRAGM
of low dryness). The expansion valve controls
the feed rate of the refrigerant at the same
time.
Fig.9 shows how the block type expansion REFRIGERANT
valve is constructed. The temperature EVAPORATOR OUTLET
sensing part is provided in the shaft of the SIDE
expansion valve to directly detect the
SHAFT
refrigerant temperature at the outlet of the
evaporator.
The diaphragm contains R134a in saturated
state. The pressure in the diaphragm changes
according to the temperature detected by the REFRIGERANT
INLET
sensor. The change in the pressure causes the
force acting upon the diaphragm to vary
BALL
accordingly.
VALVE
The high-pressure high-temperature liquid
SPRING
refrigerant that is fed from the receiver side
Fig. 9 Block type expansion valve
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
occasion, part of the refrigerant evaporates
by the very heat of the refrigerant and cooled
off. The result is that low-pressure low-
temperature damp refrigerant vapor is fed to
the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust
spring and the pressing force of the
diaphragm (the temperature of the
refrigerant at the outlet of the evaporator to
be sensed by the thermowell). The feed rate is
controlled automatically so that under the
pressure in the evaporator, the refrigerant is
properly overheated (3～8 degrees) and goes
out of the evaporator. This action is carried
out by sensing the refrigerant temperature at
the outlet of the evaporator as against the
inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure
drop in the evaporator is excessive, it is
difficult to control the overheating or the feed
rate of the refrigerant. For this reason, the
smaller the pressure drop of the evaporator,
the better.
The expansion valve senses the pressure and
the temperature at the outlet of the
evaporator and controls the overheating of
the refrigerant and the refrigerant supply to
the evaporator more securely. The air- Fig. 10 Expansion valve outside view
conditioner of this machine adopts a block
type expansion valve. 25-10
(3) Compressor (See Fig.11)

The compressor performs the following three D HOSE
functions in the cooling circuit:
1) Suction action
2) Pumping action S HOSE
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling
effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit.
This enables enables continuous cooling.
3) The compressive action, as combined with the
action of the condenser which is mentioned Fig. 11 Compressor
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as
the pressure increases. For instance, it
becomes possible to cool down the refrigerant
by the use of an outer air of 35℃ (95° F) and
liquefy it. The compressive action of the
compressor works to turn low pressure
vaporized refrigerant to high pressure vapor
refrigerant. The condenser then serves to cool
down the refrigerant. However, since the
compressive action takes place only for a
short period, the refrigerant hardly
exchanges heat with outer air. That is to say,
it takes a near form of thermally insulated
compression, so that the refrigerant
discharged by the compressor turns into
high-temperature high-pressure vapor and is
delivered to the condenser.
(4) Condenser (See Fig. 12)

This is a heat exchanger that cools the
vaporized refrigerant at high temperature
and high pressure by the use of outer air and
condenses the refrigerant. The direction in
which heat moves is from the refrigerant to
air, the opposite to the case of the evaporator.
Fins are equipped on the outer air side to
improve thermal transfer. If the refrigerant
is not cooled well by the condenser, the air in
the compartment can not be cooled
sufficiently by the evaporator. For that
purpose, it is necessary to secure ventilation
required for the cooling of the refrigerant. Fig. 12 Condenser
25-11
(5) Receiver Dryer (See Fig.13)

1) Receiver Tank REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the INLET
compressor varies greatly which causes the REFRIGERANT
proper flow of refrigerant in the cooling OUTLET
circuit to vary. It is the receiver tank that
receives the variations. When the cooling
circuit does not need much refrigerant, the
receiver tank stores extra refrigerant
temporarily and supplies it when the cooling
circuit needs much refrigerant. The receiver
tank also stores an extra amount of PRESSURE SWITCH
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or DESICCANT
clogs the circuit as the water freezes in the
expansion valve. It is desirable that the
SUCTION PIPE
amount of water mixed in the refrigerant
should be held below a concentration of
30ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in
FILTER
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 peep window with which the
refrigerant level in the circuit is determined,
the only means of confirming the inside of the RECEIVER TANK
circuit visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by
cutting off the power supply to the
compressor when high pressure increases Fig. 13 Receiver dryer
abnormally high [more than 32kgf/cm2
(460psi) ].
The pressure switch also detects the leakage
of refrigerant by cutting the power supply to
the compressor when the pressure of the
circuit falls below 2kgf/cm2 (28psi).
25-12
4. DISASSEMBLY AND ASSEMBLY

4.1 PRECAUTIONS TO BE EXERCISED IN
OPERATION
(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator Table 2 Unit : kgfycm (lbfyft)
oil SP20 for use with new refrigerant R134a.
Oils other than SP20 may not be used. Since Pipe Fastening Part Tightening Torque
SP20 tends to absorb moisture and may D hose and compressor
200～250 (14～18)
corrode paint and resin, the following points (M8 bolt)
must be noted: D hose and condenser 200～250 (14～18)
1) Keep open all pipe connections on a new L hose and condenser 120～150 (8.7～11)
compressor and the component parts of the L hose and receiver dryer
80～120 (5.8～8.7)
installed refrigeration circuit (M6 bolt)
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 120～150 (8.7～11)
of the compressor, just before connecting S hose and air-conditioner unit 300～350 (22～25)
popes. If you have removed a pipe joint for Inlet of expansion valve 120～150 (8.7～11)
repair, put a cap to both ports immediately.) Outlet of expansion valve 200～250 (14～18)
2) Use care so SP20 does not adhere to the Pressure sensing part of
expansion valve 70～90 (5.0～6.5)
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off Table 3 Unit : kgfycm (lbfyft)
immediately.
Screw Size Tightening Torque
(2) The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore, N4, T4 machine screw, M4 8～12 (0.58～0.87)
remove the valve at the pipe port N5, T5 machine screw, M5 20～25 (1.4～1.8)
immediately before connecting pipes. M6 (mounting part of
80～120 (5.8～8.7)
L hose joint)
(3) Tightening Torque
M6 (except mounting part of
1) Pipe Joints (See Table 2.) 100～120 (7.2～8.7)
L hose joint)
When connecting pipe joints, coat the O ring M8 (mounting parts of S, D
200～250 (14～18)
with special oil (SP20) and fasten to the hose joints)
tightening torque indicated in the table, M8 (mounting part of A/C unit) 100～120 (7.2～8.7)
using a double spanner. M8 (other than those
120～160 (8.7～12)
2) Screws and Bolts (See Table 3.) mentioned above)
(4) Amount of Oil for Compressor (See Table 4.) M10 400～550 (29～40)
The compressor SD7H (HD type) is filled with
135cc (8cuyin) of oil. If the oil volume is small, Table 4
seizure at high revolution and shortening of
Part to be Replaced Amount to be filled in
service life will occur. If the oil volume is
large, the cooling ability will be deteriorated. Evaporator 40cc (2.4cuyin)
Once the air-conditioner is operated, part of Condenser 40cc (2.4cuyin)
the oil is dispersed in the refrigeration Compressor Drain out the volume of oil
circuit. Therefore, when replacing the parts left in the compressor to be
in Table 4, adjust the oil level to that of table. replaced, from the new
compressor.
(5) Before performing operation, stop the engine
and turn off all power supplies to the
equipment related to the air-conditioner.
(6) After the operation is over, confirm that all
faults have been repaired completely, by
operating the air-conditioner.
25-13
4.2 REMOVAL AND INSTALLATION OF THE UNIT

(1) Removing the blower unit INNER / OUTER
AIR MOTOR
1) Remove the connectors connected to the ACTUATOR
inner/outer air select motor actuator, the CONNECTOR
blower motor and the blower controller. Also
remove the harness from the blower casing.
HARNESS
EVAPORATOR
SENSOR BLOWER
CONNECTOR CONTROLLER BLOWER MOTOR
CONNECTOR CONNECTOR
Fig. 14
2) Draw out the inner air filter from the intake
casing. Remove four cross-recessed screws INNER AIR FILTER INTAKE
T5×14 (T1) from the top of the intake casing, CASING
MOUNTING
using a screwdriver. Then remove the intake SCREWS
casing. (4 PCS.)
INTAKE
CASING
3) Remove three cross-recessed screws T5×14 BLOWER
(T1) fastening the blower casing with the unit CASING
MOUNTING
casing. Then separate the blower unit from SCREWS
the air-conditioner unit. (3 PCS.)
UNIT BLOWER
(2) Replacing the blower motor CASING
1) Disconnect the cooling hose that is connected
between the blower motor and the blower Fig. 15
casing.
2) Remove three cross-recessed screws N5×16 BLOWER CASING

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

blower motor.
BLOWER
MOTOR
3) Assembly is the reverse order of disassembly. BLOWER
CONTROLLER
(3) Replacing the blower controller COOLING
1) Remove two cross-recessed screws T4×14 HOSE
(T1) fixed from the bottom of the blower unit
casing and draw out the blower controller. BLOWER MOTOR
BLOWER MOUNTING
2) Install a new blower controller in the reverse CONTROLLER SCREWS (3 PCS.)
MOUNTING
order of removal. SCREWS (2 PCS.)
Fig. 16
z Do not disassemble the blower
controller in any circumstances.
25-14
(4) Removing the heater core

1) After discharging the cooling water,
disconnect the heater hose from heater core.
HEATER CORE
2) Remove one cross-recessed screw N5×16 (T2)
each for the AHC bracket fixing the heater PIPE CLAMP
core to the unit and for the pipe clamp. Then
remove the AHC bracket and the pipe clamp PIPE CLAMP
and draw out the heater core from the unit MOUNTING
casing. SCREW
(1 PC.)
AHC BRACKET AHC MOUNTING
3) Assembly is the reverse order of disassembly. SCREW (1 PC.)
Fig. 17
(5) Removing the upper and lower parts of the
air-conditioner unit casing
1) Draw out the connectors for the mode motor
actuator and the evaporation sensor.
2) Separate the rod 120 from the rod holder that ROD 120
REAR OF
is fixed to the lever MAL1 on the mode motor UNIT CASING
ROD HOLDER
actuator.
MOUNTING SCREW
LEVER MAL1
3) Remove three cross-recessed screws N4×22
(T2) fastening the mode motor actuator that MOUNTING BOTTOM OF
UNIT CASING
install the bottom of the unit casing to the SCREW
back of the unit casing. Then separate the MOUNTING MODE MOTOR
mode motor actuator. SCREW ACTUATOR
4) Remove eleven cross-recessed screws N5×16 Fig. 18

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

the heater core off the unit casing. EVAPORATOR ASSY
EXPANSION
VALVE
EVAPORATION
SENSOR
BOTTOM OF
UNIT CASING
TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11 PCS.)
Fig. 19
25-15
(6) Replacing the evaporator and the expansion

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

VALVE
from the evaporator assy and draw out the
evaporator sensor with the sensor holder. SOCKET HEAD
CAPSCREW
3) Remove the socket head cap screws M5×40 (2 M5×40 (2 pcs.)
pcs.) from the evaporator. Then separate the
expansion valve from the evaporator.
: 4mm EVAPORATION SENSOR
4) Attach O rings (NFO ring 5/8 and 1/2, one Fig. 20

piece each) to a new evaporator. Then install
the expansion valve to it.
: 4mm,
Tightening torque 0.7kgfym (5.1 lbfyft)
z When attaching O rings, use care so

the O rings are not caught.
3rd row
(7) Installing the evaporator sensor
Install the evaporation sensor as shown in
Fig.21. 5th and 6th rows
z When installing the casing, exercise

13th and 14th rows
care so the sensor cord is not caught
by the casing.
EVAPORATION SENSOR
(8) Replacing the motor actuator

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

SCREW ACTUATOR
Fig. 22
25-16
2) Replacing the air mix motor actuator

Disconnect the connector connected with the
motor actuator.
Separate the rod 67 linking the motor
LEVER AM ROD 67
actuator with the lever AM, from the rod
ROD HOLDER
holder.
LEVER MAL1
Remove three cross-recessed screws T4×14
AIR MIX MOTOR
(T1) fastening the motor actuator. Then ACTUATOR
remove the motor actuator with the rod
holder and the lever MAL1, from the unit.
Remove the rod holder and the lever MAL1
from the motor actuator and install them to a
new motor actuator. Assembly is the reverse
order of disassembly.
Fig. 23
3) Replacing the inner/outer air select motor
actuator
Disconnect the connector connected with the
motor actuator.
Separate the motor actuator with lever MAL2
from the unit. LEVER MAL2
Remove the lever MAL2 from the motor
actuator and install it to a new motor
actuator, in the reverse order of disassembly.
INNER / OUTER AIR

MOTOR ACTUATOR
Fig. 24
25-17
5. CHARGING REFRIGERANT
5.1 PRECAUTIONS TO BE EXERCISED IN (3) Charging
OPERATION 1) When warming the can in which refrigerant
(1) Always assign a person in charge of handling is charged, do not fail to open the service can
refrigerant. valve and the low pressure valve of the gauge
Refrigerant charge operation involves manifold and warm the can in warm water of
dangers as it handles high pressure gas.
40℃ (104° F) or below (to an extent that you
Always assign a person familiar with how
do not feel hot when you put your hand in the
work is done for handling refrigerant.
water.) If the can is put in hot water or
z Always wear protective goggles. (You
may lose your sight if the refrigerant heated by a direct fire, the pressure of the
gets in your eyes.) can may rise sharply, thereby blowing off the
z The refrigerant in liquid state is at can.
very low temperature [approx. - 2) When charging refrigerant while running the
26℃(-15° F)]. Therefore, handle it engine, do not open the high pressure valve
with care. (You may get a frostbite if (HI) of the gauge manifold in any case.
the refrigerant is sprayed over your (4) Others
skin.) Re-use of service cans is prohibited by law;
(2) Storage and Transportation never use them again. Do not allow foreign
1) Hold the service can (hereinafter called can) matter to enter the air-conditioner circuit.
less than 40℃ (104° F). Since high pressure
Air, water and dust are detrimental to the
gas of R134a is filled in the can in a
refrigeration cycle. Install the components of
saturated liguefied state, the pressure in the
the air-conditioner correctly and speedily.
can increases sharply as temperature rises.
The can may blast as the result. Pay full attention to the entry of water and
It is for this reason why the can temperature dust.
must be kept below 40℃ (104° F).
2) For storage, choose a cold bark place not z Be careful about overcharge of gas.
exposed to direct sunlight. z Fasten pipes to a specified torque.
3) If the can is placed near a fire source, it is
subject to radiation heat and gets hot. This
causes the inside pressure to rise and may
cause the can to blow out. Therefore, never
bring the can close to a fire.
4) The inside of the closed compartment gets
very hot as the radiation heat of the sunlight
enters the compartment. The areas of the
compartment which are exposed to direct
sunlight may rise to a dangerous
temperature level. Therefore, do not bring the
can into the compartment. Also, the inside of
the trunk room may rise to a dangerous
temperature level even in the summer time.
Use sufficient care, therefore, taking the
above into account.
5) Note that if the can has scratches, marks and
distortion, the strength of the can will
deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or
unloading cans and packages
containing cans, do not throw or drod
them.
6) Store cans beyond the reach of children.
25-18
5.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner 2) The “gas charging operation” consists of
consists mainly of “vacuum making filling refrigerant in the circuit after forming
operation”, and “gas charge operation”. vacuum. Filling gas not only depends upon
1) The “vacuum making operation” consists of the cooling performances of the air-
removing water in the air-conditioner circuit. conditioner, but also affects the service life of
If only a little water remains in the circuit, the component parts of the circuit. Extreme
the small holes of the expansion valve are overcharge will make the circuit pressure
frozen during operation. This causes the extremely high and causes the cooling
circuit to clog up or rust, resulting in a performance to deteriorate. On the contrary,
variety of malfunctions. Therefore, before undercharge causes poor circulation of the
filling refrigerant in the circuit, make lubricating oil of the compressor and causes
vacuum and allow the water in the circuit to seizure of the moving parts of the
boil and vaporize. Water in the circuit is thus compressor.
eliminated. The gas filling operation involves handling of
high pressure gas; filling gas according to
incorrect operation procedure is dangerous.
Fill refrigerant correctly following the
(2) Operation Chart operation procedures and cautions stated in
this manual.
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
Less than
－750mmHg Gauge reading
wrong
Charge liquid gas to a gauge
Check and correct joints pressure of 1kgf/cm2 (14 psi)
(3) Tools
Table 5 unit : mm
No. Name of Part Q’TY Sketch Service No. Name of Part Q’TY Sketch Service
1 Gauge 1 4 Quick joint 1 Low
23.5 pressure
manifold side
5 T joint 1 For service
can valve
2 Charging 3 Red : high 6 Service can 2 For service

pressure can
hose side valve
Blue : low
pressure
side
Yellow :
vacuum
pump
side
3 Quick joint 1 High 7 Vacuum 1 For
pressure vacuum
27.5 side pump adapter pump
25-19
5.3 CHARGING PROCEDURE

5.3.1 VACUUM MAKING OPERATION
HIGH
(1) Connecting Gauge Manifold (See Fig.25.) PRESSURE GAUGE
LOW PRESSURE
1) Close the high pressure valve (HI) and the GAUGE GAUGE MANIFOLD
low pressure valve (LO) of the gauge (CLOSED) LOW HIGH PRESSURE
manifold. PRESSURE VALVE
VALVE (CLOSED)
2) Connect the charging hoses (red and blue) BLUE RED
with the service valves of the compressor.
HIGH
Red hose : High pressure side (HI) of the PRESSURE YELLOW
gauge manifold→high pressure SIDE
DIS
side (DIS) of compressor LOW
Blue hose : Low pressure side (LO) of gauge PRESSURE
manifold→low pressure side SIDE
SUC
(SUC) of compressor
COMPRESSOR VACUUM PUMP

z Take care so as not to mistake the (STOP)
high pressure side for low pressure Fig. 25 Connecting gauge manifold
side and push it in till a click is
heard. BLUE
z Connect the end bent like “L” of RED
the charging hose with the service
valve of the compressor. If the CHARGING
charging hose is connected the HOSE
opposite way, the mini core valve of (MINI CORE VALVE)
the compressor does not open. (See
Fig.26.) Fig. 26 Connecting piping with compressor
3) Connect the middle valve of the gauge

manifold with the charging hose of the
vacuum pump.
Some kinds of gauge manifolds are not LOW PRESSURE VALVE (OPEN) (CLOSE)
equipped with an open/close valve in HIGH PRESSURE VALVE (OPEN) (CLOSE)
the center. More than 30 min
(2) Vacuum Making (See Fig.27.) GAUGE MANIFOLD

1) Open the high pressure valve (HI) and the
low pressure valve (LO) of the gauge
manifold.
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes. DIS
3) When vacuum making for a specified
duration is over (degree of vacuum: less than
－750mmHg), close the high pressure valve
and the low pressure valve of the gauge SUC
manifold.
4) Then turn off the vacuum pump. Fig. 27 Vacuum making operation
25-20
(3) Air-tightness Check

Close the high pressure valve and the low
pressure valve of the gauge manifold, leave it
as it is for more than five minutes and make
sure that the gauge indication does not
return toward O.
If the gauge indication swings toward

O, there is somewhere that is leaking.
Retighten pipe joints, make vacuum
again and make sure of no leakage.
5.3.2 GAS CHARGING OPERATION

(1) Charging from High Pressure Side
(See Fig.28.)
1) After making vacuum repeatedly, change the
AIR PURGE
charging hose (yellow) of the gauge manifold
CLOSE
from the vacuum pump to the service can.
RED
2) Air purge
Open the service can valve. (However, close OPEN SERVICE CAN VALVE
the high and low pressure valves of the gauge SCREWDRIVER
OR SOMETHING
manifold.) Then push the mini core valve of
BLUE YELLOW
the side service port on the low pressure side
of the gauge manifold, using a screwdriver or
something, in order to let out the air in the
charging hose by the pressure of the Fig. 28 Gas charging operation
refrigerant. (See Fig.28.) (The operation ends
when a hissing sound is heard.)
3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge
in gaseous refrigerant to a gauge pressure of
1kgf/cm2 (14psi).]
After charging, close the high pressure valve
LOW PRESSURE HIGH PRESSURE VALVE
of the gauge manifold and the service and
VALVE (CLOSE) (OPEN) (CLOSE)
valve. (See Fig.29.) RED
FILL IN 1～1.5 CANS
BLUE
OF REFRIGERANT
Do not run the compressor in any case,
DIS YELLOW
(Otherwise the refrigerant flow in
reverse direction which causes the SERVICE CAN
VALVE
service can and the hoses to rupture.
(OPEN) (CLOSE)
This is very dangerous.)
CHARGE
SUC
(2) Checking for Gas Leakage
Check for gas leakage in the cycle, using a
gas leak detector (electric type). Retighten Fig. 29 Gas charging operation
and correct leaking points. (High pressure side)
Always use R134a for the leak tester.

(The presently used fron gas affects the
sensitivity adversely.)
25-21
(3) Charging from Low Pressure Side

(See Fig.30.)
1) Make sure that the high-pressure and low-
HIGH PRESSURE
pressure valves of the gauge manifold and VALVE (CLOSE)
LOW PRESSURE
the service can valve are closed. VALVE
(MUST BE CLOSED
2) Start the engine and run the revolution to POSITIVELY)
OPEN CLOS
1500±100rpm and fully open the cab door WHEN AIR BUBBLES RED
IN THE SIGHT GLASS
and the windows.
DISAPPEAR
3) Turn on the air-conditioner switch, set the BLUE
YELLOW
DIS
fan switch to Max and the temperature
control switch to cool Max.
SERVICE CAN
4) When charging gas, set the discharge VALVE (OPEN)
pressure of the compressor to 14～16kgf/cm2 SUC
(200～230psi).
5) Open the low pressure valve of the gauge COMPRESSOR SERVICE CAN
OPERATION (DO NOT TURN IT OVER)
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass Fig. 30 Gas charging operation
of the receiver go away. (See Fig.31.) (Low pressure side)
[Total amount of gas to be charged : 800 +500 g
+0.1
(1.8 0 lbs )]
SIGHT GLASS
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
z Do not open the high pressure valve

of the gauge manifold in any
circumstances.
z Never place the service can upside
down. (The compressor valve may be
scored because the refrigerant is
sucked in a liquid state.)
Fig. 31 Receiver dryer
25-22
(4) Criterion for Checking the Amount of
Refrigerant Filled in
Judgment of refrigerant level through the sight glass of receiver dryer
Proper level After A/C is turned on,

only a little bubbles are
seen and thereafter light
milky white is seen.
Overcharge After A/C is turned on,
no air bubbles are seen.
Undercharge After A/C is turned on,

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

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

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1) Press the “L” shape metal fitting of the
charging hose (blue) on the low pressure side
against the service valve of the compressor so
the refrigerant does not leak out and loosen
the nut. As soon as the nut has been
removed, disconnect the charging hose from
the service valve.
2) Leave the high pressure side as it is till the
high pressure gauge reading falls. [below
10kg/cm2 (140psi)].
3) Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.
25-23
6. ELECTRIC CIRCUIT
6.1 WIRING DIAGRAM AND CONNECTORS
Fig. 32 Electric diagram
25-24
6.2INSPECTING FUNCTIONAL PARTS

3 1
(1)Relay (24－4PE)
1)Coil resistance : 320Ω (across 1 and 2) 4 2
2)Operating voltage : DC20～30V
3)The coil of the relay has polarity : Care is As viewed from A
needed.
A
4) Turn on and off the power to the blower
motor by controlling the controller.
5) Check: Check conductance across 3 and 4 in
the following condition :
Apply 20～30V across terminals 1 and 2 :
through
No voltage applied across terminals 1 and 2 : Fig. 33 Relay
not through
(2) Inner air sensor (C44)

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

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

1) Operating voltage : DC20～30V
2) Operating temperature range :
－30℃(－22° F) to +75℃ (167°
F)
The motor is controlled by signals (pulses)
put out by the controller.
CONNECTOR
PIN NUMBER
Fig. 36 Motor actuator
25-25
(4)Pressure Switch (Attached to Receiver PRESSURE SWITCH

Dryer)
1) Contents of checking (specification)
Low pressure side OFF pressure :
2.0±0.2kgf/cm2 (28±3psi)
Low pressure side return pressure :
OFF pressure +0.3kgf/cm2 (4.3psi) or below
High pressure side OFF pressure :
32±2kgf/cm2 (455±28psi)
High pressure side return pressure :
OFF pressure－6±2kgf/cm2 (－85±28psi)
Fig. 37 Pressure switch
LOW PRESSURE RETURN HIGH PRESSURE RETURN

(26) (30) (31) (36) (310) (430) (480)
1.8 2.1 2.2 2.5 22 30 34 kgf/cm2 (psi)
LOW PRESSURE OFF HIGH PRESSURE OFF
2) Performance
Low pressure side : To prevent actuation of
the compressor clutch
where refrigerant is
deficient
High pressure side : To prevent actuation of
the compressor clutch
where pressure rises
abnormally because of
the clogging of the
refrigeration circuit, etc.
(5) Thermistor (C19)

1) Contents of checking (specification)
Resistance across terminals
at 0℃ (32° F) : 7.2kΩ
at 25℃ (77° F) : 2.2kΩ
Note :
Normally check that there is no shortcircuit
or disconnection.
2) Performance
In order to prevent freezing of the evaporator,
the blowoff air temperature of the evaporator Fig. 38 Thermistor
is controlled by turning the compressor clutch
ON and OFF. The thermistor operates as the
sensor of the control.
25-26
7. TROUBLESHOOTING
【Temperature does not fall.】 Note) M/A : Motor actuator
If A/C switch is pushed, “HL.E” is indicated on the set temp. display of the panel.
NO YES
“HL.※” is shown on the set temp. display of the panel. Connector for air mix M/A is
Note) ※ is any of the disconnected or in poor contact.
NO YES numbers 0 ～ 9. M/A is broken.
※※E on display. Main harness shows poor conductance.
A snow mark on the A snow mark on panel is flashing.
panel is flashing. Inspect and correct or replace parts.
NO YES NO YES
Inner air sensor or harness Both inner air sensor

is disconnected or shorted. and
Inner air sensor connector is evaporation sensor are
disconnected or in poor contact. disconnected or shorted.
Inspect and correct or replace parts.

A
B
Blowout temp. falls if temp. is set
at 18.0 (64.4°
F) (COOLMAX) and the Evaporation sensor connector
blowout mode is changed to vent mode. is disconnected or in poor contact.
Evaporation sensor is
NO YES disconnected or shorted.
※1 Air mix damper is Chilly air flowing Inspect and correct or replace parts.
in COOLMAX. into inner air sensor
NO YES NO YES
If M/A is at stop Turn compressor clutch Controller is faulty Inspect duct or

halfway, eliminate on and off. Inspect and or inner air sensor eliminate cause for
cause, correct and correct electric circuits. is faulty. chilly air intrusion.
measure operating
force. [less than
Refer to Troubleshooting Inspect and replace.
1.5kgf (3.3 lbf):OK]
for refrigeration cycle. ※1 COOL-MAX
action condition
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.
25-27
【Temperature does not rise.】
HL.E is shown on the set temp. display of panel.
NO YES
HL. ※ is shown on the set temp display the panel. Note) ※ is any of the numbers 0～9
NO YES
Blowout temp. rises at blowout z Inner air sensor or harness

mode if temp. is set at is disconnected or shorted. z Air mix M/A connector is
HOTMAX 32.0℃ (89.6° F). z Inner air sensor connector off.
is off or in poor contact. z M/A is broken.
z Main harness shows
Inspect and correct or replace parts.
NO YES Inspect and correct

or replace parts.
※2 Air mix damper is Warm air is flowing into
at HOT MAX. inner sensor.
NO YES
NO YES
If M/A action is at Inspect warm water piping.
stop, eliminate cause, Controller or Inspect duct or
correct and measure inner air sensor eliminate causes
operating force. [less is out of order. for warm air entry.
than 1.5kgf (3.3lbf):OK]
Inspect and replace.
NO YES
z Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
※2 : HOT-MAX
z Clean lever link and apply grease.
operating condition.
Replace.
25-28
【Blower motor does not run.】
At air flow HI, battery voltage acts across Note) Measure with
both terminals (+) and (－) of blower motor. connector set.
NO YES
Battery voltage acts across red Blower motor fails.

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

Note 1 Blower motor rotates if white / blue / black (0.85) and
green (2.0) and red of blower earth of blower amplifier.
motor relay are direct connected.
NO YES
NO YES
Controller is out of order.
Wire harness is Battery voltage acts across Remove blower amplifier and check for
faulty. Inspect white / green (0.85) and conductance across blue / black (0.85)
and correct or replace. body of blower motor relay. and black wires ; you get conductance.
NO YES NO YES
Inspect and repair Blower turns if Eliminate cause Inspect and

harness or replace. brown / red of and replace repair
blower motor blower amplifier. harness.
relay is connected
with earth.
NO YES
Replace relay. Inspect and correct harness

or replace controller.
【Blower motor speed does not change.】
HL. ※ is shown on the set temp. display of panel. Note) ※ is any of the
numbers 0～9.
NO YES
Air flow rate is constant regardless of readings. z Inner air sensor and harness
are disconnected or shorted.
z Inner sensor connector is
disconnected or in poor contact.
Replace blower
amplifier or controller. Inspect and correct or replace parts.
25-29
【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 B Terminal voltage present across Clutch faulty.

pressure switch harness.
Replace compressor.
NO YES
Voltage acts across red and Pressure switch is faulty or gas

blue terminals of connector is under charged or overcharged.
connected to excavator.
NO YES
Inspect air-conditioner Inspect air-conditioner

and vehicle connector. harness. No fault.
Also clutch fuses.
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 Connector of inner/outer air M/A is

foreign matter disconnected or in poor contact.
or is broken. Or M/A failed or main harness failed.
NO YES
Inspect or replace.
M/A failed Remove foreign matter

and replace parts.
Replace
25-30
【Modes do not change.】
Mode display on operating

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

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

Repair. by hand, it is heavy. [more than 2kgf (4.4 lbf)]
NO YES
M/A or controller is out of z Cam or damper shaft includes

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

z Clean cam and apply new grease.
25-31
【Trouble with refrigeration cycle.】
Both high and low pressures are lower. Low pressure is higher.
Air bubbles are seen in sight glass. Air bubbles are High pressure
seen in sight glass. is lower.
NO YES
Cooling does not work Oil oozes out from Compressor Hot air Compressor
if run at high speed. piping and parts. cylinder does comes out of cylinder gets
not get hot. heater unit. very hot.
NO YES NO YES
Expansion Expansion Natural Gas leaks Expansion Water cock Compressor

valve is valve is leak from from pipe valve is mal- is mal- does not
clogged frozen or hose. joints adjusted. adjusted discharge
or mal- intruded and (too much or faulty. well.
adjusted. by water. open)
Adjust or After making Charge gas. Retighten Replace Adjust or Replace

replace vacuum, refill or replace expansion replace compressor
expansion refrigerant parts. valve. water cock.
valve. and replace
receiver.
If system is run continuously in HI idle,

High pressure is lower. it does not cool down or air flow decreases.
Frost deposits.
Air bubbles are seen in sight glass.
NO YES
Thermistor does
High pressure gets Condenser is not cool off.
lower slowly. fouled or clogged.
NO YES
YES
NO Thermostat is Thermistor position

High pressure
circuit before Air bubbles are hard to not turned off. is normal.
receiver is go out even if water
clogged up. is poured on condenser. NO YES NO YES
Functions and Thermistor Thermistor Air

Remove Clean Air is mixed. performances is faulty or position is leaks
clogging condenser Make vacuum are normal. cord is faulty. out of
or replace and refill Familiarize disconnected. Correct casing.
parts. refrigerant. the user with position.
how to use it.
25-32
E115SR
E135SR
SECTION 31 DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
1. Explaining chapter of whole disassembly and assembly ...................................... 31-1

1.1 Form for chapter of disassembly and assembly ........................................................................... 31-1
1.2 Indication of tightening torque ...................................................................................................... 31-1
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY AND ASSEMBLY
1.1 FORM FOR CHAPTER OF DISASSEMBLY AND ASSEMBLY

This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .................................................................................................................... SEC. 32

PartⅠ；Removing and Installing
PartⅡ；Disassembling and Assembling
1) Cylinder
(2) UPPER SLEWING STRUCTURE ........................................................................................ SEC. 33

1) Hydraulic pump 2) Control Valve 3) Pilot Valve (ATT)
4) Pilot Valve (Travel) 5) Slewing Motor 6) Swivel Joint
(3) TRAVEL SYSTEM ................................................................................................................. SEC. 34

1) Travel Motor
1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=10kgfym (72 lbfyft)
Tolerance is ±10% unless specified.
z Refer Code SEC. 11 TOOLS for standard tightening torque.
31-1
NOTE
31-2
E115SR
E135SR
SECTION 32 ATTACHMENTS
TABLE OF CONTENTS
Part I: Removing and installing assy

1. Attachment assy and name .................................................................................. 32-1
2.1 Removal of bucket ......................................................................................................................... 32-2
2.2 Installation of bucket ..................................................................................................................... 32-2
2.3 Procedure for adjustment of clearance between bucket and arm .................................................. 32-3
3. Arm ....................................................................................................................... 32-4

3.1 Removal of arm ............................................................................................................................. 32-4
3.2 Installation of arm ......................................................................................................................... 32-5
4. Boom .................................................................................................................... 32-6

4.1 Removal of boom .......................................................................................................................... 32-6
4.2 Installation of boom ....................................................................................................................... 32-7
5. Swing .................................................................................................................... 32-8

5.1 Removal of swing bracket and cylinder ......................................................................................... 32-8
5.2 Installation of swing bracket and cylinder ...................................................................................... 32-9
6. Dozer .................................................................................................................. 32-10

6.1 Removal ...................................................................................................................................... 32-10
6.2 Installation ................................................................................................................................... 32-10
Part II: Disassembling and assembling components

1. Cylinder .............................................................................................................. 32-11
1.2 General precautions .................................................................................................................... 32-11
1.1 Necessary tools ........................................................................................................................... 32-11
1.3 Cylinder construction (example of swing cylinder) ....................................................................... 32-12
1.4 Disassembly ................................................................................................................................ 32-12
1.5 Assembly ..................................................................................................................................... 32-17
1.6 Maintenance standards ............................................................................................................... 32-22
1.7 Jig list .......................................................................................................................................... 32-25
1.8 Possible causes for trouble and remedy ...................................................................................... 32-28
Part I: REMOVING AND ATTACHING ASSY

1. ATTACHMENT ASSY AND NAME
ARM CYLINDER HEAD PIN (D) BOOM CYLINDER ROD PIN (C) BOOM FOOT PIN (A)
BOOM TOP PIN (F) 4. BOOM
ARM CYLINDER
ARM CYLINDER ROD PIN (E)
BOOM CYLINDER
DOZER BLADE
2. BUCKET
3. ARM
BUCKET CYLINDER
HEAD PIN (G)
IDLER LINK PIN (I) BUCKET DRIVE PIN (J) BOOM CYLINDER HEAD PIN (B)
BUCKET CYLINDER IDLER LINK BUCKET LINK
BUCKET CYLINDER ROD PIN (H) BUCKET ATTACHING PIN (K)
Fig. 1-1 Front attachment name and position
2. BUCKET
2.1 REMOVING BUCKET

(1) Put the machine in position to remove
bucket.
Fig. 2-1 Position to remove bucket
A
A DRIVER
(2) Removing pin (2)
Expand slit of ring (1) with driver, and 1 2
remove it. Push out the pin (2) with driver
(－).
SECTION AA
Fig. 2-2 Removing pin (2)
32-1
(3) Removing bucket attaching pin (K).

Lift up bucket, position it so that bucket
attaching pin (K) is not loaded, adjust bucket K
link, and pull out bucket attaching pin (K).
Fig. 2-3 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, and pull out pin (J).
J
Fig. 2-4 Removing bucket drive pin

2.2 ATTACHING BUCKET
(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
continue in the reverse procedure of the
pulling out. J
z When aligning the pin holes, do not

put your finger in the pin holes in
any circumstances, but align them
visually.
z Check that the seals are not scored
and replace a faulty one if necessary.
zWhen inserting the pin, coat the shaft
with grease.
Fig. 2-5 Attaching bucket
32-2
2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and
arm 251±0.5 (9.88″±0.197″)
1) Shift O ring (3) toward the bucket boss, using 14；WASHER New bucket
a spatula. (a→b) 12；LOCK B
WASHER 3；O RING
10；CAPSCREW b
2) When adjusting clearance (B), bring the non- a
adjusting side of the bucket in contact with
the arm.
3) Measure clearance (B) and check that it is

within 1.2mm (0.05in).
7；BUSHING
4) Adjust clearance (B) where it is more than 6；PLATE

1.2mm (0.05in).
8；SHIM 13；PIN
5) An average of 5 shims (8) of 1mm (0.04in)
Install pin (13) until the top of
thickness are set in the plate (6) fixed by the
pin is even surface with bushing.
three capscrews M16×50 (10). The clearance
can be decreased by 1mm (0.04in) if one shim Fig. 2-6 Adjusting clearance between
is removed. bucket and arm
: 22mm
6) After adjustment, tighten the socket bolts

evenly.
z The gap exceeding the specified
dimension causes a rapid progress of
wear.
7) Operate the bucket and confirm that the total

sum of both clearance is within 1.2mm
(0.05in).
8) Refit O ring (3) to its original position.
z When shifting O ring (3) by means of

a spatula, use care so as not to score
O ring (3).
z Remove shims (12), push out
bushing (8) rightwards by means of
three socket bolts (10) and adjust
clearance (B) so it falls within the
standard value evenly all round.
z Check the clearance at 120 hours’
intervals in normal operation.
Shorten these intervals in special
operation. Adjust the intervals as
necessary.
32-3
3. ARM
3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder to a maximum and bring the arm
down on the ground.
Fig. 3-1 Position to remove arm

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

Plug : 4-(4)
When the removal of bucket cylinder is not

required, skip to procedure (6).
Fig. 3-2 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H) Insert resin shim
1) Loosen nut (8), remove capscrew M14×115 After adjustment of shim,
into cylinder side. SHIM
(7), and push out pin (H). the total gap should be
: 22mm within 0.6～1.0mm
(0.02～0.04in).
2) Retract cylinder rod.

7
H
H G
D A
A 8
D
DUST SEAL
Insert resin shim into cylinder side. SHIM
SECTION
Fig. 3-3 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
After adjustment of shim, the total
Loosen nut (3), remove capscrew M12×110 Insert resin shim gap should be within 0.6～2.0mm
(2), and push out pin (G). SHIM into cylinder side. (0.02～0.08in).
SHIM
: 19mm
2
G
3
SECTION
Fig. 3-4 Detail of bucket cylinder head pin (G)
32-4
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon
sling, and remove it.
Bucket cylinder weight : 90kg (200 lbs)
Fig. 3-5 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Loosen nut (6), remove capscrew (4), and
push out arm cylinder rod pin (E).
After adjustment of shim, the total gap
: 19mm should be within 0.6～2.0mm (0.02～0.08in).
Retract arm cylinder rod, and return pin (E) SHIM
to the original position (hole).
4
E
E
6
SHIM Insert resin shim into cylinder side.
SECTION
F
Fig. 3-6 Detail of arm cylinder rod pin (E)
(7) Removing boom top pin (F) After adjustment of shim, the total
Loosen remove capscrew (3), and pull out gap should be within 0.5mm (0.02in).
SHIM
boom top pin (F).
Insert resin shim
: 19mm into arm side.
SHIM
Put block between arm cylinder and boom.
Insert pin (F) into the original hole. F
SECTION
Fig. 3-7 Detail of boom top pin (F)
32-5
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight ;
E115SR; 280kg (620 lbs)
E135SR(LC); 350kg (770 lbs)
E135SRL; 350kg (770 lbs)
Fig. 3-8 Slinging arm assy
3.2 ATTACHING ARM
Install the arm in the reverse order of
removing, paying attention to the following :
1) When aligning the pin holes, do not put your
finger in the pin holes in any circumstances,
but align them visually.
2) Check that the dust seals is not scored and
replace a faulty one if necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Apply Loctite #242 to the pin-securing
capscrews and nuts and fasten them.
Pin lock nut handling procedure
5) When installing the arm and the cylinder,

inspect the clearance in the thrust direction
of the mounts and decide the thickness of
shims by referring to the Maintenance
Standard.
6) Fit resin shims to the moving side and iron
shims to the outside of the resin shims. Place
the clearance with iron shims.
7) Tightening torque Tightening torque
Classification Size kgfym (lbfyft)
M6 1.4±0.15 (10±1.1)
M-threads M12 11.7±1.2 (85±8.7)
M14 18.5±2.0 (130±14)
PF,PT 1/8″ 1.7±0.2 (12±1.4)
threads 1/4″ 3.7±0.2 (27±1.4)
Hose mouth
1/4″ 3.0±0.5 (22±3.6)
size
32－6
4. BOOM
4.1 PREPARATION FOR REMOVING AND
ATTACHING BOOM
When removing and attaching boom in the
position shown in Fig.4-1, to remove and
attach boom foot pin (A), removing and
attaching of cab and guard are required.
A
4.2 REMOVING BOOM
(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc.
giving attention for arm cylinder rod not to be
extended. BLOCK
Fig. 4-1 Position to remove boom

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

(3) Removing boom cylinder rod pin (C)
Loosen nut (8), remove capscrew (4), collar (3) After adjustment of shim, the total gap
should be within 0.6～2.0mm (0.02～0.08in).
and push out pin (C). SHIM
3
C
8
4
(4) Preparing for disconnecting cylinder pipes
Retract boom cylinder rod, and place one side
SHIM
of cylinder on block. (See Fig.4-2.)
SECTION AA
Fig. 4-3 Detail of boom cylinder rod pin (C)
32-7
(5) Disconnecting piping of arm cylinder and

bucket cylinder
Release pressure in hydraulic tank, and
disconnect pipe at section DD.
: 36mm, 41mm
After disconnection of pipe, plug every pipe.
Plug : 4-(4) BUCKET・R
ARM・R
ARM・H BUCKET・H
SECTION DD Unit : mm (inch)
(6) Lifting up boom assy temporarily Fig. 4-4 Boom piping disconnection
Lift up boom cylinder with nylon sling so that
boom foot pin (A) is not loaded.
Weight of single boom :
E115SR : 630kg (1400 lbs)
E135SR (LC) : 720kg (1600 lbs)
BOOM FOOT PIN A
Fig. 4-5 Boom assy temporary lift up procedure

(7) Removing boom foot pin (A) Insert resin shim into boom side. SHIM
1) Remove pin (3) and washer (4) and pull out After adjustment of shim, the total gap
pin (2). should be within 0.5mm (0.02in).
2) Tools to Thread M24×35 (Effective screw SHIM
thread length) for pin (1): Screw slide
hammer in. 2
Refer to Tools 10. Tools for boom foot pin.
3) Force slide hammer in until the pin is out
1 SECTION AA 3,4
Fig. 4-6 Details of boom foot pin (A) section
Fig. 4-7 Removing pin (A) using slide hammer

32-8
(8) Slinging boom assy

Sling and remove boom assy.
Weight of single boom :
E115SR : 630kg (1400 lbs)
E135SR (LC). : 720kg (1600 lbs)
Fig. 4-8 Boom assy slinging procedure

(9) Completion of removal of front attachments
When the removing and attaching of cylinder
are not required, the work is finished.
(10) Removing arm cylinder

A
Disconnect hose at A section, and plug both
ends.
Plug 4-(4)
: 32mm,
Tightening torque ; 14kgfym (100 lbfyft) 3
: 36mm, D=1
Tightening torque ; 18kgfym (130 lbfyft)
(11) Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew (2) and pull
out pin D (1).
2
SHIM
After adjustment of shim, the
total gap should be within
0.6～1.0mm (0.02～0.04in).
Insert resin shim

into cylinder side. SHIM
Fig. 4-9 Removing arm cylinder
(12) Removing boom cylinder
Disconnect hose at B section. Plug both ends. B
Plug 4-(4) Opposing flats 32
: 32mm,
Tightening torque ; 14kgfym (100 lbfyft)
(13) Removing boom cylinder foot pin (B)

Loosen capscrew (5) and pull out pin (B).
Opposing flats 32
Fig. 4-10 Removing boom cylinder
32-9
4.3 ATTACHING BOOM A

(1) Attaching boom foot pin (A)
Screw tool 10. slide hammer M24 into boom
foot pin (A) first, and fit boom assy.
Attach it in the reverse procedure of
removing, paying attention to the following B
points.
z When aligning the pin holes, do not

put your finger in the pin holes in
any circumstances, but align them B B
visually. Fig. 4-11 Boom cylinder head pin (B)
z Check that the dust seals is not
scored and replace a faulty one if After adjustment of shim,
necessary. the total gap should be
within 0.6～1.0mm
z When inserting the pin, coat the
shaft with grease.
After adjustment of
z M10 Tightening torque : 6.7kgfym
(48 lbfyft) B shim, the total gap
B
should be within
z Pin lock nut handling procedure 0.6～1.0mm
(0.02～0.04in).
z To attach shim, fit resin shim on

operating side and iron shim on the 5 (M10)
outside, and reduce the space.
SECTION BB
Fig. 4-12 Attaching boom cylinder head pin
32-10
5. DOZER 1(LH)
2(RH)
4
5.1 REMOVAL 3
(1) Removing position (See Fig. 5-1)
Put a suitable height stand on the dozer side,
and stabilize the dozer while making sure
that the dozer installing pin is not loaded.
(2) Removing cover (See Fig. 5-1)
Remove capscrews (3) (4), then remove covers
(1) (2). Fig. 5-1 Dozer removing position
: 17mm 2 1,4,5,6 3
(3) Remove hydraulic pipe, and plug connections
of both ends.
: 27mm
(4) Hanging dozer cylinder temporarily SECTION A
Hang dozer cylinder with a nylon sling, etc.
(5) Holding dozer cylinder (See Fig. 5-2、Fig. 5- Section A details
3)
Remove nut (3) and capscrew (2) of pin (1) on
the dozer cylinder rod side, pull pin (1) out,
retract the cylinder and support it with stand
SEPARATE
like timber, etc.
HYDRAULIC PIPE
: 19mm
Tag the positions where shims (4) (5)

(6) are removed.
(6) Removing dozer (See Fig. 5-4) Fig. 5-2 Dozer cylinder rod side installing pin
1) Remove nut (3), capscrew (2) and shims (5)
(6) (7), and pull pin (1) out.
2) Move the hydraulic excavator rearward
slowly, and remove the dozer.
5.2 INSTALLATION
Install the dozer by the reverse procedure of the
removal in the following points. Fig. 5-3 Holding of dozer cylinder
(1) Before inserting dozer and dozer installing
2 1 BOSS 3
pin, apply grease on the pin section.
(2) Perform the adjustment with shims referring
to the Maintenance Standard. BODY SIDE
(3) After inserting the capscrew, apply Loctite
#242 on the double nut, and lock the dozer
installing pin keeping about 2mm (0.08in)
apart from the boss. 5,6,7 4
(4) Tightening torque (DUST SEAL)
Size kgfym lbfyft

M10 6.7 48 DOZER SIDE
M12 11.7 85
SECTION AA (Fig. 5-2)
Fig. 5-4 Dozer installing pin
32-11
Part II: DISSAMBLY AND ASSEMBLY EQUIPMENT

1. CYLINDER
1.1 PREPARATION BEFORE DISASSEMBLY (2) Work bench
Before assembly, secure a dustfree workshop and The work bench must have strength and rigi-
necessary equipment and facilities. dity capable of accommodating the total
length of the cylinder in its most retracted
1.1.1 WORK AREA condition and of withstanding the repulsive
The following working area is required for force of the tightening torques of the cylinder
disassembly: head and the piston nut. Since a vise is
(1) Ample space attached to the bench, the width of the work
For the disassembly of the hydraulic cylinder, bench must be sufficiently large.
the cylinder tube and the piston rod must be (3) Support stand
drawn out. For this reason, the first condition If the clevis part of the piston rod is fully
is that the working area is long enough for extended in a free condition, the bushing and
the work. In terms of width, it is also the seals may be damaged as the rod bushing
necessary to keep sufficient space so and the piston are twisted due to the weight
disassembly, cleaning and measuring of the rod. A stand is required to support the
equipment are placed and the work can be rod to prevent such.
performed. (4) Hydraulic source
(2) Suitable working environment A Hydraulic source is required for
The hydraulic cylinder is a precision- disassembly and assembly of the cylinder
machined product that uses seals and head and piston nut and for oil leak tests
packings made of rubber and plastic after completion of assembly.
materials. For this reason full care should be (5) Jet air source
exercised so the hydraulic cylinder is free It is used for drying after oil draining and
from dust, dirt, and in particular, such hard cleaning of the cylinder.
particles as sand, metal chips, and weld slag (6) Cleaning bath, cleaning oil and detergent
(spatter). If the hydraulic cylinder is (7) Oil pan and oil reservoir
assembled with hard particles adhered on An oil pan is necessary to contain oil drained
such components as the cylinder tube and the from the cylinder and oil spilt during work.
piston rod, the tube inner surface and the rod An oil reservoir is required to collect oil spilt
surface are scratched as the cylinder on the floor and waste oil.
operates, consequently disabling it in worst (8) Others
cases. Damage to the piston seals and the rod Oil extracting hoses, wooden skids, rag and
seals will result in oil leaks. For this reason, sawdust in which oil soaked are also
grinding and welding operation should not be necessary.
performed in the neighbourhood of the working
area to keep it clean.
1.1.2 APPARATUS
The following equipment are required for
disassembly:
(1) Hoist or crane
The hoist or crane must be capable of
carrying the cylinder in an assembled
condition. It must also be capable of marking
level and liner movement under load for
retracting and extending the piston rod and
the tube.
32-12
1.1.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is
necessary to prepare the tools in Table 1-1 as a
guideline.
Table 1-1 List of Tools and Jigs
Tool / Jig Remarks Tool / Jig Remarks

Hammer 1. Steel hammer Spatula Metallic one with smooth
2. Wooden or plastic mallet corners.
Screwdriver A few types of large and small sizes Jig 1. For fitting piston seals “C”
Chisel Flat chisel 2. For hodling in slipper seals “D”
Vise One having an operation wide 3. For inserting piston rod bushing
enough to hold cylinder head O.D. “A”
and tube mounting pins (clevis) 4. For pressing in dust seal “E”
Wrench 1. Hook wrench 5. For pressing piston seal “G”
2. Allen wrench Rust remover
3. Extension pipe for wrenches
Measuring 1. Slide calipers
Gimlet A sharp-point tool may be used in instruments 2. Micrometer
place of a gimlet. 3. Cylinder gauge (Fig. 1-1)
4. V-block
z For the details of special tools and

jigs, refer to the back pages of this
manual.
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 Fig. 1-1 Cylinder gauge
soil and contamination from the cylinder with
water and steam before bringing it into the WOODEN
workshop. BLOCK
z The following describes the

PORT B
construction of boom cylinder (with V BLOCK
cushions on both sides). When
disassembling and servicing the
cylinder, confirm the construction of
cylinder referring to Parts Manual.
1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and PORT A
mount the cylinder on it to prevent it from AIR
rotating. Charge air into ports A and B
alternately to actuate the piston rod till the
OIL PAN
hydraulic oil in the cylinder is drained out. At this
time, connect a suitable hose to each port so that Fig. 1-2 Discharging oil
the hydraulic oil may not gush out.
32-13
1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF BOOM CYLINDER)

T=Tightening torque ; kgfym (lbfyft)
3 B 6
Z
→
T=1.8～2.2(13～16)
M10×1.5
28,29 27
26

VIEW Z
T=1.5(11) T=190(1400) T=100(720)
2 14 13 9 8 10 11 12 7 15 4 1 19 20 21 16 18 17 22 23 24 5
PT1/8
C
∅1.2 PT1/4
EXAMPLE Fig. 1-3 Construction of boom cylinder 25 T=21～22(150～160)

E135SR EVOLUTION (The figure shows the right cylinder.)

1 CYLINDER TUBE 1 11 WEARING; Cloth- 2 21 O RING ; 1B G100 1
containing phenol resin
2 BUSHING 2 12 DUST RING;TEFLON 1 22 BUFFER SEAL ;
Urethane rubber
1
3 DUST SEAL; 2 13 PISTON NUT 1 ROD PACKING ;
23 Urethane 1
Synthetic rubber rubber
4 PISTON ROD 1 14 SETSCREW ; M8 1 24 DUST SEAL;Urethane 1
rubber
5 PIN BUSHING 1 15 CUSHION RING 1 25 SOCKET BOLT ; M14×65 8
6 DUST SEAL 2 16 ROD COVER 1 26 BAND 1
8 O RING 1 18 CIRCLIP 1 28 CAPSCREW ; M10×30 2
9 BACK-UP RING ; NYLON 2 19 O RING ; 1B G95 1 29 LOCK WASHER 2
10 PISTON SEAL ; Bronze- 1 20 BACK-UP RING;NYLON 1
containing Teflon
32-14
1.3 DISASSEMBLY
z When disassembling and servicing

the cylinder, check the construction
and the availability of service parts
as well as necessary tools and jigs on
separate Parts Manual.
z The figures in parentheses after part
names correspond to those in Fig.1-
3.
z The explanations and quantities
below are for an boom cylinder.
Apply the same to other cylinder as
well.
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 (4) about 200mm (8in).

Because the piston rod is heavy, finish
extending it with air pressure after the
4
above-mentioned oil draining operation.
Fig. 1-4
3) Loosen and remove socket bolts (25) of the
rod cover in sequence. ALLEN WRENCH 25
Cover the extended piston rod (4) with rag

to prevent it from being accidentally
damaged during operation. Turn counterclockwise
4) Strike the corner of the rod cover flange by

means of a plastic mallet till rod cover (16) 16
comes off. Cover here with rag.
4
Fig. 1-5
32-15
z At this time, the weight of piston rod

KNOCK THIS EDGE
(4) is loaded on rod cover (16). WITH A PLASTIC
LIFT HERE.
Therefore, lift the top end of the MALLET.
piston rod with a crane or something
to the extent that only the rod
weight may be held.
1
5) Draw out the piston rod assy (4) from

cylinder tube (1). 16
4
Since the piston rod assy is heavy in Fig. 1-6 Drawing out piston rod assy (4).
this case, lift the tip of the piston rod
LIFT HERE. 1
(4) with a crane or some means and
draw it out. However, when piston rod PULL
(4) has been drawing out to STRAIGHT
approximately two thirds of its length, SIDEWAYS
HORIZONTALLY
lift it in its center to draw it
completely. However, since the plated
surface of piston rod (4) is lifted, do not
use a wire rope or something which OIL PAN
may score the surface, but use a strong

cloth, a belt or a rope. Fig. 1-7 Method of drawing out the piston rod assy
6) Place the removed piston rod assy on a

wooden V-block that is set level.
PISTON ROD ASSY
z Cover a V-block with rag.

WOODEN V-BLOCK
(PLACE RAG.)
Fig. 1-8 Method of placing the piston rod

7) Remove wear ring (11) and dust ring (12)
from piston (7). TAKE IT OFF BY WIDENING
THE SLIT TOWARD
THE ARROW
12
11
Fig. 1-9 Remove wear ring (11) and dust ring (12)
32-16
1.3.2 REMOVING PISTON ASSY 16 WOOD

1) Fix piston rod (4) by holding its clevis section 4 PIECE
in a vise. Fix the piston rod (4) rigidly as 7
piston nut (13) is tightened to a high torque.
13
z Note that the tightening torque
differs with the type, the working
pressure and the mounting method
of the piston (7), though the rod
diameter remains the same.
z It is also necessary to place a
suitable supporting block near the
piston(7). In case a V-block is used,
WOODEN V-BLOCK
put rag or something over the rod to (PLACE RAG.)
prevent it from being scored
Fig. 1-10 How to loosen piston nut (13)
2) Scrape off the caulked part of setscrew (14) of
piston nut (13) by means of a hand drill and DRILL
loosen and remove setscrew (14).
13
14
Fig. 1-11 Removing setscrew (14)

3) Loosen and remove piston nut (13). HAMMER HERE IF EXTENSION
PIPE IS NOT AVAILABLE.
Since piston nut (13) is tightened to a 1.0～1.5m
(3´3″～4´11″)
high torque, use a hook wrench
suitable for the outside diameter of
piston nut (13). Use care so the hook of TURN
the wrench is positively fixed in the COUNTER
groove of the piston nut perimeter. CLOCKWISE.
7
HOOK
WRENCH 13
Fig. 1-12 How to loosen piston nut (13)

4) Loosen piston (7) with a pin wrench as shown
in Fig.1-13, utilizing the two holes in the side HAMMER HERE IF PIPE IS NOT
face of the piston. If the O ring (8) comes off, AVAILABLE.
the piston may be turned easily by hand. 1.0～1.5m
(3´3″～4´11″)
When removing the last thread of the piston,
hold the piston by hand to receive the weight
TURN
COUNTER
CLOCKWISE.
If the piston is dropped with a bang,
PIN WRENCH
the O ring seal face on the piston
interior may be damaged with the 4 7
threads. Fig. 1-13 Removing piston (7)
32-17
5) Remove the rod cover (16) from piston rod (4). LIFT WITH A CRANE. STRIKE WITH
If it is too heavy to move, move it by striking A PLASTIC MALLET.
the flanged part of the rod cover (16) with a PULL STRAIGHT.
plastic mallet. Pull it straight with the rod NOTE:
cover (16) lifted with a crane or the like. DO NOT
DAMAGE
PISTON ROD
Take care so rod bushing (17) and the SURFACE.
lip of pistons (22), (23), (24) may not be
damaged by screw the piston rod (4).
16 17 22 23 24 4
6) Separate O ring (8) and backup ring (9) from Fig. 1-14 Removing rod cover (16)
piston (7).
After removing two backup rings (9), remove 9 10-1 10-3 10-2
O ring (8). The backup ring (9). comes off
easily if the slit on its circumference is 7
extended. O ring (8) can be taken off by
stretching it with an earpick-like spatula.
Fig. 1-15 Removing backup ring (9) and O ring (8)

1.3.3 DISASSEMBLING PISTON ASSY
HAMMER
1) Remove piston seal (10).
Cut the slipper seal (10-1) by tapping it

SCREWDRIVER (OR CHISEL)
with a screwdriver or a chisel. Take
care not to strike it too hard, otherwise
the groove may be damaged.
10-1
USE CARE NOT 10-2

7 TO DAMAGE
THE GROOVE.
Fig. 1-16 Removing piston seal (10)
32-18
1.3.4 DISASSEMBLING ROD COVER ASSY SPATULA

1) Remove O ring (21) and back-up ring (20).
Remove back-up ring (20) and O ring (21) in 21
that order. Back-up ring (20) come off if the
slit on the circumference is widened. Remove
20
O ring (21) by pulling and stretching them (REMOVE THESE
with an spatula like earpick. FIRST.)
16
Fig. 1-17 Removing the outer circumferential

2) Remove buffer seal (22) and rod packing (23). seal of rod cover (16)
Each seal is fixed in the groove on the bore
and removing in flawless is impossible. GIMLET
Stab each seal with a gimlet and pull it out of
the groove.
16 23
Take care in this operation not to
damage the grooves. 22
Fig. 1-18 Removing the inner circumferential

seal of rod cover (16)
3) Remove dust seal (24). When taking out dust
16
seal (24), fix rod cover (16) in a vise. HAMMER
SCREWDRIVER
24
WOOD PIECE
WOOD PIECE
VISE
Fig. 1-19 Removing dust seal (24)

4) Remove circlip (18) and rod bushing (17).
After taking out snap ring (18) in the same 18 17
way as mentioned above, remove rod bushing
16
(17). Rod bushing (17) is impossible to remove
as it is press fitted in rod cover (16). Machine
the bushing thin on a lathe, insert a steel SPATULA
spatula hard into the gap at the chamfered
edge of the remaining bushing and pry it up. WOOD PIECE WOOD PIECE
VISE
Center the work on a lathe sufficiently
so the bushing may be shave on a lathe
as thin as possible.
Fig. 1-20 Removing rod bushing (17)
32-19
1.3.5 REMOVING PIN BUSHING PUSH WITH A PRESS.

Cylinder tube (1) is pressed hard in the pin
bushing (2) of piston rod (4). When disassembling METAL PIECE A
them, use the jig A and push the rod with a press.
2 BASE
Fig. 1-21 Drawing out pin bushing (2)
1.4 CLEANING
1) When the cylinder has been disassembled,
wash all parts with a suitable commercial
detergent.
Do not use volatile agents (gasoline

and thinner) as they deteriorate
rubber.
2) Do not reuse the once-removed oil seals, O

rings and back-up rings even though they
have found reusable on inspection.
3) After cleaning, dry all parts with jet air and
place them on a clean work bench so that
they may not be damaged.
1.5 ASSEMBLY
Start assembly with the subassemblies listed
below:
○ Cylinder tube assy
○ Piston assy
○ Rod cover assy
PUSH WITH A PRESS

1.5.1 CYLINDER TUBE ASSY AND PISTON ROD 4
ASSY
Press fit pin bushing (2) into cylinder tube (1) and 2
piston rod (4), using a press.
OIL HOLE LOCATION
Fig. 1-22 Pressing fit pin bushing (2)
32-20
1.5.2 ASSEMBLING PISTON ASSY PRESS HERE

1) Coat O ring (8) with hydraulic oil (or vaseline METAL
if not available) and set it in place, using the
inserting jig.
2) A special jig shown in Fig. 1-23 is required to
fit slipper seal (10-1). Push slipper seal (10-1)
HOLDING
in by means of a press or something and JIG “G”
using the pressing jig that is shown in the
figure.
The slipper seal softens if heated, but

JIG
do not heat it above 100℃ (212.0° F) in
any circumstance.
7
3) After fitting, hold it down as shown
in 8
10－1
Fig. 1-24 for a few minutes, using the jig G.
z After fitting the slipper seal (10-1), Fig. 1-23 Installing slipper seal (10-1)
wind vinyl tape a few turns around
HOLDING JIG “G”
the slipper seal and do not take it off
for piston seal.
immediately before piston (7) is set
in cylinder tube (1).
z Attach wear ring (11) and dust ring
(12) when inserting piston (7) into HANDLE
cylinder tube (1).
Fig. 1-24 Installing slipper seal (10-1)
PRESS HERE. (STRAIGHT DOWN)

METAL
1.5.3 ASSEMBLING CYLINDER HEAD ASSY 17 (MAKE O.D.SMALLER
1) Press rod bushing (17) into rod cover (16) THAN ROD
using a metal ring. Thereafter fix circlip (18) BUSHING O. D.)
into the groove. Before pressing in the GROOVE FOR
FIXING CIRCLIP
bushing, coat the inner face of rod cover (16) (18)
with hydraulic oil.
PRESS BUSHING TILL
BUSHING COMES IN
Circlip (18) can be pushed in by hand, CONTACT WITH
but it can not be set in place unless rod 16 THIS FACE.
bushing (17) is press fitted full to the
stop surface. Fig. 1-25 Pressing in rod bushing (17)
PRESS HERE. (STRAIGHT DOWN)
2) Apply grease to dust seal (24) or the hole of
rod cover (16), and fit dust seal (24) to the
PRESSING JIG “E”
bottom of the hole. At this moment, press the PRESS METAL
metal ring of dust seal (24) with a jig E. RING.
24
RUBBER
CLIP
METAL RING
Fig. 1-26 Attaching dust seal (24)
32-21
3) Fit buffer seal (22) and rod packing (23) in PUT IN GROOVE FROM THIS SIDE.
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.
Fig. 1-27 Inserting a seal into the inner

circumference of rod cover.
z Rod packing (23) is harder than PUSH BAR

(WOOD OR PLASTIC)
other packing and it would be
difficult to deform them in a heart 19
shape. In such a case, put a rod 20
packing in the groove obliquely by
16
hand as deep as possible and push in
the last part with a push bar till it is
set with a click.
z Buffer seal (22) and rod packing (23)
have directions in which they should
be fixed. Therefore check their fitting
directions.
z If rod packing (23) is set upside
down, the lip may be damaged.
Check that it is positioned correctly. 22
z Attach back-up ring (20) on the open 23
air side of O ring (19). (See Fig. 1-
Open air side
28.) 24
Fig. 1-28 How to fit rod packing (23)
1.5.4 INSERTING ROD COVER ASSY TO

PISTON ROD
Fix the piston rod assy into the rod cover (16) as
follows:
1) Fix the piston rod assy into the work bench.
32-22
2) Apply hydraulic oil or grease to the O. D. of LIFT WITH A CRANE

piston rod (4), the bore of packings (22,23,24) 16
ROD COVER ASSY
and rod bushing (17). Hold the rod cover assy PRESS IN.
carefully and slide it over piston rod (4),
taking care not to damage the lip of dust seal
(24). It may be difficult in some cases to slide
the rod cover assy over the piston rod (4) TURN
because of the resistance of rod packing (23) CLOCKWISE.
and buffer seal (22). In such a case, force it
in, using a suitable plate and piston nut (13),
(See Fig. 1-29.) In this operation, hold the rod
cover assy horizontally with a crane.
3) After lifting rod cover (16) to the level where 13 AUXILIARY PLATE 17 22 23 24 4
FOR PUSHING
it is pressed by piston nut (13), remove piston
nut (13) and the plate. Press in the rod cover Fig. 1-29 Inserting rod cover
assy about 300mm (12in) further. In some
cases, the rod cover assy must be pressed into
piston rod (4) by striking the flanged part rod
cover (16) with a wooden or plastic mallet.
During the above operation, use care so

not to allow the rod cover assy to turn
with respect to piston rod (4).
1.5.5 ASSEMBLING PISTON ASSY TO PISTON

ROD
1) Install the piston assy to piston rod (4).
2) Apply hydraulic oil or grease to the inside of

CHECK THAT BACK-UP RING
the piston assembly and to the piston IS NOT OUT THE GROOVE. 4
mounting part of piston rod (4). Then install
the piston assembly as shown in Fig. 1-30,
exercising care not to damage O ring (8) and
the seal.
Always tighten the piston to a specified
torque (Refer to II-1-16.)
TURN
CLOCKWISE. V-BLOCK
8
HOLD THE POINT AS CLOSE
PISTON ASSY
TO THE PISTON AS POSSIBLE.
Fig. 1-30 Tightening piston assy
32-23
3) Turn in piston nut (13) till it gets tight.

Always tighten the piston nut (13) to a
specified torque (Refer to II-1-16.)
HOOK WRENCH
Always correct the threads of the 13
tapped hole in piston nut (13) before
fixing piston nut, using a tap. 1.0～1.5m TURN CLOCKWISE.
(3′3″～4′11
4) Screw in and set setscrew (14). Fig. 1-31 Tightening piston nut (13)
:4mm
After tightening the setscrew to a specified 14 ANTI-LOOSENING CAULKING
4
torque of 1.5kgfym (11 lbfyft), caulk the two
places of the screw threads of the piston nut
side to secure the setscrew.
5) Attach two wear rings (11) and dust rings

(12). Take off vinyl tape wound around the
perimeter of piston (7), apply high-quality
V-BLOCK
grease (or vaseline) to wear ring (11) and
13
dust ring (12) and attach the wear rings in a Fig. 1-32 Attaching setscrew (14)
manner that they may be coiled around the
groove. Set the wear rings about 90 degrees 14 11 12
4
apart with each other so that the 45 degree
slits may not point to the same direction.
13 V-BLOCK
Fig. 1-33 Attaching wear ring (11)
1.5.6 OVERALL ASSEMBLY

1) Place a V-block on a rigid work bench (A
wooden V-block is preferable.). Place the
cylinder tube assy (1) on it and fix the assy by
passing a bar through the clevis pin hole to
lock the assy.
2) Insert the piston rod assy into the cylinder
LIFT
tube assy, while lifting and moving the piston
rod assy with a crane. In this operation,
apply hydraulic oil (or vaseline) to the inner
surface of the tube mouth and the
circumference of the piston. Align the center STRAIGHT FIX IT WITH A BAR
of the piston rod assy with the center of the (A WOODEN ONE
cylinder tube assy and put it in straight PREFERABLE)
OR IN A VISE.
forward. When inserting, make sure that
wear ring (11) and dust ring (12) on the Fig. 1-34 Inserting piston rod assy
perimeter of the piston is not out on the
groove.
32-24
3) Turn up socket bolt (25). Match the bolt holes 25

of the rod cover flange to the tapped holes in
the cylinder assy, and screw in socket bolts PLACE RAG.
(25) one by one. Tighten the bolts to a
specified torque, taking care so the bolts may
not be tightened unevenly.
:12mm,
Tightening torque :
21～22kgfym (150～160 lbfyft)
Take care so as not to damage the rod ALLEN WRENCH

surface by accidentally slip a wrench. TURN
Covering the rod surface with rag or CLOCKWISE.
something is recommended to prevent Fig. 1-35 Tightening socket bolts (25)
damage to it.
For the tightening torques, refer to
“(Ⅱ-1-16)”. DIRECTIONAL VALVE
PUMP
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 H R
directional valve and make certain that it
operates without fault.
z Do not raise the hydraulic pressure HYDRAULIC CYLINDER

above the maximum pressure of Fig. 1-36 External leak test
380kg/cm2 (5400psi) for the cylinder
of the machine. MEASURE THE
z Grease coated on the O rings and the INTERNAL LEAK.
seals of the cylinder head may ooze
out. Wipe it off and retest the
cylinder in such a case.
(2) Leak test (See Fig. 1-36 and Fig. 1-37.)

1) Apply a test pressure to the retracting and FROM DIRECTIONAL VALVE
extending sides of the cylinder for three Fig. 1-37 Internal leak test
minutes independently, and check that the
CYLINDER ASSY
rod section and the welds have external leaks
and permanent deformation. For an internal
leak test, connect the cylinder with a test
unit .
2) After completing the test, apply a plug to PLUG PLUG

each port and store it (Fig. 1-38). Fig. 1-38 How to store the cylinder
For storage, place the cylinder on

wooden V-blocks and bring the cylinder
to the most retracted condition.
32-25
1.7 MAINTENANCE STANDARDS

1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see
that excessive wear, crack and other faults that
are detrimental to use are not present.
(1) Inspection Item

Table 1-2
Part Name Inspecting Section Inspection Item Remedy
Piston rod 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
5. Bend Measure degree of bend Refer to Table 1-2.
(See Fig. 1-39.)
6. Plated surface Check that:
1) Plating is not worn off 1) Replace or replate
to base metal
2) Rust is not present on 2) Replace or replate
plating.
3) Scratches are not 3) Recondition, replate or
present. replace.
7. Rod Wear of O. D. Recondition, replate or replace.
8. Bushing at mounting Wear of I. D. Replace.
part
Cylinder 1. Weld on bottom Presence of crack Replace.
tube 2. Weld on head Presence of crack Replace.
3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of faults Replace if oil leak is seen.
5. Bushing at mounting Wear on inner surface Replace.
part
Rod cover 1. Bushing 1) Wear on inner surface 1) See para. 1.7.2.
2) Flaw on inner surface 2) Replace if flaw is deeper than
coating.
(2) Repair method

Check all seals and parts to see that they do z Always regrind after replating. The
not show excessive damage and wear. For co- thickness of the plating must be
rrection of faults on the piston rod, observe maximum 0.1mm (0.004in).
the following procedure: z In case plating is removed to the
1) Correct very fine longitudinal scratches with base metal during reconditioning
an oilstone. Replace the piston rod if the with an oilstone, do not fail to
scratch is so deep as may be caught by your replate the surface.
nail.
2) In case of a smooth indention, recondition by
removing the sharp area around the inden-
tion with an oilstone. If the flaw or the in-
dention is excessive, replace or replate the
faulty part.
32-26
1.7.2 LIMIT OF SERVICEABILITY 1.7.3 TIGHTENING TORQUE

Serviceability limits represent the limits of wear
A B C
on the sliding surfaces of the cylinder tube and
the rod that have no such faults as may degrade
the sealing effect.
(1) Clearance between piston rod and rod
bushing Replace the bushing if the clearance
between the piston rod and the rod bushing Fig. 1-40
exceeds 0.25mm (0.00984in). E115SR EV.
(2) Bend of piston rod E135SR EV. Table 1-4 Unit : kgfym (lbfyft)
The allowable bend of the rod is maximum A B C
Cylinder
1mm / 1m (0.04″/3′3″). For measurement, Piston nut Piston Socket bolt
support both ends of the parallel section of 190 100 21～22
the piston rod with V-blocks, set a dial Boom
(1400) (720) (150～160)
indicator in the center between the two V-
block turn the piston rod, and read the 190 100 35～37
Arm
difference between the maximum and (1400) (720) (250～270)
minimum oscillations on the dial indicator.
190 100 21～22
Bucket
(1400) (720) (150～160)
Rod cover
90 50
Dozer 50～70
(510) (360)
(360～510)
1.7.4 VOLUME OF OIL LEAKAGE

The oil leak rates as mentioned in 1.6 (2) of Ins-
pection after Assembly are as shown in Table 1-5.
Center of rod
Table 1-5
Fig. 1-39 Measuring Method
Cylinder Volume of Internal Oil Leakage
Table 1-3 shows an example of measurement.
Boom 4.9cc (0.30cuin) or below / 10min
Arm 4.9cc (0.30cuin) or below / 10min

Table 1-3 Example of Measurement
Bucket 3.6cc (0.22cuin) or below / 10min
Distance Oscillation of the dial
between indicator in the middle Dozer 4.6cc (0.28cuin) or below / 10min
Remedy
V-blocks of the rod.
m (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.
32-27
1.8 TROUBLESHOOTING Table 1-16

Trouble Faulty Part Cause Remedy
1. Oil leakage through 1. Rod packing 1. Foreign matter is 1. Remove foreign matter.
sliding surface of piston included in the bore of
rod oil ring is formed on rod packing
piston rod, and the ring 2. Lips on outer and inner 2. Replace rod packing.
grows up to oil drops, diameter surfaces of rod
and they drip. packing are scored.
3. Other rod packing are 3. Replace rod packing.
faulty.
2. Buffer seal 1. Foreign matter is caught 1. Remove foreign matter.
in the bore of buffer seal.
2. Flaw is present on the 2. Replace buffer seal.
bore of buffer seal.
OIL LEAKS FROM HERE. 3. Other buffer seals are 3. Replace buffer seal.
faulty.
3. Dust seal 1. Foreign matter is include 1. Remove foreign matter.
in the bore of dust seal.
2. Lip on the bore of dust 2. Replace dust seal.
seal is scored.
3. Other dust seals are 3. Replace dust seal.
faulty
4. Piston rod 1. Flaw is present on the 1. Smooth out the sliding
sliding surface of piston surface with an oilstone.
rod. If leakage occurs even if
the sliding surface is
finished below 1.6S, rod
packings may be scored.
Disassemble and inspect
it and replace rod
packings as required.
If leakage will not stop by
that treatment, replace
piston rod.
2. Hard chromium plating 2. Replate.
has peeled off
2. Oil leaks from the 1. O ring 1. O ring is damaged. 1. Replace O ring.
perimeter of cylinder 2. Backup ring 1. Backup ring is damaged. 1. Replace backup ring.
head
OIL LEAKS FROM HERE.

