SERVICE MANUAL

Crawler Excavators
E175B

VERSION - C
Print No.87495893A

From S/N N7DA17001

 SERVICE
MANUAL

Crawler Excavators
E175B

VERSION - C
Print No.87495893A

From S/N N7DA17001

REPAIR MANUAL

E175B
EXCAVATOR

Shop Manual Number 87634783 NA

Issued 10-2007
CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machine Remarks
First Edition Issued 10-2007 E175B EXCAVATOR

Issued 10-2007
Book/Form Number NA
Copyright © 2006. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 E175B REPAIR MANUAL
TABLE OF CONTENTS
SECTION 1
SAFETY AND GENERAL INFORMATION
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: NA
CHAPTER 1
SAFETY PRECAUTIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: NA
CHAPTER 2
SPECIFICATIONS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: NA
CHAPTER 3
STANDARD PRECAUTIONS AND TIGHTENING TORQUES
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: NA
CHAPTER 4
MAINTENANCE STANDARDS AND TEST PROCEDURES
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Book/Form Number: NA

SECTION 2
SYSTEMS
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: NA
CHAPTER 1
MECHATRO CONTROL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: NA
CHAPTER 2
HYDRAULIC SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: NA
CHAPTER 3
ELECTRICAL SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: NA
CHAPTER 4
COMPONENTS SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Book/Form Number: NA
CHAPTER 5
AIR CONDITIONING SYSTEM
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Book/Form Number: NA

SECTION 3
GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Book/Form Number: NA
CHAPTER 1
ATTACHMENTS
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Book/Form Number: NA
CHAPTER 2
UPPER STRUCTURE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Book/Form Number: NA
CHAPTER 3
UNDERCARRIAGE (TRAVEL SYSTEM)
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Book/Form Number: NA

87634783 NA Issued 10-2007 Bur I

 E175B

SECTION 4
TROUBLESHOOTING
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: NA
CHAPTER 1
TROUBLESHOOTING BY ERROR CODES
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: NA
CHAPTER 2
TROUBLESHOOTING BY TROUBLE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Book/Form Number: NA
CHAPTER 3
TROUBLESHOOTING BY DIAGNOSIS MODE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Book/Form Number: NA

SECTION 5
ENGINE
Section Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I
Book/Form Number: NA
CHAPTER 1
ENGINE
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Book/Form Number: NA

II Issued 10-2007 Bur 87634783 NA

REPAIR MANUAL - SECTION 1

E175B
EXCAVATOR

SAFETY AND GENERAL

INFORMATION

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783-NA
 SECTION 1 - SAFETY AND GENERAL INFORMATION

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B
 SECTION 1 - SAFETY AND GENERAL INFORMATION

SECTION 1
SAFETY AND GENERAL INFORMATION
SECTION TABLE OF CONTENTS
CHAPTER 1
SAFETY PRECAUTIONS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SAFE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
SAFETY PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
CHAPTER 2
SPECIFICATIONS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CHAPTER 3
STANDARD PRECAUTIONS AND TIGHTENING TORQUES
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
PIPING JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
CHAPTER 4
MAINTENANCE STANDARDS AND TEST PROCEDURES
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
HOW TO USE THE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
PERFORMANCE INSPECTION STANDARD TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
MEASUREMENT OF ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
MEASUREMENT OF HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
ENGINE CONTROL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

NA I
 SECTION 1 - SAFETY AND GENERAL INFORMATION

NOTES

II Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 1

E175B
EXCAVATOR

SAFETY PRECAUTIONS

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

1-II Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 1
SAFETY PRECAUTIONS
TABLE OF CONTENTS

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Keep Hands and Clothes Far Off Moving Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Do Not Smoke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Do Not Look at The Welding Arc Without Proper Eye Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Transfers and Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Follow Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Prepare For Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Wear Protective Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Protect Against Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Inspect The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Use Hand Holds And Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Adjust The Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Fasten Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Move And Operate Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Operate Only From The Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Do Not Carry Person On The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Confirm Direction Where The Machine Is To Be Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Avoid Injury From Back Over And Swing Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Drive Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Avoid Overturning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Park Machine Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Investigate Job Site Before Operating The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Protecting Against The Fall Of Rocks And Landslides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Dig With Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Operate With Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Avoid Electric Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Keep Personnel Clear From Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Never Move The Bucket Over Any One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Do Not Operate In Tunnels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Never Undercut A High Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Safety Loads Moving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Avoid Excessive Digging Efforts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Pay Attention When Digging Deeply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Do Not Use The Traction Force Of The Machine For Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Do Not Use The Turret Swing For Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Do Not Use The Bucket As A Hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Avoid Operating The Cylinders To Full Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Provide Signals For Jobs Involving A Number Of Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Transporting The Machine Under Safe Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
NA Issued 10-2007 Bur 1-1
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS

SAFE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Warn Others Of Service Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
Support Machine Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
Stop The Engine Prior To Performing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
Dispose Of Waste In The Appropriate Manner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
Work In A Clean Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
Properly Light The Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-29
Keep Clean The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
Prevent Acid Scalds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
Starting The Engine With Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31
Prevent Battery Explosions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-31
Prevent Burns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
Store Attachments Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
Avoid High Pressure Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
Prevent Parts From Flying Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
Protect Against Flying Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
Handle Fluids Safely - Avoid Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
Prevent Fires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
Evacuating In Case Of Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Beware Of Exhaust Fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Use Appropriate Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Avoid Heating Near Pressurized Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Avoid Applying Heat To Lines Containing Flammable Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Remove Paint Before Welding Or Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Welding Repair Interventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
SAFETY PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39

1-2 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
GENERALITIES
Read the Operation and Maintenance Instruction
M a nu a l c a r e f u l ly b e fo r e s t a r t i n g , o p e ra t i n g ,
maintaining, fuelling or servicing the machine.
Carefully read the explanation to each and all safety
signs in the special section of this Manual before
starting, operating, maintaining, fueling or servicing
the machine.
Machine-mounted safety plates are color coded
yellow with black borders when they refer to points
where special ATTENTION must be paid and failure
to observe them may cause a serious DANGER to
the integrity of machine operators. They are white
with red borders and black lettering when they refer
to a FORBIDDEN practice.
It is fundamental that all machine operators know
very well the meaning of each safety plate as this
considerably decreases operating hazards and
accidents.
Do not allow unauthorized personnel to operate or
service this machine.
Do not wear rings, wrist watches, jewelry, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves,
ear protection, safety glasses, reflector vests,
respirators every time the job requires it. Ask your
employer about safety regulations in force and
protective equipment.
Always keep the operator’s compar tment, step
plates, grab-rails and handles clean and clear of
foreign objects, oil, grease, mud or snow to minimize
the danger of slipping or stumbling. Remove mud or
grease from your shoes before operating the
machine.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.
Never operate the machine or its attachments from
any position other than sitting in the driver’s seat.
Keep head, body, limbs, hands and feet inside the
operator’s compar tment at all times to reduce
exposure to external hazards.
NA Issued 10-2007 Bur
Be careful of possible slippery conditions of the steps
and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the
soles made of highly no-slip rubber
Do not leave the machine until it has come to a
complete stop.
Always check height, width and weight limitations
which may be encountered in the working site and
make sure the machine does not exceed them.
Assess exact paths of gas ducts, water mains,
telephone lines, sewers, overhead and underground
electric lines and all other possible obstacles.
Such paths should be oppor tunely defined by
competent Authorities. If necessary, require that the
service is interrupted or said installations are moved
prior to starting the work.
You must know the working capacity of the machine.
Define the rear upper structure swing area and
provide for opportune barriers to prevent access into
it.
Never exceed machine lifting capacity.
Remain within the limits shown in the loading
capacity chart which located on the machine.
STARTING
Never start or operate a failed machine. Walk all
around the machine before mounting.
Before operating the machine, make sure that any
possible dangerous condition has been properly
removed. Before star ting machine, check that
steering and attachment controls are in the neutral
position and the safety lever is in the LOCK position.
Immediately repor t any malfunction of par ts or
systems to the maintenance managers for proper
action.
Prior to starting the engine, check, adjust and lock
the driver’s seat for maximum riding comfort and
control accessibility. Prior to operating the machine
and/or its attachments, check that bystanders are
outside the machine operating range. Sound the
horn.
Obey all hand signals, safety indications and signs.
Due to the presence of flammable fluids, never check
fuel level, refuel, charge the batteries in the presence
of smoking materials, open flames or sparks.
make sure that nobody is within the excavator
operating area before starting the machine, swinging
the upper structure or moving in any direction.
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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
Adjust all rear view mirrors for maximum visibility of Chains and cables should be securely anchored
the area behind the machine.
Make sure that engine speed is appropriate to the job
to be carried out.
If any hydraulic control or system exhibits erratic
performance or responds abnormally, have the
machine checked for air in the system.
Air in these circuits may cause incorrect movements
with consequent accident hazard. Refer to the
Operation and Maintenance Instruction Manual
about corrective action to be taken.
OPERATING
Do not run the engine of this machine in closed
buildings without proper ventilation capable to
remove harmful exhaust gases which concentrate in
the air.
Keep the operator’s compartment free of foreign
objects, especially if not firmly secured. Never use
the machine to transport objects, unless proper
securing points are provided.
Do not carry riders on the machine. Study and
familiarize escape routes alternative to normal exit
routes. For your personal safety, do not climb on or
off the machine while it is in motion.
Make sure that bystanders are clear of the machine
operating range before star ting the engine and
operating the attachment. Sound the horn.
Obey all hand signals, safety indications and signs.
When backing, always look to where the machine is
to be moved.
Be aler t of the position of bystanders. Should
someone enter the work area, stop the machine.
Maintain a safe distance from other machines or
obstacles to make sure of re qu ired visibility
conditions.
Always give way to loaded machines.
Maintain a clear vision of the surroundings of the
travel or work area at all times. Keep cab windows
clean and repaired.
When pulling loads or towing through a cable or
chain, do not start suddenly at full throttle. Take up
slack carefully. Avoid kinking or twisting chains and
cables.
Carefully inspect the towing items for flaws or
problems before proceeding. Do not pull through a
kinked chain or cable as stresses existing in this
condition may induce failures in the kinked portion.
Always wear heavy gloves when handling chains or
cables.
1-4
using suitable hooks. Anchor points should be strong
enough to withstand the expected load.
Keep anyone clear of anchor points and cables or
chains.
D o n o t p u l l o r t o w u n l e s s t h e o p e r a t o r ’s
compartments of the machines involved are properly
protected against possible backlash in case of cable
or chain failure or detachment.
Be alert of soft ground conditions close to newly
constructed walls. The fill material and machine
weight may cause the wall to collapse under the
machine.
In darkness, check area of operation carefully before
moving in with the machine. Use all lights provided.
Do not move into low visibility areas.
If the engine tends to slow down and stall for
whatever reason under load or at idle, immediately
report this problem to the maintenance managers for
proper action.
Do not operate the machine until this condition is
corrected. Regularly check all exhaust system
components, as exhaust fumes are toxic for the
operator.
Operators must know the perfor mance of the
machine they are driving. When working on slopes or
near sudden level drops in the terrain, pay attention
not to lose adherence and avoid loose soft ground
since overturn or loss of machine control could result.
If noise level is high and exceeds 90 dB (A) over 8
hours at the operator’s ear, wear approved ear
protection in compliance with local regulations.
Do not operate the machine if you are extremely tired
or feel ill. Be especially careful towards the end of the
working shift.
Where removable counterweights are provided, do
not operate the machine if they have been removed.
When operating the machine, keep in mind height
limits of overhead doors, arches, overhead cables
and lines as well as width limits of corridors, roads
and narrow passages.
Also, get to know load limits of the ground and paving
type of the ramps you are to work on.
Beware of fog, smoke or dust that obscure visibility.
Always inspect the working area to identify potential
risks such as: inclines, overhangs, trees, demolition
rubble, fires, ravines, steep slopes, rough terrain,
ditches, crowns, ridge trenches, diggings in traffic
areas, crowded parking lots, crowded service areas,
fenced zones. In such conditions, proceed with
extreme care.
Issued 10-2007 Bur NA
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
Whenever possible, avoid crossing over obstacles Make sure the truck driver is in a safe place before
such as ver y rough terrain, rocks, logs, steps, loading the truck.
ditches, railroad tracks. Load trucks from side or rear.
When obstructions must be crossed, do so with
extreme care and at a square angle, if possible.
SLOW DOWN.
Ease up to the break-over point, pass the balance
point slowly and ease down the other side also using
the attachment, if necessary.
To overcome deep trenches or sinking ground, place
the machine perpendicular to the obstacle, drastically
reduce ground speed and start crossing using also
the attachment, if necessary, only after assessing
that ground conditions allow the traverse safely and
without risks.
The slope you may attempt to overcome is limited by
factors such as ground conditions, load being
handled, machine type and speed, and visibility.
There is no substitute for good judgement and
experience when working on slopes.
Avoid operating the attachment too close to an
overhang or high wall, either above or below the
machine. Beware of caving edges, falling objects and
landslides. Remember that such hazards are likely to
be concealed by bushes, undergrowth and such.
Avoid branches, bushes, logs and rocks. Never drive
over them, nor over any other surface irregularities
that discontinue adherence or traction with the
ground, especially near slopes or drop-off.
Be alert to avoid changes in adherence conditions
that could cause loss of control. Work with extreme
care on ice or frozen ground and on stepped slopes
or near drop-offs.
The word “bulldozing” generally refers to work in
virgin rough terrain, characterized by the presence of
all the perils and risks listed above. We emphasis the
danger represented in these conditions by large tree
limbs (possibly falling on the machine) and large
roots (which may act as a leverage under the
machine when up-rooted and cause the unit to
overturn).
Position the machine dependent upon the loading
and unloading areas in order to swing left to load to
obtain best visibility.
Never use the bucket or attachment as a man lift
or carry riders. Never use the machine as a work
platform or scaffolding. The machine must not be
improperly used for works not consistent with its
features (such as pushing railway cars, trucks or
other machines).
Always pay attention to people within the machine
operating range.
Never move or stop the bucket, other loads or the
attachment above ground personnel or truck cabs.
NA Issued 10-2007 Bur
Use only the type of bucket recommended
considering machine type, materials to be handled,
material piling up and loading characteristics, ground
type and other typical conditions of the work to be
performed.
When transporting a loaded bucket, keep it as rolled-
back as possible. Keep boom and arm as low as
possible.
Ground speed should be adequate to the load and
ground conditions.
The load must always be properly arranged in the
bucket; move with extreme care when transporting
oversize loads.
Do not lift and move the bucket overhead where
persons are standing or working, nor downhill when
working on a slope as this would decrease machine
stability. Load the bucket from the uphill side.
Loads to be raised using the machine should be
exclusively hooked to the hitch specially provided.
The excavator is no lifting and transportation means,
therefore it should not be used to position loads
accurately. Should it be exceptionally used to lift and
lay building components, special caution must be
taken as follows:
1. The machine must be equipped compulsorily
with the appropriate variant provided upon
request.
2. Secure the loads to be raised using cables or
chains fastened with appropr iate hooking
mechanisms.
3. Nobody should be allowed to remain under the
raised load or within the excavator operating
range for any reason whatever.
Never exceed specified loading capacity. Incorrect
fastening of slings or chains may cause boom/arm
failure or failure of the lifting means with consequent
bodily injuries and even death.
Always make sure that slings and chains used for
lifting are adequate to the load and in good condition.
All loading capacities are referred to the machine on
a level surface and should be disregarded when
working on a slope.
Avoid travelling across slopes. Proceed from uphill
downhill and vice-versa. If machine starts slipping
sideways when on a slope, lower the bucket and
thrust bucket teeth into the ground.
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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
Working on slopes is dangerous. Grade the working
area if possible. Reduce work cycle time if it is not
possible to grade the working area.
Do not move full bucket or a load from uphill downhill
as this would reduce machine stability. Do not work
with the bucket turned to the uphill side.
Do not wor k with the bucket tur ned uphill as
counterweights protruding downhill would reduce
machine stability on the slope and increase risk of
overturning.
We recommend to work on slopes with the bucket
downhill, after checking machine stability with the
bucket empty and attachment retracted, by slowly
swinging the upper structure by 360°.
Position the carriage at a right angle relative to
slopes, hanging walls, etc. to exit the working area
easily.
Standard use, provides for the travel controls at the
front and travel motors at the back. Should travel
motors be positioned at the front with regard to the
actual travel direction. Remind relative to travel
direction that controls are reversed.
Always check travel motor position before moving
off.
Properly judge ground conditions with particular
attention to consistency of the area you are going to
work on.
Keep the machine sufficiently far from the ditch edge.
Never dig under the machine.
Should it be necessary to dig under the machine,
a l way s m a ke s u r e t h a t r e i n fo r c i n g wa l l s a r e
opportunely propped up against landslide to prevent
the machine from falling into the trench.
Do not swing the upper structure, raise the load or
brake abruptly if not required. This may cause
accidents.
Prior to beginning the work near gas distribution
mains or other public utilities:
1. Contact the company owner of the gas mains or
its nearest branch before starting the work. Look
up the number in the telephone directory.
2. Define together which precautions should be
taken to guarantee work safety.
3. Decrease work speed. Reaction time could be
too slow and distance evaluation wrong.
1-6
4. When working near gas mains or other public
utilities installations, appoint a person in charge
of signalling duties. This person will have the
responsibility of observing the machine, any part
of it and/or the load approaching the gas mains
from a standpoint more favorable than the
Operator’s. This signal man (flag-man) must be
in direct communication with the Operator and
the Operator must pay undivided attention to the
signals supplied.
5. The gas distributing Company, if previously
advised and involved in the work, as well as
machine Operator, Owner and/or any natural
person or legal entity having rent or leased the
machine or being responsible at the time by
contract or by law, are liable for the adoption of
the necessary precautions.
Working near electric lines can be very dangerous,
th er efore some special precau tions mu st be
observed.
Within this Manual, work near electric lines means
when the attachment or load raised by the excavator
(in any position) may reach the minimum safety
distance established by local or international Safety
Regulations.
To work without risks, keep maximum possible
distance from electric lines and never trespass
minimum safety distance.
1. Contact the Company owner of the electric lines
or its nearest branch before starting the work.
2. Look up the in the telephone directory.
3. Define together with the Company representative
which precautions should be taken to guarantee
work safety.
4. All electric lines should be considered as
operative live lines even though it might be well
known that the line in question is out of work and
visibly connected to the ground.
5. The Electric Power Company, if previously
advised and involved in the work, as well as
machine Operator, Owner and/or any natural
person or legal entity having rent or leased the
machine or being responsible at the time by
contract or by law, are liable for the adoption of
the necessary precautions.
6. Decrease work speed. Reaction time could be
too slow and distance evaluation wrong.
7. Warn all ground personnel to keep clear of the
machine and/or load at all times. If the load has
to be guided down for laying, consult the Electric
Power Company to know which precautions
should be taken.
Issued 10-2007 Bur NA
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
8. Appoint a person in charge of signalling duties.
This person will have the responsibility of
observing the machine, any part of it and/or the
load approaching the electric lines from a
standpoint more favorable than the Operator’s.
This signal man (flag-man) must be in direct
communication with the Operator and the
Operator must pay undivided attention to the
signals supplied.
When working in or near pits, in ditches or very high
walls, check that the walls are sufficiently propped up
to avoid cave-in hazards.
Pay the utm ost attention whe n wor kin g near
overhang walls or where landslides may take place.
Make sure that the support surface is strong enough
to prevent landslides.
When digging, there is the risk of cave-ins and
landslides.
Always check ground conditions and conditions of
the material to be removed. Support everywhere it is
required to prevent possible cave-ins or landslides
when:
1. Digging near previous trenches filled with
material.
2. Digging in bad ground conditions.
3. Digging trenches subject to vibration from
railroads, working machines or highway traffic.
Always switch off the key-star t switch before
cleaning, repairing, or parking the machine to
prevent accidental unauthorized start up.
Never lower the attachment or auxiliary tools other
than from sitting in the operator’s seat. Sound the
horn. Make sure that nobody is within the machine
operating range. Lower the attachment slowly.
Securely block and lock the machine every time you
leave it unattended. Return keys to the safe place
previously agreed upon. Perform all necessary
operations for stopping as detailed in the Operation
and Maintenance Instruction Manual.
Drive the machine far from pits, trenches, rocky
hanging walls, areas with overhead electric lines,
and slopes before stopping it at the end of the
working day.
Align the upper structure to the tracks in order to
a l l o w t o e a s i l y g e t o n a n d o f f t h e d r i v e r ’s
compartment.
Move all controls to the position specified for
m a c h i n e s t o p p i n g . R e fe r t h e O p e ra t i o n a n d
Maintenance Instruction Manual.
Never park on an incline without accurately blocking
the machine to prevent unexpected movement.
Follow stopping instr uctions contained in the
Operation and Maintenance Instruction Manual.

STOPPING
When the machine is to be stopped for whatever
reason, always check that all controls are in the
neutral position and that the safety lever is on the
lock position to guarantee risk-free start up.
Never leave the machine unattended with the engine
running.
Prior to leaving the driver’s seat, and after making
sure that all people are clear of the machine, slowly
lower the attachment until resting it safely to the
ground. Retract possible auxiliary tools to the closed
safety position.
Check that all controls are in the neutral position.
Move engine controls to the shut-down position.
Switch off the key-start switch. Consult the Operation
and Maintenance Instruction Manual.
Park the machine in a non-operating and no-traffic
area. Park on firm level ground. If this is not possible,
position the machine at a right angle to the slope,
making sure there is no danger of uncontrolled
sliding.
If parking in traffic lanes cannot be avoided, provide
appropriate flags, barriers, flares and other signals
as required to adequately warn the oncoming drivers.

NA Issued 10-2007 Bur 1-7

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
MAINTENANCE
GENERALITIES
Carefully read the Operation and Maintenance
Instruction Manual before star ting, operating,
maintaining, fuelling or servicing the machine in any
manner.
Read all safety plates mounted on the machine and
observe instructions they contain before starting,
operating, repair ing, fuelling or ser vicing the
machine.
Do not allow unauthorized personnel to repair or
service the machine.
Follow all recommended maintenance and service
procedures.
Do not wear rings, wrist watches, jewelry, loose or
hanging garments, such as ties, torn clothing,
scarves, unbuttoned or unzipped jackets that can get
caught in moving parts. Wear certified safety clothes
such as: hard hat, no-slip footwear, heavy gloves,
ear protection, safety glasses, reflector vests,
respirators when required. Ask your employer about
safety regulations in force and protective equipment.
Do not use controls or hoses as hand holds. Hoses
and controls are movable parts and do not provide
solid support. Besides, controls may be inadvertently
moved and cause unexpected movement of the
machine or its attachments.
Do not jump on or off the machine. Always keep both
hands and one foot, or both feet and one hand in
contact with steps and/or grab rails.
Never service the machine with someone sitting in
the driver’s seat, unless this person is an authorized
operator assisting in the maintenance being carried
out.
Keep the operator’s compartment, step plates, grab
rails and handles clear of foreign objects, oil, grease,
mud or snow to minimize the danger of slipping or
stumbling.
Clean mud or grease from your shoes before
climbing on the machine or driving it.
N eve r a tt em p t t o o p era te t he m ac h i ne o r i t s
attachments from any position other than sitting in
the operator’s seat.
Keep the driver’s seat free from foreign objects,
especially if these are not secured.
Should it be necessary to move the attachment for
maintenance purposes, do not raise or lower the
attachment from any other position than sitting in the
operator’s seat. Before star ting the machine or
moving its attachment, sound the horn and require
that nobody remains near the machine.
Raise the attachment slowly.
1-8
Always lock all moving components or parts of the
machine that must be lifted for maintenance
pur poses using adequate exter nal means as
required by local and national regulations. Do not
allow anyone to pass or stay near or below a raised
attachment. If you are not absolutely sure about your
s a fe t y, d o n o t s t a y o r w a l k u n d e r a r a i s e d
attachment.
Do not place head, body, limbs, hands, feet or
fingers near articulated cutting edges deprived of the
necessary guards, unless they are suitably and
safely locked.
Never lubricate, repair or adjust the machine with the
engine running, except when this is specifically
r e q u i r e d by t h e O p e ra t i o n a n d M a i n t e n a n c e
Instruction Manual.
Do not wear loose clothing, jewelry near rotating
parts.
When service or maintenance require access to
areas that cannot be reached from the ground, use a
ladder or step platform conforming to local or national
regulations to reach the working area. If such means
are not available, use machine grab rails and steps.
Always perform all service or maintenance work with
the greatest care and attention.
Shop and/or field service platforms or ladders should
be manufactured and maintained in accordance with
local or national safety regulations in force.
Disconnect batteries and label all controls to warn
that service work is in progress, according to local
and national safety regulation requirements.
Block the machine and all attachments to be raised
according to local and national safety regulation
requirements.
Do not check or fill fuel tanks or install batteries near
burning or smoking materials and open flames due to
the presence of flammable vapors.
The fuel filler pipe nozzle must be constantly kept in
contact with the filler neck and this even before fuel
sta r t s flowing in . Keep this con tact fro m the
beginning to the end of the fuelling operation to avoid
possible generation of sparks due to static electricity.
Use a truck or trailer to haul a failed machine. Should
it be necessary to tow it, provide for suitable danger
s i g n a l s a s r e q u i r e d by t h e l o c a l n o r m s a n d
regulations and observe recommendations given in
the Operation and Maintenance Instruction Manual.
Load/unload the machine on firm level ground
providing safe support to the wheels of the truck or
trailer. Use strong access ramps, with adequate
height and angle. Keep the trailer flatbed free of mud,
oil or slippery materials. Tie the machine securely to
the trailer and block carriages and upper structure.
Issued 10-2007 Bur NA
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
Never align holes or slots using your fingers; always
use appropriate aligning tools.
Remove all sharp edges and burrs from re-worked
parts.
Use only approved and effectively grounded auxiliary
power sources for heaters, battery chargers, pumps
and similar equipment to reduce electrical shock
hazard.
Lift and handle heavy components using hoisting
devices of appropriate capacity. Ensure the parts are
supported by appropriate straps and hooks.
Use lifting eyes provided to this aim.
Pay attention to bystanders near the lifting area.
Never pour gasoline or diesel fuel into open
containers. Never use gasoline, solvents or other
flammable fluids to clean parts. Use proprietary
certified non-flammable, non-toxic solvents only.
When using compressed air to clean parts, wear
safety glasses with side shields. Limit pressure to
max. 2 bars, in accordance with local and national
safety regulations in force.
Do not run the engine of this machine in closed
buildings without proper forced ventilation capable to
remove toxic exhaust gases concentrating in the air.
Do not smoke, nor allow open flames or sparks
nearby while refuelling the unit or handling highly
flammable materials.
Do not use open flames as light sources to look for
leaks or inspect anywhere on the machine.
Make sure that all mechanical tools provided are in
good condition at all times. Never use tools with
mushroomed or damaged heads. Always wear eye
protections with side shields.
Move with extreme care when working under, on or
near the machine or its attachments.
In case of attachment tests during which the engine
should be kept running, a qualified operator must sit
in the driver’s seat at all times while the mechanic is
at work.
Keep Hands and Clothes Far Off Moving Parts.
Stop the engine and move the safety lever to the lock
position before starting adjusting or repairing an
assembly.
Do not carry out any work on the attachment without
prior authorization. Observe maintenance and repair
procedures.
In case of field service, move the machine to level
ground and block it. If work on an incline cannot be
avoid ed, se cur ely block the ma chine an d its
attachments. Move the machine to level ground as
soon as possible.
NA Issued 10-2007 Bur
Do not twist chains and cables. Never use a twisted
chain or cable for lifting or pulling. Always wear
safety gloves to handle chains or cables.
Be sure chains and cables are firmly fastened and
that the anchor point is strong enough to withstand
the expected load.
Keep all bystanders clear of the anchor point, cables
or chains. Do not pull or tow unless the operator’s
compartments of the machines involved are
fitted with proper guards against cable or chain
backlash.
Keep the maintenance area clean and dry at all
times.
Clean immediately all water and oil spillage.
Do not pile up oily or greasy rags as they represent a
major fire hazard. Always store them in closed metal
containers.
Before starting the machine or its attachment, check,
adjust and lock the operator’s seat. Also ensure that
n o b o d y i s w i th i n th e m a c h i n e o r a t ta c h m e n t
operating range before starting or operating the
machine and/or its attachments.
Sound the horn.
Rust inhibitors are volatile and flammable.
Prepare parts in well ventilated areas. Keep open
flames away.
Do Not Smoke.
Store containers in a cool well ventilated place where
they could not be reached by unauthorized people.
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments.
Wear appropriate safety clothing such as hard hat,
safety shoes and gloves, safety glasses when
splinters or other particles may be ejected.
Wear the appropriate welder’s equipment such as
dark safety glasses or mask, hard hat, protective
clothing, safety gloves and footwear always while
welding or arc-cutting. Wear dark safety glasses
when you are near a welding in progress.
Do Not Look at The Welding Arc Without Proper
Eye Protection.
Become acquainted with all your jacking equipment
and their capacity.
Make sure that the jacking point on the machine is
appropriate for the load applied. Also, be sure the
supports under the jack and between the jack and
the machine are appropriate and stable.
1-9
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
Any equipment supported by a jack represents a
possible hazard. Always suppor t the load onto
appropriate blocking means as a safety measure
before proceeding with service or maintenance work,
i n c o m p l i a n c e w i t h l o c a l o r n a t i o n a l s a fe t y Sound the horn to inform that you are about to move
regulations.
Metal cables produce steel splinters. Always wear
certified protection clothes such as safety gloves and
glasses while handling them.
Do not use makeshift jacks to adjust track sag.
Follow instructions given in the Repair Manual.
Handle all parts carefully. Keep hands and fingers
away from gaps, gears, and similar. Always use and
wear certified safety clothes such as safety glasses,
gloves and footwear.
The attachment is kept constantly in position by an
oil column trapped into the high pressure circuit.
Lower the attachment to the ground and relieve
pressure from all circuits prior to carrying out any
type of maintenance or repair work.
Do not service or repair the machine if it is parked
downhill. If this is unavoidable, in case of emergency,
b l o c k t h e c a r r i a g e s t o p r eve n t u n ex p e c t e d
movement, particularly if the work is to be carried out
on the final reduction units or travel motors.
Consult the Operation and Maintenance Instruction
Manual for correct maintenance procedure.
Areas near ar ticulated cutting edges where
mechanical parts are in motion are where personal
injuries are most likely to occur. Pay attention to
prevent possible part movements by means of blocks
or by keeping clear of such zones when motion may
take place during maintenance or repair.
Move the hydraulic system lock safety lever to the
lock positio n when stopping the m achine for
whatever reason.
Always install the safety stays for the hood and other
hinged covers before performing any maintenance or
repair work in the engine compartment.
TRANSFERS AND TRANSPORTATION
Before moving or transporting the machine, block
u p p e r s t r u c t u r e sw i n g t o p r eve n t a c c i d e n t a l
movement.
Pay particular attention during transfer on inclines,
both uphill and downhill. Keep the bucket in a
position to provide a possible anchor point into the
ground in case of slipping.
During transfers on inclines, both uphill and downhill,
keep the upper structure aligned with the carriages.
Do not travel across the slope.
1-10
Never transfer the machine in the working site, in a
crowded area, or near people without having at least
one person charged with hand-signals who could
guide the Operator.
off.
It is necessary to know load limits of bridges and
dimensional limits of tunnels. Such limits must never
be exceeded. You should also know machine height,
width, and weight. Have a signal-man help you when
clearances are limited.
Check distance between boom/arm and dimensional
limits during transfer or transportation.
Rough terrain may cause the machine to sway and
roll to such an extent that boom/arm could get to
contact electric lines or other obstacles. Cross
obstacles at a right angle at low speed. Pay attention
to machine shaking when the centre of gravity
overcomes the obstacle.
Keep the bucket down at all times during transfers.
Drive with the lights on and use appropriate signals
and flags.
G e t t o k n ow a n d r e s p e c t l o c a l a n d n a t i o n a l
regulations.
Consider boom/arm and upper structure dimensions
while turning.
Use a ramp to load the machine on a trailer. If a ramp
is not available, fabricate one using blocks. The ramp
should be sufficiently strong to support machine
weight. Always load and unload on level surface.
Tow the machine following the instructions contained
in the Operation and Maintenance Instruction
Manual.
ENGINE
Do not run the engine in closed buildings without
proper ventilation capable to remove harmful exhaust
fumes.
Do not place head, body, limbs, feet, hands or
fingers near rotating fans or belts. Be especially
careful near blower fans.
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant
level with the engine off or idling if hot. See the
Operation and Maintenance Instruction Manual.
Keep the exhaust manifold and tube free from
combustible matters. Fit the machine with shields
and guards when wor king in the presence of
combustible matter free in the air.
Do not refuel with the engine running, especially if
hot, as this increases fire hazard in case of fuel
spillage.
Issued 10-2007 Bur NA
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
Never attempt to check or adjust fan belt tensions Always use gauges of adequate capacity for
when the engine is running. pressure testing. Refer to the Operation and
Do not adjust the fuel injection pump when the Maintenance Instruction Manual or Repair Manual.
machine is operating.
TOOLS
Do not lubricate the machine with the engine running.
Always keep head, body, limbs, feet, hands, and
Do not run the engine with the air intakes open and fingers away from the bucket and attachments, when
not protected. If this cannot be avoided for service in the raised position.
reasons, place protection meshes on all intakes
before servicing the engine. Prior to any maintenance or repair work, install all
supports necessary to this aim according to local and
ELECTRICAL SYSTEM national safety regulations.