3. Oil leaks from welds. 1. Cylinder 1. Welds of cylinder are 1. Replace cylinder tube.
tube fractured.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is caught 1. Remove foreign matter.
[When the rod is loaded on the sliding surface of
with a static load equal slipper seal
to the maximum 2. Flaw is present on the 2. Replace slipper seal.
working pre-ssure sliding surface of slipper
multiplied by the area seal.
of the cylinder bore, the 3. Other back rings are 3. Replace back ring.
maximum movement of faulty.
the piston is more than 2. Wear ring 1. Sliding surface of wear 1. Replace wear ring.
0.5mm (0.02″) in ten rings is scored.
minutes.] 3. O ring 1. O ring is scored. 2. Replace O ring.
32-28
1.9 TOOLS AND JIGS LIST

The tool and jig list provides the materials and 2) The pin section of pin wrenches (symbol “PS”)
the dimensions of tools and jigs so that they may and pin hook wrenches (symbol “PF”) is
be utilized in manufacturing in a service shop. loaded with large shearing force. Therefore,
Follow the directions given below in selecting, take care when selecting pin material and
manufacturing and using the tools and jigs. welding the pin to the body. It is
recommended to use the shank section of
1) For the rod cover, piston nut and others that disused drills (Fig. 1-41).
require large tightening torques, use eye
wrenches (symbol “FS”) as much as possible.
The tools and the jigs are so designed
dimensionally that they can withstand the
maximum tightening torques even if material
USE THIS
SS400 (JIS) is used. However, the hook of the
PORTION.
tool (symbol “PS”) may be distorted if struck
with a hammer. If such occurs, apply
reinforcement weld and finish it by grinding.
Fig. 1-41
1.9.1 ALLEN WRENCH〔AW〕
(FOR CYLINDER HEAD SOCKET BOLT)
B
A MATERIAL : SNCM 6 OR SCM 3
SURFACE TREATMENT :
C
Fig. 1-42
Table 1-7 Unit : mm (inch)
Cylinder Used A B C Socket Bolt
Arm 140 (5.51″) 56 (2.20″) 14 (0.551″) M16
Boom, Bucket 125 (4.92″) 45 (1.77″) 12 (0.476″) M14
1.9.2 DUST SEAL PRESSING JIG [SYMBOL E]
D MATERIAL : SS400 (JIS)

E SURFACE TREATMENT : PARKERIZING
～
∅A
∅B
15° ∅C
Fig. 1-43
MODEL CYLINDER A B C D E
Bucket 66 (2.6″) 78 (3.1″) 8 (0.315″)
Boom 30～50 66 (2.6″) 78 (3.1″) 20～30 8 (0.315″)
E115SR
Arm (1.2″～2.0″) 76 (3.0″) 88 (3.5″) (0.8″～1.2″) 8 (0.315″)
Dozer 66 (2.6″) 78 (3.1″) 12.5 (0.49″)
Bucket 66 (2.6″) 78 (3.1″) 8 (0.315″)
E135SR LC Boom 30～50 71 (2.8″) 83 (3.3″) 20～30 8 (0.315″)
E135SR L Arm (1.2″～2.0″) 81 (3.2″) 93 (3.7″) (0.8″～1.2″) 8 (0.315″)
Dozer 66 (2.6″) 78 (3.1″) 12.5 (0.49″)
32-29
1.9.3 EYE WRENCH (SYMBOL FS)

MATERIAL: SS400 (JIS), FINISH BY GRINDING
AFTER GAS CUTTING
DRILL
MORE THAN R25 (0.984″)
STRAIGHT IN THIS AREA
Fig. 1-44

MODEL CYLINDER LOCATION A B C D E
Bucket 75 (2.95″) 65 (2.56″)
For piston
E115SR Boom 75 (2.95″) 10 (0.39″) 4 (0.16″) 65 (2.56″) 12 (0.47″)
nut
Arm 85 (3.35″) 70 (2.76″)
Bucket 75 (2.95″) 65 (2.56″)
E135SER For piston
Boom 80 (3.15″) 10 (0.39″) 4 (0.16″) 70 (2.76″) 12 (0.47″)
nut
Arm 90 (3.54″) 80 (3.15″)
80 (3.15″)
E115SR Piston nut 4.5 70 (2.76″) 12 (0.47″)
Dozer 140 10 (0.39″)
E135SR Rod nut (0.18″) 80 (3.15″) 16 (0.63″)
(5.51″)
1.9.4 WRENCH (SYMBOL PS) MATERIAL: SS400 (JIS); FINISH BY GRINDING

(For piston) AFTER GAS CUTTING
2d DRILL
PIN (S45C)
SECTION BB
Fig. 1-45

MODEL CYLINDER A R r d
Bucket 70 (2.76″) 47 (1.85″) 25 (1.0″)
E115SR Boom 70 (2.76″) 47 (1.85″) 25 (1.0″) 10 (0.39″)
Arm 85 (3.35″) 55 (2.17″) 30 (1.2″)
Bucket 70 (2.76″) 47 (1.85″) 25 (1.0″)
E135SR
Boom 75 (2.95″) 50 (1.97″) 28 (1.1″) 10 (0.39″)
Arm 90 (3.54″) 60 (2.36″) 34 (1.4″)
E115SR
Dozer 75 (2.95″) 50 (1.97″) 28 (1.1″) 10 (0.39″)
E135SR
32-30
1.9.3 BUSHING EXTRACTION JIG (SYMBOL A)

(For clevis)
MATERIAL: SS400 (JIS)
Fig. 1-46

Machine models E115SR E135SR (LC)
Cylinder Used d D D O ring
Bucket 60 (2.36″) 69 (2.72″) 60 (2.36″) 69 (2.72″)
Arm, Boom, (bottom side) 70 (2.76″) 78 (3.07″) 70 (2.76″) 78 (3.07″)
Boom (rod side) 75 (2.95″) 83 (3.27″) 80 (3.15″) 88 (3.46″)
Dozer 60 (2.36″) 69 (2.72″) 60 (2.36″) 69 (2.72″)
1.9.4 PISTON (SLIPPER) SEAL FIXING JIG

(SYMBOL C)
MATERIAL: SS400 (JIS)
Fig. 1-47
Machine
E115SR E135SR (LC)
Models
Cylinder Used
d D1 D2 Q L d D1 D2 Q L
94.5 96 75 21.5 65 94.5 96 75 21.5 65
Bucket
(3.72″) (3.78″) (2.95″) (0.846″) (2.56″) (3.72″) (3.78″) (2.95″) (0.846″) (2.56″)
94.5 96 75 21.5 65 99.5 101 80 23.5 65
Boom
(3.72″) (3.78″) (2.95″) (0.846″) (2.56″) (3.92″) (3.98″) (3.15″) (0.925″) (2.56″)
109.5 111 90 22.5 65 114.5 116 95 22.5 65
Arm
(4.31″) (4.37″) (3.54″) (0.886″) (2.56″) (4.51″) (4.57″) (3.74″) (0.886″) (2.56″)
32-31
1.9.7 SLIPPER SEAL HOLDING-DOWN JIG MATERIAL: NYLON

(SYMBOL D)
O RING
Fig. 1-48
Machine models E115SR E135SR L (LC)
Cylinder Used D O ring D O ring
Bucket 95 (3.75″) 1B P95 95 (3.74″) 1B P95
Boom 95 (3.75″) 1B P95 100 (3.94″) 1B P100
Arm 110 (4.33″) 1B P110 115 (4.53″) 1B P115
Dozer 115 (4.53″) 1B P115 115 (4.53″) 1B P115
1.9.8 SLIPPER SEAL HOLDING-DOWN JIG

(SYMBOL G)
HARD CHROMIUM PLATING
MATERIAL: SS400
Weld it before
drilling
Fig. 1-49
E115SR E135SR L (LC)

Cylinder
d D L d D L
Bucket 95 (3.74″) 110 (4.33″) 40 (1.57″) 95 (3.74″) 110 (4.33″) 40 (1.57″)
Boom 95 (3.74″) 110 (4.33″) 40 (1.57″) 100 (3.94″) 115 (4.53″) 40 (1.57″)
Arm 110 (4.33″) 125 (4.92″) 40 (1.57″) 115 (4.53″) 130 (5.12″) 40 (1.57″)
Dozer 110 (4.33″) 125 (4.92″) 40 (1.57″) 110 (4.33″) 125 (4.92″) 40 (1.57″)
32-32
E115SR
E135SR
SECTION 33 UPPER STRUCTURE
TABLE OF CONTENTS
Part I: Removing and installing assembly .................................................................. 33-1

1. Cab ....................................................................................................................... 33-1
1.1 Removal ........................................................................................................................................ 33-1
1.2 Installation ..................................................................................................................................... 33-1
2. Operator seat ........................................................................................................ 33-2

2.1 Removal ........................................................................................................................................ 33-2
2.2 Installation ..................................................................................................................................... 33-2
3. Battery .................................................................................................................. 33-3

3.1 Remove ......................................................................................................................................... 33-3
3.2 Install ............................................................................................................................................. 33-3
4. Instrument panel ................................................................................................... 33-4

4.1 Preparation for removal ................................................................................................................. 33-4
4.2 Removal ........................................................................................................................................ 33-4
4.3 Installation ..................................................................................................................................... 33-4
5. Counterweight ...................................................................................................... 33-5

5.1 Prepatation for removal ................................................................................................................. 33-5
5.2 Removal ........................................................................................................................................ 33-5
5.3 Installation ..................................................................................................................................... 33-5
6. Guard ................................................................................................................... 33-6

6.1 Preparation for removal ................................................................................................................. 33-6
6.2 Remove guard ............................................................................................................................... 33-6
6.3 Installation ..................................................................................................................................... 33-9
7. Under cover ........................................................................................................ 33-10

7.1 Removal ...................................................................................................................................... 33-10
7.2 Installation ................................................................................................................................... 33-10
8. Air cleaner .......................................................................................................... 33-11

8.1 Preparation for removal ............................................................................................................... 33-11
8.2 Removval .................................................................................................................................... 33-11
8.3 Installation ................................................................................................................................... 33-11
INDEX
9. Muffler ................................................................................................................ 33-12

9.1 Preparation for removal ............................................................................................................... 33-12
9.2 Removal ...................................................................................................................................... 33-12
9.3 Installation ................................................................................................................................... 33-12
10. Fuel tank ........................................................................................................... 33-13

10.1 Preparation for removal ............................................................................................................. 33-13
10.2 Removal .................................................................................................................................... 33-13
10.3 Installation ................................................................................................................................. 33-13
11. Hydraulic tank .................................................................................................... 33-14

11.1 Peparation for removal ............................................................................................................... 33-14
11.2 Removal .................................................................................................................................... 33-15
11.3 Installation ................................................................................................................................. 33-16
12. Pump (main) ..................................................................................................... 33-17

12.2 Removal .................................................................................................................................... 33-17
12.3 Installation ................................................................................................................................. 33-19
13. Radiator and oil cooler ...................................................................................... 33-21

13.2 Removal .................................................................................................................................... 33-22
13.3 Installation ................................................................................................................................. 33-24
14. Engine .............................................................................................................. 33-25

14.1 Preparation for removing ........................................................................................................... 33-25
14.2 Removal .................................................................................................................................... 33-27
14.3 Installation ................................................................................................................................. 33-27
15. Multi control valve (opt) ..................................................................................... 33-28

15.2 Removal .................................................................................................................................... 33-28
15.3 Installation ................................................................................................................................. 33-28
15.4 Multi control lever reassembling ................................................................................................ 33-29
16. Control valve ..................................................................................................... 33-30

16.2 Removal .................................................................................................................................... 33-30
16.3 Installation ................................................................................................................................. 33-31
17. Pilot valve (for att) .............................................................................................. 33-32

17.2 Removal .................................................................................................................................... 33-32
17.3 Installation ................................................................................................................................. 33-32
18. Pilot valve (for travel) ........................................................................................ 33-33

18.2 Removal .................................................................................................................................... 33-33
18.3 Installation ................................................................................................................................. 33-33
19. Swing unit ......................................................................................................... 33-34

19.2 Removal .................................................................................................................................... 33-34
19.3 Preparation for install ................................................................................................................. 33-35
19.4 Installation ................................................................................................................................. 33-35
19.5 Preparation for drive .................................................................................................................. 33-35
INDEX
20. Swivel joint ........................................................................................................ 33-36

20.1 Preparation for remove .............................................................................................................. 33-36
20.2 Removal .................................................................................................................................... 33-36
20.3 Installation ................................................................................................................................. 33-38
21. Upper frame ...................................................................................................... 33-39

21.2 Removal .................................................................................................................................... 33-39
21.3 Installation ................................................................................................................................. 33-40
Part II: Disassembling and assembling equipment .................................................. 33-41

1. Hydraulic pump - regulator ................................................................................. 33-41
1.1 Hydraulic pump ........................................................................................................................... 33-41
1.2 Regulator ..................................................................................................................................... 33-53
1.3 PTO gear casing .......................................................................................................................... 33-58
2. Control valve ....................................................................................................... 33-61

2.1 General precautions .................................................................................................................... 33-61
2.2 Tools ............................................................................................................................................ 33-61
2.3 Disassembly ................................................................................................................................ 33-61
2.4 Inspection after disassembly ....................................................................................................... 33-75
2.5 Reassembly ................................................................................................................................. 33-75
2.7 Troubleshooting ........................................................................................................................... 33-81
3. Pilot valve (for att) ............................................................................................... 33-84

3.1 Installation view ........................................................................................................................... 33-84
3.2 Disassembly ................................................................................................................................. 33-85
3.3 Cleaning parts ............................................................................................................................... 33-88
3.4 Assembly ...................................................................................................................................... 33-88
3.5 Maintenance standards ................................................................................................................. 33-91
3.6 Troubleshooting ............................................................................................................................. 33-91
3.7 Jig ................................................................................................................................................. 33-92
4. Pilot valve (for travel) .......................................................................................... 33-93

4.1 Construction .................................................................................................................................. 33-93
5. Swing motor unit ................................................................................................. 33-99

5.1 Construction .................................................................................................................................. 33-99
5.2 Disassembly and assembly of swing motor ................................................................................. 33-102
5.3 Disassembly and assembly of swing reduction unit .................................................................... 33-113
6. Swivel joint ....................................................................................................... 33-130

6.1 Construction view ........................................................................................................................ 33-130
6.2 Disassembly and assembly ........................................................................................................ 33-131
Part I: REMOVING AND INSTALLING ASSEMBLY

24
1. CAB
1.1 REMOVAL
(1) Remove floor mat
(2) Remove the following parts for air-con cover. 14

1) 5 bolts (1-9) for catch (24)
2) Cover (1) 1
GRILLE
3) Grille under front seat Rotate 90 degrees to remove.
4) Duct from duct (14) to under right duct on GROMMET BOLT(1-9)

COVER
cab inside.
: Cross recessed screw driver
: 13mm FLOOR MAT BRACKET
CATCH
(3) Remove the following parts for harness and

Fig. 1-1 Detaching and attaching air conditioner cover
connector.
FOR ROOM LAMP CURL CODE
1) Antenna cable from back side of tuner
2) Harness for room lamp GROMMET
FOR WINDOW
3) Harness on cab front right side WASHER
4) Harness for gauge cluster DOOR SW.
ANTENNA
(4) Remove window washer tube
(5) Remove the following parts for cab mounting GROMMET

bolt To instrument panel of main strucure
1) 5 capscrews (A1) M10 HAND RAIL

2) 4 nuts M16 TUBE GROMMET
3) Sems bolt (B2) M10, 2 pcs, on lower section of A1 B2
Remove washer
M10×5 pcs. TUNER
hand rail tube at floor.
: 17mm, 24mm TUBE
(6) Slinging cab

1) Remove 2 plastic plugs on front side of cab NUT
M16×4 pcs.
ceiling, and attach eye bolts M10, and hook ∅30 (1.18˝)
wire 3 places, 2 bolts and lifting eye, on rear HOLE FOR HAND
left side. Fig. 1-2 Removing and attaching harness
2) Then lift up slowly avoiding interference with connector and cab mounting bolts
surroundings.
Wire with hook ;
Length 1.5m (4ft 11in) × Dia. 8mm (0.315 in) M10 EYE BOLT
× 3pcs.
Weight of cab ; Approx. 200kg (440 lbs)
1.2 INSTALLATION
Mount it in reverse procedure of Dismounting
A1
according to the Tightening Torque Table.
Tightening torque
Tightening position Tool kgfym (lbfyft)
Lower section of hand rail
Sems bolt (B2) 17 4.7 (34)
Nut M16 24 19.5 (140)
Fig. 1-3 Slinging cab
Capscrew (A1) 17 4.7 (34)
33-1
2. OPERATOR SEAT
2.1 REMOVAL
(1) Remove seat. (Include upper slide). B1
1) Remove 4 sems bolts (A17) M6.
2) Remove bracket (A8).
3) Remove 4 sems bolts (A16) M8 of bracket (A5). A17
4) Remove seat M6×16
[Approx.15kg (33 lbs) with bracket] A8 M8×20
A7
: 8mm, 13mm
A11
M8×20
A16
(2) Remove slide on lower side of seat.
A17
1) Remove 4 sems boltss (A13) M8.
2) Remove support (A4). A14
3) Remove 4 capscrews (A15) M8.
4) Remove rail (A3). A5
: 6mm A4
A13
(3) Remove seat stand M8×25
1) Remove 4 capscrews (A9) M10.
2) Remove seat stand (A1).
A20-3
: 8mm A20-2
Weight of seat stand ; 17kg (37 lbs) A20-6
A3 M8×16
A15
2.2 INSTALLATION
A20-4 A11
Install it in reverse procedure of removing
according to the tightening torque table. M8×30
A20 A18
A20-5
Tightening torque A13
Tightening position Tool A14
kgfym (lbfyft) M8×25 A19
Capscrew (A7) 6 2.4 (17) A15
M8×16 A2
Capscrew (A9) 8 4.7 (34) M10×25 A6
A9 A1
Sems bolt (A13) 13 2.4 (17) A12 M8×30
Sems bolt (A16) 13 2.4 (17) A10 A18
Sems bolt (A17) 8 0.97 (7) A19
Sems bolt (A18) 13 2.4 (17)
A2
Reference : Movement on rail : 90mm (3.54in)
Forward : 30mm (1.18in)
Backward : 60mm (2.36in)
Floor plate
Fig. 2-1 Dismounting and mounting seat
33-2
3. BATTERY
RIGHT FRONT COVER
3.1 REMOVE
(1) Open right front cover.
1) Open it with engine key.
2) Open cover.
3) Fix it with stay.
Fig. 3-1
(2) Remove battery cable
1) Cable (between ground and battery _ )
(Always remove _ terminal first and install it STAY
at last. )
2) Cable (between battery + and _ )
3) Cable (between battery + and battery relay) BATTERY RELAY
: 13mm
Follow the battery removal order.

Start removing battery from grounding
side, and finish attaching to grounding
side. If this order is missed, short-
circuits may occur.
1) 2) 3)
Fig. 3-2 Grounding cable for main body
(3) Remove battery (B1)
1) Remove 2 attaching bolts (A2) M10.
: 17mm
2) Remove cover (A1).
3) Remove battery (B1).
3.2 INSTALL
A2
(1) Install counterweight in the reverse
procedure of removing.
Battery attaching bolt A3
: 17mm,
Tightening torque : 1.1kgfym (8.0 lbfyft) A1 B1
(2) Installing grounding cable

Install grounding cable last. Especially care
must be taken that the grounding face is free
from painting, rust, etc.
: 13mm
Fig. 3-3 Removing battery
33-3
4. INSTRUMENT PANEL
4.1 PREPARATION FOR REMOVAL

Remove terminal (-) from battery.
4.2 REMOVAL 12 12
(1) Remove RH, LH instrument panel
1) Remove 8 sems-bolts (12) M5.
: Cross recessed screw driver
12
12
2) Lift instrument panel
3) Remove two connectors and antenna cable on

rear side of left instrument panel
➀ 8P for air-con panel
➁ 9P for tuner.
Fig. 4-1 Around of instrument panel
4) Remove four connectors on rear side of right
panel LH instrument panel RH instrument panel
➀ 6P for key switch CAP
12
➁ 3P for accel dial 12 M5 X 16
➂ 2P & 8P for switch panel 12
12
12
(2) Remove control box

1) Remove four (4) sems-bolts (19) M8 on right and
left sides.
2) Separate control box from support.
: 13 mm ANTENNA CABLE
TUNER
Weight: Left control box 8.5 kg (19 lbs) and right
control box 7 kg (15 lbs) including pilot Fig. 4-2 Removing instrument panel
valve.
Remote hose referring to Item 1-30. PILOT VALVE
PILOT
4.3 INSTALLATION VALVE
19 M8 X 25
Install it in reverse procedure of removing according
20
to the tightening torque table. M6 X 16
Tightening Tightening torque
Tool
position kgf·m (lbf·ft) SUPPORT
Sems bolt (19) 13 2.4 (17)
cross recessed 0.27 (2.0)
Sems bolt (12)
screw driver SEAT STAND
Fig. 4-3 Removing control box
33-4
5. COUNTERWEIGHT
BONNET
(1) Removing bonnet assy.
Remove bonnet on engine. (See Fig. 6-6.)
3
(2) Remove cover (3), (4) (See GUARD Fig. 6-7.)
(3) Remove mirror stay (2).
(4) Preparing slinging jig

Remove plug (B3) and attach two eye bolts
4
M36 to the counterweight. For an additional Fig. 5-1 Lifting up counter weight
weight, use two eye bolts M24. 4 10
678
5.2 REMOVAL 9
(1) Lifting up counter weight temporarily B3
5
Hook wire rope to slinging jig, and lift it and A1 2 C4
stretch wire rope to the degree where it is B4
providing no slack temporarily. C5
Weight of counterweight ; C4
B1
E115SSR ; Approx. 2,340kg (5,160 lbs) B2
E135SSR ; Approx. 3,490kg (7,695 lbs) C1
Wire more than ∅10 (0.394″) ; B3
1.5m (4ft 11in)×2 pcs. B4
(2) Removing counterweight

1) Remove 4 capscrews (B1) C3
C2
2) Remove shim (B3), (B4).
3) Remove counterweight (A1).
COUNTERWEIGHT
(ADD-ON)
(3) Removing counterweight (Add-on)
1) Attach two eye bolts M20 to the add-on B2
counterweight and lift it up temporarily. B1
Weight of counterweight (Add-on); Fig. 5-2 Removing counterweight
E115SR, E135SR ; Approx. 600kg (4340 lbs)
2) Remove 3 capscrews (C2) M20 × 135 and (4) Apply Loctite #262 on capscrews (B1), and
Add-on counterweight (C1). tighten them with washers (B2).
: 30mm
Capscrew Tool Tightening
torque
(B1) (mm) kgfym (lbfyft)
5.3 INSTALLATION
(1) Install counterweight in the reverse SK115SR-1ES M24×120 36 105 (760)
procedure of removing. SK135SR-1ES M27×155 41 130 (940)
(2) Install shim (B3), (B4) as it was. (5) Remove slinging tools, and attach plugs (B4).
(6) Mounting Add-on counterweight
(3) Slinging counterweight 1) Apply Loctite #262 on capscrews (C2) and
Check that the attaching bolts can be tighten them with washers (C3).
screwed in by hand. : 30mm
Tightening torque : 57kgfym (410 lbfyft)
2) Remove eye bolt, and attach plugs (C4).
33－5
6. GUARD
11 1
6.1 PREPARATION FOR REMOVAL 6 2
(1) Remove guard in the following procedure.
For removing equipment 3
Items (1) to (5),(10) and (24).
For dismounting engine
Items (3) to (5) and (15).
(2) All the locked equipment, open them using

starter key.
4
10 24
Fig. 6-1 Guard assy
6.2 REMOVE GUARD
1
(1) Remove cover assy (1)
1) Open cover assy (1) and lift it up.
2) Remove two nuts (56)M12.
3) Remove cover assy (1).
: 19mm
Weight : 15kg (33 lbs)
56
Fig. 6-2 Removing cover assy (1)
(2) Remove panel assy (2)
1) Remove two sems bolts (41)M12×25. 41
2) Remove two nuts (56).
3) Remove panel assy (2).
: 19mm
56
Fig. 6-3 Removing panel assy (2)

(3) Remove cover assy (6) 6 42
1) Remove two capscrews (43)M12×45.
2) Remove three sems bolts (42)M12×30.
3) Remove a sems bolt (41)M12×25. 41
4) Remove cover assy (6).
: 19mm
Weight : 6.5kg (14 lbs)
42
43
Fig. 6-4 Removing cover assy (6)
33-6
(4) Remove bonnet assy (5)

1) Remove washer (63) and gas spring (37). 5
2) Remove four sems bolts (41) M12×30.
3) Lift up bonnet assy (5) with nylon sling.
: 19mm
41
63
37
63
Fig. 6-5 Removing bonnet assy (5)
(5) Remove guard (3)
1) Remove four capscrews (82) M10×25. 42 82
2) Remove guard (3).
: 17mm
(6) Remove guard assy (4) 3

2) Remove guard assy (4).
: 19mm
4
Fig. 6-6 Removing guard assy (3),(4)
(7) Remove cover (10)

41
1) Remove three sems bolts (45) M8×20.
24
2) Remove cover (10).
: 13mm
10
45
(8) Remove guard (24)
1) Remove two sems bolts (41) M12×25.
2) Remove guard (24).
: 19mm Fig. 6-7 Removing cover (10) and guard (24)
64
(9) Remove cover (11) 46 11
1) Remove three machine screw (46).
2) Remove cover (11).
Fig. 6-8 Removing cover (11)
33-7
(10) Remove guard (18),(19)

1) Remove six sems bolts (41) M12×25. 18 41
41
2) Remove two sems bolts (42)M12×30.
41
3) Remove guard (18),(19). 85
: 19mm
(11) Remove guard assy (26),(85)

41
1) Remove six sems bolts (41) M12×25.
26
2) Remove guard assy (26),(85).
19
: 19mm 42
Fig. 6-9 Removing guard (18),(19)

and guard assy (26),(85)
(12) Remove guard assy (17)
41
1) Remove six sems bolts (41) M12×25.
2) Remove guard assy (17). 17
: 19mm 41
41
Fig. 6-10 Removing guard assy (17)

(13) Remove bracket assy (16)
2) Remove bracket assy (16).
: 19mm
16
Weight : 8kg (18 lbs) 41
(14) Remove cover assy (73)

1) Remove two capscrews (45) M8×16.
2) Remove cover assy (73). 41
: 13mm 42
Weight : 1.5kg (3.3 lbs)
42 12
(15) Remove bracket assy (12)
1) Remove two sems bolts (42) M12×30. 45
2) Remove bracket assy (12).
73
: 19mm
Fig. 6-11 Removing bracket assy (12),(16)
(16) Remove bracket assy (27) and cover assy (73)
2) Lift up bracket assy (27) with nylon sling.
: 19mm
33-8
(17) Remove bracket assy (15) 42 42

31 62
2) Lift up guard assy (15) together with bracket
(14) with nylon sling.
: 19mm 71
Weight :
Bracket assy (15)10.5kg (23 lbs) 42
Bracket assy (14) 2.0kg (4.4 lbs)
42
14
3) Remove shim (102), (103). 27
42 15 42
42 102
103
Fig. 6-12 Removing bracket assy (15),(27)
6.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
(2) Tightening torque

: 19mm M12 8.1kgfym (59 lbfyft)
33-9
7. UNDER COVER
7.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,9)
1) Remove attaching bolts (8) M12×25.
2) Remove covers.
: 19mm
7
6-2
6
9 8 1 6-1
8
8 5
8
2
4
3 8
8
8
8
Fig. 7-1 Under cover assy
7.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,9)
: 19mm
Tightening torque : 8.1kgfym (59 lbfyft)
33-10
8. AIR CLEANER
8.1 PREPARATION FOR REMOVAL 36
(1) Opening bonnet assy (5)
5
1) Unlock it with starter key.
2) Open bonnet (5) and support it with stay (36).
(2) Opening cover assy (4)

(3) Unplug terminals on indicator lines (1-5)
(See Fig.8-2.)
8.2 REMOVAL 4
(1) Pulling out hose (3) (See Fig.8-3.).
1) Loosen clips (8), (9) on both sides of hose (3). Fig. 8-1 Preparation for removal
2) Pulling out hose (3)
: Flat-blade screw driver
(2) Pulling out hose (2) (See Fig.8-2.). 8

1) Loosen clips (7), (8) on both sides of hose (2).
2 7
2) Pulling out hose (2)
: Flat-blade screw driver
(3) Remove air cleaner assy (1)

1) Remove 4 capscrews (5) M8×14
2) Remove air cleaner assy (1) from guard
1-5
bracket.
: 13mm Fig. 8-2 Pulling out air hose (2)
8.3 INSTALLATION
(1) Installing is the reverse order of removing
with attention paid to the following items:
1) Attach grommet (4) to the guard, before
installing the air cleaner.
2) Provide an insertion allowance of 40mm 8
(1.6in) on both ends of air hoses (2),(3). 9 3
3) Tightening torque
Tightening Torque 5
No. NAME kgfym (lbfyft)
1-5 INDICATOR 0.4 (2.9)
5 CAPSCREW 2.0 (14)
8,9 CLIP 0.3 (2.2) 4
9 1
(2) Spare parts for deteriorated elements
OUTER FILTER ELEMENT (1-2) 1-2
1-5 10
INNER FILTER ELEMENT (10)
O RING (1-5)
Fig. 8-3 Removing air cleaner
33-11
9. MUFFLER
5
9.1 PREPARATION FOR REMOVAL 18
(1) Remove bonnet assy (5). (See Fig.6-5.) 19
3
(2) Remove cover (3).(See Fig.6-6.)
(3) Remove sems bolt (41), (42) then guard (18),

(19). (See Fig.9-2)
9.2 REMOVAL
(1) Remove U bolt (3).
1) Remove four nuts (5) M8.
2) Remove two U bolts (3).
: 13mm Fig. 9-1 Preparation for removal
(2) Remove clamp assy (10) 18 41 SPACE

1) Remove two capscrews (8) M10×35
2) Separate clamp assy (10) from muffler (1).
: 17mm
9.3 INSTALLATION B C
42
Installing is the reverse order of removing with
41 A
attention paid to the following items:
19 PROCEDURE OF
(1) Procedure of fastening U bolt (3) FASTENING U BOLT
1) Tighten four nuts (A) till there is no space
and make sure that the dimension C is even Fig. 9-2 Removing guard (18), (19)
all around.
2) Tighten nuts (A) to specified torque and 5
3
confirm the C dimensions on the right and
left once again. (1)
3) Tighten nuts (B) to specified torque and make
16
sure that U bolts (3) are not inclined.
5
4) Tightening torque 8
Nut A : 0.9kgfym(6.5 lbfyft) 12
Nut B : 1.1kgfym(8.0 lbfyft)
10
2
(2) Tightening torque : (4)
Tightening torque 5
No. NAME kgfym (lbfyft) REMARK
Tightening
5 NUT ; M8 1.1 (8.0) exhaust tube
8 CAPSCREW ; M10 7.2 (52)
APPLY
12 CAPSCREW ; M10 6.6 (48) Loctite #262
16 CLIP 0.3 (2.2)
(3) Deteriorated parts

NAME
MUFFLER (1)
Fig. 9-3 Removing muffler
GASKET (4)
33-12
10. FUEL TANK

From WATER
SEPARATOR
10.1 PREPARATION FOR REMOVAL OUT
(1) Draining fuel. 12
1) Open cap (A3). 12 138
7 11
2) Loosen cock (B8) under the tank. 7
From 13 12
(See Fig.10-3.) E/G FUEL
13
RETURN
10 10
3) Draining fuel 14
6 12
Capacity of tank : 168 (44gal) 13
(2) Open bonnet (5) and guard (4) and remove

covers (9), (10). (Refer to Fig.6-6, 6-7, 6-8 and
18
6-9.) 11
(3) Remove the connector for level sensor (B3). 9
(4) Remove cab assy (See 1.CAB.).
(5) Remove hose (5), (6) Fig. 10-1 Removing fuel hose (5), (6), (7)
1) Loosen clip (12) and pull out hoses (5), (6).
2) Put in plugs that match the hose bore.
(6) Remove water separator (1)

2) Separate water separator (1) from the guard
12
bracket. 1
: 13mm 6
12 15
10.2 REMOVAL
8
(1) Remove the tank, the upper frame and the
bracket connecting plates (B10). Fig. 10-2 Removing water separator (1)
1) Remove two sems bolts (B11) M12×30.
2) Remove plate (B10).
: 19mm B14
B15
A3 B16 B11
1) Remove a capscrew (B14) M12×40. B10
: 19mm
A2 B5
(2) Remove fuel tank assy (A1) B6
B4
1) Remove four capscrews (B1) M16×40.
2) Hook the wire to the lifting eye on the fuel B3
tank assy and remove the fuel tank.
: 24mm
: 200mm (Extension bar) A1
10.3 INSTALLATION A5
removing. A4
Tank attaching bolt M16×40 B1
A7
: 24mm Apply loctite #262 B2
B8 A6
Tightening torque : 22.0kgfym B17,B18
(160 lbfyft) Fig. 10-3 Removing fuel tank
33-13
11. HYDRAULIC TANK

1
(1) Upper structure 45 degrees swung. 2
Swing upper structure to make the removal
of suction hose for pump installed under
hydraulic oil tank easier.
(2) Remove cover assy (1), panel assy (2) and

other guards necessary to remove the
hydraulic oil tank. (Refer to 6. Guards.)
Fig. 11-1 Upper structure 45 degrees swung.

(3) Bleeding internal air of tank Push
Press the rubber cap by your finger tip to
bleed off the inside air.
(ELEMENT)
Keep pressing until the hissing stops.
Fig. 11-2 Bleeding internal air of tank
(4) Removing hydraulic pipe on the upper cover

of tank.
1) Remove two nuts M8 for coupling (13).
2) Stretch and remove the coupling. 11
3) Remove hose (11),(20),(22).

HYDRAULIC
TANK
20 13
22
Fig. 11-3 Removing hydraulic pipe

on the upper cover of tank
(5) Remove cover (A6) and suction strainer (A2).
A6
1) Remove six capscrews (A12) M10×20. A12
2) Remove cover (A6).
: 17mm
3) Remove suction strainer (A2).
A2
Fig. 11-4 Removing cover (A6)

and suction strainer (A2)
33-14
(6) Remove cover (A24)

A12
1) Remove six capscrews (A12) M10×20.
A13
2) Remove cover (A24) and O ring (A23).
3) Remove spring (A26-6). A24
A26-6
4) Remove filter element (A26)
A23
(7) Turn the handle of element assy. (A26-3), and
A26-3
disassemble the removed filter element (A26-1). A23
Disassemble parts : (A26-3), (A26-4), A26-4
A26-4
(A26-1), (A26-2),
(A26-5). A26-1 A26-1 A26
A26-2 A26-2
ELEMENT KIT A26-5
Fig. 11-4A Removing cover (A24) & Return filter

(A26)
(8) Draining hydraulic oil
Place pump in tank and draw up hydraulic
oil.
Capacity of tank : Approx. 94 (25gal)
Care should be taken that pump does

not damage suction strainer.
Fig. 11-5 Draining hydraulic oil

11.2 REMOVAL
(1) Draw out the suction hose (4)
1) Remove two clips (16) on tank side through
under side of swing frame.
2) Pulling out hose (4).
A1
: Flat-blade screwdriver
PILOT
RETURN
(2) Disconnecting pilot return hose (DR) HOSE
Disconnect pilot drain hoses on rear side of
tank. B1
B1
(3) Remove hydraulic tank attaching bolt

Remove three capscrews (B1) M16×35, and a
bolt (B3) M16×140.
: 24mm
A8
B3
16
4
Fig. 11-6 Draw out the suction hose (4)

Disconnecting pilot return hose (DR)
33－15
(4) Slinging hydraulic oil tank

Hook wire to neck of tank upper cover.
Tank weight : Approx. 94kg (207 lb)
If shims are attached, record the attaching
positions, and remove them.
Fig. 11-7 Slinging hydraulic oil tank

11.3 INSTALLATION
(1) Cleaning hydraulic oil tank
A6
(2) Cleaning suction hose
(3) Cleaning mount of tank. A23

Installing is done in the reverse order of
removing.
(4) Coat attaching cap screw (B1) and bolt (B3) A26-6
with Loctite #262. (See Fig. 11-6)
Fit the shims to their original positions.
: 24mm
Tightening torque : 22kgfym (160 lbfyft) A26-3
(5) Connection of suction hose (4) (See Fig. 11-6) A26-4

A2
Apply PERMATEX on pipe side of hose A26
SUCTION
connection and insert it. STRAINER
A26-1
(6) Clip (16) (See Fig. 11-6)

Tightening torque : 0.55kgfym (4.0 lbfyft) O RING A26-2
A23
(7) Assembling return element
A26-4
Assemble filter element by the use of element
kit (A100). (See Fig. 11-4A, 11-8.) A26-1
Replace O ring (A26-4) and packing A26-2
(A26-2) with new ones respectively. ELEMENT KIT (A100)

YV52V01001R100
(8) Install return element (A26-1). Fig. 11-8 Element & filter
(9) Install suction strainer (A2).
(10) Install tank cover (A9, A24) attaching

capscrew (A12), M10×20.
M10 Tightening torque : 4.7 kgfym (34.1 lbfyft) Replace O ring fitting on the backside
of tank cover (A24, A9) with new one.
33－16
12. PUMP (MAIN)

A6 A12
(1) Remove counterweight.
(2) Release pressure in hydraulic oil tank. SUCTION

STOPPER
(See item “Hydraulic Tank”.)
SUCTION
(3) Remove six capscrews (A12) M10. STRAINER
(4) Remove cover (A6)

: 17mm
(5) Take out suction strainer.
(6) Install suction stopper.

For suction stopper, see item “Tools”.
Note : Pump can be removed even when
counterweight is not removed. But
HYDRAULIC
removal of counterweight facilitates TANK
working, and the working time is also Fig. 12-1 Suction stopper installing
reduced.
(7) Remove guard (18), (19).

1) Remove six capscrews (41) M12×25.
18
2) Remove two capscrews (42) M12×30. 41
: 19mm
3) Remove guard (18), (19).
(8) Disconnect drain down pipe installed under

engine muffler.
41
42
19
Fig. 12-2 Removing guard (18), (19)

12.2 REMOVAL HYDRAULIC PUMP
(1) Loosen half clamp (11) on hoses (5), (6) and
capscrews (12) M10×35 and disconnect two HYDRAULIC
hoses (A1), (A2) on the delivery side. TANK
: 17mm
(2) Remove suction tube (1).

11 12
1) Remove four capscrews (13) M12×30.
4 13
: Special service tool No.6-1 of 5
opposing flats 10mm 11
40mm
(1.57in)
2) Remove tube (1) of suction hose (4) from 6 12 1
pump. Fig. 12-3 Removing hose (5), (6) and
suction tube (1)
33-17
(3) Removing other hoses

1) Disconnect hoses of the following ports.
(See Fig. 12-4.)
Connected A3
Port Size Tool to Remarks
Dr3 Psv1
Dr1 PF1/2 27 Tank Drain
Proportional For control B4
Psv1,2 PF1/4 19 valve block valve
Gear pump
A3 PF3/8 22 Line filter delivery port
for pilot Psv2
Suction port
B3 PF3/4 36 Tank
for pilot
Drain port
Dr3 PF3/8 22 Tank for pilot B1
C/V for Delivery port Dr1
A4 PF1/2 27 dozzer for dozer
Suction port A4 A2
B4 PF1 41 Tank A1
for dozer B3
Fig. 12-4 Pump port

2) Attach tags to hoses to identify.
(4) Remove main pump
1) Place a wire rope and tension it a little by

utilizing the eye bolt (M10) at the top of the
hydraulic pump. Temporarily loosen
capscrew (4) and remove capscrew (3).
: 14mm, weight : 95kg (209 lbs)
: 17mm
2) Draw out the power take-off assy from the

0
flywheel housing slowly, adjusting the
tension of the wire rope.
On that occasion, the coupling rubber (2-7)
4
comes out with the hydraulic pump.
3) Remove capscrew (2-4) fastening coupling

3
rubber (2-7) and remove coupling rubber (2-
7). 1
: 14mm
4) Remove hub (2-2)

If you loosen two set screws (2-5), hub (2-2) 2-3
comes off from the spline shaft of the pump. 2-4
: 14mm 2-7
2-6
5) Remove bracket (1) 2-2
2
If you loosen and remove capscrew (4), 2-5
bracket (1) comes off the pump.
: 14mm Fig. 12-5 Removing pump
33-18

12.3 INSTALLATION Do not use Loctite. (The
T=Tightening torque
Installing is done in the reverse order of removing. attached bolts are coated
with micro capsule coating.)
(1) Installing bracket (1)
2-4 1 4 T=19.5kgfym (140 lbfyft)
Install bracket (1) to the pump and
temporarily fasten them together by means of
socket bolts (4).
: 14mm
(2) Installing hub (2-2) 2
Insert hub (2-2) into the spline of the pump
till the end face of the spline enters 4mm
(0.157in) inward (Refer to the DetailⅠ.) and Ⅰ
attach two set screws (2-5).
: 14mm 2-5
T=11kgfym
Tightening torque : 11kgfym (80 lbfyft) (80 lbfyft)
(3) Installing coupling rubber (2-7)
3 T=6.6kgfym(48 lbfyft)
Insert coupling rubber (2-7) into hub (2-2) 2-3 Apply Loctite #262
T=22kgfym(160 lbfyft) equivalent
and attach socket bolts (2-4). Do not use Loctite. (The
On that occasion, do not coat socket bolts (2- attached bolts are coated
with micro capsule coating.)
4) with Loctite. (Socket bolts (2-4) are with
micro capsule coating.)
: 14mm 2-7
Tightening torque : 22kgfym (160 lbfyft) 2-2
(4) Installing the pump 2-4
Lift the pump with bracket level and dock it DETAILⅠ
in so bolts (2-3) enter the holes in coupling
2-5
rubber (2-7). (0.157˝)
Attach capscrews (3) back in position.
Fig. 12-6 Installing Hydraulic pump
: 17mm
(5) Tighten socket bolts (4) regularly. HYDRAULIC PUMP
: 14mm
Tightening torque : 19.5kgfym
(140 lbfyft)
(6) Attach hoses (5), (6) of the delivery side with
half clamp capscrews (12).
: 17mm
(7) Install the section tube (1) attaching socket
bolts (13) M12 (4pcs.)
: 10mm, (※Special service tool No.6-1) 11
Tightening torque : 10kgfym (72 lbfyft) 12
(8) Installing the hose

Tool Tightening torque 5 13
Tightening position 11
kgfym (lbfyft)
Cap nut Dr1 27 8.0 (58)
Cap nut Psv1, 2 19 3.0 (22)
Cap nut A3 22 5.0 (36) 12 1
Cap nut B3 36 12.0 (87) 6
Cap nut Dr3 22 5.0 (36) Fig. 12-7 Installing delivery hose (5),(6)
Cap nut A4 27 8.0 (58) and suction tube (1)
Cap nut B4 41 14.0 (100)
33-19
(9) Remove suction stopper
(10) Installing suction strainer
(11) To bleed air in pump, loosen plugs on

pressure measuring ports a1, a2.
(12) Check hydraulic oil level.
(13) Start engine and check it for oil leakage and

noise.
a1 a2
(14) Attach drain down pipe under engine muffler. Fig. 12-8 Bleed air in pump
(15) Install guards (18), (19)

Tool Tightening torque
Tightening position kgfym (lbfyft)
18
Capscrew (41), (42) 17 6.7 (48) 41
After replacing pump, be sure to fill

hydraulic oil to 1 (0.26gal) or more.
41
42
19
Fig. 12-9 Installing guard (18),(19)
33-20
13. RADIATOR & OIL COOLER

13.1 PREPARATION FOR REMOVAL T=Tigtening torque
Connection of hoses for air-con should

not be loosened and removed.
Refrigerant may be leaked.
T=29kgfym (210 lbfyft) B14 B19

B14
B4
B3 B1
Hose insert
allowance B2
45mm(1.8in)
A1 B19
B18
A4 B20 B8 B19
C1 B19
Hose insert allowance
45mm (1.8in)
UPPER
FRAME A2
T=16.4kgfym B5-2
B5-3 B18
(199 lbfyft)
A4 Apply Loctite #262 B8
B7
T=10.3kgfym (44 lbfyft)
B14 B15
B16 B17
B5
Sub tunk
B6
To counterweight
Fig. 13-1 Radiator & oil cooler
DETAIL OF SUB TANK
(1) Remove counter weight
(2) Bleeding internal air of hydraulic oil tank
(3) Remove cover of suction strainer, and adjust 8

oil quantity so that oil level becomes lower 2
than the return tube level.
9 3
7
(4) Remove air cleaner hose
1) Loosen clips (7), (8), (9). Refer to
2) Pulling out hose (2). air cleaner on
8
3) Pulling out hose (3). pageⅠ-10
Fig. 13-2 Removing air cleaner hose
33-21
(5) Removing under cover installed on lower side

of radiator.
1) Remove eight sems bolts (8) M12×25.
2) Remove cover (2), (3).
: 19mm
3
8
8
Fig. 13-3 Removing under cover (2), (3)
(6) Drain down of radiator
Put container 18 (4.8gal) under drain cock
hose for draining water.
(Water capacity of radiator : 7 (1.8gal))
(7) Remove washer tank (A4)

1) Pulling out hose.
2) Move washer tank. A4 A10
A5
Fig. 13-4 Removing washer tank

(8) Move air-conditioner condensers.
2) Move A/C condenser
: 10mm
(9) Move receiver tank

1) Remove two capscrews (18) M6×20 which
are used to install receiver tank with bracket. 17
2) Move receiver tank.
: 10mm
18
17
Fig. 13-5 Moving condensers and receiver tank
13.2 REMOVAL
(1) Remove radiator stay (A1)
1) Remove two sems bolts (A4) M12. A1
: 19mm A4
2) Remove stay (A1).

UPPER
B8 FRAME
A4
Fig. 13-6 Removing radiator stay (A1)
33-22
(2) Remove sub tank (B5) B5-2

1) Loosen clip (B18) on one side of hose (B8) and B5-3 B18 B8
pull out hose. B7
2) Remove four capscrews (B14) M8×20 and B14
separate sub tank (B5) from bracket (B6). B15
B16
: 13mm B17
(3) Remove fan guard (B4)

1) Remove four capscrews (B14) M8. B5
2) Remove fan guard (B4).
: 13mm
B6 To counterweight
(4) Remove water hose (B2) Fig. 13-7 Removing sub tank (B5)
1) Loosen the hose band (B19). B14
2) Remove hose (B2). B4
B2
(5) Remove radiator (C1)
Remove three capscrews (A2) M16×35.
: 24mm B19
: 24mm
C1 B19
(6) Disconnecting hydraulic oil hose (11), (12) (oil

A2
cooler)
Place a container under the hose connections
and disconnect hoses (11), (12).
Fig. 13-8 Removing guard, water hose
(7) Disconnecting hydraulic oil pipe and radiator
1) Shift radiator outward.
2) Stop up pipe ends with waste cloth, etc. 12
(8) Disconnecting water lower hose (B1)

1) Loosen the clip (B19).
2) Pulling out hose (B1).
Remove the hose while sliding the 11

radiator little by little. Fig. 13-9 Removing hydraulic oil hose
(9) Removing radiator B19

Remove radiator assy with crane.
B1
B19
Fig. 13-10 Removing water lower hose (B1)
33-23
13.3 INSTALLATION
removing.
(2) Install radiator assy

Lift up radiator by power of men or with
crane, match the catching holes for water
hose and hydraulic oil pipe and also the
position respectively, and assemble them C1
temporarily.
Water hose insert allowance 45mm (1.8in) A2
Tightening torque
16.4kgfym (119 lbfyft)
(3) Radiator attaching bolt Apply Loctite #262
Apply Loctite #262 on 3 capscrews (A2) M16,
and tighten it with washer respectively.
: 24mm
Tightening torque ; 16.4kgfym
(119 lbfyft)
Fig. 13-11 Installing radiator
(4) Adjust the clearance between the fan and the
radiator shroud to 15mm (0.6in) all over the
circumference.
(5) Clean the plastering area of the insulation

thoroughly before plastering it.
(6) Making up hydraulic oil and LLC (Long Life

Coolant)
After completion of other installation, make
up hydraulic oil and water.
33-24
14. ENGINE
14.1 PREPARATION FOR REMOVING (7) If necessary, remove pump, air cleaner,
(1) Remove guard (See Fig. 6-6, 6-7 and 6-12.) silencer and radiator.
(2) Remove counterweight (See Fig. 5-1 and 5-2.) (8) Remove harness and connector
Starter B terminal
1) Starter cable
(3) Remove battery ground (See Fig. 3-2.) E/G sub harness terminal
CN-351M
(4) Remove air cleaner hose (See Fig. 8-3.) CN-318F
2) Main harness E/G sub
CN-352F harness
(5) Remove radiator hose (See Fig. 13-8 and 13-10.)
3) Engine grounding able
(6) Remove fuel hose and heater hose, and if
necessary air-con hose. Prepare a stand which withstands the
weight of the engine assy and can place
the removed engine firmly.
THERMOSTAT SPEED
WATER
SEPARATOR
THERMO SENSOR
FUEL FILTER
ELEMENT
ALTERNATOR
ASSY
OIL SWITCH
THERMO SWITCH
OIL FILTER
ELEMENT
OIL FILTER (BY-PASS)
STARTER ASSY
ELEMENT
(FULL FLOW) V-BELT
V-BELT
(A/C)
Fig. 14-1 E115SR Outside view of engine
33-25
PIPE FOR HEATER

E/G LIFTING FITTING
TURBO CHARGER
ロ
E/G SPEED SENSOR
WATER
(COOLANT)
E/G LIFTING TEMPERATURE
FITTING FUEL FILTER ELEMENT SENSOR
THERMOSTAT
STARTER
MOTOR INJECTION
PUMP
FUEL RETURN
PIPE
ALTERNATOR
FUEL SUCTION PIPE
OIL PRESSURE SW.
OIL FILTER OIL FILTER DRAIN COCK
ELEMENT ELEMENT (FOR ENGINE BLOCK)
SAFETY RELAY (BYPASS) (FULL FLOW) DRAIN PLUG
EARTH CABLE
E115SR
Fig. 14-2 SK135SR
E135SR yDZ Outside view of Engine
33-26
14.2 REMOVAL
5
4
8 6 CAPSCREW
Apply Loctite #271
8 WASHER
4 CAPSCREW
T=23kgfym(170 lbfyft)
Apply Loctite #271
1
9 PLATE
9 2 RUBBER MOUNT
RUBBER MOUNT 1
2 13 SHIM
14 SHIM
3 RUBBER MOUNT
7 NUT
13,14 1,2
1 +1.0
0
(0.039″ +0.039″
0
)
13 3 +1.0
Adjust to 1 0
+0.039″
14 13 13 (0.039″ 0 )
using shims
3 14 14
No.13, 14.
7 3 3
7 7 Clearance Adjustment of Engine Mount
(1) Removing attaching bolt to frame 14.3 INSTALLATION

1) Remove four nuts (7) M18. (1) Installing is done in the reverse order of
2) Remove rubber mount (3) and shim (13), (14). removing.
3) Remove four capscrews (4), (5), (6) M18×90. 1) Clearance adjustment of engine mount
: 27mm Adjust the clearance between the lower
mounting surface of the engine and rubber
4) Remove two washers (8). Mount (3) to 1.0mm (0.039in), using shims
(2) Slinging engine body (13), (14).
1) Sling engine hooking wire to lifting lugs on 2) Refer to the above figure for the tightening
the front and rear sides. torques and Loctites (Adhesive).
Weight : Approx. 370kg (820 lbs)
Wire : ∅6 (0.236″)×1m (3ft 3in)－2pcs.
(3) Position engine on the mount stably.

(4) Remove other parts.
1) Remove two plates (9).
2) Remove two rubber mounts (1), (2).
33－27
15. MULTI CONTROL VALVE (OPT.)

(1) Bleed pressure air in hydraulic oil tank
(See Fig. 11-2.)
(2) Remove cover assy (1) (See Fig. 6-2 )
(3) Remove panel assy (2) (See Fig. 6-3 )
PLATE SUPPORT
(4) Remove cover assy (6) (See Fig. 6-4 )
(5) Shift bracket (1) for multi control valve if
necessary. ( See Fig. 15-1.)
(6) Tag harness and remove it. 21,22
(7) Attach tag to hose between multi control 3
valve and main C/V, and write numbers C1 to
C8 in it. 9
Remove hose on multi control valve side, and 1
plug connection. SECTION A－A
Refer to (3) Plug under 4. Tool of chapter 11.
7
15.2 REMOVAL Fig. 15-1 Removing bracket
(1) Attach tag on which hose name is entered to for multi control valve
the remote control hoses between multi
control valve and pilot V, and write numbers
C2
P1 to P8 on it.
C5
(2) Remove hoses P1 to P8 on multi control valve
C4
side and plug connection. C6
C8
Refer to (3) Plug under 4. Tool of chapter 11.
C7
(3) Remove four capscrews (21) M8×20. C1
(4) Remove multi valve (28). C3
: 13mm
(5) Removing and shifting bracket (1) for multi
control valve C2
C5
2) Remove clamp (3). C4
C6
3) Remove four capscrews (7) M12×45. C8
4) Move bracket (1). C7
C3 C1
Fig. 15-2 Connection between
15.3 INSTALLATION multi control valve and C/V
(1) Installing is done in the reverse order of P2
removing
(2) Relations between pilot valve and multi
control valve hose
P/V Hose ISO multi mark
port Size Collar operation pattern port -ing
1 1/4 Red Bucket digging P1 BK
2 1/4 Blue Bucket dump P2 BA P8
Right 3 1/4 Green Boom up P3 BR P5
side 4 1/4 Gray Boom down P4 B
P 1/4 Black Pilot primary －－
T 3/8 Black Drain －－ P4
P1
5 1/4 Gray Swing left P5 SL
6 1/4 Red Swing right P6 SR
Left 7 1/4 Blue Arm in P7 AK P6 P7
side 8 1/4 Green Arm out P8 AR P3
P 1/4 Black Pilot primary －－ Fig. 15-3 Connection between
T 3/8 Black Drain －－ P/V and multi control valve
33－28
15.4 LEVER CHANGE PROCEDURE OF MULTI 20,21 Multi valve

19
CONTROL VALVE 18
(1) Changing from " Multi valve" to "Lever less 16
multi valve" 17 9 10,1
11
1) Lower attachment to ground level and check 6
that the engine stops. Then bleed hydraulic 15
system pressure and internal pressure of oil
tank.
12 29 4
(Refer to 7. Hydraulic tank and 8. Hydraulic 8
pump.) 7
2) Remove bolt (9) and adjust lever (29) to the

position of operating pattern for "Lever less
multi valve". Fig. 15-4
3) Remove six capscrews (11) and two capscrews
(12). MULTI VALVE
: 5mm ITEM NAME Q'TY
Multi valve repair kit 1s
4) Remove "Multi valve" kit, and install "Lever 4 • COVER 1
6 • DUST SEAL 1
less multi valve" kit
7 • O RING 1
8 • O RING 1
※ Then replace O rings (7) and (8) with new 9 • BOLT 1
ones. And apply grease before installation, 10 • CAPSCREW 2
and check that it is not twisted. 12 • CAPSCREW 2
※ Put capscrew (28) to the bolthole provided on 13 • WASHER 2
the side farther away from the center. 15 • PIN 1
16 • CASING 1
: 5mm
17 • SPRING 1
Tightening torque : 1.1kgfym (8 lbfyft) 18 • KNOB 1
19 • KNOB 1
5) Tighten capscrew (11) to the specified torque. 20 • MACHINE SCREW 1
(Apply Loctite #242.) 21 • WASHER 1
: 5mm 29 • LEVER 1
Lever less multi valve
8 28 27 11
6) Check that it is set to regular switching
pattern while operating excavator slightly.
(2) Change from "Lever less multi valve" to

"Multi valve".
1) Stop engine, remove "Lever less multi valve"
kit by the reverse procedure, and change kit
to "Multi valve". Fig. 15-5
LEVER LESS MULTI VALVE
※ Apply grease slightly on the lip of dust seal, NAME
ITEM Q'TY
item (6).
Lever less multi repair kit 1s
7 • O RING 1
2) Check that the lever can be changed to 8 • O RING 1
respective pattern easily while operating 11 • CAPSCREW 2
excavator slightly. 27 • COVER 1
28 • CAPSCREW 1
Ⅰ－29
16. CONTROL VALVE

(1) Remove cover assy (1) (See Fig. 6-2.)
(2) Remove panel assy (2) (See Fig. 6-3.)
(3) Release air in hydraulic oil tank, open cover

of suction element of hydraulic oil, and lower
the level. (See Fig.12-1.)
(4) Move bracket for multi control valve (1)

(See Fig. 15-1.)
16.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name in it,
then remove hoses.
Ports Functions Ports on upper sides (on machine) Ports Functions
LEFT← FRONT SIDE →RIGHT
SIDE SIDE
PTb Travel straight PAL Travel left forward
PAr Travel right forward PBs2 Swing (Right)
PAc Bucket dump

PLc1 Boom lock valve release
Pab Boom up PAa Arm in
Drc Drain
PCb P1 bypass cut Pis Arm recirculation
PA02 Option valve
REAR SIDE
Ports Functions Ports on left sides (on machine) Ports Functions
LOWER← FRONT SIDE →UPPER

SIDE SIDE
Br Travelright reverse Ar Travel right forward
Bc Bucket digging Ac Bucket dump
Bb Boom down
Ab Boom up
REAR SIDE
33-30
Ports Functions Ports on right sides (on machine) Ports Functions

FRONT SIDE
UPPER← →LOWER
SIDE SIDE
AL Travel left forward BL Travel left reverse

PBs2 Swing (Right) PBs2
As Swing (Left) Bs Swing (Right)
PAs
Pss
Pss Swing press. sensor
PAs Swing pilot (Left)
Aa Arm in
Ba Arm out
Ao2 Option valve Bo2 Option valve
REAR SIDE
Ports Functions Ports on bottom sides (on machine) Ports Functions
LEFT← REAR SIDE →RIGHT
SIDE SIDE
PBo2 Option valve
PCa P2 bypass cut
PA1 Arm conflux
Drd Drain
PBb Boom down PBa Arm out
PLc2 Arm lock valve reliese
PBc Bucket digging PB1 Boom conflux
PBr Travel right reverse PBs Swing (Right)
PTb Travel straight PBL Travel left reverse
FRONT SIDE
(2) Remove control valve MACHINE FRONT

1) Remove two capscrews (2) M12×30 and two
capscrews (7) M12×45 from upper frame.
3
2) Remove bracket (1) together with control valve.
3) Remove two capscrews (3) M12×60 and a
8
capscrew (8) M12×70 from bracket.
: 19mm
4) Weight : 140kg (310 lbs)
16.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
: 19mm,
Tightening torque : 12.3kgfym(89 lbfyft)
(2) Make certain that attachment moves 2 7
normally in operation.
4
(3) Check oil level and that it is free from oil 1
leakage. Fig. 16-1 Removing main control valve
33-31
17. PILOT VALVE (FOR ATT)

17.1 PREPARATION FOR REMOVING
PANEL ASSY
The removing procedure for right and left is the
same, so the preparation for left side is described
29
here. 28
(1) Put attachment on ground, stop engine and
release pressure in tank.
(2) Remove panel assy referring to Section 4.

Instrument Panel.
(3) Remove one sems bolt (12) M5 from lower

side of control box.
: cross recessed screw driver 12
Fig. 17-1 Removing instrument panel
(4) Remove cover on outer surface.
BOOTS
(5) Remove sems bolt (28) and rubber sheet (29)

securing cover and control box on inner A1
surface.
: cross recessed screw driver
PILOT VALVE
(6) Remove cover on inner surface.
: cross recessed screw driver
PF3/8
(7) Remove harness connector for horn. VALVE SIDE Opposing
PF1/4
Opposing
Flats 22 Flats 19
(8) Attach tag to hoses for identification.
MARK “F”
17.2 REMOVAL
(1) Remove hoses from your side to far side in PF3/8
PF1/4
order. P PORT CONNECTOR
: 19mm,22mm HOSE SIDE (WITH FILTER)
1～4,5～6,T PORT CONNECTOR
(2) Shift boots. Fig. 17-2 Pilot valve connector
(3) Remove four socket bolts (A1) M6. FRONT OF THE MACHINE
: 5mm
T 8 ARM(R) 4 BOOM(R) 2
(GREEN) T (GRAY) BUCKET
(4) Remove pilot valve. (R)
6 (BLUE)
SWING
(5) Plug hose ends. Plug PF1/4 (R.H)
5 (RED)
SWING(L.H)
17.3 INSTALLATION (GRAY)
1
Install it in the reverse order of removal and P
P BUCKET(H)
tighten it to the below tightening torque. 7 ARM(H) (RED)
: 5mm T=1.5kgfym (11 lbfyft)
(BLUE) 3
BOOM(H)
LEFT SIDE RIGHT SIDE
Fig. 17-3 Pilot valve port position (from upper side)
33-32
18. PILOT VALVE (FOR TRAVEL)

18.1 PREPARATION FOR REMOVING
(1) Release pressure in hydraulic oil tank
(2) Remove under cover
(3) Remove floor mat
18.2 REMOVAL
7 (M10×25)
(1) Disconnect pressure sensor connectors at two
places from under floor harness.
(2) Remove two pressure sensors. Lead cable for travel

1,2 speed
: 19mm B10
Connect to under floor
(3) Disconnect lead cable CA103 for travel 1,2 PF1/4 harness with CA103 plug
speed at two places from under floor harness.
PRESSURE SENSOR
PRESSURE
(4) Attach tag, and disconnect connectors and SENSOR
hoses.
: 19mm (P port) T
: 22mm (T port, 1～4 port) CONNECTORS
P
2
(5) Plug hose ends
Plug PF1/4 1
4
(6) Remove four sems bolts (7) M10. 3 GROMMET

25 24
(7) Remove right and left levers.
(8) Remove four socket bolts (B10) M10.

: 8mm
(9) Remove four sems bolts (25) M10 and remove

two plate (24).
: 17mm
(10) Remove pilot valve lifting it upward.
(11) Stop up holes with plugs PF1/4, 3/8.
18.3 INSTALLATION
Install it in the reverse order of removal and
tighten it to the below tightening torque.
Hose
Pressure sensor Fig. 18-1 Attaching and detaching pilot V
33-33
19. SWING UNIT

19.1 PREPARATION FOR REMOVING 10
(1) Park machine on flat and solid ground and
put attachment and dozer on ground.
(2) After switch operation for release pressure, A31

operate swing control lever to release
pressure in swing circuit, then stop engine.
A32
(3) Release internal pressure through bleeder of
22
hydraulic oil tank.
(4) Remove boom as necessary to make work

easier. (Refer to chapter of Boom.)
(5) Remove cab if necessary to make work easier.

(Refer to chapter of Cab.)
(6) Remove cover under engine.
(7) Attach tag to hose.
19.2 REMOVAL Fig. 19-1 Removing swing unit piping

(1) Remove hose.
1) Remove hose (10) from the tee in the C
makeup port.
: 36mm
2) Remove hose (22) from the tee in the DB

drain port.
: 27mm
3) Remove one hose from the elbow of the PG

port (for swing parking brake).
: 19mm
4) Remove hoses (A31), (A32) from the elbows of

the A, B ports.
: 32mm
(※ special service tool No.6－3)
5) Put in plugs PF3/4, PF1/2, PF3/8 and PF1/4

into the holes in the removed ports.
33-34
(2) Loosen one nut (B12) M10 from under side of

upper frame and remove drain hose clip (B8)
for reduction unit. 1
: 17mm
(3) Removing the swing unit

Remove nine capscrews (1) M20×55 and one 0
2
socket bolt (2).
: 30mm
: 17mm
(4) Remove Tee of swing motor C port PF3/8 and

stop up holes with plug used as eye bolt.
B12
: 36mm
B8
Plug No.6－4, Eye bolt No.6－5
(5) Hook sling to eye bolts attached on C port.

Weight of swing unit ; Approx. 110kg (240
lbs)
19.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing unit and
upper frame.
Tools : spatula, cleaning fluid Fig. 19-2 Removing swing unit
(2) Apply Loctite #515 on entire mounting

surface of swing unit.
19.4 INSTALLATION
removing.
1) Attach a socket bolt (2) to the most right
tapped hole in the mounting surface of the
swing unit and attach capscrews (1) to other
nine tapped holes.
2) Tighten capscrews (1) and socket bolts (2).
: 30mm
: 17mm
Apply Loctite #262
3) Fill inside from motor drain port to casing 19.5 PREPARATION FOR DRIVE
with hydraulic oil before piping for drain. (1) Before starting operation, check that engine
oil level of swing reduction is sufficient.
Amount of charge : 1.7 (0.45gal)
(2) When starting operation, operate motor in

low idling and at low speed for several
minutes, and check it for possible oil leakage
and noise.
33－35
20. SWIVEL JOINT

20.1 PREPARATION FOR REMOVE 20.2 REMOVAL
(1) Remove attachment assy (1) Remove travel motor hose and tube
(Refer to 1. section : Attachment) [Refer to Travel section under Hydraulic
system(8)]
(2) Remove cab (Refer to 1. CAB) 1) Remove tube (A5), (A6). (E port : PF1/2)
: 32mm
(3) Remove guard (Refer to 6. GUARD) Tightening torque :
(4) Remove swing reduction unit if necessary. 2) Remove tubes (A1), (A2). (A, B port : PF1)
(Refer to 19. SWING MOTOR UNIT) : 36mm
B1 A2 Tightening torque :
B4 A4 22.0kgfym (160 lbfyft)
B1
B4 (H) 3) Remove tubes (A3), (A4). (C, D port : PF1)
B4 : 36mm
A25
B1 Tightening torque :
A3 B6
B5 22.0kgfym (160 lbfyft)
4) Remove two hoses (A13). (F, F port : PF1/4)
B2-1
B2-1 B2 A13 : 19mm
B2
B4 A13 Tightening torque : 3.7kgfym (27 lbfyft)
B1 B5 5) Remove hoses (A24), (A25). [Only dozer spec.]
A1 B5
B6 (G, H port : PF1/2)
(G)
A24 B3 : 32mm
A6
A5 FOR DOZER SPEC.
Tightening torque :
(A) 15.0kgfym (108 lbfyft)
(A)
(A)
A4 A6
A12 (D2)
A1
A13 A10 (B)
A13 A2
A15
A3 A8 (A)
A15
A5 A4
A13 (A)
B4 B1 (D)
SWIVEL JOINT (B)
A2
A13
B4
B1 (F)
A3
B2-1
B2
(C) (E) A13
B5
(A)
(F)
A1
A6
B3
A5
(A)
Fig. 20-1 Removing piping (undercarriage)
33-36
(2) Disconnecting the hoses on the top part of DRAIN HOSE

swivel joint
[Refer to Swivel Joint under, Hydraulic
system (4), (5).] A30
A29
1) Remove drain hose. (E port : PF1/2) A28
: 27mm Machine
Tightening torque : 8.0kgfym (58 lbfyft) front side
2) Remove hoses (A27), (A30).
(A, C port : 1-14UNS)
: 32mm
Tightening torque :
14.0kgfym (100 lbfyft) A27
3) Remove hoses (A28), (A29). A24
(Only on machine
(B, D port : 1-14UNS) with dozer)
: 32mm
Tightening torque :
4) Remove hose (20). 20
A25
(2-speed change over port : PF1/4) 35 (Only on machine with dozer)
: 19mm
Tightening torque : 3.0kgfym (22 lbfyft) Fig. 20-2
C3 CAPSCREW
5) Remove dozer hoses (A24), (A25). (Only on M20×120
machine with dozer) (F, G port : 1-14UNS) T=16kgfym
: 32mm (116 lbfyft)
Tightening torque : C5
(3) Remove whirl-stop of swivel joint. Fig. 20-3 Removing whirl-stop nut & the
1) Loosen the nut (C5) M20. capscrew
2) Remove a capscrew (C3)M20×120. B9
: 30mm
B13
(4) Remove joint for piping (Refer to Fig.20-2) B7
1) Remove two elbows (B5). (F, G port)
2) Remove connector (35) for travel 2-speed
change over (1). (PF1/4) B1
: 19mm
(5) Remove dust cover (B1)

1) Remove five capscrews (B9) M10×25. Fig. 20-4 Removing dust cover (B1)
: 17mm
2) Remove clip (B7).
3) Remove dust cover (B1).
33-37
(6) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and
remove three capscrews (2) M12×25.
: 19mm
(special service tool No.6－10)
EYE BOLT
LOWER FRAME
2
CAPSCREW
M12×25
LOCTITE #262
T=11kgfym(80 lbfyft)
1
SWIVEL JOINT
Fig. 20-5 Removing capscrew for installation

(7) Slinging the swivel joint
Weight :
E115SR, E135SR
For STD Approx. 30kg (66 lbs)
For Dozer Approx. 63kg (140 lbs)
20.3 INSTALLATION
LOWER FRAME
removing.
Piping tightening torque
Tool Tightening torque kgfym(lbfyft)
Size
HEX O ring type Hydraulic hose
PF1/4 19 3.7(27) 3.0(22)
PF3/8 22 7.5(54) 5.0(36)
PF1/2 27 11.0(80) 8.0(58)
PF3/4 36 16.5(120) 12.0(87)
PF1 41 26.0(180) 14.0(100)

Fig. 20-6 Slinging swivel joint
(2) Check for oil leakage and the hydraulic oil
level.
3) Check for operating.
33-38
21. UPPER FRAME

(1) Remove attachment
WIRE ROPE
(Refer to 1. ATTACHMENT) ∅16×2.5m
(0.630″) (8ft
(2) Remove cab (Refer to 1. CAB.)
CHAIN BLOCK
(3) Remove guard (Refer to 6. GUARD)
(4) Remove counter weight

(Refer to 5. COUNTER WEIGHT)
(5) Remove swivel joint

(Perform the steps (1) thru (7) of 20. SWIVEL
JOINT)
21.2 REMOVAL
(1) Lifting up upper frame temporarily LIFTING JIG No.12 FOR UPPER FRAME
Attach two upper frame lifting jigs into the
mounting holes in the counterweight, attach Fig. 21-1 Temporarily lift upper frame
two chain blocks to the boom foot, and
temporarily lift the upper frame from four
points. MATCH
Wire rope ; ∅16 (0.630″)×2.5m(8ft 2in), 2pcs. MARK
∅16 (0.630″)×1.5m(4ft 11in), 2pcs.
Chain block ; For 1,000kg (2,200 lbs) 2pcs.
(2) Marking match marks on swing bearing

Mark match marks on upper frame and
swing bearing.
(3) Removing upper frame attaching bolts

Remove 25 capscrews M16×80 and three Fig. 21-2 Matching mark on swing bearing
reamer bolts used to install swing bearing and upper frame
and upper frame.
: 24mm
(4) Slinging upper frame

Sling according to Fig.21-1, and remove
upper frame and put it on a stand.
Weight : Approx.
E115SR 2,600kg (5730 lbs)
E135SR 2,700kg (5950 lbs)
Fig. 21-3 Removing upper frame attaching bolts
33-39
21.3 INSTALLATION
removing.
(2) Cleaning mating surfaces of upper frame and Apply Loctite #515 to the race surface over the whole
circumference (hatched) on the inside of capscrew.
swing bearing.
(3) Apply Loctite #515 to the inside of the

capscrews on the contact surface. Apply loctite #262
equivalent.
(4) Slinging upper frame
Match marks and install it with one capscrew
(19) temporarily. 10,19
Fig. 21-4 Bearing mount
Confirm the capscrew position
referring to Fig. 21-5.
OUTER S ZONE POSITION
: 24mm, Tightening torque :
Apply Loctite #262
(5) Install swing bearing

Install twenty seven capscrews (10) M16×80.
: 24mm Tightening torque :
Apply Loctite #262
Fig. 21-5 Reamer bolt position (★)

Apply Loctite on section specified
by slanting lines
33－40
Part II: DISASSEMBLING AND ASSEMBLING EQUIPMENT Table 1-1
1. HYDRAULIC PUMP・REGULATOR TIGHTENING
REGULATOR TORQUE No. NAME Q’TY
kgfym (lbfyft)
1.1 HYDRAULIC PUMP
1.1.1 STRUCTURAL EXPLODED VIEW 111 SHALBF (F) 1
(1) Main pump 113 SHALBF (R) 1
116 1st GEAR 1
534 406
792 261 123 ROLLER BEARING 2
531,548 702 124 NEEDLE BEARING 2
532 774
732 710 127 BEARING SPACER 4
789
535 141 CYLINDER BLOCK 2
886 ENGINE
SIDE 151 PISTON 18
953
808 152 SHOE 18
153 PLATE 2
(RETAINER PLATE)
724
156 SPHERICAL BUSHING 2
728 719
113 467 313 157 CYLINDER SPRING 18
808 124 211 SHOE PLATE 2
127 954
123 212 SWASH PLATE 2
127 214 TILTING BUSHING 2
824 271 901
710 251 SWASH PLATE SUPPORT 1
(F)
262 312
717 252 SWASH PLATE SUPPORT 1
406 490 490 111 (R)
251 885 261 SEAL COVER (F) 1
719
262 SEAL COVER (R) 1
401 116 886 271 PUMP CASING 2
124 312 VALVE BLOCK 1
314
313 VALVE PLATE 1
141 GEAR PUMP (for CW rotation)
(FOR DOZER)
157 314 VALVE PLATE 1
(for CCW rotation)
711
156 24 (170) 401 SOCKET BOLT ; M16×175 8
886
153 885 1.2 (8.7) 406 SOCKET BOLT : M6×16 8
725
466 3.7 (27) 466 VP PLUG ; PF1/4 2
151,152 TIGHTENING
05
TORQUE No. NAME Q’TY 11 (80) 467 VP PLUG ; PF1/2 3
211
kgfym (lbfyft) 468 VP PLUG ; PF1/2 1
214 Refer to Fig.1-34
725 O RING : 1B P11 2
212 0.9 (6.5) 490 PLUG ; NPTF1/16 15
728 O RING : 1B P18 4 24 (170) 531 TILT PIN; M20×1.5 2
732 O RING : 1B P16 2 24 (170) 532 SERVO PISTON ; 2
GEAR PUMP
(FOR PILOT) 774 OIL SEAL 1 M20×1.5
789 BACKUP RING 2 534 STOPPER ( L) 2
Refer to Fig.1-2 792 BACKUP RING 2 535 STOPPER (S) 2
13 (94) 808 HEX. NUT ; M16 4 548 FEED BACK PIN 2
824 SNAP RING 2 702 O RING ; 1B G30 2
885 VALVE PLATE PIN 2
886 SPRING PIN 4 711 O RING : 1B G95 1
901 EYE BOLT ; M10 2 717 O RING ; 1B G120 2
953 SET SCREW 2 719 O RING ; 1B G115 2
954 SET SCREW 2 724 O RING ; 1B P8 18
Fig. 1-1 Structural exploded view of main pump The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
33-41
(2) Gear pump (for pilot)
433
710 361 700 354
A
434
351
435
312
353
311
732
SECTION AA 309 310 307 308 355 434 850 466 725 728 467
Fig. 1-2 Structural of gear pump (for pilot)
Table 1-2
307 POPPET 1 1.7 (12) 433 FLANGE SOCKET ; M8×40 2
308 SEAT 1 1.7 (12) 434 FLANGE SOCKET ; M8×55 2
309 SPRING SEAT 1 3.4 (25) 435 FLANGE SOCKET ; M10×35 2
310 SPRING 1 1.6 (12) 466 VP PLUG ; PF1/4 1
311 ADJUSTING SCREW 1 5.4 (39) 467 ADAPTER ; PF1/2-PF3/8 1
3 (22) 312 LOCK NUT ; M14 1 700 RING 1
351 GEAR CASE 1 710 O RING ; 1B G80 1
353 DRIVE GEAR 1 725 O RING ; 1B P11 1
354 DRIVEN GEAR 1 728 O RING ; 1B P18 1
355 FILTER 1 732 O RING ; 1B P16 1
361 FRONT CASE 1 850 SNAP RING 1
33-42
1.1.2 DISASSEMBLY AND ASSEMBLY OF MAIN

PUMP
(1) Tools Table 1-3
The following list shows the tools required for Tool name Dimension
remove and install.
Allen wrench Opposing flats 4,5,6,8,14mm
Eye wrench
Socket wrench
Wrench with double Opposing flats 19, 27mm
heads (single head)
Adjust wrench Medium size 1pc.
Screw driver Flat-bladed screw driver 1pc.
Hammer Plastic hammer 1pc.
Plier For snap ring TSR-160

Steel bar for key
Steel bar Approx.10×8×200mm
(0.40˝×0.31˝×0.79˝)
One that may be fastened to
Torque wrench specified torque
(2) Disassembling procedure
1) Selecting a place for disassembly.
z Choose a clean place.

z Spread rubber sheet or cloth on work
bench to protect parts from
damaging.
2) Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing drain port plug (467), (468).
: 27mm
REGULATOR
z Drain out oil from the plug of the
front pump and the rear pump.
4) Removing regulator and PTO gear casing

Remove the socket bolts [415 (See Fig.1-20),
435 (See Fig.1-34.)]. Then remove the
regulator and the PTO gear casing.
: 6mm, 8mm
z Regarding the disassembly of the

regulator, refer to Regulator. Fig. 1-3 Removing regulator
z Regarding the disassembly of the
PTO gear casing, refer to PTO Gear
Casing.
33-43
5) Remove socket bolt (401)

Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).
: 14mm
6) Disassembling the pump casing and the valve

block
Place the pump level on a work bench with
its mounting surface of the regulator facing
312 271
down. Then separate pump casing (271) and
valve block (312).
z When facing the mounting surface of

the regulator down, place a rubber
board or something on a work bench
so as not to score the mounting
surface.
z When the pump casing has been
separated from the valve block, draw
out the 1st gear at the same time. Fig. 1-4 Disassembling the pump casing (271)
and the valve block (312)
7) Drawing out the cylinder assy

Draw out cylinder (141) out of pump casing 271
(271) in parallel to shaft (111). At the same
141(151)
time draw out piston (151), plate (153),
spherical bushing (156) and cylinder spring 153
(157). 156
z Use care so as not to score the

sliding surface of the cylinder,
spherical bushing, shoe and the
swash plate .
Fig. 1-5 Drawing out the cylinder assy
33-44
8) Remove seal cover (F) 406

Remove socket bolt (406) and seal cover F
(261). 261
: 5mm
z The seal cover (F) may be drawn out

with ease if it is taken out by
tightening bolts in the tapped holes
(M6 tap) of the seal cover (F).
z An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score
the oil seal. Fig. 1-6 Removing seal cover F (261)
271
9) Remove seal cover (R)
Remove socket bolt (406) and seal cover R
(262). 251
: 5mm
10) Separating the swash plate support and the

pump casing
Knock lightly on the mounting flange of
swash plate support (251) from the pump
casing (271) side and separate the swash
plate support from the pump casing.
Fig. 1-7 Separating the swash plate (251)
support and the pump casing (271)
11) Remove shoe and swash plate
Draw out shoe plate (211) and swash plate 271
(212) from pump casing (271).
212 (211)
Fig. 1-8 Removing shoe (211)

and swash plate (212)
12) Drawing out the shaft
251
Tap lightly the shaft end (111, 113) by means
of a plastic hammer and draw out the shaft
from the swash plate support.
113
Fig. 1-9 Drawing out the shaft (111), (113)
33-45
13) Remove valve plate