Pay attention to connect connecting cables to correct In case the attachment is to be operated for
poles (+ to +) and (- to -) at both ends. Do not short- maintenance or repair purposes, do so exclusively
circuit terminals. Thoroughly follow instructions given while sitting in the driver’s seat. Sound the horn
in Operation and Maintenance Instruction Manual. b e fo r e s t a r t i n g t h e m a c h i n e o r m o v i n g t h e
attachment. Require that nobody remain near the
Always move the key-start switch in the lock position machine. Raise the attachment slowly.
before servicing or repairing the machine.
Do not use the machine to transport loose objects,
Batteries contain SULPHURIC ACID. Protect the unless proper securing devices are provided.
eyes when working near the batteries against
possible sprays of the acid solution. Should acid Never use gases other than nitrogen to charge the
contact skin, eyes, or clothes, RINSE IMMEDIATELY accumulators.
I N WAT E R F O R AT L E A S T 1 5 M I N U T E S .
Immediately seek medical attention.
Battery released gas is highly flammable. Leave
t h e b a t t e r y c o m p a r t m e n t c ove r o p e n d u r i n g
recharging to improve ventilation. Never check
battery charge by placing metal objects across the
posts. Keep sparks or open flames away from
batteries. Do not smoke near the battery to prevent
explosion hazard.
Before any maintenance or repair, make sure that
there are no fuel or electrolyte leaks from the
batteries. If any, correct prior to proceeding with
further work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of
explosive gas released during charging.
Disconnect batteries before working on the electrical
system or carrying out any other type of work.

HYDRAULIC SYSTEM
Pressure fluid escaping from a very small hole can
be almost invisible and still have sufficient force to
penetrate the skin. Always check any suspected
pressure leaks using a piece of cardboard or wood.
Do not use hands. If injured by escaping fluid, obtain
medical attention immediately or serious infection or
reaction may develop.
Stop the engine and ensure pressure is relieved from
all systems before removing side panels, housings,
g u a r d s a n d c o ve r s . S e e t h e O p e r a t i o n a n d
Maintenance Instruction Manual.

NA Issued 10-2007 Bur 1-11

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
RECOGNIZE SAFETY INFORMATION
This is your SAFETY ALERT SYMBOL
When you see this symbol on your machine or in
this Manual, be alert of the potential for personal
injury.
Follow recommended precautions and safe
operating practices.

GRAPHIC_ID Figure 1
UNDERSTAND SIGNAL WORDS
In this Manual you will find the following words
referring to different hazard risks:
DANGER:
WARNING:
CAUTION:
These words are always accompanied by the safety
alert symbol.
DAN G ER : I n di c a t e s a n i m m i n e n t ha z a r d o u s
situation which, if not avoided, will result in death or
serious injury.
WARNING: Indicates a potential hazardous situation
which, if not avoided, could result in death or serious
injury.
CAUTION: Indicates a potential hazardous situation
which, if not avoided, may result in m inor or
moderate injury.
IMPORTANT: Indicates a situation which, if not
avoided, may cause damage to the machine.
NOTE: Indicates an additional explanation for
information purposes.

ENVIRONMENTAL PROTECTION
This Manual also contains this symbol accompanying
i n s t r u c t i o n s fo r c o r r e c t b e h av i o r a s r e g a r d s
environmental protection.

GRAPHIC_ID Figure 2

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS
Carefully read and observe all safety signs on the
machine and read all safety precautions in this
Manual.
Safety signs should be installed, maintained, and
replaced when necessary.
If a safety sign or this Manual are damaged or
missing, obtain a replacement from your Dealer
in the same way you order a spare part (be sure
to detail machine model and serial number upon
ordering).
Learn how to operate the machine and its controls
correctly and safely. GRAPHIC_ID Figure 3
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep the machine in proper working conditions.
Unauthorized changes to the machine may
impair function and/or safety and affect machine
life.
S a fe t y m e s s a g e s i n t h i s C h a p t e r S A F E T Y
PRECAUTIONS, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover every
hazardous situation you may encounter. If you have
any doubts, consult your direct supervisor prior to
operating or servicing the machine.

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or an accident occurs.
1. Keep the first-aid kit and fire extinguisher on
hand.
2. Read and understand the label attached to the
fire extinguisher to use it properly.
3. Establish emergency priority procedures to cope
with fires and accidents.
4. Keep emergency numbers for doctors,
ambulance ser vice, hospitals and fire
department posted near the telephone.
GRAPHIC_ID Figure 4

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
WEAR PROTECTIVE CLOTHING
Wear close-fitting clothing and safety equipment
appropriate to the job.
You need:
A hard hat;
Safety shoes;
Safety glasses or face shield;
Heavy gloves;
Ear protection;
Reflective clothing;
Waterproof clothing; GRAPHIC_ID Figure 5
Respirator or filter mask;
Be sure to correctly wear equipment and clothing for
the job.
Do not take any chances.
Avoid wearing loose clothing, jewelry, or other
items that can catch on control levers or other
parts of the machine.
Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.

GRAPHIC_ID Figure 6

INSPECT THE MACHINE

Inspect the machine carefully everyday or work-shift
by an attentive visual inspection of machine outside
prior to starting it to prevent damages and personal
injuries.

GRAPHIC_ID Figure 7

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
USE HAND HOLDS AND STEPS
Falling is one of the major causes of personal injury.
1. When you get on and off the machine, always
face the machine and maintain a three-point
contact with the steps and handrails.
2. Prior to climbing or leaving the machine, check
that the fasteners of stepping points and the
handrails are tightened and are undamaged.
Repair them as required.
3. Keep the access to the machine clear of foreign
objects and clean. Remove grease or mud from
stepping points and rails to minimize the danger
of slipping or stumbling. GRAPHIC_ID Figure 8
4. Do not use the controls or the safety lever as
hand holds when climbing on or off the machine.
5. Do not climb or leave the machine running. Do
not jump on or off the machine.
6. Do not climb or leave the machine while holding
tools or other objects in your hands.
7. Do not climb or leave the machine while it is
moving.
ADJUST THE OPERATOR'S SEAT
A s e a t p o o r l y a d j u s t e d fo r o p e ra t o r o r wo r k
requirements may quickly fatigue the operator
leading to improper operations.

1. The seat should be adjusted whenever machine

operator changes.
2. The operator should be able to fully press the
pedals and correctly move the control levers with
his back resting against the seat back.
3. If not, move the seat forward and back, and
check again.
GRAPHIC_ID Figure 9

FASTEN SEAT BELT

Should the machine overturn, the operator may
become injured and/or thrown from the cab. Not only,
the operator may be crushed by the overturning
machine resulting in serious injury or even death.
1. Prior to operating the machine, thoroughly
examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
2. Be sure to remain seated with the seat belt
securely fastened at all times when the machine
is in operation to minimize injury hazard in case GRAPHIC_ID Figure 10
of accident.
3. After a significant accident, replace the seat belts
even though they do not look damaged.
NA Issued 10-2007 Bur 1-15
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.
1. Pay attention not to run over bystanders.
2. Be sure exposed personnel in the area of
operation are clear of the machine before moving
it or its attachments. Sound horn to inform
bystanders that the machine is going to be
operated.
3. When operating, swinging, or moving the
machine in a congested area use a signal man.

GRAPHIC_ID Figure 11

OPERATE ONLY FROM THE DRIVER'S SEAT

Inappropriate engine starting procedures may cause
the machine unexpected movement, possibly
resulting in serious injury and even death.
1. Start the engine only from the operator’s seat.
2. NEVER start the engine while standing on the
track or on the ground.
3. Do not start the engine by shorting across starter
motor terminals.
4. Before starting the engine, make sure that all
control levers are in the neutral position.
GRAPHIC_ID Figure 12

DO NOT CARRY PERSON ON THE MACHINE

Riders on the machine are exposed to serious
injuries.
1. DO NOT carry riders on the machine. Besides
precluding a full vision by the operator, there is
the possibility of serious bodily harm or death
due to accidental falls from the machine.

GRAPHIC_ID Figure 13

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
CONFIRM DIRECTION WHERE THE MACHINE IS
TO BE DRIVEN
Incorrect travel controls operation may result in
serious injury and even death.
1. Before driving the machine, be aware of the
undercarriage position relative to the operator’s
position. If travel motors are located at the front
of the cab, the machine will move reverse when
travel controls are moved towards cab front.

GRAPHIC_ID Figure 14

AVOID INJURY FROM BACK OVER AND SWING

ACCIDENTS
If any person is present near the machine when
backing or swinging the upper structure, the machine
may hit or run over that person, resulting in serious
injury or death.
To avoid back over and swing accidents:
1. Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
2. ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
H O R N O R OT H E R S I G N A L TO WA R N GRAPHIC_ID Figure 15
BYSTANDERS BEFORE MOVING MACHINE.
3. USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
4. Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
5. No machine motions shall be made unless
signals are clearly understood by both signalman
and operator.
6. Learn the meanings of all flags, signs, and
markings used on the job and confirm with the
person in charge of signalling.
7. Always make sure that rear mirrors are clean
and correctly adjusted. GRAPHIC_ID Figure 16
8. Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.

NA Issued 10-2007 Bur 1-17

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
DRIVE MACHINE SAFELY
Before moving the machine, confirm which way to
move travel pedals/levers for the corresponding
direction you wish to go.
1. Pushing down on the front of the travel pedals or
pushing the levers forward moves the machine
towards the idlers.
2. Traveling on a grade may cause the machine to
slip or to overturn, possibly resulting in serious
injury or death.
3. When traveling up or down a grade, keep the
bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground. GRAPHIC_ID Figure 17
4. If machine starts to skid or becomes unstable,
lower the bucket immediately.

5. Traveling across the face of a slope may cause

the machine to skid or to over tur n. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.

GRAPHIC_ID Figure 18

6. Turning on an incline may cause the machine to

tip over. If turning on an incline is absolutely
unavoidable, do so at a place where the slope is
gentle and the surface is firm.
7. Do not travel on slopes with an angle exceeding
3 0 ° . D o n o t t r ave l a c r o s s h i l l o n s l o p e s
exceeding an angle of 15°.

GRAPHIC_ID Figure 19

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
AVOID OVERTURNING
When working on a slope or on unstable terrain, the
danger of tipping over is present with the possibility
of subsequent serious damages or fatal injuries.
1. Pay the utmost attention when working on a
slope. If possible, first level the work area.
2. Avoid swing or steering the machine on a slope.
3. Decrease the operating speed and actuate the
controls carefully, to prevent sudden movements
that could result in slipping or tipping over.
4. In case the engine is cut-off, lower the bucket to
the ground, move the controls in neutral and
restart the engine. GRAPHIC_ID Figure 20

Pay the utmost attention when operating the

machine on frozen ground or in snowy conditions.
1. Frozen ground, when the ambient temperature
increases, tends to be less firm jeopardizing the
stability of the machine.
2. Operate carefully when in snowy conditions. The
snow could hide invisible dangerous spots.
3. Actuate the controls slowly and carefully to
prevent the machine from making unwanted
slippery maneuvers or movements.
4. Even on minor slopes, when snow is present and
on frozen ground, unwanted slippery maneuvers
or movements of the machine could occur.

PARK MACHINE SAFELY

To avoid accidents:
1. Park machine on a level surface.
2. Lower bucket to the ground.
3. Pull the safety lever (pilot-control shut-off lever)
to the LOCK position.
4. Turn auto/idle switch off.
5. Run engine at slow idle speed without load for 5
minutes.
6. Turn key-start switch to OFF to stop engine.
7. Remove the ignition key from the key switch.
GRAPHIC_ID Figure 21
8. Prior to leaving the machine, close the windows,
the cab door and all panels.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
INVESTIGATE JOB SITE BEFORE OPERATING
THE MACHINE
Explore the working area to identify potential risks
before starting and operating the machine. Make
sure that the structure and the conditions of the
ground are safe before starting operations.
1. Make sure that the digging area is sufficiently
stable and firm to suppor t the weight of the
machine during the work operations.
2. Working near edges and ditches presents a risk
for the stability of the machine. Check first that
edges and the walls of the digging are sufficiently
s t r o n g . I f n e c e s s a r y, p r o p t h e e d g e s
GRAPHIC_ID Figure 22
appropriately to prevent cave ins.
3. DO NOT dig too near the machine.
4. Always position the tracks perpendicular to the
edge of the digging with the travel motors on the
rear side.
5. When working on a slope or near the edge of the
road, have a flagman available.

PROTECTING AGAINST THE FALL OF ROCKS

AND LANDSLIDES
1. When operating in zones where the possibility of
falling rocks or landslides exists or when there is
the risk for front impacts with objects that could
penetrate the cab, make sure that protection
structures are installed: F.O.P.S. (Falling Object
Protection Structure) and FRONT GUARD.
1. DO NOT install any cab lifting device to the
protection structures.
2. DO NOT weld, drill or modify protective
structures. Any type of modification could
weaken the structural integrity of the safety
GRAPHIC_ID Figure 23
system, with serious consequences for the
operator, in case of collision, falling objects or
landslides.
3. After an accident, DO NOT try to straighten or
repair protective structures. Contact a Dealer to
verify the functionality, to repair or to completely
or partially replace the protective structures.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
DIG WITH CAUTION
Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
1. Before digging, check the location of cables, gas
lines, and water lines.
2. Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
3. Contact local authorities and/or the utility
c o m p a n i e s d i r e c t l y ( e l e c t r i c p owe r, g a s, GRAPHIC_ID Figure 24
telephone, water, sewers, telecommunications,
etc.) to obtain information about underground
utility lines.

OPERATE WITH CAUTION

If the front attachment or any other par t of the
machine hits against an overhead obstacle, such as
a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.
1. Take care to avoid hitting overhead obstacles
with the boom or arm.

GRAPHIC_ID Figure 25

AVOID ELECTRIC LINES

Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
1. When operating near an electric line, NEVER
MOVE any part of the machine or load closer
than 5 m (16 ft.) plus twice the line insulator
length (L).
2. Check and comply with any local regulations that
may apply.
3. Wet ground will expand the area that could
cause any person on it to be affected by electric
shock. GRAPHIC_ID Figure 26
4. Keep all bystanders or co-workers away from the
site.

NA Issued 10-2007 Bur 1-21

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
KEEP PERSONNEL CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
1. Keep all persons clear from the area of operation
and machine movement.
2. Before operating the machine, set up barriers to
the sides and rear area of the bucket swing
radius to prevent anyone from entering the work
area.
GRAPHIC_ID Figure 27

NEVER MOVE THE BUCKET OVER ANY ONE

Never lift, move, or swing bucket above anyone or a
truck cab. Serious injury or machine damage may
result due to bucket load spill or due to collision with
the bucket.

SP0030
GRAPHIC_ID Figure 28

DO NOT OPERATE IN TUNNELS

DO NOT operate the machine in enclosed spaces or,
in a ny case, witho ut appr opr ia te ve ntilation .
Operations in tunnels or underground sites where
potential explosive conditions exist are not allowed.
There is a danger for explosions and potentially
deadly injuries. Please comply with the ATEX
regulation relative to devices to be used in a
potentially explosive environment.

GRAPHIC_ID Figure 29

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
NEVER UNDERCUT A HIGH BANK
The edges could collapse or a land slide could occur
causing serious injury or death.

GRAPHIC_ID Figure 30

SAFETY LOADS MOVING

The excavator is a machine designed specifically to
perform digging/loading works, thus it must not be
used to handle suspended loads. In the event, under
exceptional conditions, it becomes necessary to
handle materials, the following indications must be
strictly implemented:
1. The machine must be equipped compulsorily
with the appropriate variant provided upon
request. Also, totally comply with the safety
precautions for the operation of the excavator as
a lifting equipment.
2. Secure the loads to be raised using cables or
chains fastened with appropr iate hooking
mechanisms.
3. Never hook cables or chains to the bucket teeth.
4. Nobody should be allowed to remain under the
raised load or within the excavator operating
range for any reason whatever.
5. Never exceed specified loading capacity.
Incorrect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means
with consequent bodily injuries and even death. GRAPHIC_ID Figure 31
6. Always make sure that slings and chains used
for lifting are adequate to the load and in good
condition.
7. All loading capacities are referred to the machine
on a level surface and should be disregarded
when working on a slope.
8. In any case, comply with the current national or
local regulations on this matter.

NA Issued 10-2007 Bur 1-23

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
AVOID EXCESSIVE DIGGING EFFORTS
Operate the machine complying with the load limits in
accordance with the table of lifting loads located
inside the cab.
1. Do not exceed the prescribed load limits.
2. Do not use the strength of the attachment to
travel or move the machine.
3. Do not try digging exploiting the mass of the
machine.

GRAPHIC_ID Figure 32

PAY ATTENTION WHEN DIGGING DEEPLY

When digging deeply, pay special attention to
prevent contacts of the attachment and the relevant
hydraulic hoses with the ground.
DO NOT swing the turret or the undercarriage when
the attachment boom is fully lowered. Under these
conditions there is the danger that the boom collides
with the track chains.

GRAPHIC_ID Figure 33

DO NOT USE THE TRACTION FORCE OF THE

MACHINE FOR DIGGING
Do not travel the machine to dig. In doing this, an
excessive stress on the front attachment could
results in damages to the str ucture. Use the
undercarriage for travelling only.

GRAPHIC_ID Figure 34

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
DO NOT USE THE TURRET SWING FOR DIGGING
Do not use the turret swing for digging or moving
rocks. An excessive stress on the front attachment
could results in damages to the structure reducing
the operating life of the swing system. Also, this
inappropriate use of the machine could cause
serious injuries or fatalities.

GRAPHIC_ID Figure 35

DO NOT USE THE BUCKET AS A HAMMER

The use of the bucket as a hammer or for piling
operations could cause serious damages to the
bucket itself and the components of the front
attachment. Also, this inappropriate use of the
machine could cause serious injuries or fatalities.

GRAPHIC_ID Figure 36

AVOID OPERATING THE CYLINDERS TO FULL

STROKE
Do not extend repeatedly the bucket and the arm
cylinders full stroke with the purpose of cleaning the
bucket from residual materials. This could cause
damages to the cylinders. To remove residues from
the bucket, use water under pressure or remove
them manually.
Tolerance A ≥ 50 mm

PROVIDE SIGNALS FOR JOBS INVOLVING A

NUMBER OF MACHINES
For jobs involving several machines, provide signals
commonly known by all personnel involved. Also, GRAPHIC_ID Figure 37
appoint a signal person to co-ordinate the job site.
Make sure that all personnel obey the signal person’s
directions.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
TRANSPORTING THE MACHINE UNDER SAFE
CONDITIONS
During loading or unloading operations of the
machine on a truck or trailer the danger for tipping
over is always present.
1. Use a truck or trailer appropriate for transporting
the machine.
2. Secure safely the machine to the trailer with
appropriate chains or cables. Please refer to the
chapter TRANSPORTATION of this Manual for
the safe loading and unloading procedures.
3. Make sure that you comply with National and
local regulations when transporting the machine
GRAPHIC_ID Figure 38
on open roads.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
SAFE MAINTENANCE
To avoid accidents:
1. Understand maintenance procedure before
starting the work.
2. Keep the working area clean and dry.
3. Do not spray water or steam inside the cab.
4. Do not lubricate or service the machine when it is
in motion.
5. Keep hands, feet and clothes far from moving
parts.

GRAPHIC_ID Figure 39

Prior to service in the machine:

1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Move the safety lever (pilot-control shut-off lever)
to the LOCK position.
4. Switch off the Auto-Idle.
5. Let the engine idle with no load for at least five
minutes until it has cooled down.
6. Move the key-start switch to the OFF position to
stop the engine.
7. Remove the ignition key from the start switch.
8. Apply the MAINTENANCE IN PROGRESS tag GRAPHIC_ID Figure 40
(see SAFETY PLATE in this Chapter). This tag
can be applied o the left-hand control lever,
safety lever or cab door.
9. Let the engine cool down.
Do not leave the machine unattended if servicing
requires the engine running.
If the machine is to be raised, place boom and arm at
an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
Never work under a machine kept raised by the
boom.
Inspect cer tain component regularly, repair or
r e p l a c e a s n e c e s s a r y. R e fe r t o t h e C h a p t e r
MAINTENANCE in this Manual.
Keep all components in good condition and properly
install. Immediately repair any fault. GRAPHIC_ID Figure 41
Immediately repair any damage. Replace worn or
failed components. Remove grease, oil, debris
buildups.
Disconnect the negative cable (-) from the battery
before carry out any work on he electrical system or
arc-welding on he machine.

NA Issued 10-2007 Bur 1-27

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
1. Before performing any work on the machine,
attach a maintenance in progress tag (see also
SAFETY PLATES in this Chapter) . This tag can
be applied o the left-hand control lever, safety
lever or cab door.

GRAPHIC_ID Figure 42

SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without
securing the machine first.
1. Always lower the attachment or tool to the
ground before working on the machine.
2. If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
3. Do not support the machine on cinder blocks or
other items that may crumble under continuous
load.
4. Do not work under a machine that is supported
solely by a jack. GRAPHIC_ID Figure 43

STOP THE ENGINE PRIOR TO PERFORMING

DO NOT perform any maintenance operation with
the engine running. Trapping by moving parts could
cause serious injuries. Stop the engine and wait that
i t c o o l s o f f p r i o r t o p e r fo r m i n g m a i n t e n a n c e
operations.
In case it is indispensable to perform maintenance
operations with the engine running, have a person
co-operating with you sitting in the operator's seat, to
cut off the engine immediately in case of necessity.

GRAPHIC_ID Figure 44

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
DISPOSE OF WASTE IN THE APPROPRIATE
MANNER
Waste improperly disposed of represents a danger
for the environment. Potentially dangerous waste
used on the excavators includes lubricants, fuel,
coolant, brake fluid, filters and batteries.
1. Used sealed containers when discharging fluids.
Do not use containers for food or beverages
which may induce drinking.
2. Do not spill waste over the ground, into drains, or
water beds.
3. Obtain information about the correct methods to
recycle or dispose of waste from local GRAPHIC_ID Figure 45
Authorities, collection centres or your Dealer.

WORK IN A CLEAN AREA

1. Before starting an operation, clean the working
area. Clear the area from all the objects that can
be dangerous for mechanics or people in the
working area.

PROPERLY LIGHT THE WORKING AREA

Properly and safely light the working area.
1. Use safe portable lamps in order to work inside
and under the machine.
2. Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire.