Remove valve plate (313, 314) from valve
block (312).
z The valve plate may come off during

the operation under 6). 312
314
(313:OPPOSITE SIDE)
Fig. 1-10 Removing valve plates (313), (314)
14) Remove other parts

If necessary, remove stopper (L) (534), 531
stopper (S) (535), servo piston (532) and
tilting pin (531) from pump casing (271), and
remove needle bearing (124) from valve block
535 534
(312). 808
532
z When removing the tilting pin, use

care so as not to score the head of
the tilting pin, using a jig. 808
z It is hard to separate the tilting pin
from the servo piston in some cases 124
312
as Locktite is coated on the mating 271
part between them. Use care so as
not to score the servo piston by
251
applying unreasonable force.
z Do not draw out needle bearings
except when their service life has
ended.
z Do not loosen hex nuts (808) of valve
block (312) and swash plate support
Fig. 1-11 Removing other parts
(251). A set flow rate changes.
33-46
(3) Installing procedure

1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly,
but notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
dry them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
2) Installing swash plate support

Attach swash plate support (251) to pump
271
casing (271) by tapping the swash plate
support lightly with a plastic hammer.
z When the servo piston, the tilting

pin, the stopper (L) and the stopper
(S) have been removed, install them
to the pump casing beforehand.
z When tightening servo piston and
tilting pin, use a jig so as not to
damage the head of the tilting pin
251
and feedback pin.
Coat the screwed part with Loctite
#262.
Fig. 1-12 Installing swash plate support (251)
3) Installing swash plate 251
Place the pump casing with its mounting 271(531)
surface of the regulator facing down, insert
the tilting bushing of the swash plate into
tilting pin (531), and fit swash plate (212) to
swash plate support (251) properly.
z Confirm by the fingers of your both

hands that swash plate moves 212
smoothly.
z The shaft be installed easily if grease
is applied to the moving parts of
swash plate and swash plate
support.
Fig. 1-13 Installing swash plate (212)
33-47
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251). 251
z Do not knock on the shaft with a

hammer or something. 123
z Fix the bearing by lightly tapping
127,824
the outer race of it by means of a
plastic hammer and set it exactly to
the end by using a steel rod and
others.
111
Fig. 1-14 Installing shaft (111)
5) Installing seal cover

Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406). 271
: 5mm,
Tightening torque : 1.2kgfym (8.8 lbfyft) 261
z Coat the oil seal in seal cover (F) 406

with a thin film of grease.
z Handle the oil seal with sufficient
care so it is not scored.
z Fit seal cover (R) (262) the same way
as above.
Fig. 1-15 Installing seal cover F (261)
6) Inserting piston cylinder sub

Assemble the piston cylinder sub [cylinder
141(151,152)
block (141), piston (151), shoe (152), plate
(153), spherical bushing (156) and cylinder 156
spring (157)].
Align the spherical bushing with the cylinder 153
spline and insert them into the pump casing.
Fig. 1-16 Inserting piston cylinder sub
33-48
7) Installing valve plate

Install valve plate (313), (314) to valve block
(312) by aligning pin.
z Do not mistake the suction and 312

delivery sides olbfhe valve plate.
8) Installing valve block 314

Install valve block (312) to pump casing (271) (313:OPPOSITE SIDE)
and fasten them together with socket bolts
(401).
: 14mm,
Tightening torque : 24kgfym (170 lbfyft) Fig. 1-17 Installing valve plates (313), (314)
z Work will be promoted if assembly is

started from the rear pump. 271
401
z Exercise care so as not to mistake
the direction olbfhe valve block
(312). (Install it so the regulator
comes up as seen from the front side
and the suction flange comes on the
right.)
z Insert the 1st gear into the valve
block beforehand and connect it with
the spline olbfhe shalbf.
Fig. 1-18 Installing valve block (312)
9) Installing regulator and PTO gear casing

Pinch feedback pin olbfilting pin in feedback
REGULATOR
lever olbfhe regulator and PTO gear casing,
install the regulator and fasten socket bolt.
Refer to [415 (See Fig.1-20.), 435[See Fig.1-
34.)].
Socket bolt (415) ............. For regulator

: 6mm,
Socket bolt (435) .............For PTO gear casing
: 8mm,
Tightening torque : 3.4kgfym (25 lbfyft) Fig. 1-19 Installing regulator and PTO gear casing
z Do not mistake the front regulator

for the rear regulator.
10) Installing drain port plug

The work is complete when drain port VP
plugs (467), (468) have been set.
: 27mm,
33-49
1.1.3 MAINTENANCE STANDARDS

(1) Replacement standards for abrasive parts However, always replace such parts that
Replace or readjust parts that exceed the show excessive damage on appearance.
following standards of wear.
Unit: mm (in)
Standard Recommended
Part name and inspection item value for Remedy
dimension replacement
Clearance between piston and 0.028 0.056
Replace piston or cylinder.
cylinder bore (D－d) (0.0011˝) (0.0022˝)
Gap between piston and caulked part 0～0.1 0.3

Replace piston shoe assy.
of shoe (δ) (0.004˝) (0.012˝)
3.9 3.7
Thickness of shoe (t) Replace piston shoe assy.
(0.154˝) (0.146˝)
31.3 30.2
Free height of cylinder spring (L) Replace cylinder spring .
(1.23˝) (1.19˝)
Combined height of retainer plate and 10.5 9.8 Replace a set of spherical
spherical bushing (H－h) (0.413˝) (0.386˝) bushing or retainer plate.
H
h
Combination of retainer plate and spherical

Clearance between piston and bushing Height=H-h
cylinder bore: D－d
t δ
L
Gap between piston and shoe : δ
thickness of shoe: t Free height of cylinder spring: L
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section) Surface roughness requiring correction 3－Z
Swash plate (shoe plate face)
Cylinder (sliding section) Standard surface roughness
(correction value) Less than 0.4Z (lapping)
Roughness of each surface
33-50
1.1.4 TROUBLESHOOTING
(1) Locating causes of troubles
The pump is usually fitted with a regulator. Check that the hunting of the regulator and
auxiliary valves and auxiliary pumps, and the attached valve’s relief valve are of regular
this makes fault location extremely difficult frequency. In case vibration and sound are
However. faults would be found out easily if abnormal, the pump may be making a
the following check items were attended to. cavitation or internally broken.
1) Inspecting the filter and drain oil 3) When two pumps are used
Inspect the filter element to check for In case two single pumps or motors are used
abnormal contaminations. Some metallic or when a double pump is used. change pump
particles will be deposited on it as the shoe pipelines. This will make clear that the
and the cylinder wear off. In case metallic pumps are faulty or the circuit after the
particles are found in large quantity, the pumps is faulty.
elements may be damaged. In that case check
the drain oil in the pump casing as well. 4) Pressure measurements
If the problem is related to control functions,
2) Checking for abnormal vibration and sound avoid disassembling the pumps carelessly,
Check that the pump does not vibrate and but look for causes by measuring pressures.
make an abnormal sound.
(2) Troubleshooting
1) Overloading to engine
Cause Remedy Remarks

1. Revolution and pressure are 1) Set pressure to specified
higher than set values. value.
2. Regulator torque is set higher 2) Readjust regulator. 2) Refer to Regulator Manual.
than normal.
3. Pump’s internal parts are 3) Replace damaged parts. 3) Check filter and drain oil to see if
seized or broken. abnormal wear particles are
present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.
33-51
(2) Pump’s oil flow rate is extremely low and delivery pressure is not available.
Cause Remedy Remark

1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pump’s internal parts are 2) Replace damaged parts. 2) Check filter and drain oil.
seized or broken.
3. Attached pump is out of order. 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Check attached valve. 4) Refer to Manual for Attached
Particularly poppet, Valve.
seat and spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.
(3) Abnormal Sound and Vibration
Cause Remedy Remark

1. Cavitation 1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil 1-2) The attached pump is in trouble.
is not clouded. 1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2) Replace piston shoe and
shoe plate.
3. Cylinder is cracked 3) Replace cylinder.
4. Pump is installed improperly. 4) Correct installation.
5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual.
6. Relief valve in attached valve 6) Repair attached valve. 6) See the Manual for Attached
is hunting. Valve.
33-52
1.2 REGULATOR
1.2.1 STRUCTURAL EXPLODED VIEW
656 402
733
627
646
624
496 601
801
924
415
543
545
541
079 756
755
614
733
887
658
724
325 418 708
496 652
897
Table 1-4
651
643 611 TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
631
079 SOLENOID PROPORTIONAL
REDUCING VALVE
1 643 PISTON 1
731
325 VALVE CASING 1 646 SPRING 1
1.2 (8.7) 402 SOCKET BOLT ; M6×16 4 651 SLEEVE 1
1.2 (8.7) 407 SOCKET BOLT ; M6×30 4 652 SPOOL 1
755
407 466 3.0 (22) 415 SOCKET BOLT ; M8×45 6 656 COVER 1
0.7 (5.1) 418 SOCKET BOLT ; M5×12 2 0.9 (6.5) 658 PLUG ; NPTF1/16 1
1.6 (12) 466 VP PLUG ; PF1/4 1 708 O RING ; 1B G75 1
0.9 (6.5) 496 PLUG 9 724 O RING ; 1B P8 5
541 SEAT 2 731 O RING ; 1B P25 1
543 STOPPER 2 733 O RING ; 1B P18 2
545 BALL 2 755 O RING ; 1B P11 2
601 CASING 1 756 O RING ; 1B P12.5 2
611 FEEDBACK LEVER 1 1.6 (12) 801 HEX. NUT ; M8 1
3.7 (27) 614 FULCRUM PLUG ; PF1/4 1 887 PIN 1
624 SPRING SEAT 1 897 PIN 1
627 PLUNGER 1 924 SET SCREW 1
631 SLEEVE 1
Fig. 1-20 Structural exploded view of regulator
33-53
1.2.2 DISASSEMBLY AND ASSEMBLY
(1) Tools
The right list shows the tools required for Table 1-5
remove and install.
Tool name Dimension
(2) Disassembling procedure Allen wrench Opposing flats 4,5,6,8mm

1) Selecting a place for disassembly. Eye wrench
Socket wrench
Wrench with double Opposing flats 19mm
z Choose a clean place. heads (single head)
z Spread rubber sheet or cloth on work
bench to protect parts from Adjust wrench Medium size 1pc.
damaging.
Screw driver Flat-bladed screw driver 1pc.
Plunger (627),
Socket bolt for drawing out (M4)
2) Cleaning
One that may be fastened to
Remove dust and rust, etc. on regulator Torque wrench specified torque
surface with wash oil.
3) Remove regulator
REGULATOR
Remove socket bolts (415) and separate the
regulator from the pump body.
: 6mm
z Exercise care so as not to lose O

rings and check valve sub (541),
(543), and (545).
Fig. 1-21 Removing regulator
4) Remove valve casing

Remove socket bolts (407) and remove valve
casing (325) with solenoid proportional
reducing valve (079).
: 5mm
325 (079)
407
Fig. 1-22 Removing valve casing (325)
33-54
5) Remove cover
Remove socket bolt (402) and cover (656).
: 5mm
z The cover is assembled with set

screw (924) and hex nut (801), but do
not loosen them. If they are 801
loosened, the pressure settings
change.
402 924 656

Fig. 1-23 Removing cover (656)
6) Remove sleeve and pilot piston

Draw out sleeve (631) and pilot piston (643)
from the regulator body.
631(643)
Fig. 1-24 Removing sleeve (631)
and pilot piston (643)
7) Remove feedback lever

Remove fulcrum plug (614) and feedback 611
lever (611).
: 19mm
8) Drawing out the spool and the sleeve

Draw out spool (652) and sleeve (651) from
the sleeve hole of the regulator casing.
HOLE FOR FULCRUM PLUG (614)

Fig. 1-25 Removing feedback lever (611)
9) Remove plunger, pilot spring and spring seat

Draw out plunger (627). Then take out pilot 627(624,646)
spring (646) and spring (624).
z The plunger comes off easily if an

M4 bolt is used.
Fig. 1-26 Removing plunger (627)
33-55
10) Drawing out the check valve 541

The disassembly is complete when the check
valve [seat (541), ball (545), and stopper
(543)] have been drawn out.
543 (545)
z The check valves are placed on two
places; the mating surface of the
pump casing and on the matching
surface of the valve casing.
601
Fig. 1-27 Drawing out the check valve.
1. Do not fail to correct parts damaged during
disassembly and get replacement parts ready
beforehand.
2. Entry of foreign matter causes faulty
functions; clean parts thoroughly, dry them
with jet air and work in a clean place.
3. Tighten bolts and plugs to specified torques.
4. Do not fail to coat the moving parts with
clean hydraulic oil, before proceeding to
assembly.
5. In principle, replace seals such as O rings
with new ones.
541
1) Placing the check valve
Fit the check valve to casing (601).
z Assemble the check valve into the 543 (545)

matching surface of the pump casing
and the matching surface of the
valve casing.
601
Fig. 1-28 Placing the check valve.
2) Fitting the sleeve and the spool

Place sleeve (651) and spool (652) into the 601
sleeve hole of casing (601).
z Make sure that the spool and the

sleeve slide smoothly in the casing
without interference.
z Beware of the direction of the spool.
651(652)
Fig. 1-29 Fitting the sleeve (651)
and the spool (652).
33-56
3) Installing feedback lever 611(897)

Insert pin (897) of feedback lever (611) into
the pin hole olbfhe sleeve and fix the
feedback lever with fulcrum plug (614).
: 19mm,
z Operate the feedback lever and

make sure that it does not have
much looseness and that it operates 614
without catching. Fig. 1-30 Installing feedback lever (611)
4) Installing spring seat, pilot spring and 646(627)

plunger
Place spring seat (624), pilot spring (646) and
plunger (627) into the hole in the sleeve.
Fig. 1-31 Installing spring seat (624),

pilot spring (646) and plunger (627)
5) Installing cover
Attach cover (656) to casing (601) and fasten
them together with socket bolts (402).
: 5mm,
Tightening torque : 1.2kgfym (8.7 lbfyft)
z The cover is fitted with set screw

(924) and hex nut (801).
601
656 402
Fig. 1-32 Installing cover (656)
6) Assembling the sleeve and the pilot piston
Assemble sleeve (631) and pilot piston (643)
into casing (601).
7) Installing valve casing

Attach valve casing (325) fitted with solenoid
proportional reducing valve (079) to casing
(601) and fasten them together with socket
bolts (407).
: 5mm, 631
Tightening torque : 1.2kgfym (8.7 lbfyft)
643
Fig. 1-33 Assembling the sleeve (631)

This completes assembly.
and the pilot piston (643).
33-57
1.3 PTO GEAR CASING

1.3.1 STRUCTURAL EXPLODED VIEW
414
117 128
126 435
826 886 711
326
128
414
115
827 886 262
728
125 468
118
125
825
435
435
Fig. 1-34 Structural exploded view of PTO gear casing
Table 1-6
115 IDLE SHALBF 1 3.4 (25) 435 FLANGE SOCKET ; M10×20 4
117 2nd GEAR 1 7.5 (54) 468 VP PLUG ; PF3/4 1
118 3rd GEAR 1 711 O RING ; 1B G85 1
125 BALL BEARING 2 728 O RING ; 1B P24 1
126 ROLLER BEARING 1 825 SNAP RING 1
128 BEARING SPACER 2 826 SNAP RING 1
262 COVER 1 827 SNAP RING 1
326 GEAR CASING 1 886 PIN 2
3.4 (25) 414 SOCKET BOLT ; M10×20 2
33-58

(1) Tools
The right list shows the tools required for Table 1-7
remove and install.
Tool name Dimension
(2) Disassembling procedure Allen wrench Opposing flats 8mm

1) Selecting a place for disassembly. Eye wrench
Socket wrench
Wrench with double Opposing flats 27mm
z Choose a clean place. heads (single head)
z Spread rubber sheet or cloth on work For snap ring RR-20
bench to protect parts from Plier For snap ring RR-72
damaging.
2) Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing drain port plug (467), (468).
FLANGE SOCKET (M10)
: 27mm
TIGHTENING TORQUE : 3.4kgfym (25ftylbs)
z Drain out the oil from the plugs of

the front pump and the rear pump.
4) Remove gear pump and cover

Remove the flange socket and the socket
bolts. Then remove the gear pump and the
cover. GEAR PUMP
: 8mm (FOR DOZER)
COVER
PTO GEAR CASING
435
GEAR PUMP
Fig. 1-35 Removing gear pump
5) Remove PTO gear casing
Remove flange socket (435) and PTO gear
casing.
: 8mm HOLE FOR FLANGE
SOCKET (435)
PTO
GEAR CASING
Fig. 1-36 Removing PTO gear casing
33-59
6) Removing the 2nd gear, the roller bearing HOLE FOR

IDLE SHAFT (115)
and the bearing spacer
Remove snap ring (827) and idle shaft (115).
Then draw out 2nd gear (117), roller bearing
(126) and bearing spacer (128). 117(126,128)
z Roller bearing (126) can not be

separated from 2nd gear (117).
Fig. 1-37 Removing 2nd gear (117)

7) Removing the 3rd gear and the ball bearing
Remove snap ring (825) and draw out 3rd
gear (118) and ball bearing (125).
z Ball bearing (125) can not be 125

separated from 3rd gear (118).
118
Fig. 1-38 Removing 3rd gear (118)

and ball bearing (125)

1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
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 Service Standard, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
1.3.3 MAINTENANCE STANDARDS

In case a pitching (1 pit is more than 1mm
(0.039in), while the area ratio is more than 5%.) is
seen on the gear tooth surface of 2nd gear (117)
and 3rd gear (118), replace the gears. Replace the
gears also in case they show excessive damage.
33-60
2. CONTROL VALVE
2.1 GENERAL PRECAUTIONS 2.3 DISASSEMBLY
1) As all the hydraulic components are precisely Regarding the construction of the control valve,
machined, it is essential to carry out refer to 4.2 Construction, 4. Control.
disassembly and reassembly in an especially The figures in parentheses after part names in
clean location. the contents represent those in the above-
2) When handling the control valve, take special mentioned Fig.1-1 structural exploded view.
care to prevent the entry of foreign matter,
such as dust or sand. Place the control valve on the workbench with the
3) Cap each port of the control valve before ports facing upward.
removing the valve from the machine. Before
disassembly, confirm that each cap is in place Disassemble the valve in a clean
and then clean the exterior of the assembly. location, and be careful not to damage
Use an appropriate workbench. Lay a clean flange surfaces or plate mounting
sheet of paper, rubber mat, or the like over surfaces.
the workbench.
4) When carrying or moving the control valve,
hold the body, and never put pressure on a
lever, an exposed spool, or the end cover.
Handle the valve with care.
5) Tests(for relief characteristics, leaks,
overload valve setting, flow resistance, etc.)
that are desired after disassembly and
reassembly require hydraulic testing
apparatus.
For this reason, do not disassemble hydraulic
units that you are capable of disassembling
but cannot test or adjust.
Prepare beforehand washing fluid, hydraulic
oil, grease, etc. . Fig. 2-1 Preparation for disassembly
(valve upper side)
2.2 TOOLS
Prepare the following tools before disassembling
the control valve.
No. Name Table

Q’ty2-1 Remarks
a Vise 1
b Box end wrench 1 of each 8,22,24,27,30,32mm
size
c Allen wrench 1 of each 4,5,6,8,10,12,14,22mm
size
e Locktite #262 1
Fig. 2-2 Preparation for disassembly
f Spatula 1
(valve lower side)
g Tweezers 1
h Adjust wrench 1
33-61
(1) Remove option valve block 213(272)

1) Loosen the socket bolts (272) and remove the
option valve (213).
: 10mm
Regarding the disassembly of the

optional valve block, refer to the
Disassembling option valve under (20).
(2) Remove plate Fig. 2-3 Removing option valve

271
plate (214).
: 10mm 214
Fig. 2-4 Removing plate (214)

(3) Disassembling arm recirculation spool
273 204(262)
spring cover (204) and the O ring (262) for
arm recirculation.
: 6mm
Fig. 2-5 Removing arm recirculation

2) Draw out, from casing A (101), the assy of spool spring cover (204)
arm recirculation spool (310), spring seat
310
(332), springs (325), (326), stopper (337) and
bolt (333).
When drawing out the spool assy, use

care so as not to score casing A (101).
Fig. 2-6 Drawing out arm recirculation spool
33-62
3) Fix the arm recirculation spool assy with vise

via a protective plate (aluminum plate, etc.)
and remove bolt (333). Then separate spring
seat (332), springs (325), (326) and stopper 333
(337) from arm recirculation spool (310).
332
326(337)
325
310
Fig. 2-7 Disassembling arm recirculation

(4) Disassembling cut spool spool assy
1) Loosen socket bolt (273) and separate spring 273 204(262)
cover (204) and O ring (262) from the cut
spool.
: 6mm
2) Draw out the assy of cut spool (309), spring Fig. 2-8 Removing cut spool spring cover (204)
seat (332), springs (325), (326), stopper (337) 309
and bolt (333) from casing A (101) or casing B
(102).
When drawing out the spool assy, take

care so as not to score casing A (101) or
casing B (102).
3) Fix the cut spool assy with vise via a Fig. 2-9 Drawing out cut spool assy
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (325), (326) and stopper (337)
from cut spool (309). 333
332
326(337)
325
309
Fig. 2-10 Disassembling cut spool assy
33-63
273
(5) Disassembling the arm spool
1) Loosen socket bolts (273) and remove spring 201(262)
cover (201) for arm and O ring (262).
: 6mm
2) Draw out the assy of arm spool (302), spring Fig. 2-11 Removing arm spool spring cover (201)
seat (332), springs (324), (329), stopper (337)
302
and bolt (333) from casing A (101).

3) Fix the arm spool assy with vise via a Fig. 2-12 Drawing out arm spool assy
333
from arm spool (302).
: 6mm 332
324(337)
4) Do not disassemble the arm spool (302) 329
further unless there is any problem.
302
Take care so as not to distort arm spool
(302) by overtightening it in the vise.
(6) Disassembling the boom spool Fig. 2-13 Disassembling arm spool assy
1) Loosen socket bolts (273) and remove spring 273
cover (201) for boom and O ring (262). 201(262)
: 6mm
Fig. 2-14 Removing boom spool spring cover

(201)
33-64
2) Draw out the assy of boom spool (301), spring 301

and bolt (333) from casing B (102).

care so as not to score casing B (102).
Fig. 2-15 Drawing out boom spool assy

3) Fix the boom spool assy with vise via a
(332), springs (328), (329) and stopper (337) 333
from boom spool (301). 332
328(337)
329
301
Fig. 2-16 Disassembling boom spool assy

4) Do not disassemble the boom spool (301)
301
further unless there is any problem.
Take care so as not to distort boom

spool (301) by overtightening it in the
vise.
(7) Disassembling the boom conflux spool Fig. 2-17 Disassembling boom spool (301)
1) Loosen socket bolts (273) and remove spring
cover (201) for boom conflux and O ring (262).
201(262)
: 6mm
273
Fig. 2-18 Removing boom conflux
spool spring cover (201)
33-65
2) Draw out the assy of boom conflux spool

(305), spring seat (332), springs (325), (326), 305
stopper (337) and bolt (333) from casing A
(101).

Fig. 2-19 Drawing out boom conflux spool assy
3) Fix the boom conflux spool with vise via a

from boom conflux spool (305).
332
326(337)
325
305
Fig. 2-20 Disassembling boom conflux spool assy
(8) Disassembling bucket spool 273

1) Loosen socket bolts (273) and remove bucket
spring cover (201) and O ring (262). 201(262)
: 6mm
Fig. 2-21 Removing bucket spool spring cover
2) Draw out the assy of bucket spool (304), 304

spring seat (332), springs (328), (329), stopper
(337) and bolt (333) from casing B (102).

Fig. 2-22 Drawing out bucket spool assy
33-66
3) Fix the bucket spool assy with vise via a

from bucket spool (304).
332
328(337)
329
304
Fig. 2-23 Disassembling bucket spool assy

(9) Disassembling the swing spool
cover (201) and O ring (262).
: 6mm
273 201(262)
Fig. 2-24 Removing swing spool spring cover
2) Draw out the assy of swing spool (303), spring
and bolt (333) from casing A (101).
303
care so as not to score casing A (101) or
casing B (102).
Fig. 2-25 Drawing out swing spool assy

3) Fix the swing spool assy with vise via a
from swing spool (303). 333
332
324(337)
329
303
Fig. 2-26 Disassembling swing spool assy
33-67
(10) Disassembling the travel spool

(left travel and right travel)
travel.
: 6mm
273 201(262)
Fig. 2-27 Removing travel (right)

2) Draw out the assy of travel spool (306), spool spring cover
spring seat (332), springs (325), (327), stopper
(338) and bolt (333) from casing A (101) or
casing B (102). 306

care so as not to score the casing A
(101) or the casing B (102).
3) Fix the travel spool assy with vise via a Fig. 2-28 Drawing out travel (right) spool assy
protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
from travel spool (306).
333
332
327(328)
325
306
(11) Disassembling travel straight spool Fig. 2-29 Disassembling travel (right) spool
1) Loosen the socket bolts (273) and remove the (306)
travel straight.
: 6mm
273 201(262)
Fig. 2-30 Removing travel straight
spool spring cover
33-68
2) Draw out the assy of travel straight spool

(307), spring seat (332), springs ※1 (325),
※2 (326), stopper ※3 (337) and bolt (333) 307
from casing B (102).

care so as not to score the casing B
(102).
Fig. 2-31 Drawing out travel straight spool assy
3) 3) Fix the travel straight spool assy with (307)
vise via a protective plate (aluminum plate,
etc.). Remove bolt (333) and separate spring
seat (332), springs ※1 (325), ※2 (326) and
stopper ※3 (337) from travel spool (307).
333
332
326(337) ※2, ※3{323(339)}
325 ※1(322)
307
Fig. 2-32 Disassembling travel straight

spool assy (307)
(12) Remove lock valve selector sub
Loosen socket bolts (L171) and remove lock L171
valve selector (211). 211
: 5mm
Do not disassemble the lock valve

selector sub assy.
Fig. 2-33 Removing lock valve selector sub assy

273
(13) Disassembling the arm conflux spool 204(262)
cover (204) and O ring (262) for arm conflux.
: 6mm
Fig. 2-34 Removing arm conflux

spool spring cover
33-69
2) Draw out the assy of arm conflux spool (308), 308

spring seat (332), spring (325), (326), stopper
(337) and bolt (333) from casing B (102).

Fig. 2-35 Drawing out arm conflux spool assy

3) Fix the arm conflux spool assy (308) with vise
via a protective plate (aluminum plate, etc.)
and remove bolt (333). Then separate spring
seat (332), springs (325), (326) and stopper
(337) from arm conflux spool (308). 333
332
326(327)
325
308
Fig. 2-36 Disassembling arm conflux spool assy

(14) Removing spool cover
273
Loosen the socket bolts (273) for the travel,
206(265)
arm, boom, bucket, swing, travel straight and
boom conflux sections. Then remove spool
cover (206) and O ring (265).
: 6mm
Fig. 2-37 Removing spool covers (206)
(15) Removing relief valve

Remove the main relief valve (601) and port
relief valve (602) from the casing.
Regarding the disassembly of the relief valve,
refer to the disassembling Main and Port
relief valve. Refer to (18) and (19).
: 30mm
601
Fig. 2-38 Removing main relief valve(601)
33-70
602
Fig. 2-39 Removing port relief valve (602)

552
(16) Remove check valve
1) Arm recirculation check valve (CAr)
Loosen plug (552) and remove poppet (512)
and spring (522).
Remove the load check valve the same way.
(CT2,CP2,LCs,CCb,LCa)
(CP1,LCc,LCb,CCa)

check valve plug (552)
512(522)

check valve poppet (512)
2) Check valve in the lock valve section.
(Arm; CRa, Boom; CRb) 556
Loosen plug (556) and remove poppet (514)

and spring (524).
Exercise care so as not to mistake them

as they all differ in kind from 1) above.
Fig. 2-42 Removing arm lock valve plug (556)
33-71
514
524
Fig. 2-43 Removing arm lock valve poppet (514)
3) Check valve in the travel straight section
(CT1)
Remove plug (552). Then remove poppets 552
(512) and spring (522).
: 10mm CT1
522
512
SECTION H´ -H´
Fig. 2-44 Removing check valve
in the travel straight section
4) Check valve in the main relief valve section
(CMR1,CMR2)
513
Remove plug (552) and remove poppet (513)
522
and spring (522). CMR1
: 10mm 552
CMR2
552
Those plugs that are not mentioned in
the foregoing disassembly procedure 522
are blind for extra holes and cast-on 513
holes; do not remove them unless SECTION C-C
necessary. Fig. 2-45 Removing check valve
in the main relief valve section
973
(17) Disassembling casing
1) Loosen socket bolts (973), (974) and separate
casing A (101) and casing B (102).
: 12mm
Fig. 2-46 Disassembling casing
33-72
(18) Disassembling main relief valve

1) Remove plug (103) and seat (541) by pulling
them by hand as snap ring (121) is fixed.
2) Draw out spring (521) and plunger (512) from
inside seat (541).
3) Remove locknut (671) and adjust screw (651).
Remove spring plate (612), spring (621) and
poppet (611).
4) Separate snap ring (121), spacer (122), O ring
(561) and backup ring (562) from plug (103).
541 121 103
Filter (125) and filter stopper (124) are
assembled with plug (103) by means of Fig. 2-47 Disassembling main relief valve
snap ring (123).
Therefore, it can not be disassembled
any further.
(19) Disassembling port relief valve

1) Loosen plug (102), remove springs (521),
(522) and seat (541) out of body (101) and
draw out piston (301) and plunger (511) out
of seat (541).
: 30mm
2) Separate locknut (671) and adjust screw (651) 102

from plug (102) and remove spring seat (612),
spring (621) and poppet (611).
Filter (125) and filter stopper (124) are

assembled with plug (103) by means of
101
snap ring (123).
Therefore, it can not be disassembled Fig. 2-48 Disassembling port relief valve
any further.
33-73
(20) Disassembling option valve

1) Loosen the socket bolts (S271) and remove
the spring cover (S202) and the O ring (S261)
for option.
: 6mm
2) Draw out the assy of option spool (S301),

spring seat (S337), springs (S323), (S324),
stopper (S333) and bolt (S334) from casing
(S101).

care so as not to score the casing
(S101).
3) Fix the option spool assy with vise via a

protective plate (aluminum plate, etc.).
Remove bolt (S334) and separate spring seat
(S337), springs (S323), (S324) and stopper
(S333) from option spool (S301).
: 6mm
4) Loosen the socket bolts (S271) and remove

the spool cover (S204) and the O ring (S262)
for option.
: 6mm
5) Remove the port relief valve (S603) from the

casing (S101).
Regarding the disassembly of the relief valve,
refer to the disassembling Main and Port
relief valve. Refer to (18) and (19).
6) Loosen the plug (S551) and remove the

poppet (S512) and spring (S522).
: 12mm
7) Remove the O ring (S161).
33-74
2.4 INSPECTION AFTER DISASSEMBLY 7) Remove any slight defects found during the
Thoroughly clean all disassembled parts with above inspection by lapping.
wash oil, and dry them with jet air. Place each 8) If any abnormal part is found, replace the
part on a clean sheet of paper or cloth for relief valve as an assy.
inspection.
(1) Control valve 2.5 REASSEMBLY

1) Inspect the entire surface of each part for 1) Here, only the reassembly procedures are
burrs, scratches, cuts, and other defects. described. Regarding drawings, refer to the
2) Confirm that the O ring groove surface of the disassembly procedures.
casing or the block is free from foreign
matter, dents or rust. 2) The figures in parentheses after part names
3) If the check valve seat of the casing or the in the contents represent those in 4. Control
block has dents or damage on its surface, Valve under SEZ. 24 Components System.
smooth it by lapping.
3) Precautions on reassembling O ring
Take care not leave lapping compound 1. Confirm that O rings are free from defects
behind in the casing or block. caused by poor handling.
2. Apply thin coat of grease or hydraulic oil to O
4) Confirm that O ring or the outer rings and their mating parts.
circumference of the sliding part of a manual 3. Do not stretch O rings to the extent that they
spool is free from scratches, dents, and the become permanently set.
like. Remove any small defects with an oil 4. When installing O rings, do not roll them into
stone or lapping compound. place. Twisted O rings do not easily untwist
5) Manually confirm that all sliding and fitted by themselves after installation, and can
parts move smoothly. Confirm that all cause oil leaks.
grooves and passages are free from foreign 5. Use a torque wrench to tighten each
matter. attaching bolt. Tighten to the torque
6) Replace any broken or deformed spring with in“Maintenance Standards.”
new one.
7) Of a relief valve malfunctions, repair it by (1) Casing
following the relief valve disassembly and 1) Fix O rings (162,163) to casing B (102). Then
reassembly procedures. fasten socket bolts (973,974) against casing A
8) Replace all O ring with new ones. (101) to the specified torque.
(2) Relief valve Confirm that the mating surface is free

1) Confirm that the seating face of each poppet from foreign matter such as dust, and
and each seat edge is free from defects and is that each O ring is securely installed in
a uniform contact surface. its groove.
2) Manually confirm that the main poppet slides
smoothly onto and off the seat. (2) Assembling check valve
3) Confirm that the outer circumference of the 1) Load check valve, conflux check valve, etc.
main poppet and the inner circumference of Fit poppet (512) and spring (522), put O ring
its seat are free from defects such as (562) in plug (552) and fasten it to the
scratches. specified torque. (10 places)
4) Confirm that each spring is free from
breakage, deformation, and excessive wear. 2) Lock valve (CRa, CRb)
5) Confirm that the orifices of the main poppet Fix poppet (514) and spring (524), put O ring
and its seat are not clogged. (562) in plug (556) and fasten it to the
6) Replace all O rings with new ones. specified torque. (2 places)
33-75
Plugs (552) and (556) look similar; use (5) Assembling travel straight spool
care of the parts combination and 1) Put a mouthpiece (aluminum plate, etc.)
assembling position. in the vise and hold the center of travel
straight spool (307) in it. Set spring seat
3) Travel straight sections (CT1) (332), springs ※1 (325), ※2 (326) and stopper
Fit poppets (512) and spring (522), put O ring ※3 (337) and tighten bolts (333) to the
(562) in plug (552) and fasten it to the specified torque.
specified torque.
z When tightening bolts (333), coat
Use care of the assembling position of them with Loctite #262.
poppet (512) for travel straight. z Be careful so as not to distort travel
straight spool (307) by over-tightening
4) Main relief valve sections (CMR1, CMR2) it in the vise.
Fit poppets (513) and spring (522), put O ring
(562) in plug (552) and fasten it to the 2) Assemble the travel straight spool assy in 1)
specified torque. into casing B (102).
(3) Installing relief valve When assembling the travel straight

1) Tighten main relief valve (601) and port relief spool assy into casings B (102), do it
valves (602) to the specified torques in correct slowly and carefully ; never force it in.
positions.
3) Fit O ring (262) to the spring side of the
Regarding the reassembly of the relief travel straight spool assy. Then attach spring
valve, refer to the (15), (16) assembling cover (201) to the assy and tighten socket
Main and Port relief valve. bolts (273) to the specified torque.
(4) Assembling arm conflux spool (6) Assembling travel spool

1) Put a mouthpiece (aluminum plate, etc.) to a 1) Put a mouthpiece (aluminum plate, etc.) in
vise. Hold the center of arm conflux spool the vise and hold the center of travel spool
(308) in the vise, set spring seat (332), (306) in it. Set spring seat (332), springs
springs (325), (326) and stopper (337) and (325), (327) and stopper (338) and tighten
tighten bolts (333) to the specified torque. bolts (333) to the specified torque.
z Before tightening bolts (333), coat z When tightening bolts (333), coat
them with Loctite #262. them with Loctite #262.
z Be careful so as not to distort arm z Be careful so as not to distort travel
conflux spool (308) by overtightening spool (306) by overtightening it in
it in the vise. the vise.
2) Fix the arm conflux spool assy in 1) into 2) Assemble the travel spool assy in 1) into
casing B (102). casing A (101), B (102).
Fix the arm conflux spool assy into When assembling the travel spool assy
casing B (102) slowly and carefully and into casings A (101), B (102), do it
never force it in. slowly and carefully ; never force it in.
3) Attach spring cover (204) with O ring (262) to 3) Fit O ring (262) to the spring side of the
the spring side of the arm conflux spool assy. travel spool assy. Then attach spring cover
Then fasten socket bolts (273) to the specified (201) to the assy and tighten socket bolts
torque. (273) to the specified torque.
33-76
(7) Assembling swing spool (9) Assembling boom conflux spool

1) Put a mouthpiece (aluminum plate, etc.) to 1) Put a mouthpiece (aluminum plate, etc.) and
the vise and hold the center of swing spool hold the center of boom conflux spool (305) in
(303). Set spring seat (332), springs (324), the vise. Set spring seat (332), springs (325),
(329) and stopper (337) and tighten bolts (326) and stopper (337) and tighten bolts
(333) to the specified torque. (333) to the specified torque.
z When tightening bolts (333), coat z When tightening bolts (333), coat
z Be careful so as not to distort swing z Use care so as not to distort boom
spool (303) by overtightening it in conflux spool (305) by overtightening
the vise. it in the vise.
2) Assemble the swing spool assy in 1) into 2) Fix the boom conflux spool assy in 1) into
casing A (101). casing A (101).
When assembling the swing spool assy When assembling the boom conflux
into casing A (101), do it slowly and spool assy into casing A (101), do it
carefully ; never force it in. slowly and carefully ; never force it in.
3) Put O ring (262) to the spring side of the 3) Fit O ring (262) to the spring side of the boom
swing spool assy and attach spring cover conflux spool assy and attach spring cover
(202) to the assy. Then tighten socket bolts (201) to the assy. Then tighten socket bolts
(273) to the specified torque. (273) to the specified torque.
(8) Assembling bucket spool (10) Assembling boom spool

1) Put a mouthpiece (aluminum plate, etc.) to 1) Put a mouthpiece (aluminum plate, etc.) in a
the vise and hold the center of bucket spool vise and hold the center of boom spool (301)
(304) in it. Set spring seat (332), spring (328), in the vise. Set spring seat (332), springs
(329) and stopper (337) and tighten bolts (328), (329) and stopper (337) and tighten
(333) to the specified torque. bolts (333) to the specified torque.
z When tightening bolts (333), coat z When tightening bolts (333), coat
z Be careful so as not to distort bucket z Be careful so as not to distort boom
spool (304) by overtightening it in spool (301) by overtightening it in
the vise. the vise.
2) Assemble the bucket spool assy in 1) into 2) Install the boom spool assembly reassembled
casing B (102). in Article 1) above in casing B (102).
When assembling the bucket spool assy When assembling the boom spool assy
into casing B (102), do it carefully and into casing B (102), do it slowly and
slowly ; never force it in. carefully ; never force it in.
3) Fit O ring (262) to the spring side of the 3) Attach O rings (262) to the spring side of the
bucket spool assy and attach spring cover boom spool assy. Then fit spring cover (201)
(201) to the assy. Then tighten socket bolts to the assy and tighten socket bolts (273) to
(273) to the specified torque. the specified torque.
33-77
(11) Assembling arm spool

1) Put a mouthpiece (aluminum plate) in the (13) Assembling arm recirculation spool
vise and hold the center of arm spool (302) in 1) Put a mouthpiece (aluminum plate) in the
the vise. Set spring seat (332), springs (324), vise and hold the center of arm recirculation
(329) and stopper (337) and tighten bolts spool (310) in the vise. Set spring seat (332),
(333) to the specified torque. springs (325), (326) and stopper (337) and
tighten bolts (333) to the specified torque.
z When tightening bolts (333), coat
them with Loctite #262. z When tightening bolts (333), coat
z Take care so as not to distort arm them with Loctite #262.
spool (302) by overtightening it in z Take care so as not to distort arm
the vise. recirculation spool (310) by over-
tightening it in the vise.
2) Fit the arm spool assy in 1) to casing A (101).
2) Fit the arm recirculation spool assy in 1) to
When assembling the arm spool assy casing A (101).
into casing A (101), do it slowly and
carefully ; never force it in. When assembling the arm recirculation
spool assy into casing A (101), do it
3) Attach spring cover (201) with O ring (262) to slowly and carefully ; never force it in.
the spring side of the arm spool assy. Then
tighten socket bolts (273) to the specified 3) Attach spring cover (204) with O ring (262) to
torque. the spring side of the arm recirculation spool
assy. Then tighten socket bolts (273) to the
(12) Assembling cut spool specified torque.
1) Put a mouthpiece (aluminum plate, etc.) in a
vise and hold the center of cut spool (309) in (14) Assembling spool covers
the vise. Set spring seat (332), springs (325), 1) Travel, boom, bucket, swing and arm.
(326) and stopper (337) and fasten bolts (333) Fit O ring (265) to spool cover (206) and
to the specified torque. tighten socket bolts (273) to the specified
torque.
z Before tightening bolts (333), coat
them with Loctite #262. 2) Travel straight and boom conflux
z Use care so as not to distort cut spool Fit O ring (265) to spool cover (206) and
(309) by overtightening it in the vise. tighten socket bolts (273) to the specified
torque.
2) Fit the cut spool assy in 1) into casing A (101)
and casing B (102). (15) Assembling main relief valve
1) Fit spacer (122), snap ring (121), O rings
When assembling the cut spool assy (163), (561) and backup ring (562).
into casing A (101), B (102), do it 2) Fix poppet (611) and spring (621) to plug
slowly with care ; never force it in. (103) in 1) above. Then fix spring seat (612)
in 2) fitted with O rings (661).
3) Attach spring cover (204) with O ring (262) to
the spring side of the cut spool assy. Then Make sure that poppet (611) is snugly
fasten socket bolts (273) to the specified placed in the seat of plug (103).
torque.
33-78
3) Temporarily assemble adjust screw (651) and (17) Assembling option valve
lock nut (671) to plug (103). 1) Fit O ring (S161) to casing (S101).
2) Assemble poppet (S512) and spring (S522) to
4) Assemble plunger (512) and spring (521) into casing (S101) and fasten plug (S551) with O
seat (541). ring (S561) to the specified torque.
3) Put a mouthpiece (aluminum plate, etc.) in
5) Assemble the seat in 4) to the plug (103) assy the vise and hold the center of option spool
under 3) and fix it with snap ring (121). (S301) in it. Set spring seat (S337), springs
(S323), (S324) and stopper (S333) and tighten
6) Pressure adjustment is performed in accor- bolts (S334) to the specified torque.
dance with “Maintenance Standard and Test
Procedure”. Leave adjust screw (651) tempo- z When tightening bolts (S334), coat
rarily assembled. them with Loctite #262.
z Be careful so as not to distort option
(16) Assembling Port Relief Valve spool (307) by overtightening it in
1) Assemble spring seat (612) with poppet (611), the vise.
spring (621) and O ring (661), into plug (102)
that is fitted with O rings (162), (561) and 4) Assemble the option spool assy in 3) into
backup ring (562). Then temporarily assem- casing (S101).
ble adjust screw (651) and locknut (671).
When assembling the option spool assy
Make certain that poppet (611) is into casing B (102), do it carefully and
snugly fitted in the seat of plug (102). slowly ; never force it in.
2) Fit O ring (563) and backup ring (564) to seat 5) Put O ring (S261) to the spring side of the
(541) and attach the seat to plunger (511) and option spool assy, attach spring cover (S202)
assemble piston (301) and springs (521), to the assy and tighten socket bolts (S271) to
(522). the specified torque.
3) Assemble the seat (541) assy in 2) into body 6) Install spool cover (S204) with O ring (S262)
(101) and tighten the plug (102) assy in 1) to and fasten socket bolt (S271) to the specified
the specified torque. torque.
Confirm that springs (521), (522) are 7) Install port relief valve (S603) to casing
guided properly. (S101) and fasten it to the specified torque.
4) Pressure adjustment is performed in accor-

dance with “Maintenance Standard and Test
Procedure” and adjust screw (651) is left
temporarily assembled.
33-79

(1) Inspection of components
Part name Inspection item Criterion and remedy

Casing 1) Look for scratches, rusting and 1) If any of the following parts are
corrosion. damaged, replace the casing.
z Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
z Part of sealing pocket through which
spool is inserted.
z Area of sealing part that is in contact
with O ring.
z Sealing and seating part of main or port
relief valve.
z Defects of other parts that seem to
prevent normal function.
Spool 1) Look for scratches, galling, rusting 1) If a defect detectable with your
and corrosion. fingernail is found on the sliding part of
the outer circumference, replace the
spool.
2) Inspect ends that are sealed with an 2) If the sliding part is damaged, replace
O ring. the spool.
3) Insert the spool in the casing bore, 3) If the spool damages the O ring or does
and move it while turning it. not move smoothly, repair or replace
the spool.
Poppet 1) Look for damage on the poppet and 1) If sealing is incomplete, correct or
the spring. replace the seal.
2) Insert the poppet in the casing, and 2) If the poppet moves lightly without
move it. catching, it is normal.
Spring and 1) Look for rust, corrosion, deformation, 1) If damaged heavily, replace.
related parts and breakage of the spring, spring
seat, plug and cover.
Spool seal and 1) Look for external oil leak. 1) Repair or replace.
related parts 2) Look for rust, corrosion and deformation 2) Repair or replace.
of sealing plate.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Port relief valve surface.
2) Inspect the contact face of the valve 2) If damaged, replace.
seat.
3) Inspect the contact face of the poppet. 3) If damaged, replace.
4) Look for spring abnormality. 4) Replace.
5) Inspect the O ring, backup ring, and 5) As a general rule, replace all parts with
seal. new ones.
33-80
2.7 TROUBLESHOOTING
1) If an abnormal condition is noticed, check to If any part of the system is to be
see if the problem is with the control valve disassembled, take dust protection measures
itself, one of the main pumps, the gear pump, beforehand.
or a circuit. To this end, you will need to 3) Moving parts must be handled with care. If
measure pilot pressure, pump delivery they are damaged, smooth the damage using
pressure, load pressure, etc. If any part of the an oil stone or the like.
system is to be disassembled for inspection, 4) Take care not to damage the contact face of O
follow the disassembly and reassembly rings. A damaged contact face will certainly
procedures in this manual. cause oil leaks.
2) Dust is the enemy of hydraulic components.
Pay strict attention to protection from dust.
(1) Control valve
Trouble Cause Remedy

1. Travel does not 1) Malfunctioning main relief valve. 1) Measure travel relief valve pressure
occur. z Foreign matter between main z Disassemble and clean. If damaged
Slow to start up poppet and seat. heavily, replace the assy as a unit.
(or poor power). z Foreign matter between poppet z Same as above.
Slow response. and seat.
z Sticking main poppet. z Smooth sticking part with oil stone.
z Broken or deformed spring. z Replace spring.
z Clogged main poppet throttle. z Remove foreign matter.
z Loosened adjusting screw. z Readjust, and tighten lock nut to
specified torque.
2. Machine does not 1) Malfunctioning travel straight 1) Measure pilot pressure.
move straight valve.
during simultane- z Sticking spool. z Smooth sticking part with oil stone.
ous travel and z Broken or deformed spring. z Replace spring.
operate z Clogged small hole in spool. z Remove foreign matter.
attachment. 2) Malfunctioning right or left 2) Measure pilot pressure.
neutral cut valve.
z Sticking spool. z Smooth sticking part with oil stone.
z Excessive clearance between right z Replace spool.
or left casing and spool.
z Clogged small hole in spool. z Remove foreign matter.
3) Malfunctioning main relief valve. 3) Replace main relief valve.
See item 1. 1) above.
33-81

3. Excessive natural 1) Excessive clearance between 1) Replace spool.
falls of attachment casing and spool.
under its own
2) Spool is not completely in 2) Measure secondary pilot pressure.
weight when spool
neutral position.
is in neutral.
z Foreign matter between casing z Disassemble, clean and smooth sticking
and spool, or sticking spool. part with oil stone.
z Clogged pilot circuit. z Remove foreign matter.
3) Malfunctioning port relief valve. 3) Measure port relief valve pressure.

Refer to item 1. 1) above. Refer to item 1. 1) above.
4) Malfunctioning anti-cavitation 4) Checking the port relief valve

check valve.
z Foreign matter between poppet z Disassemble and clean.
and casing.
5) Lock valve function is faulty. 5)

z Foreign matter between poppet z Disassemble and clean. In case
and casing. scratches are excessive, replace casing.
z Poppet is stuck. z Correct stuck part with oil stone.
z Selector spool is stuck. z Replace lock valve selector sub assy.
z Dirt is included between selector z Replace lock valve selector sub assy.
spool and bushing.
z O ring in bushing is worn out. z Replace lock valve selector sub assy.
4. When raising 1) Malfunctioning load check valve. 1)
attachment, at z Foreign matter between poppet z Disassemble and clean. If heavily
first it drops. and casing. damaged, replace control valve.
z Sticking poppet. z Smooth sticking part with oil stone.
5. Bucket, boom, arm 1) Malfunctioning main spool. 1) Measure secondary pilot pressure.
or swing does not z Excessive clearance between z Replace spool.
operate. casing and spool.
z Foreign matter between casing z Disassemble and clean.
Slow to start up
and spool.
(or poor power).
z Sticking spool. z Smooth stuck part with oil stone.
Slow response.
z Broken or deformed return z Replace spring.
spring.
z Clogged pilot circuit. z Remove foreign matter.
2) Malfunctioning main relief 2) Measure main relief valve pressure.

valve. Refer to item 1. 1) above. Refer to item 1. 1) above.
3) Malfunctioning port relief valve. 3) Measure port relief valve pressure.
Refer to item 1. 1) above. Refer to item 1. 1) above.
4) Malfunctioning pilot valve. 4) Refer to Pilot valve section.
Refer to Pilot valve section.
33-82

6. Swing priority 1) Operating fault of arm recirculation 1) The same way as 5-1).
function does not spool [the same way as 5-1) below].
operate.
7. Boom or arm 1) Malfunctioning conflux valve. 1) Measure pilot pressure.

conflux does not Refer to item 5.1) above. Refer to item 5.1) above.
operate.
(2) Relief valve

1. No pressure rise. Main or pilot poppet of relief valve is z Check for foreign matter on each
sticking and valve is open, or there is poppet.
foreign matter on valve seat. z Confirm that each component slides
smoothly.
z Clean all components thoroughly.
2. Unstable relief Damaged pilot poppet seat of relief z Replace damaged component.
pressure. valve. Pilot piston sticks against main z Clean all components thoroughly.
poppet. z Smooth surface damage.
3. Irregular relief 1) Wear due to foreign matter. 1) Disassemble and clean.

pressure.
2) Loosened lock nut or adjusting 2) Adjust pressure.
screw.
4. Oil leak. 1) Damaged seat. 1) Replace damaged or worn
Worn out O ring. component. Confirm that each
component operates smoothly before
reassembling.
2) Sticking component due to foreign 2) Confirm that there are no scratches,
matter. scores, or foreign matter present
before reassembling.
33-83
4. PILOT VALVE (FOR TRAVEL)

↓Z 33 2 36 33
4.1 CONSTRUCTION 13 12 28
(1) Sectional view 36 14 42
19
37 25
26
1,3 30
20
34 25
22 15
21 42
20
39 20
32 17
33 36 33
44,16 40
6 7 SECTION AA
18 8
24
25,42
41
27
4 10,11 35
9 31 5 29
4-M10
T=4.3±0.4 38
(31±2.9)
T=Tightening torque : kgfym (lbfyft)
24,41
SECTION BB
VIEW Z
Fig. 4-1 Sectional view of pilot valve (for travel)
☆Apply Loctite #262
TORQUE NO. NAME Q’TY TORQUE NO. NAME Q’TY
1 ORIFICE (SHIM) 4 22 SPRING 4
☆1.5 (11) 2 SEAT 2 1.0 (7.2) 24 PLUG ; PF1/8 3
3 ORIFICE (SHIM) 4 2.5 (18) 25 PLUG ; PF1/4 3
4 SPOOL 4 6.0 (43) 26 SOCKET BOLT ; M10×60 2
5 BODY 1 0.5 (3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5 (11) 28 SET SCREW ; M8 4
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN ; ∅5 4
11 SHIM t=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING ; 1A P5 4
17 GUIDE 4 39 O RING ; 1A P24 4
18 SLEEVE 4 40 O RING ; 1A P26 4
19 HOLDER 4 41 O RING ; 1B P8 3
20 RING 12 42 O RING ; 1B P11 3
21 ORIFICE (SHIM) 4 44 PISTON ASSY 4
33-93
(2) Explosion view
13
26
30
28
12 LIP DETAIL
37 14
15
6
27
18
36
DAMPER SECTION
19
8
1,3
10,11,29
REDUCING VALVE SECTION
16,44
20 21
4
34
22
20 7
20
39 40
17 32
38
24
41 5
Fig. 4-2 Explosion view of travel pilot valve
33-94
1. Tools used 3. Disassembling the damper (See Fig.4-3.)

Tool name Use (1) Draw out piston assy (44) and guide (17) from
For fixing the valve cover (15).
Vise
body z The damper is drawn out easily if it is pushed
Small vise from the ball side (36).
For disassembling the
(Place a copper plate on
reducing valve spool (2) Draw out four balls (36), holders (19) and
the mouthpiece.)
orifices (1), (3) from piston assy (44).
Allen wrench 3, 4, 5, 6, 8mm
z On that occasion, align the hole in the cover,
Scriber the piston assy and the guide as a set as each
For disassembling the
(or a sharp point rod of
U-packing part is shop fitted. Therefore, if parts for
the same shape)
Hex rod for torque different locations are assembled, functional
3, 4, 5, 6, 8mm
wrench faults may occur in some cases.
Torque wrench z Ring (20), orifice (21), spring (22) and ball
For picking up ball (36) (34) can not be separated from the piston
Magnet bar assy as they are assembled with ring (20)
and holder (19)
pressed in.
z Disassembly and assembly procedures
It is usual that disassembly and assembly are
executed at the maker’s factory, but in
unusual cases, do the work at a service shop
where skilled technicians are available.
Hydraulic parts are precision products of 37
small clearance. Therefore, disassembly and 15
assembly work shall be performed in a clean
place where there is little dust in the
following manner:
Never knock on precision parts in case they
do not operate smoothly.
Replace seal parts such as O rings and U 36
packings with new ones. 19
1,3
2. Disassembly 44,16
(1) Put a plug into each port (P,T,1,2,3,4,5,6) of 20
the valve and clean the outside. 21
(2) Fix the valve after cleaning it in a vise. 34
(3) Remove two boots (13). 22
(4) Loosen 2×2 places of socket head set screws 20
20
(28) and remove them from cam (12). 39
: 4mm 17
(5) Draw out two pins (14) from cover (15). On

that occasion, the pins may be drawn out Fig. 4-3 Disassembling the damper
with ease if the pins are pushed out of the
inside by the use of an allen wrench 4mm.
(6) Remove two cams (12).
(7) Loosen socket bolts (26) and remove two of
them with washers (30).
: 8mm
(8) Remove two dampers from the reducing

valve.
33-95
(3) Separate four O rings (39) from guide (17). (3) Draw out two balls (36) from body (5) by
(4) Remove four U packings (37) from cover (15), attracting the balls to a magnet.
using a scriber. z Balls (33), (35) are for circuit plugs and press
fitted to body (5). Therefore, they are not
4. Disassembling the reducing valve section separable.
(See Fig.4-4.)
(1) Separate three socket plugs (24) from body
REDUCING VALVE SPOOL ASSY

(5).
: 5mm 6
(2) Separate O ring (41) from socket plug (24).

(3) Remove four reducing valve spool assemblies
from body (5).
(4) Remove stopper (6) from the reducing valve
spool assy.
(5) Remove four springs (7); parallel pins (32), O 7
rings (38), (40) from body (5). 40
32
5. Disassembling the reducing valve spool assy
(See Fig.4-5.) 38
z The outer diameter of reducing valve spool (4) 24
is finished with a small clearance against the
hole of body (5). Therefore, put a copper plate 5
41
on the mouthpiece of the vise at disassembly
so as not to score the outer diameter.
Note that the spool is deformed if the vise is Fig. 4-4 Disassembling the reducing valve
tightened too much.
(1) Fix spool (4) in a vise (Put a copper plate
against the mouthpiece.) and loosen four 27
socket flange bolts (27). 18
: 3mm
(2) Draw out socket flange bolt (27), sleeve (18), 8

spring (8), shims (10), (11) and washer (29) 10,11,29
from spool (4), in that order.
z On that occasion, mate the disassembled
parts with mating parts as sets. 4
6. Disassembling the shuttle (See Fig.4-6.) Fig. 4-5 Disassembling the reducing spool assy
z The shuttle is unseparable basically as seat
(2) is fixed with adhesive agent (Loctite 33 33
#262.). 36 36
(1) Remove two socket plugs (25) from body (5). 2 2
: 6mm
33 33
(2) Remove two seats (2) from body (5).
: 5mm
z On that occasion, the Loctite comes off. 42 42

Remove it including that adhered to the 25 25
neighboring area of the screw. Fig. 4-6 Disassembling the shuttle
33-96
7. Assembly 11. Assembling the damper (See Fig.4-3.)

z Clean and degrease parts before assembly. In (1) Fit four U packings (37) to cover (15).
particular, clean the body with a nylon brush z On that occasion, place the cover so the lip of
or something. the U packing faces down (damper chamber
Foreign matter intruded into the valve causes side).
functional faults to occur. (2) Insert four piston assemblies (44) into cover
z Prepare new seals (O rings and U packings) (15).
and coat the surface with hydraulic oil or a z In that case, make sure that each piston is
thin film of grease. set in the same hole where it was before
disassembly.
8. Assembling the shuttle. (See Fig.4-7.) The performances of the piston are not
(1) Put two balls (36) into body (5). affected at all if it is placed in any direction
(2) Coat the screwed part of seat (2) with on the circumference.
Loctite#262 and fit two of them to body (5). (3) Fit O ring (39) to guide (17). Install four
: 5mm, Tightening torque : guides to cover (15).
1.5±0.1kgfym(11±0.7 lbfyft) z Fix the guide in the same hole where it was
set before disassembly.
(3) Set O rings (42) to socket plugs (25) and
fasten two plugs to body (5).
2.5±0.2kgfym (18±1.4 lbfyft) 33 33
36 36
2 2
9. Assembling the reducing valve spool assy
(See Fig. 4-5.) 33 33
(1) Fix spool (4) in a vise. (Put copper plates
against the mouthpiece.) Set washer (29),
shims (10), (11), spring (8) and sleeve (18), in
that order, and tighten them with four socket
flange bolts (27). 42 42
: 3mm, Tightening torque : 25 25
0.5±0.1 kgfym (3.6±0.7 lbfyft) Fig. 4-7 Assembling the shuttle
z On that occasion, pair parts with the 6

REDUCING VALVE
disassembled parts as sets, before performing

assembly work. Incorrect pairing may change
SPOOL ASSY
the secondary pressure.
10. Assembling the reducing valve (See Fig.4-8.)

(1) Fit four O rings (38), (40), parallel pins (32)
7
and springs (7) to body (5).
40
(2) Fit four reducing valve spool assemblies and
stoppers (6). On that occasion, use care as 32
stopper (6) has a direction in which it should
38
be installed; Place it so the concave surface of
it faces down (reducing valve spool side). 24
(3) Set O rings (41) to socket plugs (24). Fasten
three plugs to body (5). 5
41
1±0.1 kgfym (7.2±0.7 lbfyft)
Fig. 4-8 Assembling the reducing valve
33-97
(4) Set orifices (1), (3) to piston assy (44) that is In case such scratches and burrs can not be
set in the cover. corrected with ease, replace the parts with
z The orifices absorbs rattles that are made new ones in pairs.
when cam (12) is in neutral: either orifice (3) If you feel the moving parts of the reducing
may be at the top or at the bottom. valve, body (5) and spool (4) unsmooth,
z In case the cam rattles very much because correct them to be free from scratches and
the cam and the pin are worn out after long burrs, using #1000 emery paper. If it is
hours of use, increase the number of orifices. difficult to correct, replace the parts with new
However, if many orifices are set when there ones in pairs.
is no gap, the reducing valve spool is actuated (4) If you feel the moving parts of the cam
at neutral and pressure is built up in the assembly such as, cam (12), pin (14) and
secondary pressure port. When there is no cover (15), correct them to be free from
gap on the cam at neutral, do not increase the scratch and burr, using #1000 emery paper. If
orifices. it is hard to correct, replace the parts with
(5) Set four holders (19) and balls (36) to piston new ones.
assembly (44). 13
28
(6) Install two dampers on the reducing valve 36 12
and fasten them with socket bolts (26) with 19 14
washers (30). 37 15 35
16,44
In that case, parallel pin (32) set in body (5)
is placed in the hole of cover (15) to position 20
34 26
the reducing valve and the damper in place. 22
20 39 30
: 8mm, Tightening torque : 17 32
6±0.5kgfym (43±3.6 lbfyft) 40 6 1,3
18 27 21 38
(7) Set cam (12) to cover (15) and insert pin (14).
24
On that occasion, check the gap of the cam 41
8 20
and if the gap is large, increase orifices (1), 7 25,42
(3) according to item (4) above. 4 10,11,29
z Ball (36) and holder (19) can be drawn out
5
easily by magnet bar. If a magnet bar is not
available, place the valve on its side and give 13 Fig. 4-9
vibration to it.
(8) When the gap adjustment of the cam has
been finished, apply grease to the moving 28
parts of cam (12), pin (14), cover (15) and ball
(36). 12
(9) Attach 2×2 pcs. set screws to cam (12) and 26
30
tighten them.
1.5±0.1kgfym (11±0.7 lbfyft) 14
(10) Fit two boots (13).
DAMPER
12. Standard for the judgement of serviceability

of parts
(1) Replace seals with new ones at disassembly
and reassembly.
REDUCING
(2) If you feel the moving parts of the damper,

cover (15), piston assy (44) and guide (17)
VALVE
unsmooth, correct the moving surfaces and

corners to be free from scratches and burrs,
using #1000 emery paper.
33-98
5. SWING MOTOR UNIT

5.1 CONSTRUCTION
(1) Swing motor
992
351
355
051
401 488 469 051-1
303 468,487 106 981 390 438

712 451 131 444 433 391 980
V101
472
V161
707
V171
706
052 V151
982
V401-1
V401-2
114
V401
117
121
702
111 113
743 123
742 993
464
485
116 117 432 471 443 106 101 491 304 437 124 122 301
Fig. 5-1 Swing motor
33-99
101 DRIVE SHAFT 1 471 O RING ; 1B G80 1
106 SPACER 3 472 O RING 1
111 CYLINDER 1 485 O RING ; 1B P11 1
113 RETAINER 1 487 O RING ; 1B P11 2
(SPHERICAL BUSHING)
114 CYLINDER SPRING 1 488 O RING ; 1B P20 2
116 PUSH ROD 12 491 OIL SEAL 1
117 SPACER 2 702 BRAKE PISTON 1
121 PISTON 9 706 O RING 1
122 SHOE 9 707 O RING 1
123 PLATE 1 712 BRAKE SPRING 20
124 SHOE PLATE 1 742 FRICTION PLATE 3
131 VALVE PLATE 1 743 SEPARATOR PLATE 4
301 CASING 1 0.17 (1.2) 980 PLUG ; PF3/8 1
303 VALVE CASING 1 0.45 (3.3) 981 PLUG ; PF3/4 1
304 FRONT COVER 1 0.09 (0.7) 982 PLUG ; PF1/4 1
351 PLUNGER 2 6.6 (48) 992 PLUG ; PT1/2 1
355 SPRING 2 2.2 (16) 993 PLUG ; PT1/4 1
24 (170) 401 SOCKET BOLT ; M16×75 4 18 (130) 051 RELIEF VALVE ; M33 2
432 SNAP RING 2 051-1 O RING ; 1B G30 2
433 RING 1
437 SNAP RING 1 052 SWING SHOCKLESS 1
VALVE BLOCK
438 SNAP RING 1 V101 CASING 1
443 ROLLER BEARING 1 0.9 (6.5) V151 PLUG ; NPTF1/16 4
444 ROLLER BEARING 1 V161 O RING ; 1B P22 2
451 PIN 2 3 (22) V171 SOCKET BOLT ; 8
M8×60
3.7 (27) 464 VP PLUG ; PF1/4 1 7 (51) V401 SWING SHOCKLESS 2
VALVE ; M22
3.7 (27) 468 VP PLUG ; PF1/4 2 V401-1 O RING ; 1B P20 2
11 (80) 469 RO PLUG ; M22 2 V401-2 BACKUP RING 2
33-100
(2) Swing reduction unit

602 230 231 204 286 211 912 285 287 911 283 403 210
922
282
※ 921
202
203
311
285
※
312
913
402 910
801
925
920
926
102
401
915
201
z Coat the parts marked ※
with Three-Bond #1104B.
M10,Depth 20mm(0.78in)
Fig. 5-2 Swing reduction unit
102 CASING 1 401 ROLLER BEARING 1
201 DRIVE SHAFT 1 402 ROLLER BEARING 1
202 RING GEAR 1 403 NEEDLE BEARING 3
203 No.2 PLANETARY GEAR 4 10 (72) 602 SOCKET BOLT ; M12×100 10
204 No.2 SUN GEAR 1 801 OIL SEAL 1
210 No.1 PLANETARY GEAR 3 910 SPRING PIN 4
211 No.1 SUN GEAR 1 911 SNAP RING 3
282 No.2 PIN 4 915 SEAL 1
283 No.1 PIN 3 6.6 (48) 920 ADAPTER ; PT1/2 1
285 SIDE PLATE t=1 7 11 (80) 921 HOSE ; PF1/2 1
286 THRUST WASHER t=2 1 11 (80) 922 PLUG ; PF1/2 1
287 SIDE PLATE t=2 3 2.2 (16) 925 RELIEF FITTING 1s
311 LEVEL BAR 1 2.2 (16) 926 GREESE NIPPLE 1s
312 PIPE 1
33-101
5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

5.2.1 TOOLS AND JIGS
(1) Spanner wrench
Opposing
Name Size Flats mm Applicable parts Tool
CAPSCREW M6 10 Selector valve for brake Spanner, Socket wrench

SOCKET BOLT M8 6 Swing shockless valve block Allen wrench
SOCKET BOLT M16 14 Valve casing Allen wrench
PLUG M22 10 RO plug Allen wrench
PLUG PF1/4 6 ROH plug Spanner, Socket wrench
Attaching screw M22 24 Swing shockless valve Spanner, Socket wrench
Attaching screw M33 41 Relief valve Spanner, Socket wrench
(2) Other tools and jigs

Specification
Remarks
Tools
For snap ring For ∅35(1.38˝ ) shaft
Pliers
For Locking ring For ∅80(3.15˝ ) hole
Flat-bladed type,
Screwdriver
medium size 2 pcs.
10×8×200 or so 1pc.
Steel bar
(0.394˝×0.315˝×7.87˝ )
Plastic hammer
Hammer
Iron hammer 1 each
Torque adjusting range
Torque wrench
zFor 0.09～24kgfym (0.65～174 lbfyft)
Slide hammer bearing puller 2×∅7 (0.276˝ )
Brake piston drawing tool Fig. 5-3
M10 SCREW ON BOTH ENDS

(EFFECTIVE THREAD LENGTH 20 (0.787˝ )
BORE DIA.∅11
(0.433˝ )
2×NUT M10
M10
Fig. 5-3 Brake piston drawing tool
33-102
5.2.2 DISASSEMBLY PROCEDURE

1) Cleaning the swing motor
Place a wire sling around the motor, lift it up
and clean it. After cleaning, dry it with jet
air.
z Put plugs into all ports to prevent

foreign matter from entering the
motor and clean the motor to be free
from dirt and dust.
2) Draining out lube oil

Drain out the oil from the drain port of casing
(301).
3) Fixing the motor to the work bench.

Direct the shaft end of the drive shaft (101)
down and fix it on a bench convenient for 303
disassembly. On that occasion, leave a
matching mark on the mating part between
casing (301) and valve cover (303). 301
z Choose a clean place. Place a rubber Fig. 5-4 Fixing the motor to the work bench
sheet or a cloth on the work bench. and putting a matching mark
Exercise care so as not to damage
parts.
303
4) Remove relief valve 051
Loosen relief valve (051) and separate it from
valve cover (303).
: 41mm
5) Remove swing shockless valve block

Loosen socket bolt (V171) and separate
swing shockless valve block (052) from valve
casing (303).
: 6mm Fig. 5-5 Removing relief valve
6) Removing the anti-cavitation check plunger

V171 052 303
Separate RO plug (469) from valve casing
(303) and draw out spring (355) and plunger
(351).
: 10mm
z Exercise care so as not to score the

plunger seat.
Fig. 5-6 Removing swing shockless valve block
33-103
7) Remove valve casing and valve plate

Loosen socket bolt (401) and separate valve
casing (303) from casing (301). [If the socket
401
bolt (401) are loosened, the valve casing floats
off casing (301) by the force of brake spring
(712).] 303
Then separate valve plate (131) from valve
301
casing (303).
: 14mm
z Work with care so the valve seat

does not come off from the valve Fig. 5-7 Removing valve casing No.1
casing. (In some cases, the valve
plate is adhered on the cylinder 303
side.)
When inserting a screwdriver or
something between the matching
surfaces, use care so as not to score 712
the matching surfaces.
8) Remove brake spring 301

Draw out brake spring (712) from brake
piston (702).
Fig. 5-8 Removing valve casing No.2
9) Remove brake piston

Draw out brake piston (702) from casing
(301), using a jig (slide hammer).
702
z Hold it upright, utilizing the bolt
holes in the brake piston.
301
Fig. 5-9 Removing brake piston

10) Remove cylinder
Place the motor level and draw out the 301
cylinder (111) from the drive shaft (101).
Then draw out piston (121), retainer plate
(123), spacer (117) and shoe plate (124).
z Use care when drawing out the

cylinder as push rod (116) tends to
come off. Exercise care so as not to
score the sliding surfaces of the
cylinder, retainer and shoe.
z In case the shoe plate does not come 111
off, remove it after the work Fig. 5-10 Removing cylinder
sequence 12).
33-104
11) Remove separator plate

437
Draw out friction plate (742) and separator
plate (743) from casing (301).
304
301
Fig. 5-11 Removing snap ring

12) Remove front cover
Take off snap ring (437) with pliers and
separate front cover (304) from casing (301).
z When drawing out the front cover,

take care so as not to score the 304
sliding surface of the oil seal.
z You may remove the front cover with
the drive shaft.
301
Fig. 5-12 Removing front cover

13) Remove drive shaft
Separate drive shaft (101) from casing (301)
by lightly tapping the end face of the valve
casing side (303) of drive shaft (101), using a
plastic mallet.

sliding surface of the oil seal.
14) Remove shoe plate

Draw out shoe plate (124) from the housing
101 301
side of roller bearing (443) of casing (301) by
lightly tapping it with a steel rod. Fig. 5-13 Removing drive shaft
PRESS
15) Remove inner race of roller bearing (443)
Remove snap ring (432) and spacer (106) DRIVE SHAFT
from drive shaft (101) and draw out the inner
race of roller bearing (443) by means of a
ROLLER BEARING
press.
z You may knock on the inner race of

the roller bearing with a steel bar,
but knock on it evenly all around so Put the press bench
the bearing is not damaged. on the inner race.
Do not use the removed bearing again.
Fig. 5-14 Removing inner race of roller bearing
33-105
16) Remove oil seal

Draw out oil seal (491) from front cover (304),
utilizing the jig.
304
(491)
z Do not reuse the removed oil seal.
ROUND PLATE PRESS

OIL SEAL
FRONT COVER
Fig. 5-15 Removing oil seal
17) Remove roller bearing
Separate roller bearing (444) from valve
casing (303), using a slide hammer bearing
puller.
444
z Do not reuse the removed bearing.
303
Fig. 5-16 Removing roller bearing (444)
5.2.3 ASSEMBLY PROCEDURE

1) Holding casing
Place the casing (301) facing its valve casing 301
(303) downward.
2) Installing inner race of roller bearing

Fit snap ring (432) and spacer (106) to drive
shaft (101), insert the inner race of roller
bearing (443), and shrinkage fit the inner
race.
Put spacer (106) in and fix snap ring (432).
Fig. 5-17 Holding casing
z Beware of the orientation of the

inner race of the roller bearing.
OUT PUT SHAFT SIDE

Set the spacer to the
R (round) side of the 444
bearing inner race.
101
106
SPACER
Fig. 5-18 Installing roller bearing (443)
33-106
432
Fig. 5-19 Installing snap ring

3) Shrinkage fitting inner race of roller bearing
(444)
Shrinkage-fit the inner race of roller bearing
444
(444) to drive shaft (101). Then fit snap ring
(433).
4) Installing outer race of roller bearing (443) 101

Place drive shaft (101) with roller bearing
(443) on its output shaft, and insert the drive
shaft into casing (301). Then lightly knock on
the outer race of roller bearing (443) via a
steel bar, using a hammer.
Fig. 5-20 Shrinkage fitting inner race
z Knock on the outer circumference of of roller bearing (444)
the outer race evenly all round till it
stops at the step of the casing.
5) Insert oil seal

Put oil seal (491) into front cover (304), using
a jig.
z Be careful about the direction of the

oil seal.
z Fix the oil seal till it stops at the
304 (491)
step of the casing.
Fig. 5-21 Inserting oil seal
6) Fit O ring
Fit O ring (471) to casing (301).
471
301
Fig. 5-22 Fitting O ring
33-107
Wind protective tape
101
Fig. 5-23 Wind tape around the spline

of the drive shaft
7) Installing front cover
Fit front cover (304) to casing (301) by lightly 304
tapping the cover with a plastic mallet
z Coat the lip of the oil seal with a

thin film of grease and put it in with
care so as not to score the lip of it.
(Wind tape on the spline of the drive
shaft so the lip of it is not scored by
the spline.) Tap the outer
circumference evenly round to
prevent it from being scored.
Fig. 5-24 Installing front cover
8) Fitting the snap ring
Fit snap ring (437) to casing (301), using 124
pliers.
9) Put shoe plate (124) into casing (301).
z Put the larger chamfer side of the

301
shoe plate into the casing side.
Coat the matching surface with a
thin film of grease to prevent the
shoe plate from falling off.
Fig. 5-25 Inserting shoe plate

10) Insert push rod
Put push rod (116) in cylinder (111).

sliding surface of the cylinder. 111
(Put two push rods into one hole.)
116
Fig. 5-26 Inserting push rod
33-108
11) Installing retainer 113

Then mount retainer (113) fitted with spacer
(117) on the cylinder.
117
Fig. 5-27 Installing retainer

12) Installing the piston sub assy to the plate
Set piston sub assy (121,122) to plate (123). 123
121,122
13) Assembling the piston sub assy into the cylinder Fig. 5-28 Installing the piston sub assy to
Assemble piston sub assy (121,122) with the plate
plate (123) into cylinder (111) and insert it in
121,122,123
place, aligning it with the spline of drive
111
shaft (101).
z The drive shaft can be set easily if

the phase of the retainer (113) and
the cylinder spline is matched.
101
14) Installing separator plate and friction plate
Fig. 5-29 Assembling the piston sub assy
Replace casing (301) so front cover (304) side
into the cylinder
faces down. Then Assemble separator plate
(743) and friction plate (742) into casing
(301), in that order. 743
Fit four separate plates and three friction
plates.
z Assemble four notches in

the gear teeth of friction
plate so the same phases
301
are aligned up and down.
Fix notches in the four
claws of separator plate
in the position in Fig.5-
30. Selector valve mount Fig. 5-30 Installing separator plate
33-109
742
301
Fig. 5-31 Installing friction plate

15) Fit O ring
Fit O rings (706) (707) to casing (301). 707
z In that case, coat the O rings with

grease beforehand. This will prevent
the O rings from breaking when 301
inserting brake piston.
Fig. 5-32 Fitting O ring

16) Installing brake piston
Fit brake piston (702) to casing (301).
702
z Install the brake piston
2-M8 BRAKE PISTON
so four slits of it are
positioned as shown in
301
the figure on the right.
(Match the M8 screws to
the figure on the right.)
If brake piston is hard to
enter because of the
SLIT
resistance of the O rings,
Selector valve mount
screw in socket bolt M8
Fig. 5-33 Installing brake piston
into the brake piston and
knock on it evenly by
702 712
means of a plastic mallet.
17) Installing brake spring

Fit brake spring (712) to brake piston (702).
z At that time, make sure that the

spring is set snugly in the spotface of
the brake piston.
Fig. 5-34 Installing brake spring
33-110
18) Insert outer race of roller bearing

Insert the outer race of roller bearing (444)
into valve casing (303), knocking it lightly by
means of a steel bar.
444
z Knock on the outer circumference of
the outer race evenly around and fix
303
it so it stops at the step of the valve
casing.
Fig. 5-35 Inserting outer race of roller bearing

19) Installing valve plate
Assemble valve plate (131) into valve casing 131
(303) and then fit O ring (472) in place.
z Coat the contact surface of the valve

plate with a thin film of grease.
(To prevent it from falling off.)
Apply grease.
Fig. 5-36 Installing valve plate

20) Installing valve casing
Attach valve casing (303) to casing (301) and
fasten it with socket bolt (401).
24kgfym (170 lbfyft)
z Beware of the direction of the valve

casing. 303
z Be careful so the valve plate does not
come off.
301
z Use care so the brake spring does
not fall down.
z Fasten the socket bolts evenly all
Fig. 5-37 Installing valve casing
around.
21) Fitting plunger 401 351

Place plunger (351) and spring (355) into
valve casing. Fasten RO plug (469) with O
ring (488) into valve casing.
11kgfym (80 lbfyft)
z Make sure that the plunger moves

smoothly.
355
Fig. 5-38 Fitting plunger
33-111
22) Installing relief valve

Fit backup ring (162) and O ring (161) to 051(161,162) 303
relief valve (051) and fasten the relief valve
against valve casing (303).
23) Installing plugs (464),(468)

Fit O ring (487) to plug (468), attach it to
valve casing (303), fit O ring (485) to plug
(464) and fasten it against casing (301). Fig. 5-39 Installing relief valve
052(V161) 303
V171
24) Installing swing shockless valve block
Fit O ring (V161) to the swing shockless valve
block. Then fasten the valve block against
valve casing (303) with socket bolts (V171).
Fig. 5-40 Installing swing shockless valve block
33-112
5.3 DISASSEMBLY AND ASSEMBLY OF SWING

REDUCTION UNIT
(1) Tools
NAME REMARKS
Allen wrench Opposing flats 6,10mm
Socket wrench
Adjust wrench
Double ended wrench
Hammer
Plastic mallet
Screwdriver
Torque wrench
Liquid packing Three-Bond #1104B
Oil container for
shrinkage fit work 80～100℃ (176～212°
F)
(2) Jigs 2) Roller bearing (401) removing jig

1) Oil seal fitting jig
3) Roller bearing (402) fitting jig
33-113
5.3.2 DISASSEMBLY PROCEDURE

(1) Remove swing motor unit and drain oil
Remove the swing motor unit from the
machine, loosen plug (902) at the oil outlet,
discharge the gear oil and place the unit on a
work bench.
211
z Receive gear oil in a clean container
and inspect for the presence of worn
particles.
(2) Remove hydraulic motor

Loosen socket bolts (602) and remove the
hydraulic motor.
: 10mm
(3) Remove No.1 sun gear (211) Fig. 5-41 Removing No.1 sun gear
(4) Remove No.1 carrier assy

Remove the No.1 carrier assy with the No.1
planetary gear (210) and others.
210
Fig. 5-42 Removing No.1 carrier assy

(5) Disassembly No.1 carrier assy
z Put a matching mark on each of the

planetary gears and pins so
combination and pairing do not
change.
1) Remove snap ring (911). Then remove side 911

plate (287) at the top.
287
2) Remove No.1 planetary gear (210) and needle Fig. 5-43 Removing snap ring
bearing (403).
403 210
Fig. 5-44 Removing needle bearing
33-114
3) Remove side plate (285) under the planetary

285
gear.
Fig. 5-45 Removing side plate

4) After removing three No.1 planetary gears
(210), remove thrust washer (286) in the
center.
286
z Do not remove No.1 pin (283) from
No.1 carrier (231) unless there is
anything wrong.
If the No.1 pin is removed, you need
a special caulking tool at
reassembly. ∅2 (0.079˝ )
(OIL HOLE)
However, make sure that the
∅2(0.079˝ ) oil hole of No.1 pin (283)
is directed outwards with respect to
the center of No.1 carrier (231).
(Refer to Fig.5-46 below.)
Fig. 5-46 Removing thrust washer
(6) Remove No.2 sun gear (204)

204
Fig. 5-47 Removing No.2 sun gear

No.2 CARRIER ASSY
(7) Remove No.2 carrier assy
Fig. 5-48 Removing No.2 carrier assy
33-115
(8) Disassembly No.2 carrier assy
z Do not disassemble the No.2 carrier

assy further unless there is anything
wrong. In this condition, inspect the
parts according to the inspection
procedure specified under 5.4.2 (1).
As mentioned above, it is
recommended that the No.2 carrier
assy be replaced as a pair, but in
case part of it must be replaced for
an unavoidable reason, do it as 282,910
below:
1) Push spring pin (910) in further and draw out

203,285
No.2 pin (282).
z Do not reuse the removed No.2 pin.
Fig. 5-49 Removing No.2 pin
2) Draw out No.2 planetary gear (203) and side 202

plate (285) sideways.
(9) Remove ring gear (202)

The bottom of the two holes is provided with
M12 screw threads to draw out the ring gear.
Utilise motor mounting socket bolts (602) to
draw it out.
: 10mm
Fig. 5-50 Removing ring gear
(10) Separate snap ring (913) from drive shaft

(201). 913
201
Fig. 5-51 Removing snap ring
33-116
(11) Remove drive shaft

Support the flanged part of the drive shaft so
the shaft end faces down and place the drive
shaft on a work bench. Draw out the shaft
downwards, while tapping the center of it
with a plastic mallet.
z Do not disassemble it further unless

there is anything wrong.
At this stage, inspect the parts
according to the inspection
procedure specified under 5.4.2(1).
PRESS
As mentioned above, we recommend
that the drive shaft assy be replaced
as a set. In case part of it must be JIG 2
replaced for an unavoidable reason,
do as follows:
z If nothing faulty is discovered on
inspection at this stage, no further
disassembly is needed.
(12) Remove roller bearing

As shown on the figure on the right, support
the drive shaft assy, and draw out bearing 915
seal (915) and roller bearing (401), using a
press.
401
z Roller bearing (402) is left in the
casing. Since the shaft falls down,
use care so as not to damage it.
z The removed oil seal and the bearing
seal can not be used again.
Fig. 5-52 Removing roller bearing
(13) Remove oil seal (801) from casing (102).

102
801
Fig. 5-53 Removing oil seal
33-117
5.3.3 ASSEMBLY PROCEDURE

402
(1) Assembly drive shaft assy
801
1) Insert bearing seal 102
GREASE
Insert bearing seal (915) into drive shaft
(201). 401
915
201
2) Press-fitting roller bearing Fig. 5-54 Assembling drive shaft
Coat the inside of roller bearing (401) with
sufficient grease and press it into the drive
shaft, using a press. Set the inner race firm GREASE
into the shaft by knocking on the steel bar,
till the hammer springs back. Then apply
grease so it reaps as shown in Fig.5-55.
z Grease : EP type
(Shell Alvania grease EP2)
z Roller bearing (401) has a bank in
the middle. Push grease in to both
sides before assembling the bearing
into the shaft. 201
Fig. 5-55 Applying grease to roller bearing
(2) Place casing (102) on a level bench.
(3) Installing drive shaft assy

Lift the drive shaft assy upright, using the
screw in the end of the shaft and put it into
the casing.
Thread size : M10, Depth 20mm
z Lightly tap the outer race of the 201

bearing so it is completely level. If
the outer race is tilted, it does not 102
enter by light tapping in some cases.
On such occasion, pull it out once,
place it level and do the job once
again. Fig. 5-56 Installing drive shaft assy
(4) Place the casing by supporting the flanged

part so the shaft end faces down.
(5) Installing oil seal

Insert oil seal (801) into casing (102).
z Use the jig 1) under 5.3.1 (2).

z Place the oil seal level and fix it so
the lip is not scored.
33-118
(6) Press-fitting roller bearing

JIG
Insert roller bearing (402) by using the jig
that holds down both the inner race and the
outer race and also using a press.
Always use the jig [5.3.1 (2)] and set it
properly.
402
Fig. 5-57 Press-fitting roller bearing

(7) Fit snap ring (913)
913
(8) Fitting the oil filling plug

Fill up the oil inlet with grease, wind seal
tape around plug (902) and set it to the
casing.
Grease : EP type (Shell Alvania EP2)
Grease volume : about 500cc (31 cuin)
Fig. 5-58 Fitting snap ring

(9) Assembly No.2 carrier assy
1) Place side plate (285) by matching it to the 230 285 282 203
pin holes.
2) Put No.2 planetary gear (203) in.
3) Check the hole location, peeping through it
from above. Match the No.2 pin (282) with
the hole for spring pin (910) and the hole in
the No.2 carrier and set the pin, while
tapping it lightly. 910
Fig. 5-59 Assembling No.2 carrier assy
(10) Apply liquid packing to the matching surface
between casing (102) and ring gear (202).
z Three-Bond #1104B
(11) Installing ring gear 202

Install ring gear (202) to casing (102),
checking the location of the matching marks
102
and temporarily fasten them together by
means of four capscrews or socket bolts
M12×100. [Tightening torque : 8kgfym (58
lbfyft) or over]. Always place plain washers on
the bolts so the matching surface of the motor
is not scored.
: 19mm or : 10mm Fig. 5-60 Installing ring gear
33-119
(12) Installing No.2 carrier assy

Install the No.2 carrier assy into the ring
gear. No.2
CARRIER
ASSY
Fig. 5-61 Installing No.2 carrier assy

(13) Installing No.2 sun gear
Put in No.2 sun gear (204).
204 286 211 285 287 283 403 210
(14) Assembly No.1 carrier assy 231

1) Place No.1 carrier (231) on a level bench.
2) Make sure that all three ∅2(0.079˝ ) oil holes

of No.1 pin (283) are directed outwards with
respect to the center of No.1 carrier (231), as
shown in the figure. ∅2 (0.079˝ )
(OIL HOLE)
Fig. 5-62 Assembling No.1 carrier assy
231
286
3) Installing thrust washer
Put in thrust washer (286) in the center.
Fig. 5-63 Installing thrust washer

4) Installing side plate
Put in side plates (285).
z The upper and lower side plates 286

differ in thickness; take care so as
not to mistake one for another.
403
285
Fig. 5-64 Installing side plate
and needle bearing
33-120
5) Installing needle bearing and No.1 planetary

gear
Fit needle bearing (403) and No.1 planetary
gear (210).
210
Fig. 5-65 Installing planetary gear

6) Installing side plate
Put side plate (287) in and fit snap ring (911).
(15) Installing No.1 carrier assy

Assemble the No.1 carrier assy. Make sure
that thrust washer (286) in the center sits in 911
the convex part of No.2 sun gear (204).
287
(16) Installing No.1 sun gear
Assemble No.1 sun gear (211). Fig. 5-66 Installing side plate and snap ring
(17) Apply liquid packing No.1 CARRIER ASSY

Remove the temporarily fastened bolts and
coat the mounting surface of the hydraulic
motor of ring gear (202) with liquid packing 286
(Three-Bond #1104B).
(18) Installing hydraulic motor

Fit snap ring (912) to the drive shaft of the
hydraulic motor, lower it vertically, assemble
the hydraulic motor in place, while matching
it with the spline position and fasten it with
socket bolt (602). Fig. 5-67 Installing No.1 carrier assy
10kgfym (72 lbfyft)
211
(19) Wind seal tape around oil drain plug (902)
and fit it to the casing.
(20) Filling oil

Fill in gear oil through the oil inlet.
Lubricating oil :
SAE#90～#140, API GL class 3～4
(Shell Spirax 90EP filled up at shipping) Fig. 5-68 Installing No.1 sun gear
Lubricant volume : 1.7 (0.45gal)
z Temporarily fit the level bar to the

pipe and check the level.
33-121

5.4.1 SWING MOTOR
(1) Replacement standards for parts
If part are worn out beyond the below
standards, replace or recondition them.
However if they show excessive damage on
their surface, replace them.
Recommended
Standard Value for
Item Dimension Replacement Remedy
mm (in) mm (in)
Clearance between piston and
cylinder bore (D-d)
0.016 0.046
Replace piston or cylinder.
d D (0.00063) (0.00181)
Gap between piston and caulked

part of shoe (σ)
0.3
0 Replace piston and shoe assembly.
(0.012)
σ
Thickness of shoe (t)
4.0 3.8
Replace piston and shoe assembly.
(0.157) (0.150)
Assembled height of shoe plate and

retainer (H-h)
5.5 5.0 Replace a spherical bushing and a

H (0.217) (0.197) retainer plate as a pair.
h
Thickness of friction plate
3.5 3.1
t Replace.
(0.138) (0.122)
33-122
(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface
of a part exceeds the following standard,
correct it or replace the part.
Standard for correcting sliding surfaces

Standard surface Surface roughness
Name of part roughness requiring correction
0.8－Z (Ra=0.2)
Shoe 3－Z (Ra=0.8)
(lapping)
0.4－Z (Ra=0.1)
Shoe plate 3－Z (Ra=0.8)
(lapping)
1.6－Z (Ra=0.4)
Cylinder 12.5－Z (Ra=3.2)
(lapping)
0.8－Z (Ra=0.2)
Valve plate 6.3－Z (Ra=1.6)
(lapping)
z Lap each sliding surface to a z If the sliding surface of the cylinder

standard roughness level or finer. block, valve plate, retaining plate or
spherical bushing is roughened,
replace parts in pairs.
33-123

(1) Parts inspection and replacement standards
1) If pitching is seen on the tooth surface of the
sun gear, the planetary gear and the ring
gear; (Single pit is more than ∅1mm(0.039in)
and the area occupancy of all pits is more
than 5%.)
2) Oil seal
Replace the oil seal if the lip face of it is
scored and worn.
Always replace when the reduction gear is
disassembled for inspection or some reason.
3) Drive shaft roller bearing (Front side)

Inspect as below without drawing it out from
the drive shaft:
① Inspect the race surface and the rollers as
far as you can see and make sure that
there is no pitching and flaking.
② Inspect the following as well:
a) The gear oil does not contain large
worn particles.
b) Large worn particles are not deposited
between the roller and the retainer.
c) The bearing turns smoothly by hand.
Replace it if there is any fault on the
above inspection.
Do not reuse the bearings drawn out of
the shaft.
4) Drive shaft roller bearing (Rear side)

Replace the bearing if the race surface and
the rollers show pitching and flaking.
5) No.2 planetary gear

Check for the circumferential gap between
the No.2 planetary gear and the No.2 pin
without disassembling the No.2 carrier assy.
Replace the planetary gear if the gap is more
than 0.5.
6) Thrust plate and thrust washers

Replace the gear if the sliding surface in
contact with the No.2 sun gear is extremely
scored.
7) If pitching and flaking are seen on the rolling

surfaces of the needle cage and the No.1 pin
that support the No.1 planetary gear; Replace
such faulty parts.
33-124
(2) Table of parts to be replaced together
◯ marks represent such parts that must be

replaced together.
△ marks represent such parts that should
preferably be replaced together.
Note: Replace the inner race and the outer race of

the roller bearing together.
Parts to be replace together
No. 201 401 402 203 230 282 285 910 210 231 283 403
No.2 planetary gear
No.1 planetary gear

Roller bearing
Roller bearing
No.2 carrier
No.1 carrier
Needle cage
Drive shaft
Spring pin
Side plate
No.2 pin
No.1 pin
NAME
201 Drive shaft － ○ ○
401 Roller bearing △ － △
402 Roller bearing △ △ －
203 No.2 planetary gear － △ ○ △ ○

Parts for replacement
230 No.2 carrier △ － ○ △ ○
282 No.2 pin △ △ － △ ○
285 Side plate △ △ ○ － ○
910 Spring pin △ △ ○ △ －
210 No.1 planetary gear － △ △ △
231 No.1 carrier △ － ○ △
283 No.1 pin △ ○ － △
403 Needle cage △ △ △ －
33-125
5.5 TROUBLESHOOTING
5.5.1 SWING MOTOR
(1) Hydraulic motor does not rotate.

Pressure does not 1. Relief valve in circuit is not set 1. Set to correct value.
rise. correctly.
2. Malfunction of relief valve. 2.
2-1. Sticking plunger. 2-1. Correct the stuck areas or
replace the plunger.
2-2. Orifice on plunger is clogged. 2-2. Disassemble and clean.
3. Plunger seat is faulty. 3. Check the seat surface and
replace the plunger if scored.
4. Swing shockless valve seat is faulty. 4. Replace the swing shockless
valve cartridge or block.
Pressure rises. 1. Overload. 1. Eliminate overload.
2. Moving parts are seized. 2. Inspect and repair piston, shoe
3. Brake release pressure is not and cylinder valve plate.
working on the motor 3. Check circuit and correct it.
4 Brake piston is stuck. 4. Disassemble and check.
5. Friction plate is seized. 5. Disassemble, check and repair.
Replace one that is seized.
(2) Rotating direction is opposite.

Rotating direction 1. Motor’s assembling direction is reversed. 1. Assemble correctly.
is opposite. 2. Piping inlets and outlets are reversed. 2. Pipe correctly.
33-126
(3) Revolution does not rise to set value.

Revolution does not 1. Oil inflow is deficient. 1. Check pump’s delivery rate and
rise to set value 2. Oil leaks are excessive due to high circuits to motor.
temperature. 2. Lower oil temperature.
3. Sliding surfaces are worn or broken. 3. Replace.
(4) Brake torque is insufficient.

Brake torque is 1. Friction plate is worn. 1. Disassemble and check. Replace if
insufficient. wear is beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not released. 3. Check and correct circuit.
4. Spline of friction plate is broken. 4. Disassemble and check.
Replace broken part.
(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor.
If it is less than 200cc/min(12cuyin/min), you
should think that the motor is not faulty.

The swing motor 1. Relief valve malfunctions. 1.
drifts much when it is Same as (1). Same as (1).
actuated by external 2. Plunger seat is faulty. 2. Replace.
torques. (e.g. Machine 3. Seat of the swing shockless valve is 3. Replace the swing shockless valve
is on a slope.) no good. cartridge or block.
33-127
(6) Oil leaks

1) Oil leak from oil seal
Oil leaks from oil 1. Lip of seal contains dirt and 1. Replace oil seal.
seal damaged. 2. Shift the lip and shaft positions or
2. Shaft is damaged or worn. replace oil seal.
3. Repair drain piping if clogged up.
3. Casing inner pressure has risen
abnormally high, with the result that
lip of oil seal has turned up. 4. Disassemble and correct.
4. Shaft is rusted.
2) Oil leak from matching surface

Oil leak from 1. O ring is missing. 1. Set O ring correctly and assemble
matching surface it.
2. O ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or broken. 4. Tighten to specified torque or
replace.
33-128
1)Reduction unit does not turn.
Hydraulic motor inlet pressure has risen. Overloaded Reduce the motor of load.
Reduction unit is broken. Replace reduction unit.
Parking brake of the Inspect the release

hydraulic motor is not pressure and the brake.
released.
Check the release

Hydraulic motor inlet pressure has not risen.
command pressure.
Rotating sound is heard from Motor shaft is broken. Replace hydraulic motor.
hydraulic motor.
Reduction unit is broken. Replace reduction unit.
Rotating sound is not heard Pump and valve are out of Check for fault and correct.
from hydraulic motor. order.
2) Oil leakage
Oil leaks through matching surface. Liquid packing is not applied. Disassemble and apply
liquid packing.
Bolts are not fastened tight. Disassemble, apply

The matching surface is liquid packing and
moving because of loosening. reassemble as specified.
The matching surface is scored. Replace faulty parts.
Oil leaks from shaft. Oil seal is scored. Disassemble reduction

unit and replace oil seal.
3) Temperature is high.
Temperature of reduction unit casing The gear oil is not filled up or Check oil level and fill oil
is high. the oil level is low. up to a specified level.
The amount of grease is small. Fill up grease.
Gear and bearing are

damaged. Replace reduction unit.
33-129
6. SWIVEL JOINT
6.1 CONSTRUCTION VIEW
(1) Specification 1 (2) Specification 2
STANDARD SPECIFICATION DOZER SPECIFICATION
10 H E
D H
12
F
B
C
F 11
E
E
X
A F
SECTION XX G 2
X
E 6
1
2
6 D
C
1
B
D
A
C
G
B
F
5
A
5 7
7
3 3 4 E 8 9
13 9
E E
8
Table 6-1
Q’TY Q’TY
NO. NAME NO. NAME
Spec.1 Spec.2 Spec.1 Spec.2
1 BODY 1 1 7 O RING(1A G95) 1 1
2 STEM 1 1 8 SOCKET BOLT (M8×20) 2 2
3 THRUST PLATE 1 1 9 SOCKET BOLT (M8×30) 4 4
4 COVER ― 1 10 PLUG ― 1
5 SEAL ASSY 5 7 11 PLUG ― 2
6 O RING ― 2 12 PLUG 1 ―
SEAL ASSY 2 ― 13 COVER 1 ―
Fig. 6-1 Construction of swivel joint
33－130
6.2 DISASSEMBLY AND ASSEMBLY

6.2.1 TOOLS Table 6-2
Symbol Tool Name Used for Remarks
1. Steel hammer
a Hammer
2. Wooden or plastic mallet
b Rubber mat 750mm (30in) square or more
1. Allen wrench
c Wrench 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 10kgfym (72 lbfyft)

Grind the tip of“a nail”to shape
as a screwdriver.
e Pin Disassembly
Made from a hack-saw blade
Disassembly Approx. 120mm (4.72 in)

f Spatula
Assembly
Vinyl tape Remove the edge completely

and make corner round smooth.
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite #290
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
6.2.2 APPARATUS 6.2.3 CLEANING OUTSIDE

(1) Hoist or crane Clean the swivel joint to be free from dirt and
The lifting device should be capable of lifting dust, using steam and cleaning oil.
the swivel joint assy.
(2) Work bench z Keep all ports plugged up while
The work bench should have an area of cleaning.
1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare waste cloth, wooden block and
oil pan.
33-131
6.2.4 DISASSEMBLY 2
1
The part numbers used in this disassembly 4
procedure correspond to those of a construction 9
drawing in Fig.6-1.
(1) Removing cover

1) Mark cover (4) and body (1) with matching
marks for convenient reassembly.
ALLEN
WRENCH
2) Place a V-block on a work bench, place a V-BLOCK PIPE
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and
wrench. Alternately, the swivel joint may be Fig. 6-2 Removing cover (4)
fixed by holding stem (2) in a vise.
: 6mm
3) Remove cover (4) from body (1) and draw out

7 4
O ring (7) from cover (4).
Fig. 6-3 Removing O ring (7)
1 BODY
(2) Removing thrust plate 3 THRUST PLATE
Loosen socket bolt (8) fastening thrust plate 8 SOCKET BOLT
(3), in the same manner as the removing of
the above-mentioned cover.
z When removing thrust plate (3) by

fixing body (1), support stem (2) so it PIPE
may not fall down.
: 6mm
(3) Removing stem

2
Place body (1) on a V－block. Put a wooden STEM
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 Fig. 6-4 Removing thrust plate (3)
the body, it can be easily pulled out by hand. WOODEN BLOCK Secure
FOR PROTECTOR with hands 1
Stem weight ; 12kg(26 lbs) 2
WORK BENCH V-BLOCK

Fig. 6-5 Drawing out stem (2)
33-132
(4) Removing seals SPATULA(f)

1) Pull out O ring (6) from the O ring groove
with the aid of a spatula.
6
Use the tip of the spatula taking not to mar
the body. Also do not strike the spatula.
2) Stick pin (e) to seal (5) and extract slipper

ring (5). Fig.6-7 shows the use of one pin, but
by using two pins, this can be extracted with Fig. 6-6 Taking out O ring (6)
more sureness.
As the backup ring is of rubber substance,
remove this in the same procedure as O ring
(6). SLIPPER RING
BUCK-UP RING
DETAIL(5)
GROOVES
FOR O RING
GROOVES
FOR
HYDRAULIC PIN(e)
GROOVES
FOR 5
SLIPPER SEAL
SEAL ASSY
6.2.5 ASSEMBLY Fig. 6-7 Taking out seal assy (5)

Prior to assembly, clean each parts (excluding the
O ring and slipper ring), and arrange in the
sequence of assembly.
(1) Assembling seals to body

1) Coat O ring (6) lightly with hydraulic oil and
install in the O ring groove. Also make sure
that the O ring is not distorted after
installation.
2) Make sure that oiliness, such as hydraulic oil
and grease, has been completely removed.
3) Slipper ring is assembled, after first inserting
the backup ring, by slightly-distorting the
shape as shown in Fig.6-8. Also after
inserting all of the seals, be certain that these
are installed in the seal groove by use of the Fig. 6-8 Inserting slipper ring into backup ring
spatula. {seal (5)}.
33-133
(2) Assembling stem

Lightly coat the outer circumference of stem Press in by applying your weight
(2) and the inner surface of body (1) with by your both hands.
grease or vaseline and slowly insert stem (2)
into body (1).
2 STEM
It stem (2) is pressed in too fast, the seal
may be damaged. Do it slowly.
The clearance between body (1) and stem (2)
is about 0.1mm (0.004in). Push stem straight O RING 6
along the shaft center.
1 BODY
5
SEAL ASSY
WORK BENCH
Fig. 6-9 Inserting stem (2)

(3) Assembling thrust plate
1) While holding stem (2) and body (1), match
the hole of thrust plate (3) and the stem (2) 8 3 2
hole.
2) Next, after removing any oil from the thread
of socket bolt (8), coat it with Loctite #290
and tighten to stem (2).
: 6mm,
Tightening torque : 3.1 kgfym
(22 lbfyft)
Fig. 6-10 Tightening socket bolt (8)
(4) Assembling cover

1
After installing O ring (7) to cover (4) and
MATCHING MARK
aligning the matching marks of the cover (4)
and body (1), coat socket bolt (9) with Loctite
#290 and tighten it which will then complete 9
assembly. 4
: 6mm,
Tightening torque : 3.1 kgfym
(22 lbfyft)
ALLEN
WRENCH
PIPE
33-134

6.3.1 INSPECTION PROCEDURE AND REMEDY
Table 6-3
Interval Check Item Checking Procedure Remedy
2,000Hrs. Seal for oil Check oil leakage outside Replace O ring, if any oil leakage can be
leakage outside found.
4,000Hrs. All sealing Replace all sealing parts such as slipper
In principle, parts seal with back-up ring and O ring.
disassemble
and check re- All sliding parts Check abnormal wear, scoring Repair or replace referring to their limit
gardless of oil or corrosion caused by foreign of serviceability.
leakage or not. matters or seizure.
When All parts Check them for seizure, foreign Repair or replace referring to their limit
disassembled matters, abnormal wear, and of serviceability.
for repair defect of seals. O rings should be replaced.
6.3.2 USABLE LIMIT OF THE PARTS
Table 6-4
Parts Maintenance Standards Remedy
Sliding surface with

Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface 1) Worn abnormality or damaged more than 0.1mm Replace
between body and (0.004in) in depth due to seizure or contamination.
stem other than
Body, Smooth with
sealing sections 2) Damaged less than 0.1mm (0.004in) in depth.
Stem oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface 2) Worn less than 0.5mm (0.02in). Smooth

with thrust plate 3) Damage due to seizure or contamination remediable Smooth
within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface 2) Worn less than 0.5mm (0.02in). Smooth
Cover
with thrust plate 3) Damage due to seizure or contamination remediable Smooth
within wear limit 0.5mm (0.02in).
33-135
Parts Maintenance Standards Remedy
1) Protruded excessively from seal groove.

Replace
PROTRUSION (With back-
up ring)
BACK-UP RING
2) Slipper ring 1.5mm (0.06in) narrower than seal

groove, or narrower than back-up ring. Replace
(With back-
Slipper ring
up ring)
1.5mm (max.)
(0.06in)
BACK-UP RING
3) Worn unevenly more than 0.5mm (0.02in)

0.5mm (max.) Replace
(0.02in) (With back-
up ring)
33-136
6.6.3 INSPECTION AFTER ASSEMBLY

After completion of assembly, inspection for oil 1
leakage, pressure resistance, etc., using a device
as shown in the figure right.
9
(1) High pressure port(A,B,C,D port) Connect to
Install a changeover valve and pressure body side
gauge to the stem side port and body side
2
port respectively, and while watching the
Connect to
pressure gauge (for high pressure) installed stem side
on the body side and also by regulating high
pressure relief valve (7), gradually increase
3
the pressure and when the pressure has
reached 1.5 times the maximum working 8
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 7
at this time.
(2) Low pressure port

(Drain port, return port : E,F port.)
Similar to the high pressure port, install a
changeover valve and pressure gauge on each
port of the stem side and body side.
Hydraulic 6 5
Open stop valve (6) on the side of low pres- source
sure relief valve (5) and while watching the
pressure gauge (for low pressure) connected Fig. 6-12 Hydraulic circuit for inspection
to the body side and also by regulating low equipment
pressure relief valve (5), gradually increase
the pressure and check for outside leakage
with a color check at a pressure of 5 kgf/cm2
(71 lbs / in2).
Table 6-5
Item Description Remarks
High and Low Pressures
1 Pressure Gauge
are required.
2 Swivel Joint
3 Stop Valve
Relief Valve for Setting Pressure :
5
low pressure 5kgf/cm2 (71psi)
6 Stop Valve
Relief Valve for Setting Pressure
7
high pressure (Working pressure×1.5times)
8 Directional Valve
9 Piping, etc.
33－137
6.4 TROUBLESHOOTING
Table 6-6

1. External leakage of Defective O ring Replace all seals.
hydraulic oil
2. Internal leakage of 1) Defective slipper seal 1) Replace all seals.

2) Sliding face worn 2) Replace assy.
hydraulic oil
excessively
1) Stem and body 1) Grind and hone.
seized Replace assy, if stem and body
are too loose and causing oil
3. Swivel joint seized leakage.
2) Inappropriate swivel 2) Reinstall
stopper bracket Secure 2～3mm (0.08～0.12in)
allowance for bolt stopper.
4. Loose swivel stem and Socket bolt tightened Retighten.
cover insufficiently.
33-138
E115SR
E135SR
SECTION 34 TRAVEL SYSTEM
TABLE OF CONTENTS
Part I: Removing and installing assy ................................................................ 34-1

1. Name of travel system .......................................................................................... 34-1
2. Crawler ................................................................................................................. 34-1

2.1 Removing and installing iron crawler ............................................................................................. 34-1
2.2 Removing and installing rubber crawler ......................................................................................... 34-3
2.3 Construction ................................................................................................................................... 34-4
2.4 Maintenance standard .................................................................................................................... 34-6
2.5 Tools and jigs ................................................................................................................................. 34-8
3. Upper roller ........................................................................................................... 34-9

3.1 Upper roller assy ........................................................................................................................... 34-9
3.2 Removing ...................................................................................................................................... 34-9
3.3 Installing ........................................................................................................................................ 34-9
3.4 Construction ................................................................................................................................ 34-10
3.5 Disassembly and assembly ......................................................................................................... 34-10
3.6 Maintenance standard ................................................................................................................. 34-13
3.7 Tools and jigs ............................................................................................................................... 34-14
4. Lower roller (track roller) ..................................................................................... 34-15

4.1 Lower roller assy ......................................................................................................................... 34-15
4.2 Removal ...................................................................................................................................... 34-15
4.3 Installation ................................................................................................................................... 34-15
4.4 Construction ................................................................................................................................ 34-16
4.5 Disassembly and assembly ......................................................................................................... 34-16
4.6 Maintenance standard ................................................................................................................. 34-20
4.7 Tools and jigs ............................................................................................................................... 34-21
5. Crawler idler (idler adjuster assy) ....................................................................... 34-22

5.1 Crawler idler assy ........................................................................................................................ 34-22
5.2 Removing .................................................................................................................................... 34-22
5.3 Idler assy ..................................................................................................................................... 34-23
5.4 Idler adjuster assy ......................................................................................................................... 34-28
INDEX
6. Sprocket ............................................................................................................. 34-34

6.1 Removing ...................................................................................................................................... 34-34
6.2 Installing ....................................................................................................................................... 34-34
6.3 Maintenance standard ................................................................................................................... 34-35
6.4 Tools and jigs ................................................................................................................................ 34-37
7. Travel motor ........................................................................................................ 34-40

7.1 Travel motor installing ................................................................................................................... 34-40
7.2 Removing ...................................................................................................................................... 34-41
7.3 Installing ....................................................................................................................................... 34-42
8. Swing bearing .................................................................................................... 34-43

8.1 Swing bearing assy ....................................................................................................................... 34-43
8.2 Removing ...................................................................................................................................... 34-43
8.3 Installing ....................................................................................................................................... 34-44
8.4 Construction .................................................................................................................................. 34-44
8.5 Disassembly and assembly .......................................................................................................... 34-44
8.6 Maintenance standard ................................................................................................................... 34-45
Part II: Disassembling and assembling equipment .......................................... 34-46

1. Removal and installation of travel motor unit ...................................................... 34-46
1.1 Construction of travel motor .......................................................................................................... 34-46
1.2 Tools and jigs ................................................................................................................................ 34-49
1.3 Preparation for disassembly .......................................................................................................... 34-53
1.4 Assembly ...................................................................................................................................... 34-70
1.5 Service standards ......................................................................................................................... 34-90
1.6 Troubleshooting ............................................................................................................................. 34-93
1A. Removal and installation of travel motor unit .................................................... 34-96

1.1 Construction of travel motor (for L type) ........................................................................................ 34-96
1.2 Tools and jigs ................................................................................................................................ 34-98
1.3 Disassembly ................................................................................................................................. 34-53
1.4 Assembly .................................................................................................................................... 34-100
1.5 Service standards ....................................................................................................................... 34-111
1.7 Precautions when installing travel motors ................................................................................... 34-134
Part I: REMOVING AND INSTALLING

1. NAME OF TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
DOZER BLADE
7. TRAVEL MOTOR
6. SPROCKET GUARD 5. FRONT IDLER
LOWER FRAME
3. UPPER ROLLER GREASE NIPPLE OF THE
4. LOWER ROLLER
TRACK SPRING ADJUSTER
(TRACK ROLLER)
Fig. 1-1 Designation and location of undercarriage
2. CRAWLER
z This machine is equipped with iron

crawlers. Rubber crawlers are
equipped as an option.
2.1 REMOVING AND INSTALLING IRON

CRAWLER
(1) Removing
1) Position the machine to remove crawler.
2) Pushing out master pin.
1. Set master pin to positions shown in the
figure.
2. Slacken crawler.
: 19mm
z When loosening the grease nipple of Fig. 2-1 Crawler removing position
the adjuster, do not loosen it more
than one turn.
z Where grease does not come out
Projection
well, move the machine back and Master pin
forth. The over loosening of grease
nipple may cause it to jump out
incurring danger of injury. So be
careful not to over loosen the grease
nipple.
3. Pushing out master pin
Apply jig on master pin and strike it out with
a mallet.
Master pin
z If you use a hammer, wear a long- drawing jig
sleeved garment and protective
goggles to protect yourself from Fig. 2-2 Pushing out master pin.
flying.
34-1
3) Removing crawler
Put attachment on ground so that weight is
not loaded to the lower frame, and remove Removing
master pin
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. 2-3 Removing crawler

(2) Installing
removing.
Front
1) Checking crawler installation direction. idler side
Place the track links on the ground so they
converge, facing the front idler, as shown in
the figure on the right.
Fig. 2-4 Installing direction of crawler

2) Installing crawler
1. Preparation for installation
Treat paint flaking protection with care not
to damage lower flame.
2. Winding crawler
Insert an iron pry into the hole of the master
pinhole. Bring the attachment down on the
ground, holding it by hand as shown in Fig.
2-5. Then hold up the lower frame by 1 to
2cm (0.4 to 0.8in) so the machine weight is
not exerted upon the shoes. Then put an lever
into the hole of the master pin. Holding the
top end of the track link by hand as shown in Fig. 2-5 Winding crawler
Fig.2-5, rotate the sprocket in the backward
direction and roll up the crawler around.
3) Preparation for press fitting master pin

1. Preparing for installation
Put square wood under the shoe plate.
2. Aligning master pin holes

Aligning master pin holes through fine
adjustment turning sprocket.
Connecting
position of master pin
Fig. 2-6 Preparation for press fitting master pin
34-2
4) Press fitting of master pin

Apply press fitting jig on master pin, and
strike it with a mallet to press fit.
If you use a hammer, wear a long-

sleeved garment and protective goggles
to protect yourself from flying objects.
z Coat the master pin with

molybdenum disulfide grease, before
pressing it in. Press fitting jig
on master pin
5) Adjusting crawler tension(See Fig. 2-8) Fig. 2-7 Press fitting of master pin
After installing, adjust tension of crawler.
: 19mm
MODEL DIMENSION “A”

Proper 270～300mm
E115SR
tensioning of (10.6in～11.8in)
the iron 320～350mm
crawler E135SR
(12in～13in)
2.2 REMOVING AND INSTALLING RUBEER
CRALWER
(1) Removing “A
1) Position the machine to remove crawler. Fig. 2-8 Adjusting crawler tension
(See Fig. 2-1)
2) Loosen grease nipple (1) for crawler adjuster
to loose tension of crawler.
: 19mm
Since the rubber crawler is of endless

type, discharge grease from the grease
nipple till the idler is pushed to the 1
deepest end.
Fig. 2-9 Tensioning and loosening the crawler
Use care that high-pressured grease is
not spouted or the nipple is not come
out by turning nipple abruptly or
overloosening.
One turn of the adjust grease nipple is

sufficient, but if grease does not come
out well, discharge grease by turning
the crawler.
Lower frame
Square timber
3) Lift the one side of machine with attachment,
and place square timber or equivlent under Fig. 2-10 Supporting lower frame with
lower frame to support machine. square timber or equivalent
34-3
4) Insert iron pipe in the crawler, turn sprocket

Rotating direction
backward slowly, and slide crawler at the
point where rubber crawler is floated from
the pipe to remove.
Weight of rubber crawler (one side) :
E115SR 675kg (1490 lbs)
E135SR 790kg (1740 lbs)
(2) Installing
1) Install crawler by reversing the procedure of PIPE
removal. That is, engage crawler with Fig. 2-11 Removing rubber crawler
sprocket, place it upper roller, and engage it
with idler using bar while turning sprocket GREASE NIPPLE
slowly.
2) Check that rubber crawler retaining
projection is matched with front idler,
sprocket, lower roller respectively and
completely, and then tighten grease nipple
for crawler adjuster, and adjust the tension
while applying grease.
: 19mm,
Tightening torque of grease nipple: “A”
6kgfym (43 lbfyft) Fig. 2-12 Adjusting crawler tension
MODEL DIMENSION “A”

2.3 CONSTRUCTION Proper
(1) Shoe assy E135SRLC tensioning of E115SR 165～170mm
the rubber E135SR(LC) (6.5～6.7in)
Shoe ; 600 (STD) crawler
• Shoe ; 700
SHOE • Shoe ; RUB PAD500
•
7
ASSY Shoe ; 500
4
Shoe ; F500
• 3
Shoe ; T800
No. NAME Q’TY REMARKS 7
8
• TRACK LINK ASSY 1 ←
1 • • TRACK LINK (R.H) 44 ←
2 • • TRACK LINK (L.H) 44 ←
1
5 11
3 • • BUSHING 43 ←
4 • • PIN 43 ←
5 • • MASTER BUSHING 1 ←
8 2
6 • • MASTER PIN 1 ←
7 • • SEAL 86 ←
6
8 • • MASTER COLLAR 2 ← 9
9 • SHOE ; 600 (STD) 46 ―
• SHOE ; 700 46 ―
• SHOE ; RUB PAD500 46 ―
• SHOE ; 500 46 ―
• SHOE ;F500 ― 46
• SHOE ;T800 ― 46
10 • SHOE BOLT 184 ―
• SHOE BOLT ― 184
11 • SHOE NUT 184 ←
10
Fig. 2-13(1/2) Shoe assy
34－4
(2) Shoe assy E115SR

7
Shoe ; 600 (STD) 4
• Shoe ; 700 3
SHOE • Shoe ; RUB PAD500
•
7
ASSY Shoe ; 500 8
Shoe ; F500
•
Shoe ; T800
No. NAME Q’TY REMARKS
1
• TRACK LINK ASSY 1 ← 5 11
1 • • TRACK LINK (R.H) 41 ←
2 • • TRACK LINK (L.H) 41 ← 8 2
3 • • BUSHING 40 ← 6
4 • • PIN 40 ←
5 • • MASTER BUSHING 1 ← 9
6 • • MASTER PIN 1 ←
7 • • SEAL 80 ←
8 • • MASTER COLLAR 2 ←
9 • SHOE ; 600 (STD) 41 ―
• SHOE ; 700 41 ―
• SHOE ; RUB PAD500 41 ―
• SHOE ; 500 41 ―
• SHOE ;F500 ― 41
• SHOE ;T800 ― 41 10
10 • SHOE BOLT 164 ― Fig. 2-13(2/2) Shoe assy
• SHOE BOLT ― 164
11 • SHOE NUT 164 ←
(3) Shoe assy E135SR (4) Shoe assy E135SRL
SHOE SHOE
ASSY ASSY
• TRACK LINK ASSY 1 • TRACK LINK ASSY 1
1 • • TRACK LINK (R.H) 44 1 • • TRACK LINK (R.H) 42
2 • • TRACK LINK (L.H) 44 2 • • TRACK LINK (L.H) 42
3 • • BUSHING 43 3 • • BUSHING 41
4 • • PIN 43 4 • • PIN 41
5 • • MASTER BUSHING 1 5 • • MASTER BUSHING 1
6 • • MASTER PIN 1 6 • • MASTER PIN 1
7 • • SEAL 86 7 • • SEAL 82
8 • • MASTER COLLAR 2 8 • • MASTER COLLAR 2
9 • SHOE ; 600 44 9 • SHOE ; 700 42
10 • SHOE BOLT 176 10 • SHOE BOLT 168
11 • SHOE NUT 176 11 • SHOE NUT 168
35－5
(3) Rubber crawler
E135SR width
E115SR 500mm(19.7in)
Fig. 2-14 Rubber crawler assy

2.4 MAINTENANCE STANDARD
CORE
(1) Rubber crawler
Steel cord center line

h
Fig. 2-15 Section of rubber crawler

Item Standard value Repairable level Service limit Remedy
Flaws and cuts on Where the depth of them does Where the depth of them
1 NO Replace
rubber crawler not reach to the steel cord. reaches to the steel cord.
2 Cuts on steel cord NO NO YES Replace
Contact surface of Where a half of core is
Where 10 percent of core is
3 rubber crawler NO visible from rubber Replace
visible from rubber crawler.
and lower roller crawler.
4 Height H 134.5 (5.30) － 100 (3.94) Replace
5 Groove depth h 43 (1.69) － 10 (0.394) Replace
34-6
(2) Track link assy STD LC
E F
G D
B
Fig. 2-16
Table 1-2 Unit：mm(in)

REPAIRABLE
No. ITEM STANDARD VALUE LEVEL SERVICE LIMIT REMEDY
Replace the link
A Link pitch 171.07±0.1(6.74±0.004) 175 (6.89) 179 (7.05) assy if the
+0.29 service limit is
B O.D. of bushing ∅47+0.24 (1.85+0.0114
+0.0094 ) 43 (1.69) 42 (1.65) exceeded
C Height of link 90(3.54) 84 (3.31) 82 (3.23) Replace
Basic
dimension Tolerance Fit Fit
Interference
D between bushing Shaft ＋0.29
and link ∅47 ＋0.24 Interference Interference
(1.8504) ＋0.0114 0.05 (0.0020) 0 Replace
＋0.0095
Shaft ＋0.14
Interference ∅30 Interference Interference
E ＋0.11
between track pin (1.1811) ＋0.0055 0.05 (0.0020) 0
and link ＋0.0043
Shaft ＋0.01
Interference ∅30 －0.02 Interference Interference Replace
F between master (1.1811) 0.05 (0.0020) 0 Link
＋0.0004
pin and link ＋0.0008
Clearance 1.2 (0.05) 8 (0.32) 10 (0.39)
G Replace
between links (both side) (both side) (both side)
Tightening torque
H of shoe bolt 41±4kgfym (300±29 lbfyft) Reassembly
34-7
(3) Track link assy L Type

G E F
B D
Fig. 2-16 H
Table 1-2(2/2) Unit：mm(in)
REPAIRABLE
No. ITEM STANDARD VALUE LEVEL SERVICE LIMIT REMEDY
A Link pitch 190±0.1 (7.48±0.004) 194.5 (7.66) 198 (7.80)

Replace
B O.D. of bushing ∅58.78±0.05 (2.31±0.002) ∅55 (2.17) ∅53 (2.09)
C Height of link 106.0±0.3 (4.17±0.012) 102 (4.02) 98 (3.86) Replace
Basic
Interference
D between bushing
and link ∅57.78 ±0.05 Interference Interference
(2.3142) Shaft 0.10 (0.0039) 0
(0.0020) Replace
Interference ∅36.63 Interference Interference

E between track pin Shaft ±0.05
(1.4421) (0.0020) 0.14 (0.0055) 0
and link
－0.03
Interference ∅36.6 Interference Interference
F between master (1.4409) Shaft －0.068 0.05 (0.0020) 0 Replace
－0.0018
pin and link －0.0027
Clearance 3.0 (0.12) 8 (0.32) 10 (0.39)
G Replace
between links (both side) (both side) (both side)
Tightening torque
H 87±5kgfym (630±36 lbfyft) Reassembly
of shoe bolt
2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig
Unit : mm (in)
NAME OPPOSING FLATS NAME SHAPE
Socket 19
Master pin
fixing jig
for iron
crawler
34－8
3. UPPER ROLLER
3.1 UPPER ROLLER ASSY 3 4 4 2
E115SR
UPPER
E135SR
ROLLER
ASSY E135SRLC IDLER SIDE
E135SRL
5
2 CAPSCREW 2 2 4 ─M20×110
CAPSCREW ─── 4 M20×100
3 NUT 2 2 4 4 M20
Fig. 3-1 Upper roller assy
4 WASHER 4 4 8─
5 ROLLER ASSY 2 ───
ROLLER ASSY ─2 4 ─
ROLLER ASSY ─── 4
3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned). 2
(2) Removing upper roller (5)

1) Remove nuts on support tightening section,
and also remove capscrew. Fig. 3-2 Removing upper roller
: 30mm (M20)
IDLER SIDE
DRILL POINT
5
3.3 INSTALLING Apply Loctite
#262
3
removing.
(1) Inspection
4 up
Before reassembling, check it that it rotates
smooth manually and for leakage.
2
(2) Installing upper roller (5)
1) Fit it directing nut toward idler side.
Fig. 3-3 Installing upper roller
2) Insert it until collar comes in contact with
support.
3) Fit it directing the countersinking mark of

shaft end upward.
4) Apply Loctite #262 on capscrew and tighten it

to the specified torque.
: 30mm (M20),
Fig. 3-4 Installing upper roller(5)
34－9
STD, LC 7 3 2
3.4 CONSTRUCTION
E115SR STD
ROLLER ASSY
E135SR(LC) STD,LC
E135SRL L
1 ROLLER 1 7 FLOATING SEAL 1

2 SHAFT 1 8 O RING 1
3 COLLAR 1 9 BOLT(Pre-coat) 2 11 10 8 5 4 9 6 1
4 PLATE 1 10 SNAP RING 1
3 7 6 4 8 10
5 COVER 1 11 PLUG PT1/4 1 L
6 BUSHING 1

(1) Disassembly
1) Draining out oil
Remove plug (11) and drain out oil.
: 6mm 11
2 1 9 5
2) Removing snap ring (10) Fig. 3-5 Construction of upper roller
Mount the end face inside upper roller (1) on 10
9
stand jig (f) and separate snap ring (10), 4 11
8
using snap ring pliers. 5
1
3) Removing cover (5)

Take off cover (5) upwards, utilizing the
screwed hole for the plug.
f
4) Removing O ring (8)

Separate O ring (8) from cover (5).
Fig. 3-6 Preparation for disassembly
5) Removing plate (4) Push with press

Loosen two bolts (9) and draw out plate (4)
from upper roller (1).
: 8mm
6) Removing shaft (2)

2
Put the extrusion jig (h) against the end face
of shaft (2) and extrude shaft (2) with
retainer for floating seal (7), using a press or
hammer. 3
Fig. 3-7 Extruding shaft
34－10
7) Removing floating seal (7).

Take out floating seal (7) from upper roller 7
(1).
7
Fig. 3-8 Removing floating seal

8) Removing floating seal (7). Push with press
Take out, from collar (3), floating seal (7) that
is located on the side from which shaft (2)
was disparted. g
Collar (3) is press fitted into shaft (2).

Therefore do not disassemble it. 6
9) Removing bushing (6)

1
Since the bushing is thin, machine it on a
lathe or scrape it off, exercise care so as not
to damage the bore of roller (1).
If the bushing is not worn much, mount
upper roller (1) on jig (f), insert jig (g) into the f
end face of bushing (6) and push it out with a
press. Fig. 3-9 Removing bushing
Push with press
(2) Assembly
Assembly of the upper roller is done in the
reverse order of disassembly. i
1) Place upper roller (1) on the top end face of 2
jig ( f ) , with its floating seal setting side
6
facing down.
2) Confirm that the outer surface of bushing (6)
is not seized and coat the outer surface of the 1
inserting side of the bushing, with
molybdenum disulfide grease.
3) Put jig (i) into bushing (6) and press it in,
using the bore of the bushing and the bore of
the roller as guides. f
In that case, the end face of bushing (6) is
pressed in 2mm (0.079in) from the end face of Fig. 3-10 Pushing in bushing
plate (4) of upper roller (1) by means of jig (i). 2
7
If you fail in this operation by pressing

7
the bushing unevenly, the bushing is
distorted and gets unserviceable. In 1
that case, do not re-use the bushing as
it may develop malfunctioning after 3
assembly.
Fig. 3-11 Fixing floating seal
34-11
Push with press

4) Installing floating seals (7).
Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 2
z Prior to placing floating seal (7) in,

apply engine oil lightly to seal
surface.
5) Inserting shaft (2).

Coat shaft (2) with a thin film of oil and
1
insert it into upper roller (1).
6) Installing plate (4).
Mount upper roller (1) on the stand jig ( f )
and attach plate (4) to the end face of the
shaft with bolt (9). In that case, coat the
screwed part of bolt (9) with Loctite #242
beforehand. Fig. 3-12 Inserting shaft
: 8mm,
9 10
11.7kgfym (85 lbfyft) 4
8
5
7) Installing O ring (8).
1
Fit O ring (8) to the groove of cover (5).
z Apply grease to O ring.
8) Installing cover (5).

Attach cover (5) to upper roller (1). Use a
f
press in this operation as a press fit is used.
9) Installing snap ring (10).

Fix snap ring (10) into upper roller (1), using
snap ring pliers.
Fig. 3-13 Installing cover
10) Filling oil

Fill in the engine oil API grade CD#30 through
the plug hole in cover (4).
STD, LC ; 20cc (1.22cuyin) 1
L ; 50cc (3.05cuyin)
11) Installing plug (11).

Wind seal tape around plug (11) and screw it
into the plug hole of cover (4).
: 6mm,
Tightening torque : 2.3kgfym (17 lbfyft) f
z After assembling the upper roller,

confirm that oil is not leaking from it
and that it rotates smoothly by hand.
Fig. 3-14 Filling oil
34－12

B
STD, LC L D D
B
C
A
E
F
C
A
E G
Fig. 3-15 Upper roller
E135SR(LC) STD, LC
E115SR STD
No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
A Tread dia. ∅100 (3.94) ∅99 (3.90) ∅92 (3.62) ∅88 (3.46)
B Tread width 130 (5.12) 140 (5.51) －－
Basic
Tolerance Fit Fit
dimension
Clearance between －0.025
C Replace
shaft and bushing ∅38 －0.050 Clearance Clearance
Shaft bushing.
(1.4961) －0.0010 0.7 (0.028) 1.0 (0.04)
－0.0020
＋0.025
Interference between ∅42 0 Interference Clearance
D Hole
roller and bushing (1.6535) ＋0.0010 0 0.01 (0.0004)
0
Tightening torque of Apply
E 6.7kgfym (48 lbfyft)
socket bolt Loctite #262.
F Oil Engine oil API grade CD #30, 20cc (1.22cuyin) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly

E115SRL L
A Dia. ∅140 (5.51) ― ―
B Width 150 (5.91) ― ―
C Tread dia. ∅120 (4.72) ∅110 (4.33) ∅108 (4.25) Replace
D Tread width 33 (1.30) ― ―
Basic
Tolerance Fit Fit
dimension
Clearance between shaft －0.025
E and bushing ∅45 －0.040 Clearance Clearance
Shaft
(1.7717) －0.0010 0.7 (0.028) 1.0 (0.039) Replace
－0.0016 bushing.
＋0.030
Interference between ∅50 0 Interference Clearance
F Hole
roller and bushing (1.9685) ＋0.0012 0 0.01 (0.0004)
0
Tightening torque of Apply
G socket bolt 11.7kgfym(85 lbfyft) Loctite #262.
Oil Engine oil API grade CD #30, 50cc (3.05cuyin) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
34－13
3.7 TOOLS AND JIGS

(1) Tightening tools
For STD & LC Type For L Type
Unit : mm (in) Unit : mm (in)

NAME OPPOSING FLATS NAME OPPOSING FLATS
Socket 19, 24 Socket 30
Allen wrench 8 Allen wrench 6, 8
(2) Jigs
No. NAME SHAPE No. NAME SHAPE
∅100 (3.94˝) ∅140 (5.51˝ )
(3.23˝) ∅100 (3.94˝ )
∅82
160 (6.30˝ )
160(6.30˝)
f Stand jig f Stand jig
∅40 (1.57˝) ∅52.5 (2.07˝ )
For For
(0.709˝ )
(0.709˝)
g extruding g extruding 18
18
bushing bushing
∅37 (1.46˝) ∅49 (1.93˝ )

For For
(1.18˝ )
extruding extruding
(1.18˝)
h h
30
30
shaft shaft
)
(1.953˝ +0.004
+0.
0
(2.05˝)
(2.36˝ )
∅49.6 1
0
∅52
(1.6339 +0.0039 )
Bushing Bushing
i i
)
∅41.5 +0.1
31 2 (0.0787˝)
+0.1
0
+0.0039
fixing jig fixing jig

0
0
(1.22˝)
∅37.6
(1.4803 0
36 40 20 50
(1.42˝) (1.57˝) (0.787˝ ) (1.97˝ )
76 70
(3.00˝) (2.76˝ )
34－14
4. LOWER ROLLER (TRACK ROLLER)

4.1 LOWER ROLLER ASSY
E115SR
LOWER E135SR
ROLLE
R ASSY E135SRLC
E135SRL
2 CAPSCREW 48 48 56 ─ M16×75
CAPSCREW ─ ─ ─ 56 M18×80
3 ROLLER ASSY 12 ─ ─ ─ 2 Apply Loctite #262.
ROLLER ASSY ─ ─ ─ 14 STD, LC : T=28.5kgfym (206 lbfyft) 3
ROLLER ASSY ─ 12 14 ─ L : T=40.5kgfym (293 lbfyft)
Fig. 4-1 Lower roller assy
4.2 REMOVAL
(1) Where crawler is removed
1) Preparation for removal
Loosen grease nipple to slacken the link.
Put square timbers on the front and rear
sides of under section of lower frame, and
stabilize the machine.
2) Removing lower roller
Remove cap screw (2).
: STD, LC : 24mm (M16)
: L : 27mm (M18)
Weight of lower roller :
STD, LC : Approx.27kg (60 lbs) Fig. 4-2 Holding up the lower frame
L : Approx.34kg (75 lbs)
(2) Where crawler is installed.
1) Preparation for removal
Slacken crawler, and stop engine keeping
lower frame lifted up with front attachment.
2) Put safe blocks under the front and rear sides
of lower frame.
3) Remove lower roller
Remove capscrew (2) in the same procedure
as that shown in Fig.4-1.
4.3 INSTALLATION
(1) Securing lower roller temporarily
Apply Loctite #262 on 4 capscrews (2) and Fig. 4-3 Installing lower roller
tighten them temporarily.
: STD, LC : 24mm (M16)
: L : 27mm (M18)
GREASE NIPPLE
(2) Securing lower roller regularly.
Bring the machine completely down on the
ground and tighten attaching cap screws (2)
to a specified torque.
Tightening torque :
STD, LC : 28.5kgfym (206 lbfyft)
L : 40.5kgfym (293 lbfyft)
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
: 19mm,
Tightening torque : 6kgfym (43 lbfyft) Fig. 4-4 Adjusting tension of crawler
34－15
4.4 CONSTRUCTION
ROLLER E115SR
ASSY E135SR(LC) 8
E135SRL
No. NAME Q’TY
1 ROLLER 1
2 SHAFT 1
3 BUSHING 2
4 PIN 2
FLOATING
5 SEAL 2
7 1 2 3 5 6 4 7
6 O RING 2
7 COLLAR 2
Fig. 4-5 Construction of lower roller
8 PLUG 2

(1) Disassembly
1) Drain oil
Remove plug (8) and drain out oil. 7
: 6mm
4
2) Removing pin (4)
Put both ends of lower roller assy on the
V-shaped blocks (K), apply push-out bar ( )
on upper end face of pin (4), and push pin out
striking with mallet. K
Fig. 4-6 Drawing out collar fixing pin (4)
3) Removing collar (7), O ring (6)

Push with press
Put lower roller on jig (m) for repair stand so
that the shaft is perpendicularly located,
apply push-out jig (P) on shaft end on upper
side, and push shaft (2) until the O ring JIG P
separate from collar (7) with press or mallet, 6
7
and take out collar (7) and O ring (6).
1
4) Removing shaft (2)
In addition, push out and remove shaft (2)
2
together with the lower collar (7) and O ring
(6).
JIG m
The shaft (2) extrusion operation may

cause the remaining lube oil to flow out
and contaminate the working floor.
Prepare an oil container beforehand.
Fig. 4-7 Removing shaft (2), collar (7), O ring (6)
34－16
5) Removing collar (7), O ring (6)

Insert shaft (2) with collar (7) and O ring (6)
5
removed in the said procedure into roller (1)
directing the collar (7) side upward, and take
out collar (7) and O ring (6) from shaft (2) in
the same procedure as that described in Item
3).
7
6) Removing floating seal (5)
Take out floating seal (5) from collar (7).
Fig. 4-8 Removing out floating seal (5)
7) Removing floating seal (5)

5
Take out floating seal (5) from roller (1).
Fig. 4-9 Removing out floating seal (5)

Since thickness of bushing (3) is thin
[thickness is 2.75mm (0.108in) or less],
remove it through lathe or strip it with care
not damage inner hole of roller. When the
wear of bushing is not large, place upper n
roller (1) on jig (m) for repair stand and apply
the end of push-out jig on the end face of 1
bushing (3) end, and push it out striking it
with mallet.
3
Hammer the inside surface of roller
lightly so as not to damage the surface.
JIG m
Put the extrusion jig (n) uniformly over
the circumference of bushing (3) and
extrude it perpendicularly little by Fig. 4-10 Removing bushing (3)
little.
34-17
(2) Installing
6 2
1) Attach O ring (6) to one side
Install O ring (6) to groove on shaft.
z Replace O ring with new one.
z Grease O ring.
Fig. 4-11 Attach O ring (6) to one side

2) Press fitting bushing (3)
Align inner hole of roller (1) and bushing (3)
and press fit it vertically in capacity of press Push with press
fit load, 3600kg (7940 lbs), in the condition JIG Q
that bushing push-in jig (Q) is inserted into
bushing (3).
3
z Apply molybdenum disulfide grease
on press-fit section of bushing, and
press fit it in ordinary temperature.
z Bushing which fails to press-fit

because of the one-side pressing
should not be fitted. Fig. 4-12 Press fitting bushing (3)
3) Press fitting collar (7)

Fit O ring to the one side of shaft (2) mating
pin hole of collar (7) on which floating seal (5)
is fit with pin hole of shaft (2) in advance.
5
z Care should be taken not to damage 4
O ring (6) while press-fitting collar
(7) to shaft.
2
4) Inserting pin (4)
Press-fit pin (4) to pin hole on aligning pin
holes of shaft (2) and collar (7).
6 7
5) Attach floating seal (5) to roller side
Fit floating seal (5) to inner holes on both Fig. 4-13 Inserting pin (4)
ends of roller (1).
z Check that the seal surface is free
from flaws, rusts, etc. before reusing
the floating seal.
6) Inserting roller (1)

Insert roller (1) from the side where collar (7), 5
O ring (6) is not press-fitted to the shaft (2).
Fig. 4-14 Inserting roller (1)
34-18
7) Installing O ring (6) Press

Install O ring (6) to groove on shaft.
z Replace O ring with new one.

z Grease O ring. 7
8) Press fitting collar (7)

Press-fit collar (7) to shaft (2). 6
z Press-fit collar (7) on aligning pin (4)

hole.
2
9) Inserting pin (4)
Press-fit pin (4) in to the pin hole mating pin
hole of collar (7) with pin hole on the end side
of shaft (2).
10) Filling oil Fig. 4-15 Installing O ring (6), collar (7)
Remove plug (8) and fill in 150cc (9.2cu・in)
of engine oil API grade CD#30.
11) Check it for leakage

Before tightening plug (8), check it for
leakage in the condition of air pressure
2.0kgf/cm2 (28psi). 8
Tightening
torque
12) Installing plug (8)
2.4kgfym
Apply oil resistant sealant on plug (8), and (17 lbfyft)
tighten it in the plug hole on the collar (7)
end face.
:6mm,
Tightening torque : 2.4kgfym (17 lbf yft)
7
After assembling the lower roller,
confirm that oil is not leaking and that Fig. 4-16 Installing filling oil plug (8)
the roller rotates smoothly by hand.
34-19

C C
Clearance 2.5±0.5mm
(0.1in±0.02in)
A B D E
Fig. 4-17 Lower roller (Track roller)
E135SR(LC)
E115SR Table 4-1 Unit : mm (in)
A O.D. of flange ∅170 (6.69) Reinforcement

B Tread dia. ∅140 (5.51) ∅130 (5.12) ∅126 (4.96) weld, repair or
replace
C Flange width 22 (0.87) 18 (0.71) 16 (0.63)
Basic
Tolerance Fit Fit
dimension
Clearance between
－0.060
D shaft and bushing
∅50 －0.090 Clearance Clearance
(Wrapped bushing) Shaft
(1.9685) －0.0024 1.0 (0.04) 1.5 (0.06) Replace
－0.0035 bushing.
＋0.03
Interference
∅57 0 Interference Clearance
E between roller and Hole
(2.2441) ＋0.0012 0 0.01 (0.0004)
bushing
0
Oil Engine oil API grade CD #30, 150cc (9.2cuyin) Refill
Roller rotation Rotates smoothly by hand. Reassembly
E135SRL Table 4-2 Unit : mm (in)

A O.D. of flange ∅185 (7.28) Reinforcement

B Tread dia. ∅150 (5.91) ∅134 (5.3) ∅128 (5.0) weld, repair or
replace
C Flange width 23.5 (0.93) 18 (0.71) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
－0.060
D shaft and bushing
∅65 －0.090 Clearance Clearance
(Wrapped bushing) Shaft
(2.5591) －0.0024 0.7 (0.03) 1.0 (0.04) Replace
－0.0035 bushing.
＋0.030
Interference
∅69 －0.020 Interference Clearance
E between roller and Hole
(2.7165) ＋0.0012 0 0.01 (0.0004)
bushing
－0.0008
F Oil Engine oil API grade CD #30, 150cc (9.2cuyin) Refill
Clearance between
G Keep 2.5±0.5 (0.10±0.02).
roller and collar
H Plug (8) Execute air leak test at 2.0kgf/cm2 (28psi) before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
34－20
4.7 TOOLS AND JIGS

For STD & LC type For L type

Socket 19,24 Socket 19,27
Allen wrench 6 Allen wrench 6
(2) Jig Unit : mm (in) Unit : mm (in)

k V-block k V-block
∅100 (3.94˝ ) ∅100 (3.94˝ )

Pin (4) Pin (4)
extrusion ∅14 (0.551˝ ) extrusion ∅14 (0.551˝ )
rod rod
200 (7.87˝) 200 (7.87˝ )

Bushing Bushing
n extrusion ∅16 (0.630˝) n extrusion ∅16 (0.630˝ )
rod rod
245 (9.65˝) 290 (11.4˝ )
m Stand jig m Stand jig

(4.92˝ )
(6.30˝ )
∅120 ∅170
∅125
∅160
(4.72˝) (6.69˝)
270 (10.6˝) 270 (10.6˝ )

Shaft Shaft
P extrusion p extrusion
∅49 (1.93˝) ∅64 (2.52˝ )
jig jig
∅70 (2.76˝) ∅86 (3.39˝ )

30 (1.18˝) 30 (1.18˝ )
(3.72˝ )
80
94.5
(2.54˝ )
Bushing 50 (3.15˝) Bushing

64.5
Q (1.97˝) q
fixing jig fixing jig
+0.1
∅49.5±0.1 ∅64.6 0
(1.949±0.004˝) (2.543˝ +0.004
0
)
34－21
5. CRAWLER IDLER (IDLER ADJUSTER ASSY)

5.1 CRAWLER IDLER ASSY
CRAWLER E115SR 1
IDLER E135SR(LC)
1-1
ASSY
1-2
E135SRL
1 • CRAWLER IDLER 2 ──
• CRAWLER IDLER ─2─
• CRAWLER IDLER ── 2
1-1 • • IDLER ASSY 1 ──
• • IDLER ASSY ─1─ 1-4 1-3
• • IDLER ASSY ── 1 Apply Loctite #262 Grease nipple is
equivalent positioned on the
1-2 • • ADJUST ASSY 1 ── M12 : T=11.7kgfym(85 lbfyft) outside of machine.
• • ADJUST ASSY ─1─ M16 : T=28.5kgfym(210 lbfyft) T=6kgfym (43 lbfyft)
• • ADJUST ASSY ── 1
1-3 • • GREASE NIPPLE 1 ←← Fig. 5-1 Front idler assy
1-4 • • CAPSCREW 2 ←─ M12×35
• • CAPSCREW ── 2 M16×45
5.2 REMOVING
Remove crawler. (Above mentioned)
BAR
(2) Removing idler assy
Sling idler assy, and push it forward with bar.
Weight STD, LC : 129kg (280 lbs)
L : 209kg (460 lbs)
Keep away from the front side of front

idler.
(3) Installing
removing. Fig. 5-2 Removing and installation the front idler
1
(4) Where idling assy (1) has to be separated
Loosen capscrew (4), and separate idler assy
(1) from idler adjuster assy (2).
: STD, LC : 19mm
Weight of idler assy : 71kg (160 lbs)
2
Weight of idler adjuster assy : 58kg (130 lbs)
: L : 24mm
Weight of idler assy : 107kg (236 lbs)
Weight of idler adjuster assy : 103kg (227 lbs)
3
4
z The separated idler assy should be
placed on square timbers. Fig. 5-3 Separating idler assy (1)
from idler adjuster assy
34－22
5.3 IDLER ASSY STD, LC 1

5.3.1 CONSTRUCTION
8 4
IDLER E115R STD
ASSY E135R(LC) STD, LC 6
1 IDLER 1 －
IDLER － 1 7
2 SHAFT 1 ←
2
3 BUSHING 2 ←
3
4 COLLAR 2 ←
5 PIN 2 ←
6 FLOATING SEAL 2S ← 8
L
7 O RING 2 ← 1A G55
8 PLUG 2 ← PT1/8 1 4
3
IDLER ASSY L 4
7
1 IDLER 1
2 SHAFT 1 2
3 BUSHING 2 5
4 COLLAR 2 6
5 PIN 2
6 FLOATING SEAL 2S
7 O RING 2 1A G70 Fig. 5-4 Idler assy
8 PLUG 2 PT1/8
5
5.3.2 REMOVING AND INSTALLING R
(1) Removing
1) Drain oil
Remove plug (8) on the side of collar (4) to
drain.
: 5mm
Push with press
2) Removing pin (5)
Apply pin push bar (jig R) to the top of pin, Fig. 5-5 Removing pin (5) S
2
and take out striking bar (jig R) lightly by 4
hammer. 1
3) Removing collar (4)

Put idler (1) on repair stand (U), apply
push-out jig (S) on shaft (2), push out shaft U
(2) with collar (4), then remove collar (4). Push with press
4) Removing collar (4) from shaft (2) S Fig. 5-6 Removing collar (4)
If removal of collar (4) on the opposite side is 2 4
required, turn over front idler and proceed
with the procedure described in Item 3).
Fig. 5-7 Removing collar (4)
34－23

With idler (1) mounted on the stand, tap
bushing (3) lightly by hammer, while placing
the bushing drawing rod (T) against the end
face of bushing (3) evenly all round, till it
comes out.
6) Removing floating seals (6) T 3

Take out floating seals (6) from idler (1), 1
collar (4). 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 in pairs by placing card board
between the sealing faces.
7) Removing O ring (7)

U
Separate O ring (7) from shaft (2).
Fig. 5-8 Removing bushing (3)
(2) Assembly
1) Pressing in bushing (3)
Align inner hole of idler (1) and bushing (3) 3 Push with press V
and press fit it vertically with press so that 1
jig (V) for bushing press-fitting jig (V) is
inserted into bushing (3).
2) Installing O ring (7)

Fit O ring (7) to O ring groove on shaft (2).
z Apply grease to O ring Fig. 5-9 Pressing in bushing (3)
3) Installing collar (4) (See Fig. 5-11) Pressing

Press fit the O ring installed side of shaft into
collar (4), and drive pin (5). 2
4) Installing floating seal (6)

Fit the half of floating seal (6) on each side of 3
5
collar (4) and idler (1).
5) Inserting idler (1)

Insert floating seal (6) fitted side of idler (1) Fig. 5-10 Installing collar (4), shaft (2)
into shaft (2).
2
6
6) Installing floating seal (6)
Fit floating seal (6) on the other side of idler
1
(1).
Fig. 5-11 Inserting idler (1) and installing

floating seal (6)
34-24
7) Installing collar (4)

Fit the half of floating seal (6) on the other 8 2
collar (4), press fit it in shaft, and drive pin 4
(5) in with hummer. 5
8) Filling oil・Inspection 1
Fill in 200cc (12.2cuyin) of engine oil API
grade CD #30 through the plug hole of collar
(4), wind seal tape and tighten plug (8).
: 5mm Fig. 5-12 Installing collar (4) and filling oil
z After installing the idler assy to the

idler adjuster assy, make certain
that no oil leaks from floating seal
and plug (8) and that idler (1)
rotates smoothly.
5.3.3 MAINTENANCE STANDARD
DETAIL OF TREAD
E135SR(LC) E115SR
Fig. 5-13 Front idler
E115SR
E135SR(LC) Table 5-1 Unit : mm (in)
A-1 Dia. of idler ∅510 (20.1) ∅504 (19.8) ∅502 (19.8)
A-2 projection ∅491 (19.3) ∅485 (19.1) ∅483 (19.0)
B Tread dia. ∅456 (18.6) ∅450 (17.7) ∅448 (17.6) Replace
C-1 58 (2.28) 52 (2.05) 50 (1.97)
Flange width
C-2 68 (2.68) 62 (2.44) 60 (2.36)
Basic
Clearance －0.030
D between shaft ∅60
and bushing Shaft
－0.060 Clearance Clearance
(2.3622) －0.0012 1.5 (0.059) 2.0 (0.079) Replace
－0.0024 bushing.
＋0.030
Interference ∅64 0 Interference Clearance
E between idler Hole
and bushing (2.5197) ＋0.0012 0 0.01 (0.0004)
0
F Oil Engine oil API grade CD#30, 200cc (12.2cuyin) Refill
Idler rotation Rotates smoothly by hand. Reassemble
34－25
160 (6.30″)
C
Fig. 5-13 Front idler
L Type Table 5-2 Unit : mm (in)

Dia. of idler
A projection ∅535 (21.1) －－
B Tread dia. ∅497 (19.6) ∅490 (19.3) ∅487 (19.2) Replace
C Flange width 84±0.5 (3.307±0.020) 78 (3.1) 76 (3.0)

Basic
Clearance －0.030
D between shaft ∅75
and bushing Shaft
－0.060 Clearance Clearance
(2.9528) －0.0012 1.5 (0.06) 2.0 (0.08) Replace
－0.0024 bushing.
＋0.036
Interference ∅83 0 Interference Clearance
E between idler Hole
and bushing (3.2677) ＋0.0014 0 0.01 (0.0004)
0
F Oil Engine oil API grade CD#30, 200cc (12.2cuyin) Refill
Idler rotation Rotates smoothly by hand. Reassemble
34－26

For E115SR For E135SRL
For E135SR(LC)
Socket 19 Socket 24
Allen wrench 5 Allen wrench 5
(2) Jigs
(1.18˝ )
∅15 ∅30 (1.18˝) ∅15
∅30
(0.591˝) (0.591˝ )
Pin Pin
R R
striking jig striking jig
80 15 105 15
(3.15˝) (0.591˝) (4.13˝ ) (0.591˝ )
340 (13.4˝) 340 (13.4˝ )

Shaft Shaft
S push out S push out
jig ∅59 (2.32˝) jig ∅74 (2.91˝ )
300 (11.8˝) 300 (11.8˝ )

Bushing Bushing
T drawing ∅16 (0.630˝) T drawing ∅16 (0.630˝ )
rod rod
About 100 (3.94˝) About 150 (5.91˝)

About 500 About 600
(19.7˝) (23.6˝)
Repair Repair
U U
stand About stand About
350 400
(13.8˝) (15.7˝)
2 pcs. 2 pcs.
∅87 (3.43˝) ∅105 (4.13˝ )

(2.76˝ ) (0.787˝ )
30 (1.18˝)
20
Bushing Bushing
(3.54˝ )
85
90
V Press 55
(3.35˝) V Press
70
fitting jig (2.17˝) fitting jig
+0.
∅59.5±0.1 ∅74.61
(2.343±0.004˝) (2.937˝ +0.004
0 )
∅80 (3.15˝) ∅103 (4.06˝ )

Collar Collar
W Press W Press
30 (1.18˝) 30 (1.18˝ )
fitting jig fitting jig
34－27
5.4 IDLER ADJUSTER ASSY STD, LC

1
5.4.1 CONSTRUCTION
IDLER E115SR 8
ADJUSTER ASSY STD 7
4
1 GREASE CYLINDER 1
9
2 BRACKET 1
3 NUT 1 M45×P3 3
4 SPRING PIN 1 ∅6×63 9
5 SPRING 1 2
6 PISTON 1
7 O RING 1 1B G65
10
8 OIL SEAL 1
9 PIN 2
5
10 COVER 1
L
E135SR(LC) 2 4 3 12 1 5 8 7 6
IDLER STD, LC
ADJUSTER ASSY
E115SR L
No. NAME Q'TY REMARKS
1 GREASE CYLINDER 1
2 BRACKET 1
3 NUT 1 M48×P2
4 SPRING PIN 1 ∅8×80
5 SPRING 1 11 9
6 PISTON 1
7 O RING 1 1B G80
Fig. 5-14 Idler adjuster assy
8 OIL SEAL 1
9 PIN 2
11 COVER 1
12 COLLAR 1
34－28

(1) Disassembly M30 HOLDING-DOWN NUT
1) Spring set special jig
Before disassembling and assembling the RETAINER PLATE
idler adjuster assy, prepare spring setting jig
(V).
Capacity of hydraulic jack : more than 20 V

tons (44000 lbs)
HYDRAULIC JACK
: 46mm
Large power is needed to set the

spring. Prepare a special jig before BASE
disassembly and assembly.
Fig. 5-15 Spring set special jig (V)
2) Preparation for working
Place a hydraulic jack between the jig base
and the stand.
Loosen the holding-down nuts of the jig and
draw out the retainer plate upward.
: 46mm
3) Draw out grease cylinder (See Fig. 5-14)

Draw out piston (6) from grease cylinder (1)
of the idler adjuster assy.
4) Removing oil seal (8), O ring (7) 5

(See Fig. 5-14)
Taken out oil seal (8) and O ring (7) from
grease cylinder (1).
V
5) Slinging work idler adjuster Fig. 5-16 Slinging work idler adjuster
Set the idler adjuster assy on the stand of
the jig, with its bracket side facing up.
34-29
6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten 3
holding-down nuts alternately, and secure
idler adjuster assy.
HOLDING-DOWN NUT
: 46mm
3 RETAINER PLATE
Fig. 5-17 Fixing idler adjuster assy
7) Compression of spring (5)
Remove spring pin (4), press spring (5) lifting
it with jack so that nut (3) can be turned 5
freely, and remove nut (3).
: 46mm
Fig. 5-18 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to retract slowly till
the spring is extended to its free length.
Remove the retainer plate and take off RETAINER PLATE
bracket (2).
The free length of the spring :
about 423mm(16.7in)
2
: 46mm
Fig. 5-19 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M45 on
W
grease cylinder (1) top end and hoist it. Then, 1
remove the set of grease cylinder (1) and
spring (5) using crane from the jig.
Remove spring (5), grease cylinder (1), in that 5
order.
Fig. 5-20 Removing spring (5), grease cylinder (1)
34-30
(2) Assembly W
Assembly is done in the reverse order of
disassembly.
1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1) into spring (5) and
attach lifting eye nut (W) to screw M45 at the
5
tip of the grease cylinder. Lift the grease
cylinder by crane and erect it in the center of
the jig stand upright.
2) Fixing idler adjuster assy

Install bracket (2) on top of spring (5). Center Fig. 5-21 Attach spring (5) and grease
the rod of grease cylinder (1) and the holes in cylinder (1) to the jig
bracket (2). Attach the retainer plate and HOLDING-DOWN NUT
four holding-down nuts. Fasten the nuts
RETAINER PLATE
evenly all round and fix the idler adjuster
assy to the jig body.
: 46mm
3) Compressing spring (5) and removing nut (3)

2
Extend the hydraulic jack, compress spring
4
(5) to a set length and screw in nut (3) to the
screwed part at the tip of grease cylinder (1). 3
Set length of the spring : 358mm (14.1in) 5

1
4) Installing spring pin (4)
Tighten nut (3) till the holes for locking
spring pins (4) are aligned. Then fit spring Fig. 5-22 Compression of spring (5), and
pin (4). attaching nut (3) and spring pin (4)
: 46mm
: 70mm(M45)
: 75mm(M48)
5) Removing idler adjuster assy

Remove idler adjuster assy from jig.
Fig. 5-23 Removing idler adjuster assy
34－31
6) Installing oil seal (8), O ring (7) 1

Fit oil seal (8) and O ring (7) to grease
8
cylinder (1).
7
z Grease oil seal (8) and O ring (7). 6
7) Filling grease cylinder(1) with grease.