GRAPHIC_ID Figure 46

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
KEEP CLEAN THE MACHINE
Keep clean the engine compar tment, radiator,
batteries, hydraulic pipes, fuel tank and operator's
position.
1. The engine compartment temperature can
quickly rise, after stopping the engine. IN THESE
CASES, BE CAREFUL TO POSSIBLE FIRES.
Open the access doors in order to quicken the
engine cooling process and clean the
compartment.
Remove all the traces of grease, oil and deposits, in
order to avoid people accidents or damages to
things. GRAPHIC_ID Figure 47

1. Do not spray water or steam in the cab.

GRAPHIC_ID Figure 48

PREVENT ACID SCALDS

The sulfur ic acid, contained in the batter y, is
poisonous. It is strong enough to scald the skin,
corrode clothes and cause blindness, if it is sprayed
into the eyes.
To avoid dangers:
1. Fill the batteries in airy areas.
2. Always wear eye protections and rubber gloves.
3. Avoid breathing the electrolyte vapors when
topping off.
4. Avoid spilling or dripping the electrolyte.
5. Use proper emergency starting techniques. GRAPHIC_ID Figure 49
If you are touched with acid sprays:
1. Rinse your skin well with water.
2. Put on your skin sodium bicarbonate or clay to
help the acid neutralization.
3. Rinse your eyes with water for 10-15 minutes.
4. Immediately see a doctor.
If you have swallowed the acid:
1. Immediately see a doctor.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
STARTING THE ENGINE WITH BOOSTER
BATTERIES
If the engine is to be started using booster batteries,
make sure to comply with all procedures detailed in
the chapter OPERATING INSTRUCTIONS.
1. The operator should be sitting in the driver’s seat
to keep the machine under control when the
engine starts. Starting the engine with booster
batteries is a two man operation.
2. Do not use batteries that have been stored in the
cold for a long time.
3. Mistakes in following procedures detailed for
starting the engine with slave batteries may GRAPHIC_ID Figure 50
cause the batteries to explode or machine to
move unexpectedly.

PREVENT BATTERY EXPLOSIONS

Battery gas can explode.
1. Keep sparks, lighted matches, and flames away
from the top of battery.
2. Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
3. Do not charge a frozen battery; it may explode.
Warm battery to 16 °C (60 °F).
Battery electrolyte is poisonous. If the battery should
explode, battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
GRAPHIC_ID Figure 51
1. Be sure to wear eye protection when checking
electrolyte specific gravity.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines. Skin contact with
escaping hot water or steam can cause severe
burns.
1. To prevent possible injury from hot spraying
water. Do not remove the radiator cap until the
engine is cool. When opening, turn the cap
slowly to the stop. Allow all pressure to be
released before removing the cap.
2. The hydraulic oil tank is pressurized. Again, be GRAPHIC_ID Figure 52
sure to release all pressure before removing the
cap.

Hot fluids and surfaces:

Engine oil, reduction gear oil and hydraulic oil also
become hot during operation. The engine, hoses,
lines and other parts become hot as well.
1. Wait for the oil and components to cool down
before starting any maintenance or inspection
work.

GRAPHIC_ID Figure 53

STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
breakers and blades can fall and cause serious injury
or death.
1. Securely store attachments and implements to
prevent falling.
2. Keep bystanders away from storage areas.

GRAPHIC_ID Figure 54

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
AVOID HIGH PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
1. Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
2. Tighten all connections before applying
pressure.
3. Search for leaks with a piece of cardboard; take
care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
eye protection.
4. In an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

GRAPHIC_ID Figure 55
PREVENT PARTS FROM FLYING OFF
Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
1. NEVER attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
2. As pieces may fly off, be sure to keep body and
face away from valve.
Travel reduction gears are under pressure.
1. As pieces may fly off, be sure to keep body and
face away from air release plug to avoid injury.
Reduction gear oil is hot. Wait for gear oil to cool
SP0047
down, then gradually loosen the air release plug GRAPHIC_ID Figure 56
to release pressure.

NA Issued 10-2007 Bur 1-33

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
1. Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
2. Keep bystanders away from the working area
before striking any object.

GRAPHIC_ID Figure 57

HANDLE FLUIDS SAFELY - AVOID FIRES

Handle fuel with care: it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
possibly resulting in serious inject or death.
1. DO NOT refuel the machine while smoking or
when near open flame or sparks.
2. Always stop the engine before refuelling the
machine.
3. Fill the tank outdoors.

GRAPHIC_ID Figure 58

All fuels, most lubricants, and some antifreeze fluids

are flammable.
1. Store flammable fluids well away from fire
hazards.
2. Do not burn or puncture pressurized containers.
3. Do not store oily rags; they can ignite and burn
spontaneously.

GRAPHIC_ID Figure 59

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
PREVENT FIRES
Check for Oil Leaks:
1. Fuel, hydraulic oil and lubricant leaks can lead to
fires.
2. Check for missing or loose clamps, kinked
hoses, lines or hoses that rub against each
other, damage to the oil cooler, and loose oil
cooler flange bolts which may cause oil leaks.
3. Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil cooler and oil
cooler flange bolts.
4. Do not bend or strike high pressure lines.
GRAPHIC_ID Figure 60
5. Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
1. Short circuits can cause fires.
2. Clean and tighten all electrical connections.
3. Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
4. Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
5. DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc.
Clean up Flammables:
1. Spilled fuel, lubricants, trash, grease, debris,
accumulated coal dust, and other flammables
may cause fires.
2. Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
Check Key-start Switch:
1. If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
2. Always check key-start switch function before
operating the machine every day:
A. Start the engine and run it at slow idle.
B. Turn the key-start switch to the OFF position
to confirm that the engine stops.
3. If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:
1. Damaged or missing heat shields may lead to
fires.
2. Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the
following way:
1. Stop the engine by turning the key-start switch to
the OFF position if there is time.
2. Use a fire extinguisher if there is time.
3. Exit the machine.

GRAPHIC_ID Figure 61

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
1. If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.

SP0062
GRAPHIC_ID Figure 62

USE APPROPRIATE TOOLS

Use tools appropriate for the job to be performed.
1. Inappropriate tools, parts and procedures might
generate dangerous conditions.
2. Use tools of correct size to tighten or loosening
securing elements, in order to avoid injuries
caused by a wrench getting out of control.
3. Do not use U.S. Standard or British Standard
tools on metric fasteners and vice versa.
Use only genuine spare parts (please refer to the
SPARE PARTS CATALOGUE).
GRAPHIC_ID Figure 63

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when heat
goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials when welding, soldering, etc.
GRAPHIC_ID Figure 64

AVOID APPLYING HEAT TO LINES CONTAINING

FLAMMABLE FLUIDS
Do not weld or flame cut pipes or tubes that contain
flammable fluids.
Clean them with non-flammable solvent before
welding or flame cutting them.

REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paints are
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
1. Avoid breathing potentially toxic fumes and dust.
2. Do all such work outside or in a well ventilated
area.
3. Dispose of paint and solvents properly.
4. Remove paint before welding or heating:
A. If you sand or grind paint, avoid breathing the
dust. Wear an approved respirator.
GRAPHIC_ID Figure 65
B. If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
WELDING REPAIR INTERVENTIONS
Welding repair interventions must be performed only
by a certified welder with sufficient experience. Also,
appropriate safety rules must be implemented by all
the personnel involved in the operations. The
duration through time of the welding depends upon
the quality and the accuracy with which the operation
is performed.
1. Identify first all the fracture points and the zones
in which welding is required.
2. Clean accurately the zones involved.
3. Remove all paint and inspect the parts with
penetrating liquid or a magnetic particle tester. GRAPHIC_ID Figure 66
4. Move the starter switch into position OFF and
wait for 4 seconds to cutoff electricity from the
system.
5. Disconnect the negative terminal (-) from the
battery.
6. Connect the ground cable of the welder at least 1
m (3 ft.) from the component to be welded.
7. Make sure that the ground cable is NOT
connected to a seal or bearing and that there are
no seals or bearings between the ground cable
and the part to be welded.
8. Avoid welding pieces at low temperature ie.
below 16 °C (60 °F). If necessary, warm up the
part involved prior to welding it.
9. Remove paints from all surfaces prior to warming
up or welding. Painted surfaces, when warmed
up or when welded, can generate toxic fumes.
10. Use appropriate masks or protective glasses.
11. Wear gloves and adequate clothing to protect the
skin.

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
SAFETY PLATES

2 1

SP0090

1 2

SP0091

GRAPHIC_1D Figure 67

1. ATTACHMENT OPERATING RANGE SAFETY PLATE. 2. TRACK ADJUSTER PLATE.

NA Issued 10-2007 Bur 1-39

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS

14 5 4 3

12

11
13 8
10

SP0089
GRAPHIC_1D Figure 68

3. COUNTERWEIGHT OPERATING RANGE SAFETY PLATE.
4. READ-YOUR-MANUAL PLATE.
5. BOOM AND ARM MOVEMENT WARNING PLATE
(TRIPLE ARTICULATION VERSION).
6. OPEN WINDSCREEN WARNING PLATE
(INSIDE THE CAB).
7. TAG INDICATING MAINTENANCE IN PROGRESS.
8. ENGINE HOOD WARNING PLATE.
9. CONTROLS LOCK/UNLOCK PLATE (SAFETY LEVER).
10. HYDRAULIC OIL PRESSURIZED TANK WARNING PLATE.
11. BURNS WARNING PLATE.
12. SAFETY DISTANCE PLATE.
13. NO-STEPPING WARNING PLATE.
14. SPECIAL EQUIPMENT MOVEMENT WARNING PLATE

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
1. Attachment operating range safety plate
Make sure that any person near the working site is
outside the machine operating range before starting
the machine or operating the attachments. Sound the
horn.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 69

2. Track adjuster plate

It shows that obligation is made to consult the
Operation and Maintenance Instruction Manual prior
to acting on the track adjust valve.
Danger of severe injuries.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 70

3. Counterweight operating range safety plate

Make sure that any person near the working site is
outside the machine operating range before starting
the machine or operating the attachments. Sound the
horn.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 71

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
4. Read-your-manual plate
It is positioned in the cab to recommend to carefully
read the Operation and Maintenance Instruction
Manual prior to star ting, operating, ser vicing,
refuelling or carrying out any other work on the
machine.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 72

5. Boom and arm movement warning plate

(triple articulation version)
It shows the danger represented by the bucket hitting
the cab.
Pay special attention as no stops are provided to
prevent this problem.
Background: yellow
Border and icons: black

SP0073

GRAPHIC_ID Figure 73

6. Open windscreen warning plate

It indicates the risk of injuries deriving from the
windscreen not being locked or being improperly
locked in the open position.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 74

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
7. Tag indicating maintenance in progress
Maintenance staff is obliged to apply the tag that
indicates that the machine is not fully efficient and
warns about maintenance staff being located in not
visible positions. This tag should be applied to the
left-hand control lever, safety lever or cab door.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 75

8. Engine hood warning plate

It highlights the obligation to stop the engine before
opening engine hood.
Danger of severe injuries following the presence of
rotating parts such as fan, pulleys, and belts.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 76

9. Controls lock/unlock plate

It shows the position that the safety lever can
assume when the engine is running.
When the operator is about to leave the cab with the
engine running, even if for a short time, he must
move the safety lever to the LOCK position. Controls
are disabled and therefore no accidental machine or
attachment movement is possible.
Background: white
Border and icons: black

GRAPHIC_ID Figure 77

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 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
10. Hydraulic oil pressurized tank warning plate
It indicates that the hydraulic oil is pressurized.
Consult the Operation and Maintenance Instruction
Manual. Prior to intervening on the hydraulic oil tank,
bleed the pressure by actuating the appropriate
bleeding button located on the cap. The hydraulic oil,
at operating temperature, can cause burns in case of
contact with the skin.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 78

11. Burns danger plate

It indicates that a burns danger exists, since the zone
is characterized by high temperature.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 79

12. Safety distance plate

It instructs to keep at a safe distance from a zone
dangerous for personal safety.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 80

1-44 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
13. No-stepping warning plate
It instructs not to step on the zone where this decal is
attached.
Background: yellow
Cross: red
Border and icons: black

GRAPHIC_ID Figure 81

14. Special equipment movement warning plate

It shows the danger represented by the special
equipment hitting the cab.
Pay special attention as no stops are provided to
prevent this problem.
Background: yellow
Border and icons: black

GRAPHIC_ID Figure 82

NA Issued 10-2007 Bur 1-45

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 1 - SAFETY PRECAUTIONS
NOTES

1-46 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 2

E175B
EXCAVATOR

SPECIFICATIONS

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

2-II Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 2
SPECIFICATIONS
TABLE OF CONTENTS

MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Main Components – Upper Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Main Components – Under Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Main Components – Front Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Swing Motor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Travel Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Excavator Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Main Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Digging Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Monoblock Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Triple Articulation Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Transporting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Monoblock Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Triple Articulation Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Bucket Applications As A Function Of The Arms E175b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Monoblock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Triple Articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

NA Issued 10-2007 Bur 2-1

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS

NOTES

2-2 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
MAIN COMPONENTS

GRAPHIC_1D Figure 1
1. BUCKET 11. SWING MOTOR 21. TRACK LINK
2. BUCKET LINK 12. FUEL TANK 22. BATTERIES
3. IDLER LINK 13. HYDRAULIC OIL TANK 23. UPPER ROLLER
4. BUCKET CYLINDER 14. CONTROL VALVE 24. TRACK GUIDE
5. ARM 15. ENGINE MUFFLER 25. LOWER ROLLER
6. ARM CYLINDER 16. HYDRAULIC PUMP 26. AIR CLEANER
7. BOOM 17. ENGINE 27. CRAWLER ADJUSTER
8. BOOM CYLINDER 18. COUNTERWEIGHT 28. FRONT IDLER
9. CAB 19. ENGINE RADIATOR 29. SHOE PLATE
10. SWIVEL JOINT 20. TRAVEL MOTOR

NA Issued 10-2007 Bur 2-3

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
MAIN COMPONENTS – UPPER STRUCTURE

2
6

3 4
SM1051

GRAPHIC_1D Figure 2
1. CONTROL CAB 5. HYDRAULIC PUMP
2. PROPORTIONAL SOLENOID VALVE BLOCK 6. CONTROL VALVE
3. RADIATORS 7. SWING MOTOR UNIT
4. ENGINE 8. CENTER JOINT

2-4 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
MAIN COMPONENTS – UNDER CARRIAGE

1
2
3

section A - A
SM0013
GRAPHIC_1D Figure 3
1. RIGHT TRAVEL MOTOR UNIT
2. LEFT TRAVEL MOTOR UNIT
3. CENTER JOINT
4. SWING GEAR
5. FRONT IDLER ASSY

NA Issued 10-2007 Bur 2-5

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
MAIN COMPONENTS – FRONT ATTACHMENT

2 7

1
3

4 6 2 8 7

3
1

SM0014

GRAPHIC_1D Figure 4

1. BOOM CYLINDER
2. ARM CYLINDER
3. BUCKET CYLINDER
4. POSITIONING CYLINDER (TRIPLE ARTICULATION VERSION)
5. MONOBLOCK BOOM
6. BOOM (TRIPLE ARTICULATION VERSION)
7. ARM
8. POSITIONER (TRIPLE ARTICULATION VERSION)

2-6 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
HYDRAULIC COMPONENTS

Hydraulic Pump

Item Main Pump Gear Pump For Pilot

Pump K7V630TP112R-OE13-V ZX10LPRZ2-07G

Variable displacement plunger
Type Fixed displacement type gear pump
pump: regulator attached type

Max. displacement capacity cm3 65 x 2 10

rpm
(Clockwise
Revolution Rated 2200 ¨
seen from
shaft end)
Rated 34.3
Pressure MPa 5.0
ATT boost 37.8

Max. flow L/min 143 x 2 at 7.8 MPa 22

Max. input Power

kW 78.3 3.4
(at 2000 rpm)
Max. input torque Nm 340 14.7
(at 1200 rpm) (pound-feet) (251) (10.8)

Model KR76-OE13-V

Control Electric flow control, positive flow control, total power control at emergency
Regulator
function mode and power shift control

Others With solenoid proportional reducing valve (KDRDE5K-31/30C50)

Mass kg (lbs) 88 (194)

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.

Control Valve

Item STD VALVE

Model KMX13YD / B44061

Max. flow rate L/min 143 x 2

Main relief valve set pressure MPa 34.3 at 60 x 2 L/min

When power boost pressure 37.8 at 55 x 2 L/min

Over load relief valve set pressure MPa

Boom H, Bucket H, Arm R 39.7 at 30 L/min
Boom R, Bucket R, Arm H 37.8 at 30 L/min

Mass kg (lbs) 155 (342)

Item OPT VALVE

Model KADV22Y / 501103A

Over load relief valve set pressure MPa

Positioner R 39.7 at 30 L/min
Positioner H 37.8 at 30 L/min

Mass kg (lbs) 11 (24)

NA Issued 10-2007 Bur 2-7

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
Pilot Valve

ATTACHMENT TRAVEL
Model PV48K2004 6TH6NRZ
Primary pressure 5.0 MPa 4.9 MPa
Secondary pressure 0.6 ~ 3.2 MPa 0.54 ~ 2.35 MPa
Rated flow 20 L/min 25 L/min
Mass Approx. 2 kg Approx. 8 kg

Swing Motor Unit

Model M5X130CHB–10A–59B/285-122

Type Swash-plate type, fixed-displacement plunger motor

Displacement cm3 121.6

Hydraulic motor

Working pressure MPa 34.3

Max. flow L/min 148

Nm
Braking torque 583 (430)
(pound-feet)

Release pressure MPa 2.3~5.0

Relief set pressure MPa 28

Mass kg (lbs) 49 (108)

Type 2KAR6P72/240-712
Antireaction
valve block Mass kg (lbs) 2.5 (5.5)

Hydraulic motor assy mass kg (lbs) 51.5 (114)

Speed reduction type Planetary 2-stage

Reduction ratio 15.38

Reduction unit

Lubrication oil Gear oil SAE90 (API class GL–4 grade)

Lubrication oil volume L (gal) 3.0 (0.8)

Grease Extreme pressure lithium base # 2 grease

Grease volume kg (lbs) Approx. 1.0 (2.2)

Mass kg (lbs) 144.2 (313.5)

Total mass kg (lbs) Approx. 196 (432)

2-8 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
Travel Device

Reduction gear unit Epicycloidal, three-stage planetary type

Model 709 C3 K
Gearbox ratio 1 : 63.1
Travel motor Two speed, axial piston swash plate type
Model MAG 85 VP-17
high speed 50.4 cm3/rev
Displacement
low speed 87.3 cm3/rev
Max. flow 130.4 L/min

Max. gearbox output high speed 17378 Nm (12818 pound-feet)

torque low speed 30087 Nm (22191 pound-feet)
static 234 Nm (173 pound-feet)
Parking brake torque
dynamic 194 Nm (143 pound-feet)
Min. pressure parking brake release 14 bar
cracking 311 bar at 1.5 L/min
Relief valve set pressure
total flow 353 bar at 37 L/min
Mass 245 kg (540 lbs)

Cylinders

Center distance
Cylinder bore / Stroke of pins
Mass
Rod Dia. Full extend B /
Use Cushion kg
mm mm Full retract A
(lbs)
(in.) (in.) mm
(in.)
Ø 110 / Ø 80 1150 2815 / 1665 With cushion
Boom 149 (328)
(4.33 / 3.15) (45.28) (110.83 / 65.55) on rod side
Ø 125 / Ø 90 1290 3060 / 1770 With cushion
Arm 194 (428)
(4.92 / 3.54) (50.79) (120.47 / 69.68) on both sides
Ø 105 / Ø 75 1025 2565 / 1540 With cushion
Bucket 128 (282)
(4.13 / 2.95) (40.35) (100.98 / 60.63) on rod side
Ø 135 / Ø 85 1012 2555 / 1543
Positioning Without cushion 196 (432)
(5.31 / 3.35) (39.84) (100.59 / 60.75)

NA Issued 10-2007 Bur 2-9

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
EXCAVATOR PERFORMANCE
GRADEABILITY .................................................................................................................................................. 70%
TRAVEL SPEED

Excavator
E175B
Speed
First speed 3.0 km/h

Second speed 5.4 km/h

ENGINE DATA

Main Specifications
Manufacturer ............................................................................................................................................... CNH U.K.
Model........................................................................................................................................................ 445TA/MLF
Type .................................................................................................... Diesel, 4 stroke, direct injection, turbocharged
Number of cylinder ......................................................................................................................................... 4 in-line
Bore ................................................................................................................................................................104 mm
Stroke .............................................................................................................................................................132 mm
Total displacement....................................................................................................................................... 4485 cm3
Compression ratio ............................................................................................................................................. 17.5:1
Net power at flywheel (at 2000 rpm) (ISO 14396) .............................................................................................93 kW
Torque (at 1200 rpm) ...........................................................................................................525 Nm (387 pound-feet)
Engine idle at no-load.....................................................................................................................................800 rpm

INJECTION PUMP
Type......................................................................................................................................... VI4/12 F 1000 L935
Injection order ............................................................................................................................................. 1-3-4-2

BATTERY
Voltage - Capacity ....................................................................................................................... 2 x 12 V - 100 Ah

STARTER MOTOR
Manufacturer .............................................................................................................................................. BOSCH
Voltage - Output .................................................................................................................................... 24V - 4 kW

ALTERNATOR
Manufacturer .............................................................................................................................................. BOSCH
Type........................................................................................................................................... NCB1 28V 35-70A
Voltage - Output ......................................................................................................................................24V - 70A

2-10 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
DIGGING DATA

Monoblock Version

G
E

B'
B

A
A' NH0350
GRAPHIC_1D Figure 5

Arm 2200 2600 3100

A 8488 (27.85) 8844 (29.02) 9349 (30.67)
A’ 8676 (28.46) 9024 (29.61) 9520 (31.23)
B 5649 (18.53) 6049 (19.85) 6549 (21.49)
B’ 5401(17.72) 5820 (19.09) 6363 (20.88)
C 9155 (30.04) 9325 (30.59) 9685 (31.77)
D 6478 (21.25) 6669 (21.88) 7010 (22.99)
E 2991 (9.81) 2835 (9.30) 2895 (9.50)
F 3820 (12.53) 3471 (11.39) 2984 (9.79)
G 4339 (14.24) 4731 (15.52) 5060 (16.60)

Dimensions in mm (ft)

NA Issued 10-2007 Bur 2-11

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
Triple Articulation Version

E C

B'
B

A
A' NH0351
GRAPHIC_1D Figure 6

Arm 2200 2600 3100

A 8345 (27.38) 8704 (28.56) 9385 (30.79)
A’ 8536 (28.01) 8888 (29.16) 9212 (30.22)
B 5271 (17.29) 5655 (18.55) 6162 (20.22)
B’ 5146 (16.88) 5538 (18.17) 6054 (19.86)
C 9804 (32.17) 10066 (33.02) 10497 (34.44)
D 7056 (23.15) 7317 (24.01) 7749 (25.42)
E 2350 (7.71) 2110 (6.92) 2174 (7.13)
F 4091 (13.42) 3645 (11.96) 3155 (10.35)
G 2423 (7.95) 2760 (9.06) 2988 (9.80)
Dimensions in mm (ft)

2-12 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
TRANSPORTING DIMENSIONS

Monoblock Version

G D

H F

I C
L

M A
N B
NH0352

GRAPHIC_1D Figure 7

VERSIONS A B C D E F G H I L
[1] 8723 [1] 2973
(28.62) (9.75)
mm 3280 4087 1021 2520 [2] 8672 [2] 2846 2490 3008 950 490
E175BL
(ft) (10.76) (13.41) (3.35) (8.27) (28.45) (9.34) (8.17) (9.87) (3.12) (1.61)
[3] 8678 [3] 2928
(28.47) (9.60)
[1] 8723 [1] 2973
(28.62) (9.75)
mm 3280 4087 1021 2520 [2] 8672 [2] 2846 2490 3008 950 490
E175BLC
(ft) (10.76) (13.41) (3.35) (8.27) (28.45) (9.34) (8.17) (9.87) (3.12) (1.61)
[3] 8678 [3] 2928
(28.47) (9.60)
Arm:dimensions in mm (ft)
[1] 2200 mm
[2] 2600 mm
[3] 3100 mm

E175BLC
E175BL

mm 500 600 700 800 500 600 700 800 900

M Track shoe width
(ft) (1.64) (1.97) (2.29) (2.62) (1.64) (1.97) (2.29) (2.62) (2.95)

mm 2490 2590 2690 2790 2690 2790 2890 2990 3090

N Gauge
(ft) (8.17) (8.50) (8.83) (9.15) (8.83) (9.15) (9.48) (9.81) (10.14)

kg 17250 17500 17750 18000 17550 17800 18050 18300 18550

(*) Working weight
(lbs) (38030) (38580) (39130) (39683) (38691) (39242) (39793) (40345) (40896)

Spec. ground pres. bar 0.46 0.39 0.34 0.30 0.47 0.39 0.34 0.30 0.27

(*) With arm 3100 mm and bucket 0.51 m3

NA Issued 10-2007 Bur 2-13

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
Triple Articulation Version
E

G D

H F

I C
L

M A
N B
NH0353
GRAPHIC_1D Figure 8

VERSIONS A B C D E F G H I L
[1] 8574 [1] 3008
(28.13) (9.87)
E175BL mm 3280 4087 1021 2520 [2 ]8520 [2] 2878 2490 3008 490
(ft) (10.76) (13.41) (3.35) (8.27) (27.95) (9.44) (8.17) (9.87) (1.61)
[3 ]8525 [3] 2993
(27.97) (9.82)
[1] 8574 [1] 3008
(28.13) (9.87)
mm 3280 4087 1021 2520 [2 ]8520 [2] 2878 2490 3008 950 490
E175BLC
(ft) (10.76) (13.41) (3.35) (8.27) (27.95) (9.44) (8.17) (9.87) (3.12) (1.61)
[3 ]8525 [3] 2993
(27.97) (9.82)
Arm:dimensions in mm (ft)
[1] 2200 mm
[2] 2600 mm
[3] 3100 mm

E175BLC
E175BL

mm 500 600 700 800 500 600 700 800 900

M Track shoe width
(ft) (1.64) (1.97) (2.29) (2.62) (1.64) (1.97) (2.29) (2.62) (2.95)

mm 2490 2590 2690 2790 2690 2790 2890 2990 3090

N Gauge
(ft) (8.17) (8.50) (8.83) (9.15) (8.83) (9.15) (9.48) (9.81) (10.14)

kg 17650 17900 18150 18400 17950 18200 18450 18700 18950

(*) Working weight
(lbs) (38912) (39463) (40014) (40565) (39573) (40124) (40675) (41226) (41778)

Spec. ground pres. bar 0.53 0.45 0.39 0.34 0.54 0.45 0.39 0.35 0.31

(*) With arm 3100 mm and bucket 0.51 m3

2-14 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
BUCKET APPLICATIONS AS A FUNCTION OF THE ARMS E175B

Monoblock

BUCKETS E175BL E175BLC

Capacity Arm (mm) Arm (mm)
Width Mass
(dm3)
mm kg
SAE J296 2200 2600 3100 2200 2600 3100
(ft) (lbs)
(ISO 7451)
500 375
236 1 1 1 1 1 1
(1.64) (822)
780 472
430 1 1 1 1 1 1
(2.56) (1041)
880 509
510 1 1 1 1 1 1
(2.89) (1122)
1030 561
633 1 1 1 1 1 1
(3.38) (1237)
1230 610
793 1 1 2 1 1 1
(4.04) (1344)
1330 664
878 1 1 3 1 1 2
(4.36) (1464)

1)General digging work (specific weight of material < 1.8 t/m3)

2)Slightly heavy digging work (specific weight of material < 1.5 t/m3)
3)Loading work (specific weight of material < 1.2 t/m3)