Fill grease cylinder (1) with grease, remove
grease nipple from piston (6), and press
piston by hand to discharge air through 10
grease nipple hole. Fig. 5-24 Grease cylinder (1)
z Direct grease nipple hole downward

to make air discharge easier.
8) Installing grease nipple

Tighten grease nipple (10) to piston (6).
: 19mm
34-32
5.4.3 MAINTENANCE STANDARD

E115SR
STANDARD
No. ITEM
VALUE
A Installed length of spring mm 354.8 (14.0in)
About 423
B Free length of spring mm
(16.7in)
C Stroke mm 40 (1.57in) C
D Set length mm 606 (23.9in) E
Nor scoring
E Outside view of piston and rusting
Tightening torque of 6kgfym
F grease nipple (43 lbfyft)
3.2 A, B
F
(0.13in) D
Fill this space with grease and bleed air.
E135SR(LC)
SK135SRL
STANDARD
No. ITEM
VALUE
A Installed length of spring 429mm (16.9in)
About. 531.1mm
B Free length of spring
(20.9in)
C Stroke 52mm (2.0in)
D Set length 630mm (24.8in)

Nor scoring
E Outside view of piston and rusting
Tightening torque of 6kgfym
F grease nipple (43 lbfyft)
F
A, B
D
Fig. 5-25 Idler adjuster assy
34－33
6. SPROCKET
6.1 REMOVING
Remove crawler referring to Section 1.
"Crawler", lift up crawler frame with
attachment, and put it on square timbers to
float and stabilize.
Fig. 6-1 Preparation for removal

(2) Removing sprocket
Loosen capscrews (2) (M16) for the attaching
of the sprocket by means of a socket and
remove the sprocket.
Weight of sprocket :
STD, LC : 36kg (80 lbs)
L : 65kg (143 lbs)
: 24mm
STD, LC : 15pcs.
L : 21pcs.
2
1
Fig. 6-2 Removing sprocket
6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.
(2) Securing sprocket temporarily

Coat the sprocket attaching capscrews with
Loctite #262 and fasten the sprocket
temporarily.
(3) Securing sprocket completely

Take out square timbers placed under
crawler frame, and tighten capscrews to the
specified torque.
: 24mm,
Fig. 6-3 Securing sprocket completely
33－34

Table 6-1 (1/3)
86.34mm NUMBER
PITCH 21
(3.40in) OF TEETH
ROLLER ∅47 PITCH ∅580.38
DIA. (1.85in) DIA. (22.85in)
(1.102˝) B
R28 R15(0.591˝)
C
R5(0.197˝)
A
Fig. 6-4(1/3) Sprocket
E115SR Table 6-2-1 Unit:mm(in)
No. NAME STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
∅601±3 ∅590 ∅588 Reinforcement weld,
A O.D. of sprocket
(23.661±0.118) (23.2) (23.1) repair or replace.
Width of sprocket
B teeth 49－30 (1.923－0.118
0 ) 44 (1.73) 42 (1.65) Replace.
Width of sprocket Reinforcement weld,
C 37 (1.46) 32 (1.93) 30 (1.18)
bottom repair or replace.
Table 6-1 (2/3)

86.69mm NUMBER
PITCH 21
(3.78in) OF TEETH
ROLLER ∅53.8 PITCH ∅581.669
DIA. (2.12in) DIA. (22.90in)
B
C
A
Fig. 6-4(2/3)
E135SR(LC) Table 6-2-2 Unit:mm(in)
∅594±3 Reinforcement weld,
A O.D. of sprocket ∅585 (23.0) ∅583 (22.9)
(23.4±0.1) repair or replace.
Width of sprocket
B teeth 60－30 (2.4－0.1
0
) 53 (2.1) 50 (2.0) Replace.
Width of sprocket Reinforcement weld,
C bottom 48 (1.9) 41 (1.6) 38 (1.5) repair or replace.
34－35
Table 6-1 (3/3)

96.07mm NUMBER
PITCH 21
(3.78in) OF TEETH
ROLLE ∅58.72 PITCH ∅644.602
R DIA. (2.31in) DIA. (25.38in)
C
A
Fig. 6-4(3/3) Sprocket
E135L Table 6-2-3 Unit:mm(in)

Reinforcement weld,
A O.D. of sprocket ∅664 (26.1) ∅656 (25.8) ∅654 (25.7) repair or replace.
Width of
B 70－40 (2.751 －0.157
0 ) 64 (2.52) 62 (2.44) Replace.
sprocket teeth
O.D. of sprocket Reinforcement weld,
C bottom 585.6 (23.1) 577.6 (22.7) 575.6 (22.7) repair or replace.
34－36
6.4 TOOLS AND JIGS

(1) Sprocket tooth profile gauge : W
E115SR
Fig. 6-5 (1/3) Tooth profile gauge
34－37

E135SR(LC)
34－38

L Type
34－39
7. TRAVEL MOTOR
Apply Loctite #262
7.1 TRAVEL MOTOR INST. T=28.5kgfym (210 lbfyft)
STD, LC, DZ E115SR/ 135SR(LC) 2
INSTALL ASSY
1 SPROCKET 2
2 CAPSCREW 70 M16×45
D2(PF1/2) 2
Apply Loctite #262
B(PF3/4) equivalent
P(PF1/4) Ⅰ
A(PF3/4)
D1(PF1/2)
VIEW Ⅰ
Fig. 7-1(1/2) Installing travel motor
L Type E135SRL
2 Apply Loctite #262
INSTALL ASSY
1 SPROCKET 2
3 CAPSCREW 60 M16×60 1
4 WASHER 60
3,4
D2(PF1/2)
Apply Loctite #262
B(PF3/4) equivalent
P(PF1/4) Ⅰ
A(PF3/4)
D1(PF1/2)
VIEW Ⅰ
Fig. 7-1(2/2) Installing travel motor
34－40
7.2 REMOVING 1
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize. 7
(2) Removing cover (1)

Remove capscrew (7) M12 × 25 and also
remove covers (1).
: 19mm
(3) Preparation of oil pan Fig. 7-2 Removing and installing cover (1)
(4) Removing hydraulic pipe

Bleed air in hydraulic oil tank, remove all
pipes connecting to travel motor. Then plug
up all pipes and joint section to protect them
from entry of dust.
: 19mm, 27mm, 32mm, 36mm

Refer to tool 4.plug (1).
Fig. 7-3 Removing and installing hydraulic pipe

(5) Removing sprocket
Removing capscrews (2) M16.
: 24mm
2 STD, LC : 15pcs.
L : 21pcs.
Fig. 7-4 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 capscrews (2) M16.
: 24mm
2
STD, LC : 20pcs.
L : 30pcs.
Fig. 7-5 Removing and installing travel motor

attaching bolts
34－41
(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 :
STD, LC, DZ : Approx. 144kg (320 lb)
L : Approx. 240kg (529 lb)
Fig. 7-6 Slinging travel motor
7.3 INSTALLING
Installing of the travel motor piping is performed
Tightening
in the reverse order of removal. Torque
RE-MA
NAME SIZE Tools No. RKS
1) Cleaning kgfym(lbfyft)
Check that contact surface of travel motor Sems bolt M12 19 5 8.5 (61) Apply
Loctite
and crawler frame is free from burr and Capscrew M16 24 2 28.5 (210) #262
stain.
Flareless ∅10×1.5 19 － 5 (36)
nut for
2) Tightening torque ∅ 18×2.5 32 － 15 (110)
pipes,
Tighten capscrew and hydraulic pipes to the sleeve ∅ 22×3.0 36 － 22 (160)
torque specified in "Tightening Torque".
PF1/4 19 P 3.7 (27)
3) Fill inside from motor drain port to casing Connector PF1/2 27 D1,D2 11 (80)
with hydraulic oil before piping for drain. PF3/4 36 A,B 16.5 (120)
When starting operation, operate motor in
low idling and at low speed for several
minutes, and check it for possible oil leakage
and noise.
34－42
8. SWING BEARING
8.1 SWING BEARING ASSY
ASSY
1 SWING BEARING 1
2 CAPSCREW 36 M16×45 FRONT
3
Inner S zone section of
swing bearing
Fig. 8-1 Swing bearing assy
SECTION A－A
8.2 REMOVING
(1) Matchmarks SWING BEARING
Remove upper structure, apply matchmarks OUTER RACE
on inner race of swing bearing and lower
frame.
INNER RACE
(2) Remove thirty six capscrews (3) M16×45 for
installation inner race.
MATCH MARKS
: 24mm
(3) Drawing out grease

Remove grease in grease bath. Fig. 8-2 Matchmarks
(4) Removing swing bearing

Attach eyebolt on swing bearing and sling it.
Weight of swing bearing : 145kg (320 lbs) SWING BEARING
EYE BOLT
GREASE BATH
Fig. 8-3 Removing and installing swing bearing
34－43
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces
of swing bearing and lower frame are free
from dust and stain.
FRONT A A
(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark
on inner race as shown in the figure.
(3) Temporary fastening of inner race Inner S zone section of

Coat the threads of the capscrews (3) with swing bearing
Loctite #262 and tighten all the capscrews Fig. 8-4 Location of S mark on swing bearing
temporarily.
: 24mm
(4) Regular tightening of inner race 1

Tighten the capscrews (3) at 180 degrees
intervals alternately to a specified torque.
: 24mm, 3
Apply Loctite #262
Tightening torque : T=28.5kgfym (210 lbf yft)
28.5kgfym (210 lbf yft)
SECTION A－A
(5) Filling grease.
Fill grease bath with 6.4kg (14 lbs) of grease
NLGI-2 (containing molybdenum disulfide) or Fig. 8-5 Removing and installing capscrew (3)
equivalent.
8.4 CONSTRUCTION
3・ 62
ASSY
No. NAME Q’TY No. NAME Q’TY 1
1 OUTER RACE 1 6 SEAL 1 9
2 INNER RACE 1 7 GREASE NIPPLE 7
3 BALL 108 (PT1/8) 1 8
4 RETAINER 108 8 TAPER PIN 1 5
5 SEAL 1 9 PLUG 1 Fig. 8-6 Cross-sectional view of swing bearing

(1) Disassembly
1) Take out seal (5) fitted in the groove in the
EYE BOLT
outer circumference under inner race (2) and 6 2
seal (6) fitted in the groove in the inner 8
circumference on top of outer race (1) and
place them level on a square wooden block or 1
something. SQUARE
WOODEN BLOCK
2) Draw out taper pin (8), using a hammer and
an extrusion rod.
3) Draw out plug (9), utilizing an pull bolt 9
inserted in the screwed hole (M10) in the 5
center of the plug and using a puller. Fig. 8-7 Removing swing bearing
34－44
4) While rotating outer race (1) little by little,
take out ball (3) and retainer (4) through plug 1
hole, in that order.
To draw out ball (3) and retainer (4),

use a hooked rod, etc., to protect
persons from injury from inserting
fingers into plug hole.
2
4
3
Fig. 8-8 Removing balls (3) and retainers (4)
(2) Installing
1) After cleaning grooves for seal (6) on inner
surface on the upper side of outer race (1),
and for seal (5) on the outer surface of inner
race (2), apply adhesive agent Cyano-bond
PO-1, fit seal (5), and place them on a surface 1
plate. PUSH ROD 6
2) Lower outer race (1) to the position where
2
upper surface of inner race (2) and lower
portion of seal groove is mated, put adjusting 3
5
washer under outer race (1) so that outer SQUARE
WOODEN BLOCK
raceway surface of ball (3) aligns with inner
raceway, and support it. Fig. 8-9 Fitting balls (3)
3) Insert ball (3) and retainer (4), on which
grease is applied, through plug (9) hole on Eye bolt
outer race (1), alternately.
To insert ball (3) and retainer (4), use a

push rod, etc., to protect persons from HOOKED ROD
injury from inserting fingers into plug

hole.
4) Fit plug (9) to outer race (1) while checking it 4

for direction and position of taper pin hole.
SQUARE
5) Apply adhesive agent Cyano-bond PO-1 to WOODEN BLOCK
seal (6), and fit it to groove of outer race (1).
6) Check that grease nipple (7) is properly Fig. 8-10 Fitting retainer (4)
fitted, and fill it with grease. Then, check
bearing for smooth rotation and flaws on seal
lip portion.

Maintenance standard concerning wear of swing
bearing is described in the section “Maintenance
Standard and Test Procedure” in the separate
volume.
34-45
Part II: DISASSEMBLING AND ASSEMBLING EQUIPMENT
1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
1.1 CONSTRUCTION OF TRAVEL MOTOR
1.1.1 CROSS-SECTIONAL VIEW OF TRAVEL
MOTOR ASSEMBLY
135 116 115 117 104 105 107 106 111 108 103 167 149 171 4 132 5
139 23
128 125 123 127 130 137 121
112 35
136 138 143 22
109
124 126 154 20
164 14
142 138
166
A 25
163
9
165
7
138
15
101 B 6
141
8
199
36
195 102
194 169
193 19
220 3
A
214 33
213 21
210 224
29
204 215 140
191
205 212
192 161
202 222
168 150 179 27 30 113 2 145 31 114 110 151 1 17 162
203 216
209 206 217 209 221 201 211 208 170 174
146
190 SECTION BB
SECTION AA
Fig. 1-1 Cross-sectional view of travel motor assembly
34-46
132
21 149 171
167
1.1.2 EXPLODED VIEW OF REDUCTION UNIT 1.1.3 EXPLODED VIEW OF HYDRAULIC MOTOR
103
31 102
106
105
107
169
22 111
104
191 110
2 114
162
161
110
21 145
30 108
5
23 151
126
9 137
130
23
127 150
4 124 121 117
136 138 154
141 115
27 128
27
1 116
125
135
139
142
166 112
164 109 113
163
17 33 168
138
165 140 179 127
130
192 137
195 126
29 199 101
202
146 190 143 194
209 123
25 211 193
7 208
14 211 217 138 125
215
20 209 224
128
22 216
35 204 212 136
210 217 124
217 209
3 205
203 222 217
8 206 211
201 221 208 211
36 209
222 202
6 213 222
15 214 220
221
174 201
206
170
19 203
Fig. 1-2
205 210
204
Fig. 1-3
34-47
1 HUB 1 124 • PLUG 2 132 OIL SEAL 1

125 • SPRING RETAINER 2 135 O RING 1
SPINDLE KIT 1 126 • PLUG 2 138 O RING 4
• SPINDLE ASSY 1 127 • VALVE 2 139 O RING 1
2 • • SPINDLE 1 128 • SPRING 2 141 PARALLEL PIN 1
3 • • HOLD FLANGE 1 136 • O RING 2 142 PARALLEL PIN 2
19 • REAMER BOLT 3 137 • O RING 2 143 SOCKET BOLT 8
140 • O RING 2 145 SNAP RING 1
RV GEAR ASSY 1 149 BEARING 1
• RV GEAR KIT 1 • SPOOL KIT 1 150 BEARING 1
4 • • RV GEAR A 1 163 • • SPOOL 1 151 ROLLER 3
5 • • RV GEAR B 1 164 • • OIL STOPPER 1 167 PIVOT 2
9 • CRANKSHAFT 3 165 • PLUG 1 169 COLLAR 1
22 • BEARING 6 166 • SPRING 1 170 SOCKET BOLT 4
23 • BEARING 6 168 • BALL 2 171 PARALLEL PIN 2
192 • PLUG 2 174 SUPER LOCK WASHER 4
6 INPUT GEAR 1 193 • O RING 2 191 SPRING 1
194 • HOSE 2
SPUR GEAR KIT 1 VALVE KIT 2
7 • SPUR GEAR 3 PISTON ASSY 1 201 • VALVE 1
161 • PISTON 1 202 • SLEEVE 1
8 COVER 1 162 • SHOE 1 203 • SPRING RETAINER 1
14 DISTANCE PIECE 3 204 • PLUG 1
15 COUPLING 1 102 SHAFT 1 205 • SHIM 1
17 PIN 24 103 SWASH PLATE 1 206 • SPRING 1
20 SNAP RING 3 208 • O RING 1
21 BEARING 2 CYLINDER & PISTON KIT 1 209 • O RING 1
25 SNAP RING 3 104 • CYLINDER BLOCK 1 210 • O RING 1
27 O RING 2 211 • BACK UP RING 2
29 O RING 1 • PISTON KIT 1 221 • PISTON SEAL 1
30 O RING 1 • • PISTON ASSY 9
31 FLOATING SEAL 2 105 • • • PISTON 1 BODY KIT 1
33 SOCKET PLUG 2 106 • • • SHOE 1 • BODY PISTON KIT 1
35 SOCKET PLUG 10 107 • RETAINER PLATE 1 212 • • BODY 1
36 BALL 1 213 • • PISTON 1
108 THRUST PLATE 1 209 • O RING 2
REAR FLANGE ASSY 1 109 TIMING PLATE 1 214 • PLUG 1
• REAR FLANGE KIT 1 110 WASHER 2 215 • PLUG 2
101 • • REAR FLANGE 1 111 WASHER 1 216 • BALL 2
123 • • SPOOL 1 112 PISTON 1 217 • BACK UP RING 4
146 • • SOCKET PLUG 1 113 SPRING 8 220 • O RING 1
154 • • SOCKET PLUG 9 114 SPRING 1 222 • SOCKET PLUG 6
179 • • FILTER 1 115 FRICTION PLATE 3 224 • O RING 2
190 • • ORIFICE 1 116 SEPARATOR PLATE 3
195 • • ORIFICE 2 117 SEPARATOR PLATE 1
199 • • NAME PLATE 1 121 PLUG 1
34-48
1.2 TOOLS AND JIGS

(1) Standard tools
NAME SIZE Q’TY
Allen wrench 6 (For M8) 1 of each

10 (For M12) 1 of each
Socket wrench 1
(Ratchet handle)
Torque wrench Dial type 30kgfym (220 lbfyft) or so 1

Dial type 90kgfym (650 lbfyft) or so 1
Adapter for torque wrench Nominal 17, 19, 27, 32, 36 Socket 1 of each
Nominal 6, 8, 10 Hex key 1 of each
Extension bar 150mm (6in) 1
Hammer Nominal 12 1
Plastic mallet L=300 (12″) or so 1
Flat-bladed screw driver 150mm (6in) or so 1
Snap ring pliers For shaft 1

For bore 1
Lifting tool Lifting capacity: 300kg (661 lbs) or over 1set

Eye bolt (For M16) (2)
Eye bolt (For PT1/2) (2)
Wire with hook (1)
Container Vat for general use W450×D300×H120 2

(W18″×D12″×H5″)
Leather gloves 1pair
34-49
(2) Tightening torque
APPLICATION BOLT・NUT OPPOSING TIGHTENING

ITEM Q’TY TORQUE
(No.) NAME SIZE FLATS (mm) kgfym (lbfyft)
19 Reamer bolt M27 (P2.0) 36 3 70 (510)
33 Socket plug PT1/2 10 2 6 (43)
35 Socket bolt M12 (P1.75) 10 12 10.4 (75)
121,165 Plug PF1/2 10 1 10 (72)
124 Plug M30 (P1.5) 36 2 36 (260)
126 Plug M24 (P1.5) 10 2 13 (94)
143 Socket bolt M10 (P1.5) 8 8 5.9 (43)
146 Socket plug PT1/8 5 1 1.25 (9.0)
154 Socket plug NPTF1/16 4 8 1 (7.2)
170 Socket bolt M8 (P1.25) 6 4 3 (22)
192 Socket plug PF1/4 6 2 3 (22)
202 Sleeve PF5/8 27 2 13 (94)
204 Plug M18 (P1.5) 10 2 8 (58)
214 Plug PF1/2 10 1 10 (72)
215 Plug PF1/4 6 2 3 (22)
222 Socket plug NPTF1/16 4 6 11 (80)
(3) Tools
NAME SIZE APPLICATION ITEM (No.)

General work bench Disassembly and assembly
Cleaning bath For rough cleaning and finish cleaning Cleaning the parts
Work bench for press Pressing capacity 200kg (441 lbs) or over 104,149
Heating bath Heating capacity 100℃ (212 °F) or over 149
volume 500×500×500 (20in×20in×20in)
Compressed air Pressure 3～5kgf/cm2(43～71psi) Drying after cleaning
Lathe Hold flange machining for

bearing (21) pre-load
(4) Measuring instrument

NAME SIZE APPLICATION ITEM
Thickness gauge × 2 Measurement 0.04～0.3mm For snap ring (20)
(0.00016～0.0118in) thickness adjustment
Outside micrometer Measured value: 0～25mm (0～0.984in) For snap ring (20)
Minimum graduation: 0.01 (0.00039in) thickness adjustment
Single depth micrometer Measured value: 0～25mm (0～0.984in) For bearing (21) pre-load
Minimum graduation: 0.01 (0.00039in) adjustment
34-50
(4) Jigs
No. NAME No. NAME
Working bench for travel motor Retainer metal (Ⅲ)
1 5
This is used to carry out the work for This is used to press fit oil seal (132) into oil
assembly and disassembly of travel motor seal fitting hole of spindle (2).
easy and safe.
Fixing metal Retainer metal (Ⅳ)
2 6
Apply it on outer race of bearing fitted on

This is used to connect spindle (2) and hub crankshaft (9) of RV gear assy, then strike it
(1). to insert RV gear assy securely.
Retainer metal (Ⅰ) Jig for adjusting the preload to the bearing
3 7
Special nut
This is used to insert / remove spring (114), This is used to press fit bearing (21) in hub
washer (110), snap ring (145) into / from (1), and also used to measure clearance of
cylinder block (104). bearing (21) in shaft direction.
Retainer metal (Ⅱ) Pointed punch
4 8
This is used to pull out or insert bearing This is used to remove outer race of bearing
(149) from shaft (102). (21).
34-51
No. NAME No. NAME
Fixing jig Floating seal (F/S) fitting tool (Ⅰ)
9 13
Retainer bar Floating seal (F/S) fitting tool (Ⅱ)
10 14
Aluminum bar Floating seal (F/S) fitting tool (Ⅲ)
11 15
Lifting tool (Ⅰ)
12
34-52
1.3 PREPARATION FOR DISASSEMBLY 1.3.3 DISASSEMBLING PROCEDURE.

1.3.1 GENERAL PRECAUTIONS FOR (1) Cleaning travel motor.
DISASSEMBLY (2) Place travel motor.
1) All the hydraulic equipment is manufactured (3) Drain lubricating oil.
in precision, so the work should be carried (4) Remove cover.
out in a clean and dust free place. Also use (5) Remove input gear and spur gear.
clean tools and wash oil, dry them by (6) Remove rear flange.
compressed air, and don’ t use waste cloth, (7) Remove parts installing rear flange.
paper, etc. (8) Disassemble brake valve section on rear
2) Prior to starting work, plug every port on the flange.
removed travel motor, and remove soil, oil, (9) Disassemble the 2-speed selector valve.
etc. on the surface of motor. (10) Disassemble the inner parts of shockless
3) Matchmarks are put on the mating surfaces relief valve.
of part while disassembling. Carry out the (11) Disassemble parking brake section.
work putting every removed part in order, (12) Disassemble hydraulic motor section.
and taking care not to cause damage. (13) Take out spring from cylinder block.
4) Sealing parts, such as O ring, backup ring, (14) Pull out shaft.
etc. are not to be reused. (15) Remove the bearing inner race.
While disassembling, all parts should be (16) Remove hold flange.
prepared collating removed parts with parts (17) Remove retainer metal.
on the seal kit list. (18) Remove spindle.
5) Some parts are supplied and replaced as a (19) Remove bearing, RV gear assy and pin.
sub-assy. For those parts, refer to the “Parts (20) Take out bearing.
Manual”. (21) Remove spindle.
(22) Disassemble hold flange.
z Figures in parenthesis ( ) noted (23) Rough cleaning of every part.
immediately after part name (24) Finish clean
correspond to the figures in the
construction drawing. (Fig. 1-1, 1-2,
1-3) 1.3.4 WEIGHT OF COMPONENT
1.3.2 CLASSIFICATION OF DISASSEMBLY NAME WEIGHT 〔kg (lbs)〕

This travel motor assembly consists of hydraulic Travel motor assy Approx. 144 (320)
motor, reduction unit, brake valve, and parking
Hub Approx. 30 (70)
brake as one assembly.
The disassembly works consist of the following Spindle Approx. 38 (85)
items basically. Rear flange assy Approx. 13 (30)
Select the required parts to disassemble between
hydraulic motor, reduction unit, brake valve, and
parking brake. Decide the order of parts to be
disassembled, and perform a service work
according to the respective maintenance procedure.
z Don’
t perform unnecessary disassembly.
34-53
1.3.5 REMOVING
(1) Cleaning travel motor Eye bolt
1) Tighten the eye bolts into the tapped holes of
the spindle (2). 2
Eye bolt ; M16
z Fasten two eye bolts into the tapped

holes for the spindle so they are
located diagonally opposite to one
another.
2) Place a wire sling in the eye bolts, lift the

travel motor by hoist, and carry in to the Fig. 1-4 Attaching eye bolt
cleaning bath.
Travel motor assy weight :
Approx. 144kg (320 lbs)
3) Clean the travel motor with a car brush. (2)
z Since soil and sand are entered in

the clearance (where the floating
seal is fixed) between hub (1) and
spindle (2), clean it with particular 1
care.
Fig. 1-5 Cleaning travel motor
(2) Installing travel motor

1) Placing travel motor on working bench.
z Align threaded holes of hub (1) and

working bench, and place travel
motor in fixing hole of working bench
1
slowly.
Fig. 1-6 Placing travel motor on working bench
2) Fix travel motor with two socket bolts on

working bench.
: 14mm
Socket bolt
Fig. 1-7 Fixing travel motor on working bench
34-54
(3) Draining lubricating oil.

z If you want to disassemble only the
rear flange, go to (6) 1).
1) Turn over the travel motor. 35
2) Loosen and remove two socket plugs (33).

: 10mm 33
z When draining out the lubricating

oil, place a container under the work
bench.
Fig. 1-8 Removing plug (33)
3) Draw out the lube oil by reversely turning the
travel motor slowly.
Eye bolt(PT3/8)
(4) Removing cover. 8
1) Turn over the travel motor.
2) Remove ten socket bolts (35). 29
: 10mm
3) Fix PT3/8 eye bolts to the two tapped holes of

cover (8) (to which socket plugs (33) and fixed
usually).
4) Place a hook and a wire sling on the PT eye Fig. 1-9 Removing cover (8)
bolts, lift it up and remove cover (8).
z In case the cover (8) is hard to

remove because of the resistance of
the O ring (29), lift it up while
lightly tapping the outer rim of the
cover by means of a plastic mallet.
5) Remove O ring (29) from cover (8).
z Do not reuse removed O ring (29).
(5) Removing input gear and spur gear.

1) Remove ball (36) and input gear (6).
6
Fig. 1-10 Removing input gear (6)
34-55
1) Remove three snap rings (25) from 9

crankshaft (9).
z When removing the snap ring, the

snap ring jumps out of the snap ring
hole if the tip of the pliers comes off
the hole by accident: Use care so as
not to injure yourself by it.
25
Fig. 1-11 Removing snap ring (25)
2) Remove three spur gears (7) from crankshaft 9
(9).
3) Remove coupling (15) from shaft (102).
7
Fig. 1-12 Removing spur gear (7)
(6) Removing rear flange (101)
1) Turn over the travel motor
z This work is intended to remove the
plug easily when removing the inside
of the rear flange. On that occasion,
loosen the plug so it can be removed
by hand.
z Do not loosen the plug if you do not
remove the inside of the rear flange.
2) Loosen two plugs (124)
: 36mm
3) Loosen two plugs (126)
: 10mm
z When disassembling the inside of
body (212), loosen plugs (204), (214) 170
and sleeve (202) before loosening
socket bolts (170).
4) Loosen four socket bolts (170), and remove 212
body (212) from rear flange (101).
: 6mm
5) Remove two O rings (138) and two balls 101

(194) from rear flange.

Fig. 1-13 Removing rear flange (101)
34-56
6) Remove eight socket bolt (143).

: 8mm
143
Fig. 1-14 Removing socket bolts (143)
7) Remove rear flange (101) from spindle (2).
z Hold the rear flange by both hands,

hold it up gently upright and remove
101
it.
Forced prying or striking it may
cause timing plate (109) to fall and
damage it.
109 (141)
8) Remove eight springs (113). 113
9) Remove parallel pins (142) from spindle (2).
10) Remove O ring (27),(30) from spindle (2).
z Do not reuse removed O ring (27),

(30).
Fig. 1-15 Removing rear flange (101)
(7) Removing the rear flange fittings
1) Place rear flange (101) on a work bench, with
the mating surface for spindle (2) facing up.
2) Remove timing plate (109) from rear flange
(101).
z If it is hard to remove the rear flange

101
in some cases as the mating surface
of it is stuck with oil, insert a
spatula into the draft groove of the
mating surface on the rear flange
side and hold the timing plate up. 150
Then the rear flange comes off. If a Fig. 1-16 Removing bearing (150)
sharp tool like screwdriver is put
into the mating surface, the mating
surface is scored, causing an oil
leakage ; do not use sharp tools.
3) Remove parallel pins (141) from rear flange

(101).
4) Remove bearing (150) from rear flange (101).
34-57
(8) Removing the brake valve from the rear

flange.
1) Remove two plugs (124) from rear flange
(101). 101
: 36mm
2) Remove O ring (136) from plug (124).

124
3) Remove two spring ritainer (125) and two Fig. 1-17 Removing plug (124)
springs (128) from rear flange (101).
4) Remove spool (123) from rear flange (101).

101
z To remove spool (123), place your
hand on one part of the plug port of
rear flange (101) and tilt it down.
128
Then spool (123) falls down. Hold the
tip and remove it.
123 128 125

Fig. 1-18 Removing spool (123)
5) Remove two plugs (126) from rear flange 126
(101).
: 10mm
101

7) Remove two springs (130) and two valves
(127) from the rear flange (101).
8) Remove plug (121).

: 10mm
101
130
126
127
Fig. 1-20 Removing valve (127)
34-58
(9) Disassemble the 2-speed selector valve

1) Remove plug (165) from rear flange (101).
: 10mm
165
101

2) Remove spool kit [(163), (164)] and spring
(166) from rear flange (101).
101
163,164,166
Fig. 1-22 Removing spool kit (163),(164)
(10) Disassembling shockless relief valve.
1) Remove plug (214)
: 10mm
z Remove plug (214) in the condition
where shockless relief valve is 214
installed on rear flange (101) to
make the work easier.
2) Remove O ring (220) from plug (214)


3) Remove piston (213) from body (212).
212
z Since clearance of body (212) and

piston (213) is determined so as to
suit actual clearance in the work
shop, store it allowing the
combination to be known easier.
213
Fig. 1-38 Removing piston (213) [method 1]
34-59
z When it is difficult to remove, attach PISTON(213)

thread M3 to threaded hole (M3)
used to disassemble piston (213) and
M3
pull it out.
z Then take care not to damage piston
bore.
BODY
Fig. 1-25 Removing piston (213) [method 2]

4) Remove two plugs (215)
: 6mm
z Loosen it with vise for easy working
5) Separate O ring (224) from plug (215)
215
Fig. 1-26 Removing piston (215)
6) Remove out two balls (216) from body (212)
216 212
Fig. 1-27 Removing ball (216)
7) Remove sleeve (202) from body.
: 27mm
z Before loosing sleeve (202), loosen

plug in the condition where rear
flange (101) is installed for easy of 202
loosening.
Fig. 1-28 Removing sleeve (202)
34-60
8) Remove O rings (208), (209) and two backup

rings (211) from sleeve (202).
202 212

(209) and backup ring (211).
9) Remove O ring (209) and two backup rings

(217) from body (212).
z Do not reuse removed O ring (209)

and backup ring (217). Fig. 1-29 Removing sleeve (202)
10) Remove plug (204) from sleeve (202).

: 10mm
z For internal parts of sleeve (202),

since the relief pressure is set and
the thickness of shim (205) is
determined, keep them so as not to
be mixed up with other ones.
z Do not reuse removed O ring (210). 204 202

12) Remove shim (205) from plug (204).
205
204
Fig. 1-31 Removing shim (205)
13) Remove spring retainer (203), spring (206)
and valve (201) from sleeve (202).
202
201
Fig. 1-32 Removing spring retainer (203)
34-61
206 202
Fig. 1-33 Removing spring (206)
201 202
Fig. 1-34 Removing valve (201)

14) Disassemble another sleeve in the same way.
z When replacement of parts in sleeve

(202) is required, if the replacement
of parts other than O ring (210) and PISTON SEAL(221)
piston seal (221) is necessary, the
replacement of a part is not allowed
because the relief pressure is already
set. So replace the valve kit with a
new one. VALVE(201)
Fig. 1-35 Cross-sectional view of valve (201)
(11) Disassembling the parking brake
z The sudden blowing of compressed
air may cause parts to fly out
Protect cover
incurring the danger of injury. Cover
piston (112) for protection.
Air hose
1) Blow jet air into the passage hole for the

paring brake of the spindle (2) and remove
the piston (112) from the spindle (2).
2 112
Fig. 1-36 Blowing jet air
34-62
2) Remove O ring (135),(139) from piston (112). 112

(135,139)
(139).
Fig. 1-37 Removing piston (112)

(12) Disassembling the hydraulic motor section
104
z When placing the travel motor on its
side, oil spills; place a container
under the travel motor.
1) Lay down the travel motor through 90
degrees.
2) Drain out the oil of the travel motor.
3) Hold cylinder block (104) by hand, turn it
both ways a few times alternately and
separate shoe (106) from swash plate (103).
z If cylinder block (104) is drawn out
in that condition, shoe (106) stays
with swash plate (103). Then parts
(pistons, shoes, etc.) attached to Fig. 1-38 Removing cylinder block (104)
cylinder block (104) come off from
cylinder block (104) and fall into
spindle (2). Care should be used
about it.
4) Hold the cylinder block (104) and remove the
shaft (102).
z Also, friction plate (115) and
separator plate (116) are also
removed with cylinder block (104).
5) Remove friction plate (115) and separator
plate (116), (117) attached on the removed
cylinder block (104).
6) Remove piston assy[piston (105) and shoe
(106)] and retainer plate (107) from cylinder
block (104).
z When removing the cylinder block,
hold the retainer plate (107) by both
hands and remove it with the piston
assy.
z Cylinder block (104) and piston assy
[piston (105) and shoe (106)] are the
minimum parts unit as cylinder &
piston kits. When they have to be
replaced, replace the cylinder & piston
kit as a set. (Refer to the parts manal).
34-63
7) Remove the piston assy (105),(106) from

retainer plate (107).〔Nine pistons〕
8) Remove thrust ball (108) from cylinder block

(104).
9) Draw out washer (111) from cylinder block

(104).
10) Remove three needle rollers (151) from

cylinder block (104). 151
104
Fig. 1-39 Removing roller (151)
(13) Remove spring from inside of cylinder block.
1) Place cylinder block (104) on the press bench.
z Do not remove the spring except
when spring is replaced.
z When removing the spring, align the
Jig (Ⅰ) with the washer in order to
prevent the cylinder block from
being damaged by contact.
z Put a plastic sheet over the sliding
surface of the cylinder block so as
not to damage it.
104
2) Place the retainer metal jig (I) on washer
(110) and remove snap ring (145) from the
snap ring groove of cylinder block (104) by
145
means of snap ring pliers, while holding
down the jig (I).
z If the press is loosened too suddenly,

the spring jumps out and injure
yourself. Always loosen the press
slowly.
Fig. 1-40 Removing snap ring (145)
3) Loosen the press slowly till the spring action
is released.
4) Remove the snap ring (145), washer (110),

spring (114), and washer (110) from inside
the cylinder block (104). 114
104
Fig. 1-41 Removing spring (114)
34-64
(14) Removing out shaft (102).

1) Removing swash plate (103) from spindle (2).
z When removing it, check that pivot

(167) is not adhered on swash plate.
2
2) Draw out shaft (102) from spindle (2). On
that occasion, the inner race of bearing (149) 149
comes off with the shaft.
3) Draw out two pivots (167), two parallel pins 102

(177) and the outer race of bearing (149) from Fig. 1-42 Removing shaft (102)
spindle (2).
162
4) Draw out the 2-speed switch piston
assy[piston (161) and shoe (162)] and spring
(191) from spindle (2). 161
191
Fig. 1-43 Removing 2-speed switching piston assy

(15) Removing inner race of bearing (149).
z Remove it only when replacing the
Press
ball bearing.
1) Place the retainer metal (Ⅱ) on a press bench Shaft

and put the shaft (102) in it. Bearing
2) Hold down the tip of the shaft by press and (Inner race)
remove the collar (169) and inner race of
bearing (149) from the shaft. Retainer
z Do not reuse the bearing. metal (Ⅱ)
(16) Remove hold flange Fig. 1-44 Removing bearing (149)

2) Place fixing metals (2 sets) on hub (1) and
spindle (2) so they are located in diagonal
positions. Then fasten and fix them.
z If you remove hold flange (3) without
fastening the fixing metals, hub (1)
comes off from spindle (2) and
spindle (2) falls down from the work
bench: Always attach the fixing
metals.
34-65
When removing the snap ring, the snap ring

jumps off if the tip of pliers comes off from the
snap ring hole. Use care so as not injure yourself.
4) Remove three snap rings (20) from hold

flange (3).
5) Put matching mark on snap ring (20) and

hold flange (3) with an oil paint marker.
z This is to place them in the same

positions as at installation.
6) Loosen three reamer bolts (19).

: 36mm 19
z The threaded portion of reamer bolt
(19) is provided with adhesive agent
and may cause the seizure on the
reamer portion where the adhesive
agent is applied, leading to the
difficulty of disassembling. Therefore
loosen reamer bolt (19) slowly. If it
turns tightly in the middle way,
tighten it one more time, then loosen
it again.
z Tightening torque : 70kgfym (510 lbfyft)
or more Fig. 1-45 Loosening reamer bolt (19)
7) Remove hold flange (3) from spindle (2).
3
8) Put match marks on hold flange (3) and
spindle (2) with paint marker.
z This is intended to install the hold

flange (3) in the same position as the
spindle (2).
z The three holes for reamer bolts in
the spindle (2) and hold flange (3)
are machined together. When they
must be replaced, replace the spindle
(2) and the hold flange (3) together Fig. 1-46 Removing hold flange (3)
as a set (assy).〔Hereafter called
spindle assy〕
(17) Removing fixing metal.

2) Remove two fixing metal.
34-66
(18) Removing spindle.

1) Tighten two eye bolts into the tapped holes of Eye bolt M16
spindle (2) so they are located in diagonally
opposite positions.
2) Hook sling to eye bolt, lift spindle (2) up and

remove it from hub (1). Then, floating seal 2 (22,31,132)
(31), outer race of bearing (22), and oil seal
1
(132) are also removed together.
z Lift up bearing (21) slowly and
gently so it is not damaged.
Fig. 1-47 Removing spindle (2)
(19) Removing bearing RV gear assy and pin
1) Remove floating seal (31) from hub (1).
z Remove bearing (21) striking 3 or 4
points of perimeter evenly taking
care for bearing not to be stuck.
z When the fit section of outer race of
bearing (21) is separated, bearing
(21), RV gear assy and pin (17) drop
from hub (1). So spread rubber mat
under the working bench to protect
them from damage.
2) Remove bearing (21) from hub (1) striking
pin(17) end face with punch and mallet. Mallet
Then, RV gear assy [RV gear A (4), RV gear B
(5), crankshaft (9), bearing (22), (23) and pin Pin punch
(17)] are also removed together.
3) Separate RV gear A (4), RV gear B (5) and
crankshaft (9) from RV gear assy.
Pin (17)
z Never remove bearing (22), (23) from
crankshaft (9) except for replacement.
Bearing(21)
(20) Removing bearing

z The bearing (21) drops from hub (1),
place a rubber mat under the work Fig. 1-48 Removing bearing (21) [1/2]
bench so as not to score the parts.
2) Push bearing (21) from hub (1), strike the
outer race of the bearing (21) end using pin
punch and mallet from the cover (8) side of Mallet
hub (1). Pin punch
Bearing(21)
Fig. 1-49 Removing bearing (21) [2/2]
34-67
(21) Removing the spindle fittings.

1) Remove floating seal (31) from spindle (2).
31 2
Fig. 1-50 Removing floating seal (31)

2) Remove the outer races (3 pcs.) of bearing
(22) from spindle (2).
z It is sometimes hard to remove the outer race

of the bearing (22) as the outer race of the
taper roller bearing comes in close contact
with the mounting surface of the spindle by
oil films of lubricating oil. In that case, tap
the center of the mounting hole of spindle (2)
by means of an aluminum rod. Then the
outer race is removed easily as the oil film is
cut.
3) Remove oil seal (132) from spindle (2).
z Never reuse removed oil seal (132).

Oil seal
Fig. 1-51 Removing oil seal (132)
(22) Disassembling hold flange

1) Remove outer race of bearing (22) from hold
flange (3).
22
Fig. 1-52 Removing the outer race of bearing
34-68
(23) Rough washing of parts. 2 3

1) Distinguish the four parts ; hub (1), spindle
(2), cover (8), and rear flange (101) from other 101
parts (hereafter called built-in parts).
2) Put the hub, spindle, cover and rear flange in
a cleaning bath and clean them.
z Soil and sand are adhered to the

outer surface of parts in some cases ;
clean them and remove soil and sand
from the parts.
z Wash oil is combustible. Be careful 1
not to cause fire and get burns.
z Before cleaning stained parts, Fig. 1-53 Rough washing of parts
immerse them in wash oil until dust
and stain become soft and are floated
to protect them from damaging when
cleaning.
3) Put the built-in parts in a rough cleaning

container containing wash oil and clean the
parts.
(24) Finish cleaning

1) Put parts in a finish cleaning container
containing wash oil and clean them well,
turning them slowly.
2) Blow parts with dry air to remove cleaning 3

oil.
z Blow compressed air in the inner

surface of hub (1), spindle (2) and
hold flange (3) to dry in the dust free
and dry conditions. After drying,
apply hydraulic oil to every part. Fig. 1-54 Finish cleaning
z Inner surface of rear flange (101),
hydraulic motor components, and RV
gear assy are to be dried naturally in
the dust free and dry conditions.
After drying every part, apply
hydraulic oil to every part.
z Use care not to damage the surface
of twenty four pins (17) or lose them
while handling.
2
Fig. 1-55 Finish cleaning
34-69
1.4 ASSEMBLY
1.4.1 GENERAL PRECAUTIONS FOR ASSEMBLY 2) Replacement parts that need adjustment of
(1) Assembly it by reversing the procedure of the axial clearance of bearing (22):
disassembly. Spindle kit
RV gear assy
(2) Assemble it in clean air condition.
(2) The assembling procedure varies according
(3) Don’t use cloth gloves during assembly. to the procedure of the above described parts.
(4) Replace or repair the damaged parts during 1.4.3

disassembly according to the instructions in No Procedure for
assembling
the “Maintenance standard”.
Replace O ring, oil seal, etc. with new one.
Replace
(5) Clean every part sufficiently, and blow them part. 〔Parts to be replaced〕
with compressed air don’t use waste cloth. zHub (1)
zSpindle kit
(6) Prior to assembling, apply clean hydraulic oil zBearing (21)
to moving and sliding portions of hydraulic Yes
motor valve. 1.4.4
Procedure for
(7) Tighten bolt and plug to the specified torque adjusting the pre-
using torque wrench. load of bearing (21)
(8) Replace reamer bolt with new ones. If it is 〔Parts to be

unavoidably reused, remove completely the replaced〕
adhesive agent on reamer bolt, repair flaws zSpindle kit
on bolt seat surface with oilstone, and
degrease it.
1.4.5
Procedure for
(9) Prior to assembling, apply grease to lip adjusting thickness
portions of O ring, oil seal, and floating seal of snap ring (20).
to protect it from being damaged, and to
moving section and sliding section.
Where replacing the above parts, the
(10) After assembly, plug every port to protect the previously adjusted parts should be
entry of dust, etc. used. If unadjusted parts are used, the
travel motor moves abnormally,
1.4.2 PREPARATORY ARRANGEMENT FOR causing early breakage.
ASSEMBLY
(1) After replacing parts with new ones, adjust
the pre-load of bearing and thickness of snap
ring without fail.
1) When the following parts are replaced, the

pre-load adjustment of bearing is required.
Hub (1)
Spindle kit
Bearing (21)
34-70
1.4.3 INSTALLING PROCEDURE

(1) Installing hub (1).
1) Install two eye bolts into the tapped holes of

hub (1) so they are located in diagonally
opposite positions.
2) Sling and eye bolt of hub (1), and lift up and
place it on working bench.
z Align hub (1) to the mounting holes
of the work bench, while matching
the holes in hub (1) with those in the
work bench.
3) Install hub (1) to the work bench and fasten

socket bolts so they are located in diagonal
positions.
z Fasten the socket bolts securely. If

the bolts are not tightened
sufficiently, the travel motor may
fall when turned over, which is
dangerous.
4) Press fit bearing (21) into hub (1), using the

pressing jig and a hammer.
Mallet
z To coat the O ring of the floating seal Bearing (21)
Fixing jig
with grease, remove the O ring from
Hub
the floating seal and coat the O ring
with a thin film of grease.
z Coat the floating seal of the spindle
(2) with grease the same way.
Fig. 1-53 Pressing bearing (21)

5) Coat the O ring of floating seal (31) with
grease and put it into the floating seal groove
of hub (1).
F/S fixture (Ⅱ)
z To fix the floating seal, mount F/S
fixture (I), the floating seal and F/S Floating seal
fixture (II), in that order and push
F/S fixture (Ⅰ)
the F/S fixture (II) in till it comes in
contact with the F/S fixture (I).
Remove the fixtures and make
certain that the end face of the hub
is level, within 1mm (0.0394in), with
Hub
the surface of the floating seal.
Fig. 1-54 Fixing floating seal (31)
34-71
(2) Assembling spindle section.

1) Apply grease on O ring of floating seal (31), F/S fixture (Ⅱ)
and fit floating seal in the groove of spindle
Floating seal
(2).
z To fix the floating seal, mount F/S F/S fixture(Ⅲ)
fixture (I), the floating seal and F/S
fixture (II), in that order and push
the F/S fixture (II) in till it comes in
contact with the F/S fixture (I).
Remove the fixtures and make
Spindle
certain that the end face of the
groove of spindle is level, within Fig. 1-55 Installing floating seal (31)
1mm (0.0394in), with the surface of
the floating seal. Eye bolt
2) Tighten two eye bots in the threaded holes on 2

spindle (2) so they are located diagonally
opposite to one another.
3) Tighten eye bolt, and lift up spindle (2) and

place it in hub (1). 1
4) Fix hub (1) and spindle (2) with fixing metal

in diagonal position.
Fig. 1-56 Inserting spindle (2)
5) Turn over the travel motor. 2
6) Insert three outer races of bearing (22) in

22
holes of spindle (2) respectively.
z Align the inner race of the

crankshaft bearing with the hole in
the outer race of bearing (22) set in
spindle (2). Then fit the RV gear
assembly gently to the spindle. Fig. 1-57 Installing the outer race of bearing (22)
z If the RV gear assembly is set by (22)
jerkily lowering it onto the spindle,
the bearing is damaged, resulting in
malfunction of the travel motor.
2
7) Assemble the RV gear assembly into spindle
(2), while holding the tip of crankshaft (9).
8) Coat 24 pins (17) with lube oil and insert

them between the pin grooves of hub (1) and
the gear tooth space.
9
Fig. 1-58 Fitting RV gear assy

34-72
(3) Installing hold flange Mallet

1) Insert bearing (21) to hub (1)
Fixing jig
z The O.D. of bearing (21) is set to the Bearing (21)
bore of hub (1) by press fitting.
Hammer the press fitting jig lightly
little by little till they are set evenly. Hub
In that case, set bearing (21) in hub
(1) scurely.
2) Check that hub (1), spindle kit, two bearing

(21) are not replaced with new ones. Fig. 1-59 Inserting bearing (20)
z If they are not replaced, proceed the

next process 3).
z If there is any one of the parts that

needs replacement, follow " (1.4.4)
Procedure of Pre-load to the
Bearing" and proceed to next process
3).
3) Install the outer race of bearing (22) to the

bearing of the RV gear assembly.
4) Fit hold flange (3) to inner race of bearing 1

(21) in hub (1).
z Install hold flange (3) to bearing (21) 3

on the same position as it was, put
matchmarks on spindle (2) and
crankshaft (9). 21
z If it is difficult to insert hold flange
(3) in inner race of bearing (21),
strike hold flange (3) lightly and
evenly with mallet to insert in
bearing (21). Fig. 1-60 Installing hold flange (3)
(4) Tightening reamer bolt.
z If oil and grease are adhered to the

tapped hole for reamer bolts (19) in
spindle (2), degrease and clean them.
z Degrease reamer bolts (19).
1) Apply anti-seize agent to the reamer part of

reamer bolts (19). Then coat the screw
threads with Loctite #638.
34-73
z Fasten three reamer bolts (19) 19

equally little by little. If you fasten
one or two bolts first, hold flange (3)
tilts, making bearing (21) unable to
be pressed into hold flange (3). This
causes reamer bolts (19) to seize
themselves. Therefore, tighten them
evenly all round.
2) Tighten three reamer bolts (19) to the

specified torque.
: 36mm, Fig. 1-61 Tightening reamer bolt (19)

4) Remove (two) fixing metal.
(5) Fixing snap ring.
z If the tip of the pliers gets out of the

hole of the snap ring, the snap ring
jumps out. Be careful about it.
1) Check that spindle kit, RV gear assy are not

replaced.
z Go to next process 2) if nothing is

replaced.
z Even if one of them is replaced, 20
Adjust axial clearance of bearing
1.4.5 and proceed to next process (6). 3
z When replacement of snap ring (20)
only is required, use the same snap 21
ring as the removed snap ring (20) or
select one equivalent to the removed
one from 12 kinds.
Fig. 1-62 Installing snap ring (20)
2) Fix snap ring (20) to the snap ring groove in
hold flange (3).
z Fit three snap rings (20) to the same

locations in hold flange (3) as they
were before disassembly. If new ones
are used, fit the snap rings (20) (of
which thicknesses were selected in
the previous process) to the snap
ring grooves.
34-74
(6) Installing spur gear (7). 7

9
1) Install three spur gears (7) to crankshaft (9).
z Put the matching marks (punched)
of three spur gears (7) as shown
below and fix them to crankshaft (9).
Position the
matching marks
(punched) on the
spur gears (7) and
install them.
Hold flange
Fig. 1-63 Installing spur gears (7)

z Fit the snap ring with its sharp
corner facing up.
2) Fix three snap rings (25) into the snap ring
grooves of crankshaft (9).
25 9 7
Fig. 1-64 Fixing snap rings (25)
(7) Press fitting shaft Press
1) Put collar (169) into the shaft (102).
Shaft
2) Put bearing (149) in a heating bath and heat
it at 100±10℃ (212±18° F) for ten minutes Bearing
and pressing it into shaft (102). (Inner race)
Retainer
metal (Ⅱ)
z Carry out the insertion work with
leather gloves. Use care so as not to
get burns.
Fig. 1-65 Pressing bearing (149)

(8) Install oil seal (132)
1) Turn over travel motor.
2) Coat the lip of the oil seal with lithium grease

and fix oil seal (132) into the oil seal hole in
spindle (2), using retainer metal and a
hammer.
3) Assemble the outer race (with roller) of 2

bearing (149) into spindle (2).
Fig. 1-66 Pressing oil seal (132)
34-75
4) Fix two parallel pins (171) into the pin holes

of spindle (2). 2
5) Coat two pivots (167) spherical side with
lithium grease and fix it into parallel pins
(171) of spindle (2). 162
6) Coat spring (191) with grease and fit it to
161
piston assy [piston (161) and shoe (162)].
7) Apply hydraulic oil to the moving parts of the
piston assy [piston(161) and shoe (162)]. Then 191
install the assy into the piston hole of spindle
(2).
Fig. 1-67 Installing piston assy

(9) Assembling the inside of cylinder block
110
z Put snap ring (145) in with its sharp
corner directed to the inlet.
z Insert washer (110) in contact with
snap ring (145) with its sharp corner 114
directed to snap ring (145).
104
Fig. 1-68 Inserting spring (114)

1) Place washer (110), spring (114), washer
(110) and snap ring (145), in that order into
2) Place cylinder block (104) on the press bench.
104
z Pressing force of spring (114) :

more than 120kgf (265 lbs) 145
z Put a plastic sheet over cylinder Fig. 1-69 Fixing snap ring (145)
block (104) so the contact surface of
cylinder block is not scored in
contact with timing plate (109).
3) Mount the retainer metal (I) on washer (110),

hold it down with a press, and fit snap ring
(145) into the snap ring groove of cylinder
block (104), using pliers.
34-76
(10) Assembling hydraulic motor

1) Put three rollers (151) into the holes of
cylinder block (104) and place washers (111)
and thrust balls (108) on them.
151
104
Fig. 1-70 Installing rollers (151)
2) Fit nine piston assy to retainer plate (107).
z After fixing it, immerse the whole
unit in hydraulic oil.
3) Fit retainer plate (107) and 9 piston assｙ to
z Match retainer plate (107) with the
spherical part of thrust ball (108) 105, 106 107
and install them.
108
4) Assemble cylinder block (104) fitted with
swash plate (103), thrust ball (108), washer 104 (151)
(111), retainer plate (107), piston assy (105),
(106) and roller (151), to shaft (102) that is
placed level. (to make a hydraulic motor assy) Fig. 1-71 Assembling piston assy
5) Place the lifting tool (I) to the tip of shaft and retainer plate (107)
(102) and place the shaft upright.
6) Attach the lifting tool (Ⅰ) and lift it up by
crane.
z Lower the shaft slowly till the pivot
hole in swash plate (103) matches
pivot (167) fitted into spindle (2).
z Lower the shaft so as not to score oil
seal (132).
7) Assemble the hydraulic motor assy to spindle Lifting tool
(2), while lowering it slowly.
8) After assembling it, remove the lifting tool
(Ⅰ).
9) Make certain that there is no rattling of
cylinder block (104) by turning it by hand.
z After assembly, do not hold up 2 103
cylinder block (104). Otherwise,
washer (111) comes off from thrust
ball (108), and the hydraulic motor
does not rotate properly.
Fig. 1-72 Assembling hydraulic motor
34-77
(11) Installing parking brake.

115
z Immerse friction plate (115) in 104

hydraulic oil before fitting it.
1) Assemble separator plate (117) into the inner

groove of spindle (2) that houses cylinder
block (104).
2) Assemble three friction plates (115) and

separator plates (116), by turns, into the
outer groove of cylinder block (104) and into
the inner groove of spindle (2). On that
occasion, fix the friction plates first and then Fig. 1-73 Fitting friction plate and separator
the separator plates. plate
3) Fit O rings (135),(139) to the O ring grooves

of piston (112). In that case, coat O rings
(135), (139) with a thin film of grease.
4) Fitting piston (112) into spindle (2).

z If it is hard to fit the piston (112)
into the spindle (2) due to the
112
resistance of O rings (135),(139), (135,139)
lightly tap the end face of the piston
(112), using a plastic mallet. 2
z Take care so as not to score the O
rings when installing the piston Fig. 1-74 Fitting piston (112)
(112).
(12) Installing the brake valve parts into rear

flange
1) Fit two O rings (137) to two plugs (126).
z Coat O ring (137) with grease.
2) Install valve(127) and spring (130) on plug

126
(126). Then, apply grease on it to fit valve,
spring and plug with the adhesion.
3) Coat the screw threads of plug (126) with

HERME SEAL. 101
4) Install valve (127) and spring (130), and

tighten the plug (126) assembled in one piece
in rear flange (101) temporarily.
: 10mm
Fig. 1-75 Temporally fastening plug (126)
34-78
z Coat the spool with hydraulic oil and

insert the spool into the rear flange.
z Insert the spool by aligning the hole
of the rear flange with the spool and
prevent the inner surface of the rear
flange and the outer surface of the
spool from being damaged by mutual 123
interference.
z In case damage resulting from inter-
ference should occur to the holes in the
rear flange and the outer surface of
the spool, internal leaks will occur
after assembly, ultimately
101
deteriorating the performances of the Fig. 1-76 Inserting spool (123)
travel motor.
5) Install spool (123) into rear flange (101).
6) Fit O ring (136) to plug (124).

7) Fit spring retainer (125) and spring (128) to

101
plug (124).
124
8) Temporarily fasten two plugs (124) into rear Fig. 1-77 Temporarlly fastening plug (124)
flange (101).
: 36mm
z When screwing the plug into the
rear flange, exercise care so the
spring is not deformed.
(13) Assembling of 2-speed switching valve 101

1) Put O ring (138) in plug (165). 166
2) Put spring (166) in spool kit[163), (164)] and
insert the kit into rear flange (101).
163
z Coat O ring (138) with grease. (164)
z When inserting spool (163) into rear
flange (101), coat spool (163) with Fig. 1-78 Inserting spool (163)
hydraulic oil.
z If the bore surface of rear flange
(101) and the outer surface of spool
(163) have dents or scores internal
leakage occurs after reassembly.
This results in deterioration of the
functions of the travel motor.
z On that occasion, insert spool (163)
by aligning the hole of rear flange
(101) with spool (163). This is to
prevent the bore surface of rear
flange (101) and the outer surface of
spool (163) from being scored.
34-79
3) Assemble plug (165) into rear flange (101)

and tighten it up to a specified torque.
Tightning torque :10kgfym (72 lbfyft)

165
(14) Installing fittings to rear flange.
1) Place rear flange (101) directing the contact
surface with spindle (2) upward.
101
Fig. 1-79 Tightening plug (165)

2) Apply hydraulic oil to bearing (150), and
install it in rear flange (101).
3) Drive parallel pin (141) in pin hole of rear

flange (101).
101
4) Apply the surface of timing plate (109) in
contact with rear flange (101).
z Fix timing plate (109) till it comes in

contact with rear flange (101). Take
measures to prevent the timing plate 150
from falling off from the rear flange. Fig. 1-80 Installing bearing (150)
5) Install timing plate (109) on rear flange(101)

taking parallel pin (141) as a guide.
z Coat spring (113) with sufficient

grease so it does not come off from
rear flange (101).
6) Attach 8 springs (113) to rear flange (101)

and adhere them with grease.
(15) Connecting rear flange with spindle.

1) Fix O ring (27),(30) into the O ring groove of
spindle (2).
z Fix O ring (27), (30) without

application of grease. Application of
grease may cause taking the seeped
grease out of contact face of rear
flange and spindle for the leaking oil.
So never apply grease on O ring.
34-80
2) Install two parallel pins (142) to spindle (2). 101
3) Fill hydraulic oil 1.2 (0.32gal) into spindle

(2).
109 (141)
113
4) Align two parallel pins (142) set in spindle (2)
with the pin holes of the rear flange and
install rear flange (101) to spindle (2).
Fig. 1-81 Installing rear flange (101)

5) Instal eight socket bolt (143) to spindle (2)
and tighten them up to the specified torque.
: 8mm,
6) Tighten plug (124) to the specified torque.

: 36mm,
7) Tighten plug (126) to the specified torque.

: 10mm,
Tightening torque: 13kgfym (94 lbfyft)
143
(16) Assembling shockless relief valve.
z Coat O ring (208), (209), (210) with

grease.
1) Attach O ring (209) and two backup rings

(217) to body (212).
2) Attach O ring (208), (209) and two backup

rings (211) to sleeve (202).
3) Fit O rings (210) to plug (204).
z When fixing plug (204), shim (205)

falls off in some cases. Coat it with
hydraulic oil or grease so it does not
fall off.
205
4) Put shim (205) to plug (204).
z Since relief pressure is set with

shims, install the removed shim as it
was.
204
Fig. 1-140 Installing shim (205)
34-81
z Piston seal (221) consists of an O

ring and a Teflon ring.
z Coat piston seal (221) with grease.
z Put in the O ring and the Teflon PISTON SEAL (221)
ring, in that order, when attaching
piston seal.
VALVE (201)
Fig. 1-84 Installing piston seal (221)

5) Install piston seal (221) to valve (201).
z Apply hydraulic oil on valve (201)

and insert it in sleeve (202).
z Insert it aligning centers of sleeve
hole and valve. (To protect sleeve
hole from damaging.)
zParts inside of sleeve are installed
meeting actual profile in the work
shop as a sleeve kit, so take care not
to make a wrong combination.
201 202
Fig. 1-85 Inserting valve (201)
6) Insert valve (201), spring (206), spring
retainer (203) in sleeve (202), and install plug
(204) in which shim (205) is placed to the
specified torque.
: 10mm, 202 206
Fig. 1-86 Inserting spring (206),

spring retainer (203)
7) Fit another sleeve in the same way.
204 202
34-82
8) Install the assembled sleeve (202) to body 202 212

(212) to the specified torque.
z When inserting sleeve (202), exercise

care so as not to bite backup rings
(217),(211).
: 27mm
z Fix it with vise to make tightening Fig. 1-88 Fixing sleeve (202)
work easier.
9) Install another sleeve (202) to body (212) in

the same way.
202
Fig. 1-89 Tightening sleeve (202)

10) Put two balls (216) into body (212).
11) Install O ring (224) to plug (215). (two)
216 212
Fig. 1-90 Inserting ball (216)
12) Install two plugs (215) to body (212) to the
specified torque.
: 6mm
z Fix it with vise to make tightening

work easier.
Fig. 1-91 Tightening plug (215) 215
34-83
zCoat piston (213) with hydraulic oil 212

and put it in. To set piston (213),
align the hole of body (212) with the
axis of the piston. (in order to
prevent the body hole from being
scored by contact)
z Do not change the pairing of piston
(213) and body (212) as they are shop
fitted.
13) Inserting piston (213) in body (212). M3 213

Fig. 1-92 Inserting piston (213)
14) Attach O ring (220) to plug (214).
15) Fit plug (214) to body (212) to the specified

torque.
: 10mm, 214
z Fix it with vise to make tightening

work easier.
(17) Installing input gear.

2) Fit coupling (15) to shaft (102).
zFix input gear (6) to shaft (102) by

matching the teeth of three spur
gears (7). When gear is not engaged,
check it for possible error.
3) Fit input gear (6) to coupling (15).
z Apply grease on ball (36) to protect it

from dropping when installing cover 6
(8). Fig. 1-94 Installing input gear (6)
4) Put ball (36) in the hole of input gear (6). Eye bolt
(18) Installing cover 8

z Apply grease to O ring (29).
29
1) Fit O ring (29) into the O ring groove of cover
(8).
2) Fit two eye bolts into the tapped plug holes of

cover (8), lift the cover and place it into hub
(1).
Fig. 1-95 Fitting cover (18)
34-84
3) Match the bolt holes in cover (8) to the tapped

holes in hub (1).
4) Tighten ten socket bolts (35) to a specified
torque. 35
: 10mm,
Tightening torque: 10.4kgfym (75.2 lbfyft)
33
Fig. 1-96 Tightening socket bolts (35)

5) Fill in 2.5 (0.66ga ) of lube oil.
6) Wind seal tape around two socket bolts (33). 33

7) Tighten socket plug (33) against cover (8), to
a specified torque. 8
: 10mm,
Tightening torque :6kgfym (43.3 lbfyft)
Fig. 1-97 Tightening socket plug (33)

(19) Installing body (212)
170
2) Install two O rings (193) and two balls (194)
to rear flange.
z Coat ball (194) with grease before
assembly, to prevent it from falling 212
off.
3) Install body (212) to rear flange (101) and

fasten them together with four socket bolts 101
(170) to the specified torque.
: 6mm,
Fig. 1-98 Tightening socket bolts (170)
(20) Dismounting
1) Remove the travel motor attaching bolts from
the work bench.
2) Tighten two eye bolts into the threaded holes
of spindle (2).
z Tighten two eye blots so they are
located in diagonally opposite
positions.
3) Place the hook and wire sling in the eye bolts,

lift the travel motor up by hoist and dismount
it from the work bench.
34-85
1.4.4 THE SPECIFIED PRE-LOAD MUST BE

APPLIED TO BEARING (21)
z Therefore, when the parts exerting

influences on the pre-load are
replaced, assemble it temporarlly in
the following procedure and check
the pre-load. If it is assembled
without checking the pre-load, the
malfunction of hydraulic motor may
be caused and the life may be
Torque wrench
shortened.
z Parts exerting influences on the pre-
load.
Hub (1), spindle kit [spindle (2), hold Special nut Bearing pre-load
adjusting jig
flange (3)] and bearing (21).
z When the above parts are not Hub
replaced, omit this procedure, and Spindle
proceed to the procedure shown in
Item (3) 1.4.3.
z Pre-load checking and pre-load
adjusting procedure are described
below.
Fig. 1-99 Pre-loading
(1) Procedure of adjusting the pre-load to
bearing. Depth micrometer
1) Attach the bearing pre-load jig to spindle (2),
tighten the special nut and pre-load bearing B
(21). C A
Tightening torque of special nut :
Hub
9kgfym (65 lbfyft)
Spindle
2) Determine the depth “A” through the
measuring hole of the bearing pre-load
adjusting jig, using a depth micrometer. Bearing pre-load
adjusting jig
3) Since the dimension “B” of the bearing pre- Fig. 1-100 Determining clearance “C”
load adjusting jig is known, determine the
clearance “C” by the following formula :
A : Actual value
“C”=“A”－“B” B : Dimensions of jig body
C : Dimension to be
specified
34-86
4) Then determine dimension “D” of hold D Surface E

flange (3).
5) After measurement steps 2)～4), adjust hold HOLD FLANGE(3)

flange (3) as follows :
Dimension “C” is the specified dimension
of the hold flange.
I. The dimension“D”of an actual hold

flange (3) is smaller than a specified
dimension“C”by more than 0.02mm
(0.0008in):
Remove the surface E of hold flange (3) to
a specified dimension“C”on a lather.
Ⅱ. The dimension“D”of an actual hold Fig. 1-101 Dimension“D”of hold flange

flange (3) is within ±0.02mm (0.0008in)
of tolerance of a specified dimension“C”:
Use the existing hold flange as it is.
Ⅲ. The dimension“D”of an actual hold

flange (3) is larger than a specified
dimension“C”by 0.02mm (0.0008in) or
over. Replace it with a new spindle assy. A
new hold flange (3) is always provided
with allowance for adjustment.
z Since hold flange and spindle are

drilled at the same time, they are
integrated in an assembly unit.
Therefore they can not be replaced
separately. Replace them as an
assembly unit, that is, together with
spindle.
This assy is called as spindle assy.
z To replace the spindle assy,
disassembling and assembling works
should be performed again.
6) Remove bearing pre-load adjustment jig from

spindle (2).
7) After completion of hold flange adjustment in

the procedure, proceed to the procedure
shown in Item (3) 1.4.3.
34-87
1.4.5 PROCEDURE OF AXIAL CLEARANCE

ADJUSTMENT OF BEARING (22) Retainer (Ⅳ)
When the following parts have been BEARING (22)

replaced, it is necessary to adjust the
axial clearance of taper roller bearing
RV gear assy
(22) to a specified value by adjusting
the thickness of snap ring (20).
If it is installed without adjustment,
malfunction of hydraulic motor may be
caused and the life may be shortened.
Spindle kit, RV gear assy
z When the above parts are not Fig.1-101 Insert the RV gear assy securely
replaced, the adjustment of
thickness of snap ring is
unnecessary. Proceed to the regular
assembly shown in Item (6) 1.4.3.
z The clearance adjustment procedure
in shaft direction is described below.
1) Lightly tap the outer race of bearing (22)

attached to crankshaft (9). Thickness gauge
z Put the RV gear assy in spindle (2)
securely.
Fig. 1-103 Measuring the clearance between
2) Fix the thinnest snap ring (20) into the snap snap ring (20) and bearing (22)
ring groove in hold flange (3).
3) Lightly tap the side face of snap ring (20).

z Confirm that the RV gear assy is
securely set in spindle (2).
20
4) Insert a thickness gauge between snap ring
(20) and bearing (22) and measure the
clearance.
5) Thickness measurement of snap rings Fig. 1-104 Installing snap ring satisfying
z Set thickness of snap ring (max.) the set thickness
Thickness of Thickness of
MAX.= thickness + presently set
gauge snap ring
z Set thickness of snap ring (min.)

Thickness of Thickness of 0.05
MIN.= thickness + presently set － mm
gauge snap ring (0.002in)
6) After deciding the thicknesses of the snap

rings, choose one out of the 12 kinds and fix it
into the hold flange.
Refer to (2) “Dimensional table of snap ring” on
next page.
7) After setting the snap ring of a set thickness,
go to 1.4.3 (6) “Installing the Spur Gear”.
34-88
(2) Dimensional table of snap ring
No. SHAPE DIMENSION

1 Snap ring [20]
Code Thickness : t mm (inch)

A Over 2.20 to 2.25 (0.087 to 0.089)
B Over 2.25 to 2.30 (0.089 to 0.091)
C Over 2.30 to 2.35 (0.091 to 0.093)
D Over 2.35 to 2.40 (0.093 to 0.094)
E Over 2.40 to 2.45 (0.094 to 0.096)
F Over 2.45 to 2.50 (0.096 to 0.098)
G Over 2.50 to 2.55 (0.098 to 0.100)
t H Over 2.55 to 2.60 (0.100 to 0.102)
I Over 2.60 to 2.65 (0.102 to 0.104)
J Over 2.65 to 2.70 (0.104 to 0.106)
K Over 2.70 to 2.75 (0.106 to 0.108)
L Over 2.75 to 2.80 (0.108 to 0.110)
34-89
1.5 SERVICE STANDARDS

1.5.1 SERVICE STANDARDS FOR PARTS
(1) Replace all seals (O ring, oil seal, floating seal) once used even if no damage is seen.
(2) Wear parts maintenance standard

1) Replace any part that shows damage on appearance.
2) Replace such parts that show the following abnormalities, as well.
Item
No. Parts Trouble Reference value Allowable value
Spindle kit
(2) Spindle z Severe damage to
(3) Hold flange appearance
(19) Reamer bolt z Abnormal wear such as
scoring is present.
RV gear assy
(4) RV gear (A) z The RV gear tooth surface
(5) RV gear (B) shows uneven wear.
(9) Crankshaft z Crankshaft－related parts
(22) Taper roller bearing do not move smoothly when
(23) Needle roller bearing crankshaft (9) is turned.
20 Snap ring z The end face of the

circumference is abnormally
worn.
21 Bearing z Dent is present.

z Flaking is seen.
z Uneven wear is present.
Rear flange kit

(101) Rear flange z Part in contact with spool
(123) is scratched.
z Clearance with spool is Clearance on diameter Clearance on
large. 10～20μ diameter 25μ
(0.0004～0.0008in) (0.001in)
z Surface in contact with valve

(127) is scratched.
z Depth to the contact surface
(123) Spool with valve (127) is large.
z Outer circumference is
scored.
z Outer circumference is worn
unevenly.
102 Shaft z Contact surface with oil seal

(132) is worn.
z Spline is worn.
34-90
Item
No. Parts Trouble Reference value Allowable value
103 Swash plate z Seizure is present.

104 Cylinder block z Spline is worn.
z Bore surface is worn badly.
z Sliding surface with timing
plate (109) is scored or worn
unevenly.
Piston Assy
(105) Piston z Clearance is present in the Clearance Clearance
(106) Shoe axial direction between 0.05mm 0.15mm
piston (105) and shoe (106). (0.0020in) (0.0059in)
z Shoe is worn abnormally.
z Shoe is worn unevenly.
107 Retainer plate z The end face of the
circumference is worn
unevenly.
108 Thrust ball z Spherical sliding part with
retainer plate (107) is worn
unevenly.
109 Timing plate z Sliding surface is seized or
worn unevenly.
115 Friction plate z Both end faces are worn Braking torque
unevenly. 18.2kgfym
116 Separator plate z Specified torque can not be (132 lbfyft)
117 Separator plate reached. or over
z Seizure is seen.
127 Valve z Seat surface is scored.
149 Bearing z Dent is present.

150 Bearing z Flaking is seen.
z Uneven wear is present.
Sleeve kit
(201) Valve z Seat surface is scored. Clearance on diameter Clearance
z Valve (201) has large 7～12μ on diameter
clearance (0.0003～0.0005in) 20μ
(202) Sleeve z Outer circumference is (0.0008in)
scored.
unevenly.
Body・Piston kit
(212) Body z Sliding part of piston (213) is Clearance on diameter Clearance
scored. 15～20μ on diameter
z Piston (213) has large (0.0006～0.0008in) 25μ
(213) Piston clearance. (0.0010in)
z Outer circumference is
scored.
unevenly.
34-91
1.5.2 PERFORMANCE INSPECTION
z After completing the maintenance, carry out the performance inspection in the following procedure
1) Required measuring instrument

1 Pressure gauge 〔35kgf/cm2(500psi)〕 2 pcs
2 Measuring cylinder〔5 (1.3gal)〕 1 pc
3 Stop watch 1pc
2) Test procedure
Mounting ............ Install motor in body (sprocket section), and connect pipe.
1
hydraulic motor
However, don’t install crawler.
and piping
[To carry out performance test of motor (No load)]
Note : 1. Connect pipes so that pressure gauge is installed,
and the drain rate of hydraulic motor can be
measured.
2. Never use hammer to mount motor, but mount it
using bolts holes softly.
Running-in of ............. Hydraulic motor Rotation

2 Speed Condition Operating time
hydraulic motor revolution direction
1st 10rpm Forward Every one
No load
2nd 20rpm Reverse minute or more
3 Performance inspection
of motor
Warming up ............Warm up motor until the temperature rises to the following temperature
1 z Hydraulic oil temp 45～55℃ (113～131°
F)
z Reduction unit outer temp. 40～80℃ (104～176°
F)
Performance test.... Measure the following items, and determine if it is allowable or not.
2 Allowable standard－Hydraulic motor drive pressure 16kgf/cm2 (228psi) or less at 10rpm
(1st-speed) Hydraulic motor drain rate 1.2 (0.32gal) / min. or less at 10rpm
Allowable Not allowable
Install crawler Disassemble and adjust again
34-92
1.6 TROUBLESHOOTING
Relief set pressure is low. …… Set it correctly.
No Pump fails. …… Check that motions other

pressure than travel are okay and
remedy if out of order.
Directional valve is out of …… Check if spool is normal and

order. repair if necessary.
Motor does
not start. Brake valve is out of order. …… If spool or valve is seized,
replace it. On other cases,
repair.
Hydraulic motor fails. …… Replace motor or check hy-

draulic oil. If faulty, replace
hydraulic oil.
Pressure
is okay.
Gear (in reduction unit) is …… Replace motor with
broken. reduction unit.
Motor is overloaded. …… Eliminate load.
Correct surface with

Scratches on matching face …… grindstone, sand paper, etc.
Through
matching
faces Bolts loosened …… Check after retightening
Plug is loosened …… Retighten

From
casing
Replace motor with
Casing cracked by stone, …… reduction unit.
Oil leaks.
Sliding surface is worn. …… Replace motor with
From reduction unit.
floating
seal
Deterioration occurs to …… Replace floating seal
O rings.
Bolts are loosened. …… Retighten

From
hydraulic O ring is damaged. …… Replace O ring.
motor
Seal face is scored. …… Correct with grindstone, pa-
per, etc.
Motor has poor volumetric …… Replace motor with reduc-

efficiency. tion unit.
Machine slides down on a Internal leakage from brake …… Replace brake valve.
slope. valve increased (Replace rear flange.)
Parking brake is not working.
Spring is broken. …… Replace spring.

Friction plate is worn. …… Replace friction plate and
separator plate.
34-93
Gear oil is short. …… Refill to a proper level.

Surface temperature of
reduction unit casing is Pitching occurs to bearing. …… Replace motor with reduction
high. unit.
Hydraulic oil intruded into gear …… Replace oil seal.

casing.
It occurs at low pressure.

Delivery rate differs on RH …… Repair pump.
and LH motors.
Machine deviates.
Drain rate differs on RH and …… Replace motor with reduction
LH motors. unit.
It occurs at high pressure.

Delivery rate differs on RH …… Repair pump and regulator.
and LH motors.
Drain rate differs on RH and …… Replace motor with reduction
LH motors. unit.
RH and LH brake valves …… Replace brake valve.
moves differently. (Replace rear flange.)
Relief pressure of either the …… Set pressure to a correct
RH or LH control valve is value.
low. Replace relief valve.
The delivery rate of the pump is

low.
The pump regulator does not …… Repair the regulator.
work correctly.
The pump has a large …… Repair or replace the pump.
amount of external leakage.
Speed does not raise.
The motor has a large amount of …… Replace motor with reduction

external leakage. unit.
Abnormal sound is heard. Motor or reduction unit is broken. …… Replace motor with reduc-
tion unit.
Piping vibrates. …… Clamp piping.
34-94
Speed does not change from High speed select check valve …… Inspect.
low to high. does not operate properly Repair or replace if necessary.
Select valve does not operate …… Check if spool is normal and

properly. repair or replace if necessary.
Pilot pressure is low. …… Set to a specified value.
1,2-speed select piston does …… Inspect.

not operate properly. Repair or replace if necessary.
Speed does not change from Select valve does not operate …… Check if spool is normal and
high to low. properly. repair or replace if necessary.
1,2-speed select piston does …… Inspect.

not operate properly. Repair or replace if necessary.
34-95
1A. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT

1A.1 CONSTRUCTION OF TRAVEL MOTOR (for L type)
29
13
4 30
2
39 12
36 24
7 27
19
34
1 32
24
33
40
23 20
31
10
37 14
3 25
6
9 25
14
20
5
35
8
17
15
165 115
164 116
166
163
139
147
112
126 113
156 109
130
127 121
154
138
150
101
148
135
124
155
128 125 122
118 106
190 142 120133
198 105
141 119 108 107
192,193 151
104
198 192,193 127 110
130
143 114
168 156 110 132
126 145 167
199 149
123,194
140
156 102
125
137
136 157 128
519 191
155
171 158 162
124
170 155 161
124
103
153
34-96
No. PART NAME Q’TY No. PART NAME Q’TY No. PART NAME Q’TY
REDUCTION GEARS HYDRAULIC MOTOR 142 PARALLEL PIN 2

1 HUB 1 101 REAR FLANGE 1 143 SOCKET BOLT 9
2 SPINDLE 1 102 SHAFT : DRIVE 1 145 SNAP RING 1
3 CARRIER 1 103 SWASH PLATE 1 147 BACK UP RING 1
4 RING GEAR (A) 1 104 CYLINDER BLOCK 1 148 BACK UP RING 1
5 RING GEAR (B) 1 105 PISTON 9 149 ROLLER BEARING 1
6 CLUSTER GEAR 3 106 SHOE 9 150 BALL BEARING 1
7 SUN GEAR (A) 1 107 RETAINER PLATE 1 151 ROLLER 6
8 COUPLING GEAR 1 108 THRUST BALL 1 153 THRUST PLATE 1
9 SHAFT (G) 3 109 TIMING PLATE 1 154 EXPANDER 5
10 DISTANCE PIECE 1 110 WASHER 2 155 O RING 3
12 DISTANCE PIECE 1 112 PISTON 1 156 O RING 4
13 COVER 1 113 SPRING 12 157 STOPPER 1
14 THRUST COLLAR 6 114 SPRING 1 158 SPRING 1
15 RING 1 115 FRICTION PLATE 2 159 SPRING 1
17 PIN 10 116 SEPARATOR PLATE 2 161 PISTON 1
19 COUPLING 1 118 VALVE SEAT 1 162 SHOE 1
VALVE : PARKING
20 THRUST BEARING 2 119 1 167 STEEL BALL 2
BRAKE
23 SEAL RING 1 120 SPRING 1 168 STEEL BALL 2
24 BALL BEARING 2 121 PLUG 2 170 SOCKET BOLT 4
25 NEEDLE BEARING 6 122 RING 1 172 SPRING PIN 1
27 PARALLEL PIN 10 123 SPOOL:BRAKE VALVE 1 173 VALVE 1
29 O RING 1 124 PLUG 3 174 SPRING 1
30 SOCKET PLUG 3 125 STOPPER 2 175 STEEL BALL 2
31 FLOATING SEAL 1 126 PLUG 2 176 EXPANDER 2
32 CAPSCREW 20 127 VALVE 2 177 SPRING 1
SUPER LOCK
33 20 128 SPRING 2 178 PLUG 1
WASHER
SPOOL : TWO SPEED
34 PARALLEL PIN 3 130 SPRING 2 186 1
CHANGEOVER
35 SOCKET BOLT 10 132 OIL SEAL 1 187 OIL STOPPER 1
36 STEEL BALL 1 133 O RING 1 189 SPRING 1
37 O RING 1 135 O RING 1 190 ORIFICE 1
39 O RING 2 136 BODY 1 191 SPRING 1
40 O RING 1 137 SPOOL : SURGE CUT 1 192 PLUG 2
139 O RING 1 194 ORIFICE 2
141 PARALLEL PIN 2 199 NAME PLATE 1
34-97
1A.2 TOOLS AND JIGS

(1) Tools
No. TOOLS DESCRIPTION Q’TY
About 28 kgfym Dial type

1 Torque wrench 1
About 56 kgfym Dial type
2 Impact wrench
3 Ratchet handle Tumbler type 1
4 Adapter for wrench Key wrenches 6, 10, 14 sockets 19, 41 1 each
5 Extension bar Nominal 150 1
6 Hammer About #1 1
7 Plastic mallet 1
Lifting capacity : more than 400kg (882 lbs)

8 Lifting gear Wire slings 1 set
Lifting bolts (for M12, M16 and PT 1 / 2)
9 Flat-blade screwdriver About 150mm (5.91˝ ) 1
10 Key wrench 14 1
11 Pliers for snap rings For hole 1
12 Punch About 10mm (0.39˝ ) 1
13 Compressed air Nozzle for 3～5 kgfycm2 (43～71 psi) 1 set
14 Press bench Press capacity : more than 500kg (1102 lbs) 1 set
Heating capacity : above 100℃ (212.0°

F)
15 Heating bath 1 set
Volume : 500×500×500 or over
Coverage : 0～25mm (0˝～0.98˝ )

16 Depth micrometer 1
Min. scale : 0.01
17 Container General-purpose vat 2
18 Leather gloves 1 pair
19 Mug 1
20 Sealing tape 1
21 Paint marker 1
34-98
(2) Jigs
No. Name of Jig Q’ty No. Name of Jig Q’ty

Lifting jig (Ⅰ) Sharp-point punch
1 1 9 1
Holding-down jig (Ⅰ) Sharp-point steel rod
2 1 10 1
Holding-down jig (Ⅱ) Steel rod
3 1 11 1
Holding-down jig (Ⅲ) Holding-down rod
(0.46˝ )
∅11.8
4 1 12 1
150
(5.91˝ )
Main bearing fixing jig Coupling gear lifting jig
5 1 13 1
Aluminum rod Clearance measuring jig
6 1 14 1
Thrust bearing adjusting tool Temporary assembling jig for sun gear
7 1 15 1
Lifting jig (Ⅱ)
8 1
34-99
1A.3 DISASSEMBLY
1A.3.1 GENERAL PRECAUTIONS TO BE EXERCISED
1) Since hydraulic components are precision
finished, handle them in a less dusty, clean
place. Use clean tolls and cleaning oil. For
drying, use compressed air ; avoid using
rag and paper for cleaning.
2) After the travel motor is removed from the
machine, put a plug in each port and clean
the outer surface to be free from dirt, oil and
other foreign matter.
3) Before disassembly, leave matching marks on
the matching faces of each component and
take care so as not to damage or lose parts.
Arrange removed parts in order as
disassembly goes on.
4) Once seals are removed, replace them with
new ones in principle, regardless of whether
or not they are damaged. Therefore, get
replacement seals ready beforehand.
5) Some parts are not available in loose state
and only available in subassemblies. Get
them ready beforehand, looking them up in
the part manual.
6) Do not reuse seals, such as O rings and
backup rings.
7) The numerals in parentheses after part
names represent those in the structural
drawings (Fig.1).
1A.3.2 DISASSEMBLING THE BRAKE VALVE

(1) Removing brake valve
1) Removing the surge cut valve
Loosen the four socket head bolts (170) and
separate body (136) from rear flange (101).
2) Take off two O rings (140, 156) from the rear
flange. Fig. 2 Removing surge cut valve
: 6mm
3) Removing rear flange (101)

Remove nine socket head bolts (143).
: 14mm
Fig. 3 Removing rear flange mounting bolts
34-100
4) Separate rear flange (101) from spindle (2).
Tools used : Lifting fittings 1set

Lifting bolt (for M12) 1pc.
Fig. 4 Removing rear flange

(2) Removing brake valve spool
1) Separate two plugs (124) from rear flange
(101). Take out O ring (155) from plug (124).
In separating two plugs (124) from rear

flange (101), the work will be promoted
if plug (124) is loosened with rear
flange (101) mounted to spindle (2).
: 41mm
Fig. 5 Removing plug (124)

2) Take out two springs (128), two stoppers
(125) and a spool (125) from rear flange (101).
z Use care so as not to score the outer

surface of spool (123) and the sliding
surface of rear flange (101).
z Rear flange (101) is selectively fitted
to spool (123) ; where either of them
is to be replaced, replace both as a
kit.
Fig. 6 Removing brake valve spool

(3) Removing check valve
1) Separate two plug (126) from rear flange
(101).
z In removing two plugs (126) from

rear flange (101), the work will be
promoted if plugs (126) are loosened
with rear flange (101) mounted to
spindle (2).
: 10mm
34-101
2) Draw out two springs (130) and valves (127)

from rear flange (101).
z Exercise care so as not to score the

seats of rear flange (101) and valves
(127).
3) Take out O ring (156) and plug (126).
Fig. 8 Removing check valve (127) on the low

pressure side
REAR FLANGE
(4) Disassembling 2-speed changeover valve
1) Take out plug (121) from rear flange (101).
: 10mm
PLUG
Draw out
2) Separate O ring (138) from plug (121). REAR FLANGE
3) Draw out spool (186) and spring (189) from
inside rear flange (101).
SPOOL
Draw out
(5) Removing parking brake valve (119) Fig. 10 Removing spool for 2-speed changeover
1) Press valve seat (118) in rear flange (101) by
means of a steel rod. In that condition, push
the notch of ring (122) by means of a sharp- STEEL ROD
point steel rod, as shown on the right. This
causes ring (122) to deform and get out of the
ring groove of rear flange (101). In this way,
RING (122)
ring (122) can be taken out of rear flange
VALVE SEAT (118)
(101).
RING (122)
z If ring (122) is removed, the hole will SHARP-POINT
be scored. Therefore, correct the hole SPRING STEEL ROD
after removing the ring (122). (120)
z Remove ring (122) only when VALVE
(119)
removing valve (119).
NOTCH
z Tools to be used :
○Sharp-point steel rod Fig. 11 Removing valve (119)
○Steel rod
34-102
2) Plug the hole in valve seat (118), blow in jet

air into the passage hole for the parking
brake and draw out valve seat (118).
z In drawing out valve seat (118) with

jet air, insert spool (123) into rear
flange (101).
○Compressed air (3～5kgf/cm2)
(43～71psi)
○Nozzle
3) Hold rear flange (101) and shake it lightly

with the hole facing down. Then valve (119)
and spring (120) can be taken out. Take out
valve (119) and spring (120) from the hole in
rear flange (101), using tweezers.
4) Draw out O ring (133) from valve seat (118).
(6) Disassembling the parts in surge cut valve

body kit
1) Separate plug (124) from body (136)
z In separating plug (124) from body

(136), the work will be facilitated if
plug (124) fixed in rear flange (101)
is loosened.
: 41mm
Fig. 12 Removing plug (124) for surge cut valve

2) Separate O ring (155) from plug (124).
3) Take out springs (158), (159), stopper (157)
and spool (137) in sequence.
z Do not reuse O ring (155) once

removed.
z Body (136) is selectively fitted with
spool (137). Therefore, where
replacing either of them, replace
them as a kit.
z When drawing out spool (137), use
care so as not to score the moving
surface of the spool. Fig. 13 Removing surge cut valve spool
34-103
1A.3.3 DISASSEMBLING HYDRAULIC MOTOR

(1) Removing timing plate
Separate timing plate (109), two pins (141),
12 springs (113), ball bearing (150) and two O
rings (29, 39) from rear flange (101) and
spindle (2).
(2) Removing parking brake parts Fig. 14 Removing timing plate (109)
1) Blow in jet air into the passage hole for the
parking brake of spindle (2) and draw out
piston (112).
z If jet air is blown in too jerkily,
piston (112) will jump out which is
dangerous. The piston can be drawn
out safely if a protective cover is
placed over it.
(43～7psi)
○Nozzle Fig. 15 Blowing in jet air
2) Draw out O rings (135, 139) and backup rings
(147,148) from piston (112).
(3) Drawing out the parts inside the hydraulic

motor
1) Place the hydraulic motor on its side.
z If the hydraulic motor is placed on Fig. 16 Removing parking brake piston (112)
its side, oil will drop down ; place a
container under the hydraulic motor.
2) Empty oil out of the hydraulic motor.
3) Hold cylinder block (104) by both
hands and draw it out of spindle (2).
z Before drawing out the cylinder
block (104), hold it by hand, turn it a
few times by turns and separate
shoe (106) from swash plate (103). If
cylinder block (104) is drawn out
without doing the above-mentioned
treatment, the shoe remains adhered
to the swash plate. Be careful as the Fig.17 Removing cylinder block
parts (piston, shoe, etc.) fixed to the
cylinder block come off from the
cylinder block and fall into the
spindle.
34-104
4) Separate two separator plates (116) and two

friction plates (115) from the outer
circumference of cylinder block (104) that was
thus drawn out.
5) Separate from cylinder block (104), the piston
assembly that consists of piston (105), shoe
(106), retainer plate (107), thrust ball (108)
and six rollers (151).
6) Draw out swash plate (103) from inside
spindle (2). Fig. 18 Removing piston assembly
7) Draw out two steel balls (167) from spindle
(2).
8) Draw out from spindle, the 2-speed

changeover piston assembly (consisting of
piston (161) and shoe (162)) and spring (191),
by blowing in jet air through the passage hole
of spindle (2).
z Piston (161) is integrated with shoe

(162). Where either of them must be
JET AIR INLET
replaced, replace them as piston SPINDLE (2)
assembly.
(43～71psi) Fig. 19 Removing 2-speed changeover piston
○Nozzle assembly
(4) Disassembling cylinder block

1) Place cylinder block (104) on a press bench,
draw out snap ring (145), using snap ring
pliers, while putting holding-down jig ( Ⅰ )
against washer (110).
z Press load more than 100kg (220 lbs)

○Press bench
○Holding-down jig (Ⅰ)
○Snap ring pliers Fig. 20 Taking off snap ring (145) for holes
z Put a vinyl sheet over the sliding
surface of the cylinder block for
protection.
2) Take out snap ring (145), washer (110) spring

(114) and washer (110) in sequence from
inside cylinder block (104).
z Remove spring (114) only where it

must be replaced.
Fig. 21 Removing parts out of cylinder block
34-105
(5) Removing drive shaft (102)

1) Draw out shaft (102) from spindle (2).
On that occasion, roller bearing (149) comes
out with shaft (102). However, oil seal (132)
can not be drawn out.
Fig.22 Removing shaft (102)

2) Place holding-down jig (Ⅱ) on a press bench
and put shaft (102) (with roller bearing (149)) Press
in it. Separate the inner race of roller bearing
(149),holding down the tip of the shaft by the
press. INNER RACE OF SHAFT (102)
ROLLER BEARING (149)
z Take off the inner race only where

roller bearing (149) must be
replaced. HOLDING-DOWN JIG (Ⅱ)
z Do not reuse roller bearing (149)
once removed.
○Press bench
○Holding down jig (Ⅱ)
Fig. 23 Removing the inner race of

roller bearing
1A.3.4 DISASSEMBLING REDUCTION UNIT

(1) Removing carrier
1) Turn over the press bench 180 ° so the
motor cover (13) faces up.
2) Take off socket head plug (30).
3) Remove 20 socket head bolts (32) and 20
super lock washers (33).
: 19mm
Fig. 24 Separating reduction unit cover (13)
4) Lift and remove cover (13) in hook.

5) Draw out thrust bearing (20).
6) Draw out the carrier assembly, using lifting
jig (Ⅰ).
7) Take out steel ball (36), sun gear (A)(7),
coupling (19) and thrust bearing.
○Lifting fittings 1set Fig.25 Removing carrier assembly
○Lifting jig (Ⅰ)
34-106
8) Turn over the bench 90°and drain lube oil

out of the reduction unit.
z On that occasion, place a container

under the bench to receive lube oil.
z Container : 4 lit (1.1 gal) capacity
Fig. 26 Draining out oil

(2) Removing ring gear (A) (4)
1) Before removing ring gear (A)(4), put
matching marks on ring gear (A)(4) and hub
(1).
2) Remove the face of ring gear (A) (4), by
applying a crowbar or something to ring gear
(A) (4).
z After removing ring gear (A) (4),

clean up adhesive (Three Bond)
stuck to the matching surface of ring
gear (A) (4) and hub (1). RING GEAR (A) (4)
3) Separate ten parallel pins (27) from hub (1).
CROWBAR
(3) Removing hub(1), ring gear (B)(5) and Fig. 27 Removing ring gear A (4)
coupling gear (8)
1) Take off 10 socket head bolts (35).
: 14mm
z Since the screw thread of socket

head bolts (35) are coated with
adhesive material, the torque more
than the tightening torque is
required for loosening them.
z Tightening torque : 35.5±5.5kgfym
(257±40 lbfyft)
When removing socket head bolts
(35), use sufficient care so as not to Fig. 28 Taking off the mounting bolts of coupling
seize the threads. gear (8)
2) Before separating coupling gear (8) from

spindle (2), put matching marks on coupling
gear (8) and spindle (2).
34-107
(3) Separating hub (1) from spindle (2)

Lift up
Put the lifting bolt into the M12 tapped hole
in hub (1), lift it up and separate hub (1) from
spindle (2). SPINDLE (2) HUB (1)
On that occasion, two ball bearings (24) seal
ring (23), Oring (40), coupling gear (8) ring
gear (B) (5), ring (15) and distance piece
(12) come off together.
○Lifting bolt M12 (2 or 4pcs)
○Lifting fittings 1set
Fig. 29 Removing hub (1) (Ⅰ)

z In case the hub and the spindle can
not be removed by the
above-mentioned method, do it as
follows :
Turn over the reduction unit body
180° till the spindle comes upright.
Separate hub (1) from spindle (2) by
tapping the end faces of hub (1),
using an aluminum rod and a
hammer.
On that occasion, the following parts
come off together.
Two ball bearing (24), seal ring (23),
O ring (40), coupling gear (8), ring
gear B (5), ring (15) and distance
piece (12).
○Aluminum rod Fig. 30 Removing hub (1) (Ⅱ)
○Hammer
○Rubber mattress
HAMMER
FLAT BLADED
(4) Disassembling spindle (2) SCREWDRIVER
1) Take off O ring (29) from spindle (2).
2) Turn over spindle (2) 180°.
3) Separate oil seal (132) from spindle (2).
(To remove the oil seal, out a flat-bladed
screwdriver against the cylindrical end face SPINDLE (2)
of the oil seal and tap it with a hammer.)
z Remove oil seal (132) only for

replacement.
OIL SEAL (132)
○Flat-bladed screwdriver Fig. 31 Removing oil seal (132)
34-108
4) Separate distance piece (10) from spindle

FLAT BLADED SCREWDRIVER
(2).
DISTANCE PIECE (10)
z Remove distance piece (10) only
where floating seal (31) must be
replaced.
○Flat-bladed screwdriver
5) Take off O ring (37) from spindle (2).

SPINDLE (2)
Fig. 32 Removing distance piece
(5) Disassembling the inside of hub (1)

1) Removing floating seal (31).
Separate floating seal (31) from hub (1).
Fig. 33 Removing floating seal

2) Separate ball bearing (24) from hub (1) as
HAMMER
shown on the right.
On that occasion, seal ring (23) comes off HUB (1) STEEL ROD
together.
z Since ball bearing (24) is shrinkage

fitted to hub (1), do not separate ball
bearing (24) from hub (1), in
principle. BALL BEARING (24)
z Do not reuse ball bearing (24) once
removed. SEAL RING (23)
Fig. 34 Removing ball bearing and seal ring
3) Then, place hub (1) on the bench so the
spindle side faces up. HAMMER
4) Separate another ball bearing (24) from hub
(1), as shown on the right.
HUB (1)
STEEL ROD
BALL BEARING (24)
Fig. 35 Removing ball bearing

5) Take off O ring (40) from hub (1).
34-109
(6) Disassembling coupling gear (8)

1) Separate ring (15) from ring gear (B) (5).
z Do not reuse ring (15) once removed.

○Sharp-point steel rod
2) Separate coupling gear (8) from ring gear (B)

(5).
z Do not disassemble coupling gear (8) Fig. 36 Removing ring (15)

and ring gear (B) (5) only where they
must be replaced.
(7) Disassembling carrier assembly

Do not disassemble the carrier assembly any
more.
In case it needs replacement because of
damage to some component part, replace the
carrier assembly as a whole.
z Construction of carrier assembly

○Carrier (3)
○Cluster gear (6)
○Shaft (9)
○Thrust collar (14)
○Needle roller bearing (25) Fig. 37 Carrier assembly
○Parallel pin (34)
34-110
1A.4 ASSEMBLY
1A.4.1 GENERAL PRECAUTIONS TO BE EXERCISED
1) For assembly, choose a clean place. 5) Always coat the moving and sliding parts of
2) Do not use cloth gloves for assembly. the hydraulic motor valve with clean
3) At disassembly, correct scored parts referring hydraulic oil, before assembly.
to the service standards or replace parts. 6) Tighten up capscrews and plugs, using a
Always replace oil seals with new ones. torque wrench.
4) Clean parts thoroughly with cleaning oil and
dry them with jet air. Do not use rag in any
circumstances.
1A.4.2 ASSEMBLING BRAKE VALVE

(1) Installing check valve
2) Put spring (130) and valve (127) into plug

(126), apply grease to valve (127) and spring
(130) and temporarily secure spring (130).
3) Put one-piece plug (126) in rear flange (101)

and tighten it to a specified torque.
: 10mm
z Tightening torque : 13.5±2 kgfym
(97.6±14.5 lbfyft)
Fig. 38 Installing check valve
34-111
(2) Installing spool

1) Insert spool (123) into rear flange (101).
z Coat spool (123) with hydraulic oil

and put it into rear flange (101).
z To fit the spool, align the center of
the hole in the rear flange with the
shaft center of the spool and insert it
in place. (To prevent damage to the
inside surface of the rear flange and
the outer surface of the spool
because of mutual contact.) Fig. 39 Inserting spool (123)
z If scoring by contact develops in the
hole of the rear flange and the outer
surface of the spool, internal leakage
occurs after re-assembly. Be careful
as such internal leakage may
deteriorate the performances of the
hydraulic motor.
3) Fit stopper (125) and spring (128) into plug

(124). Tighten two plugs (124) against rear
flange (101) to a specified torque.
: 41mm
z Tightening torque : 34±5 kgfym

(246±36.2 lbfyft)
z Where rear flange (101) or spool
(123) is to be replaced, always
replace them as a rear flange kit.
Fig. 40 Tightening plug (124)
(3) Assembling surge cut valve
1) Insert spool (137) into body (136). On that
occasion, coat spool (137) with hydraulic oil
and insert it into body (136).
z To fit spool (137), align the center of

the hole in body (136) with the center
of the spool axis and insert it in place.
(To prevent damage to the inside
surface of the body and damage to the
outer surface of the spool.)
z If damage by contact occurs to the
hole in the body and to the outer
surface of the spool, internal leakage
develops after re-assembly, which
deteriorates the performances of the Fig3 41 Inserting surge cut valve spool (137)
hydraulic motor.
34-112
3) Assembly stopper (157) and springs (158),

(159) to plug (124).
4) Tighten plug (124) against body (136) to a
specified torque 34±5 kgfym (246±36.2 lbfyft).
: 41mm
z In screwing in plug (124) into body Fig. 42 Fastening plug (124)

(136), take care so as not to distort
springs (158), (159).
(4) Assembling 2-speed changeover valve

REAR FLANGE
2) Insert spring (189) and spool (186), in that

order,into rear flange (101). SPOOL
To insert spool (186), align the center of the
hole in rear flange (101) with the center of
the axis of spool (186). (To prevent the inside Insert
of rear flange (101) and the outer surface of
spool (186) from being damaged by contact.) Fig. 43 Inserting spool into 2-speed changeover
valve
z In inserting spool (186) into rear
flange (101), coat spool (186) with
hydraulic oil.
z If the bore surface of rear flange
(101) and the outer surface of spool
(186) are scored by contact, internal
leakage develops that results in
deterioration of the performances of
the hydraulic motor.
3) Fit plug (121) to rear flange (101) and tighten REAR FLANGE
it to a specified torque.
: 10mm
z Tightening torque : 10±2kgfym PLUG

(72.3±14.5 lbfyft)
Insert
Fig. 44 Fastening plug (121)
34-113
(5) Installing parking brake valve

1) Place O ring (133) in valve seat (118).
2) Fit valve (119), spring (120) and valve seat

(118), in sequence, to rear flange (101).
3) Fold new ring (122) a little, put it into rear
flange (101) and set it in the ring groove.
z Use a new ring (122).

z Ring (122) is deformed when it is set Fig. 45 Installing the parking brake valve
in rear flange (101). Therefore,
expand ring (122), using snap ring
pliers (for hole) and place it in the
Expand
ring groove of rear flange (101).
(Right side)
1A.4.3 ASSEMBLING REDUCTION UNIT AND Fig. 46 Ring (122)

HYDRAULIC MOTOR
If the following parts are replaced for
reassembly, clearance adjustment becomes
necessary :
1. Distance piece (12) of proper thickness
2. Thrust bearing (20) of proper thickness
In addition, confirm before assembly that the
following parts have been replaced :
No 3.3.3 Assembly
Parts replacement
required
<Parts replaced>
z Hub kit 3.3.4 Adjusting the thickness
z Spindle kit of distance piece (12)
z Ball bearing (24)
Yes
<Parts replaced>
z Carrier assy 3.3.5 Selecting thrust bearing (20)
z Cover (13) of proper thickness
z In case the above-mentioned parts are replaced for reassembly , do not fail to adjust each of
the parts before reassembly. If unadjusted parts are reassembled, the hydraulic motor
develops malfunctioning, consequently leading to early breakdown.
34-114
(1) Re-assembling hub (1)

1) Heat hub (1) to 90° ±5℃ in a hot bath and
place it on the work bench so the mounting MAIN BEARING FIXING JIG
HAMMER
side of cover (13) faces up.
2) Place ball bearing (24) into hub (1), using the
main bearing fixing jig. BALL BEARING
HUB
z Where the main bearing fixing jig is
not available, put ball bearing (24)
into hub (1) and hammer it in place.
Fig. 47 Inserting ball bearing (24)
3) Turn over hub (1) 180°so the mounting side

of spindle (2) faces up.
4) Insert ball bearing (24) into hub (1), using the
main bearing fixing jig.
5) Fit O ring (40) to hub (1).
z Fit ball bearing (24) by heat

shrinkage.
z Coat O ring (40) with a thin film of
grease.
6) Fit seal ring (23) to hub (1).

If it is hard to set the seal ring in place, tap
the end face of the seal ring evenly all
around, using a plastic mallet.
z In fixing seal ring (23) to hub (1), use

care so as not to score O ring (40).
(2) Placing distance piece (10)

1) Fit O ring (37) to spindle (2).
2) Then fit distance piece (10) to spindle (2).
z Fit distance piece (10), holding it

down by hand.
z If distance piece (10) is hard to enter,
tap it lightly with a plastic mallet.
Fig. 48 Fixing distance piece (10)
34-115
3) Fit floating seal (31) to hub (1).
z Coat floating seal (31) with a thin

film of grease.
z Exercise sufficient care so the
sealing surface is free from dust and
other foreign matter.
(3) Assembling hub (1) and spindle (2)

1) Place spindle (2) on the work bench with its Fig. 49 Fitting floating seal (31)
cover side facing up.
2) Attach lifting bolts to hub (1), lift it up by a
lifting jig and insert it gently into spindle (2).
z If it is hard to place hub (1) in

spindle (2) because of ball bearing
(24) , strike the top face of hub (1)
evenly by means of a plastic mallet.
(4) Assembling coupling gear (8) with ring gear B

(5) Fig.50 Assembling hub (1) with spindle (2)
1) Fit coupling gear (8) to ring gear B (5).
2) Put ring (15) into the ring groove of ring gear
B (5).
z Do not reuse ring (15) once removed :

Always replace it with a new one.
(5) Fitting coupling gear (8)

1) Mount distance piece (12) to coupling gear
(8).
z On that occasion, coat the mounting

surface of coupling gear (8) with a
thin film of grease to prevent
distance piece (12) from falling
down.
Hub kit
Selecting distance piece (12) of
Parts replacement Spindle kit
proper thickness (3.3.4)
required Ball bearing (24)
Parts replacement not required Go to next paragraph
34-116
2) Attach coupling gear (8) (with ring gear B (5)

) to the coupling gear lifting jig, lift it up with
a lifting fitting and mount it to the spindle.
3) Align the matching mark on coupling gear (8)
with that on spindle (2).
4) Fit ten pins (17) and caulk the end face of the
pin holes of coupling gear (8).
z Do not reuse pins (17) ; always

replace them with new ones.
Fig. 51 Fitting coupling gear (8)
5) Tighten 10 socket head bolts (35) to a
specified torque, using a torque wrench.
z Tightening torque : 35.5±5.5 kgfym
(257±40 lbfyft)
z Degrease the screw threads and the
pin holes of spindle (2) thoroughly
and coat them with adhesive
material.
z Degrease socket head bolts (35)
thoroughly and coat the stem of bolts
with Molycoat (molybdenum
disulfide base grease).
6) Turn over the hydraulic motor through 180° Fig. 52 Fastening socket head capscrews (35)
so the spindle faces up.
(6) Assembling oil seal (132)

1) Put oil seal (132) into the oil seal fixing hole
of spindle (2).
z Coat the lip of oil seal (132) with

white vaseline or lithium containing
grease.
z Use a new oil seal.
(7) Fit roller bearing (149) to shaft (102) by

shrinkage fit technique. Fig. 53 Fixing oil seal (132)
z If roller bearing (149) has been

drawn out of shaft (102) during
disassembly, replace it with a new
one and fix it by shrinkage fit
technique.
z Shrinkage fit temperature : 100±10℃
(212.0±40.0° F)
z Coat the outer contact surface of roller
bearing (149) with molybdenum
desulfide grease.
z In inserting roller bearing (149),
wear leather gloves and be careful so Fig. 54 Fixing roller bearing (149)
as not to get yourself burnt.
34-117
(8) Fixings piston assembly [ (161), (162) ] SPRING (191)

1) Fit piston assy [ (161), (162)] and spring (191)
to the piston hole of spindle (2). PISTON KIT (161,162)
SPINDLE
Fig. 55
Fig. 56 Installing piston assembly (161), (162)
(9) Fixing steel balls (167)

1) Put two steel balls (167) into the steel ball
holes in spindle (2).
(10) Assembling parts into cylinder block

1) Place washer (110), spring (114) and washer
(110) into cylinder block (104) and fit snap
ring (145) (for hole).
Fig. 57 Fitting cylinder block (104)

2) Place the above-mentioned cylinder block on
the press bench. Put holding -down jig (Ⅰ)
against washer (110), hold down spring (114)
and fix snap ring (145).
z Cover the sliding surface of the

cylinder block with a vinyl sheet for
protection.
z Pressing force of spring (114) : more
than 100kg.
Fig. 58 Fixing snap ring (45)
34-118
(11) Installing motor assy

1) Fit six rollers (151) to cylinder block (104).
Then install thrust ball (108) on it.
2) Put piston assy (105) (106) in retainer plate
(107).
Fig. 59 Fitting roller (151) and thrust ball (108)

3) Install the piston assy to cylinder block (104).
After installation, immerse it in hydraulic oil.
Fig. 60 Installing piston assy

4) Attach swash plate (103), thrust plate (153),
thrust ball (108), retainer plate (107), roller LIFTING JIG (Ⅱ)
(151), cylinder block (104) and piston assy
(105) (106) to shaft (102), as shown right. Fit 151
a lifting jig to the shaft and place it upright. 104
In the case, fit the outer race of roller bearing
(149) to spindle (2) beforehand. 105
108
106
z Match the spherical parts of retainer 153
plate (107) with thrust ball (108) 103
correctly before assembly. SPINDLE(2)
5) Lift up the motor assy by means of the lifting

jig (Ⅱ) and place it into spindle (2). Fig. 61
z Assemble parts gently so that the

steel ball holes in swash plate (103)
match well with steel balls (167) and
that it is not scored by contact with
spindle (2) and others.
z After mounting the motor assy, turn
the cylinder block by hand and
confirm that it turns without
rattling. In case of rattling , inspect
the assy.
Fig. 62 Attaching motor assy
34-119
(12) Assembling parking brake

1) Fit separator plate (116) and friction plate
(115) alternately in that order into the
circumferential groove of cylinder block (104).
On that occasion, use care so as not to
mistake the order of installation of friction
plates (115) (2 pcs) and separator plate (116)
(2 pcs).
z Immerse friction plates (115) in

hydraulic oil before installation.
Fig. 63 Fitting friction plates and companion plates
2) Fix O rings (135) (139) and backup rings
(147) (148) to piston (112).
z Coat O rings (135) (139) with a thin

film of grease.
Fig. 64 Placing piston O rings and backup rings

3) Fit piston (112) into spindle (2).
z In case piston (112) is hard to enter

spindle (2) because of the resistance
of the O rings, tap the end face of
piston (112) lightly and evenly, using
a plastic mallet.
In that operation, take care so as not
to score the O rings.
Fig. 65 Placing piston

4) Arrange twelve springs (113) in the spring
mounting holes of piston (112).
Fig. 66 Attaching springs (113)
34-120
5) Put two O rings (39) and O ring (29) into the

O ring grooves of spindle (2).
z Coat two O rings (39) with a thin

film of grease.
z Do not coat O ring (29) with grease.
(If the O ring is coated with grease
and fixed, the grease may ooze out of
the matching faces of rear flange
(101) and spindle (2). This may be
taken as an oil leakage in some
cases.)
Fig. 67 Fitting O rings (29) (39)
6) Fill spindle (2) with hydraulic oil.
Volume required : 1.2 (0.32gal)
(13) Attaching rear flange (101) to spindle (2)
1) Attach ball bearing (150) to rear flange (101).
2) Insert parallel pins (141) (2 pcs) into the pin
holes of rear flange (101).
3) Fit timing plate (109) with parallel pins (141)
as guides.
On that occasion, apply grease to the matching
surfaces between timing plate (109) and rear
flange (101).
z Install timing plate (109) till it

comes in close contact with rear
flange (101). (To prevent the timing
plate from falling off the rear flange.)
4) Insert two parallel pins (142) into spindle (2).
Fig. 68 Attaching parallel pins (142)

5) Attach rear flange (101) to spindle (2).
On that occasion, match the pin holes with
two parallel pins (142) fixed to spindle (2).
z In attaching rear flange (101) to

spindle (2), always use a lifting gear
as rear flange (101) is rather heavy.
Fig. 69 Attaching rear flange (101)
34-121
6) Tighten nine socket head bolts (143) against

spindle (2) to a specified torque.
: 14mm
Tightening torque 25.7±4kgfym
(186±28.9 lbfyft)
z In case piston (112) does not enter
spindle (2) to the fully by the
resistance of the O rings under the
foregoing para. 12.3, attach rear
flange (101) to spindle (2) as follows :
Note : Attach four socket head bolts
(143) in diagonal directions and
fasten rear flange (101) evenly so as
not to distort it. Fig. 70 Fastening rear flange (101)
(14) Attaching surge cut valve assy to rear flange

(101)
1) Attach two O rings (140) (156) to rear flange
(101).
2) Attach body (136) of the surge cut valve (3) to
rear flange (101). Then fasten four socket
head bolts (170) against rear flange (101) to a
specified torque.
: 6mm Tightening torque 3±0.5kgfym
(21.7±3.62 lbfyft)
z Coat O rings (140) (156) with a thin
film of grease.
(15) Installing carrier assy Fig. 71 Mounting surge cut valve

1) Install one of two thrust bearings (20) to
coupling gear (8).
z Coat thrust bearing (20) with a thin

film of molybdenum disulfide grease.
Hub kit
Parts replacement Spindle kit Selecting thrust bearing (20) of
required Carrier assy suitable thickness see section.
Cover (13)
Parts replacement not required Go to next paragraph.
2) Attach coupling (19) to shaft (102).
z Coat the spline of coupling (19) with

a thin film of molybdenum disulfide
grease.
34-122
3) Put steel ball (36) in sun gear (7). Then put

sun gear (7) in coupling (19).
Fig. 72 Inserting sun gear (7)

4) Deciding the assembly timing point of parts
in the carrier assembly.
Insert the carrier assy into hub (1) and
MATCHING MARK TEMPORARY SUN GEAR
perform the following operation to have POSITION FIXING JIG
cluster gear B (6) meshed correctly with
ring gear (B) (5).
a. Align the matching marks of three cluster
gears (6) in the illustrated positions.
CARRIER
b. In that condition, engage the temporary (3)
sun gear fixture with cluster gear (6) and CLUSTER

GEAR (6)
fix them together.
c. Then insert the carrier assy into hub (1).
At that time, the temporary sun gear Fig. 73 Deciding the assembly timing point of
fixture comes off by itself. carrier assy parts
5) Insert the carrier assy into hub (1) and

engage ring gear (B) (5) correctly with cluster
gear (6).
(16) Installing ring gear (A) (4)

1) Match the matching mark of ring gear (A) (4)
with that of hub (1). Then attach ring gear Fig. 74 Inserting carrier assy
(A) (4) to hub. On that occasion, confirm that
Insert
ring gear (A) is engaged well with cluster
gear (6). MATCHING MARK RING GEAR (A) (4)
z After degreasing the matching faces

between hub (1) and ring gear (A) (4) HUB (1)
thoroughly, coat it with a thin film of

Herme seal No. SS60F.
2) Turn hub (1) and match the matching marks

on ring gear (A) and the hub.
3) Fit ten parallel pins (27) to hub (1). Fig. 75 Attaching ring gear (A)
4) Fill the reduction gear with lube oil.
34-123
(17) Attaching cover (13)

1) Attach thrust bearing (20) to carrier (3).
z Coat thrust bearing (20) with a thin

film of molybdenum disulfide grease.
Hub kit
Parts replacement Spindle kit Selecting thrust bearing (20) of
required Carrier assy suitable thickness .
Cover (13)
Parts replacement not required Go to next paragraph
2) Attach cover (13) to hub (1).
z Coat the mounting surface of the

hub of cover (13) with a thin film of
Herme Seal No. SS60F.
Fig. 76 Installing cover (13)

3) Fasten cover against hub (1) with 20 socket
head bolts (32) and 20 super lock washers
(33), to a specified torque.
: 19mm
z Tightening torque 10.4±1.6kgfym

(75.2±11.6 lbfyft)
z Coat socket bolts (32) with a thin
film of Locktite 242 before using
them.
Fig. 77 Fastening cover (13)
4) Tighten three socket head plugs (30) against
cover (13), to a specified torque.
: 10mm
z Tightening torque 6±2kgfym

(43.4±14.5 lbfyft)
z In attaching socket head plug (30) to
cover (13), place seal tape around it.
z Fasten socket head plug (30)
within±1 thread below the end face
of cover (13).
34-124
1A.4.4 SELECTING DISTANCE PIECE (12) OF DEPTH MICROMETER

SUITABLE THICKNESS DISTANCE PIECE
CLEARANCE MEASURING
Where the following parts have been replaced, JIG
select a distance piece (12) of proper thickness, as
follows : SPINDLE
After selection, proceed to Section 5. Regular (2)
“A”
“B”
Assembly.
Hub kit
“X”
Parts replaced Spindle kit
Ball bearing (24)
(1) Attach the distance piece clearance
measuring jig to the spindle without fitting
BALL BEARING
distance piece (12). HUB (1) (24)
(2) Fasten socket head bolts (35) lightly.
A : Dimension to be measured
z Fasten the Jig by three socket head B : Dimension on jig
bolts (35) evenly. Fig. 78
(3) Measure dimension “A” as shown in the

figure on the right, using a depth micrometer.
(4) Measure dimension “C” of coupling gear (8)
that is to be fixed. (See the figure on the
right.)
(5) Based on the result of clearance
measurement mentioned above, determine a
distance piece having suitable thickness by
the following formula :
① Determine the clearance between the end
face of spindle (2) and the end face of ball Fig. 79 Measuring dimension A
bearing (24). Let this clearance be “X”.
“X”=“A”－“B” DISTANCE PIECE(12) COUPLING GEAR(8)
② Then determine a distance piece of proper

thickness. Let this dimension be “T”. C
“T”=(“C”＋“X”)±0.1 T
X
(6) As the result of (1)～(5), choose a thickness of
the nine thicknesses in the below table and SPINDLE (2)
proceed to regular assembly :

TYPE THICKNESS “t”mm
A 3.70 to 3.80 (inclusive)
Fig. 80 Assembly drawing
B 3.80 to 3.90 (inclusive)
C 3.90 to 4.00 (inclusive)
D 4.00 to 4.10 (inclusive) MARKING STAMP
(TYPE CODE)
E 4.10 to 4.20 (inclusive)
F 4.20 to 4.30 (inclusive)
X 3.40 to 3.50 (inclusive) t
Y 3.50 to 3.60 (inclusive) ∅231 (∅9.09″)
Z 3.60 to 3.70 (inclusive) ∅256 (∅10.08″)
Distance piece kit Fig. 81 Distance piece (12)
34-125
1A.4.5 SELECTING THRUST BEARING (20) OF

PROPER THICKNESS
If the following parts have been replaced, choose
thrust bearing (20) of proper thickness, as
follows : After selection, proceed to regular
assembly.
Hub kit
Parts to be replaced
Spindle kit
Carrier assy
Cover (13)
Fig. 82 Inserting carrier assy parts
(1) Attach one of two thrust bearings (20) to
coupling gear (8).
Insert
At that time, use a distance piece having the MATCHING MARK RING GEAR (A) (4)
smallest thickness.
z On that occasion, do not coat thrust HUB (1)

bearing (20) with molybdenum
disulfide grease.
(2) Attach coupling (19) to shaft (102).

(3) Insert sun gear (7) into coupling (19).
(4) Insert the carrier assy into hub (1) and Fig. 83 Installing ring gear
engage ring gear (B) (5) with cluster gear (6).
After determining the assembly timing point
of the carrier assembly parts proceed to DEPTH MICROMETER
assembly. THRUST BEARING
(5) Match ring gear (A) (4) to the matching mark ADJUSTING JIG
and attach it to hub.
On that occasion, make sure that cluster gear “A”
“B”
(6) meshes correctly with ring gear (A) (4). “X”
(6) Attach the thrust bearing adjusting jig to hub

(1) and fasten two socket head bolts (M12)
CARRIER (3)
lightly.
z On that occasion, do not fit thrust RING GEAR (A)(4)

bearing (20). Fig. 84 Installing thrust bearing adjusting jig
(7) Measure dimension “A” with a depth

micrometer, as shown in the figure on the
right.
Fig. 85 Measuring dimension “A”
34-126
(8) Next, measure dimension “C” of cover (13).
(9) Based upon the result of measurement of the

above clearance, determine a thrust bearing
of appropriate thickness by the following
formula :
① Determine the dimension between the end
face of carrier (3) and the end face of ring
gear A (4). Let this dimension be “X”.
COVER (13)
“X”=“B”－“A”
“A”=dimension to be measured “C”

“B”=dimension of jig
Fig. 86 Measuring dimension C
② Then determine a thrust bearing of
appropriate thickness.
“T”=(“C”－“X”) －(0.3 to 0.6)
(10) As the result of steps (7) ～ (9) , choose a

thrust bearing of proper thickness of the
three types in the below table and proceed to
regular assembly. MARKING STAMP (TYPE CODE)
t
TYPE CODE t±0.05 mm
∅90(∅3.54″)
1 5.7
∅117(∅ 4.61″)
2 6.0
Fig. 87 Thrust bearing (20)
3 6.3
Thrust bearing kit
34-127
1A.5. SERVICE STANDARD

1A.5.1 PERFORMANCE VERIFICATION TEST 1A.5.2 SEAL KIT PARTS
(1) Objective
No. PART NAME Q’TY REMARKS
When the brake valve, the motor, the
29 O RING 1
reduction unit and others have been serviced
31 FLOATING SEAL 1 ES100-250-A
properly, fill the motor casing with hydraulic
37 O RING 1
oil and perform performance verification test 39,140 O RING 3
in the following manner : 40 O RING 1
(2) Condition 132 O RING SEAL 1 TCN-38×58×11
1) Hydraulic oil : ISO VG46 133 O RING 1
Lube oil : API Classification for “Service 135 O RING 1
CD” SAE30 3.0 (0.8 gal) 138 O RING 2
Operating oil temperature : 50±5℃ 139 O RING 1
(122±31° F) 147 BUCK-UP RING 1 SUN-2BP195
Drain pressure : 0.8 kgf / cm2 (11 psi) 148 BUCK-UP RING 1 SUN-2BP180
(3) Preparation 155 O RING 3

156 O RING 4
Install the hydraulic motor assy to the lower
193 O RING 2
frame and pipe them. Run in the hydraulic
motor without installing track links.
Break-in running condition
Item Duration Remark

Run in both
10 rpm 1 min
directions
No load
Run in both
20 rpm 1 min
directions
Run in both
100 kgf /cm2 20 rpm 2 min
(4) Measurement and judgment directions
Item Condition Pressure difference

Pressure difference at no 1-speed at 10 rpm 20 kgf /cm2 (284psi) or below
load 2-speed at 20 rpm 30 kgf /cm2 (427psi) or below
Amount of motor drain 1 ,2-speeds at 10 rpm 1.5 /min (0.4 gal /min) or below
1A.5.3 TIGHTENING TORQUE

Tightening Torque Table
Part No. Nomenclature Screw size Q’TY Tightening torque kgfym (ftylbs)
30 Hex. socket plug PT- 1 /2 3 6±2 kgfym (43±14ftylbs)
32 Hex. head bolt M12 (P 1.75)×50 20 10.4±1.6 kgfym (75±12ftylbs)
35 Hex. socket bolt M16 (P 2.0)×30 10 35.5±5.5 kgfym (257±40ftylbs)
121 Plug PF 1 /2 1 10±2 kgfym (72±14ftylbs)
124 Plug M36 (P 1.5) 3 34±5 kgfym (246±36ftylbs)
126 Plug M28 (P 1.5) 2 13.5±2 kgfym (98±14ftylbs)
143 Socket head bolt M16 (P 2.0)×40 9 25.7±4 kgfym (186±29ftylbs)
152 Socket head plug PT 1/ 4 2 3±0.5 kgfym (22±4ftylbs)
170 Socket head bolt M8 (P 1.25)×60 4 3±0.5 kgfym (22±4ftylbs)
34-128
1A.5.4 SERVICE STANDARDS FOR PARTS

When disassembling and inspecting the motor, Replace such parts that show the following
follow the standards set forth herein. Handle abnormalities, as well.
parts with caution, particularly the moving and Replace all seals once removed even if no damage
sliding parts, so as not to score them. Replace any is seen.
part that shows outstanding damage on
appearance.
Part Nomenclature Symptom Reference value Allowable value

No. (Standard dimension) (Criterion)
Spindle kit
• Spindle assy
(2) •• Spindle • Critical damage to appearance.
(8) •• Coupling gear • Abnormal wear such as score is
(17) • Pin present.
Carrier assy • The cluster gear (6) tooth
(3) Carrier surface is worn unevenly or
(6) Cluster gear scratched.
(9) Shaft
(14) Thrust collar • The cluster gear do not move
(25) Needle roller bearing smoothly when the cluster gear
(34) Parallel pin (6) is turned.
Hub kit
(1) Hub • Tooth surface is worn unevenly
(4) Ring gear (A) or scored.
(27) Parallel & Pin
• Tooth surface is worn unevenly
5 Ring gear (B)
or scored.
• Tooth surface is worn unevenly
7 Sun gear or scored.
• Spline is worn.
19 Coupling • Spline is worn.
Clearance between
coupling gear and
20 Thrust bearing • Thrust bearing is worn. cover (13) Clearance 0.8
0.3 to 0.6(0.012～0.024˝ (0.031˝ )
)
• Sliding surface is scored.
12 Distance piece • Sliding surface is abnormally
worn.
• Pressed mark is present.
24 Ball bearing • Flaking is seen.
• Uneven wear is present.
Rear flange kit • Part in contact with spool (123)
(101) Rear flange is scratched.
(123) Spool • Clearance with spool (123) is
(154) Expander Clearance on
large. Clearance on
(192) Plug diameter
• Surface in contact with valve diameter 25μ
(193) O ring 10～20μ
(127) is scratched.
(198) Hex. socket plug • Depth to the contact surface
(199) Name plate with valve (127) is large.
• Contact surface with oil seal
102 Shaft (132) is worn.
• Spline is worn.
103 Swash plate • Seizure is present.
34-129
Part Nomenclature Symptom Reference value Allowable value

No. (Standard dimension) (Criterion)
104 Cylinder block • Spline is worn.
• Bore surface is worn badly.
• Sliding surface with timing plate
[109] is scored or worn unevenly.
Piston Ass’y
(105) Piston • Clearance is present in the axial Clearance
(106) Shoe direction between piston [105] 0.05mm 0.15mm
and shoe [106]. (0.0020˝ ) (0.0059˝ )
• Shoe is worn abnormally.
• Shoe is worn unevenly.
• The end face of the circumference

107 Retainer plate is worn unevenly.
108 Thrust ball • Spherical sliding part with
re-tainer plate [107] is worn
une-venly.
109 Timing plate • Sliding surface is seized or worn
unevenly.
115 Friction plate • Both end faces are worn unevenly. Braking torque Braking torque
• Specified torque can not be 27 kgfym 27 kgfym
116 Separator plate reached. (195 ftylbs ) (195 ftylbs )
• Seizure is seen. or over or under
118 Valve seat • Seat surface is scored.
• Outer circumference is scored.

119 Valve
• Seat surface is scored.
Body kit
(136) Body • Sliding surface with spool [137] Clearance on
is scratched. diameter 20μ
• Clearance with spool [137] is 7～15μ
large.
(137) Spool • Outer circumference is scored.
• Outer circumference is worn
unevenly.
149 Roller bearing • Pressed mark is present.
• Flaking is seen.
150 Ball bearing • Uneven wear is present.
• Outer circumference is scored.

186 Spool • Seat surface is scored.
34-130
1A.6. TROUBLESHOOTING
Relief set press is low. ••• Set it correctly.
No Pump fails. ••• Check that motions other

pressure than travel are okay and
remedy if out of order.
Directional valve is out ••• Check if spool is normal

of order. and repair if necessary.
Motor does
not start. Brake valve is out of order. ••• If or valve is seized, replace
i spool t. On other cases,
re-pair.
Hydraulic motor fails. ••• Replace motor or check

hydraulic oil. If faulty,
replace hydraulic oil.
Pressure is
okay.
Gear (in reduction unit) is ••• Replace motor.
broken.
Motor is overloaded. ••• Eliminate load.
Correct surface with

Through Scratches on matching face ••• grindstone, emery paper,
matching
faces Bolts loosened ••• Check after retightening
Plug is loosened ••• Retighten

From casing
Casing cracked by stone,etc. ••• Replace motor.
Oil leaks.
Sliding surface is worn. ••• Replace motor.
From
floating seal
Creep occurs to O rings. ••• Replace motor.
Bolts are loosened. ••• Retighten

From
hydraulic O ring is damaged. ••• Replace O ring.
motor
Seal face is scored. ••• Correct with grindstone,
pa-per, etc.
Motor has poor volumetric ••• Replace motor.

efficiency.
Machine slides down on a Internal leakage from brake valve ••• Replace brake valve.
slope. increased (Replace rear flange.)
Parking brake is not working.
Spring is broken. ••• Replace spring.

Friction plate is worn. Replace friction plate and
separator plate.
34-131
Gear oil is short. ••• Refill to a proper level.

Surface temperature of
Pitching occurs to bearing. ••• Replace reduction unit.
reduction unit casing is high.
Hydraulic oil intruded into gear ••• Replace oil seal.

casing.
It occurs at low pressure.

Delivery rate differs on RH ••• Repair pump.
and LH motors.
Machine zigzags.
Drain rate differs on RH ••• Replace motor.
and LH motors.
It occurs at high pressure.
Delivery rate differs on RH ••• Repair pump and

regulator.
and LH motors.
Drain rate differs on RH and ••• Replace motor.

LH motors.
RH and LH brake valves ••• Replace brake valve.

(Replace rear flange.)
moves differently.
Relief pressure of either the Set pressure to a

•••
RH or LH control valve is correct level.
low.
The delivery rate of the pump is

low.
The pump regulator does not ••• Repair the regulator.

work correctly.
Speed does not go up.
The pump has a large ••• Repair or replace the
amount of external leakage.
The motor has a large amount of ••• Replace motor.

leakage.
Abnormal sound is heard. Motor or reduction unit is broken. ••• Replace motor or
reduction unit.
Piping vibrates. ••• Clamp piping.
34-132
The speed does not change Malfunction of high pressure ••• Check it.
from low to high. selector check valve If necessary, repair or
replace it.
Malfunction of speed change ••• Check that spool operates

normally, and if
necessary, repair or
replace it.
Pilot pressure is low. ••• Set the pressure to the

specified value.
Malfunction of 2 speed change ••• Check it.

piston If necessary, repair or
replace it.
The speed does not change Malfunction of selector valve ••• Check that the spool
operates normally.
from high to low.
If necessary, repair or
replace it.
Malfunction of 2 speed change ••• Check it.

piston If necessary, repair or
replace it.
34-133
1A.7 PRECAUTIONS WHEN INSTALLING TRAVEL MOTOR

The inside of the motor case should be filled with
hydraulic oil without fail to protect travel motor
(GM24V) from possible damage before restarting
the operation of the motor after new installation,
repair or replacement.
(1) When newly installing or replacing the assy. Remove plug

Before installing a travel motor on the lower
frame, direct the travel motor sideways,
remove the plug of the drain port, and fill the
casing of the hydraulic oil section with
hydraulic oil through the drain port on the
other side, bleeding air at the same time.
Thereafter, install the travel motor on the
lower frame.
z Oil quantity required for casing 1.2 .

(0.32gal)
(2) When replacing the hydraulic motor unit.

1) When the hydraulic motor unit is replaced, Shoe
fill the inside of the casing of the hydraulic
Travel motor
motor section with hydraulic oil using oil jug,
etc. though the drain port (put on the drain
pipe side) on the upper side leaving the travel
motor installed on the lower frame.
However, it takes time because it is very
difficult to bleed air from the casing. Install plug
At this time, be sure that the drain port on
the lower side is stopped with a iron plug.
Then, install all pipes.
z Oil quantity required for casing 1.2 .

(0.32gal)
2) After installation of hydraulic motor, install Shoe

pipes other than drain pipe. At that time, be
sure that the drain port on the lower side is Travel motor
stopped with a iron plug. After that, lock the Sprocket
shoe with iron pipe, etc. or move the travel
lever slightly to the degree just before the Stopper like pipe,
travel motor starts rotating until the lumber, etc.
hydraulic oil is drained through drain port on

the upper side (piping side). And install the Install plug
drain pipe. Or after installing all pipes and
locking the shoe with iron pipes, etc., operate
the travel lever fully to make it in the relief
condition, and hold it for about one minute.
The inside of the motor case is filled with
hydraulic oil.
34-134
E115SR
E135SR
SECTION 41 TROUBLESHOOTING (MECHATRO CONTROL)
TABLE OF CONTENTS
1. Outline .................................................................................................................. 41-1

1.1 Judgment of actual thing at site ..................................................................................................... 41-1
2. Table of actuator for troubleshooting: mechatro control ......................................... 41-2
3. Troubleshooting outline: mechatro control ............................................................. 41-3
4. Check points for mechatro system (for troubleshooting) ........................................ 41-4

4.1 Attaching position of sensor and electric equipments .................................................................... 41-4
4.2 Equipment ..................................................................................................................................... 41-6
1. OUTLINE
Troubleshooting provides process locating for the

cause of trouble in the order that trouble
occurred. This manual describes how to solve the
specific phenomenon systematically as early as
possible. For troubleshooting concerning the
inside of equipment, refer to troubleshooting for
each manual of equipment.
1.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of
trouble and field, and notify person of arrival
time.
(2) Verify background of trouble occurred

1) Model name and serial number
YR-B76
2) Kind of attachment Attending the field to verify actual thing.
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional
works.
5) Recurrence of past trouble, or problems on
the additional 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, YR-B76
surmise causes systematically. Verifying background of trouble occurred.

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
flaws on the piston rod. And the method of
using the machines should be explained so YT-B87
that the same kind of trouble does not Confirm the symptoms of the trouble.
reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and
returned are evidence so they should be
handled with care. Protect them from entry of
water, soils, etc. into port of hydraulic unit,
etc. and return them. And also use care not to
flaw and damage those surfaces. YR-B76
Diagnosing fail by means troubleshooting.
41-1
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ; MECHATRO CONTROL
Electric Hydraulic
Arm variable recirculation

Control valve Motor Cylinder Other
Hi pressure sensor (P1)
Hi pressure sensor (P2)
P1 Pump proportional
P2 Pump proportional
Low pressure sensor
proportional valve
Proportional valve
proportional valve
proportional valve
Actuator
Safety lock lever

Travel 1-2spead
Travel straight
Solenoid valve
Solenoid valve
Solenoid valve
P1 bypass cut
P2 bypass cut
Arm variable recirculation

Swing P/B
Travel straight valve

valve
valve
P2 bypass cut valve

P1 bypass cut valve
Boom conflux valve
Travel right motor

Arm conflux valve
Travel left motor
Boom lock valve
Arm lock valve

S S S P P P P S S S P P
Swing motor
Travel right
E E E S S S S V V V S S
Travel left
│ │ │ V V V V │ │ │ V V
Bucket
Bucket
22 23 1 │ │ │ │ 1 3 4 │ │
Swing
Boom
～
Boom
valve
Arm
A B C D
Arm
Operating condition 1 2
10
Boom up inching operation ○ ○ ○ ○ ○ ○ ○
Boom up full lever operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Boom down operation ○ ○ ○ ○ ○ ○ ○
Arm out inching operation ○ ○ ○ ○ ○ ○ ○

Independent operation
Arm out full lever operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm in inching operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm in full lever operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Heavy duty arm in full lever
operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Bucket digging ○ ○ ○ ○ ○ ○
Bucket dump ○ ○ ○ ○ ○ ○
Swing operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Travel LH / RH operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(1st. speed)
Travel LH / RH operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(2nd speed)
41-2
3. TROUBLESHOOTING OUTLINE ; MECHATRO CONTROL
OPERATING Pilot secondary pressure Pressur sensor Pump proportional valve Proportional valve
Arm variable recirculation valve

ATT High pressure Low pressure P2 bypass cut proportional valve
Lever position Att Travel P1 P2
TRAVEL (Pump) (Pilot) Travel straight proportional valve
P1 bypass cut proportional valve
ATT Arm variable recirculation proportional valve
Bucket digging
Neutral ; 665mA
Bucket dump Max Max
Control lever at More than More than Min ; 323mA
Approx 35kgf/cm2 Approx 24kgf/cm2 Max 742 mA Max 742 mA
Boom up full stroke 2.9V 3.7V
(500psi) or over (340psi) or over P2 bypass cut proportional valve
Boom down
Neutral ; approx 350mA
Swing left
Max ; 700mA
Swing right
Travel straight proportional valve
Arm in
Neutral ; approx 350mA
Arm out
Max Neutral Neutral
Max Max ; 532mA
TRAVEL Approx Less than Less than (Hi idle) (Hi idle)
Lever at neutral Approx6.0kgf/cm2
6.0kgf/cm2 0.5V 0.5V
(85psi) or less P1 bypass cut proportional valve
Forward (85psi) or less 350mA 350mA
Reverse Neutral ; approx 350mA
Max ; 700mA
41-3
4. CHECK POINTS FOR MECHATRO SYSTEM (FOR TROUBLESHOOTING)
4.1 ATTACHING POSITION OF SENSOR AND ELECTRIC EQUIPMENTS
(1) Position of under floor harness and proportional valve
block STRAIGHT PSV. (PSV-C) EXTRA DIS PRESS SOL. (SV-24) SAFETY LOOK LEVER SOL. (SV-4)
TRAVEL TO INST-HARNESS
P1 BY-PASS CUT PSV. TRAVEL TWO-SPEED SOL. (SV-3)
OPT. EXTRA (PSV-D)
PRESS. SENSOR
(P1 OPT.) (SE-20)
P2 BY-PASS
CUT PSV. (PSV-B)
ARM VALUABLE
RECIRCULATION PSV.
(PSV-A)
PRESS, SENSOR
(TRAVEL LEFT) (SE-10)
PRESS, SENSOR
(TRAVEL RIGHT) (SE-9)
OPT. N&B
PRESS. SENSOR
(P2 OPT.) (SE-11)
HYD. FUID TEMP SW.

(SW-37)
TRAVEL TWO-SPEED SWITCH GROUND CONNECTOR SWING PARKING SOL.
(SV-1)
Fig. 1 Attaching position of under floor sensor and proportional valve
connector
(2) Position
P of high pressure sensor and pump proportional
valve
PROPORTIONAL SOL.
(PUMP P1) (PSV-P1)
PROPORTIONAL SOL.
(PUMP P2) (PSV-P2)
PRESS. SENSOR (PUMP P1) (SE-22)

PRESS. SENSOR (PUMP P2) (SE-23)
Fig. 2 Position of high pressure sensor and pump proportional
valve
41-4
(3) Attaching position of low pressure sensor Tightening torque Tightening torque
3.5kgfy m (25 lbsy ft ) 3.5kgfy m (25 lbsy ft )
(SE-2) BUCKET DUMP (SE-3) BOOM UP
Tightening torque
3.5kgfy m (25 lbsy ft ) Tightening torque
(SE-5) SWING L&R 3.5kgfy m (25 lbsy ft ) Tightening torque
(SE-7) ARM IN 3.5kgfy m (25 lbsy ft )
(SE-4) BOOM DOWN
VIEW Ⅰ
Tightening torque
3.5kgfy m (25 lbsy ft )
(SE-1) BUCKET DIGING
Ⅱ
Tightening torque
3.5kgfy m (25 lbsy ft )
(SE-8) ARM OUT VIEW Ⅱ
Fig. 3 Low-pressure sensors attached to C/V and multi Tower block
41-5
4.2 EQUIPMENT
(1) Solenoid proportional valve block
4 3 1
T
T
Tightening torque P1
0.7±0.07kgfym
(5±0.5 lbsy ft ) D C B A
HYDRAULIC SYMBOLS
4 3 1
P1
D C B A
P1
Fig. 4 Proportional valve block
(2) Low pressure sensor (3) High pressure sensor
AMP MQS-TYPE 3P (B-TYPE)

A OTHER PARTY CONNECTOR (FEMAIL) A
HOUSING
TERMINAL (GOLD-PLATING)
TERMINAL NO.
1-COMMON
2-OUT PUT (+)
3-POWER SUPPLY (+)
19×21.9 HEX
HEX 22
VIEW A
O RING P11 O RING P14
PF3/8
PF1/4
DETAIL OF SENSOR CONNECTOR
41-6
E115SR
E135SR
SECTION 42 TROUBLESHOOTING (HYDRAULIC)
TABLE OF CONTENTS
1. Trouble diagnosis: hydraulic system....................................................................... 42-1
2. Troubleshooting ..................................................................................................... 42-2

1. TROUBLE DIAGNOSIS ; HYDRAULIC SYSTEM
Oil pressure
Component Pump Control valve
Swing
Travel motor Cylinder Other valve Proportional valve block Relief valve
motor
Travel straight proportional valve

Travel Swing
Safety lock lever sol. valve

Arm variable recirculation valve
Travel 1-2speed sol. valve
Swing parking sol. valve
Counter balance check valve
Pilot valve (1-2speed select)
Counter balance valve
Check valve for relief
Travel straight spool
P2 bypass cut valve

P1 bypass cut valve
Boom conflux spool
Pilot valve (travel)

Load check valve
Pilot valve (ATT)
Main relief valve

Pilot relief valve
Reduction parts
Bucket cylinder
Right shockless
Right shockless
Bucket digging
Boom lowering
E/G revolution
Boom cylinder
Parking brake
Parking brake
Left shockless
Left shockless
Bucket dump
Shuttle valve
Boom raising
Arm cylinder
Bypass valve
Bucket spool
Travel spool
Swing spool
Swivel joint
Boom spool
Pilot pump
Classification
Lock valve
Arm spool
P1 pump
P2 pump
Arm out
Group No.
Arm in
Motor
Trouble
Device No. 1 2 3 4 5 6 7 8 9 10 11
No operation is possible. ○ ○ ○ ○ ○ ○ ○
(1) Machine operates freely even
though lever is in neutral. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
All actions ○ ○ ○ ○ ○ ○
Speed is low.
Bucket digging and dump ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Down ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(2) Boom
Attachment operation
Up ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm in conflux ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm out conflux ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Power lacks.
All motions ○ ○ ○ ○ ○ ○
Bucket digging and dump ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(3)
Boom Up ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Hydraulic systems
Arm in ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Bucket digging ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Fine operation
impossible.
Boom Up&Down ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(4)
Swing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm in and out ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Travel 1, 2 speed change
(5) impossible ○ ○ ○ ○
Travel operation
(6) Travel speed is low. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

(7) Travel power is low. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Machine cannot travel straight
(8) or deviates in one direction or ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
zigzags.
Machine does not stop still on a
(9) slope. ○ ○ ○ ○ ○ ○ ○
(10) Swing motion does not work.
Swing operation
(11) Swing speed is low. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Swing power is poor. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(12)
Swing motion drifts very large. ○ ○ ○ ○ ○ ○
Swing parking is not held on a
(13) slope. ○ ○ ○ ○ ○
42-1
2. TROUBLESHOOTING
(1)-1
No operation is possible.
24V is alive across orange/white and black terminals of connector NO To electric

(CN-253F) of lever lock solenoid (SV-4). troubleshooting
YES
Is the main relief valve pressure
Only the hydraulic pilot system NO within a standard value? NO Pilot relief valve NO Replace relief
(ATT and travel motion) not pressure is about
P1,P2 ;350kgf/cm2(4980psi),
※1 valve.
operative? 50kgf/cm2 (710psi).
(OPT)-P4 ; 210kgf/cm2(2990psi)
YES YES Inspect or replace pump.
YES Also inspect pump
coupling.
Inspect if there is any other cause.
Machine does not operate if

Travel straight valve port PTb NO connector(CN-258F) for travel NO
To electric troubleshooting
pressure is about 5.7kgf/cm2 straight proportional valve(PSV-C) is
(81psi) disconnected.
YES YES Replace proportional valve NG Replace proportional valve

for travel straight. block.
NO
The primary pressure of pilot pump is about 50kgf/cm2 (710psi). Inspect or replace pilot pump and pilot relief valve.
YES
NO
The pilot valve P port inlet pressure is approx. 50kgf/cm2 (710psi). Inspect or replace lever lock solenoid valve.
YES
NO
The secondary pressure of pilot valve is approx. 50kgf/cm2 Inspect or replace pilot valve.
Note ; ※1 marked shows E135SR.

In the case of E115SR value is P1,P2 330kgf/cm2 (4690psi).
42-2
(1)-2
Machine moves freely with levers in neutral.
Machine stops moving freely if the connector (CN-257F,CN-259F) for YES

proportional valve P1,P2 bypass cut is disconnected. To electrical troubleshooting
NO
Pump NO The secondary pilot pressure of the system YES Inspect or replace pilot
delivery that is moving freely is generated when the
pressure in lever is in neutral. valve.
unloaded
NO
condition is
approx. The spool returning spring of the circuit that YES Inspect or replace spool
is moving freely is broken. assy and pilot cover.
5kgf/cm2
(71psi)or NO
lower. The spool of the system that is operating NO The outer YES
circumference of Replace spool assy.
YES freely moves smoothly by hand. (Remove
pilot cover.) spool is scratched.
NG
YES NO
Replace control valve.
Pilot pressure at ports PCa, PCb (P1, P2 YES Inspect or replace the proportional valve for bypass cut
bypass cut valve) is approx. 5.5kgf/cm2 valve that is defective.
(78psi).
NG
NO
Inspect or replace proportional valve block.
Return spring of bypass cut valve spool is YES Inspect or replace bypass cut valve spool assy and pilot
broken. lid.
NO
Bypass cut valve spool moves smoothly by NO Spool is scored on YES Replace bypass cut valve
hand. (together with P1 and P2 bypass cut inspection. spool assy.
valves)
NO NG
YES

When the lock valve, body seat and selector
Boom or YES YES Replace lock valve and correct body seat or replace
parts were inspected, faults such as scratch
arm? body or replace selector.
were discovered.
NO NO
Faults such as scratch are discovered in load YES
check valve and seats in conflux passage and Replace check valve, correct body seat or replace body.
recirculation passage.(CCb,CCa, CAr)
NO
Spool of the circuit that operates freely is scored on inspection. Replace spool assy.
NO Inspect or replace NG Inspect the cylinder of the circuit that NG Inspect or replace control
overload relief valve. operates freely and replace if faulty. valve.
(Inside leak)
42-3
(2)-1
All attachment motions are slow.
(Service diagnosis)
Command current readings of pump NO The sum of pump NO To electric
proportional valve are at standerd levels(below) pressures(P1+P2)during check
during operation. troubleshooting.
operation is
P1 ; approx. 645mA by bucket operation, ※1 460kgf/cm2 (6540psi).
P2 ; approx. 645mA by swing operation, ※2
YES Inspect or replace boost
YES check, bypass check piping.
Do motions get normal if the coupler(PSV-C) for YES
travel straight proportional valve is To electric troubleshooting.
disconnected?
NO
NO Inspect or replace pilot pump
Primary pilot pressure is 50kgf/cm2 (710psi). and pilot relief valve.
YES
Secondary pilot pressure at PTb port (travel YES Inspect or replace travel
straight) is approx. 5.7kgf/cm2 (81psi). straight proportional valve.
NO NG
Inspect or replace
proportional valve block.
NO Inspect or replace travel

Return spring of travel straight spool is broken. straight spool assy and pilot
cover.
YES
NO Outer circumference of travel YES Replace travel straight spool
Travel straight spool moves smoothly by hand.
straight spool is scored.
(Remove the pilot cover.) assy.
YES NO NG
Main relief pressure lies within standard level NO Inspect or replace main relief NG Replace control valve or
P1,P2 ; 350kgf/cm2 (4980psi), ※3 valve. pump.
YES
Note ; ※1~※3 marked show E135SR.

In the case of E115SR values are ※1 ; 645mA,
※2 ; 640mA and ※3 ; 330kgf/cm2 (4690psi).
42-4
(2)-2
Only the bucket motion is slow.
Is the motion normal if connector (CN-257F) for P2 YES

bypass cut proportional valve is disconnected? To electrical troubleshooting.
NO
Secondary pilot pressure at PBc, PAc ports (bucket NO
digging and dump ports) is 50kgf/cm2 (710psi). Inspect or replace pilot valve.
YES
(Service diagnosis) Pump pressure during check operation lies
Command current readings of pump NO within standard value(below). YES To electrical
proportional valve are within standard P1 ; digging approx 50kgf/cm2(710psi) troubleshooting.
levels(below) during full lever operation. dump approx 150kgf/cm2(2130psi)
655mA in bucket operation, ※1 P2 ; approx 5kgf/cm2(71psi)
YES
NO Inspect or replace boost NG
Inspect or replace control valve.
check, bypass check piping.
Relief pressure lies within standard levels(below) Inspect overload relief valve
NO Relief pressures for both YES
when bucket operation is changed. digging and dump operations on the faulty pressure side
350kgf/cm2(4980psi), ※2 are abnormal. and replace valve if defective.
YES NO Confirm the check valve
before main relief valve for NG
control valve. Check the seat Replace control valve.
of it as well. (CMR1,CMR2)
YES
Return spring for bucket spool is broken. Replace bucket spool assy.
NO
Bucket spool moves smoothly by hand. (Remove NO Outer circumference of YES
pilot cover.) Replace bucket spool assy.
bucket spool is scored.
YES NO NG
Is the motion slow if coupler for travel straight NO To electric troubleshooting.

proportional valve is disconnected? (to“All motions are slow.”)
YES
Pilot pressure at port PTb (travel straight) is NO Inspect or replace travel
approx. 5.7kgf/cm2 (81psi). straight proportional valve.
YES NG
Inspect or replace
Return spring for travel straight spool is broken.
proportional valve block.
NO YES Inspect travel straight spool
assy and pilot cover and
replace them if faulty.
NO Outer circumference of travel YES Replace travel straight spool

Travel straight spool moves smoothly by hand.
straight spool is scored. assy.
YES NO NG
Is the motion slow if pump delivery ports P1 and NO

P2 are exchanged. Inspect or replace pump.
YES
Note ; ※1~※2 marked show E135SR. Inspect bucket cylinder for oil
tightness and replace if
In the case of E115SR values are ※1 ; 640mA defective.
and ※2 ; 330 kgf/cm2 (4690psi).
42-5
(2)-3 Service Diagnosis 26 ; mechatoronic (C-1) controller

Only the boom raise motion is slow.
(Service diagnosis 26)
Control current of P2 bypass cut proportional NO
valve is approx. 670mA when full lever To electric troubleshooting.
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port PCa (P2 bypass NO Inspect or replace P2 bypass NG Inspect or replace
cut valve) is approx. 25kgf/cm2 (360psi). cut proportional valve. proportional valve block.
YES
Pilot pressure at PAb, PB1 ports (boom raise NO Inspect or replace ATT pilot
and boom conflux) is 50kgf/cm2 (710psi). valve.
YES
Does the pump delivery
(Diagnosis 24,25)
pressure lie at normal levels
Command current readings for pump NO during check operation? NO
To electric troubleshooting.
proportional valve lie within standard levels Normal values for P1 & P2 ;
(below) during the above operation. approx. 130kgf/cm2(1850psi)
P1 ; approx. 650mA, ※1 YES
P2 ; approx. 650mA, ※2 Hasn't the weight changed by NO Change ATT to normal one
YES the change of ATT's? and reconfirm.
YES
Inspect or replace boost NG Inspect or replace control
check, bypass check piping. valve.
Relief pressure lies within standard level

(below) when boom up lever is turned to the full. NO Adjust boom port relief NG Replace overload relief valve
350kgf/cm2(4980psi), ※3 pressure. at port Ab (boom head side).
YES
Return spring for P2 bypass cut valve spool is YES Inspect or replace P2 bypass
broken. cut spool assy and pilot cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut valve spool moves smoothly by
bypass cut valve spool is assy.
hand. (Remove pilot cover.)
scored.
YES NG
NO
Return spring of boom spool is broken. YES Inspect or replace boom spool
(Remove pilot cover.) assy and pilot cover.
NO
Boom spool moves smoothly by hand. NO Outer circumference of boom YES
Replace boom spool assy.
(Remove pilot cover.) spool is scored.
YES NO NG
YES Inspect or replace boom spool

Return spring for boom conflux spool is broken. assy and Pilot cover.
NO
NO Outer circumference of boom YES Replace boom conflux spool
Boom conflux spool moves smoothly by hand. conflux spool is scored. assy.
YES NO NG
Note ; ※1~※3 marked show E135SR.

In the case of E115SR values are ※1 ; 635mA,
※2 ; 635mA and ※3 ; 330kgf/cm2 (4690psi).
42-6
(2)-4
Motions other than boom down are slow.
Control current for travel straight proportional
valve is approx. 350mA. NO
To electric troubleshooting
(Are the motions slow if coupler (PSV-C) for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PTb (travel straight) is YES Inspect or replace travel NG Inspect or replace
approx. 5.7kgf/cm2(81psi). straight proportional valve. proportional valve block.
NO
Inspect or replace travel
YES
Return spring for travel straight spool is broken. straight spool assy and pilot
cover.
NO
Outer circumference of travel YES
Travel straight spool moves smoothly by hand. NO Replace travel straight spool
(Remove pilot cover.) assy.
YES NO NG

(2)-5
Only arm in action is slow.

Control current readings for arm recirculation NO
proportional valve are about 460mA when To electric troubleshooting
H-mode arm in lever is turned to the full.
YES
Inspect or replace arm
Pilot pressure at arm variable recirculation is NO NG Inspect or replace
variable recirculation
port Ais approx. 12.6kgf/cm2(180psi). proportional valve block.
proportional valve.
YES
Command current readings for pump Does the pump delivery pressure
proportional valve lie within standard levels NO lie at normal levels during check YES
(below) during the above operation. operation? To electric troubleshooting
P1 ; approx. 400mA, ※1 Normal values for
P1 ; approx. 5kgf/cm2(71psi)
P2 ; approx. 700mA, ※2
P2 ; approx. 100kgf/cm2(1420psi)
YES
NO Inspect or replace boost
check, bypass check piping.
Secondary pilot pressure at PAa, PLC2 ports NO
(arm in, lock valve release) is approx. 50kgf/cm2 Inspect or replace pilot valve.
(710psi).
YES
Adjust or replace overload
Relief pressure lies within standard levels NO
relief valve on the arm head
when arm in is operated. (H) side.
350kgf/cm2(4980psi), ※3
YES
Inspect or replace arm spool,
Arm spool or recirculation spool return spring is YES
recirculation spool and pilot
broken. cover.
NO Outer circumference of arm
Arm spool or recirculation spool moves smoothly NO YES Replace arm spool or
spool or recirculation spool is
by hand. (Remove pilot cover.) recirculation spool assy.
scored.
YES NO NG

Note ; In the case of E115SR values are ※1 ; 400mA,
※2 ; 680mA and ※3 ; 330kgf/cm2 (4690psi).
42-7
(2)-6
Only arm out operation is slow.