Triple Articulation
BUCKETS E175BL E175BLC
Capacity Arm (mm) Arm (mm)
Width Mass
(dm3)
mm kg
SAE J296 2200 2600 3100 2200 2600 3100
(ft) (lbs)
(ISO 7451)
500 375
236 1 1 1 1 1 1
(1.64) (822)
780 472
430 1 1 1 1 1 1
(2.56) (1041)
880 509
510 1 1 1 1 1 1
(2.89) (1122)
1030 561
633 1 1 1 1 1 1
(3.38) (1237)
1230 610
793 1 1 2 1 1 1
(4.04) (1344)
1330 664
878 1 1 3 1 1 2
(4.36) (1464)

1)General digging work (specific weight of material < 1.8 t/m3)

2)Slightly heavy digging work (specific weight of material < 1.5 t/m3)
3)Loading work (specific weight of material < 1.2 t/m3)

NA Issued 10-2007 Bur 2-15

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 2 - SPECIFICATIONS
NOTES

2-16 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 3

E175B
EXCAVATOR

STANDARD PRECAUTIONS AND

TIGHTENING TORQUES

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

3-II Issued 05-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 3
STANDARD PRECAUTIONS AND TIGHTENING TORQUES
TABLE OF CONTENTS

PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Preparations For Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Disassembling and Assembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Disassembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Assembling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Bleeding Air from Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Floating Seal Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Bolt Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Specified Tightening Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Bolt Tightening Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Service Recommendations for Split Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Nut and Bolt Lockings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Lock Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Lock Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
PIPING JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Pipe Thread Connection / Union Joint Tightening Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Union Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
O-ring Seal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Screwed-In Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Seal Tape Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Low Pressure Hose Clamp Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Connecting Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

NA Issued 10-2007 Bur 3-1

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES

NOTES

3-2 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
PREPARATIONS FOR DISASSEMBLY
Wash the machine before bringing it into the shop.
Bringing a dirty machine into the shop may cause
machine components to be contaminated during
disassembling/assembling, resulting in damage to
m a c h i n e c o m p o n e n t s, a s we l l a s d e c r e a s e d
efficiency in service work.
Be sure to understand all disassembling/assembling
procedures beforehand, to help avoid incorrect
disassembling of components as well as personal
injury.
Check and record the items listed below to prevent
problems from occurring in the future.
1. The machine model, machine serial number, and
hour meter reading.
2. Reason for disassembly (symptoms, failed parts,
and causes).
3. Clogging of filters and oil, water or air leaks, if
any.
4. Capacities and condition of lubricants.
5. Loose or damaged parts.
Prepare the necessary tools to be used and the area
for disassembling work.
Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves.
Confir m the position of first-aid kit and fire
extinguisher, and also where to make contact for
emergency measure and ambulance to prepare for
accidents and fire.
Attach DON’T OPERATE tag to control lever, and
begin with a meeting before starting the work.
DISASSEMBLING AND ASSEMBLING
HYDRAULIC EQUIPMENT
Before removing pipes, release the pressure of
hydraulic oil tank, or open the cover on the return
side to tank, and take out the filter.
Drain the oil in the removed pipes into pan to prevent
the oil from spilling on the ground.
Plug or cap pipes to prevent oil leaking, entry of dust,
etc.
Clean the outside surface of equipment, etc. before
disassembling, and drain hydraulic oil and gear oil.
DISASSEMBLING HYDRAULIC EQUIPMENT
Since perfor mance and function of hydraulic
equipment after disassembly and assembly results in
immunity from responsibility on the manufacture’s
side, disassembly, assembly and modification
without permission are strictly prohibited.
NA Issued 10-2007 Bur
If it is unavoidably necessary to disassemble and
modify, it should be carr ied out by exper ts or
personnel qualified through service training.
Make match mark on parts for assembling.
Before disassembling, read DISASSEMBLING
INSTRUCTION in advance, and determine if the
disassembly and assembly are permitted or not.
For parts which are required to use jig and tools,
don’t fail to use the specified jig and tools.
For parts which can not be removed in the specified
procedure, never force removal. First check for the
cause.
Inspecting parts. Measure the wear of parts and
clearance, and record the measured values.
If an abnormality is detected, repair or replace the
parts.
The removed parts should be put in order and tagged
so as to install on proper places without confusion.
For common parts, pay attention to the quantity and
places.
ASSEMBLING HYDRAULIC EQUIPMENT
During the parts cleaning, ventilate the room.
Remove adhering oil by compressed air, and apply
hydraulic oil or gear oil, and then assemble them.
Replace the removed O-ring, backup rings and oil
seal with new ones, and apply gear oil on them
before assembling.
Remove dirt and water on the surface on which liquid
sealant are applied, degrease them, and apply liquid
sealant on them.
Before assembling, remove rust preventives on new
parts.
Use special tools to fit bearings, bushing and oil seal.
Assemble parts matching to the marks.
After completion, check that there is no omission of
parts.
3-3
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
INSTALLING HYDRAULIC EQUIPMENT
Confirm hydraulic oil and lubrication oil.

Bleeding Air from Hydraulic System

Air release is required in the following cases:
1. Change of hydraulic oil
2. Replacement of parts on suction pipe side
3. Removing and attaching hydraulic pump
4. Removing and attaching swing motor
5. Removing and attaching travel motor
6. Removing and attaching hydraulic cylinder

IMPORTANT: If hydraulic oil and lubricating oil are

not filled and also air bleed is not performed, the
hydraulic equipment may be damaged.
For air bleed of hydraulic pump and swing motor,
loosen drain plug on the upper part, start engine, and
run in low idling, then bleed air until hydraulic oil is
coming out. After bleeding of air, tighten plug
securely.
For air bleed of travel motor and hydraulic cylinder,
start engine and operate it for 10 minutes or more at
no-load and low speed.

GRAPHIC_ID Figure 1

IMPORTANT: For cylinder, don’t move it to the

stroke end at the beginning.
Air in pilot circuit can be bleed out by only operating
digging, swing and travelling motions thoroughly.
Check hydraulic oil level.
Move attachments to hydraulic oil check position, as
indicated in the figure.
Open the hydraulic pump compartment door, then
check the oil level on visual indicator (1) located on
the hydraulic oil reservoir. If the indicator is within
level marks, the oil quantity is acceptable.
GRAPHIC_ID Figure 2

3-4 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
Floating Seal Precautions
In general, replace the floating seal with a new one. If A
the floating is to be reused, follow these procedures:
1. Keep seal rings together as a matched set with
seal r ing faces together. Inser t a piece of
cardboard to protect surfaces.
2. Check the seal ring face (A) for scuffing, scoring,
corrosion, deformation or uneven wear.
3. Check O-Ring (B) for tears, breaks, deformation
or hardening.
B
SM0172
GRAPHIC_ID Figure 3

If incorrectly assembled, oil leakage or damage will

occur. Be sure to do the following, to prevent trouble.
1. Clean the floating seal and seal mounting bores
with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, dry parts with compressed air.
2. Clean the floating seal and seal mounting bores,
as dust on them tends to enter the floating seal
when installing it.
3. Check that the O-Ring is not twisted, and that it
is installed correctly on the seal ring. RIGHT

4. After installing the floating seal, check that seal

ring surface (C) is parallel with mating face (A)
by measuring the distances (a) and (b), as WRONG
illustrated.
If these distances differ, correct the O-Ring (B)
seating.

SM0173

GRAPHIC_ID Figure 4
RIGHT WRONG

a
A a

b b
a=b a≠b
SM0174
GRAPHIC_ID Figure 5

NA Issued 10-2007 Bur 3-5

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
ELECTRICAL EQUIPMENT
The disassembly of electrical equipment is not
allowed.
Handle equipment with care so as not to drop it or
bump it.
Connectors should be removed by unlocking while
holding the connector. Never put tension on the wire
by pulling on the wire.
Check that connector is connected and locked
completely.
Engine key off before removing and connecting
connector.
Engine key off before touching terminals of starter
and alternator.
Wash machine with care so as not to splash water on
electrical equipment and connector.
When water has entered in the water proofed
connector, removing the water is not easy. So check
the removed waterproofed connector with care to
protect it from entry of water. If moisture adheres on
it, dry it completely before connecting.
Remove battery grounding terminal before beginning
work close to battery and battery relay with tools.

WARNING
Battery fluid is dangerous. The battery fluid is dilute
sulfuric acid, and causes scald and loss of eyesight
by adhering on eyes, skin and clothes. When the fluid
has adhered on them, take an emergency measure
immediately and see a doctor for medical advice.
1. When it has adhered on skin:
wash with soap and water.
2. When it has got in eyes:
wash in water for 10 minutes or more
immediately.
3. When it was swallowed:
drink milk or water.

3-6 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
TORQUE CHART

WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.

GRAPHIC_ID Figure 6

BOLT TYPES
Tighten nuts or bolts correctly to torque
specifications. Two kinds of bolts, hexagon bolts T Hexagon T Bolt Socket Bolt
and socket bolt, each made of different material, are
used. Make sure to employ the correct bolts and
tighten them to specification when assembling the
machine or components.
SM0175

GRAPHIC_ID Figure 7

SPECIFIED TIGHTENING TORQUE CHART

Hexagon Wrench T Bolt, Socket bolt

Bolt Dia. Wrench Size
Size Nm (pound-feet)
M18 13 6 29.5 (21.8)
M10 17 8 64 (47)
M12 19 10 108 (80)
M14 22 12 175 (129)
M16 24 14 265(195)
M18 27 14 390 (288)
M20 30 17 540 (398)
M22 32 17 740 (546)
M24 36 19 930 (686)
M27 41 19 1370 (1010)
M30 46 22 1910 (1409)
M33 50 24 2550 (1881)
M36 55 27 3140 (2316)

NA Issued 10-2007 Bur 3-7

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
IMPORTANT
1. Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their
friction coefficients.
2. Torque tolerance is ± 10%.
3. Be sure to use bolts of correct length. Bolts that
are too long cannot be tightened, as the bolt tip
comes into contact with the bottom of the bolt
hole. Bolts that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart are for general
use only.
5. Do not use these torques if a different torque is
given for a specific application.
6. Make sure that the nut and bolt threads are clean
before installing. Remove dirt or corrosion, if any.

BOLT TIGHTENING ORDER

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

Equally tighten upper

and lower alternately Tighten diagonally Tighten from center and diagonally

1.4 1 12 9 4 1 6 7 14
6 3

4 5
2.3 13 8 5 2 3 10 11
2

SM0176

GRAPHIC_1D Figure 8

3-8 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
SERVICE RECOMMENDATIONS FOR SPLIT
FLANGE
IMPORTANT
1. Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal
wear. Unevenness causes seal extrusion. If
SM0177
defects cannot be polished out, replace the
component. GRAPHIC_ID Figure 9

2. Be sure to use only specified O-rings. Inspect O-

rings for any damage. Take care not to file O-ring WRONG
surfaces. When installing an O-ring into a
groove, use grease to hold it in place.
3. Loosely assemble split flange halves. Make sure
that the split is centrally located and
perpendicular to the port. Hand-tighten the bolts
to hold the parts in place. Take care not to pinch
the O-ring.
4. Tighten bolts alternately and diagonally, as
shown, to ensure even tightening. GRAPHIC_ID Figure 10

5. Do not use air wrenches. Using an air wrench

often causes tightening of one bolt fully before
tighten the others, resulting in damage to O-rings
or uneven tightening of bolts.

NUT AND BOLT LOCKINGS

SM0179

Lock Plate GRAPHIC_ID Figure 11

IMPORTANT: Do not reuse lock plates. Do not try to RIGHT WRONG

bend the same point twice.

Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Do not bend it round
holes in the bolt and nut while tightening, not while Bend along edge sharply

loosening.

Lock Wire RIGHT RIGHT WRONG

IMPORTANT: Apply wire to bolts in the bolt-

tightening direction, not in the bolt-loosening
direction.

GRAPHIC_ID Figure 12

RIGHT RIGHT WRONG

RIGHT WRONG
Loosen
Tighten

SM0181

GRAPHIC_ID Figure 13

NA Issued 10-2007 Bur 3-9

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
PIPING JOINT
1 4 3 5 2
PIPE THREAD CONNECTION / UNION JOINT
TIGHTENING TORQUE SPECIFICATIONS

UNION JOINT
Metal sealing faces (4) and (5) of adaptor (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. Joint Body SM0182

GRAPHIC_ID Figure 14

IMPORTANT
1. Do not over-tighten union nut (3). Excessive
force will be applied to metal sealing surfaces (4)
37°
and (5), possibly cracking adaptor (1). Be sure to
tighten union nut (3) to specifications. 37°
2. Scratches or other damage to sealing surfaces
(4) or (5) will cause oil leakage at the joint.
3. Take care not to damage them when connecting Male Union Joint Female Union Joint
/disconnecting. SM0183

GRAPHIC_ID Figure 15

Wrench Size Tightening Torque

Type
Union Nut Joint Body Nm (pound-feet)

37° Union Joint 19 17 29 (21.5)

22 19 39 (28.8)

27 22 78.5 (58)

36 30, 32 157 (116)

41 36 205 (151)

50 46 323.6 (239)

NOTE: Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.

3-10 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
O-RING SEAL JOINT
O-Ring (6) seats against the end face of adaptor (7)
to seal pressure oil.
7 6 9
IMPORTANT
1. Be sure to replace O-Ring (6) with a new one
when reconnecting.
2. Before tightening union nut (9), confirm that O-
Ring (6) is seated correctly in O-Ring groove (8).
T i g h t e n i n g u n i o n nu t ( 9 ) w i t h O - R i n g (6 )
8 10 Joint body
displaced will damage O-Ring, resulting in oil SM0184
leakage.
3. Take care not to damage O-Ring groove (8) or
sealing face (10). Damage to O-Ring (6) will GRAPHIC_ID Figure 16
cause oil leakage.
4. If union nut (9) is found to be loose, causing oil
leakage, do not tighten it to stop the leak.
Instead, replace O-Ring (6) with a new one, then
tighten union nut (9) after confirming that O-Ring
(6) is securely seated in place.

Wrench Size Tightening Torque

Union Joint
Nm (pound-feet)
Nut Body
19 17 29.4 (21.7)
22 19 68.6 (50.6)
27 22 93 (68.6)
30 27 137.3 (101.3)
36 30 175 (129)
41 36 205 (151)
50 46 320 (236)

NA Issued 10-2007 Bur 3-11

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
SCREWED-IN CONNECTION
IMPORTANT: Many types of screwed-in connec-
tions are used for hose connections. Be sure to
PT PF
confirm that the thread pitch and thread type (tapered
or straight) are the correct type before using any 30°
screw-in connection.

Male Tapered Thread

Wrench Tightening Torque
Male Tapered Thread Male Straight Thread
Joint Body Nm (
SM0185
17, 19 34 (25)
22 49 (36.1)
GRAPHIC_ID Figure 17
27 93 (68.6)
36, 32 157 (115.8)
41 205 (151)
50 320 (236)
60 410 (302)

SEAL TAPE APPLICATION

Seal tape is used to seal clearances between male Internal Thread
and female threads, so as to prevent any leakage
between threads.
Clearance
Be sure to apply just enough seal tape to fill up
External Thread SM0186
thread clearances. Do not overwrap.
Application Procedure
GRAPHIC_ID Figure 18
Confirm that the thread surface is clean, free of
dirt or damage.
Leave one to two pitch threads uncovered
Apply seal tape around threads as shown. Wrap
seal tape in the same direction as the threads.

SM0187

GRAPHIC_ID Figure 19

LOW PRESSURE HOSE CLAMP TIGHTENING

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

T-Bolt Type Band Clamp:

SM0188
4.4 Nm (3.2 pound-feet) SM0189

GRAPHIC_ID Figure 20 GRAPHIC_ID Figure 21

Worm Gear Type Band Clamp:
5.9 - 6.9 Nm (4.4 - 5 pound-feet)

3-12 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
CONNECTING HOSE
WRONG RIGHT
WARNING
When replacing hoses, be sure to use only genuine
parts. Using hoses other than genuine hoses may
cause oil leakage, hose rupture or separation of
fitting, possibly resulting in a fire on the machine.
Do not install hoses kinked. Application of high oil
pressure, vibration, or an impact to a kinked hose
may result in oil leakage, hose rupture or separation SM0190
of fitting.
Utilize print marks on hoses when installing hoses to GRAPHIC_ID Figure 22
prevent hose from being installed kinked.
If hoses rub against each other, wear to the hoses will WRONG RIGHT
result, leading to hose rupture. Take necessary
Rubbing Against Each Other
measures to protect hoses from rubbing against each
other.
Take care that hoses do not come into contact with
moving parts or sharp objects.

SM0191

GRAPHIC_ID Figure 23

WRONG RIGHT

Clamp Clamp

Rubbing

SM0192

GRAPHIC_ID Figure 24

WRONG RIGHT

Rubbing
Clamp

SM0193

GRAPHIC_ID Figure 25

NA Issued 10-2007 Bur 3-13

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 3 - STANDARD PRECAUTIONS AND TIGHTENING TORQUES
NOTES

3-14 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 4

E175B
EXCAVATOR

MAINTENANCE STANDARDS
AND TEST PROCEDURES

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

4-II Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION

CHAPTER 4
MAINTENANCE STANDARDS AND TEST PROCEDURES
TABLE OF CONTENTS

HOW TO USE THE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Standard and Cautions to be Exercised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Cautions to be Exercised at Judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Other Cautions to be Exercised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Preparation For Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Test Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Make Precise Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
PERFORMANCE INSPECTION STANDARD TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
MEASUREMENT OF ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Warming Up Of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Engine Speed Measured Value Through Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
MEASUREMENT OF HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Preparing To Measure Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Place To Install Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Pressure Adjustment Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pilot Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Swing Over Load Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Procedure For Adjusting Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Pilot Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
2-Stage Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Over Load Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Over Load Relief Valve (Swing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Over Load Relief Valve (Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Measuring Travel Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Deviation of Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Performances of Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Drain Rate of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Drain Rate of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Measuring Swing Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Performance of Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Performance of Swing Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Drain Rate of Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Measuring Attachment Operating Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Operating Time of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Oil Tightness of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Measuring Performances of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
ENGINE CONTROL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Engine Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Engine Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Governor Motor and C–1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Work Mode Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Adjustment of Mechatro Controller Output (A-B-C Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

NA Issued 10-2007 Bur 4-1

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES

Purpose of the Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

In Cases Where the Adjustment of Mechatro Controller Is Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Adjusting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
Operations in the Event of a Failure of Equipment of Mechatro Controller . . . . . . . . . . . . . . . . . . . . . . . . .4-34

4-2 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
HOW TO USE THE MAINTENANCE DETERMINING CORRECTION, ADJUSTMENT OR
REPLACEMENT
STANDARD AND CAUTIONS TO BE EXERCISED Machine performances deteriorate with time as parts
wear and some deteriorated performances may be
Application restored to new levels. Therefore, deter mine
WHEN THE MACHINE IS NEW correction, adjustment or replacement, depending
Confirm that the performances are in accordance u p o n t h e o p e ra t i n g h o u r s, k i n d o f wo r k a n d
with standard specifications as compared to the circumstances in which the machine is placed, and
performance standards. condition the machine performances to its most
desirable levels.
AT SPECIFIC SELF INSPECTION (RULE BY
COUNTRY) Other Cautions to be Exercised
Use the data for the criterion, for the purpose of
PARTS LIABLE TO DEGRADE
correction, adjustment and replacement.
Rubber products, such as, hydraulic hoses, O-Rings,
WHEN PERFORMANCES ARE DETERIORATED and oil seals deteriorate with time; replace them at
Determine whether it is caused by a fault or end of regular intervals or at overhauls.
service life after long hours of operation, to be used PARTS REQUIRING REGULAR REPLACEMENT
for safety and economical considerations.
Out of critical hoses that are necessary to secure
WHEN MAIN COMPONENTS ARE REPLACED
safety, we designate Very Important Parts (V.I.P)
For example, use data to restore performances of and recommend that they should be replaced
pumps and others. regularly.
INSPECTION AND REPLACEMENT OF OILS AND
Terminology
GREASES
STANDARD VALUES In performing maintenance, it is necessary for the
Values to be used to condition or assemble a new user to familiarize himself with how to handle the
machine. Where special notes are not given, these machine safely, cautions to be exercised and
values represent standard specifications (machine inspection/lubrication procedures. Refer to the
with standard attachments and standard shoes). operators manuals as well.
REFERENCE VALUES FOR REMEDY
Values at which readjustment is required. In order to
ensure performance and safety it is strictly prohibited
to use the machine over the specified values.
SERVICE LIMIT
This is the limit value at which reconditioning is
impossible without replacement of parts. If the value
is expected to exceed the service limit before next
inspection and correction are performed, replace the
parts immediately. The operation over the specified
values causes increase of damage and requires the
down time of machine, and also causes safety
problems.

Cautions to be Exercised at Judgment

EVALUATION OF MEASURED DATA
Disagreement of measuring conditions, variations of
data peculiar to a new machine, and measuring
errors are to be evaluated. Determine generally at
what levels measured values are located, instead of
determining whether or not values fall within or run
out of the reference values.

NA Issued 10-2007 Bur 4-3

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
PREPARATION FOR PERFORMANCE TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.

The Machine
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.

Test Area
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m, and to make a full
swing with the front attachment extended. GRAPHIC_ID Figure 1
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.

Precautions
1. Before starting to test, agree upon the signals to
b e e m p l oy e d fo r c o m m u n i c a t i o n a m o n g
coworkers. Once the test is started, be sure to
communicate with each other using these
signals, and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid
accidents due to landslides or contact with high-
voltage power lines. Always confirm that there is
sufficient space for full swings.
4. Avoid polluting the machine and the ground with GRAPHIC_ID SM1232
Figure 2
leaking oil. Use oil pans to catch escaping oil.
Pay special attention to this when removing
hydraulic pipings.

Make Precise Measurement

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.

4-4 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
PERFORMANCE INSPECTION STANDARD TABLE
NOTE: Unless otherwise specified, measure it on H mode.

Measuring Position Standard Adjusting Measuring

Inspection Item Unit
Position Size Port Value Point Condition

NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank Class - Sampling
or less
Hydraulic oil temperature Tank surface 50 ± 5 - Atmospheri
c
°C temp
Water temperature Radiator surface 75 ± 15 - 50 °C ~ -10
°C
Low
H mode Lo idle 1000 ± 50
throttle
Full throttle
Engine speed

H mode Hi idle 2200 ± 50

Measure the engine speed (Hi Idle)
Adjustment
at multi display on the
Auto-Idle 1050 ± 50 min-1 not Perform all
gauge cluster, or measure
required measurem
B mode Hi idle with diesel speed meter 2200 ± 50
ent with the
A mode Hi idle 2200 ± 50 air-
conditioner
S mode Hi idle 2000 ± 50 “OFF”
Pilot primary pressure circuit G pump a5 5.0 +0.5 PR1 HI idle
P1 a1
valve pressure

ATT Travel 34.3 +0.7 MR1 Boom up

Main relief

P2 a2

P1 a1
Power boost 37.8 +1.0 MR1
P2 a2

H 39.7 +0 OR3 Boom up

Boom a1
R 37.7 +0 Boom
OR4
down
High pressure circuit

Bucket
H 39.7 +0 OR1
digging
Over load relief valve pressure

Main pump

Bucket a1
PF 1/4 MPa Bucket
R 37.7+0 OR2
dump
H 37.7 +0 OR7 Arm in
Arm a2
R 39.7 +0 OR8 Arm out

LH OR5 Swing LH
Swing a2 28.0 +6.0
RH OR6 Swing RH

Forward
RH a1 34.4+0.7 Simultaneo
Reverse us
Travel

Operation
Forward of travel
LH a2 34.4+0.7 RH and LH
Reverse

NA Issued 10-2007 Bur 4-5

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES

Measuring
Inspection Item Standard value Unit
condition
Sprocket 1st speed 28~24
revolution min-1
(RH, LH) 2nd speed 46~41

In 3.4~4.0
Arm
2.4~3.0
Operating speeds

Out

Operating time Digging 3.5~4.1

Bucket s (At no load)
of cylinder Dumping 2.1~2.7

Up 4.0~4.6
Positioner
Down 6.5~7.1

Swing speed RH - LH 4.9~5.9 s / 1 rev

1st speed Iron shoe 28.2~31.2

Travel speed s / 3 rev
2nd speed Iron shoe 16.8~18.6
Amount of
2nd speed 0~240 mm / 20 m
travel deviation
Parking brake
15° Gradient 0 mm / 5 min
drift
Performance of Neutral position after 55~75 degree
Swing brake 180° full speed swing
Prestazioni

Swing parking
15° Gradient 0 mm
brake drift
Tip of the bucket tooth 90

ATT amount of Boom cylinder 3

mm / 5 min (A vuoto)
drift Arm cylinder 4.2

- -

Amount of horizontal play at the bucket tooth 30~50 mm

NOTE: Over load relief valves OR1 - OR8 described

in advance correspond to the following operations.
1. BUCKET DIGGING
2. BUCKET DUMP
(8) (4)
3. BOOM UP
4. BOOM DOWN
5. SWING LEFT (5) (6) (1) (2)
6. SWING RIGHT
7. ARM IN (7) (3)
8. ARM OUT

GRAPHIC_ID Figure 3

4-6 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
MEASUREMENT OF ENGINE SPEED
WARMING UP OF ENGINE
Start engine to raise the coolant temperature of
engine to 60 to 90°C (140 to 194°F) at surface of
radiator upper tank.
The E/G coolant temperature gauge is used to
measure.
The range in white color shows the temperature of
approx. 65 to 105°C (149 to 221°F), so confirm that
the pointer indicates the temperature within the white SM0600
range.

GRAPHIC_ID Figure 4

ENGINE SPEED MEASURED VALUE THROUGH

SERVICE DIAGNOSIS
GAUGE CLUSTER
1. Turn ON the starter switch with the buzzer stop
switch pressed.
2. A program No. and an actual engine revolution
are displayed as the No.2 Item.
3. The screen advances like No.2, No.3....each
time the Wiper Switch on the gauge cluster is BUZZER STOP
pushed. SWITCH
4. The screen returns like No.45, No.44....each
time the Washer Switch is pushed. WASHER
SWITCH
5. The display does not disappear unless the
starter switch is turned to OFF.
WIPER
SWITCH
SCREEN CHANGE SWITCH SM0851

GRAPHIC_ID Figure 5

NO.2 ENG
G-3 SPEED SET 1000
MEAS 1000
G-5 ENG PRS. LIVE
WATER TEMP 20 °C OFF

MODE H
H-1 ACCEL VOLT. 0.3 V
POS. 0%
G-1 MOTOR STEP 30
POS. 0%
COIL A 1.5 A
COIL B 1.5 A
G-2 LIMIT SW. OFF
SM0852

GRAPHIC_ID Figure 6

NA Issued 10-2007 Bur 4-7

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
MEASUREMENT OF HYDRAULIC PRESSURE
PREPARING TO MEASURE HYDRAULIC
PRESSURE
E175B a3
HYDRAULIC EQUIPMENT
Psv2 Psv1
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for
analysis: 1 set
A3
Dr2
MEASURING CLEANLINESS OF HYDRAULIC OIL Dr1

WARNING B1
a5
Dr3
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and B3
measure with the instrument for analysis. If the (a1) Dr1 PH2
measured value is higher than the standard value, (a2)
SM1281
replace the return filter or change the hydraulic oil.
GRAPHIC_ID Figure 7

PLACE TO INSTALL PRESSURE GAUGE

MAIN CIRCUIT
After releasing the pressure in hydraulic oil tank and
system, replace plugs PF1/4 of main pump gauge
ports (a1) (a2) with plugs for pressure measurement,
and attach pressure gauge 49 MPa (7100 psi).

PILOT CIRCUIT
Replace pilot gauge plug (a5) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).

4-8 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
PRESSURE ADJUSTMENT POSITION
MAIN CONTROL VALVE
Relief valve position on main control valve.
PLUG FOR
ARM (H) OPTIONAL RELIEF
OR7

FRONT
MACHINE

MAIN RELIEF BOOM (H) BUCKET (R)

GRAPHIC_1D (ATT & TRAVEL) OR3 OR2 Figure 8

BOOM (R) BUCKET (H)

OR4 OR1

MACHINE
FRONT

PLUG FOR
ARM (R) OPTIONAL RELIEF
OR8
View from the bottom of the machine SM1284
GRAPHIC_1D Figure 9

NA Issued 10-2007 Bur 4-9

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
PILOT RELIEF VALVE A3

The pilot relief valve PR1 is located on the gear

pump that is attached to the main pump.
a5

Dr3

B3
PR1
SM1285
GRAPHIC_ID Figure 10

SWING OVER LOAD RELIEF OVERLOAD RELIEF

OVERLOAD RELIEF
The swing motor is equipped with plugs PA, PB for OR5 OR6
pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2).
(B) (A)

PB
PA

GRAPHIC_ID Figure 11

E175B a3
Psv2 Psv1

A3
Dr2
Dr1

a5
B1
Dr3

GRAPHIC_ID Figure 12

4-10 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
PROCEDURE FOR ADJUSTING RELIEF VALVE

Pilot Relief Valve

Adjust it with adjust screw (311).

Tightening torque: 29.4 Nm (22 pound-feet)

No. of turns of adjust Pressure change MPa

screw (psi)
1 turn Approx. 2.1 (305)

LOCK NUT HEX24

GRAPHIC_ID 311 SM1287

Figure 13

2-Stage Main Relief Valve

(Common for travel and ATT sections)
Start from the boosting side, first. Loosen nut (1),
1 2
adjust the pressure with adjusting screw (2) and
tighten nut (1) after completion of the adjustment on
the boosting side.
Then, loosen nut (3), adjust the pressure on the
standard side with adjusting screw (4) and tighten nut
(3) after completion of the adjustment.
4 3

Tightening torque: 27.4-31.4 Nm (20-23 pound-feet)

SM0859

No. of turns of adjust Pressure change MPa GRAPHIC_ID Figure 14

screw (psi)
Boosting side 1 turn Approx. 17.6 (2560)
STD side 1 turn Approx. 17.6 (2560)

Over Load Relief Valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw
(2).

Tightening torque: 27.4-31.4 Nm (20-23 pound-feet)

No. of turns of adjust Pressure change MPa

screw (psi)
2 1
1 turn Approx. 17.7 (2560)

SM0860

GRAPHIC_ID Figure 15

NA Issued 10-2007 Bur 4-11

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Over Load Relief Valve (Swing)
When the adjustment of pressure is required, loosen
lock nut (1) and adjust the pressure with cap (2).
1 2

Tightening torque: 118 Nm (87 pound-feet)

No. of turns of adjust Pressure change MPa

3
screw (psi) R
1 turn Approx. 10 (1450)
SM0861

GRAPHIC_ID Figure 16

Over Load Relief Valve (Travel)

This valve was adjusted by valve maker. When
adjustment is required, loosen nut (1) and adjust the
pressure with adjusting screw (2). 1

SM0862

GRAPHIC_ID Figure 17

4-12 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
MEASURING TRAVEL PERFORMANCES

Travel Speed
PURPOSES
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.

CONDITIONS
Hydraulic oil temperature: 45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly. SM0863
GRAPHIC_ID Figure 18

PREPARATION
Attach the reflection panel with a magnet to the travel
motor cover.
REFLECTION
Swing the swing frame through 90° as shown in PANEL
Figure and make the crawler on one side take off the
ground, using the attachment.
MEASUREMENT
Engine revolution: Hi idle
2-speed travel switch: 1st speed and 2nd
speed
Measuring points: Right and left
Method, example 1: GRAPHIC_ID SM0864
Figure 19
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.

Sprocket revolution Unit: min-1

Referenc
Measurement Standard e Service
item value value for limit
remedy
H
mode 17.3 or
28-24 22-19.5
1st less
RH & speed
LH H
mode 29.7 or
46-41 35.9-32
2nd less
speed

NA Issued 10-2007 Bur 4-13

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Deviation of Travel
PURPOSE
Measure the amount of deviation at 20 m (66 ft)
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the travel
drive system.

CONDITION
Hydraulic oil temperature: . . . . . . . . . . . . . 45~55 °C Approx. 30~40 cm
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .(113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground GRAPHIC_ID SM0865
Figure 20
Engine revolution: Hi idle.

PREPARATION
1. Straight course more than 30 m (108 ft).
2. Travel position in which the bottom of the bucket
is lifted by about 30 cm (1 ft).
MEASUREMENT
1. Measure the max. deviation distance of the
A
circular arc in the 20 m (66 ft) length, excluding
the preliminary run of 3-5 m (10-16 ft). 20m
2. Operate the travel lever at the same time.

Travel deviation Unit: mm(in)/ 20 m(66ft)

Reference
Measuring Standard Service GRAPHIC_ID\ SM0866
Figure 21
value for
position value limit
remedy
240 (9.45) 720
A 480 (18.9)
or less (28.4)

4-14 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Performances of Parking Brake
PURPOSE
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 15 degree slope. BOOM FOOT PIN
CONDITION
A slope with (Approx. 15 degrees) gradient and a
stopped condition in a no-load travel position. ARM TOP PIN

15 degree slope

SM0867
GRAPHIC_ID Figure 22

PREPARATION
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide frame
rib on the track frame and put a mark (matching
mark) on the shoe plate.

MEASUREMENT
Five minutes after the engine stops, measure the ANGLE METER
GUIDE FRAME C
movement distance of the matching mark.

Parking brake Units: mm (in)/ 5 minutes

SM0868
Reference
GRAPHIC_ID Figure 23
Measuring Standard
value for Service limit
position value
remedy
C 0 1 (0.04) 2 (0.08)

NA Issued 10-2007 Bur 4-15

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Drain Rate of Travel Motor
PURPOSE
FORWARD 90 o 10
To measure the drain rate of the travel motor and to (3.54") (0.394")
confirm the performances of the travel motor. o 22 PIPE 40
(0.866") (1.57")
CONDITIONS
Hydraulic oil temperature: . . . . . . . . . . . . . . 45-55°C RIB "A" 150
STOPPER (5.91")
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (113-131°F) "B"
Engine revolution: Hi idle
o 80
(3.15")
ROTARY DIRECTION
PREPARATION
SM0869
1. Place a stopper under the RH and LH travel
sprockets. GRAPHIC_ID Figure 24

2. Stop the engine and release pressure from the

hydraulic circuit.
3. Connect a hose with the drain port of the travel
motor and take drain in a container.
MEASUREMENT AT TRAVEL LOCK

WARNING
Unless you observe the rotary force direction at travel
lock, rib A may be broken by stopper B in some
cases.

1. Start the engine and relieve pressure at the full

stroke of the travel lever.
2. Measure the drain rate for 30 seconds of
relieving.
SM0870

GRAPHIC_ID Figure 25

Drain Rate of Travel Motor

Drain rate of travel Units: L(gal)/30 s

motor
Reference
Measuring Standard
value for Service limit
position value
remedy
Drain rate 5 (1.3) 13 (3.4) 15 (4.0)

4-16 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
MEASURING SWING PERFORMANCES

Swing Speed
PURPOSE
M e a s u r e t h e sw i n g t i m e a n d c o n f i r m t h e
performances between the hydraulic pump and the
swing motor of the swing drive system.

CONDITIONS
Hydraulic oil temperature: . . . . . . . . . . . . . 45~55°C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . (113~131°F)
Firm, level ground
Engine revolution: Hi idle

PREPARATION
Put the bucket empty and extend the boom, arm and
bucket cylinder fully.
And the machine becomes a position of minimum
reach.

MEASUREMENT AT TRAVEL LOCK

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.
GRAPHIC_ID Figure 26

Swing speed Units: sec/rev

Reference
Measuring Standard
value for Service limit
position value
remedy
Swing
speed at 4.9-5.9 6.2-7.5 7.8
min. reach

NA Issued 10-2007 Bur 4-17

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Performance of Swing Brake
PURPOSE
Confirm the braking torque performances by the
swing relief valve. BOOM FOOT
ARM TOP
PIN PIN

CONDITIONS
Hydraulic oil temperature: . . . . . . . . . . . . . . 45-55°C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (113-131°F)
Firm, level ground
SM0872
Engine revolution: Hi idle

GRAPHIC_ID Figure 27

PREPARATION
1. Put the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. And
move the boom so that the ar m top pin is
positioned at same height with boom foot pin.
2. Put a matching mark on the outer circumference
of the swing bearing of the upper frame side and
of the track frame side. Place two poles (flags)
on the front and back of the extended line of the
matching mark.
MEASUREMENT AT TRAVEL LOCK
1. When operating in regular swing speed, by MEASURING THE LENGTH OF THE ARC OVER
shifting lever to neutral position at pole position THE OUTER CIRCUMFERENCE OF OUTER RACE

the swing operation stops. MATCHING MARKS ON

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

Amount of deflection of MATCHING MARKS

matching marks [m (ft-in)] ON INNER RACE

Swing
drift ______________________ GRAPHIC_ID Figure 28
angle X 360 °
= _
(°)
Circumference length of
swing race [m (ft-in.)]

Swing brake Units: degree

performance
Reference
Measuring Standard
value for Service limit
position value
remedy
Swing 180° 75° 85° 90°

4-18 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Performance of Swing Parking Brake
PURPOSE
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.

CONDITIONS
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the boom
so that the arm top pin is positioned at same height
with boom foot pin. GRAPHIC_ID Figure 29

PREPARATION
Put the angle meter on the shoe plate and make sure MEASUREING THE LENGTH OF THE ARC OVER
that the angle is more than 15 degree. THE OUTER CIRCUMFERENCE OF OUTER RACE

Put a matching mark on the outer race side and on MATCHING MARKS ON
OUTER RACE
the inner race side.

MEASUREMENT AT TRAVEL LOCK

When five minutes has passed after the engine
stops, measure the length of the movement of the
matching marks. MATCHING MARKS
ON INNER RACE

GRAPHIC_ID Figure 30

Performance of swing Units: mm(in)/ 5 minutes

parking brake
Reference
Measuring Standard
value for Service limit
position value
remedy
C 0 1 (0.04) 2 (0.08)

NA Issued 10-2007 Bur 4-19

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Drain Rate of Swing Motor
PURPOSE
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.

CONDITIONS
Hydraulic oil temperature: . . . . . . . . . . . . . . 45-55°C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (113-131°F)
Firm, level ground
Engine revolution: Hi idle
PREPARATION
GRAPHIC_ID Figure 31
1. Stop the engine.
2. Release pressure from inside the hydraulic
circuit.
3. Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take oil
in a container.
4. Put a plug to the tank side.

MEASUREMENT AT SWING LOCK

1. Start the engine and put the side faces of bucket
against the inside of the right or left shoe plates.
2. Relieve the swing motor at full stroke of the
swing motion.
3. Collect the amount of drained oil in a container
for 30 seconds.

Drain rate of swing Units: L (gal)/ 30 sec

motor
Reference
Measuring Standard
value for Service limit
position value
remedy
Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 (1.6)

4-20 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
MEASURING ATTACHMENT OPERATING
PERFORMANCES

Operating Time of Cylinders

PURPOSE
Measure the operating time of the arm, positioning
and bucket and confirm the performances between
t h e hy d r a u l i c p u m p a n d t h e c y l i n d e r o f t h e
attachment drive system.

CONDITIONS
Hydraulic oil temperature: . . . . . . . . . . . . . . 45-55°C
. . . . . . . . . . . . . . . . . . . . . . . . . . . . (113-131°F)
Engine revolution: . . . . . . . . . . . . . . . . . . . . . . Hi idle
Operating time excluding the cushion stroke.

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

Cylinder operating time Units:sec

Reference
Measuring Standard
value for Service limit
position value
remedy
30 cm (1 ft)
1 3.5-4.1 4.4-5.2 5.4
2 2.1-2.7 2.7-3.4 3.5
7 3.4-4.0 4.2-5.0 5.4
9
8 2.4-3.0 3.0-3.8 4.0
9 4.0-4.6 5.0-5.7 5.9
10 6.5-7.1 8.2-9.0 9.4 10

30 cm (1 ft)

SM0877
GRAPHIC_ID Figure 32

NA Issued 10-2007 Bur 4-21

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Oil Tightness of Cylinders
PURPOSE
Confirm that the cylinder oil tight by checking the
B
moving length of the cylinder rods.
BOOM FOOT PIN
CONDITIONS C
Hydraulic oil temperature: . . . . . . . . . . . . . .45~55°C A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .(113~131°F)
Firm, level ground D

After cylinders are replaced, bleed off air from the

ARM TOP PIN
cylinders, before checking for oil tightness. SM0878

Retract the arm cylinder rod 50mm (2in) from stroke

end so that the piston does not match a same range GRAPHIC_ID Figure 33
of the cushioning mechanism.

PREPARATION
Put the bucket empty. Extend the arm cylinder rod
50mm (2in) from the most retracted position. And
extend the bucket cylinders fully. Then hold the boom
so that the arm top pin is positioned at same height
with boom foot pin.
MEASUREMENT
Measure the items five minutes after the engine is
turned off.

Oil tightness of cylinder Units: mm(in)/ 5 minutes

Reference
Measuring Standard
value for Service limit
position value
remedy
A 3 (0.12) 5 (0.2) 7 (0.28)
B 4.2 (0.17) 7 (0.28) 10.5 (0.41)
C - - -
D 90 (3.54) 150 (5.9) 225 (8.86)

4-22 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
MEASURING PERFORMANCES OF SWING
BEARING
PURPOSE
Measure the gap between the lower frame and the
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.

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

Measure the displacement of the outer race in the

axial direction in position 1 [The arm at 90°~110° and
the crawler front is lifted by attachment about 30cm GRAPHIC_ID Figure 34
(1ft)] and in position 2, using a dial indicator.

Axial play of swing Units: mm(in)

bearing
Reference
Measuring Standard 90 ~100
value for Service limit
position value
remedy
0.8-1.8
2.3-3.3
A (0.03- 3.6 (0.14)
(0.09-0.13)
0.07) 30cm

GRAPHIC_ID Figure 35
POSITION 1

ARM TOP BOOM FOOT

PIN PIN

SM0872

GRAPHIC_ID Figure 36
POSITION 2

NA Issued 10-2007 Bur 4-23

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Measuring position 3
Retract the arm cylinder fully and extend the bucket
cylinder fully. And move the boom so that the arm top
pin is positioned at same height with boom foot pin.
ARM TOP BOOM FOOT
Then swing the bucket right and left by man power. PIN
PIN
But in this case, the gap of the attachment is
included.

Right and left

movement of the ti of Units: mm(in )
bucket
SM0872
Reference
Measuring Standard
value for Service limit
position value
remedy GRAPHIC_ID Figure 37
30-50 POSITION 3
Benna (1.18- 80 (3.15)) 120 (4.72)
1.97)

4-24 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
ENGINE CONTROL INPUT/OUTPUT

M-2:
GOVERNOR MOTOR

E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX

ENGINE
ENGINE SPEED
SENSOR

PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER

SM0881

GRAPHIC_1D Figure 38

NA Issued 10-2007 Bur 4-25

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
ENGINE CONTROL

Engine Control Assembly

10 Section B-B

HIGH
3
LOW
HIGH LOW 1

2
4
11
3
5
12
3
3

Detail aa Section A-A

9
7 6 8
2

Section C-C
9 SM1280

GRAPHIC_1D Figure 39

1. GOVERNOR MOTOR 7. NUT M10 10.7 NM (7.89 POUND-FEET)

2. LEVER ASSEMBLY 8. NUT M10 10.7 NM (7.89 POUND-FEET)
3. SEMS-BOLT M8X25 (Q.TY 6) 23.5 NM (17.3 POUND-FEET) 9. NUT M8 (Q.TY 2) 23.5 NM (17.3 POUND-FEET)
4. BRACKET 10. SEMS-BOLT M6X20 (Q.TY 2) 4.4 NM (3.25 POUND-FEET)
5. CAPSCREW (Q.TY 3) 19.6 NM (14.5 POUND-FEET) APPLY
11. SEMS-BOLT M6X20 9.6 NM (7.08 POUND-FEET)
LOCTITE #242
6. ROD 12. BRACKET

4-26 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
ENGINE CONTROL EQUIPMENT REDUCTION GEAR SECTION
OIL SEAL
MOTOR SECTION
Governor Motor and C–1 Controller OUTPUT
1. By operating accel dial, the input voltage change SHAFT
is sensed by CN102–8 pin of C–1 controller.
2. The C–1 controller computes the input voltage,
and outputs command to governor motor (M–2), CAM
and incline governor lever of engine to the swing LIMIT
angle corresponding to accel dial set value. SWITCH
3. The limit switch in the governor motor is the
starting point of the governor motor.

SM0883
GRAPHIC_ID Figure 40

Speed Sensor
Installing place: engine flywheel housing.
Sensor attaching procedure: push it into place and fix
with partially self-sealing cylindrical screw M6x12,
tightening torque 8 ± 2 Nm (5.9 ± 1.5 pound-feet).
CN-136F

SM0884

GRAPHIC_ID Figure 41

Work Mode Select Switch

If the work mode select switch is pressed, a signal is
transmitted to the C–1 controller and changes the
work modes in the order of H→B→A→S and back to
H again.

WORK MODE
SELECT SWITCH

SM0885
GRAPHIC_ID Figure 42

NA Issued 10-2007 Bur 4-27

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
ADJUSTMENT OF MECHATRO CONTROLLER
OUTPUT (A-B-C ADJUSTMENT)

Purpose of the Adjustment

There are 3 kinds of adjustment of mechatro
controller as shown below; every adjustment is an
essential function to ensure performance of machine.
1. Adjustment of engine (A adjustment)
This adjustment is performed to set the relation
between the stepping command output from
mechatro controller to governor motor and the
engine speed.
2. Adjustment of pump (B adjustment)
This adjustment is performed to correct the
output variation by coordinating the output
hydraulic pressure with engine rated output.
3. Adjustment of unloading valve (C adjustment)
This adjustment is performed to correct the open
variation of unloading valve to improve the
operability further.

In Cases Where the Adjustment of Mechatro

Controller Is Required
When the following parts are replaced or repaired,
carry out the adjustment without fail:
1. Mechatro controller
2. Engine
3. Hydraulic pump or hydraulic pump proportional
valve
4. Unloading proportional valve, spool of unloading
valve.

Preparation
1. Raise the oil temperature to about 50°C (122°F)
to warm up the engine.
2. Turn the air-con OFF.
3. Turn the starter key switch OFF to stop the
engine.
When the mechatro controller was replaced, the
following error code is displayed because the
adjustment data is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above
may suggest failures of machine, repair the machine
into the ordinary operating condition according to
Error Code List.

4-28 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
Adjusting Procedure

MULTI DISPLAY

BUZZER STOP SWITCH WORK MODE SELECT SWITCH

WASHER SWITCH

WIPER SWITCH
SELECT SWITCH
SM0886

GRAPHIC_1D Figure 43
ADJUSTMENT OF ENGINE (A ADJUSTMENT)
PROCEDURE
1. Turn starter key switch ON keeping the work
mode selector switch on the gauge cluster
pressed, and hold it for 5~10 seconds, and then
release it. (If the engine is started, the following
indication is not displayed. Therefore do not start
the engine.)
2. Keep buzzer stop switch on gauge cluster
pressed for 5 seconds and release it and the
screen for selecting adjustment is displayed.
When adjustment data is not entered in
mechatro controller, READY is indicated. If the GRAPHIC_ID Figure 44
adjustment operation is once performed, FIN is
i n d i c a t e d . A n d t h e l eve r l o ck s o l e n o i d i s
automatically released, disabling all operations.
3. Press selector switch on gauge cluster to display
START ENG. Engine SPEED, P1, P2 PUMP
PRESSURE and STEP (stepping command) are
indicated.

NA Issued 10-2007 Bur 4-29

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
4. After starting engine, press selector switch on
gauge cluster, and MEMORY ENG is displayed,
the engine speed is automatically increased, and
the adjustment of engine is performed.
(When tr ying to limit engine speed, press
selector switch on gauge cluster at the speed as
it is, and the adjustment of engine is terminated.
The torque adjustment and unloading adjustment
required later are not performed, and default FINISH ENG
ENGINE SPEED
value is written). 2000rpm
PUMP PRESSURE
C-1 2.0M C-2 2.0M
5. When normal HIGH idling speed is detected, the STEP
400
adjustment is completed. And FINISH ENG is
displayed.
SM0888
(Press the buzzer stop switch on gauge cluster GRAPHIC_ID Figure 45
w h i l e t h i s d i s p l ay i s a p p e a r e d , a n d t h e
adjustment of engine is completed. The torque
adjustment and unloading adjustment required
later are not performed, and default value is
written.)
ADJUSTMENT OF PUMP
(B ADJUSTMENT)
PROCEDURE
1. The adjustment automatically shifts from engine
to pump, the speed shifts from LOW idling to
HIGH idling. And MEMORY PUMP is displayed.
And the unloading proportional valve and pump
propor tional valve actuate, accordingly the FINISH PUMP
ENGINE SPEED
loading of pump is increased.The ENGINE 2000rpm
PUMP PRESSURE
SPEED, P1, P2 PUMP PRESSURE and P1, P2 C-1 35.0M C-2
PROPO-VALVE
35.0M

pump PROPO-VALVE current (command value) E-1 300mA E-2 300mA

are indicated.
2. After detection of the engine rated speed, the GRAPHIC_ID SM0889
Figure 46
adjustment of pump is automatically completed.
And FINISH PUMP is displayed.
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the adjustment
is completed. The unloading adjustment required
later is not performed, and default value is
written.).

4-30 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
ADJUSTMENT OF UNLOADING VALVE ENGINE SPEED
2000rpm
(C ADJUSTMENT) PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
PROCEDURE D-1 300mA D-2 300mA

1. The adjustment shifts from pump to unloading,

and the unloading valve actuates, accordingly
the pump pressure is detected.
And MEMORY UNLOAD is displayed.The
ENGINE SPEED, P1, P2 PUMP PRESSURE
and P1, P2 PROPO-VALVE voltage (command
value) are indicated.
2. When the unloading valve operates to the
specified value, the adjustment of unloading
proportional valve is automatically terminated.
And FINISH UNLOAD is displayed.
The speed is shifted to the speed corresponding
to acceleration potentiometer.The adjusting
current value is indicated on the display of GRAPHIC_ID Figure 47
current of P1, P2 unloading proportional valves.
The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically
stored.).

C O R R E C T I V E AC T I O N TA K E N W H E N T H E
ADJUSTMENT CAN BE NOT PERFORMED
1. In cases where the adjustment of engine can not
be performed; And ERROR ENG is displayed.
Judging condition: The read engine speed is
50rpm lower than the last value.

It is conceived that the error is caused by the

speed read error, pump load applied to the
engine and unusual stepping command applied
to the gover nor motor in the course of
adjustment.
A. Checking speed sensor:
check that it is free from wrong reading of
speed due to engine vibrations.
B. Checking load applied to pump:
check that it is free from abnormal increase of
pump pressure during adjustment of engine
through adjustment screen.

NA Issued 10-2007 Bur 4-31

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
2. In cases where the adjustment of pump can not
be performed; And ERROR PUMP is displayed.
Judging condition 1:
P1 and P2 average pump pressure at the time
when the adjustment is completed is 25MPa or
less.
Judging condition 2:
The adjustment does not complete although the
pump proportional valve current reaches to the
specified value. SM0891

The P1 and P2 pump pressures usually increase

to 33~38MPa. When the pressure does not
increase: GRAPHIC_ID Figure 48
A. Identify the reason why the pressure does not
increase,
Check that the relief valve operates normally.
Check that the hydraulic circuit is free from leak
of pressure.
Check that the pressure sensor functions
normally. And so on.
B. Identify the reason why the actual flow rate
does not increase,
C h e ck t h a t t h e p u m p p r o p o r t i o n a l va l ve
operates normally.
Ch eck tha t th e pum p regu la tor ope rate s
normally. and so on.

3. In cases where unloading valve can not be

performed; And ERROR UNLOAD is displayed.
Judging condition 1:
the pump pressure does not increase up to the
pressure in the range of the specified adjustment. Or
the increased pressure is held as it is.
Judging condition 2:
pressure sensor of either P1 pump or P2 pump is
failed.
SM0892
Normally the pump pressures of P1 and p2 pumps
gradually increase to 10~25MPa.
(It may be affected by operating oil temperature.)
When the pump pressure does not increase: GRAPHIC_ID Figure 49
A. Identify the reason why the pressure does not
increase,
Check that the relief valve operates normally.
Check that the hydraulic circuit is free from leak
of pressure.
Check that the pressure sensor functions
normally. And so on.

4-32 Issued 10-2007 Bur NA

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
OTHER PRECAUTIONS
1. In the event of a failure, there is case where the
adjustment may not be performed normally.
First ser ve the machine, and perfor m the
adjustment work.
2. In the condition where large load is constantly
applied to engine, the adjustment could not be
performed normally.

W H EN T H E AD J U S T M E NT O F U N L OA DI N G
VALVE ONLY IS PERFORMED (C ADJUSTMENT)
In the event where only unloading valve and
unloading proportional valve are replaced, perform
the adjustment of unloading valve only.

PROCEDURE (EXAMPLE)

1. Turn starter switch ON keeping the work mode

selector switch on the gauge cluster pressed,
and hold it for 5~10 seconds, and then release it.
(If the engine is started, the following indication is
not displayed. Therefore do not start the engine.)
2. Keep buzzer stop switch on gauge cluster
pressed for 5 seconds and release it and the
screen for selection of adjustment type is
displayed. And ADJUST is displayed.
When adjustment data is not entered in
mechatro controller, READY is indicated. If the
adjustment operation is once performed, FIN is
i n d i c a t e d . A n d t h e l eve r l o ck s o l e n o i d i s
automatically released, disabling all operations.
3. Change the adjusting items with washer switch (
) and wiper switch ( ), and select ADJUST
UNLOAD.
Like the output adjustment, when adjustment
data is not entered in mechatro controller,
READY is indicated. If the adjustment operation GRAPHIC_ID Figure 50
is once performed, FIN is indicated.
4. Press selector switch on gauge cluster to display
START ENG.
ENGINE SPEED, P1, P2 PUMP PRESSURE
and STEP (stepping command) are indicated.

NA Issued 10-2007 Bur 4-33

 SECTION 1 - SAFETY AND GENERAL INFORMATION
CHAPTER 4 - MAINTENANCE STANDARDS AND TEST PROCEDURES
5. After starting engine, press selector switch on
g a u g e c l u s t e r a n d M E M O RY U N L OA D i s MEMORY UNLOAD
indicated, the engine speed is automatically ENGINE SPEED
2000rpm
increased and the adjustment of unloading valve PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
is performed. D-1 300mA D-2 300mA

ENGINE SPEED, P1, P2 PUMP PRESSURE

and PROPO-VALVE are indicated.
6. When the unloading proportional valve operates
to th e s p e c i fi ed va l u e, t he a d j us tm e nt o f
unloading propor tional valve automatically
completes. FINISH UNLOAD is indicated.
The speed is shifted to the speed corresponding
to acceleration potentiometer. The value of
SM0894
adjusting current is indicated on the display of GRAPHIC_ID Figure 51
current of P1 and P2 unloading proportional
valves. The adjusting range is usually
520~635mA.
Stop the engine. (The adjusted data is automatically
stored.)
Operations in the Event of a Failure of Equipment
of Mechatro Controller
PUMP EMERGENCY MODE
In the event where a failure of P1 or P2 pump
propor tional valve represented in items of self
diagnosis is indicated on multi display provided on
the gauge cluster, the full power control of pump and
positive control through mechatro controller are
un availa ble. The n the P1 a nd P2 p um ps are
automatically switched to emergency mode, making
the operation with the power shift control of pump
and the constant power control by means of self-
pressure possible. But be careful that, at emergency
mode, the accuracy of inching becomes poor, the
frequency of engine down is increased, and the
engine stalls in LOW speed condition.