Command current for P1 bypass cut proportional NO
valve is approx. 670mA when arm out lever is To electrical troubleshooting
shifted to the full.
YES
Secondary pilot pressure at port Pbc NG
(P1 bypass cut valve) is approx. 25kgf/cm2
NO Inspect or replace P1 bypass Inspect or replace
cut proportional valve. proportionate valve block.
(360psi).
YES
Secondary pilot pressure at port PBa (arm out) NO
Inspect or replace pilot valve.
is approx. 50kgf/cm2 (710psi) or over.
YES
(Service diagnosis 24,25)
Command current readings for pump
proportional valve lie within standard levels Pump delivery pressure lies
(below) during the above operation. NO within standard level during YES
the above operation. To electrical troubleshooting
P1 ; approx. 550mA, ※1
P2 ; approx. 550mA, ※1 P1,P2 ; approx.
180kgf/cm2(2560psi), ※2
YES Inspect or replace boost
NO check, bypass check piping.
Relief pressure lies within standard level

NO Inspect or replace overload
(below) when arm out is turned to the full. relief valve at port Ba (arm
350kgf/cm2(4980psi) ※3 rod side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken. assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
spool is scored. Replace arm spool assy.
(Remove pilot cover.)
YES NO NG
Return spring of P1 bypass cut valve spool is NO Inspect or replace P1 bypass cut
broken. valve spool assy and pilot cover.
YES Outer circumference of P1
P1 bypass cut valve spool moves smoothly by NO YES Replace P1 bypass cut valve
bypass cut valve spool is
hand.(Remove pilot cover.) scored. spool assy.
YES NO NG
Inspect or replace arm

NO conflux spool assy and pilot
Arm conflux spool return spring is broken.
cover.
YES
Arm conflux spool moves smoothly by hand. NO Outer circumference of arm YES Replace arm conflux spool
(Remove pilot cover.) conflux spool is scored. assy.
YES NO NG
Note ; In the case of E115SR values are ※1 ; 530mA,

※2 ; 200kgf/cm2(2840psi) and ※3 ; 330kgf/cm2(4690psi).
42-8
(3)-1
All ATT operating power is poor.
Each independent operating speed is within a NO Refer to“All motions are

standard value. slow.”.
YES
Relief pressure lies within standard level NO Adjust main relief pressure NG Replace the relief valve of
P1,P2 ; 350kgf/cm2(4980psi), ※1 of control valve. main control valve.
YES
Primary pilot pressure is approx. 50kgf/cm2 NO Replace pilot pump and relief
Adjust pilot relief pressure. valve.
(710psi).
YES Inspect or replace travel
YES
Travel straight spool return spring is broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves smoothly by hand. NO Outer circumference of travel YES Replace travel straight spool
(Remove pilot cover.) straight spool is scored. assy.
YES NO NG
Inspect or replace control

valve or pump.
(3)-2
Bucket digging power is poor.
No-load independent operating speed is within a NO Refer to “Only bucket

standard value. motion is slow.”
YES
Relief pressure lies within standard level NO Adjust overload relief valve NG Replace overload relief valve
(below) when bucket digging lever is turned to on bucket digging side. at port BC (bucket head side).
the full. 350kgf/cm2 (4980psi), ※1.
( )
YES
Secondary pilot pressure at port PBC (bucket NO

digging) is approx. 50kgf/cm2 (710psi).
YES
YES Inspect or replace bucket
Bucket spool return spring is broken. spool assy and pilot cover.
NO
Bucket spool moves smoothly by hand. (Remove NO Outer circumference of YES
bucket spool is scored. Replace bucket spool assy.
pilot cover.)
YES NO NG
Replace control valve or

pump.

In the case of E115SR value is 330kgf/cm2 (4690psi).
42-9
(3)-3
Boom up operating power is poor.
No-load independent operating speed is within a NO Refer to“Only boom raise

standard value. motion is slow.”
YES
Relief pressure lies within standard level NO Adjust or replace overload relief
Adjust main relief on control NG
(below) when boom up lever is turned to the full. valve at port Ab (boom head
350kgf/cm2(4980psi), ※1 valve. side).
YES
Secondary pilot pressure at boom raise PAb port NO
and boom conflux PB1 port is 50kgf/cm2(710psi)
YES
Boom spool return spring is broken. assy and pilot cover.
NO
NO Outer circumference of boom YES
Boom spool moves smoothly by hand. Replace boom spool assy.
spool is scored.
YES NO NG

Boom conflux spool return spring is broken. assy and pilot cover.
NO
NO Outer circumference of boom YES
Boom conflux spool moves smoothly by hand. Replace boom conflux spool assy.
conflux spool is scored.
YES NO NG
Inspect or replace control valve

or pump.

In the case of E115SR value is 33 0kgf/cm2 (4690psi).
42-10
(3)-4
Arm in power is poor.
No-load independent operating speed is within a NO Refer to“Only arm in is

standard value. slow.”.
YES
Adjust or replace overload
Relief pressure during arm in for both P1 and NO Adjust main relief on control NG
relief valve at port Aa (on
P2 pumps lies within standard levels. valve. arm head side).
P1,P2 ; 350kgf/cm2(4980psi), ※1
YES
Control current readings for arm recirculation NO To electric trouble shooting.
proportional valve are about 460mA when
Refer to“Only arm in is
H-mode arm in lever is turned to the full.
YES
NO Inspect or replace arm NG Inspect or replace

Pilot pressure at arm variable recirculation port variable recirculation
Pis is about 12.6kgf/cm2(180psi) proportional valve block.
proportional valve.
YES
Secondaly pilot pressure at arm in port PAa and NO
arm lock valve release PLC2 port is Inspect or replace pilot valve.
50kgf/cm2(710psi)
YES
YES Inspect or replace arm spool
Arm spool return spring is broken. assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
Replace arm spool assy.
(Remove pilot cover.) spool is scored.
YES NO NG
Arm variable recirculation spool return spring is YES Inspect or replace arm spool
broken. assy and pilot cover.
NO
NO Outer circumference of arm YES Replace arm variable
Arm variable recirculation spool moves smoothly
variable recirculation spool is recirculation spool assy.
by hand. (Remove pilot cover.)
scored.
YES NG
NO
Replace control valve or

pump.

42-11
(4)-1
Machine can not perform fine operation of bucket digging and dump.
Machine returns normal if connector of P1 bypass cut proportional YES

valve (PSV-D) is disconnected. To electric troubleshooting.
NO
Unload pressure of P1 NO No-load independent operating NO Refer to “Only bucket
pump is less than 5kgf/cm2 speed is within a standard
motion is slow.”.
(71psi) when bucket digging value.
lever is at neutral.
YES
YES Secondary pilot pressure at
port PCb (P1 bypass cut valve) YES Inspect or replace P1 NG Inspect or replace
bypass cut proportional
is approx. 5.7kgf/cm2 (81psi) proportional valve block.
valve.
when lever is at neutral.
NO
P1 bypass cut spool return YES Inspect or replace P1 bypass
spring is broken. cut spool assy and pilot cover.
NO
P1 bypass cut spool moves NO Outer circumference of YES Replace P1 bypass cut
smoothly by hand. (remove P1 bypass cut spool is
spool assy.
pilot cover.) scored.
NG
YES NO
Secondary pressure of pilot Replace control valve.

valve is approx. 5.5kgf/cm2
(78psi) when bucket close NO
lever is just shifted a little.
YES
Pilot spool return spring is YES Inspect or replace bucket
broken. spool assy or pilot cover.
NO
Bucket spool moves NO Outer circumference of bucket YES
smoothly by hand. (Remove Replace bucket spool assy.
spool is scored.
pilot cover.) NG
NO
YES
42-12
(4)-2
Machine can not perform fine operation of boom up and down motions.
Machine gets normal if connector of P1 bypass cut proportional YES

To electrical troubleshooting.
valve (PSV-D) is disconnected.
NO
Unload pressure of P1
pump is less than 5kgf/cm2 NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
port PCb (P1 bypass cut valve) proportional valve for
(71psi) when boom lever is proportional valve
is approx. 5.7kgf/cm2 (81psi). P1 bypass cut valve.
at neutral. block.
NO
YES
Return spring of P1 bypass cut YES Inspect or replace P1 bypass
spool is broken. cut spool assy and pilot cover.
NO Outer circumference of
P1 bypass cut spool moves NO P1 bypass cut spool is YES Replace P1 bypass
cut spool assy.
smoothly by hand. scored.
YES NO NG
Secondary boom pilot pressure is approx. NO

5.5kgf/cm2 (78psi) when lever is just shifted.
YES
Return spring of boom spool is broken. assy and pilot cover.
NO
Boom spool moves smoothly NO Outer circumference of boom YES
by hand. spool is scored. Replace boom spool assy.
YES NO NG
Does boom lock valve move NO

smoothly by hand? Inspect or replace lock valve.
YES
42-13
(4)-3
Machine can not perform fine swing operation.
Machine gets normal if connector (CN-257F) for P2 bypass cut YES

proportional valve (PSV-B) is disconnected.
NO
Machine gets normal if connector (CN-254F) for swing parking YES
brake solenoid (SV-1) is disconnected. To electrical troubleshooting
NO
Secondary pressure of swing pilot valve is approx. 6kgf/cm2 YES Inspect or replace swing NG Inspect or replace
(85psi), while pilot pressure of parking brake solenoid valve is parking solenoid valve. proportional valve
0kgf/cm2 (0psi).
block.
NO
Unload pressure of P2 Pilot pressure of port PCa (P2
pump is approx. 5kgf/cm2 NO bypass cut valve) is approx. YES Inspect or replace NG Inspect or replace
proportional valve for
(71psi) or less when swing 5.7kgf/cm2 (81psi) when swing proportional valve
P2 bypass cut valve.
lever is at neutral. lever is at neutral. block.
YES NO
Return spring for P2 bypass cut YES Inspect or replace P2 bypass
spool is broken. cut spool and pilot cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES Replace P2 bypass
smoothly by hand. (Remove P2 bypass cut spool is
cut spool assy.
pilot cover.) scored.
NG
YES NO
Secondary pilot pressure of parking brake solenoid valve is

NO Inspect or replace swing NG Inspect or replace
0kgf/cm2 (0psi) when secondary pressure of pilot valve is proportional valve
approx. 6kgf/cm2 (85psi). parking solenoid valve.
block.
YES
Secondary pressure of pilot

valve at startup is approx. NO
5.5kgf/cm2 (78psi).
YES
Return spring for swing YES
spool is broken. Replace swing spool assy.
NO
Swing spool moves NO Outer circumference of swing YES
smoothly by hand. spool is scored. Replace swing spool assy.
YES NO NG
42-14
(4)-4
Machine can not perform fine operation of arm in and out.
Machine gets normal if connector (CN-257F) of P2 bypass cut YES

proportional valve (PSV-B) is disconnected. To electrical troubleshooting
NO
P2 pump unload pressure is NO Secondary pilot pressure at NO Inspect or replace NG Inspect or replace
less than 5kgf/cm2 (71psi) port PCa (P2 bypass cut valve) proportional valve for proportional valve
when arm lever is at is approx.5.7kgf/cm2 (81psi). P2 bypass cut valve. block.
neutral.
YES
YES Return spring of P2 bypass cut YES Inspect or replace P2 bypass
spool is broken. cut spool assy and pilot cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES Replace P2 bypass
smoothly by hand. P2 bypass cut spool is
cut spool assy.
(Remove pilot cover.) scored.
NG
YES NO
Secondary pressure is Replace control valve.

approx. 5.5kgf/cm2 (78psi)
when arm lever is shifted a NO
little.
YES
Return spring of arm spool YES
is broken. Replace arm spool assy.
NO
Arm spool moves smoothly NO Outer circumference of arm YES
by hand. spool is scored. Replace arm spool assy.
YES NO NG
Arm lock valve moves NO

Inspect or replace lock valve.
smoothly by hand.
YES
(5)
Travel 1st and 2nd speeds can not be changed over.
24V is alive across light green/black and black NO

of connector (CN-255F) for travel 1-2 speed To electrical troubleshooting
solenoid (SV-3).
YES
Pilot pressure of travel 1-2 speed select solenoid NO Inspect or replace travel 1-2 NG Inspect or replace
(SV-3) is approx. 50kgf/cm2 (710psi). speed select solenoid valve. proportional valve block.
YES
Travel 1-2 speed select can not be done in heavy NO Inspect travel motor (throttle in passage to 1-2 select valve, inclusion of
duty condition on a steep slope or on a muddy
foreign matter in shuttle valve, etc.) or replace it.
land.
YES Since the delivery rate of pump is small at heavy duty, the difference
between 1st and 2nd speeds gets smaller. This makes you feel sometimes
that speed is not changed. But this is normal.
42-15
(6)
Travel independent speed is low.
Is the travel motion in both speeds slow

at no load? NO Refer to “Travel
(H-mode, Hi idle, 1st-speed, sprocket independent deviates.”.
revolution ; approx. 33rpm)
YES
Since the pump delievery
Machine is slow on steep slopes and in YES rate is decreased at high
muddy fields? load, travel speed is
NO decreased, but it is normal.
Pump pressure
Current readings of pump proportional NO during travel idling NO Inspect or replace NG Inspect or replace
valve lie within standard levels during is 50~70kgf/cm
2
boost check, bypass
control valve.
both travel speeds. (710~1000psi). check piping.
P1,P2;approx. 727mA
YES
YES Secondary pressure for travel NO Inspect or replace pilot valve
pilot valve is for travel.
approx.24kgf/cm2 (340psi).
YES
(Service diagnosis 22) To electrical troubleshooting.
Control current of travel straight
proportional valve is approx. 350mA.
NO
Is the machine slow even if connector To electrical troubleshooting.
for travel straight proportional valve
is disconnected.
YES
Is the pivot turn possible? NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
port PTb (travel straight valve) travel straight proportional valve
(in both directions)
is approx. 5.7kgf/cm2 (81psi). proportional valve. block.
YES
NO
Return spring of travel straight
straight spool assy and pilot
spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of YES Replace travel
travel straight spool is
smoothly by hand. straight spool assy.
scored.
YES NG
NO
Return spring of travel YES Inspect or replace travel

spool is broken. spool assy and pilot cover.
NO
Travel spool moves NO Outer circumference of travel YES
smoothly. spool is scored. Replace travel spool assy.
YES NO NG
Relief pressure during both Replace control valve.

travel speeds lies within NO Inspect or replace travel
standard value.
motor relief valve.
350kgf/cm2 (4980psi), ※1
motor.
Note ; ※1 marked show E135SR.

42-16
(7)
Travel power is poor.
Both travel speeds are slow during idle

traveling. NO Refer to “Travel
(H-mode, Hi idle, 1st-speed, sprocket independent is slow.”.
revolution ; approx. 33rpm)
YES
Command current for travel straight NO
proportional valve is approx. 350mA.
YES
YES Since the delivery rate of pump is small and travel speed is
Power lack is felt on a steep slope or in
low in heavy duty condition, power lack is felt in some cases,
muddy fields.
but it is normal.
NO
Is the secondary pilot NO Inspect or replace travel pilot
pressure for travel approx.
valve.
24kgf/cm2 (340psi)?
YES
Is a pivot turn possible? NO Pilot pressure at port PTb NO Inspect or replace NG Inspect or replace
(travel straight valve) is travel straight proportional valve
(in both directions)
approx. 5.7kgf/cm2 (81psi). proportional valve. block.
YES
YES
Return spring of travel straight
spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of YES Replace travel
travel straight spool is
smoothly by hand. straight spool assy.
scored.
YES NO NG
Return spring of travel YES Inspect or replace travel

spool is broken. straight spool and pilot cover.
NO
Travel spool moves NO Outer circumference of travel YES
smoothly by hand. spool is scored. Replace travel spool assy.
YES NO NG
Relief pressure lie within
standard value in both NO Inspect or replace travel
travel speeds. motor relief valve.
350kgf/cm2 (4980psi), ※1
YES
Inspect or replace travel
motor.

42-17
(8)-1
Machine does not travel straight.
Control current for travel NO

straight proportionate valve To electrical troubleshooting
(PSV-C) is 535mA.
YES
Secondary pilot pressure at
port PTb (travel straight NO Secondary pressure of travel NO Inspect or replace travel pilot
pilot valve is approx. 24kgf/cm2
valve) is approx. 17kgf/cm2 valve.
(340psi).
(240psi).
YES Inspect or replace NG Inspect or replace
YES travel straight proportionate valve block.
proportionate valve.

Return spring of travel
straight spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of travel YES Replace travel straight spool
smoothly by hand. straight spool is scored. assy.
YES NO NG
(8)-2
Machine deviates in travel independent motion.
In idle run, the right and the left crawlers rotate Does the machine deviates in
NO NO Inspect or replace control
at different speeds. (H-mode, Hi idle, opposite direction if delivery valve.
1st-speed) ports are exchanged?
YES YES
Pump pressure for P1 and P2
Current readings for travel straight NO lies within NO Inspect or replace control
proportional valve(PSV-C) for both P1 and P2 valve.
50~70kgf/cm2 (710～1000psi)
are approx.670mA during travel idling.
YES YES
Secondary pilot pressure for NO Inspect or replace travel pilot
travel is 24kgf/cm2 (340psi). valve.
YES
Relief pressure lie within

Machine deviates in opposite direction if the right NO standard valve in both travel NO Inspect or replace travel
and left pipes between control valve and travel motor relief valve.
speeds.
motor are exchanged and connected.
350kgf/cm2 (4980psi), ※1
YES
motor.

Return spring of travel straight spool is broken. straight spool assy and pilot
cover.
NO
NO Outer circumference of travel YES
Travel straight spool moves smoothly by hand. Replace travel straight spool
YES NO NG

2
Note ; In the case of E115SR value is ※1 ; 330kgf/cm (4690psi).
42-18
(9)
Machine drifts on a slope. (Machine can not be held on a slope.)
Machine can not be held on a slope when engine YES Inspect or replace travel
is off. motor.
NO
Secondary pilot pressure for travel is 0kgf/cm2 NO Inspect or replace remote
(0psi). control valve.
YES
YES Inspect or replace travel spool
Return spring of travel spool is broken. assy and pilot cover.
NO
NO Outer circumference of travel YES
Travel spool moves smoothly by hand. spool is scored. Replace travel spool.
YES NO NG
42-19
(10)
Swing motion dose not work.
Machine moves if connector(CN-254F) of swing YES

parking SOL(SV-1) is disconnected. To electrical troubleshooting
NO
Is the pilot pressure of parking SOL reduce to NO Inspect or replace swing NG
0kgf/cm2 (0psi)when the secondary pressure of Inspect or replace
pilot valve is 6kgf/cm2(85psi)? . parking solenoid. proportional valve block.
YES In case of a machine with a

multi select valve, check if
the condition returns normal
by vertical operation swing
lever.
Secondary pressure of swing pilot valve is NO Dirt or something is stuck in YES Inspect or replace slow return
the restrictor of slow return valve.
50kgf/cm2(710psi) for both ways.
valve.
YES NO
YES Inspect or replace swing spool
Return spring of swing spool is broken.
assy and pilot cover.
NO
NO Outer circumference of swing YES
Swing spool moves smoothly.(Remove pilot cover.) Replace swing spool assy.
spool is scored.
YES NO NG
YES Inspect or replace P2 bypass cut

Return spring of P2 bypass cut spool is broken..
valve spool assy and pilot cover.
NO
P2 bypass cut spool moves smoothly.(Remove NO Outer circumference of P2 YES
pilot cover.) bypass cut spool is scored. Replace P2 bypass cut assy.
YES NO NG
Swing relief pressure lies within standard level. NO Inspect or replace swing
285kgf/cm2(4050psi), ※1 motor relief.
YES NG
Machine can be held on a slope during swing NO Inspect or replace swing

motion. reduction unit and swing motor.
YES
Machine drifts very much when swing parking YES Inspect or replace swing
is released (arm in action) on a slope. motor.
NO Inspect or replace swing
reduction unit and swing motor.

42-20
(11)
Swing speed is slow.
Command current of P2 bypass cut proportional NO

valve (PSV-B) is 585mA when swing lever is To electrical troubleshooting
turned to the full.
YES In case of a machine with a
by vertical swing lever.
Secondary pilot pressure for swing motion is NO Dirt or something is stuck in YES
approx. 50kgf/cm2 (710psi) when lever is turned Inspect or replace slow return
the restrictor of slow return
to the full in either direction. valve.
valve.
YES NO NG
Secondary pilot pressure at PCa port (P2 bypass NO Inspect or replace P2 bypass NG Inspect or replace
cut valve) is approx. 25kgf/cm2 (360psi) when
cut proportional valve. proportional valve block.
swing lever is shifted to the full.
YES
YES Inspect or replace P2 bypass
Return spring of P2 bypass cut spool is broken. cut spool assy and pilot cover.
NO
P2 bypass cut spool moves smoothly by hand.
bypass cut spool is scored. assy.
YES NO NG
285kgf/cm2(4050psi), ※1
motor relief.
YES NG
NO
NO
Swing spool moves smoothly. Replace swing spool assy.
spool is scored.
YES NO NG

IN the case of E115SR value is 265kgf/cm2 (3770psi).
42-21
(12)-1
Swing power is poor.
Swing speed lies within standerd level NO Refer to“Swing speed is

; (H-mode HI idle is approx. 11rpm or over.) slow.”.
YES
YES Inspect or replace P2 bypass
Return spring of P2 bypass cut spool is broken. cut spool assy and pilot cover.
NO
P2 bypass cut spool moves smoothly by hand. bypass cut spool is scored. assy.
YES NO NG
In case of a machine with a
Secondary pilot pressure for swing motion is NO Dirt or something is stuck in YES
approx. 50kgf/cm2 (710psi) when lever is turned the restrictor of slow return Inspect or replace slow return
to the full in either direction. valve. valve.
YES NO
Inspect or replace pilot valve .
285kgf/cm2(4050psi), ※1 motor relief.
YES NG
NO
The pressure at the P/B(PG) port of swing motor NO Inspect or replace P2 bypass NG
is 50kgf/cm2(710psi) when swing lever is turned Inspect or replace
cut proportional valve. proportional valve block.
to the full or during arm in action.
YES
NO
Swing spool moves smoothly.(Remove pilot cover.) spool is scored. Replace swing spool assy.
YES NO NG

42-22
(12-2)
Swing motion drifts very large.
285kgf/cm2(4050psi), ※1
motor relief valve.
YES
Macine can be held on a slope during swing NO Replace the lining of swing
motion. motor parking brake.
YES
NO
In case of a machine with a

Secondary pilot pressure in swing motion NO Dirt or something is stuck in YES

decreases within 0.2second when swing lever is Inspect or replace slow return
the restrictor of slow return
brought to neutral. valve.
valve.
YES NO
Inspect or replace pilot valve .

NO
Swing spool moves smoothly by hand. Replace swing spool assy.
spool is scored.
YES NO NG

42-23
(13)-1
Swing parking is not held on a slope.
Command voltage is built up in swing parking YES

solenoid. To electrical troubleshooting
NO Inspect or replace swing

motor and reduction unit.
(13)-2
Abnormal sound is heard
during swing motion.
Abnormal sound occurs during swing relief YES Inspect or replace swing
action. motor relief valve.
NO
YES Inspect or replace swing
Abnormal sound occurs when swing motion stops.
shockless valve.
NO
Swing relief pressure lies within standard level. Control current for P2
NO bypass cut proportional valve NO
285kgf/cm2(4050psi), ※1 To electrical troubleshooting
is approx. 585mA.
YES
YES
Pressure at P2 bypass cut port PCa
NO Inspect or replace NG Inspect or replace
is about 20kgf/cm2(280psi)during P2 bypass cut proprotional valve
swing operation. proprotional valve. block.
YES
Main relief pressure lies YES Inspect or replace NO Inspect or replace
within standard level. swing motor relief
swing motor.
350kgf/cm2(4980psi), ※2 valve.
NO
Outer circumference of P2 YES Inspect or replaceP2 bypass
cut valve spool is scored. cut valve spool assy and pilot
cover.
NO
P2 bypass cut spool moves
smoothly by hand.
YES Inspect or replace main relief
(Remove pilot cover) valve.
NO
Outer circumference of P2 YES Replace P2 bypass cut valve
bypass cut valve spool is
spool assy.
scored.
NO NG
NO
Swing spool moves smoothly by hand. NO Outer circumference of swing YES
(Remove pilot cover) spool is scored. Replace swing spool assy.
YES NO NG
Machine can be held on a slope during swing NO Inspect or replace swing

motion. motor or reduction unit.
Inspect or replace swing motor
YES
pinion gear, swing bearing race
and swing bearing gear.
Note ; In the case of E115SR value are ※1 ; 265kgf/cm2 (3770psi) and ※2 ; 330kgf/cm2 (4690psi).
42-24
E115SR
E135SR
SECTION 43 TROUBLESHOOTING (ELECTRIC)
TABLE OF CONTENTS
1. Trouble diagnosis table: electric ............................................................................. 43-1
2. Self diagnosis table ............................................................................................... 43-4
3. Service diagnosis table .......................................................................................... 43-4

Electric systems
System
Option Swing operation Travel operation Attachment operation
Group No.
(3)
(2)
(4)
(8)
(14)
Fine operation Power is poor Speed is slow
impossible.
neutral.
(9) Machine
Trouble
Arm in
Boom up
All operate
All operate
and arm in.
Arm in, out
Swing left, right

straight are impossible.
Bucket digging
Bucket digging
Boom up, down
(11) Swing speed is slow

No motions operate.
(12) Swing power is poor

(7) Travel power is poor
1.
not stop still on a slope

Travel deviates, zigzags.
ATT travel combined and travel
Component
(10) Swing motion does not work
Auto idle stop is not actuated

(at
Only bucket speed is slow.

Pin No.
combined
Swing fine operation impossible

Only arm in motion is slow.
(13) Swing can not be held on a slope

Only boom up speed is slow.
(6) Travel independent speed is low.

Only arm out motion is slow.
operation Connector No.
with ATT
(5) Travel 1-2 speeds can not be changed

Motions are slow except boom up
drifts on a downhill and does

(1) Machine moves freely when lever is at
swing)
○
○
○
○
○
Boom up pressure sensor
Boom down pressure sensor
○
○
Arm in pressure sensor
・・・・
・・・・
3 6 9 12
2 5 8 11
1 4 7 10
○ ○
○ ○
○ ○
○ ○
○
○ ○
○ ○
Arm out pressure sensor
・
・
15
14
13
Bucket digging pressure sensor

・
・
18
17
16
Bucket dump pressure sensor

CN-11
・
・
21
20
19
○
○
○
○
○
○ ○ ○ ○ ○ ○ ○
○
○
○
Swing pressure sensor

・
・
27
26
25
○
Travel right pressure sensor
Operation pressure sensor
・
・
30
29
28
○ ○ ○ ○ ○ ○ ○ ○ ○
Travel left pressure sensor
・
・
33
32
Accelerator potentio
Accel motor start point indexing LS
P1 pump pressure sensor
○ ○
○ ○
○ ○
○ ○
3 6 9
2 5 8
・・・
・・・
Option P1 side pressure sensor
Alternator voltage
TROUBLE DIAGNOSIS ; ELECTRIC SYSTEM
Key SW ON
Key SW GLOW
CN-12
○
Travel 1-2speed SW.
○
○
○
Swing P/B release SW.
KPSS release SW.
Power supply & other signal
・
21
Engine speed sensor

Sealed grounding
Offset left
3 6
2 5
31 34 1 4 7 13 15 16 17 18 19 20 22 1 4
・・
・・
○ ○
○ ○
Offset right
CN-13
1
Engine water temp high LS

2
Engine oil pressure low LS

3
Air filter clogging LS

4
Conflux single select sw.

5
Overload sw.
6
7
Extra pressure sw.

8
Fuel level thermister

CN-14
C1 mechatro controller
Flow control connector

Switch & relay
Wiper motor relay

Washer motor relay
Front working light relay
・
・
27
26
Gauge cluster
Sealed grounding
2
11 13 15 16 25 28 1
・
Accelerator motor A phase

3
Sealed grounding
○
○
P1 bypass cut proportional valve D

○
○
○
○
○ ○
○ ○
○ ○
○
○ ○
P2 bypass cut proportional valve B

○
○
○
○
Travel straight proportional valve C
Arm variable recirculation proportional valve A

○
・・・・・
5 7 9 11 13
Power supply +24V

Battery backup
CN-15
Accelerator motor B phase

P1 pump proportional valve
・・・
16 18 20
○
○ ○
P2 pump proportional valve

○
Travel 1-2speed SOL

○
○
○
Swing parking SOL

Battery relay
Power supply grounding
26 4
4 6 8 10 12 14 15 17 19 21 22 24 25 3
Governor motor & proportional & SOL
・・
Swing flasher relay

8
Auto accel release SW.

Swing Flasher select SW.
CN-17
Timer relay
10 11 13
Auto idle stop select SW.

43-1

Electrical equipments
Proportional valve C D E L M R
Arm variable recirculation proportional valve
Travel straight proportional varve

P2 bypass cut proportional varve
P1 bypass cut proportional varve
P1 pump proportional varve

P2 pump proportional varve
Air conditioner amplifiter
Cab working light relay 1

Cab working light relay 2
Boom working light (left)
Component
Swing flasher RH&LH

Working light (right)
Washer motor relay

Boom working light
Working light relay

Speaker left (OPT)
Wiper motor relay

Fuel supply pump
Engine room light
Cab working light
Cab working light
Fuel pump (OPT)

DC-DC converter
Tuner AM & FM
Cigarette lighter
Governor motor
Air compressor
Receiver dryer
Washer motor
Gauge cluster
Speaker right
Starter motor
Flasher relay
Battery relay
Power socket
Travel alarm
Wiper motor
Rotary light
Safety relay
Timer relay
Hourmeter
Room light
Horn relay
Glow relay
Alternator
Fuse box
Resistor
Battery
Battery
Diode
Horn
P P P P P P B C C D D D D D E E E E E E E E E E E E E E E L L L L L L L L L M M M M M M R R R R R R R R R R R R R R
Group No.
S S S S S S 1 2 4 1 2 3 4 5 1 2 3 4 6 7 8 9 10 11 14 15 16 17 25 1 2 3 4 8 9 10 11 15 1 2 3 4 9 11 1 3 4 5 6 7 8 10 11 18 19 20 28 29
Trouble ・
System
V V V V V V ・ 5 ・
Pin No. │ │ │ │ │ │ 5 ・ 12
A B C D P P 6
1 2 ・
7
No motions operate. ○ ○ ○
neutral. ○ ○
All operate ○ ○ ○
Speed is slow
Only bucket speed is slow. ○

Only boom up speed is slow. ○ ○
(2) Motions are slow except boom up

and arm in. ○
Only arm in motion is slow. ○ ○
Only arm out motion is slow. ○ ○
○ ○
Power is poor
All operate
Bucket digging
(3)
Boom up
Arm in ○
Fine operation
Bucket digging ○
Electric systems
impossible.
(4) Boom up, down
Arm in, out ○ ○

(5) Travel 1-2 speeds can not be changed
Travel operation
(6) Travel independent speed is low. ○

with ATT
combined
operation
(8) straight are impossible.

swing)
Travel deviates, zigzags. ○

(at
(9) Machine drifts on a downhill and does

not stop still on a slope
(10) Swing motion does not work
Swing operation
(11) Swing speed is slow ○

(12) Swing power is poor ○
Swing left, right ○
(13) Swing can not be held on a slope
Option
Auto idle stop is not actuated ○ ○

(14)
43-2
Electrical equipments
SE SV SW
Low pressure sensor Pressure sensor
Engine water temperature, oil pressure,

Engine water temperature sensor
Component
Swing flasher select switch
Single/Conflux select SW.

Auto idle stop select SW.

Work light switch (OPT)
Wiper inter lock switch
Engine room light SW.

Swing P/B release SW.
Overload indicate SW.

Safety lock lever SOL
Travel 1-2 speed SOL
Safety lock lever SW.

Travel 1-2 speed SW.
KPSS release switch

Engine speed sensor
Swing parking SOL
Extra pressure SW.

Horn switch (right)
Swing left & right
Jib pressure SW.

Rotary light SW.
Option ; Nibbler
Bucket digging
Option ; Offset
Over load SW.

Option ; Extra
Bucket dump
Horn switch
Travel right
Boom down
Fuel sensor
Accelerator
Key switch
Revolution
A/C switch
Travel left
filter clogging
Boom up
Arm out
Arm in
Group No.
Trouble S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
System
E E E E E E E E E E E E E E E E E E E V V V W W W W W W W W W W W W W W W W W W W W W W W
Pin No. 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 20 22 23 26 1 3 4 1 3 4 5 6 10 11 13 16 17 20 21 22 23 30 32 37 38 39 42 43 44 52
・・
7
11 ・
8
No motions operate. ○ ○ ○ ○
neutral. ○ ○ ○ ○
All operate
Speed is slow
Only bucket speed is slow. ○ ○ ○ ○

Only boom up speed is slow. ○ ○
(2) Motions are slow except boom up

and arm in.
Only arm in motion is slow. ○
Only arm out motion is slow. ○
Power is poor
All operate
Bucket digging
(3)
Boom up
Arm in
Fine operation
Bucket digging ○ ○
Electric systems
impossible.
(4) Boom up, down ○ ○

Arm in, out ○ ○ ○ ○
(5) Travel 1-2 speeds can not be changed ○ ○
Travel operation
(6) Travel independent speed is low. ○ ○ ○ ○ ○ ○ ○

with ATT
combined
operation
(8) straight are impossible.

swing)
Travel deviates, zigzags. ○ ○ ○ ○ ○ ○ ○ ○ ○

(at
Machine drifts on a downhill and does

(9) not stop still on a slope
(10) Swing motion does not work ○ ○ ○
Swing operation
(11) Swing speed is slow ○

(12) Swing power is poor ○
Swing left, right ○ ○ ○ ○ ○ ○
(13) Swing can not be held on a slope ○ ○ ○ ○
Option
Auto idle stop is not actuated ○ ○

(14)
Regarding the C-1 mechatro controller, refer to two pages back. 43-3
2. SELF DIAGNOSIS TABLE 3. SERVICE DIAGNOSIS TABLE
The self diagnosis detects errors in the control I/O´s of the pressure sensors and the proportional valves The results of service diagnosis at this time point are displayed in up to 22 items according to data
while the machine is in operation and shows them on the multi display of the gauge cluster. from the mechatro controller.
Displaying procedure:
DISPLAY ITEM
1) Turn“ON”the starter switch with the buzzer stop switch pressed.
No Contents Display of monitor No Contents Display of monitor 2) A mechatro controller parts number and a program version are displayed as the No.1 item.
3) The display advances like No.2, No.3.... each time the screen change switch is pressed.
P1 by-pass cut
1 Mechatro controller fail 16 4) The display returns like No.40, No.39... each time the buzzer stop switch is pressed.
propo-valve fail
5) The display does not disappear unless the starter switch is turned“OFF”.
P2 by-pass cut
2 ROM data 17
propo-valve fail E135SR(LC) E115SR
E135SRL
Travel priority
3 Mechatro set error 18 No.1 No.1
propo-valve fail
MAIN CONTROLLER MAIN CONTROLLER
Boom up pressure Arm variable recircula- PROGRAM VERSION PROGRAM VERSION
4 19
sensor fail tion propo-valve fail VER 5.70 VER 5.70
Multi display
Boom down pressure
5 20 Pump P1 propo-valve fail
sensor fail Screen change sw.
Arm in pressure sensor Buzzer stop sw.
6 21 Pump P2 propo-valve fail SERVICE DIAGNOSIS DISPLAY
fail
No. DISPLAY No. DISPLAY No. DISPLAY No. DISPLAY
Arm out pressure sensor Travel two-speed No.1 No.8 No.14 No.24
7 22 MAIN CONT. P/No. RELAY PRESS. SENSOR PROPO-VALVE
fail solenoid valve fail
YV22E00008F1 I－2 BAT. RELAY C－1 PUMP P1 E－1 P1 PUMP
Bucket digging pressure Swing parking solenoid 1 or 8 COMP. OFF 14 3.4V 350k 24 COMP. 727mA 29k
8 23 YY22E00022F1 MEAS. OFF C－2 PUNP P2 MEAS. 727mA 29k
sensor fail valve fail PROGRAM VER KEY SWITCH OFF 3.4V 350k POWER SHIFT 100mA
VER 5.70
Bucket dump pressure Governor motor current No.2 No.9 No.15 No.25
9 24 E/G SET 2310 PRESS. SENSOR PRESS. SENSOR PROPO-VALVE
sensor fail fail
MEAS 2310 B－1 BOOM UP B－16 P1 OPT. E－2 P2 PUMP
Swing right pressure Governor motor starting 2 E/G PRS. LIVE 9 4.9V 30k 15 4.9V 30k 25 COMP. 727mA 29k
10 25 KPSS SW H B－2 BOOM DOWN B－17 P2 OPT. MEAS. 727mA 29k
sensor fail point indexing fail 4.9V 30k 4.9V 30k POWER SHIFT 100mA
Travel right pressure No.3 No.10 No.20 No.39

12 26 Accel potentio meter fail
sensor fail H－1 PRESS. SENSOR PROPO-VALVE MECHATRO ADJT.
ACCEL VOLT. 4.2V B－3 ARM OUT D－1 P1 BYPASS CONT. SW TEST
Travel left pressure Gauge cluster→ 3 POS. 100% 10 4.9V 30k 20 COMP. 670mA 25k 39 CONT. VOL 100%
13 27 Mechatro controller MOTOR STEP 440 B－4 ARM IN MEAS. 670mA 25k PROG. SW OFF
sensor fail communication failure POS. 100% 4.9V 30k
Pump P1 pressure No.4 No.11 No.21 No.40

14 28 Battery relay fail
sensor fail GOVERNOR MOTOR PRESS. SENSOR PROPO-VALVE RELEASE SW
G－1 COIL A 1.0A B－5 BUCKET DIG D－2 P2 BYPASS KPSS TEST
Pump P2 pressure 4 G－1 COIL B 1.0A 11 4.9V 30k 21 COMP. 670mA 25k 40 SWING BRAKE OFF
15 29 Draining hyd. pressure G－2 LIMIT OFF B－6 BUCKET DUNP MEAS. 670mA 25k
sensor fail 4.9V 30k
30 Fail drain hyd. pressure No.5 No.12 No.22

SOL.VALVE PRESS. SENSOR PROPO-VALVE
F－2 SWING-BRAKE B－7 SWING (R) D－3 S-TRAVEL
5 COMP. OFF 12 4.9V 30k 22 COMP. 670mA 25k
MEAS. OFF B－8 SWING (L) MEAS. 670mA 25k
RELEASE SW OFF 4.9V 30k
No.6 No.13 No.23

SOL.VALVE PRESS. SENSOR PROPO-VALVE
F－3 1/2-TRAVEL B－9 TRAVEL (R) D－6 A-RECIRCULAT
6 COMP. OFF 13 4.9V 3.0k 23 COMP. 670mA 25k
MEAS. OFF B－10 TRAVEL (L) MEAS. 670mA 25k
SWITCH OFF 4.9V 3.0k
43-4
4. TROUBLESHOOTING
(1)-1
No motions operate.
Note: (1)-1 matches the Groupe No.
Lever stand down

24V is alive across
white/blue and black of YES To hydraulic
connector (CN-253F) for troubleshooting
lever lock solenoid.
NO
24V is alive across white Harness between lever

and blue of connector YES lock switch (SW-11) and YES
Inspect harness.
(CN-46F) for lever lock lever lock solenoid
switch (SW-11). (SV-4) is disconnected.
NO
Lever lock switch (SW-11) YES

Replace switch (SW-11).
is faulty.
24V is alive across white
and black of connector YES
(CN-46F) for safety lock
lever switch (SW-11).
NO Lever lock switch (SW-11) YES
is attached improperly. Adjust and replace.
24V is alive across white Harness between fuse box

YES YES
and black of connector and lever lock switch Inspect harness.
(CN-38M) on fuse box. (SW-11) is disconnected.
NO
YES YES Inspect the shorted point

Fuse No.15 is blown. Harness shorted to frame.
of harness.
NO
Inspect if there is no
disconnection in fuse box.
43-5
(1)-2
Machine moves freely when lever is at neutral.
(“P1 bypass cut proportional valve”and“P2 bypass cut

proportional valve”are displayed on the gauge cluster.)
The machine operates freely if the YES To hydraulic

connector(CN-257F) for the P1 bypass
troubleshooting
cut proportional valve is removed.
NO
(Service diagnosis No.10)
Arm out operation pressure sensor Arm out operation
YES Trouble disappears if arm out operation YES pressure sensor (SE-8) is
(SE-8) shows more than 1.3V even
pressure sensor (SE-8) is replaced. faulty.
NO
NO Arm out pilot pressure is 6kgf/cm2 (85psi) YES
Inspect ATT pilot valve.
NO
Replace C-1 controller.
Arm in operation pressure sensor YES YES Arm in operation
Trouble disappears if arm in operation
(SE-7) shows more than 1.3V when pressure sensor (SE-7) is
pressure sensor (SE-7) is replaced.
lever is at neutral. faulty.
NO
NO YES
Arm in pilot pressure is 6kgf/cm2 (85psi)
C-1 controller is fauity.
NO
The machine operates freely if the YES To hydraulic

connector(CN-257F) for the P2 bypass
troubleshooting.
cut proportional valve is removed.
NO
Boom raise operation pressure sensor Boom raise operation
(SE-3) shows more than 1.3V when
YES Trouble disappears when boom raise ope- YES pressure sensor (SE-3) is
ration pressure sensor (SE-3) is replaced. faulty.
NO NO
Boom raise pilot pressure is more than YES
6kgf/cm2 (85psi) when lever is at neutral.
NO

Swing left operation pressure sensor YES Swing left operation
Trouble disappears when swing left ope- YES pressure sensor (SE-5) is
(SE-5) shows more 1.3V when lever is
ration pressure sensor (SE-5) is replaced. faulty.
at neutral.
NO
NO YES
Swing left pilot pressure is more than
NO

Swing right operation pressure sensor YES Trouble disappears if swing right operation YES Swing right sensor
(SE-5) show more than 1.3V when pressure sensor (SE-5) is replaced. (SE-5) is faulty.
lever is at neutral. NO
NO Swing right pilot pressure is more than YES
6kgf/cm2 (85p0si) when lever is at neutral. Replace C-1 controller.
NO
Replace ATT pilot valve.
43-6
(2)-2
Only bucket motion is slow.

The bucket operating pressure sensor value YES To hydraulic
is more than 4.0V when the bucket
troubleshooting
operating lever is turned to the full.
NO
Bucket opration pressure
Trouble disappears if bucket operation YES sensor (SE-1,or SE-2) is
pressure sensor (SE-1,or SE-2)is changed.
faulty.
NO
If the harness for the bucket operation Harness between bucket
NO
pressure sensor is connected another opeeration pressure sensor
pressure sensor, the pressure sensor gets and controller is faulty.
out of order.
YES
Bucket pilot pressure is more than approx. YES
35kgf/cm (500psi) when lever is at full.
NO To hydraulic
(2)-3 troubleshooting
Only boom up speed motion is slow.

The boom up operation pressure sensor
(SE-3) value is more than 4.0V when the YES To hydraulic
boom up operating lever is turned to the troubleshooting
full.
NO
Boom up operation
Trouble disappears if boom up operation YES
pressure sensor is replaced. pressure sensor (SE-3) is
fauly.
NO
If the harness for the boom up operation
pressure sensor is connected another YES Inspect ATT pilot valve.
pressure sensor, the pressure sensor gets
out of order.
NO To hydraulic
Only boom up and arm in motions are slow.

Command current for travel straight
NO To hydraulic
proportional valve is approx. 350mA or over
troubleshooting
at boom up or arm in motions.
YES (Service diagnosis No.13)

Travel right operation pressure sensor
YES Trouble disappears when travel right YES Travel right operation
(SE-9) shows more than 1.3V when travel operation pressure sensor (SE-9) is pressure sensor (SE-9) is
right lever is at neutral. replaced. faulty.
NO NO
Travel right pilot pressure is more than YES Inspect travel pilot valve.
NO Inspect harness between
travel right operation
pressure sensor (SE-9) and
controller.
Travel left operation pressure sensor (SE-
YES Trouble disappears if travel left opera- YES Travel left operation
10) shows approx. 1.3V or over when travel pressure sensor (SE-10) is
tion pressure sensor (SE-10) is replaced.
left lever is at neutral. faulty.
NO
Travel left pilot pressure is more than YES Inspect travel pilot valve.
travel left operation
pressure sensor (SE-10)
and C-1 controller.
43-7
(2)-5
Only arm in motion is slow.

Arm in operation pressure sensor shows YES To hydraulic
4.0V or over when arm in lever is shifted to
troubleshooting
the full.
NO
Trouble disappears if arm in operation YES Arm in operation pressure
pressure sensor (SE-7) is replaced. sensor (SE-7) is faulty.
NO
Faulty symptom changes if the harness for Harness between arm in
YES
the arm in operation pressure sensor is operation pressure sensor
connected with another pressure sensor. and controller is faulty.
NO
Arm in pilot pressure is approx. 35kgf/cm2
YES
(500psi) or over when arm in lever is shifted Inspect ATT pilot valve.
to the full.
NO To hydraulic
Only arm out motion is slow.

Arm out operation pressure sensor shows
YES To hydraulic
4.0V or over when arm out lever is shifted to
troubleshooting
the full.
NO
Arm out operation
Trouble disappears if arm out operation YES pressure sensor (SE-8) is
pressure sensor (SE-8) is replaced. faulty.
NO
If the harness for the arm out operation Harness between arm out
YES
pressure sensor is connected another operation pressure sensor
pressure sensor, the pressure sensor gets and controller is faulty.
out of order.
NO
Arm out pilot pressure is approx. 35kgf/cm2
(500psi) or over when arm out lever is
YES
NO To hydraulic
Fine operation of bucket digging and dump motions can not be performed.

Bucket digging (dump) Trouble gets normal if
operation pressure NO connector on P1 bypass NO To hydraulic
sensor shows cut proportional valve troubleshooting.
0.7V or over when (PSV-D) is disconnected.
YES Arm in operation pressure
Trouble disappears if arm
sensor (SE-7) shows YES in operation pressure YES Arm in operation pressure
approx. 1.3V or over when sensor (SE-7) is faulty.
sensor (SE-7) is replaced.
NO
NO
Arm in pilot pressure is
6kgf/cm2 (85psi) or over YES
arm in operation pressure
sensor (SE-7) and C-1
controller.
Continued on the P9. Continued on the P9.
43-8
Continued from P8. Continued from P8.
YES NO
Arm out operation pressure YES Trouble disappears if arm YES Arm out operation
sensor (SE-8) shows approx. out operation pressure pressure sensor (SE-8) is
1.3V or over when lever is at sensor (SE-8) is replaced. faulty.
neutral.
NO
NO Arm out pilot pressure is
YES
more than 6kgf/cm2 (85psi) Inspect ATT pilot valve.
Inspect harness between
NO arm out operation pressure
sensor (SE-8) and
C-1 controller.

Trouble disappears if bucket digging
(dump) operation pressure sensor SE-1
YES Bucket digging (dump) operation pressure
sensor is faulty.
(SE-2) is changed.
NO
If the harness for the bucket digging Harness between bucket digging (dump)
operation pressure sensor is connected YES
operation pressure sensor and controller is
another pressure sensor, the pressure faulty.
sensor gets out of order.
NO
(4)-2 Replace C-1 controller.
Fine operation of boom up and down motions can not be performed.
(Service diagnosis No. 9) (”P1 bypass cut proportional valve” is displayed on the guage cluster.)
Boom up (down) Trouble gets normal if
operation pressure NO connector of P1 bypass cut NO To hydraulic
sensor shows 0.7V proportional valve troubleshooting
or over when lever (PSV-D) is disconnected.
is at neutral.
YES Arm in operation pressure
Trouble disappears if arm in YES Arm in operation pressure
sensor (SE-7) shows approx. YES
operation pressure sensor
1.3V or over when lever is sensor (SE-7) is faulty.
(SE-7) is replaced.
at neutral.
NO
NO Arm in pilot pressure is
6kgf/cm2 (85psi) or over YES
sensor (SE-7) and
C-1 controller.
Arm out operation pressure Trouble disappears if arm
sensor (SE-8) shows approx. YES out operation pressure YES Arm in operation pressure
at neutral.
NO
NO
Arm out pilot pressure is YES
NO arm in operation pressure
sensor (SE-8) and
C-1 controller.
Trouble disappears if boom up (down) Replace C-1 controller.

operation pressure sensor SE-3 (SE-4) is
changed. YES Boom up (down) operation pressure sensor SE-
3 (SE-4) is faulty.
NO
The harness between bucket digging operation
If the harness for the bucket YES
pressure sensor SE-1 and the bucket dump
digging(dump) operation pressure sensor
operation pressure sensor SE-2 is faulty.
is connected to another pressure sensor,
the faulty symptom changes.
NO Replace C-1 controller.

43-9
(4)-3
Fine operation of swing motion can not be performed.

(”P2 bypass cut proportional valve” is displayed on the guage cluster.)
Trouble gets Swing peration pressure Trouble is corrected if swing
normal if YES sensor (SE-5) shows approx. YES operation pressure sensor YES Swing operation pressure
sensor (SE-5) is faulty.
connector of P2 1.3V or over when lever is at (SE-5) is replaced.
bypass cut neutral.
proportional NO
valve (PSV-B) is NO Swing pilot pressure is more YES
disconnected. than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
NO swing operation pressure
controller.
Boom up operation pressure
Trouble disappears if boom
sensor (SE-3) shows approx. YES YES Boom up operation
up operation pressure
1.3V or over when lever is pressure sensor (SE-3) is
at neutral. faulty.
NO NO
Boom up pilot pressure is YES
NO boom up operation
pressure sensor (SE-3) and
(Service diagnosis No.10) C-1 controller.
Arm out operation pressure Trouble disappears if arm
sensor (SE-8) shows 1.3V or YES out operation pressure YES Swing left operation
pressure sensor (SE-5) is
over when lever is at sensor (SE-8) is replaced. faulty.
neutral.
NO NO
Arm out pilot pressure is
6kgf/cm2 (85psi) or over
YES
NO
Arm in operation pressure
sensor (SE-7) shows 1.3V or YES Trouble disappears if arm in YES Arm in operation pressure
over when lever is at operation pressure sensor sensor (SE-7) is faulty.
neutral. (SE-7) is replaced.
NO
Arm in pilot pressure is
YES
6kgf/cm2 (85psi) or over Inspect ATT pilot valve.
Trouble gets NO
normal if
connector of NO To hydraulic
swing parking troubleshooting
solenoid (SV-1) is
disconnected.
YES

Swing operation pressure
Trouble gets normal if swing
sensor (SE-5) shows approx. NO YES Swing operation pressure
(SE-5) is replaced.
NO
Swing pilot pressure is Inspect harness between
approx. 35kgf/cm2 (500psi) YES swing operation pressure
or over when lever is shifted sensor (SE-5) and C-1
to the full. controller.
NO
43-10
(4)-4
Fine operation of arm in and out motions is not possible.
(Displays Service Diagnosis No21.)

Trouble gets normal if
connector of P2 bypass cut NO To hydraulic
proportional valve (PSV-B) is troubleshooting
disconnected.
sensor (SE-5) indicates YES Trouble gets normal if swing YES Swing operation pressure
operation pressure sensor sensor (SE-5) is faulty.
approx. 1.3V or over when
(SE-5) is replaced.
NO
NO
Swing pilot pressure is more YES
than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
NO swing sensor (SE-5) and C-
(Service diagnosis No.9) 1 controller.
Boom up sensor (SE-3) Trouble disappears if boom YES
YES Boom up sensor (SE-3) is
indicates approx. 1.3V or up operation pressure sensor
over when lever is at neutral. (SE-3) is replaced. faulty.
NO NO
Boom up pilot pressure is
YES
boom up operation
(Service diagnosis No.10) pressure sensor (SE-3) and
Arm out operation pressure C-1 controller.
sensor (SE-8) indicates 1.3V YES YES Arm out operation
out operation pressure
or over when lever is at pressure sensor (SE-8) is
neutral. faulty.
NO
NO
Arm out pilot pressure is YES
sensor (SE-7) indicates 1.3V YES Trouble disappears if arm in YES Arm in operation pressure
or over when lever is at sensor (SE-7) is faulty.
(SE-7) is replaced.
neutral.
NO NO
Arm in pilot pressure is more YES
than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
NO
43-11
(5)
Travel 1-2 speeds can not be changed.
24V is alive across light green/black

and black wires of connector YES To hydraulic
(CN-255F) for travel 1-2 speed select troubleshooting
solenoid (SV-3).
NO
If ”Switch ” travel 1-2 speed select Each time the switch turns ”ON ”
switch(SW-3) is pressed in the YES and ”OFF ” by turns in the servic YES
service diagnosis No.6, ”ON ” is diagnosis No.6, the 2nd digit and 1st Replace C-1 controller.
displayed, and if the switch is not digit numbers turn to 1 and 0
pressed, ”OFF ” is displayed. alternately. Inspect harness (light
green and black) between
NO NO travel 1-2 speed select
If the plugs(two females) connecting solenoid (SV-3) and
the travel 1-2 speed select C-1 controller.
switch(SW-3) with the main harness YES Replace travel 1-2 speed
are connected together, the switch is
select switch (SW-3).
turned ”ON ” and if the plugs are
disconnected, the switch is turned
”OFF ”.
NO
Harness (pink and blue) between
travel 1-2 speed select switch YES
Repair harness.
(SW-3) and C-1 controller is
disconnected.
NO
43-12
(6)
Travel independent speed is low.

Command current of travel straight
NO To hydraulic
proportional (PSV-C) is more than
349mA during traveling. troubleshooting

Bucket digging operation pressure Bucket digging operation
YES Trouble disappears if bucket digging YES pressure sensor (SE-1) is
sensor (SE-1) indicates 1.3V when operation pressure sensor (SE-1) is
lever is at neutral. replaced. faulty.
NO NO
Bucket digging pilot pressure is YES
more than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
Bucket dump operation pressure
YES Trouble disappears if bucket dump YES Bucket dump operation
sensor (SE-2) indicates more than operation pressure sensor (SE-2) is pressure sensor (SE-2) is
1.3V when lever is at neutral. replaced. faulty.
NO NO
Bucket dump pilot pressure is more YES
than 6kgf/cm2 (85psi) when lever is Inspect ATT pilot valve.
at neutral.
Boom up operation pressure sensor YES Trouble disappears if boom up YES Boom raise operation
(SE-3) indicates more than 1.3V operation pressure sensor (SE-3) is pressure sensor (SE-3) is
when lever is at neutral. replaced. faulty.
NO NO
Boom up pilot pressure is more than YES
6kgf/cm2 (85psi) when lever is at Inspect ATT pilot valve.
neutral.
Boom down operation pressure
sensor (SE-4) indicates more than
YES Trouble disappears if boom down YES Boom lower operation
operation pressure sensor (SE-4) is pressure sensor (SE-4) is
1.3V when lever is at neutral. replaced. faulty.
NO NO
Boom down pilot pressure is more YES
than 6kgf/cm2 (85psi) when lever is Inspect ATT pilot valve.
at neutral.
Swing operation pressure sensor YES Trouble disappears if swing YES Swing operation pressure
(SE-5) reads more than 1.3V when operation pressure sensor (SE-5) is sensor (SE-5) is faulty.
lever is at neutral. replaced.
NO NO
Swing pilot pressure is more than YES
neutral.
Continued on the P14
43-13
Continued from P13
NO (Service diagnosis No.10)

Arm in operation pressure sensor Trouble disappears when arm in
(SE-7) reads more than 1.3V when
YES operation pressure sensor (SE-7) is YES Arm in operation pressure
sensor (SE-7) is faulty.
lever is at neutral. replaced.
NO NO
Arm in pilot pressure is more than YES
neutral.
NO
Arm out operation pressure sensor
YES Trouble disappears if arm out YES Arm out operation
(SE-8) reads more than 1.3V when operation pressure sensor (SE-8) is pressure sensor (SE-8) is
lever is at neutral. replaced. faulty.
NO NO
Arm out pilot pressure is more than YES
neutral.

(8)
Machine does not travel straight.
Command current of travel straight YES To hydraulic

proportional valve (PSV-C) is 650mA or over. troubleshooting
NO
Check harness (green / black and gray /
“ TRAVEL PROP-VALV ”is displayed on YES
black) between travel straight proportional
gauge cluster.
valve (PSV-C) and C-1 controller.
NO (Service diagnosis No.12)
Machine deviates YES sensor (SE-5) reads more NO Trouble disappears if swing YES Swing operation pressure
operation pressure sensor sensor (SE-5) is faulty.
to the left. than 4.0V when lever is
(SE-5) is replaced.
NO NO
YES
Swing pilot pressure is more Check harness between
than approx. 35kgf/cm2 YES swing operation pressure
(500psi) when lever is sensor (SE-5) and C-1
shifted to the full. controller.
NO Inspect ATT pilot valve.
Arm out operation pressure
sensor (SE-8) indicates more NO Trouble disappears if arm YES Arm out operation
out operation pressure pressure sensor (SE-8) is
than 4.0V when lever is
sensor (SE-8) is replaced. faulty.
YES NO
Arm out pilot pressure is Inspect harness between
approx. 35kgf/cm2 (500psi) YES arm out operation pressure
or over when lever is shifted sensor (SE-8) and
to the full. C-1 controller.
NO
Continued on the P15 Continued on the P15
43-14
Continued from P14 Continued from P14
NO YES (Service diagnosis No.10)

sensor (SE-7) reads more NO in operation pressure YES Arm in operation pressure
than 4.0V when lever is sensor (SE-7) is faulty.
NO
Arm in pilot pressure is Inspect harness between
approx. 35kgf/cm2 (500psi) YES arm in operation pressure
or over when lever is shifted sensor (SE-7) and C-1
to the full. controller.
NO

Boom up operation
Boom up operation
pressure sensor NO Trouble disappears if boom YES
(SE-3) reads more up operation pressure pressure sensor (SE-3) is
than 4.0V when sensor (SE-3) is replaced. faulty.
lever is shifted to NO
the full. Boom up pilot pressure is Inspect harness between
YES approx. 35kgf/cm2 (500psi) YES boom up operation
or over when lever is shifted pressure sensor (SE-3) and
NO
Boom down NO Trouble disappears if boom YES Boom down operation
operation pressure down operation pressure pressure sensor (SE-4) is
sensor (SE-4) reads sensor (SE-4) is replaced. faulty.
approx. 4.0V or
NO
over when lever is
Boom down pilot pressure is Inspect harness between
approx. 35kgf/cm2 (500psi) YES boom down operation
YES or over when lever is shifted pressure sensor (SE-4) and
NO
Bucket digging Bucket digging operation
NO Trouble disappears if bucket YES pressure sensor (SE-1) is
operation pressure digging operation pressure
approx. 4.0V or
over when lever is
NO
shifted to the full. Bucket digging pilot Inspect harness between
pressure is approx. YES bucket digging operation
YES 35kgf/cm2 (500psi) or over pressure sensor (SE-1)
when lever is shifted to the and C-1 controller.
full.
NO
Bucket dump
NO Trouble disappears if bucket YES Bucket dump operation
operation pressure dump operation pressure pressure sensor (SE-2) is
approx. 4.0V or
over when lever is
NO
shifted to the full. Bucket dump pilot pressure Inspect harness between
is approx. 35kgf/cm2 (500psi) YES bucket dump operation
YES or over when lever is shifted pressure sensor (SE-2) and
NO
43-15
(10)
Swing motion does not work.
Swing motion works if connector

(CN-254F) of swing parking NO To hydraulic
solenoid (SV-1) is disconnected. troubleshooting
Swing operation pressure sensor NO Trouble disappears if swing YES Swing operation pressure
(SE-5) reads approx. 1.3V or over operation pressure sensor (SE-5) sensor (SE-5) is faulty.
when lever is shifted to the full. is replaced.
NO
Swing pilot pressure is approx. Inspect harness between
35kgf/cm2 (500psi) or over when YES swing operation pressure
lever is shifted to the full. sensor (SE-5) and C-1
controller.
NO
(11)
Swing speed is low.
Actual current readings of P2

pump proportional valve are YES To hydraulic
more than 619mA when the troubleshooting
swing lever is turned to the full.
NO
pump proportional valve are YES
more than 619mA when the Replace C-1 controller.
NO
The swing operation pressure Trouble disappears if swing YES
sensor value is more than 4.0V
NO Swing operation pressure
operation pressure sensor (SE-5)
when the swing operation lever sensor is faulty.
is replaced.
is turned to the full.
NO
YES If the harness for the bucket
operating pressure sensor is put YES Harness between swing
into another pressure sensor, the operation pressure sensor
pressure sensor gets out of order. and controller is faulty.
NO
Swing pilot pressure is approx. YES Inspect or replace ATT
35kgf/cm2 (500psi) or over when
pilot valve
lever is shifted to the full.
NO
Check piping
P1 or P2 pump pressure sensor

YES Trouble disappears if P1 or P2 YES P1 or P2 pump pressure
reads more than 0.7V when lever pump pressure sensor is
sensor is faulty.
is at neutral. changed.
NO NO
Faulty symptom changes if the Harness between pressure
YES
harnesses for P1 and P2 pump sensor and controller is
pressure sensors are exchanged. faulty.
NO
Swing operating pressure is YES

normal.
NO To hydraulic
troubleshooting
43-16
(12)
Swing power is poor.

pump proportional valve are YES To hydraulic
more than 619mA when the troubleshooting
NO
pump proportional valve are YES
more than 619mA when the Replace C-1 controller.
NO
The swing operation pressure Trouble disappears if swing YES
NO Swing operation pressure
sensor valve is more than 4.0V operation pressure sensor (SE-5)
when the swing operation lever sensor (SE-5) is faulty.
is replaced.
is turned to the full.
NO
YES If the harness for the bucket
operating pressure sensor is put YES Harness between swing
into another pressure sensor, the operation pressure sensor
pressure sensor gets out of order. and controller is faulty.
NO
Swing pilot pressure is approx. YES Inspect or replace ATT
35kgf/cm2 (500psi) or over when
pilot valve
lever is shifted to the full.
NO
Check piping
P1 or P2 pump pressure sensor YES Trouble disappears if P1 or P2 YES P1 or P2 pump pressure

reads more than 0.7V when lever pump pressure sensor is
changed. sensor is faulty.
is at neutral.
NO NO
Faulty symptom changes if the YES Harness between pressure
harnesses for P1 and P2 pump sensor and controller is
pressure sensors are exchanged. faulty.
NO
Swing operating pressure is YES
normal.
NO To hydraulic
troubleshooting
43-17
(13)-1
Swing motion can not be held on a slope.
YES
24V is alive across
pink/black and black wires YES
To hydraulic
of connector (CN-254F) for
troubleshooting
swing parking solenoid
(SV-1).
NO
Swing parking release NO
switch (SW-4) is at Turn to NORMAL.
NORMAL.
YES
YES Trouble gets normal if YES Swing operation pressure
sensor (SE-5) reads more
swing operation pressure sensor (SE-5) is faulty.
than 1.3V when lever is at
neutral.
NO NO
Swing pilot pressure is more YES
than 6kgf/cm2 (85psi) is Inspect ATT pilot valve.
swing operation pressure
controller.
Arm in operation pressure Trouble gets normal if arm YES
sensor (SE-7) reads more YES in operation pressure sensor Arm in operation pressure
than 1.3V when lever is at (SE-7) is replaced. sensor (SE-7) is faulty.
neutral.
NO
NO Arm in pilot pressure is YES
NO
sensor (SE-7) and
C-1 controller.
Inspect that harness (pink

If swing right (or swing left,
YES and black) between swing
or arm in) lever is operated,
parking brake solenoid
SWINGBRAKE SOLENOID
(SV-1) and C-1 controller is
is indicated.
not disconnected.
NO
43-18
(14)
Auto idling stop (AIS) does not function. (E/G does not stop after an elapse of 60
seconds after the lock lever was moved upward to locked position.)
In auto warm-up (OPT)
operation, AIS does not work.
Switch warm-up SW off or
Is WARM-UP displayed?
check on it after completion of
warming up.
NO
When overheating is detected,
AIS does not work to protect
Is E/G water temperature E/G.
warning indicated? Check on it in normal
NO operation condition.
When AIS selector SW is off,

it does not work. Switch AIS
Is AIS selector SW off? SW on and check on it.
NO
Are mechatrocontroller
17-13 pin and grounding
NO Check the line between
grounding - AIS selector SW -
connected? controller.
YES
Is E/G speed indication on E/G
speed display or Service Check speed sensor gap, or
diagnosis display normal. NO check between controller and
(About 2220 rpm in high speed sensor for continuity.
idling, about 1000 rpm in low
idling)?
YES
Is ATT operation possible
even if the lock lever is moved Adjust or replace lock lever
upward to locked position ? limit switch.
NO
Is 24 V loaded on mechatro
Check the line between lock
controller 17-11 when the lock
lever limit switch and
lever is moved upward to
controller.
locked position?
NO
Replace fuse, or check the line
Is fuse No.15 blown? around the fuse.
NO
* Is set time (60 seconds) until

the AIS is tripped correct? Replace controller.
NO
*Adjust set time.
NOTE :
1. AIS is Auto Idling Stop.
2. For checking and adjusting method of AIS set time shown
by mark *, contact an authorized Dealer.
43-19
NOTE
43-20
E115SR
E135SR
SECTION 44 TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS
1. Trouble diagnosis table: engine .............................................................................. 44-1

Engine 1.
Rotation trouble System
Other trouble Drop in output Starting trouble
(7)
(6)
(5)
(4)
Group No.
(11)
start.
Over heat
revolution.
does not off.

modes are changed.
Idling unsmooth
warming-up E/G
(8) Exhaust gas is white
key is turned off.

Trouble
not work properly.

Does not reach max
Component
Exhaust gas is black

(1) Starter does not run.
not disappear after idling.)

(3) High speed unsmooth
Knocking occurs after
The moment the key is

Medium speed hunting
E/G deficiency in output

Accel potentiometer does
(2) Starter runs but does not
(12) turned to OFF, but power

(In cold state, white smoke does
(9) Excessive oil consumption.
Engine does not stop when

Max. revolution is too high.
(10) Excessive fuel consumption.

Revolution does not change if work
○
Fuel not filled up or leaking.
○
Oil cooler element clogged.
Fuel system trouble(Air or water entered.)
○
○
○
○
○
OiL filter clogged.
○
○ ○
○
Air cleaner clogged.
Filters
Gauze filter clogged.

TROUBLE DIAGNOSIS TABLE; ENGINE
○
○
○
○ ○
○ ○ ○
Fuel filter clogged.
○
V-belt slips.
Inspection
○
Breather hose bent.
Cooling water level
Fuel is of poor quality or leaking.
○
○ ○
Specific gravity of battery fluid
○
Fluid
Viscosity of engine oil is not suited, engine oil is
○
○
○
leaking, or the engine oil level not proper.
Poor quality fuel is used or heavy oil is used.

○
○
○ ○ ○
Service man
○ ○
Blowby gas is much.
Gas leaks from valve and gasket.
○ ○
○ ○
○ ○ ○
○ ○ ○ ○
○
○
Engine oil is oo much.
Visual check
Gas / fluid
Battery fluid level

Fuse
○
Starter key
○
○ ○ ○ ○
Battery relay
○
○
○
Mechatoronic controller
Mechatoro “A” adjust.
Shovel side
○
○
○ ○
○
Stepping motor
Electrical fittings
○ ○
○ ○ ○
Accel potentiometer
○
Connector and electric wiring

○ ○
Safety relay
Glow relay
○ ○
Glow
Starter motor
Engine side
○ ○
Starter relay
Electrical fittings
Alternator
Feed pump function
○
○ ○
Check injection timing

Fuel
○ ○
Inspect nozzle.
system
○
○ ○ ○
○ ○
○ ○
Stop
Injection pump
position
○ ○ ○ ○
○ ○ ○ ○
Valve clearance
○ ○ ○ ○ ○ ○
Valve spring is fatigued.

system
exhaust
Suction /
○ ○ ○ ○
Air cleaner & muffler

Check if engine oil level goes up and down.
○
○
○
○
Check relief valve.

Oil strainer clogged.
system
Lubrication
Fuel is mixed.
○
○
○
○
Check thermostat.
○ ○ ○
Cooling
Oil cooler eleent damaged.

○
○
○
○
Compression pressure low.

Engine dealer
Control rack movement unsmooth.

○ ○
○ ○
○
○ ○
○ ○ ○
Governor spring fatigued.

Crank shaft oil seal no good.
Piston liner worn.
○ ○ ○
○
Piston ring worn.

○ ○
○ ○ ○
Valve spring fatigued.

Main structure
○ ○ ○
Internal parts stuck.

Check fuel feed.
○
○
○ ○
Head gasket faulty.

○ ○ ○
Flywheel gear damaged.

44-1

2. TROUBLESHOOTING
(1)
Starter does not run.
NO Check battery fluid level

Check battery voltage. Charge or replace battery.
and specific gravity.
OK
The voltage at B1 NO
Check battery relay B1
terminal of battery is Replace fusible link 60A.
voltage.
24V ore more.
OK
The voltage at outlet
side of 20A fuse for NO
Check fuse box voltage. keyswitch is 24V or Replace fuse.
more.
OK OK
The voltage at inlet side YES Check electric wiring and
of 20A fuse for keyswitch
connectors.
is lower than 24V.
Measure the voltage at

L terminal of battery NO Check electric wiring
relay instead of M
and connector.
terminal of keyswitch to
check 24V of the M
Check key switch terminal.
voltage. Check key switch.
Measure the voltage at S
terminal of safety relay
on wire No.63 instead of NO Check electric wiring
ST terminal of keyswitch and connector.
to check the voltage at
NO
ST terminal.
Check electric wiring
OK and connector.
The voltage at L YES

Check voltage of battery
terminal of battery relay Replace battery relay.
relay.
is 24V or more.
OK
Check voltage of battery
relay A. Also check 24V is alive on A side,
voltage of battery relay but not on A1. Replace fusible link 60A.
A1.
OK
Check voltage of starter 24V is alive on terminal
motor. B of starter motor.
OK OK
Replace starter motor.
Check voltage of starter 24V is alive on terminal

motor. C of starter motor.
OK
Check voltage of safety 24V is alive on terminal YES

relay. S of safety relay.
OK Replace safety relay.
The voltage across safety NO
Check voltage of safety relay and starter
relay. motor(across coil) is 24V.
Condition ; Check keyswitch in START position.

Emergency stop knob (engine stop) is back in position.
44-2
(2)
Starter turns but engine is hard to start.
Check starter power is strong or WEAK Check battery fluid level and
Charge or replace battery.
weak. specific gravity.
OK
Check compression
Check engine itself. pressure and valve
clearance. Check that
valve spring is not
Check that air filter clogged
Check air suction system. fatigued, that piston
lamp lights.
liner is not worn, that
OK OK piston ring is not worn,
Check that air cleaner clogged that head gasket is not
sensor. faulty and that flywheel
gear is not damaged.
Also check radiator and
thermostat.
E/G side Check gauze filter. Check feed pump

OK performance, injection
Check fuel feed system. pump, injection nozzle
Check fuel gauge and water and injection timing.
Machine
separator. Check that poor
side
quality fuel is not used.
YES
Check electric system. E/G side 24V is alive on glow plug. Glow plug is faulty.
NO
Harness between glow
24V is alive on wire No. 66 (5W) YES relay and glow plug is
of CN-153F on glow relay (R-3). faulty.
NO
Harness between glow
24V is alive on wire No.53 (5Y) NO
relay and battery relay
of CN-154F on glow relay (R-3).
is faulty.
OK
24V is alive across wire No. 62 YES
of CN-155F on glow relay (R-3) Replace glow relay.
and earth.
NO Harness between key
NO
Ground connection is poor. switch and glow relay is
faulty.
Check E/G oil of viscosity if it is NO

Check viscosity of E/G oil. suited to atmospheric Replace engine oil.
temperature.
Checking condition ;E/G starter key is in ON position.
CN-154F CN-153F ① ③
① ②
③ ④
CN-155F CN-155F
② ④
Internal connection Fig.1 Glow relay terminals and connector
44-3
(3)
E/G revolution is faulty.
Check high pressure pipe

and injection nozzle. Check
that compression
Idling not smooth.
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling is faulty.
※1
Idling revolution is too
high. Adjust mechatro“A”.
Medium revolution is Hunting occurs at medium Check control rack.

faulty. revolution. Change over governor
spring.
Check that air is not mixed YES

in fuel. Bleed air.
OK
Check that air cleaner is
Check air suction system. not clogged.
OK
Check fuel gauge, water
separator and gauze filter.
Check fuel feed system.
Check also that poor
OK quality fuel is not used.
High idling is faulty.
Check injection nozzle,

injection pump and
injection timing.
E/G does not reach max.

revolution. ※1
Adjust mechatro“A”.
Max revolution is too high.
Checking condition ; E/G water temperature is more than 50℃ (122°

F).
※1 ; Refer to Electric Troubleshooting.
44-4
Note ; (6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Check that E/G water OK
temperature lamp is on and Check the contents of
Overheat
that buzzer sounds. excavating.
NO
Check E/G water
temperature switch, gauge
Inspect electric system.
cluster, electric wiring and
OK connectors.
Check cooling water level.

Check that fan belt does
Check cooling system.
not slip.
OK Check thermostat.
Also check that radiator.
Oil cooler is not clogged.
Check that poor quality

Check fuel system.
fuel is not used.
OK
Check E/G oil system. Check E/G oil filter.
Check air suction Check that air filter clogged OK Check that air cleaner is
system. display of warning not clogged.
OK
Check fuel feed Check that air is not mixed in
system. fuel. Bleed air.
OK OK
Check water separator and Check feed pump
gauze filter. Check also that performance, injection
poor quality fuel is not used. pump, injection nozzle and
injection timing.
Check E/G oil of viscosity if it

Check E/G oil. is suited to atmospheric Replace engine oil.
temperature.
OK
Check compression
Check that blowby gas is not pressure and valve
much, that gas does not leak clearance. Check that
Check engine
from gasket, and that engine valve spring is not
itself.
oil level does not go up and fatigued. Check that
down. control rack moves
smoothly. Check that
Checking condition ; High idling piston ring is not worn.
Check also that head
gasket is not faulty.
(7)
Knocking occurs after warming-up E/G.
OK
Check that poor quality fuel is
Check fuel system. not used. Replace fuel.
Check that engine oil does not Judge it if oil is there on

Check E/G itself. rise. exhaust port.
OK
Check that blowby gas is not Check compression
much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.
Checking condition ; E/G water temperature is more than 50℃ (122°

F).
44-5
(8)
Exhaust is abnormal.
OK
Check that air cleaner is not
Exhaust gas is black. clogged. Replace air element.
OK
Check engine oil viscosity.
Check that engine oil is not too
much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is not
fatigued and that piston ring is
not faulty.
Check that water is not mixed

Exhaust gas is white. in fuel. Check water separator.
OK
Check that engine oil goes up
and down. Blowby gas is Check compression pressure
much. A lot of gas leaks from and injection timing.
gasket.
Checking condition ; Engine water temperature is more than 50℃ (122°

F).
(9)
Excessive oil consumption.
Check leakage by checking the

Check that engine oil is not Retighten.
ground under E/G or by placing
leaking. Replace packing and seal.
an oil pan under E/G.
(Check that engine oil is not
filled up too much.) OK
Check that breather hose is not
bent or clogged. Replace breather hose.
OK
not used. Advise to replace fuel.
OK
Check viscosity of engine oil. Advise to replace engine oil.
OK Check that; CR shaft oil seal is
Checking condition ; No engine oil leaks. Check that engine oil does not not faulty, piston liner is not
go up and down. worn, or piston ring is not
worn.
(10)
Excessive fuel consumption.

Check fuel leakage. not used. Advise to replace fuel.
OK
Blowby gas is much.
Check that gas does not leak
Check nozzle function.
from gasket.
OK
Check injection timing.
Checking condition ; Use proper fuel. Check compression pressure.
44-6
(11)
E/G does not stop Confirm governor Check if governor Check that governor
when starter key is lever stop bolt motor is not faulty motor link
turned off. position. mechanically. connecting bolts are
not loose.
OK
Wire number 60 of Check resistance
Check that terminal instrument panel NG across terminals M Replace starter key
M of starter key right harness and B on starter if resistance across
switch shows 0V. CN-43F shows 0V. key. M and B is 0Ω.
See Fig.3.
OK
Check that battery Does resistance
relay terminal B2 Wire No.805 of body NG across C1 controller
measures 0V four harness CN-150F Check C1 controller. terminals 11-1 and
seconds after key is measures 0V. 15-24 measure 72
turned off. Ω?
(12) OK
When starter key is Replace C1
Does battery NG Replace battery
turned off, power is Check that battery controller if
terminals A and B
cut off but engine relay operates. relay. resistance measures
measure 0Ω?
does not stop. 0Ω.
See Fig.2.
Checking condition ; Starter key is off.