CAUTION
The emergency mode should be used in only case of
emergency. We recommend that the defective section
is repaired by troubleshooting as early as possible.

4-34 Issued 10-2007 Bur NA

REPAIR MANUAL - SECTION 2

E175B
EXCAVATOR

SYSTEMS

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - SYSTEMS

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B
 SECTION 2 - SYSTEMS

SECTION 2
SYSTEMS
SECTION TABLE OF CONTENTS
CHAPTER 1
MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SUMMARY OF MECHATRO CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
MECHATRO CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
CHAPTER 2
HYDRAULIC SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
HYDRAULIC CIRCUITS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CHAPTER 3
ELECTRICAL SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
ELECTRICAL SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ELECTRICAL SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHAPTER 4
COMPONENTS SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
HYDRAULIC PUMP ASSEMBLY OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
PILOT VALVE (ATT) OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
PILOT VALVE (TRAVEL) OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
CONTROL VALVE OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
SWING DEVICE OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
TRAVEL DEVICE OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
SWIVEL JOINT OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
CYLINDERS OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
CHAPTER 5
AIR CONDITIONING SYSTEM
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
CHARGING REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
ELECTRIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

NA I
 SECTION 2 - SYSTEMS

NOTES

II Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS

CHAPTER 1

E175B
EXCAVATOR

MECHATRO CONTROL SYSTEM

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

1-II Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS

CHAPTER 1
MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SUMMARY OF MECHATRO CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Mechatro Control System In General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Unload Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Positive Control and P-q Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Boom Up Conflux Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Arm in Recirculation and Conflux Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Arm-in Anti-cavitation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Arm-out Conflux Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Bucket Digging (Dump) Conflux Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Bucket Digging Anti-cavitation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Swing Priority Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Travel Straight Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Pressure Release Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
N&b Switch Control (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Option Conflux Control (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
MECHATRO CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Summary Of Multi Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Warning Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Self Diagnosis Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Service Diagnosis Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Trouble History Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
Trouble Diagnosis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
Set Procedure of Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
Adjusting Procedure of Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
For Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
Function for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49
Setting the Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
Setting Adjusting Mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
Adjusting Overload Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
Drain Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
Mechatro Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
C-1 Mechatro Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53
Gauge Cluster (Symbol C-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
Relay & Fuse Box (Symbol E-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59
High Pressure Sensor : YN52S00048P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
Low Pressure Sensor : YX52S00013P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

NA Issued 10-2007 Bur 1-1

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

NOTES

1-2 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
PREFACE
This chapter explains only those related to the
electro hydraulic conversion as Mechatro control.
This chapter summarizes the Mechatro system and
the function of the Mechatro controller related
apparatuses. Regarding the conditions before and
after each conversion, refer to the hydraulic system
and the electric system.

NA Issued 10-2007 Bur 1-3

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
SUMMARY OF MECHATRO CONTROL SYSTEM
MECHATRO CONTROL SYSTEM IN GENERAL
CONTROLLER INPUT SIGNAL
HYDRAULIC  
PILOT SECONDARY PRESSURE VOLTAGE OUTPUT L1
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT

LH RH LH RH
OPTION PILOT VALVE

PILOT VALVE
PILOT VALVE FOR TRAVEL
FOR ATT

SE-9
SE-10

SE-11
LOW PRESSURE SENSOR
SE-4
(4)
SE-3
(3) L2
GAUGE CLUSTER
SENSOR BLOCK

SE-2 L3
(2)
LCD DISPLAY
SE-1
FOR SELECTION (1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
SWITCH
SCREEN CHANGE SE-7
(7)
BUZZER STOP
L4
MODE (6)
WASHER
WIPER SE-5
(5)
OUTPUT VOLTAGE

TRAVEL
AUTO-IDLE

PSV-R
SERIAL COMMUNICATION

SERIAL COMMUNICATION

SHORT-CIRCUIT PROPORTIONAL
ACCEL DIAL VALVE VALVE

SE-16
SE-23

HIGH PRESSURE SENSOR

C-1 SE-22 L5
MECHATRO CONTROLLER ENGINE A1 A2 A3
GOVERNOR
MOTOR
SPEED SENSOR
M-2 SE-13

PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
: GOVERNOR MOTOR P2 PUMP PROPORTIONAL VALVE

: E/G SPEED SENSOR L6

: LOW PRESSURE SENSOR
(ATT : 7pcs, TRAVEL : 2pcs) L7
VOLTAGE 24V
PROPORTIONAL COMMAND CURRENT

GRAPHIC_1D Figure 1

1-4 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

MAIN CONTROL VALVE

L1

SE-29

ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) SV-13

P1 UNLOAD

ATTACHMENT BOOST

SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED

TRAVEL RIGHT
ARM 2 SPEED

ARM 1 SPEED
TRAVEL LEFT

N&B
BUCKET

P2 UNLOAD

OPTION
STRAIGHT

SWING
TRAVEL

PL1
SOL

P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3

L4

SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE

SAFETY LOCK LEVER

ATTACHMENT BOOST

TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED

L5
P1 UNLOAD

P2 UNLOAD

ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4

(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX

L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
GRAPHIC_1D Figure 2

NA Issued 10-2007 Bur 1-5

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
UNLOAD VALVE CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
VALVE OPTION

SWING

BOOM
STRAIGHT
SOLENOID

TRAVEL
P2 UNLOAD
P2 P1

PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL

LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0118
GRAPHIC_1D Figure 3
1. On starting any one of operations, the control 3. Each unload pressure proportional valves output
pilot secondary pressure switches spools and pilot secondar y pressure according to the
enters in respective low pressure sensors. command output by Mechatro controller and
2. The output voltage of low pressure sensor is switches each unload spools.
input to Mechatro controller and the Mechatro 4. With this operation, the bleed opening according
controller processes pilot signal and outputs to lever manipulated movement is obtained,
command according to the input voltage to each consequently the pump pressure which is used
unload pressure proportional valve. to actuate each actuators are delivered and
makes each actuator start operating.

1-6 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
POSITIVE CONTROL AND P-Q CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
OPTIONAL
PILOT VALVE
P2 P1

SE-23 SE-22

SE-11

(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE

PILOT VALVE
FOR TRAVEL

LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8

pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi

pi

P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

SM0119

GRAPHIC_1D Figure 4

NA Issued 10-2007 Bur 1-7

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Positive control
1. On starting any one of operations, pilot secondary pressure switches each spool and is input to each low
pressure sensor.
2. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3. Each pump proportional valve outputs pilot secondary pressure according to the command output by Mechatro
controller and changes the tilting angle of each pump and controls the delivery rate.
4. With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and
consequently the working speed according to the lever manipulated movement will be obtained.

P-Q control
1. The output voltage of high pressure sensor provided on each pump line is input to Mechatro controller and the
Mechatro controller processes pilot signal and operates the command according to the input voltage (load
pressure).
2. The lower value between command values calculated by positive control and operated value found by P-Q
control {operated value found in item 1)} is selected and is output to each pump proportional valve as
command value.
3. Each pump proportional valve outputs pilot secondary pressure according to the command output by Mechatro
controller and changes tilting angle of each pump and controls the delivery rate.
4. With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.

POSITIVE CONTROL P-Q CONTROL

PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE

SECONDARY PRESSURE
PUMP PROPORTIONAL

PUMP PROPORTIONAL

PILOT PRESSURE PUMP DELIVERY PRESSURE

SM0120

GRAPHIC_1D Figure 5

1-8 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
BOOM UP CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

LOW
PRESSURE
SENSOR
SE-3

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE SM0121
GRAPHIC_1D Figure 6
1. On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by Mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve.
4. With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and
also with the command by Mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched
and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up
operation.
NA Issued 10-2007 Bur 1-9
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
ARM IN RECIRCULATION AND CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED

ARM 2 SPEED
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
PILOT
VALVE
P2 P1

LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7

CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE

P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D

PILOT SECONDARY PRESSURE

pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE

P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE
SM0122

GRAPHIC_1D Figure 7

1-10 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Recirculation and Conflux (Low loading)
1. On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool
and low pressure sensor.
2. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves,
P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. In case of combined
operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage
is input to Mechatro controller. And the Mechatro controller processes pilot signal according to the combined
operation and outputs command, which is different from the arm-in independent operation, to P1 pump
proportional valve, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool.
3. Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it
switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls
recirculation rate and conflux rate.). The other proportional valves output proportional secondary pressure
according to command from Mechatro controller. These proportional valves change the delivery rate of P1, P2
pump, and switch P1, P2 unload valve.
4. The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload
spools and arm 2 spool are switched according to the command output by Mechatro controller, and
consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during
arm operation.
Recirculation cut
The voltage output by high pressure sensor on P2 side is input to Mechatro controller, and when the load is raised
during arm operation the Mechatro controller processes pilot signal processing according to the pressure detected
by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2
spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command
output by Mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation
passage is blocked.

NA Issued 10-2007 Bur 1-11

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
ARM-IN ANTI-CAVITATION CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE

P2 P1

LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7

pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE

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

ARM IN PILOT SECONDARY PRESSURE

pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi

ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
SM0123

GRAPHIC_1D Figure 8
1. On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to
low pressure sensor.
2. The engine speed command output by accel potentiometer is input to Mechatro controller.
3. Low pressure sensor output voltage is input to Mechatro controller, and the Mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional valve.
4. And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
5. Each proportional valve outputs pilot secondary pressure according to each command output by Mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump
delivery rate is low due to low engine speed.

1-12 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
ARM-OUT CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM OUT PILOT SECONDARY PRESSURE

pi

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

ARM OUT PILOT SECONDARY PRESSURE

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
ARM OUT PILOT SECONDARY PRESSURE
SECONDARY PRESSURE SM0124
GRAPHIC_1D Figure 9
1. On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
2. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves
and P1 and P2 unload proportional valves.
3. Each proportional valve outputs pilot secondary pressure according to the command output by Mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valves.
4. With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by Mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out
operation.
NA Issued 10-2007 Bur 1-13
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
BUCKET DIGGING (DUMP) CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE P2 P1

LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SM0125
SECONDARY PRESSURE
GRAPHIC_1D Figure 10
1. On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
3. Each proportional valve outputs pilot secondary pressure according to the command output by Mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of the control valve.
4. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
1-14 Issued 10-2007 Bur NA
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
BUCKET DIGGING ANTI-CAVITATION CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED

ARM 2 SPEED
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
PILOT
VALVE
P2 P1

LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
ACCEL VALVE PSV-B
POTENTIO
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE

PILOT SIGNAL
pi PROCESS
BUCKET ATT BOOST
ANTI-CAVITATION SOLENOID VALVE
PROCESS SV-2

ENGINE SPEED (COMMAND VALUE)

MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE SM0126

GRAPHIC_1D Figure 11

NA Issued 10-2007 Bur 1-15

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
1. On starting bucket digging operation, bucket digging operating pilot pressure switches bucket spool and is
input to low pressure sensor.
2. The engine speed command output by accel potentiometer is input to Mechatro controller.
3. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload proportional valves and travel straight proportional valve.
4. Each proportional valve outputs pilot secondary pressure according to the command output by Mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel
straight valve of control valve.
5. The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump
delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
6. ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.The control of spool stroke
makes the prevention of cavitation possible even if engine speed is low and pump delivery rate is low.
7. When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the
pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the
stroke limit of bucket spool.

1-16 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
SWING PRIORITY CONTROL

BOOM UP CONFLUX

P1 UNLOAD
PILOT

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
VALVE

TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

LOW
PRESSURE
SENSOR
SE-5 SE-7

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL

MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE SM0127
GRAPHIC_1D Figure 12
1. During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low
pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation
pilot secondary pressure switches swing spool and is input to low pressure sensor.
2. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for
arm 2 spool.
3. Each proportional valve outputs pilot secondary pressure according to the command output by Mechatro
controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight
spool, arm 2 spool.
4. With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by Mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched
enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil
on arm cylinder rod side is recirculated into arm cylinder head side.
5. Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery
rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with
minimum speed drop possible.
NA Issued 10-2007 Bur 1-17
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
TRAVEL STRAIGHT CONTROL

BOOM UP CONFLU

P1 UNLOAD
OPTIONAL

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL

SOLENOID SHORT CIRCUIT

VALVE

LOW
SE-10 SE-9 SE-11 PRESSURE
SENSOR

VALVE SIGNAL
TRAVEL STRAIGHT SIGNAL

pi
PILOT SIGNAL PROPORTIONAL
PROCESS VALVE PSV-R
IN SHORT-CIRCUIT
VALVE

‫ޓޓ‬
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

‫ޓޓ‬
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT‫ޓޓޓ‬
SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT ‫ޓ‬
SECONDARY PRESSURE
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

GRAPHIC_1D Figure 13

1-18 Issued 10-2007 Bur NA

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

ATT operation Boom Arm Bucket Swing Option

Right travel operation (P1)
Left travel operation (P2)

GRAPHIC_1D Figure 14

NA Issued 10-2007 Bur 1-19

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
PRESSURE RELEASE CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1

SE-23 SE-22

ENGINE
(M-2)

PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE SM0130
CONTROLLER SECONDARY PRESSURE
GRAPHIC_1D Figure 15
1. Change Mechatro controller to PRESSURE DRAING MODE by operating switch on gauge cluster.
For detail of changing mode method, refer to Pressure draining (releasing) circuit on GROUP 2 - HYDRAULIC
CIRCUIT.
2. Once Mechatro controller decides it as pressure release control, regardless of each input signal (operating
pilot, accel potentiometer, etc.) the Mechatro controller;
A. Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to
minimum tilt angle.
B. Outputs command of pressure release to control step-by step motor (M2) and fixes engine speed to
pressure release control speed.
C. Outputs maximum command to P1 and P2 unload proportional valves and each pilot secondary pressure
fixes P1 and P2 unload valves to the maximum opening.
3. Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays DRAINING HYD. PRESS or FAIL DRAIN HYD. PRESS on gauge cluster.
4. Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to
be released by operating each control lever and switching spool with the unload valve opened.
1-20 Issued 10-2007 Bur NA
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
N&B SWITCH CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR

BUCKET
OPTION
SE-29

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

A MODE

B MODE

GAUGE CLUSTER

pi

B MODE SWITCH MECHATRO

CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID SM0131

GRAPHIC_1D Figure 16
Nibbler circuit
1. Select A mode through gauge cluster.
2. Nibbler display appears on gauge cluster.
3. The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4. When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output. It is in
normal when there is no output from sensor in A mode, and in cases of other than above, error display is
output to gauge cluster.
Breaker circuit
1. Select B mode through gauge cluster.
2. Breaker display appears on gauge cluster.
3. The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4. When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
5. It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display is
output to gauge cluster.
NA Issued 10-2007 Bur 1-21
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
OPTION CONFLUX CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD
PILOT VALVE

TRAVEL
P2 P1

SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE SM0132
GRAPHIC_1D Figure 17
1. Select the Conflux with the aid of Conflux/Single switch.
2. On starting option operation, option operating pilot pressure switches option spool and is input to low pressure
sensor.
3. The output voltage of low pressure sensor is input to Mechatro controller and the Mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional
valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve.
4. Each proportional valves output pilot proportional valve secondary pressure according to the command output
by Mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
5. The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1
pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
MECHATRO CONTROLLER
SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
1. Controls

SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER

SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.

FUSE &
STARTER SWITCH RELAY BOX

ACCEL DIAL
DETAIL A

SM0133
A
GRAPHIC_1D Figure 18
2. Gauge cluster

No. Name
1 Engine coolant temperature gauge 11
2 Fuel level gauge
22:00
3 Screen change switch
4 Buzzer stop switch H

5 Work mode select switch

1
6 Washer switch
7 Wiper switch
8 Travel high speed, low speed select switch 2
3
9 Auto accel switch
10 Select switch
10
11 Multi display (LCD) 6
4 9 8 5 7
SM0134
GRAPHIC_ID Figure 19

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
3. Screen selection by work mode select switch
After starting engine, S mode is usually set.
The work modes S, H, B and A are selected in order every time ( ) is pressed.
Select efficient work mode according to the working condition and the purpose from the following table.
The selected mode is displayed on the left lower corner on multi display.

S mode: For standard digging work

H mode: For heavy duty digging work
B mode: For works with breaker
A mode: For works with crusher (nibbler)
10:25
H

SM0135

GRAPHIC_ID Figure 20

Work
Display Contents
mode

10:25 S mode is suitable for standard digging and loading works and is in fuel saving and is
S mode
maintained well-balanced relations with workload.
㧿
GRAPHIC_ID Figure 21

10:25 H mode is suitable for heavy duty digging work which gives priority to the workload at
H mode
the high speed.
㧴
GRAPHIC_ID Figure 22

10:25
B mode For the work with breaker, select B mode without fail.
㧮
GRAPHIC_ID Figure 23

10:25
A mode For the work with crusher (nibbler), select A mode.
㧭
GRAPHIC_ID Figure 24

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

1) Pump flow rate adjustment (A mode /B mode)

1 2 3 4
No. Switches
1 Screen change switch
2 Buzzer stop switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch 5
7 Auto accel switch 8 7 6 SM0140

8 Select switch
GRAPHIC_ID Figure 25
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 210L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.

Main screen Attachment mode (A mode)

10:25 Flow
rate 130 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m

Enter
H A A
(a) (b) (d)
Increase/Decrease

In Breaker mode (B mode)

Flow Flow Flow

rate 130 L/m rate 100 L/m rate 100 L/m

Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 130 L/m rate 130 L/m

A B
(b) (c) SM0141

GRAPHIC_1D Figure 26
1. Turn starter key switch on and display main screen (a).
2. The display on the left lower corner of screen is changed in order of S →H →B →A each time the MODE
switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select A and A mode screen is displayed, and select B and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and the
screen (d) is displayed. In this condition, press FEED ▲ (4)/ ▼(5) and the flow rate value increases or
decreases.
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.

NA Issued 10-2007 Bur 1-25

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
4. MAINTENANCE SCREEN DISPLAYS
Replacement interval
This screen displays the remaining time to the end of
recommended replacement/change interval specified Item Default
for filter/oil. Engine oil 500 Hr
Fo r t h e i n i t i a l s e t v a l u e o f r e c o m m e n c e d Fuel filter 500 Hr
replacement/change time, see the following table. 1,000 Hr
Hydraulic oil filter
Hydraulic oil 5,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.
1. Remaining time display to the engine oil change
This display shows the remaining time to the coming engine oil change.
492Hr
ENGINE OIL
H
GRAPHIC_ID Figure 27
2. Remaining time display to the coming fuel filter replacement
This display shows the remaining time to the coming engine fuel filter replacement.
492Hr
FUEL FILTER
H
GRAPHIC_ID Figure 28
3. Remaining time display to the coming hydraulic oil filter replacement
This display shows the remaining time to the coming hydraulic oil filter replacement.
992Hr
HYD. FILTER
H
GRAPHIC_ID Figure 29
4. Remaining time display to the coming hydraulic oil change
This display shows the remaining time to the coming hydraulic oil change.
4992Hr
HYD. OIL
H
GRAPHIC_ID Figure 30

NOTE: The display automatically changes to the

main screen, if switch is not operated for 30 seconds.

NOTE: For the setting procedure of maintenance

time to be performed to the coming oil change in
each type and filter replacement, see the paragraph
SET PROCEDURE OF MAINTENANCE
SCHEDULE.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
5. Gauge cluster display
After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The
display functions of multi display are explained below.

CLOCK DISPLAY

SELF DIAGNOSIS / WARNING

MACHINE CONDITION

H
MULTI DISPLAY INDICATIONS
SM0146
GRAPHIC_1D Figure 31
1. Display function for operator ............................................................. Screen usually displayed during operation
1.1 Clock display function ......................................................................................... Current time is displayed.
1.2 Self-diagnosis display When abnormality is detected on Mechatro system like sensor, proportional valve,
etc., this displays error code.
1.3 Warning display .............When machine was thrown into dangerous state, or was failed, displays warning
symbol. (For warning contents, see items shown on the next page.)
1.4 Machine condition display ............................................................... Displays machine operating condition.
2. Display function for maintenance ............Displays remaining time up to replacement/change of following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3. Failure history display function ..... Stores abnormality occurred on Mechatro system in the past and displays in
order of recent occurrence.
4. Mechatro adjustment displayDisplays procedure for adjustment of Mechatro system like output adjustment and
unload adjustment, etc.
5. Service diagnosis display................ Displays information like pressure sensor sensed value, proportional valve
command, etc. output by Mechatro controller
6. Failure diagnosis mode display function ........... Specifies failed section automatically for failures which are not
detected by self diagnosis and displays the results.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Warning Table

These descriptions indicate error codes stored as trouble history code

W009 W005 W011

GRAPHIC_ID Figure 32 GRAPHIC_ID Figure 33 GRAPHIC_ID Figure 34
CAUTION ATTACHMENT LOW ENG OIL PRESS. PREHEAT

W006
GRAPHIC_ID Figure 35 GRAPHIC_ID Figure 36 GRAPHIC_ID Figure 37
POWER BOOST ON HIGH ENG WATER TEMP. CHARGE ERROR

CPU W004
GRAPHIC_ID Figure 38 GRAPHIC_ID Figure 39 GRAPHIC_ID Figure 40
DATA COMMUNICATION ERROR LOW ENG WATER LEVEL LOW FUEL LEVEL

W001 W010
GRAPHIC_ID Figure 41 GRAPHIC_ID Figure 42 GRAPHIC_ID Figure 43
SWING BRAKE DISENGAGED DRAIN WATER SEPARATOR AUTO WARMING UP

W008
GRAPHIC_ID Figure 44 GRAPHIC_ID Figure 45 GRAPHIC_ID Figure 46
ENG LOW PRESSURE (ENGINE CLOGGED AIR FILTER CHANGE ENG OIL
STOP)
NOTE: Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Warning Condition
Trouble
Level Only Buzzer sounds
Priority Screen Condition Engine History
(*) Key
Run Type Auto Manual Code
ON (**) Stop Stop

A 1 DATA COMMUCATION Data from Mechatro O O 3 x O

ERROR controller is not received
1 SWING BRAKE The swing parking brake O O 2 O O W001
DISENGAGED switch is turned ON
1 ENGINE STOP Engine is stopped after O 1 O x
engine oil pressure low
2 FAIL DRAIN HYD. Impossible to drain hyd. O O 1 x O
PRESSURE Pressure
2 DRAINING HYD. PRESS. Possible to drain hyd. O 4 x O
Pressure
1 CAUTION ATTACHMENT The selector valve (OPT) is O 2 x O W009
malfunction
2 POWER BOOST ON The power boost switch is O O -
turn ON
2 FINISH WARM-UP After finishing warming up O 2 O x
control
Low engine oil pressure O 2 x O W005
3 LOW ENG OIL PRESS.
Disconnection O

3 HIGH ENG. WATER The engine water is more O O 3 x O W006

TEMP. than 105 °C
3 DRAIN WATER SEPA Water in water separator O O 3 x O W010
filter is increased
B 3 CLOGGED AIR FLTR The air filter is clogged O O 3 x O W008

3 (SELF DIAGNOSIS According to the self O O 3 x O

SCREENS) diagnosis control
3 PREHEAT The heater relay contact is O O 3 O W011
faulty
4 CHARGE ERROR No signal from the O -
alternator
4 LOW FUEL LEVEL The fuel level is less than O O -
10 %
4 LOW ENG WATER The water engine coolant O - W004
LEVEL reservoir is low
5 AUTO WARMING UP The auto warming up O -
control is activated
5 CHANGE ENG OIL The remaining time is O O -
reached zero hours

(*) 1.These extremely influence safety and the (**) 1.Continuation

machine performance. 2.Beep ON 0.2 sec. OFF 0.3 sec.
2.These warn the machine control mode is 3.Beep ON 0.5 sec. OFF 0.5 sec.
switched.
4.Beep ON 0.5 sec. OFF 1.0 Sec.
3.Fatal failure.
4.Normal priority warning
5.Low priority message

NA Issued 10-2007 Bur 1-29

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Self Diagnosis Display
1. Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine
operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector
No. and pin No., refer to the section Mechatro Control Equipment explained later. Electric circuit diagram or
harness is available to identify wire No. and wire color.
2. I/O configuration

CONTROL
Pressure sensor, Governor motor SERIAL COMMUNICATION
INPUT Proportional valve, Battery relay
Gauge cluster
Selector valve (SOL) (Buzzer sound)
SM0147

GRAPHIC_1D Figure 47

3. Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.

Alphabet: Decide system failure occurred.

10:25 B 01 3 Last 2nd and 3rd digits: Specifies failed section.
B013
Last 1 digit: Specifies failure type.
This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE SM0148
GRAPHIC_1D Figure 48

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
ALPHABET
A B C D E F G H I K R
Low High Proportional Proportional
Controller Solenoid Speed Potentiometer Communic Battery Relay
pressure pressure valve for valve for
memory valve sensor etc. ation relay output
sensor sensor valves pumps
nd rd
2 AND 3 DIGIT
Wiper ark
Engine Step Battery
01 Boom up P1 pump P1 unload P1 pump ATT boost Throttle prevention
adjust data motor relay
relay

Swing Wiper ark

Torque Boom Step forward
02 P2 pump P2 unload P2 pump parking
adjust data down motor rotation
brake
Wiper ark
Unload Boom Travel Travel 1,2 reverse
03 Arm out
adjust data head straight speed rotation

Option Washer
04 Arm in
selector motor

Bucket
05
digging

Bucket Arm 2 spool

06
dump for arm in

07 Swing

Travel
09 Fuel sensor
right

Travel
10
left

Selector
11 position
direction

13

14

PSV-R
15 Short Circuit
valve

P1 side
16 AIS relay2
option

P2 side Engine
17
option stop relay

Safety
18 lock lever
relay

Adjustment Safety
21
data sector 1 relay

NA Issued 10-2007 Bur 1-31

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Adjustment
22
data sector 2

Hourmeter
23
sector 1

Hourmeter
24
sector 2

Proportional
25 valve adjust
data

Cluster
31 communic
ation
LAST DIGIT
Larger Larger
0 than than
normal normal

Transistor
OFF
1 -
failure/
Grounding

Wrong Wrong Transistor Transistor

2 - Over run
output output ON failure ON failure

Transistor
Disconn Disconnect Disconnecti Disconnecti ON failure / Disconn Disconnectio Time is
3 -
ection ion on on Disconnect ection n over

Power Power Contact Power

source source Power source point is source
4 -
short short short circuit melted and short
circuit circuit adhered circuit

Abnormal
5
data

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
SERVICE DIAGNOSIS DISPLAY FUNCTION
The current service diagnosis is displayed on multi display based on the data received from Mechatro controller.
This section explains the operating procedure and examples of each screen. The values in display changes
according to the conditions like engine speed, attachment position, etc.
Service diagnosis display screen operating procedure
A. Turn starter switch ON keeping buzzer stop switch pressed.
B. After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen Mode No.1, Screen No.1 is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in Screen
No.1.
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
Mode No.1: Screen No.1~No.30
Mode No.2: Screen No.1, Screen No.31~No.40
Mode No.3: Screen No.1, Screen No.41~No.50
C. The screen changes each time each switch is pressed from now on.

Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)

Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)

Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1.
(No.1→No.2→No.3→No.1→...)

Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3.
(No.3→No.2→No.1→No.3→...)

D. Turn key switch OFF and the display of service diagnosis mode is closed.

NA Issued 10-2007 Bur 1-33

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
2. Service diagnosis display screen (Example)
The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed
and lever to neutral position.)
A. Service diagnosis Mode No.1

No. Displays Contents No. Displays Contents

1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00207F1 P/No. indication K-1 AIS RELAY 2 ON Indicated value
PROGRAM VERSION K-2 SAFETY RLY ON Indicated value
1-VER 2.00 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 0.00 KEY SWITCH ON Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
SWITCH ON Switch

2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 1000 No load setting rpm B-1 BOOM RAISE
MEAS 1000 Actual rpm 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-5 ENG PRS. LIVE Engine oil pressure B-2 BOOM LOWER
WATER TEMP 20 °C OFF Coolant temperature sensor / Coolant tempreature switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
B-3 ARM OUT
MODE H Work mode 0.4 V 0.0 M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 0.3 V Potentiometer voltage B-4 ARM IN
POS. 0% Voltage % indication 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-1 MOTOR STEP 30 Number of step B-5 BUCKET DIG
POS. 0% Step % indication 0.4 V 0.0 M Sensor voltage / Pressure converted value
COIL A 1.5 A A phase current B-6 BUCKET DUMP
COIL B 1.5 A B phase current 0.4 V 0.0 M Sensor voltage / Pressure converted value
G-2 LIMIT SW. OFF Limit switch

3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL (R)
SWITCH OFF Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL (L)
COMP. ON Set value in computer 0.4 V 0.0 M Sensor voltage / Pressure converted value
MEAS. ON Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 0.4 V 0.0 M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 0.5 V 0.0 M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 0.0 V 0.0 M Sensor voltage / Pressure converted value
B-19 DOZER 2
0.0 V 0.0 M Sensor voltage / Pressure converted value

SM0149

GRAPHIC_1D Figure 49

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
p y p y
7 16
NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11
0.4 V 0.3 M Sensor voltage / Pressure converted value 0.4 V 0.0 M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
0.4 V 0.0 M Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
0.0 V 0.0 M
C-3 BOOM-HEAD
B-13
0.5 V 0.9 M
Sensor voltage / Pressure converted value 0.0 V 0.0 M Sensor voltage / Pressure converted value
C-4 BOOM-ROD
0.0 V 0.0 M B-14
PROPO-VALVE Sensor voltage / Pressure converted value 0.0 V 0.0 M Sensor voltage / Pressure converted value
E-3 OPT RELIEF 1 B-15
COMP. 0 mA 2.0 M Set value in computer / Converted value from pressure 0.0 V 0.0 M Sensor voltage / Pressure converted value
MEAS. 0 mA 2.0 M Measured value / Converted value from pressure B-20
E-4 OPT RELIEF 2 0.0 V 0.0 M Sensor voltage / Pressure converted value
COMP. 0 mA 2.0 M Set value in computer / Converted value from pressure
MEAS. 0 mA 2.0 M Measured value / Converted value from pressure

8 18
NO.8 PROPO-VALVE NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI2 ON ON/OFF indication
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 750 mA 3.0 M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 750 mA 3.0 M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 --- ON/OFF indication
Mechatro
COMP. 350 mA 0.6 M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 350 mA 0.6 M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 750 mA 0.0 M Set value in computer / Converted value from pressure DI11 --- ON/OFF indication
MEAS. 750 mA 0.0 M Measured value / Converted value from pressure DI12 --- ON/OFF indication
DI13 ON ON/OFF indication
DI14 --- ON/OFF indication
9 19
NO.9 PROPO-VALVE NO.19 DIGITAL INPUT
E-1 P1 PUMP DI15 --- ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0 mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 30 L Flow rate of pump P1 DI19 --- ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 417 mA 1.0 M Set value in computer / Converted value from pressure DI21 --- ON/OFF indication
MEAS. 417 mA 1.0 M Measured value / Converted value from pressure DI22 --- ON/OFF indication
POWER SHIFT 0 mA Power shift DI23 ON ON/OFF indication
FLOW RATE 30 L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 ON ON/OFF indication
DI26 --- ON/OFF indication
DI27 OFF ON/OFF indication
DI28 --- ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
1.2 V 77% Fuel level DI30 --- ON/OFF indication
H-10 HYD.OIL TEMP DI31 --- ON/OFF indication
0.0 V 0 ͠ Hydraulic oil temperature DI32 --- ON/OFF indication
GLOW --- Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 --- ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 --- ON/OFF indication
ENG OIL FILTER --- Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 --- ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW --- Command from grid heater DI39 --- ON/OFF indication
HEATER OFF Engine oil level DI40 OFF ON/OFF indication
ENG OIL LEVEL OK Coolant level DI41 --- ON/OFF indication
COOLANT LEVEL OK DI42 ---
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. --- Set value in computer MEAS. OFF Measured value
MEAS. --- Measured value DO5 COMP. --- Set value in computer
F-6 MEAS. --- Measured value
COMP. --- Set value in computer DO6 COMP. --- Set value in computer
MEAS. --- Measured value MEAS. --- Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
15 22
NO.15 PROPO-VALVE NO.22 DIGITAL OUTPUT
D-11 P1 I-TRAVEL DO8 COMP. ON Set value in computer
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure MEAS. ON Measured value
MEAS. 0 Ma 0.0 M Measured value / Converted value from pressure DO9 COMP. OFF Set value in computer
D-12 P2 I-TRAVEL MEAS. OFF Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO10 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
D-15 P1 BY PASS VALVE DO11 COMP. OFF Set value in computer
COMP. 347 mA 0.6 M Set value in computer / Converted value from pressure MEAS. OFF Measured value
MEAS. 347 mA 0.6M Measured value / Converted value from pressure DO12 COMP. --- Set value in computer
D-16 P2 BY PASS VALVE MEAS. --- Measured value
COMP. 0 mA 0.0 M Set value in computer / Converted value from pressure DO13 COMP. --- Set value in computer
MEAS. 0 mA 0.0 M Measured value / Converted value from pressure MEAS. --- Measured value
DO14 COMP. --- Set value in computer
MEAS. --- Measured value
GRAPHIC_1D Figure 50

NA Issued 10-2007 Bur 1-35

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

No. Displays Contents

23
NO.23 DIGITAL OUTPUT
DO15 COMP. --- Set value in computer
MEAS. --- Measured value
DO16 COMP. ON Set value in computer
MEAS. ON Measured value
DO17 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO18 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO19 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO20 COMP. --- Set value in computer
MEAS. --- Measured value
DO21 COMP. ON Set value in computer
MEAS. ON Measured value
24
NO.24 DIGITAL OUTPUT
DO22 COMP. --- Set value in computer
MEAS. --- Measured value
DO23 COMP. OFF Set value in computer
MEAS. ON Measured value
DO24 COMP. --- Set value in computer
MEAS. --- Measured value
DO25 COMP. --- Set value in computer
MEAS. --- Measured value
DO26 COMP. --- Set value in computer
MEAS. --- Measured value
DO27 COMP. --- Set value in computer
MEAS. --- Measured value
DO28 COMP. --- Set value in computer
MEAS. --- Measured value
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW ON Wiper rise-up switch
REVERSE SW ON Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention
CW MOTOR RLY OFF relay
CCW MOTOR RLY OFF Wiper normal rotation relay
WASHER SW OFF Wiper reverse rotation relay
MOTOR RELAY OFF Washer switch
Washer motor relay

SM0151
GRAPHIC_1D Figure 51

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
B. Service diagnosis Mode No.2

No. Displays Contents No. Displays Contents

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1 PUMP 0.2 M Pump pressure sensor
YN22E00207F1 P/No. indication C-2 P2 PUMP 0.0 M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 417 mA Command current
1-VER 2.00 Program version indication E-2 P2-PSV 417 mA Command current
2-VER 0.00 MERIT controller program version D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current
SERVICE DIAG 2 Service diagnosis mode 2 D-3 S-TRAVEL 350 mA Command current
B-5 BUCKET DIG 0.0 M Bucket digging pressure sensor
B-6 BUCKET DUMP 0.0 M Bucket dump pressure sensor
G-3 ENG SPEED 1000 Engine actual speed
POWER SHIFT 0 mA Power shift current

31 34
NO.31 BOOM NO.34 TRAVEL
C-1 P1 PUMP 0.2 M Pump pressure sensor C-1 P1 PUMP 0.2 M Pump pressure sensor
C-2 P2 PUMP 0.0 M Pump pressure sensor C-2 P2 PUMP 0.0 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
E-2 P2-PSV 417 mA Command current E-2 P2-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current D-2 P2-UL(BPC) 750 mA Command current
B-1 BOOM RAISE 0.0 M Boom up pressure sensor D-3 S-TRAVEL 350 mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0 M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0 M Travel left pressure sensor
POWER SHIFT 0 mA Power shift current Pi-P1 0.0 M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0 M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current

32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1 PUMP 0.2 M Pump pressure sensor C-1 P1 PUMP 0.2 M Pump pressure sensor
C-2 P2 PUMP 0.0 M Pump pressure sensor C-2 P2 PUMP 0.0 M Pump pressure sensor
E-1 P1-PSV 417 mA Command current E-1 P1-PSV 417 mA Command current
E-2 P2-PSV 417 mA Command current E-2 P2-PSV 417 mA Command current
D-1 P1-UL(BPC) 750 mA Command current D-1 P1-UL(BPC) 750 mA Command current
D-2 P2-UL(BPC) 750 mA Command current D-2 P2-UL(BPC) 750 mA Command current
D-3 S-TRAVEL 350 mA Command current D-3 S-TRAVEL 350 mA Command current
D-6 ARM-IN-2 750 mA Command current E-3 OPT RELIEF 110 mA Command current
B-3 ARM OUT 0.0 M Arm out pressure sensor B-16 P1 OPT 0.0 M P1 side option pressure sensor
B-4 ARM IN 0.0 M Arm in pressure sensor B-17 P2 OPT 0.0 M P2 side option pressure sensor
B-1 BOOM RAISE 0.0 M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 0.0 M Swing pressure sensor DOUBLE FLOW SW OFF Conflux/ Single selector switch
G-3 ENG SPEED 1000 Engine actual speed G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0 mA Power shift current POWER SHIFT 0 mA Power shift current

SM0152
GRAPHIC_1D Figure 52
C. Service diagnosis Mode No.3

No. Displays Contents No. Displays Contents

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00207F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 2.00 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 0.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode 3 CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time

41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2230 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515 mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
7 mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0 M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 930 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 565 mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 565 mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 0 0 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 0 0 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 0 0 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 0 0 Angle adjustment

SM0153

GRAPHIC_1D Figure 53

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Service diagnosis data list
Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data to
decide normal/abnormal status.
The values in following display are reference values with standard attachment attached machine.
The value of pressure sensor is calculated taking variation into accounts. When compared to performance check
reference criteria, measure it with the aid of calibrated measuring instrument.
The current of proportional valve is not the measured value, but command value. The measured value should be
confirmed by the value in the displayed value for each proportional valve.
The current value of pump proportional valve is reference value because it varies according to pump pressure and
adjusted torque value.
The value in display during operation shows the value in steady state, rather than, at start of operation.
Check on machine after sufficiently warming up machine.
The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
1970~203 1770~183
G-3 ENG SPEED G-3 ENG SPEED
0 0
POWER SHIFT 0 mA POWER SHIFT 0 mA

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in
H mode Hi idle operation
H mode Hi idle
No.31 BOOM
C-1 33.0~35.8 M No.31 BOOM
P1-PRES
C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 33.0~35.8 M
C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 415~525 mA
E-1 P1-PSV 560~750 mA
E-2 P2-PSV 415~525 mA
E-2 P2-PSV 560~750 mA
D-1 P1-UL(BPC) 360 mA
D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA
B-1 BOOM RAISE 3.0 M
B-1 BOOM RAISE 3.0 M
B-2 BOOM LOWER 0.0 M
B-2 BOOM LOWER 0.0 M
G-3 ENG SPEED 1970~2060
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA
POWER SHIFT 0 mA

Operation No.5 : Boom down in full lever operation & in Operation No.6 : Arm-in full lever operation & relief
operation H mode Hi idle
H mode Hi idle
No.32 ARM, SWING
No.31 BOOM C-1 33.0~35.8 M
P1-PRES
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 33.0~35.8 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 415~525 mA
E-1 P1-PSV 600~617 mA
E-2 P2-PSV 415~525 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 360 mA
D-2 P2-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA
B-1 BOOM RAISE 0.0 M
D-6 ARM-IN-2 200 mA
B-2 BOOM LOWER 3.0 M
B-3 ARM OUT 0.0 M
G-3 ENG SPEED 1970~2060
B-4 ARM IN 3.0 M
POWER SHIFT 0 mA
B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Operation No.7 : Operation No.8 :

Arm-in full lever operation & in operation Arm-out in full lever operation & relief
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 12.5~16.5 M C-1 P1-PRES 33.0~35.8 M
C-2 P2-PRES 12.5~16.5 M C-2 P2-PRES 33.0~35.8 M
E-1 P1-PSV 550~750 mA E-1 P1-PSV 415~525 mA
E-2 P2-PSV 550~750 mA E-2 P2-PSV 415~525 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 400 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
1970~206 1970~206
G-3 ENG SPEED G-3 ENG SPEED
0 0
POWER SHIFT 0 mA POWER SHIFT 0 mA

(*) Measure the values after a lapse of 5 minutes or

after release of low temperature mode.

Operation No.9 : Operation No.10 :

Arm-out in full lever operation & in operation Swing in full lever operation & relief
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 15.0~22.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 15.0~22.0 M C-2 P2-PRES 28.0~35.8 M
E-1 P1-PSV 488~677 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 488~677 mA E-2 P2-PSV 528~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 3.0 M
1970~206 1970~206
G-3 ENG SPEED G-3 ENG SPEED
0 0
POWER SHIFT 0 mA POWER SHIFT 0 mA

(*) Measure the values after a lapse of 5 minutes or

after release of low temperature mode.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Operation No.11 : Operation No.12 :

Swing in full lever operation & in operation Bucket digging in full lever operation & relief
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.33 BUCKET
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 33.0~35.8 M
C-2 P2-PRES 10.0~15.0 M C-2 P2-PRES 33.0~35.8 M
E-1 P1-PSV 350 mA E-1 P1-PSV 415~525 mA
E-2 P2-PSV 750 mA E-2 P2-PSV 415~525 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 720 mA
D-6 ARM-IN-2 750 mA B-5 BUCKET DIG 3.0 M
B-3 ARM OUT 0.0 M B-6 BUCKET DUMP 0.0 M
B-4 ARM IN 0.0 M G-3 ENG SPEED 1970~2060
B-1 BOOM RAISE 0.0 M POWER SHIFT 0 mA
B-7 SWING 3.0 M
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA

Operation No.13 : Operation No.14 :

Bucket digging in full lever operation & in operation Bucket dump in full lever operation & relief
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 4.0~8.0 M C-1 P1-PRES 33.0~35.8 M
C-2 P2-PRES 4.0~8.0 M C-2 P2-PRES 33.0~35.8 M
E-1 P1-PSV 650~750 mA E-1 P1-PSV 415~525 mA
E-2 P2-PSV 540~563 mA E-2 P2-PSV 415~435 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Operation No.15 : Operation No.16 :

Bucket dump in full lever operation & in operation P2 side option in full lever operation & relief
H mode Hi idle A mode Hi idle
No.33 BUCKET No.35 OPT
C-1 P1-PRES 6.0~15.0 M C-1 P1-PRES 22.5~26.0 M
C-2 P2-PRES 6.0~15.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 577~750 mA E-1 P1-PSV 459~584 mA
E-2 P2-PSV 415~435 mA E-2 P2-PSV 459~584 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 0.0 M E-3 OPT RELIEF 0 mA
B-6 BUCKET DUMP 3.0 M B-16 P1 OPT 0.0 M
G-3 ENG SPEED 1970~2060 B-17 P2 OPT 2.0~2.6 M
POWER SHIFT 0 mA F-4 OPT SELECT NIB
DOUBLE FLOW SW. ON
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA

(*) Conflux switch is ON. Relief set pressure is value

of shipping.

Operation No.17 :
P2 side option in full lever operation & relief
B mode Hi idle
No.35 OPT
C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 500 mA
E-2 P2-PSV 665~750 mA
D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT BRK
DOUBLE FLOW SW. OFF
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA

(*) Conflux switch is ON. Relief set pressure is value

of shipping.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Operation No.18 : Operation No.19 :

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
H mode Hi idle H mode Hi idle
No.34 TRAVEL No.34 TRAVEL
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
E-1 P1-PSV 750 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-9 TRAVEL (R) 2.0~2.5 M B-9 TRAVEL (R) 0.0 M
B-10 TRAVEL (L) 0.0 M B-10 TRAVEL (L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
G-3 ENG SPEED 1970~2060 G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA POWER SHIFT 0 mA

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
TROUBLE HISTORY DIAGNOSIS
The items of error detected by Mechatro controller self diagnosis function are stored in Mechatro controller as one
of history. And the errors are able to be indicated on the multi display.
A part of warning contents is stored (the stored items are listed in warning table).
The error code for self diagnosis is stored.
1. How to display
A. Turn starter switch on.
B. Press buzzer stop switch continuously 5 times and the trouble history screen is displayed.

(Example)
No errors NO ERROR

Error detected in the past

SM0154

GRAPHIC_1D Figure 54
C. Transmit trouble history data (One or many) and hour meter to gauge cluster.
Hour meter and 4 failure data are displayed on screen.
In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
D. Paging (Up and down)
Press washer switch ( ▲ ) A, and the item moves upward.
Press wiper switch ( ▼), and the item moves downward.
E. Turn starter switch off, and the display is disappeared.

2. How to delete contents of trouble history

A. Display trouble history screen.
B. Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
C. When NO ERROR is displayed, the deletion is completed.
D. Turn starter switch off.

NOTE: All the stored items are erased. It is impossible to erase data partially.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
TROUBLE DIAGNOSIS MODE
The failure diagnosis mode is used to automatically
specify the failed sections for the failures which can
not be detected through the use of self diagnosis
function (the failure can be specified through the use
of error code) like disconnection and abnormal
o u t p u t . T h i s i s u s e f u l t o s a v e t h e t i m e fo r
troubleshooting.
1. Function
There are two types of trouble diagnosis mode.
A. Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system.
B. Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are automatically
actuated, the sensor detects the machine status and the Mechatro controller identifies the normal condition
or failed condition of the system.

For details of how to use, refer to Chapter: TROUBLESHOOTING TROUBLE DIAGNOSIS MODE.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
SET PROCEDURE OF MAINTENANCE SCHEDULE
This machine is equipped with multi-display which allows confirmation of remaining time to the coming
replacement/change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining
time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the
initial setting by the following order.

NOTE: Interval of replacement of parts is mentioned

below:
Screen change Buzzer stop KPSS work mode
Engine oil : 500 Hr switch switch select switch
Fuel filter : 500 Hr
Washer
Hydraulic filter : 1,000 Hr switch

Hydraulic oil : 1,000 Hr

Select Wiper
switch switch
Auto accel Travel speed
switch select switch
SM0155

GRAPHIC_ID Figure 55

Procedure Operating Procedure Display on Multidisplay

After several seconds,

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

Press " " switch press once display

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

Press " " switch press once select

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
H

When required to adjust the interval to the coming

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

When desired to return to the initial set time,

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL

time is stored. H

SM0156

GRAPHIC_1D Figure 56

NOTE:
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance
time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does
not sound.

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
ADJUSTING PROCEDURE OF DISPLAY

For Operator
1 2 3 4
1) Clock Adjustment Switches
No. Switches
1 Screen Change Switch
2 Buzzer Stop Switch
3 Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
5
6 Travel Speed Select Switch 8 7 6 SM0140
7 Auto Acceleration Switch
8
GRAPHIC_ID Figure 57
Select Switch

Main screen (a)

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

(c) (d) (e)

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15

Select Year/Month/Day/Hour/Minute Increase/Decrese

SM0157

GRAPHIC_1D Figure 58
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display SWITCH STATUS CLOCK/CONTRAST select screen (b).
2. In operations of FEED ▲ (4) and FEED ▼ (5), move cursor to CLOCK/CONTRAST screen (c) and then press
select switch (8) and the ADJUST CLOCK ADJ CONTRAST screen (d) is displayed.
3. In operations of FEED ▲(4) and FEED ▼(5), move cursor to ADJUST CLOCK and then press select switch (8)
and the ADJUST CLOCK screen (e) is displayed.
4. Select any of Y•M•D•H•M in operation of FEED ▲(4) and FEED ▼(5) and vary the values in operations of
FEED > (6) and FEED < (7).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).

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 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

2) Contrast Adjustment Switches

1 2 3 4
No. Switches
1 Screen Change Switch
2 Buzzer Stop Switch
3 Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch 5
7 Auto Acceleration Switch 8 7 6 SM0140

8 Select Switch
GRAPHIC_ID Figure 59

Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST

H
(a) (b)

(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H

(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555

Adjustable range
11111~99999 Increase/Decrease
(Default 55555) SM0158
GRAPHIC_1D Figure 60
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display SWITCH
STATUS CLOCK CONTRAST select screen (b).
2. In operations of FEED ▲ (4) and FEED ▼(5), move cursor to SWITCH STATUS CLOCK CONTRAST screen
(c) and then press select switch (8) and the ADJUST CLOCK ADJ CONTRAST screen (d) is displayed.
3. In operations of FEED ▲(4) and FEED ▼(5), move cursor to ADJUST CLOCK ADJ CONTRAST and then
press select switch (8) and the ADJUST CLOCK ADJ CONTRAST screen (e) is displayed.
4. Press select switch (8) and the ADJ CONTRAST 55555 screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED ▼(4) and FEED ▼(5).
The available setting range is in 9 steps from 11111 to 99999.
[Example] 11111 (faint) →99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).

1-48 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Function for Service
Following items are provided for adjustment of service function.
LANGUAGE/LOGO

Function Explanation Note Range Default

All language data is stored in 15
LANGUAGE To change language ISO
one gauge cluster languages
LOGO To change Company Logo 5 Logos NHK

ADJUSTING MODE 1

Function Explanation Note Range Default

To change wiper control, when
RISE-UP WIPER special CAB is installed on OFF is for special CAB ON/OFF ON
demolition machine
P1 OPT SENSOR To activate the self-diagnosis when Switch to ON when 2PB is ON/OFF OFF (*)
ACTIVE P1 OPT pressure sensor is failed installed
P2 OPT SENSOR To activate the self-diagnosis when Switch to ON when N&B ON/OFF OFF (*)
ACTIVE P2 OPT pressure sensor is failed option is installed
Only for EU, to activate the priority
PRIORITY MODE ON/OFF OFF
valve
To use P1 option pedal for P4-
LEFT PEDAL
rotation circuit, releasing auto accel. ON/OFF OFF
ACTIVE
And not activating unload valve
1:No selector valve
SELECT OPT Switch to ON when N&B
2:Selector Valve + Mechanical relief 1 or 3 1 or 3 (*)
SYSTEM option is installed
3:Selector Valve + Electrical relief
ADJ OVERLOAD To change the pressure for overload 10 - 27 18
PRESS alarm in EU
ENG SPEED To activate the engine speed ON/OFF OFF
DISPLAY information for customer
6, 8, 10, 12,
AUTO ACCEL To change auto accel control type 18
14, 16, 18
To change the starting MODE X: return to default MODE S, H, B, A,
START MODE S
(S,H,B,A) when key sw is ON X
To cancel the low temp. mode to
CANCEL LOW OFF = Low Temp. Mode
prevent hydraulic hunching at low ON/OFF OFF
TEMP MODE ACTIVE
temp.
DRAIN HYD. To activate the drain hydraulic When switch is ON, this ON/OFF OFF
PRESS pressure function function starts.
20 - 35
15 Mpa (at
ADJ OPT To adjust Pressure and Flow for Pressure
Follow setting procedure 220 L/min)
HAMMER Hammer (9set) 30 - 220
220 L/min
Flow rate
20 - 35
15 Mpa (at
ADJ OPT To adjust Pressure and Flow for Pressure
Follow setting procedure 220 L/min)
NIBBLER Nibbler (9set) 30 - 220
220 L/min
Flow rate

(*) Autodetect

NA Issued 10-2007 Bur 1-49

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Setting the Language
To modify the language, proceed as follows:
1. Keep BUZZER CUT-OFF button (1) pressed
and, at the same time, move the STARTER
SWITCH to ON; the screen shows display (A).
10:25
2. Keep BUZZER CUT-OFF button (1) pressed,
then press SELECT button (2) three times; the
S
screen shows display (B).
3. Press SELECT button (2); the screen shows
display (C) indicating the symbol of the language
1
previously set, for example: ENG (English).
4. Press WIPER button (3) or WINDSHIELD
WASHER button (4), once or more until the 4
symbol of the desired language is displayed, for
example FRA (French); the screen shows 5
display (D). 3
2
5. Press SELECT button (2) to memorize the
language selected, the screen shows display (E). SM0069
At this stage, the language is selected and after
about three seconds returns automatically to GRAPHIC_ID Figure 61
display (B).
To ex i t th e p r o gra m , m ove t h e S TA RT E R
SWITCH to OFF.
List of the languages available:
NO. 1
EU (ISO icons only) MAIN CONT. P/N

(A) YN 22E 00207 F1

PROGRAM VERSION
ITA 1 VER 2.00
2 VER 0.00
SERVICE DIAG 1
USA
CHN 1 2
LANGUAGE/LOGO
IDN ADJUSTING MODE 1
THA PRESET BY FACTORY
(B)
ESP
FRA
DEU SELECT LANGUAGE

VNM ENG
(C)
MYS FEED

MMR
TAM 4
POR
3
ENG
SELECT LANGUAGE
JPN
FRA
(D)
FEED

SELECT LANGUAGE
FRA
(E)
FEED

SM0070
GRAPHIC_ID Figure 62

1-50 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Setting Adjusting Mode 1
To enter the displays Adjusting Mode 1 proceed as NO. 1
MAIN CONT. P/N
follows: (A)
YN 22E 00207 F1
PROGRAM VERSION
1 VER 1.00
2 VER 0.00
1. Keep BUZZER CUTOFF button (1) pressed and, SERVICE DIAG 1

at the same time, move the STARTER SWITCH x3

to ON; the screen shows display (A) 1 2
LANGUAGE/LOGO
2. Keep BUZZER CUT-OFF button (1) pressed,
ADJUSTING MODE 1
then press SELECT button (2) three times; the PRESET BY FACTORY
(B)
screen shows display (B).
3. Press WINDSHIELD WASHER button (3) to get
ADJUSTING MODE 1, the screen shows display 3
(C).
LANGUAGE/LOGO
4. By pressing SELECT button (2) you enter the ADJUSTING MODE 1
Adjusting Mode 1 functions; the first function is (C) PRESET BY FACTORY

shown on the screen, display (D).