CN-152F
TERMINAL A1 LOCK
Flowing direction of
main current
TERMINAL A,A1 B,B1 TERMINAL

A A
FLW
TERMINAL B1
FLW
2.0sq 2.0sq TERMINAL A VIEW Ⅰ
FLW2.0sq
TERMINAL B
G B2 FLW2.0sq
W L P COIL
H COIL
BRACKET EARTH
TERMINAL B2
Circuit diagram
L TERMINAL
L TERMINAL Ⅰ
AVS1,25L B2 TERMINAL EARTH

AVS1,25G TERMINAL
EARTH CABLE
AVS1,25B CN-150M
Fig. 2 Battery relay
Fig. 3 Key SW. terminal
44-7
NOTE
44-8
E115SR
E135SR
SECTION 51 ENGINE
TABLE OF CONTENTS
Section 1. General .................................................................................................... 51-1
Section 2. Engine proper ........................................................................................ 51-21
Section 3. Lubrication system ................................................................................. 51-63
Section 4. Cooling system ...................................................................................... 51-67
Section 5. Fuel system ........................................................................................... 51-73
Section 6. Troubleshooting ..................................................................................... 51-77
Section 7. Special tools .......................................................................................... 51-83
Section 8. Repair standard ..................................................................................... 51-85
Section 9. Turbocharger .......................................................................................... 51-99
Section 10. Starter ................................................................................................ 51-105
Section 11-1 Alternator (24V-50A) ........................................................................ 51-129
Section 11-1 Alternator (24V-30A) ........................................................................ 51-146

51-I
NOTES
51-II
SECTION 1: GENERAL
TABLE OF CONTENTS
Repair in general ......................................................................................................................................... 51-2
How to read the repair manual .................................................................................................................... 51-4
Principal particulars ..................................................................................................................................... 51-6
Tightening torque specifications.................................................................................................................. 51-9
Locations of packings used ....................................................................................................................... 51-16
Inspection and maintenance ..................................................................................................................... 51-17
Lubricants used ......................................................................................................................................... 51-20
51-1
51-2
51-3
51-4
51-5
51-6
E115SR E135SR LC
51-7
E135SR LC E115SR
51-8
51-9
51-10
51-11
51-12
51-13
51-14
51-15
51-16
51-17
51-18
51-19
51-20
SECTION 2: ENGINE PROPER
TABLE OF CONTENTS
General view of engine ............................................................................................................................. 51-22
Disassembly .............................................................................................................................................. 51-23
Inspection and replacement ...................................................................................................................... 51-33
Assembly ................................................................................................................................................... 51-49
51-21
51-22
51-23
51-24
51-25
51-26
51-27
51-28
51-29
51-30
51-31
51-32
51-33
51-34
51-35
51-36
51-37
51-38
51-39
51-40
51-41
51-42
51-43
51-44
51-45
51-46
51-47
51-48
51-49
51-50
51-51
51-52
51-53
51-54
51-55
51-56
51-57
51-58
51-59
51-60
51-61
NOTES
51-62
SECTION 3: LUBRICATION SYSTEM
TABLE OF CONTENTS
Lube oil circulation diagram ...................................................................................................................... 51-64
Oil pump .................................................................................................................................................... 51-65
51-63
51-64
51-65
51-66
SECTION 4: COOLING SYSTEM
TABLE OF CONTENTS
Cooling water circulation system diagram ................................................................................................. 51-68
Water pump ............................................................................................................................................... 51-69
Thermostat ................................................................................................................................................ 51-71
51-67
51-68
51-69
51-70
51-71
NOTES
51-72
SECTION 5: FUEL SYSTEM
TABLE OF CONTENTS
Fuel circulation system disgram ................................................................................................................ 51-74
Injection nozzle and holder ....................................................................................................................... 51-75
51-73
51-74
51-75
NOTES
51-76
SECTION 6: TROUBLESHOOTING
51-77
51-78
51-79
51-80
51-81
51-82
SECTION 7: SPECIAL TOOLS
51-83
51-84
SECTION 8: REPAIR STANDARD
51-85
51-86
51-87
51-88
51-89
51-90
51-91
51-92
51-93
51-94
51-95
51-96
51-97
51-98
SECTION 9: TURBOCHARGER
TABLE OF CONTENTS
Construction ............................................................................................................................................ 51-100
Cautions to be exercised on handling ..................................................................................................... 51-101
Inspection procedure ............................................................................................................................... 51-102
Troubleshooting ....................................................................................................................................... 51-104
51-99
51-100
51-101
51-102
51-103
51-104
SECTION 10: STARTER
TABLE OF CONTENTS
Features .................................................................................................................................................. 51-106
Specification ............................................................................................................................................ 51-106
Construction and function ....................................................................................................................... 51-107
Connection and function ......................................................................................................................... 51-117
Disassembly ............................................................................................................................................ 51-118
Inspection and maintenance ................................................................................................................... 51-121
Assembly ................................................................................................................................................. 51-124
Maintenace standard ............................................................................................................................... 51-127
Handling .................................................................................................................................................. 51-128
51-105
51-106
51-107
51-108
51-109
51-110
51-111
51-112
51-113
51-114
51-115
51-116
51-117
51-118
51-119
51-120
51-121
51-122
51-123
51-124
51-125
51-126
51-127
51-128
SECTION 11-1: ALTERNATOR (24V-50A)
TABLE OF CONTENTS
Outlines ................................................................................................................................................... 51-130
Specification ............................................................................................................................................ 51-131
Construction ............................................................................................................................................ 51-132
Explanation of functions .......................................................................................................................... 51-134
Disassembly of alternator ........................................................................................................................ 51-137
Inspection ................................................................................................................................................ 51-140
Reassembly ............................................................................................................................................ 51-142
Bench test ............................................................................................................................................... 51-143
Diagnosis ................................................................................................................................................ 51-145
51-129
51-130
51-131
51-132
51-133
51-134
51-135
51-136
51-137
51-138
51-139
51-140
51-141
51-142
51-143
51-144
51-145
NOTES
51-146
SECTION 11.2: ALTERNATOR (24V-30A)
TABLE OF CONTENTS
Features .................................................................................................................................................. 51-148
Construction ............................................................................................................................................ 51-149
Explanation of functions .......................................................................................................................... 51-150
Disassembly and assembly ..................................................................................................................... 51-153
Inspection ................................................................................................................................................ 51-155
51-147
51-148
51-149
51-150
51-151
51-152
51-153
51-154
51-155
51-156
51-157
51-158
51-159
NOTES
51-160
1. LIST OF ADDITIONAL PARTS

How to utilize the list of additional modification parts
This manual describes the parts which are added and canceled on the basis of “Parts Manual” for
standard machines when the machine is modified into the machines equipped with breaker.
The manual consists roughly of two sections : Breaker and Nibbler & Breaker. Each of the section is
divided into five parts, 1. Upper structure, 2. Boom, 3. 2.45m (8′) arm, and 2.95m (9′8″) arm, 4.
Connector, 5. Idler link, each being assigned a kit number. The cab guard should be ordered optionally.
In the case of the arm, select a kit No. suited for the length of arm and attachment (Nibbler, Breaker) for
ordering.
1.1 COMPARISON TABLE FOR KIT AND ASSY NO. BY COUNTRY

(1) BREAKER E135SR
Classifi-
NAME
cation
Upper structure modification kit No.
• Modification of the control valve
• Install of the guard
• Hydraulic tank assy
• Instrument panel assy
(1) Upper
• Remote control piping

• Block control piping
• Main control piping
• Upper hydraulic piping
• Install of the name plate
Boom modification kit No.

(2) Boom
• 4.6M (15′1″) Boom

• 4.6M (15′1″) Boom hydraulic piping
2.45M (8′) Arm modification kit No.

• 2.45M (8′) Arm assy
• 2.45M (8′) Arm hydraulic piping
(3) Arm
2.95M (9′8″) Arm modification kit No.

• 2.95M (9′8″) Arm
• 2.95M (9′8″) Arm hydraulic piping
No kit No. is given because it is provided after selection

(5) Idler (4) Connector
• Connector assy ; NPK

• Connector assy ; TOKU, KRUPP
No kit No. is given because only one sort of part is provided

link
• Idler link (Right)

• Idler link (Left)
63-1
(2) NIBBLER & BREAKER E135SR LC EVOLUTION

Classifi-
NAME
cation
Upper structure modification kit No.
• Modification of the control valve
• Install of the guard
• Hydraulic tank assy
• Instrument panel assy
(1) Upper
• Remote control piping

• Block control piping
• Main control piping
• Install of the name plate
Boom modification kit No.

(2) Boom
• 4.6M (15′1″) Boom

• 4.6M (15′1″) Boom hydraulic piping
2.45M (8′) Arm modification kit No.

• 2.45M (8′) Arm assy
• 2.45M (8′) Arm hydraulic piping
(3) Arm
2.95M (9′8″) Arm modification kit No.

• 2.95M (9′8″) Arm
• 2.95M (9′8″) Arm hydraulic piping
(4) Connector
No kit No. is given because it is provided after selection

• Connector assy
No kit No. is given because only one sort of part is provided

(5) Idler
link
• Idler link (Right)

• Idler link (Left)
63-2
1.2 ADDITIONAL PARTS FOR THE MODIFICATION OF THE BREAKER

(1) UPPER STRUCTURE BREAKER
Applicable
No. NAME Q’TY REMARK
Machines
Upper structure modification KIT No. BREAKER
• INSTALL OF THE GUARD

93 • • GUARD ASSY 1
• HYDRAULIC TANK ASSY

27-100 • • REPAIR KIT 1
• REMOTE CONTROL PIPING (P/V)

1 • • HOSE 1
2 • • HOSE 1
3 • • HOSE 1
4 • • NUT 1
5 • • PIN 1
6 • • WASHER 3
7 • • CAPSCREW 2
8 • • WASHER 2
9 • • BRACKET 1
10 • • PIN 1
11 • • PIN 1
12 • • CONNECTOR 1
13 • • CUSHION RUBBER 1
14 • • ELBOW 2
15 • • PILOT VALVE 1
16 • • PRESSURE SENSOR 1
18 • • LOCK ASSY 1
19 • • PEDAL 1
20 • • COVER 1
21 • • WASHER 1
23 • • PLATE 2
24 • • TEE 1
• BLOCK CONTROL PIPING

11 • • ELBOW 1
• MAIN CONTROL PIPING (C/V) STD

• MAIN CONTROL PIPING (C/V) Boom safety
• MAIN CONTROL PIPING (C/V) Boom / arm safety
1 • • TEE 1
11 • • ELBOW 1
18 • • HOSE 1
22 • • TUBE 1
• UPPER HYDRAULIC PIPING

1 • • BRACKET 1
2 • • BLOCK 1
3 • • BUSHING 1
5 • • ELBOW 1
7 • • ELBOW 1
8 • • CLIP 1
10 • • O RING 1
63－3
BREAKER
Applicable
Machines
11 • • O RING 1
12 • • HOSE 1
13 • • PLUG 1
14 • • HOSE 1
15 • • HOSE 1
18 • • WASHER 4
19 • • WASHER 4
20 • • CLIP 1
22 • • BUSHING 1

1 • • BRACKET 1
4 • • CLAMP 1
24 • • WASHER 1
• INSTAL OF THE NAME PLATE

21 • • LABEL 1
22 • • LABEL 1
(2) BOOM NOTE) COMMON TO NIBBLER & BREAKER BREAKER

Applicable
Machines
Boom modification KIT No. N&B, BREAKER
• 4.6M(15′1″) BOOM ASSY

2 • • TAPPED BLOCK 1
8 • • CLIP 1
9 • • CLIP 2
• 4. 6M(15′1″) BOOM HYDRAULIC PIPING

1 • • TUBE 1
2 • • TUBE 1
3 • • TUBE 1
4 • • TUBE 1
5 • • PLUG 2
6 • • CLAMP 3
7 • • CLAMP 3
8 • • CLAMP 1
12 • • LOCK WASHER 3
15 • • O RING 1
16 • • O RING 3
17 • • O RING 1
18 • • O RING 1
63－4
(3) 2.45M (8′) ARM BREAKER

Applicable
Machines
2.45M(8′) Arm modification KIT No. BREAKER
• 2.45M(8′) ARM ASSY

2 • • PLATE 1
• 2.45M(8′) ARM HYDRAULIC PIPING

1 • • TUBE 1
2 • • TUBE 1
3 • • HOSE 1
4 • • HOSE 1
5 • • STOP VALVE 2
7 • • CLAMP 1
8 • • CLAMP 1
9 • • BRACKET 2
14 • • WASHER 8
15 • • WASHER 4
18 • • O RING 3
19 • • O RING 1
2.95M (9′8″) LONG ARM NOTE) COMMON TO NIBBLER & BREAKER BREAKER
Applicable
Machines
2.95M(9′8″) Long Arm modification KIT No. N&B, BREAKER
• 2.95M(9′8″) LONG ARM ASSY

2 • • PLATE 1
3 • • PLATE 1
4 • • PLATE 2
5 • • PLATE 1
6 • • PLATE 1
• 2.95M(9′8″) LONG ARM HYDRAULIC PIPING

1 • • TUBE 1
2 • • TUBE 1
3 • • HOSE 1
4 • • HOSE 1
7 • • CLAMP 1
8 • • CLAMP 1
9 • • BRACKET 2
63－5
BREAKER
Applicable
Machines
14 • • WASHER 8
15 • • WASHER 4
18 • • O RING 3
19 • • O RING 1
(4) CONNECTOR ASSY NOTE) COMMON TO OCEANIA & ASIA SPEC. BREAKER
Applicable
Machines
No Kit No. is given because it is provided after selection.
• CONNECTOR ASSY
2 • • PLUG 1
3 • • O RING 1
• CONNECTOR ASSY
2 • • PLUG 1
3 • • O RING 1
(5) REINFORCING THE IDLE LINK NOTE) COMMON TO OCEANIA & ASIA SPEC. BREAKER
Applicable
Machines
Kit No. is not given because only one sort of part is provided.
• IDLER LINK (Right)

• IDLER LINK (Left)
1 • • PLATE 2 RH, LH
63－6
1.3 ADDITIONAL PARTS FOR THE MODIFICATION OF THE NIBBLER & BREAKER
(1) UPPER STRUCTURE N&B
Applicable
Machines
Upper structure modification KIT No. NIBBLER & BREAKER
• INSTALL OF THE GUARD

93 • • GUARD ASSY 1
• HYDRAULIC TANK ASSY

27-100 • • REPAIR KIT 1
• INSTRUMENT PANEL ASSY

39 • • SWITCH (SINGLE/CONFLUX) 1
• REMOTE CONTROL PIPING (P/V)

1 • • PILOT VALVE 1
2 • • PRESSURE SENSOR 1
4 • • PLUG 1
5 • • ELBOW 3
6 • • ELBOW 1
7 • • WASHER 3
8 • • HOSE 1
9 • • HOSE 1
10 • • HOSE 1
11 • • HOSE 1
12 • • PIN 1
13 • • PEDAL 1
14 • • RUBBER 1
15 • • LOCK ASSY 1
20 • • WASHER 4
21 • • NUT 1
• BLOCK CONTROL PIPING

11 • • ELBOW 1
• MAIN CONTROL PIPING (C/V)

11 • • ELBOW 1
23 • • ELBOW 1

1 • • BRACKET 1
2 • • SELECTOR VALVE 1
3 • • BUSHING 1
7 • • ELBOW 1
8 • • ELBOW 1
9 • • ELBOW 1
10 • • O RING 3
11 • • O RING 1
12 • • HOSE 1
13 • • HOSE 1
14 • • HOSE 1
15 • • HOSE 1
63－7
N&B
Applicable
Machines
18 • • WASHER 4
19 • • WASHER 4
20 • • CLIP 1
23 • • CLIP 1
25 • • LABEL 1

1 • • BRACKET 1
4 • • CLAMP 1
24 • • WASHER 1
• INSTAL OF THE NAME PLATE

20 • • LABEL 1
21 • • LABEL 1
22 • • LABEL 1
(2) BOOM NOTE) COMMON TO BREAKER N&B

Applicable
Machines
Boom modification KIT No. N&B, BREAKER
• 4.6M(15′1″) BOOM ASSY

8 • • CLIP 1
9 • • CLIP 2
• 4.6M(15′1″) BOOM HYDRAULIC PIPING

1 • • TUBE 1
2 • • TUBE 1
3 • • TUBE 1
4 • • TUBE 1
5 • • PLUG 2
6 • • CLAMP 3
7 • • CLAMP 3
8 • • CLAMP 1
15 • • O RING 1
16 • • O RING 3
17 • • O RING 1
18 • • O RING 1
63－8
(3) 2.45M (8′) ARM N&B

Applicable
Machines
2.45M(8′) Arm modification KIT No. NIBBLER & BREAKER
• 2.45M(8′) ARM ASSY

2 • • PLATE 1
3 • • PLATE 1
4 • • PLATE 2
5 • • PLATE 1
6 • • PLATE 1
• 2.45M(8′) ARM HYDRAULIC PIPING

1 • • TUBE 1
2 • • TUBE 1
3 • • HOSE 1
4 • • HOSE 1
7 • • CLAMP 1
8 • • CLAMP 1
9 • • BRACKET 2
14 • • WASHER 8
15 • • WASHER 4
18 • • O RING 3
19 • • O RING 1
2.95M (9′8″) LONG ARM NOTE) COMMON TO BREAKER N&B

Applicable
Machines
2.95M(9′8″) Long Arm modification KIT No. N&B, BREAKER
• 2. 95M(9′8″) LONG ARM ASSY 1

2 • • PLATE 1
3 • • PLATE 1
4 • • PLATE 2
5 • • PLATE 1
6 • • PLATE 1
• 2.95M(9′8″) LONG ARM HYDRAULIC PIPING

1 • • TUBE 1
2 • • TUBE 1
3 • • HOSE 1
4 • • HOSE 1
7 • • CLAMP 1
8 • • CLAMP 1
63－9
N&B
Applicable
No. PART No. NAME Q’TY REMARK
Machines
9 YW43H01044P1 • • BRACKET 2
10 ZS18C08025 • • CAPSCREW 8
11 ZS18C12045 • • CAPSCREW 4
12 ZS18C12055 • • CAPSCREW 1
13 ZS18C14060 • • CAPSCREW 1
14 ZW16H08000 • • WASHER 8
15 2418T10357 • • WASHER 4
16 ZW26X12000 • • LOCK WASHER 5
17 ZW26X14000 • • LOCK WASHER 1
18 ZD12A01800 • • O RING 3
19 ZD12A02100 • • O RING 1
(4) CONNECTOR ASSY N&B

Applicable
Machines
－ No Kit No. is given because it is provided after selection.
LP43H00004F1 • CONNECTOR ASSY

1 2444P1744D2 • • CONNECTOR 1
2 2420T4404 • • PLUG 1
3 ZD12P02400 • • O RING 1

1 2444P1745D2 • • CONNECTOR 1
2 2420Z1228D4 • • PLUG 1
3 ZD12P02400 • • O RING 1

1 LP43H01012P1 • • CONNECTOR 1
2 ZA82P28000 • • PLUG 1
3 ZD12P02400 • • O RING 1
(5) REINFORCING THE IDLE LINK N&B

Applicable
Machines
－ Kit No. is not given because only one sort of part is provided.
YY12B01006P1 • IDLER LINK (Right)

YY12B01007P1 • IDLER LINK (Left)
1 YN12B01321P1002 • • PLATE 2 RH, LH
63－10
2. SUMMARY
2.1 GENERAL PRECAUTIONS (1) • Specification prescribed
(1) Applications of Breaker or Nibbler & Breaker For specifications for nibbler & breaker, the
Breaker piping ................... Applicable only when modification of control valve is not required.
a breaker is mounted.
Nibbler & breaker piping .. Applicable only when (2) Functions of the option valve :
a nibbler and a The option valve is equipped with spool which
breaker are mounted. functions to send the pressure oil into nibbler
and breaker, and also to switch the flow
(2) Modifying a Breaker and a Nibbler & direction to the rod side or head side of the
Breaker nibbler cylinder.
There are specific procedures to be followed
when modifying a breaker and a nibbler & (3) Action of the single / conflux flow switch :
breaker. Therefore, when they are to be The single/conflux flow select switch is
modified at our service shop, contact the provided on the instrument panel and is
nearest breaker and nibbler manufacturer’s connected to the harness to actuate the
office, and obtain instructions, so that you single/conflux flow select spool.
install the pipes and handle the machinery
correctly. (4) Installing the operation pedal :
A pedal and a pilot valve are mounted to the
(3) Differences between a Breaker Piping and a floor plate and a remote control piping is
Nibbler & Breaker Piping placed between the option valves and pedal,
z Breaker Piping in order to operate the breaker or the nibbler.
There is a single oil flow from pump
P2 to the breaker. The oil returns to (5) Installing the selector valve :
the hydraulic tank directly. The flow For the machines equipped with nibbler and
is single flow. breaker, the selector valve which functions to
change the oil flow direction according to the
use of breaker or nibbler is provided on the
If the return oil from the breaker is fed back to the main C/V in the inside of guard on the right
control valve, the pulsation of the breaker is side of slewing motor.
transmitted to the oil cooler. This causes the
machine to break down. (6) Reinforcement of the attachment :
Reinforcement plates are welded to the
z Nibbler Piping standard arm (civil engineering services : for
The oil flows to the nibbler is conflux general use) and to the idler links of the
flow ; the oil flow is changed to the nibbler & breaker attached machine.
rod and the head of the nibbler
cylinder. (7) Replace the return filter with new standard
filter.
2.2 BASIC METHOD TO BE TAKEN WHEN
MOUNTING
When mounting the breaker or nibbler,
always execute the following seven items :
63－11
2.3 LAYING OF PIPING

(1) Breaker specification
6.1.2 or 6.1.3
ARM HYDRAULIC
PIPING 6.1.1
HYDRAULIC PIPING FOR BOOM
STOP 4.7
VALVE UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
6.1.2 or 6.1.3 4.4 FILTER FOR BREAKER
ARM 4.3 OPTION VALVE
(ADD-ON VALVE)
6.3
HYDRAULIC
ARM TOP
BREAKER 4.3
PIPING
MAIN CONTROL VALVE
4.6
OPERATING
PEDAL
4.2 FLOOR MAT

4.6 REMOTE CONTROL PIPING
Fig. 1 Outside view of Breaker-attached machine
(2) Nibbler & Breaker specification

6.1.2 or 6.1.3
ARM HYDRAULIC
PIPING
6.1.1
HYDRAULIC PIPING FOR BOOM
5.4
UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
STOP
VALVE 4.4
FILTER FOR
BREAKER 5.4
6.2.1 or 6.1.3
SELECTOR VALVE
ARM
4.3
HYDRAULIC 6.4 OPTION VALVE
BREAKER ARM TOP (ADD-ON VALVE)
Replacing the PIPING
4.3
breaker with
the nibbler is MAIN CONTROL VALVE
OPERATING
possible. PEDAL
5.2
FLOOR MAT 5.3
REMOTE CONTROL PIPING
5.5 SINGLE / CONFLUX FLOW SELECT SWITCH
Fig. 2 Outside view of Nibbler & Breaker-attached machine
63-12
3. HYDRAULIC CIRCUIT DIAGRAM BREAKER SPECIFICATION
No. NAME
3.1 FUNCTION NOTE : 50 CONTROL VALVE (OPT.2)
(1) Hydraulic circuit for breaker 1. This hydraulic circuit is used to add to following circuit. 51 STOP VALVE
52 PILOT VALVE
REMARK
53 RETURN FILTER
E115SR STD
E135SR STD
(1) Circuit for Breaker

2. Selection condition and proportional valve command when breaker is in service.
1) Breaker pedal operation
CONDITIONS FOR COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE z Pedal
SELECTION (W : ○ , W/O : ―)
SINGLE/CONFLUX TRAVEL Foot pedal depressing section. Operating condition.
SELECT SWITH P1 PUMP P2 PUMP STRAIGHT P1 CUT P2 CUT Pedal in neutral position. Breaker stop operating
NIBBLER CONFLUX FLOW CONFLUX FLOW (ON) ○ ○ ○ ○ ○ Depress heel section. Breaker starts operating.
NIBBLER SINGLE FLOW CONFLUX FLOW (OFF) ― ○ ― ― ○
2) Mechatro system
BREAKER CONFLUX FLOW (OFF) ― ○ ― ― ○
Turn the single/conflux flow select switch to
the single side (opposite side of nibbler
conflux) and the function of mechatro
controller is switched into the breaker
specification as shown in Note 2. Depress the
breaker foot pedal and the pilot secondary
pressure flows into low pressure sensor (SE-
12), low pressure sensor output voltage is
input into the mechatro controller, and
consequently the mechatro controller
executes the pilot signal processing and
outputs the command value corresponding to
the input voltage, resulting in the function
shown by mark ○ in Note 2.
3) Pilot circuit
By depressing breaker pilot valve (52), the
pilot secondary pressure flows into PA02 port
of C/V and switches the breaker spool. The P2
bypass proportional valve secondary pressure
flows into PCa port of C/V and switches the
P2 bypass cut proportional valve.
4) Main circuit
The P2 pump delivery oil flows out through
A02 port of C/V and reaches to the breaker.
The return oil from the breaker flows into the
tank directly.
Fig. 3 Hydraulic circuit for breaker
63-13
(2) Hydraulic circuit for Nibbler & Breaker NOTE : NIBBLER & BREAKER SPECIFICATION
This hydraulic circuit is used to add to following circuit. No. NAME
REMARK
50 CONTROL VALVE (OPT.2)
51 SELECTOR VALVE
E115SR STD
52 STOP VALVE
E135SR STD
53 PILOT VALVE
2. The OPT valve port relief pressure is adjusted before shipment. 54 RETURN FILTER
However, when it is required to install at site, the relief pressure should be adjusted at site.
(5) Circuit for Nibbler & Breaker
3. Marking of selector valve (51.)
1) Nibbler & Breaker switch & pedal operation
Stamped N : NIBBLER
z Single / Conflux flow select switch
Stamped B : BREAKER
Single/Conflux Function of
4. Selection condition and proportional valve command when any of nibbler single & conflux Specification
flow select switch mechatrocontroller
flow or breaker is in service. Nibbler conflux flow Nibbler conflux flow(ON) Refer to Note 4.
"Selection condition
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE Nibbler single flow Nibbler conflux flow(OFF) and proportional
CONDITIONS FOR SELECTION (W : ○ , W/O : ―) valve command when
SELECTOR Breaker Nibbler conflux flow(OFF) breaker is in service".
SINGLE/CONFLUX VALVE TRAVEL
SELECT SWITH P1 PUMP P2 PUMP STRAIGHT P1 CUT P2 CUT
(No.51) z Pedal
NIBBLER CONFLUX FLOW CONFLUX FLOW (ON) N ○ ○ ○ ○ ○ Foot pedal depressing
N&B Operating condition.
CONFLUX FLOW section.
NIBBLER SINGLE FLOW N ― ○ ― ― ○ Depress toe section. Nibbler close
(OFF) Nibbler
CONFLUX FLOW Depress heel section. Nibbler open
BREAKER B ― ○ ― ― ○ Depress toe section. Breaker stop operating.
(OFF) Breaker
Depress heel section. Breaker starts operating.
2) Mechatro system
the nibbler conflux side and the function of
mechatro controller is switched into the
nibbler conflux specification as shown in Note
4. Depress the N&B foot pedal and the pilot
secondary pressure flows into either of low
pressure sensors(SE-11), low pressure sensor
output voltage is input into the mechatro
controller, consequently the mechatro
controller executes the pilot signal processing
and outputs the command value
corresponding to the input voltage resulting
in the function shown by mark ○ in Note 4.
3) Pilot circuit
Depress N&B pilot valve (53), the pilot
secondary pressure flows into PA02 port of
C/V through B port and switches the N&B
spool. And the solenoid proportional valve
secondary pressure switches the travel
straight valve of C/V, P1 by-pass cut valve
and P2 bypass cut valve.
However, when the breaker is used with the 4) Main circuit
N&B circuit or the breaker circuit, the pedal P1,P2 pump delivery oil is confluxed in the
operation is reversed, that is, the port the C/V, is discharged through A02 port and is
pilot secondary pressure flows into is changed fed into nibbler H side, and consequently the
from PA02 to PB02, and the main circuit nibbler starts the closing action.
supply port is from A02 to B02. And the The return oil from the nibbler R side flows
return oil flows into the tank directly by into the hydraulic tank through B02 port of
Fig. 4 Hydraulic circuit for Nibbler & Breaker switching the selector valve. C/V.
63-14
3.2 ELECTRIC SYSTEM DIAGRAM FOR
NIBBLER & BREAKER
C-1 : MECHATRO CONTROLLER
SW-22 : SINGLE / CINFLUX FLOW

SELECT SWITCH
(1) Control of N&B

the nibbler conflux side, and grounding signal
flows to 14-4 pin of the mechatro controller
and switches the function as shown in Note 4.
in Fig. 4.
Fig.5 Single / Conflux flow select switch
63-15
3.3 HYDRAULIC COMPONENTS 2-M10-20/27 (FOR LIFTING) 3.3.3 PILOT VALVE FOR NIBBLER & BREAKER
4-M10 SCREW DEPTH 13
3.3.1 CONTROL VALVE ASSY
OPTION VALVE (BREAKER, NIBBLER & BREAKER) SECONDARY
PRESSURE OPERATING TORQUE
E115SR E135SR
CONTROL VALVE CONTROL VALVE
SECONDARY PRESSURE
ASSY (STD) ASSY (STD)
OPERATING FORCE
WITH OPT2 WITH OPT2
CIRCUIT DIAGRAM
OPERATING ANGLE
3-M10-20/27 (FOR LIFTING) T CONTROL DIAGRAM
P1(P2)
TRAVEL
PTb TRAVEL TRAVEL PAL PBL
TRAVEL LEFT LEFT
STRAIGHT STRAIGHT PBs2
Dra,Drb SWING PBs1
PBr TRAVEL SWING PAs
PAr
LEFT TRAVEL Pss
BUCKET RIGHT BOOM CUT PCa
PB1 CONFLUX
PBc PAc BOOM
BUCKET
CONFLUX PLc2
BOOM PAa ARM
Drd
PBb PAb BOOM ARM
ARM
P1 CUT Pis RECIRCU-
LATION
ARM
PA1 PCb P1 CUT ARM
CONFLUX
RECIRCULATION
PAo2 PBo2
OPTION 2
(P4)
(P3)
Fig. 6 Control valve (Breaker,Nibbler & Breaker)
3.3.2 PILOT VALVE FOR BREAKER

SECONDARY
PRESSURE OPERATING FORCE
4-PF1/4
JISB2351 O
2-∅11THROUGH
Fig. 8 Pilot valve (Nibbler & Breaker)
CIRCUIT DIAGRAM
CONTROL DIAGRAM
Fig. 7 Pilot valve (Breaker)
63-16
4. MODIFICATION PROCEDURE FOR BREAKER

4.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a breaker-mounted
machine are as follows :
Table 1
Main modification Reference Main items to be
No. ITEM
points pages added and change
4.2 Modification of floor mat Cutout of floor mat. 4-1 Floor mat
Modification of the Install of the option Option valve

4.3 control valve 4-2
valve Capscrew
Replace return
Modification of the filter
4.4 hydraulic tank Replace return filter 4-3 Plug (for return)
canceled
Part of the guard
4.5 Install of the guard 4-3 Guard
changed
Remote control Pilot valve
Pilot valve
piping Pilot Install of the pedal
valve Control piping Pedal
4-4
Block control Install of the block
Block
Control piping (Block) and piping
4.6
piping
Main control
Control piping for Hose
piping 4-5
(Option valve) option valve Connector
Control
valve→Hydraulic Hose
piping for breaker
4.7 Upper hydraulic piping 4-6
Replace hose fitting Bracket
clamp Clamp
4.8 Install of the name plate Add label 4-8 Label
4.2 FLOOR MAT (BREAKER)

Make slits (notch) to face of the standard floor CUT OUT
mat according to Fig. 1 and cut out the hatching.
Floor mat for breaker.
Fig. 1 Modification of floor mat
63-17
4.3 MODIFICATION OF THE CONTROL VALVE

(BREAKER, NIBBLER & BREAKER)
4.3.1 MODIFICATION PROCEDURE
Install the additional parts listed in Table 2
to the control valve of the standard machine,
as shown in Fig. 2. On that occasion, some
parts become unnecessary.
Table 2
MODIFICATION OF THE CONTROL VALVE
No. NAME Q’TY REMARK 1

Standard
CONTROL VALVE (1) machine
1 OPTION VALVE 1
2
Fig. 2 Modification of control valve
4.3.2 PARTS TO BE DISUSED

When the option valve is installed, the parts
shown in Table 3 and Fig. 3 are disused from
the standard machine.
Table 3
271
Fig. 3 Parts to be disused
63-18
4.4 REPLACEMENT OF RETURN FILTER OF 4.5 MODIFICATION OF THE GUARD
THE HYDRAULIC TANK (BREAKER, NIBBLER & BREAKER)
VALVE
(BREAKER, NIBBLER & BREAKER) 4.5.1 MODIFICATION PROCEDURE
When the standard machine is modified to nibbler Install the additional parts listed in Table 5 to the 93
& Breaker machine, replace the return filter with guard of the standard machine, as shown in Fig.
new one. 6. On that occasion, some parts become
unnecessary.
Table 5
z Be sure to release the internal pressure
INSTALL OF THE
remaining in the hydraulic tank and hydraulic
GUARD
oil circuit before inspection, maintenance and
repair. No. NAME Q’TY REMARK
93 GUARD ASSY 1
Supplementary Explanation : Fig.4 Drain pressure for hydraulic tank

The internal pressure in the hydraulic tank can be
CAPSCREW
released by pushing the valve with the rubber cap Fig.6 Install of the guard
on the upper surface of the tank 5 or 6 times. WASHER
COVER
4.4.1 REPLACING PROCEDURE
Remove the capscrew, on the hydraulic tank and 4.5.2 PARTS TO BE DISUSED
7
take out the spring, check valve and filter Concerning the guard install, the parts listed in 17
element. table 6 and in Fig. 7 are disused from the
Replace them with return filters shown below SPRING
standard machine.
according to the procedure shown in table 4 and Turn this handle,
and remove element Table 6
Fig.5. Replace it by the reverse procedure of
disassembly. No. NAME Q’TY REMARK
CHECK 17 GUARD ASSY 1
Table 4 VALVE
4
HYDRAULIC TANK ASSY
1
No. NAME Q’TY REMARK ELEMENT
ASSY
27-100 REPAIR KIT
1 FILTER ELEMENT 1 PLATE
4 O RING 1 5 Fig.7 Parts to be disused

5 PACKING 1
7 O RING 1
Fig.5 Replace of return filter
63－19
4.6 CONTROL PIPING (BREAKER) Table 8
4.6.1 REMOTE CONTROL PIPING & BLOCK BLOCK CONTROL PIPING
CONTROL PIPING NOTE :
(1) Modification procedure z Before starting the modification work, check parts
Assemble the additional parts listed in Table according to the Additional Parts List. B8 CONNECTOR 1 PF1/4
7 and 8 to the control valve of the standard z When disconnecting and reconnecting pipes, B11 ELBOW 1 PF3/8-PF1/4
machine, as shown in Fig. 8 and 9. On that take care, so as not to allow dirt and foreign
occasion, some of the existing parts must be matter to enter.
used and some of them become unnecessary.
REMOTE CONTROL PIPING Table 7

No. NAME Q’TY REMARK No. NAME Q’TY REMARK
A1 HOSE L=3200 1 PF1/4 A13 CUSHION RUBBER 1
A2 HOSE L=400 1 PF1/4 A14 ELBOW 2 PF1/4
A3 HOSE L=500 1 PF1/4 A15 PILOT VALVE 1
A4 NUT 1 A16 PRESSURE SENSOR 1
A5 PIN 1 A17 CAPSCREW 2
A6 WASHER 3 A18 LOCK ASSY 1 R.H
Fig. 9 Block control piping reconstruction
A7 CAPSREW 2 A19 PEDAL 1
A8 WASHER 2 A20 COVER 1
A9 BRACKET 1 A21 WASHER 1 (2) Parts to be disused
A10 PIN 1 A22 CONNECTOR 1 PF1/4 Concerning the block control piping, the parts
A11 PIN 1 A23 PLATE 2 listed in table 9 and Fig. 10 are disused from
PF1/4
A12 CONNECTOR 1 With filter A24 TEE 1 PF1/4 the standard machine.
TIGHTENING TORQUE Table 9

A5 A19 A20
Capscrew(10T) No. NAME Q’TY REMARK
A18
A6 A7 Thread Spanner Tightening torque C9 PLUG 1 PF3/8
A4 A18 A11 (mm) kgfym (lbfyft)
A21 size C13 PLUG 1 PF1/4
A17
A6 A8 M8 13 3.6 (26)
A18 A9 Hydraulic hose

O ring type coupling Fig. 10 Parts to be disused
A23 (30°flare)
Thread Spanner Tightening torque Tightening torque
A18 A18 A10
size
(mm) kgfym (lbfyft) kgfym (lbfyft)
A18 A13 (PF) (3) Parts to be disused
1/4 19 3.7 (27) 3.0 (22) 4
Concerning the remote control piping, the
A14 A15 parts listed in table 10 and in Fig. 11 are 8
A12 disused from the standard machine. 2
A14
A3 Table 10
A2 2 SUPPORT 1
4 COVER 1
A16 A24 A22 A1
8 SEMS BOLT 2
Er
A2
A3 A1
Fig. 8 Remote control piping (Breaker)
63-20
4.6.2 MAIN CONTROL PIPING (BREAKER) Table 11 TIGHTENING TORQUE
Modification Procedure CONTROL VALVE PIPING O ring type coupling Hydraulic hose
Install the additional parts listed in Table 11 No. NAME Q’TY REMARK Thread Spanner Tightening torque Tightening torque
size
to the main control piping of the standard 1 TEE 1 PF1/4 (PF) (mm) kgfym (lbfyft) kgfym (lbfyft) Note)
machine, as shown in Fig. 12. 8 CONNECTOR 1 PF1/4-PF3/8 1/4 19 3.7 (27) 3.0 (22) ※ Remove the existing plug
11 ELBOW 1 PF1/4-PF3/8 3/8 22 7.5 (54) PF3/8 and install this Elbow
(connector).
NOTE : 18 HOSE 1 PF1/4
z Before starting the modification work, check parts 22 HOSE GUARD 1

according to the Additional Parts List.
z When disconnecting and reconnecting pipes,
take care, so as not to allow dirt and foreign
matter to enter.
Fig. 12 Main control piping (Breaker)
63-21
4.7 UPPER HYDRAULIC PIPING (BREAKER)
Fit the additional parts in table 12 and 13, NOTE :
according to Fig. 13. z Before starting the modification work, check parts
On that occasion, some parts become according to the Additional Parts List.
unnecessary. z When disconnecting and reconnecting pipes,
TIGHTENING TORQUE
Hydraulic hose matter to enter.
(ORS Type) z At assembly, use care of O rings do not come off.
Spanner Tightening torque
Thread size
(mm) kgfym (lbfyft) z Regarding the tightening torque of O ring type
1-14UNS 32 14 (100) joints, hydraulic hoses and flareless joints, refer
1 3/16-12UN 36 18 (130) to the Remark of Table 12, 13 and the Tightening
Torque Table.
Hydraulic hose
O ring type coupling (30°flare)
size
(PF) (mm) kgfym (lbfyft) kgfym (lbfyft)
3/8 22 7.5 (54)
1/2 27 11(80)
3/4 36 16.5 (120)
1 41 26 (190) 14 (100)
Capscrew
Tightening torque
Thread size
kgfym (lbfyft)
M8 3.6 (26)
M10 7.2 (52)
M12 12.3 (89)
UPPER HYDRAULIC PIPING Table 12

1 BRACKET 1 12 HOSE L=3100 1 1-14UNS
2 BLOCK 1 PF3/4 13 PLUG 1 PF3/4
3 BUSHING 1 14 HOSE L=1950 1 1 3/16-12UN
4 CONNECTOR 1 PF1-PF3/4 15 HOSE L=850 1 PF1
1-3/16-
5 ELBOW 1 12UN-PF3/4 16 CAPSCREW 4
1-14UNS-
6 CONNECTOR 1 PF3/4 17 CAPSCREW 3
7 ELBOW 1 PF1 18 WASHER 4
8 CLIP 1 19 WASHER 4
9 CAPSCREW 1 20 CLIP 1
10 O RING 1 1-14UNS 21 CONNECTOR 1 PF1
11 O RING 1 1 3/16-12UN 22 BUSHING 1
Table 13
1 BRACKET 1
4 CLAMP 1
24 WASHER 1
48 BUSHING 1 Fig. 13 Upper hydraulic piping (Breaker)
63-22

Concerning the return hydraulic piping, the parts B4
listed in table 14 and Fig. 14 are disused from the
standard machine.
Table 14
No. PART Q’TY REMARK
NAME
B4 PLUG 1 PF1

With the extension of breaker circuit, the parts
shown in Table 15 and Fig. 15 are canceled from
A46
Table 15
No. PART Q’TY REMARK
A45
NAME
A45 BRACKET 1
A46 CLAMP 1
63-23
4.8 INSTALL OF THE NAME PLATE (BREAKER)

Fit the labels shown in Table 16 to the cab of the 22
standard machine, according to Fig. 16.
Table16
INSTALL OF THE NAME PLATE
21 LABEL 1
22 LABEL 1
(21)
21
RIGHTHAND VIEW OF CAB INTERIOR
(22)
Attachment operation by foot pedal.

Always check the foot pedal control pattern
before operation.
Always read operators manual before
operating machine.
Fig. 16 Labeling position
63-24
5. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER
5.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a nibbler & breaker-
mounted machine are as follows :
Table 1
Main modification Reference Main items to be
No. ITEM
points pages added and change
5.2 Modification of floor mat Cutout of floor mat. 5-1 Floor mat
Refer
to Modification of the Install of the option Option valve
4-2
4.3 control valve valve Capscrew
Refer
to Modification of the Replace return filter
Replace return filter 4-3 Plug (for return)
4.4 hydraulic tank canceled
Refer
to Part of the guard
Install of the guard 4-3 Guard
4.5 changed
Remote control piping Pilot valve Install of the Pilot valve
Pilot valve pedal control piping Pedal
5-3
Block control Install of the block
Block
Control piping (Block) and piping
5.3
piping
Main control piping Control piping for Hose
5-4
(Option valve) option valve Connector
Control
valve→Hydraulic piping Hose
5.4 Upper hydraulic piping for breaker 5-5
Replace hose fitting Bracket
clamp Clamp
Modification of the Install of the single
5.5 conflux flow select 5-6 Switch
instrument panel switch
5.6 Install of the name plate Add label 5-6 Label
5.2 FLOOR MAT (NIBBLER & BREAKER)

Make slits (notch) to face of the standard floor CUT OUT
mat according to Fig. 1 and cut out the hatching.
Floor mat for breaker.
Fig. 1 Modification of floor mat
63-25
5.3 CONTROL PIPING (NIBBLER & BREAKER) Table 3
5.3.1 REMOTE CONTROL PIPING & BLOCK BLOCK CONTROL PIPING
CONTROL PIPING NOTE :
(1) Modification procedure z Before starting the modification work, check parts
Assemble the additional parts listed in Table according to the Additional Parts List. B8 CONNECTOR 1 PF1/4
2 and 3 to the control valve of the standard z When disconnecting and reconnecting pipes, B11 ELBOW 1 PF3/8-PF1/4
machine, as shown in Fig. 2 and 3. On that take care, so as not to allow dirt and foreign
occasion, some of the existing parts must be matter to enter.
used and some of them become unnecessary.
REMOTE CONTROL PIPING Table 2

A1 PILOT VALVE 1 A12 PIN 1
A2 PRESSURE SENSOR 1 A13 PEDAL 1
A3 CONNECTOR 1 PF1/4 A14 RUBBER 1
A4 PLUG 1 PF1/4 A15 LOCK ASSY 1 R.H
A5 ELBOW 3 PF1/4 A16 CAPSCREW 2
PF1/4
A6 ELBOW 1 With filter A17 CAPSCREW 2
A7 WASHER 3 A18 CAPSCREW 2
A8 HOSE L=500 1 PF1/4 A19 LOCK WASHER 2 Fig. 3 Block control piping reconstruction
A9 HOSE L=400 1 PF1/4 A20 WASHER 4
A10 HOSE L=3200 1 PF1/4 A21 NUT 1 (2) Parts to be disused
A11 HOSE L=2900 1 PF1/4 Concerning the block control piping, the parts
listed in table 4 and Fig. 4 are disused from
TIGHTENING TORQUE
Capscrew Table 4
Thread size
Tightening torque No. NAME Q’TY REMARK
kgfym (lbfyft)
M8 3.6 (26) C9 PLUG 1 PF3/8
M10 7.2 (52) C13 PLUG 1 PF1/4
O ring type coupling Hydraulic hose

size
(mm) kgfym (lbfyft) kgfym (lbfyft)
(PF)
1/4 19 3.7 (27) 3.0 (22)
(3) Parts to be disused
Concerning the remote control piping, the 4
parts listed in table 5 and in Fig. 5 are 8
disused from the standard machine. 2
Table 5
2 SUPPORT 1
4 COVER 1
8 SEMS BOLT 2
Fig. 2 Remote control piping (Nibbler & Breaker)

63-26
5.3.2 MAIN CONTROL PIPING (NIBBLER & BREAKER) TIGHTENING TORQUE
Modification Procedure Table 6 O ring type coupling Hydraulic hose
Install the additional parts listed in Table 6 CONTROL VALVE PIPING Thread Spanner Tightening torque Tightening torque Note)
size
to the main control piping of the standard No. NAME Q’TY REMARK (PF) (mm) kgfym (lbfyft) kgfym (lbfyft) ※ Remove the existing
machine, as shown in Fig. 6. 11 ELBOW 1 PF1/4-PF3/8 1/4 19 3.7 (27) 3.0 (22) plug PF3/8 and install this
Elbow .
23 ELBOW 1 PF1/4-PF3/8 3/8 22 7.5 (54)
NOTE :
z Before starting the modification work, check parts
according to the Additional Parts List.
z When disconnecting and reconnecting pipes,
matter to enter.
Fig. 6 Main control piping (Nibbler & Breaker)

63-27
5.4 UPPER HYDRAULIC PIPING ((NIBBLER & BREAKER)
Fit the additional parts in table 7 and 8, NOTE :
according to Fig. 7. z Before starting the modification work, check parts
On that occasion, some parts become according to the Additional Parts List.
unnecessary. z When disconnecting and reconnecting pipes,
TIGHTENING TORQUE take care, so as not to allow dirt and foreign
matter to enter.
Hydraulic hose
(ORS Type) z At assembly, use care of O rings do not come off.
Spanner Tightening torque z Regarding the tightening torque of O ring type
Thread size
(mm) kgfym (lbfyft)
1-14UNS 32 14 (100)
joints, hydraulic hoses and flareless joints, refer
1 3/16-12UN 36 18 (130)
to the Remark of Table 7, 8 and the Tightening
Torque Table.
Hydraulic hose
O ring type coupling (30°flare)
size
(PF) (mm) kgfym (lbfyft) kgfym (lbfyft)
3/4 36 16.5 (120)
1 41 26 (190) 14 (100)
Capscrew
Tightening torque
Thread size
kgfym (lbfyft)
M8 3.6 (26)
M12 12.3 (89)
UPPER HYDRAULIC PIPING Table 7

1 BRACKET 1 14 HOSE L=1950 1
2 SELECTOR VALVE 1 15 HOSE L=850 1
3 BUSHING 1 16 CAPSCREW 4
4 CONNECTOR 1 PF1-PF3/4 17 CAPSCREW 3
1-14UNS-
5 CONNECTOR 1 PF3/4 18 WASHER 4
1-14UNS-
6 CONNECTOR 1 PF3/4 19 WASHER 4
7 ELBOW 1 PF1 20 CLIP 1
1-14UNS-
8 ELBOW 1 PF3/4 21 CONNECTOR 1
1 3/16UN-
9 ELBOW 1 PF3/4 22 BUSHING 1
10 O RING 3 23 CLIP 1
11 O RING 1 24 CAPSCREW 1
12 HOSE L=3050 1 25 LABEL 1
13 HOSE L=1540 1 Changing over procedure of the selector valve
TO TANK
Table 8 TO TO
ATTACHMENT ATTACHMENT
No. NAME Q’TY REMARK TO CONTROL TO CONTROL
VALVE (A02) VALVE (A02)
1 BRACKET 1
4 CLAMP 1 WHEN USING BREAKER WHEN USING NIBBLER
24 WASHER 1
48 BUSHING 1 Fig. 7 Upper hydraulic piping (Nibbler & Breaker)
63-28
5.5 MODIFICATION OF THE INSTRUMENT 5.6 INSTALL OF THE NAME PLATE
22
PANEL (NIBBLER & BREAKER) (NIBBLER & BREAKER)
5.5.1 MODIFICATION PROCEDURE Fit the label shown in table 11 to the cab of the
Install the additional parts listed in Table 9 to the standard machine, according to Fig. 10.
instrument panel assy of the standard machine, Table 11
as shown in Fig. 8. On that occasion, some parts INSTALL OF THE NAME PLATE
become unnecessary.
20 LABEL 1
Table 9
21 LABEL 1
INSTRUMENT PANEL ASSY 22 LABEL 1
No. NAME Q’TY REMARK 39 23 LABEL －
For single /
39 SWITCH 1 conflux Fig. 8 Modification of instrument panel
switching
(20) 21
RIGHTHAND VIEW OF CAB INTERIOR

When the instrument panel is modificated, the
parts shown in Table 10 and Fig. 9 are disused
from the standard machine.
Table 10 (21)
13 CAP 1
13
LEFTHAND VIEW OF CAB INSTRUMENT PANEL
(22)
Attachment operation by foot pedal.

Always check the foot pedal control pattern
before operation.
Always read operators manual before
operating machine.
(23)
20
Do not set this switch to nibbler conbined flow
operation position when using breaker.
VIEW Ⅴ
Fig. 10 Labeling position
63-29
6. MODIFICATION PROCEDURE FOR ATTACHMENT
6.1 MODIFICATION ITEM FOR BREAKER ATTACHMENT
The main item that are needed to modify the standard boom and standard arm into a breaker-mounted
machine are as follows:
Table 1
Reference Modification
No. Specification Types of attachment
page item
Tapped
Modification of the 4.6M (15´1˝) boom 6-2
block weld
Breaker
6.1.1 6-3
N/B Install of
4.6M (15´1˝) boom hydraulic piping
the piping
6-4
Tapped
Breaker Modification of the 2.45M (8´) arm 6-5
block weld
6.1.2
Breaker Install of
2.45M (8´) arm hydraulic piping 6-6
N/B the piping
Tapped
Modification of the 2.95M (9´8˝) arm 6-7
Breaker block weld
6.1.3
N/B Install of
2.95M (9´8˝) arm hydraulic piping 6-8
the piping
6.3 Breaker Install of the
Connector assy 6-11
6.4 Nibbler connector
Breaker
6.5 Reinforcing of the idler link 6-12 Plate
N/B
63-30
6.1.1 MODIFICATION OF THE 4.6M (15fty1in) BOOM

(1) Modification of the 4.6M (15ft-1in)
boom〔Breaker, Nibbler & Breaker〕 NOTE :
Weld the additional parts listed in table 2 to z Use weld symbol B welding rod (mild steel 50kg
the boom of the standard specification, grade).
according to Fig. 1. z Seal the unwelded areas of the tapped block.
Table 2
BOOM
ASSY
No. NAME REMARK
1 BOOM ASSY ─ STD
BOOM ASSY (1) STD
2 TAPPED BLOCK ─
3 TAPPED BLOCK 1
4 TAPPED BLOCK ─
5 TAPPED BLOCK 2
6 TAPPED BLOCK ─
7 TAPPED BLOCK 1
8 TAPPED BLOCK 2
9 TAPPED BLOCK 1
10 TAPPED BLOCK 1
11 CLIP 1
12 CLIP 2
Fig. 1 Modification of the 4.6M (15ft-1in) boom (Breaker, Nibbler & Breaker)
63－31
(2) Hydraulic piping for 4.6M (15ft-1in) boom

(Breaker, Nibbler & Breaker) NOTE :
1) Spec. z Apply Loctite #242 to the clamp mounting bolts.
Install the additional parts listed in table 3 to z At assembly, use care of O rings do not come off.
the 4.6m (15ft-1in) boom modified under par.
6.1.1 (1) as shown in Fig. 2.
HYDRAULIC PIPING
FOR 4.6M (15´1˝ )BOOM
Table 3
1 TUBE 1 11 CAPSCREW 3
2 TUBE 1 12 LOCK WASHER 3
5 PLUG 2 15 O RING 1
6 CLAMP 3 16 O RING 3
9 CAPSCREW 3 19 CAPSCREW 2
10 CAPSCREW 1
NOTE :
z For M-threads Tightening torque z Tightening torque of ORS coupling nuts.
Thread size Tightening torque Thread size Tightening torque
M10 6.7kgfym (48.5 lbfyft) 1-14UNS 14kgfym (101 lbfyft)
M12 11.7kgfym (85 lbfyft) 1 3/16-12UN 18kgfym (131 lbfyft)
M14 18.5kgfym (133 lbfyft) 1 7/16-12UN 21kgfym (152 lbfyft)
z For PF, PT-threads Tightening torque 1 11/16-12UN 33kgfym (241 lbfyft)
Thread size Tightening torque z Remove item 5 plug as necessary, and install an
PF1, PT1 26kgfym (188 lbfyft) accumulator recommended by the breaker
maker.
Fig. 2 Hydraulic piping for 4.6M (15ft-1in) boom (Breaker, Nibbler & Breaker)
63－32
6.1.2 MODIFICATION OF THE 2.45M (8ft) ARM

(BREAKER)
(1) Modification of the 2.45M (8ft) arm
When the additional parts listed in table 5 to NOTE :
the arm of the standard specification, z Use weld symbol B welding rods (mild steel 50kg
according to Fig. 4. grade).
z Seal the unwelded areas of the tapped block.
Table 5
2.45M (8ft) ARM ASSY

ARM (1) －
1 STD
ARM － (1)
2 PLATE 1 －
3 TAPPED BLOCK 1 2
4 TAPPED BLOCK 1 －
5 TAPPED BLOCK 2 2
Fig. 4 Modification of the 2.45M (8ft) arm (Breaker)
63－33
(2) Hydraulic piping for 2.45M (8ft) arm

This hydraulic piping applies to both the z Apply Loctite #242 to the clamp mounting bolts.
breaker machine and the nibbler & breaker z For M-threads
machine. Install the additional parts listed in Thread size Tightening torque
table 6 to the 2.45m (8ft) arm body modified M8 3.4kgfym (25 lbfyft)
under par. 6.1.2 (1) as shown in Fig. 5. M12 11.7kgfym (85 lbfyft)
Table 6 z For PF,PT-threads Tightening torque
HYDRAULIC PIPING FOR Thread size Tightening torque
2.45M (8ft) ARM
PF3/4, PT3/4 16.5kgfym (120 lbfyft)
z Tightening torque for ORS cupling nuts.
1 TUBE 1
Thread size Tightening torque
2 TUBE 1
1 3/16-12UNS 18kgfym (130 lbfyft)
3 HOSE 2
z At assembly, use care of O rings do not come off.
4 STOP VALVE 2
5 CONNECTOR 2
6 CLAMP 2
7 BRACKET 2
8 CAPSCREW 8
9 CAPSCREW 4
10 CAPSCREW 2
11 WASHER 8
12 WASHER 4
13 LOCK WASHER 6
14 O RING 4
3
1
3
2
14
5,14
4 8,11 10,13
10,13 6
9,12,13
7
8,11
7 SECTION SECTION
9,12,13
Fig. 5 Hydraulic piping for 2.45M (8ft) arm (Breaker, Nibbler & Breaker)
63-34
6.1.3 MODIFICATION OF THE 2.95M (9ft-8in)

ARM
(1) Modification of the 2.95M (9ft-8in) arm
When the additional parts listed in table 7 to NOTE :
Table 7 z Seal the unwelded areas of the tapped block.
2.95M (9ft-8in) ARM ASSY
1 ARM (1) STD
2 PLATE 1
3 PLATE 1
4 PLATE 2
5 PLATE 1
6 PLATE 1
7 TAPPED BLOCK 1
8 TAPPED BLOCK 1
9 TAPPED BLOCK 2
10 TAPPED BLOCK 1
Fig. 6 Modification of the 2.95M (9ft-8in) arm (Breaker)
63－35
(2) Hydraulic piping for 2.95M (9ft-8in) arm

This hydraulic piping applies to both the z Apply Loctite #242 to the clamp mounting bolts.
breaker machine and the nibbler & breaker z For M-threads
machine. Install the additional parts listed in Thread size Tightening torque
table 8 to the 2.95m (9ft-8in) arm body as M8 3.4kgfym (24.5 lbfyft)
shown in Fig. 7. M12 11.7kgfym (85 lbfyft)
Table 8 M14 18.5kgfym (133 lbfyft)
HYDRAULIC PIPING FOR z For PF,PT-threads Tightening torque
2.95M(9ft-8in) ARM Thread size Tightening torque
No. NAME Q’TY REMARK PF3/4, PT3/4 16.5kgfym (120 lbfyft)
1 TUBE 1 z Tightening torque for ORS cupling nuts.
2 TUBE 1
3 HOSE 1 Thread size Tightening torque
4 HOSE 1 1 3/16-12UNS 18kgfym (130 lbfyft)
5 STOP VALVE 2 1 7/16-12UN 21kgfym (152 lbfyft)
6 CONNECTOR 2 z At assembly, use care of O rings do not come off.
7 CLAMP 1
8 CLAMP 1
9 BRACKET 2
10 CAPSCREW 8
11 CAPSCREW 4
12 CAPSCREW 1
13 CAPSCREW 1
14 WASHER 8
15 WASHER 4
16 LOCK WASHER 5
17 LOCK WASHER 1
18 O RING 3
19 O RING 1
1,18,19 4
2,18 3
18
5,18
5 10,14 13,17
12,16 7 8
11,15,16
9
14,10
11,15,16 9 SECTION SECTION
Fig. 7 Hydraulic piping for 2.95M (9ft-8in) arm (Breaker, Nibbler & Breaker)
63-36
6.2 MODIFICATION ITEM FOR NIBBLER & BREAKER ATTACHMENT

The main item that are needed to modify the standard boom and standard arm into a nibbler & breaker-
mounted machine are as follows:
Table 1
Reference Modification
No. Specification Types of attachment
page item
Tapped block
Modification of the 4.6M (15´1˝ ) boom 6-2
Breaker
Refer to weld
6.1.1 N/B 6-3 Install of the
4.6M (15´1˝ ) boom hydraulic piping
6-4 piping
Tapped block
6.2.1 N/B Modification of the 2.45M (8´) arm 6-10
weld
Breaker
Refer to Install of the
2.45M (8´ ) arm hydraulic piping 6-6
6.1.2 N/B piping
Modification of the 2.95M (9´8˝ ) Tapped block
6-7
Breaker
Refer to arm weld
6.1.3 N/B Install of the
2.95M (9´8˝ ) arm hydraulic piping 6-8
piping
Refer to
Install of the
6.3 Breaker Connector assy 6-11
connector
6.4 Nibbler
Refer to Breaker
Reinforcing of the idler link 6-12 Plate
6.5 N/B
63-37
6.2.1 MODIFICATION OF THE 2.45M (8ft). ARM

(NIBBLER & BREAKER)
(1) Modification of the 2.45M (8ft) arm
1) When the additional parts listed in table 2 to NOTE :
Table 2 z Seal the unwelded areas of the tapped block.
2.45M (8ft) ARM ASSY

ARM (1) －
1
ARM － (1)
2 PLATE 1 1
3 PLATE 1 1
4 PLATE 2 2
5 PLATE 1 1
6 PLATE 1 －
7 TAPPED BLOCK 1 2
8 TAPPED BLOCK 1 －
9 TAPPED BLOCK 2 2
Fig. 1 Modification of the 2.45M (8ft) arm (Nibbler & Breaker)
63－38
6.3 CONNECTOR ASSY (BREAKER)

2 3 1
When using the machine with a breaker, attach
1-1/16-12UNF
the below parts to the tip of the stop valve. For
use with NPK, TOKU and KRUPP breakers.
Table 3
CONNECTOR ASSY FOR NPK
No. NAME Q’TY REMARK PF3/4
1 CONNECTOR 1 B : FOR NPK
2 PLUG 1
3 O RING 1 1B P24
Fig. 2 Connector assy (NPK)
Table 4
CONNECTOR ASSY 2 PF3/4 1 3 PF3/4
FOR TOKU, KRUPP
1 CONNECTOR 1
2 PLUG 1
3 O RING 1 1B P24
A : FOR TOKU, KRUPP
Fig. 3 Connector assy (TOKU, KRUPP)
6.4 CONNECTOR ASSY (NIBBLER) 2 1 3

When using the machine with a nibbler, attach
M36×1.5
the below parts to the tip of the stop valve.
Table 5
CONNECTOR ASSY
1 CONNECTOR 1
2 PLUG 1 PF3/4
3 O RING 1 1B P24
Fig. 4 Connector assy (NIBBLER)
63-39
6.5 REINFORCING THE IDLER LINK

When using the machine as a nibbler & breaker 501±0.2 (19.7±0.0079)
machine, the right and left idler links need
reinforcement. Reinforce them according to table
(0.866) (1.14)
(2.17)
22 29
55
6 and Fig. 5.
(0.984)
25
100 100
Table 6 (3.94) (3.94)
IDLER LINK (R.H)
IDLER LINK (L.H)
0
0 IDLER LINK (1) (RH)
0 IDLER LINK (1) (LH)
RH and LH
1 PLATE 2 in common
(0.394)
(1.77)
10
45
100 100
60 (3.94) 381 (15) (3.94) 60
(2.36) (2.36)
1
IDLER LINK (L.H)
501±0.2 (19.7±0.0079)
(0.866) (1.14)
(2.17)
22 29
55
(0.984)
25
100 100
(3.94) (3.94)
60 1 381 (15) 60
(2.36) 100 (3.94) 100 (3.94) (2.36)
(1.77)
45
(0.394)
10
0
IDLER LINK (R.H)
Fig. 5 Reinforcing the idler link
63-40
7. REMINDERS ON THE USE OF NIBBLER & BREAKERS

7.1 CHANGING OVER THE SELECTOR VALVE
A nibbler & breaker-attached machine is
equipped with a selector valve in both the
operation circuit and the main circuit. When
running the machine after completion of
modification, always set the selector valves
according to a nibbler or a breaker used.
LOW PRESSUSE SIDE

NOTE : Incorrect setting of the selector valves not (RETURN)
only deteriorates operating efficiency and
HIGH PRESSUSE SIDE
decreases speed but also causes failure of
the machine. Therefore, confirm completion
of the modification and give proper advice PLUG
to the user.
BOOM
z Tools used
For main circuit changeover
: 5mm
: 24mm
Changing over procedure of the selector

valve
WHEN USING WHEN USING
1) Remove socket bolt with allen wrench. BREAKER NIBBLER
2) Turn the nibbler or the breaker to its TO TANK TO TANK
operating position, using a spanner.
3) Stop it at a specified position and tighten the TO C/V
TO ATT
TO C/V
TO ATT
(Ao2) (Ao2)
setscrew.
ALLEN WRENCH (HEX 5mm)
SPANNER (HEX 24mm) Fig. 2 Changing over procedure of the selector

valve
Fig. 1 Changing over procedure of the selector

valve
63-41
7.2 FLUSHING METHOD

After completion of piping work, connect the high
pressure side and the low pressure side, as shown
in Fig. 3, open the stop valves on both sides and (ON) (OFF)
depress the operating pedal to perform flushing.
CONNECTOR(PF3/4)
z Before beginning flushing, run the
engine at low speed, depress the STOP VALVE
HOSE
breaker operating pedal and then
run the engine at high speed.
z Perform flushing operation for at
least 40 minutes, and during the
operation, make sure of no oil
leakage from each of the connections
of the newly attached breaker circuit An example of flushing time (23min.) in a single
and the nibbler & breaker circuits. process
7.3 REPLACING HYDRAULIC OIL AND RETURN

FILTER
Contamination and deterioration of hydraulic oil 5 min 1 min 5 min 1 min
may develop malfunctioning of the control valve, Flushing Stop Flushing Stop
early wear and seizure of the hydraulic pumps
and malfunctioning of the entire hydraulic 5 min 1 min 5 min
circuits : always replace hydraulic oil at regular Flushing Stop Flushing
intervals, based on table 1.
Fig. 3 Flushing method
Table 1
Inspection / Replacement intervals
Item
maintenance points First replacement 2nd replacement Regular replacement
Hydraulic oil Hydraulic oil tank －－ Every 600h
Return filter Hydraulic oil tank 50h 250h Every 250h
7.4 OPERATING PROCEDURE

This machine is provided with breaker single
circuit and nibbler and breaker combined
(conflux) circuit. To use breaker or nibbler, select
circuit appropriate to the specification through
single / conflux select switch on the left rear side
of driver's seat.
7.4.1 SWITCH OPERATING

(NIBBLER & BREAKER SPECIFICATION)
Specification Switch position Circuit
Breaker ( ) OFF Single flow
Nibbler ( ) ON Conflux flow
Never turn switch on (conflux) to operate NIBBLER & BREAKER SPECIFICATION

breaker. It may cause trouble of machine.
63-42
7.4.2 THROTTLE POTENTIOMETER

When operating the machine with a hydraulic
breaker, do the following operations :
Use the throttle potentiometer on the high idle
side. (Refer to Fig. 4.)
Fig. 4 Throttle potentiometer position
7.4.3 CONTROL PEDAL

(1) Hydraulic breaker single circuit
Release pedal lock on the right front side of
driver’s seat to operate pedal.
RELEASE
Precaution for pedal operation LOCK

The operation varies in the specifications, so PUSH LOCK PULL LOCK ROD
before operating, read the Operator Manual ROD FORWARD BACKWARD
carefully. TO RELEASE TO LOCK PEDAL
Foot pedal
depressing section Operating condition.
BREAKER ONLY
Depress heel section Breaker starts operation.
Pedal in neutral position. Breaker stops operating.
(2) Nibbler and breaker combined (conflux)
circuit.
Release pedal lock on the right front side of
driver’s seat to operate pedal.
z Hydraulic breaker
Foot pedal
Pedal in neutral position. Breaker stops operating.
Depress heel section. Breaker starts operation.
z Nibbler
Foot pedal
Depress toe section Nibbler close
Depress heel section Nibbler open N&B PEDAL
63-43
9. REFERENCE
Typical combinations are quoted from breaker When fitting a breaker, read through reminders
manufacturers’ catalog use as below, but on the use of breakers and cautions instructed by
concerning applicable breaker models, decide it breaker manufacturers.
after consultation with the breaker manufacturer.
Table 1
Working press Oil volume Total weight Total length Bucket
Applicable
Manufacturer kgf/cm2 used /min kg mm capacity m3
breaker
(psi) (gal/min) (lbs) (in) (cuyd)
120～140 160～200 1,450 2,156
H-10XB
(1,710～1,990) (42.2～52.8) (3,200) (84.9˝ )
N P K
130～150 35～60 410 1,644
H-4XB
(1,850～2,130) (9.24～15.8) (900) (64.7˝ )
100～140 110～140 1,000 0.55～0.70
TNB-10B
(1,420～1,990) (29.0～37.0) (2,210) (0.72～0.92)
120～140 140～160 1,400 0.70～0.90
TNB-14B
(1,710～1,990) (37.0～42.2) (3,100) (0.92～1.18)
100～160 45～80 391 1,476 0.25～0.35
T O K U TNB-6B
(1,420～2,280) (11.9～21.1) (860) (58.1˝ ) (0.33～0.46)
120～170 100～140 997 1,850 0.55～0.70
TNB-10E
(1,710～2,420) (26.4～37.0) (2,200) (72.8˝ ) (0.72～0.92)
130～170 130～170 1,500 2,190 0.70～0.90
TNB-14E
(1,850～2,420) (34.3～44.9) (3,300) (86.2˝ ) (0.92～1.18)
150～160 80～110 1,100～1,250 2,278 0.50～0.90
MKB1100
(2,130～2,280) (21.1～29.0) (2,430～2,760) (89.7˝ ) (0.65～1.18)
K R U P P
150～180 90～130 1,120～1,200 0.55～1.00
MKB1200
(2,130～2,560) (23.8～34.3) (2,470～2,650) (0.72～1.31)
150～180 110～ 1,450 2,240 0.70～
UB 11
(2,130～2,560) (29.0～ ) (3,200) (88.2˝) (0.92～ )
O K A DA
130～160 110～155 1,070 2,040 0.55～0.70
OUB 310
(1,850～2,280) (29.0～40.9) (2,360) (80.3˝ ) (0.72～0.92)
150～170 100～120 1,330 〔1,596〕 0.60～0.90
T A I S E I TF-150
(2,130～2,420) (26.4～31.7) (2,930) (62.8˝ ) (0.78～1.18)
160～180 125～150 1,400 2,119
FURUKAWA HB20G
(2,280～2,560) (33.0～39.6) (3,100) (83.4˝ )
[ ] Excludes chisels.
General precautions to be exercised on the installation of breakers by different manufacturers
Table 2
Installation of Installation of Restriction of
Manufacturer engine High-low speed changeover
accumulators a relief valve revolution
◎ NPK ○ × × changeover type not available.
TOKU
◎ △ ○ × changeover type not available.
Series B
TOKU
◎ ※○ × × changeover type not available.
Series E
changeover type available for large
― KRUPP △ ○ ○
machines.
changeover type available on
― OKADA △ ○ ○
special request.
― FURUKAWA △ ○ ○ changeover type not available.
― TAISEI △ ○ ○ changeover type not available.

○ One that must be installed. △ One that must be adjusted at installation.
× One that does not need to be installed. ※ Capacity 1 liter, pressure is 70kgf/cm2 (1,000psi)
◎ Adaptation test completed.
63-46
8. PRECAUTIONS TO BE EXERCISED ON BREAKERS

OF DIFFERENT MANUFACTURERS
There are some differences between manufac- Low pressure Measure the inlet pressure of the
turers as to the piping to breakers and the side: line filter on the breaker side by
handling of breakers. For this reason, consult actuating the breaker at full
with the manufacturer when mounting a breaker engine revolution in the H mode,
in the field. The following is a summary of how and in case the maximum
breakers should be handled that is extracted from pressure exceeds 55kgf/cm2 (780
manu-facturers’ catalog use and operation psi), install a low pressure
manuals. accumulator.
NOTE : This is a general outline of how breakers Max. < 55kgf/cm2 (780 psi)
should be used and may differ with excavator Regarding the capacity and the
models. Always contact the breaker charge pressure of accumulators,
manufacturer before field mounting. contact the breaker manufacturer
before installation.
(1) Placing high and low pressure accumulators
NPK They must be placed basically (2) Installation of a relief valve
(depending upon models). NPK Installation is not necessary.
(Contact the breaker manufacturer
T O K U
Check the oscillation of the as it is necessary depending upon
K R U P P pulsation of the breaker models.)
pressure and if pulsation is
O K A D A
large, always install accumu- Installation is necessary.
FURUKAWA lators. T O K U A relief valve is specified by
each breaker manufacturer.
Standard of judgment on the installation of K R U P P
Since the method of pressure
accumulators O K A D A setting of the relief valve
H
High pressure Measure the pulse oscillation by differs with breaker manufac-
side: pressure on the high pressure T A I S E I
side of the breaker at the turers, install a relief valve
inspection port for the pump’s FURUKAWA according to the manufac-
delivery pressure by actuating the turer’s instructions.
breaker at the full revolution of NOTE : Only the B series TOKU machine requires
the engine in mode H and set the a relief valve to be installed.
maximum pressure difference to
within 20% of the excavator’s INSTALLATION OF A RELIEF VALVE
system pressure 330kgf/cm2
(4690psi).
In case it exceeds 20%, install a
high pressure accumulator.
NOTE : The pulse oscillation is 330×20%=
2
66kgf/cm (940psi). Therefore, if it is more
than this level, an accumulator must be LOW PRESSURE SIDE (RETURN)
installed. HIGH PRESSURE SIDE
Install accumulator referring to the
result of verification test.
max PLUG
BOOM
min
Max. press－Min press < system press × 20%
63-44
6 (4) Changing over the breaker to high and low

4 speeds
N P K
2 These breakers are not so
T O K U
(PF1) 3 constructed as to be switched
TO TANK
T A I S E I over to high and low speed.
FURUKAWA
RETURN SIDE
5 1
KRUPP Breakers on and after MKB1200 are
constructed with a switching function.
It can be operated from inside the cab
by the installation of a solenoid valve.
TO BREAKER OIL SUPPLY SIDE For piping work, consult with the
breaker manufacturer.
1. HIGH PRESSURE HOSE 4. PLUG
2. NIPPLE 5. ELBOW NOTE : Piping work is not required in some cases if
3. ADAPTER 6. RELIEF VALVE a high-low changeover function is not
Fig. 2 necessary at user’s request.
On that occasion, it is necessary to fix the
(3) Restriction of engine revolution changeover valve contained in the breaker
N P K Full engine revolution may be used. to the low speed side beforehand. Consult
with the breaker manufacturer in that case.
T O K U There are restriction on the It is prohibited to use the high-low speed
K R U P P engine revolution. Since a changeover valve without laying high-low
specified revolution differs speed piping and without fixing the high-low
O K A D A
with breakers, follow the speed changeover valve.
T A I S E I breaker manufacturer’s inst-
FURUKAWA ructions.
HIGH-LOW SPEED
CHANGEOVER VALVE
NOTE : In the case of a breaker for which the
engine revolution is limited, the breaker
does not increase impact power and cycles
even at full engine revolution.
Since extra hydraulic oil returns to the RELIEF VALVE HYDRAULIC
BREAKER
hydraulic oil via the relief valve, it causes
the hydraulic oil temperature to rise and the TO CONTROL VALVE
fuel consumption to increase. Plaster the
label (furnished by the breaker maker)
indicating the revolution (Check the engine TO TANK
revolution.), to the throttle potentiometer
position. Always observe the indicated
CHECK VALVE
revolution.
Fig. 3
63-45

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Copyright © New Holland

Printed by Studio ti - 20005

ADDITIONAL REFERENCE MANUALS

• In addition to this Workshop Manual, refer also to

- Operation and maintenance instruction

DESCRIPTION OF THE COMPLETE

VOLUME MACHINE TYPE PRINT No.

Most accidents, whether they occur in industry, on the farm, at home or on

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION

All rights reserved. Reproduction of text and illustrations in whole or in part, is

Section 21 - Mechatro control system

Section 31 - Disassembling and assembling

Section 41 - Troubleshooting (mechatro control)

Section 63 - Mounting the breaker and nibbler & breaker

SAFETY PRECAUTIONS 5. Do not work on any machine that is supported

The serviceman or mechanic may be unfamiliar with

7. Lower the bucket, dozer, or other attachments to

16. Do not damage wiring during removal operations.

17. Be sure all protective devices including guards

18. The maintenance and repair work while holding

19. Loose or damaged fuel, lubricant and hydraulic

20. Tighten connections to the correct torque. Make

1. General precautions for repairs .............................................................................. 1-1

2. International unit conversion system ...................................................................... 1-4

1. GENERAL PRECAUTIONS FOR REPAIRS

3) Stop the engine before starting inspection and

(3) Move away the articles in advance that may cause

(3) Precautions for handling hydraulic oil

2. INTERNATIONAL UNIT CONVERSION SYSTEM

※1 Units that are allowed to use

1. Name of components .............................................................................................. 2-1

2. General dimension .................................................................................................. 2-2

3. Weight of components ............................................................................................ 2-3

4. Transportation dimension and weight ..................................................................... 2-4

5. Specifications and performance ........................................................................... 2-12

6. Type of crawler ...................................................................................................... 2-14

7. Type of bucket ....................................................................................................... 2-16

8. Combinations of attachment ................................................................................. 2-17

9. Engine specification .............................................................................................. 2-18

*Marked dimensions do not include height of shoe lug.

*Marked dimensions do not include height of shoe lug.

*Marked dimensions do not include height of shoe lug.

3. WEIGHT OF COMPONENTS Unit : kg (lbs)

4. TRANSPORTATION DIMENSION AND WEIGHT

● OVERALL DIMENSIONS OF WITHOUT ARM AND BUCKET

● OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

● OVERALL DIMENSIONS OF BOOM

Weight kg (lbs) 940 (2,080)

● OVERALL DIMENSIONS OF ARM+BUCKET

Weight kg (lbs) 970(2,140)

● OVERALL DIMENSIONS OF ARM

Weight kg (lbs) 580(1,280)

● OVERALL DIMENSIONS OF BUCKET

Type Hoe bucket

Type Hoe bucket V-bucket Slope finishing bucket

z Hoe bucket z V-bucket z Slope finishing bucket

● OVERALL DIMENSIONS OF WITHOUT ARM AND BUCKET

● OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

● OVERALL DIMENSIONS OF BOOM

Weight kg (lbs) 790 (1,740)

● OVERALL DIMENSIONS OF ARM+BUCKET

Weight kg (lbs) 820(1,810)

● OVERALL DIMENSIONS OF ARM