To enter the other functions, actuate WIPER
button (3), to move forward or WINDSHIELD
WASHER button (4), to return back. 11
RISE-UP WIPER
ON
(D)
FEED

4 3
SM0071
GRAPHIC_ID Figure 63
Adjusting Overload Pressure
(Tip Over Momentum Device)
To modify the value of the pressure at which the 2
pressure sensor goes ON to operate the tip-over 3
momentum device, proceed as follows:
63
1. In function Adjusting Mode 1, display (C), press
ADJ OVERLOAD PRESS
SELECT button (2) to enter the functions and (E) 18
use WIPER button (3), to select function 63 - FEED
ADJ OVERLOAD PRESS on display (E).
2. Press SELECT button (2) to choose the number
relative to the setting pressure, display (F). 63
18 = 180 bar ADJ OVERLOAD PRESS
(F) 18
3. Press WINDSHIELD WASHER button (4), to FEED
increase the pressure, or WIPER button (3), to
decrease it.
4. Set the desired pressure value (for example: 11), 4 3
d i s p l ay (G ) , p r e s s S E L EC T bu t t o n ( 2 ) t o
63
memorize it. ADJ OVERLOAD PRESS
By pressing SCREEN CHANGE button (5) you (G) 11

return to display (C). FEED

To ex i t th e p r o gra m , m ove t h e S TA RT E R
SWITCH to OFF.
63
ADJ OVERLOAD PRESS
11

FEED

5
SM0073
GRAPHIC_ID Figure 64
NA Issued 10-2007 Bur 1-51
 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Drain Hydraulic Pressure
To drain the hydraulic pressure from the system,
LANGUAGE/LOGO
proceed as follows: ADJUSTING MODE 1
1. In function Adjusting Mode 1, display (C), press (C) PRESET BY FACTORY

SELECT button (2) to enter the functions and

using WIPER button (3), select on the display
function DRAIN HYD. PRESS, display (H). 2 3
2. Press SELECT button (2) to show the writing
OFF, display (I). DRAIN HYD PRESS
(H) OFF
3. Press WINDSHIELD WASHER button (4) to FEED
activate function ON, display (L).
4. Press SELECT button (2) and start the engine.
The screen shows display (M). At this point, with
the engine in operation, actuate the pilot valves DRAIN HYD PRESS
perfor ming all the movements so that the (I) OFF
pressure is drained from all the actuators. FEED
The function is automatically deactivated by
returning the STARTER SWITCH to OFF.
4
NOTE: If the monitor displays FAIL DRAIN HYD
PRES. this means that the pressure draining DRAIN HYD PRESS
operation has not been performed correctly. In this (L) ON

case, repeat the operation. FEED

(M)
10:25
PR

S
SM0072

GRAPHIC_ID Figure 65

1-52 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
MECHATRO CONTROL EQUIPMENT
C-1 Mechatro Controller
1. Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34

27 22 18 16 12 28 22
CN101 CN102 CN103 CN104

CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21

21

31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16

GRAPHIC_1D Figure 66
2. List of connectors
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V㧕
26 GP 0V
27 CANH1 CAN communication
Spare
28 CANL1 CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Extra pressure release Output EARTH/OPEN
33 DO 24 Spare Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
SM0160
GRAPHIC_1D Figure 67

NA Issued 10-2007 Bur 1-53

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Connector No. Pin No. Port name Function Input/putput Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN

Connector No. Pin No. Port name Function Input/putput Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved
SM0161

GRAPHIC_1D Figure 68

1-54 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

2 A17 Boom head (Over load) Input 0.5~4.5V

3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Spare Input 0.5㨪4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Engine coolant
Input Resistor
14 GA temperature
15 A22
Fuel level Input Resistor
16 GP
17 A23 Resistor
Spare Input
18 GA
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Extra pressure source Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Spare Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Starting point of accel motor Input GND / OPEN

Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V 20~32V
Battery relay output side
2 +24V 20~32V

3 +24V Battery relay output side 20~32V

4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
9 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
21 GND Battery (-) 0V
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Spare Output +0~800mA
26 D7- -0~800mA
27 D8+ Spare Output +0~800mA
28 D8- -0~800mA
29 D9+ Spare Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
SM0162
GRAPHIC_1D Figure 69

NA Issued 10-2007 Bur 1-55

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Connector No. Pin No. Port name Function Input/putput Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase Output 1.5A
4 F1- Accel motor A phase Output 1.5A
5 F2+ Accel motor B phase Output 1.5A
6 F2- Accel motor B phase Output 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ Bypass valve Output +0~800mA
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication

Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 Grid heater feedback Input +24V/OPEN
2 DI 8 Engine coolant temperature Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Spare Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 Heater temperature of fuel filter Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Spare Input EARTH / OPEN
15 DI 40 Heater temperature Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved
SM0163

GRAPHIC_1D Figure 70

1-56 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

Connector No. Pin No. Port name Function Input/putput Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Water separator Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 Spare Input GND / OPEN
6 DI 16 Wiper rise up㩩 Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Spare Input GND / OPEN
10 DI 21 Spare Input +24V / OPEN
11 DI 22 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation Input GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Spare Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 Spare Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Spare Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved
25 H1+ Spare 0~5V
26 H2- 0V
27 H2+ Spare 0~5V
28 H2- 0V

Connector No. Pin No. Port name Function Input/putput Signal level
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Spare Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Spare Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Grid heater Output GND / OPEN
15 Reserved
16 GP 0V
17 TXD2 Tranmission RS232C communication
18 RXD2 Reception RS232C communication
Spare
19 RTS RS232C communication
20 CTS RS232C communication
21 SHG2 Shiled GND
22 DO 10 Spare SV 24V/OPEN
SM0164

GRAPHIC_1D Figure 71

NA Issued 10-2007 Bur 1-57

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Gauge Cluster (Symbol C-2)
1. General view

4. BUZZER

1. MULTI
DISPLAY LCD

2. COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
5. SCREEN
CHANGE
SWITCH ETC.

6. BUZZER STOP SWITCH 7. WORK MODE SWIHCH

SM0165

GRAPHIC_1D Figure 72
2. Connector CN-600 (Harness side)

Wire Wire
No. Item name No. Item name
color color
Gauge cluster →Mechatro controller GND source (+24V Battery direct Yellow /
1 White 5
(RS232C communication) connection) Black
Mechatro controller →Gauge cluster
2 Red 6 GND Black
(RS232C communication)
3 — — 7 Source (+24V starter switch ON) White
4 — — 8 GND (RS232C communication) Black

3. Function
A. It processes signals by communication between the gauge cluster and the Mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
B. It outputs coolant temperature signals, fuel level signals and panel switch signals to the Mechatro controller
through the communication port.
4. Summary of display and drive item

No. Item Remarks

1 Monitor display LCD dot 120× 168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch

1-58 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
Relay & Fuse Box (Symbol E-1)
1. General view

(Overhead view of box)

LABEL INSIDE

Note) These circles indicate the parts

which are used in standard specification

1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17

20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2

22 1 3 1 3
11
13 26 13 26 9 20 CN14 CN15

1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME
SM0166
GRAPHIC_1D Figure 73

NA Issued 10-2007 Bur 1-59

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
2. Circuit diagram

SM0167

GRAPHIC_1D Figure 74

1-60 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

SM0168
GRAPHIC_1D Figure 75

NA Issued 10-2007 Bur 1-61

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

SM0169

GRAPHIC_1D Figure 76

1-62 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM
High Pressure Sensor : YN52S00048P1

ECONOSEAL SERIES MARK(+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER

COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM

O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft) SM0170

GRAPHIC_1D Figure 77

Low Pressure Sensor : YX52S00013P1

Tightening torgue
Vout
29.434.3N.m (21.725.3lbf.ft)
PF1/4

Vcc GND

ELECTRIC CONNECTING DIAGRAM

(Ex. Construction of internal controller)

SPECIFICATION :
PRESSURE RANGE : 0 3.0 MPa
RATED VOLTAGE : 5.0+0.5V DC
OUTPUT CHARACTERISTIC INSURANCE RESISTANCE : 50M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)

SM0171

NA Issued 10-2007 Bur 1-63

 SECTION 2 - SYSTEMS
CHAPTER 1 - MECHATRO CONTROL SYSTEM

1-64 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS

CHAPTER 2

E175B
EXCAVATOR

HYDRAULIC SYSTEM

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

2-II Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS

CHAPTER 2
HYDRAULIC SYSTEM
TABLE OF CONTENTS

SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
HYDRAULIC CIRCUITS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Hydraulic Circuit Diagram (Monoblock Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
N&B Hydraulic Circuit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
N&B Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Holding Valve For Boom and Arm (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Holding Valve For Boom And Arm Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Positioning Circuit (Triple Articulation Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Postioning Circuit Diagram (Triple Articulation Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Color Coding Standard For Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Neutral Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Operation of Bypass Cut Valve and Unloading Valve Housed in Control Valve . . . . . . . . . . . . . . . . . . . . 2-12
Safety Lock Lever and Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Pump Positive Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Pump P-q Curve Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Neutral Circuit: Positive Control Function At Safety Lock Lever Down (Unlocked Position) . . . . . . . . . . . . . 2-13
Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Travel Forward Pilot Simultaneous Operation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2-Speed Travel Solenoid Command Circuit and Auto 1st Speed Return Function . . . . . . . . . . . . . . . . . . 2-14
Travel Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Travel Motor Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Travel Circuit: Travel 2nd Speed, RH & Simultaneous Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Pilot Circuit For Bucket Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Auto Acceleration Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Flow Control in the Work Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Bucket Digging and Travel Priority Confluence (Conflux) Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Bucket Spool Stroke Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Bucket Circuit: Bucket Digging (Travel Priority Conflux, Auto Acceleration And Standby Flow Rate Constant
Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Boom Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Boom Raise Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Boom Up 2 Pumps Conflux Main Circuit in C/V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Boom Circuit: Boom Up Operation, Confluence Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Boom Down Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Prevention Of Natural Fall By Lock Valve And Actuation At Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Constant Recirculation Function of Boom Down Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Boom Circuit: Boom Down Operation and Prevention of Natural Boom Falling. . . . . . . . . . . . . . . . . . . . . 2-21
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Pilot Circuit for Left Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Swing Auto Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Swing Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Swing Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Swing Circuit: Swing Operation (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Arm Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Arm In, Light-load Operating Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Arm In, Light-load Variable Normal Recirculation, Internal Conflux Main Circuit . . . . . . . . . . . . . . . . . . . . 2-24
Arm Circuit: Arm In (Light Load) Operation, Arm Variable Recirculation and Cavitation Function . . . . . . 2-25
Arm In, Heavy Load Operating Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Arm In, Heavy Load Operating Recirculation Cut Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

NA Issued 10-2007 Bur 2-1

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

Arm Circuit: Arm In (Heavy Load) Operation, Arm Confluence And Recirculation Cut Function . . . . . . . .2-27
Arm Out Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Arm Out 2 Pumps Conflux Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Natural Fall Protection with Arm Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Arm Circuit: Arm Out Operation, Confluence Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
Combined Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Boom Up / Travel, Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Boom Up / Travel, Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Combined Circuit: Boom Up And Travel Forward 1st Speed Operation, Travel Priority Function. . . . . . . .2-31
Swing / Arm In Light Load, Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Swing / Arm In, Swing Priority Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Combined Circuit: Swing / Arm In Operation, Swing Priority Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
Pressure Draining (Releasing) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Pressure Releasing Pilot Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Pressure Releasing Main Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Pressure Draining (Releasing ) Circuit: At Pressure Release Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

2-2 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM
SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability,
safety,mass volume handling and low fuel consumption.
Performance Device Function Features
Travel straight Travel straight at combined operation
Travel 2-speed change & Auto 1st 1-2 travel speed change and low speed / high torque at
(low) speed return heavy duty
Travel Auto parking brake Automatic braking when parking
Motor overrun protection Prevents overrunning of travel motor on the down hill slope.
Prevents hunting by the built in travel shockless
Travel pilot operation
mechanism
Reverse rotation protective Easy positioning to protect it from swinging back when
function stops swinging.
Swing priority circuit
Swing Easy operation of stable swing speed, arm slanted leveling,
(simultaneous operation of arm in
swing press digging
and swing motions)
Automatic swing parking brake Swing parking brake when operating at on a slope
Hydraulic pilot control system Light action with operating lever
Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Easy
operability and Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
safety Attachment Prevention of boom falling when boom head side piping
Holding valve for boom (Option)
breaks
For safety, this valve lowers risen attachment to the ground,
Emergency manual valve for
if the machine stops with engine trouble, and the pressure
lowering attachment
in the cylinder of attachment can be released.
To prevent hydraulic oil from entering dust and to promote
Pressurized hydraulic oil tank
self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter; pilot circuit To prevent pilot operating circuit from malfunctioning
Return circuit oil filter To prevent hydraulic oil from contamination
Others Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being deteriorated.
Pressure draining circuit To release the main circuit pressure for piping repair work.
Main control valve with optional
Optional piping and additional work are easy
valve
Switching of return line for N&B Switching of return line for N&B machine is able to change
machine in the cab (Option) with a switch in the cab
Pump delivery rate control by a current command to the
Electric flow controlled variable
solenoid proportional valve of the variable displacement
displacement pump
pump
Pump
Positive flow rate control Flow control by positive pilot control pressure
Backup control by hydraulic when the electric flow
Mass handling Hydraulics backup control
controlled variable displacement pump fails.
capability
Boom up conflux circuit Speed up of boom up operation
Arm conflux circuit Speed up of arm operation
Attachment Bucket conflux circuit For speed-up of bucket operation (digging & dump)
Optimum operation by work mode
Efficient operation in all work modes
select (H,S,A,B)
Reduce fuel consumption and noise by lowering engine
Low fuel Auto accel
Microcomputer speed when control lever is in neutral position.
consumption

2-3 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM
HYDRAULIC CIRCUITS AND COMPONENTS

Hydraulic Diagram Reading Key

Item Component name
1 Hyd. pump assy
2 Control valve (main)
3 Swing motor unit
4 Travel motor unit
5 Boom cylinder (RH & LH)
6 Arm cylinder
7 Bucket cylinder
8 Swivel joint
9 Pilot valve (ATT)
10 Pilot valve ( travel)
11 Inline filter
12 Suction strainer
13 Solenoid valve assy
14 Return filter
15 Air breather
16 Restictor
17 Shuttle Valve
18 Short-circuit valve
19 Low pressure sensor block

2-4 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

HYDRAULIC CIRCUIT DIAGRAM (MONOBLOCK VERSION)

18

1 8

11

15 14

19
12

9
17

10
5

16
16

GRAPHIC_1D 13 Figure 1

5-10680 NA Issued 02-2008 Bur 2-5

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

N&B HYDRAULIC CIRCUIT (OPTION)

N&B Hydraulic circuit reading key
ITEM COMPONENT NAME
50 Selector valve
51 Stop valve
52 Pilot valve
53 Overload relief valve

The hydraulic circuit for N&B is used to add to standard circuit

Selection condition and proportional valve command
when any of nibbler single & conflux flow or breaker
are in service.
COMMAND SIGNAL OF SOLENOID
SELECTION
PROPORTIONAL VALVE (W:O, W/O: -)
Electromagnetic command
Conflux/single flow Travel P1 P2
signal of selector valve (50) P1 Pump P2 Pump
changeover switch Straight Unload Unload
(W:O, W/O: -)
Conflux flow of
Conflux ON - O O O O O
nibbler
Single flow of
Conflux OFF - - O - - O
nibbler
Breaker Conflux OFF O - O - - O

When using nibbler, according to specification of

nibbler installed.
Adjust overload relief valve (53) of optional port to
customize specification ordinary set pressure.

2-6 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

N&B Hydraulic Circuit Diagram

51

53

52

53

50

SM1264
GRAPHIC_1D Figure 2

5-10680 NA Issued 02-2008 Bur 2-7

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

HOLDING VALVE FOR BOOM AND ARM (OPTION)

Holding Valve For Boom
The holding valve for the boom prevents the boom
failing in case of head side cylinder piping breaks.
Holding Valve For Arm
The holding valve for arm prevents the arm failing in
case of rod side cylinder piping breaks.
Hydraulic Circuit Reading Key
ITEM COMPONENT NAME
54 Holding valve for boom cylinders
55 Holding valve for arm cylinder

2-8 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Holding Valve For Boom And Arm Hydraulic Circuit Diagram

54 55

GRAPHIC_1D Figure 3

5-10680 NA Issued 02-2008 Bur 2-9

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

POSITIONING CIRCUIT (TRIPLE ARTICULATION VERSION)

Hydraulic Positioning Circuit Reading Key
ITEM COMPONENT NAME
56 P1 OPT valve
57 Holding valve for positioner cylinder
58 Positioner cylinder
59 Positioning pilot valve

Operation

When the operation for positioning is performed, the

pilot proportional secondary pressure is delivered
through port A of the positioning pilot valve (59) and
flows to PAo1 port of the P1 OPT valve (56) then, the
spool of P1 OPT valve (56) is switched. The pressure
oil by P1 pump is supplied to (R) side of positioner
cylinder (58) through Ao1 port of P1 OPT valve (56).
On the other hand, the return oil from (H) side of
positioner cylinder returns to the tank circuit thorough
Bo1 port of P1 OPT valve (56).
The holding valve (57) prevents the positioning
failing in case of rod side cylinder piping breaks.

2-10 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Postioning Circuit Diagram (Triple Articulation Version)

57

R
POSITIONING
CYLINDER

H 58

59

56

GRAPHIC_1D Figure 4

5-10680 NA Issued 02-2008 Bur 2-11

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

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

2-12 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

NEUTRAL CIRCUIT: POSITIVE CONTROL FUNCTION AT SAFETY LOCK LEVER DOWN (UNLOCKED POSITION)

18

651 652
646 8
1
611
643

532

11

14
15

19
12

9
17

10
5

16
16

13
GRAPHIC_1D Figure 5

5-10680 NA Issued 02-2008 Bur 2-13

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM
TRAVEL CIRCUIT
This section describes the following.
Travel forward pilot simultaneous operation circuit
2 speed travel solenoid command circuit and auto 1-
speed return function
Travel main circuit
Travel motor function
Travel Forward Pilot Simultaneous Operation
Circuit
1. Purpose:
Light operating force and shockless operation
2. Mechatronics :
1. If the travel lever with damping mechanism is
operated for travel right, left and forward
motions, the secondary pilot proportional
pressure comes out of the 3, 1 ports of P/V
(10). The higher of the pressures is selected,
comes out of the 6, 5 ports and acts upon the
low pressure sensors (SE-9) (SE-10).
2. The pilot secondary pressure flows to PAr
and PAL ports of the control valve (2), moves
the travel spool, and switches the main
circuit.
3. The low pressure sensor output voltage is
input into mechatro controller. The mechatro
controller performs signal processing and
outputs current corresponding to the increase
of flow rate to P1 pump proportional valve
(PSV-P1) and P2 pump proportional valve
(PSV-P2), and at the same time the
command current is output to P1 unloading
valve (PSV-D) and P2 unloading valve (PSV-
B).
4. The secondary pressures output by P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exert on pump
regulator, actuating the pump on the delivery
flow rate increase side.
5. The secondary pressure delivered in P1
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is fed to PBp1, PCb, PBp2 and
PCa ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 and PBp2
ports holds the bypass cut spool on CLOSE
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa
ports switches the unloading spool in CLOSE
side.
2-14
2-Speed Travel Solenoid Command Circuit and
Auto 1st Speed Return Function
1. Purpose:
Change travel motor speed with switch.
2. 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.
3. Operation:
If the rabbit marked switch on the gauge cluster
is pressed, the solenoid (SV-3) of the
proportional valve block (13) is excited and
changes the proportional valve. Then the
solenoid command pressure is issued from port
A3, enters the Ps port of the travel motor (4),
opens the oil passage to the 2nd speed select
piston, and causes the motor to run in the 2nd
speed tilting mode by its self pressure.
However, when the main circuit pressure rises
above 27.3 MPa (3960 psi) the motor’s self
pressure pushes the 2nd speed select piston
back to the 1st speed.
Travel Main Circuit
1. Operation:
The delivery oil from Pump A1 and A2 ports by
changing the travel spool with the operation of
travel pilot flows into P1 port on the left side
motor (4) and P2 port on the right side motor (4)
through C,D ports of swivel joint (8) from AL, AR
ports of C/V, and rotates the travel motor.
Travel Motor Function
1. Function:
1. Prevents the motor from over running on a
slope.
2. Check valve that prevents cavitation of the
hydraulic motor.
3. Shockless relief valve and anti cavitation
valve when inertia force stops.
4. High/Low 2 step speed change mechanism
and auto 1st speed return at high load.
5. Travel parking brake.
Issued 02-2008 Bur 5-10680 NA
 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Travel Circuit: Travel 2nd Speed, RH & Simultaneous Operation.

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GRAPHIC_1D
13 Figure 6

5-10680 NA Issued 02-2008 Bur 2-15

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM
BUCKET CIRCUIT
This section describes the following.
Bucket digging pilot circuit
Auto acceleration operation
Flow control in the work mode
Bucket digging travel priority main circuit
Bucket spool stroke limiter
Pilot Circuit For Bucket Digging
1. Mechatronics :
1. When the operation for bucket digging is
performed, the pilot proportional secondary
pressure is delivered through port 1 of the
right pilot V (9), flows to PAc port, and acts on
the low pressure sensor (SE-1), and at the
same time the bucket spool is switched.
2. The voltage output by low pressure sensor
(SE-1) inputs in mechatro controller. The
mechatro controller performs signal
processing and outputs current
corresponding to the increase of pump flow
rate to pump proportional valves (PSV-P1)
and (PSV-P2) on the P1 and P2 pump sides,
and at the same time the command current is
output to P1 unloading valve (PSV-D), P2
unloading valve (PSV-B) and travel priority
proportional valve (PSV-C).
In th e fo l l ow i ng pa g es , th e re l a tio n o f
operation of low pressure sensor to both the
increase of pump flow rate and unloading
proportional valve is the same. Therefore the
explanation is omitted.
3. The secondary pressure output by P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exerts on pump
regulator, actuating the pump onto the
delivery flow increase side.
4. The secondary pressure delivered in P1
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2 and
PCa ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 and PBp2
ports holds the bypass cut spool on CLOSE
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa
ports switches the unloading spool in CLOSE
side.
2-16
5. The secondary pressure delivered in travel
priority proportional valve (PSV-C) is led to
PTb port provided in control valve (2) and
shifts the travel priority valve one stage.
Auto Acceleration Operation
1. Principle:
Auto acceleration actuates according to signals
from low pressure sensor.
2. Operation:
<When lever is set to neutral position>
In the event where the sensor does not receive
signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the
engine speed should be raised to 1050 rpm.
<When lever is operated>
When the pressure 0.6MPa (87psi) is input to
low pressure sensor in STD specification (travel,
bucket, swing, arm), proportional voltage from
low pressure sensor inputs in mechatro
controller, and then the engine speed returns to
the dial set position corresponding to the lever
operation.
Flow Control in the Work Mode
1. Principle:
When the engine speed is intermediate speed or
lower, command current value to have the pump
delivery rate constant is output.
2. Operation:
Even if the engine speed specified by
acceleration potentiometer is low speed, as the
delivery rate corresponds to the intermediate
speed, the actuator moves earlier than the
movement equivalent to the control lever angle
rate in light load operation.
Bucket Digging and Travel Priority Confluence
(Conflux) Main Circuit
1. Operation:
1. The oil delivered through A1 port of P1 pump
goes into P1 port of C/V (2), opens load
check valve LCc through parallel circuit and
enters in bucket spool.
2. On the other hand, the oil delivered through
A2 port of P2 pump goes into P2 port of C/V
(2), confluences with oil from P1 pump
through travel priority valve, and goes into
bucket spool. (Confluence of oil from 2
pumps)
SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM
3. 3)With the function of pilot circuit, the oil flow
is switched from bucket spool, and is fed into
bucket cylinder head side through Ac port of
C/V (2). On the other hand, the return oil from
cylinder rod (R) side is throttled by bucket
spool and returns to tank circuit from Bc port
of C/V (2).
References:
In bucket dumping operation, the travel
priority valve also switches like digging
operation, resulting in confluence with travel
straight.
When the bucket operation and other
operation are simultaneously performed, the
travel priori ty valve does not actuate,
resulting in single flow of bucket circuit.
Bucket Spool Stroke Limiter
1. Purpose:
To secure simultaneous operability of boom and
arm on boosting up attachment pressure (Pump
flow rate decreases.) and to prevent cavitations
at low engine speed.
2. Operation:
On boosting up attachment pressure, pilot
primary pressure exerts on PCc port of C/V(2)
through attachment booster solenoid valve,
operates stroke limiter of bucket spool, and
throttle oil path of spool. As a result, P1 pump
pressure increases, making the simultaneous
operation of boom up and bucket digging
possible.
Even though the engine speed is low, similarly
the cavitations can be prevented by actuating the
stroke limiter.
Issued 02-2008 Bur 5-10680 NA
 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Bucket Circuit: Bucket Digging (Travel Priority Conflux, Auto Acceleration And Standby Flow Rate Constant Control)

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GRAPHIC_1D Figure 7

5-10680 NA Issued 02-2008 Bur 2-17

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

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

Boom Raise Pilot Circuit

1. Operation:
1. If boom up operation is performed, the
secondary pilot proportional pressure from
the right pilot valve (9) gets out of port 4 and
acts upon the low pressure sensor (SE3). At
the same time, the pressure acts upon the
PAb and PB1 ports.
2. The secondary pressure which enters the
PAb port of C/V (2) shifts the boom spool.
The secondary pressure which enters the
PB1 port shifts the boom conflux spool.

Boom Up 2 Pumps Conflux Main Circuit in C/V

1. Purpose:
Boom up speed up
2. Principle:
Confluxing oil from 2 pumps
3. Operation:
1. The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2. Then the oil passes through boom spool,
opens lock valve of boom lock valve CRb,
and is led into (H) side of boom cylinder
through C/V (2) Ab port.
3. Meanwhile, the oil delivered from the A2 port
of the P2 pump enters the P2 port of C/V (2)
and due to shut off the P2 unloading valve,
the oil then passes through the parallel circuit
and via the restrictor on the circumference of
the boom conflux spool, pushes the load
check valve CCb open from the boom conflux
circuit, and combines the oil delivered by the
P1 pump internally.
4. The return oil from boom cylinder (R) side
flows into tank circuit through boom spool
from C/V (2) Bb port.

2-18 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Boom Circuit: Boom Up Operation, Confluence Function.

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GRAPHIC_1D 13 Figure 8

5-10680 NA Issued 02-2008 Bur 2-19

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

This section describes boom lower operation. Constant Recirculation Function of Boom Down
Boom down pilot circuit Main Circuit

Prevention of natural fall by lock valve and actuation 1. Purpose:

at lowering Prevention of cavitation during boom lowering
motion.
Constant recirculation function of boom down main
circuit 2. Principle:
The oil returning from the boom cylinder head
Boom Down Pilot Circuit (H) is recirculated to the rod (R).

1. Operation: 3. Operation:
When the oil is supplied to the boom cylinder rod
1. If the boom down operation is performed, the (R) side during boom down operation, the boom
secondary pilot proportional pressure comes moves faster than it should do in some cases by
out of port 2 of the right pilot valve (9) and the self weight of the attachment.
acts upon the low pressure sensor (SE-4). On that occasion, the circuit pressure on the rod
At the same time, the pressure acts upon the (R) side is on the negative side.
PBb port of C/V (2). The oil supplied to the boom cylinder rod (R)
2. The voltage output of the low pressure sensor flows into the A1 port of the P1 pump and the P1
(SE-4) enters the mechatro controller and port of C/V. The oil then passes through the
processed in it. boom spool and goes out of the Bb port.
3. Then, the proportion secondary pressure fed On that occasion, the oil returning from the head
into C/V (2) PBb port and branches off in two (H) goes through the recirculation path in the
lines and switches boom spool and releases boom spool, pushes the check valve in the spool
boom lock valve. open, is recirculated to the Bb port and is
supplied to the rod (R). When the (R) pressure is
Prevention Of Natural Fall By Lock Valve And larger than the head (H) pressure, the check
Actuation At Lowering valve in spool closes.
There upon, the recirculation is stopped.
1. Purpose:
Prevention of natural fall when the lever is
neutral
2. Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
3. Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.

2-20 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Boom Circuit: Boom Down Operation and Prevention of Natural Boom Falling.

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GRAPHIC_1D
13 Figure 9

5-10680 NA Issued 02-2008 Bur 2-21

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

SWING CIRCUIT Swing Main Circuit

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

Swing Auto Parking Brake

1. Purpose:
Swing lock in neutral position and parking
2. Principle:
Release mechanical brake only when required to
operate swing and arm in.
3. Operation:
1. The swing parking system excites the swing
parking SOL (SV-1) usually if the key switch
is turned on and works by the action of the
mechanical brake.
2. The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing
and arm in actions acts upon any of the low
pressure sensors (SE-5, 7).
3. The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing
low pressure sensors (SE-5) is reduced to
zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the
moment the pressure of the arm in low
pressure sensor (SE-7) is reduced to zero.
This causes the mechanical brake to operate.

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 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Swing Circuit: Swing Operation (LH)

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GRAPHIC_1D Figure 10

5-10680 NA Issued 02-2008 Bur 2-23

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM
ARM CIRCUIT
This section describes the following operations.
Arm in, light-load operating pilot circuit
Arm in, light-load variable normal recirculation main
circuit / internal conflux main circuit
Arm In, Light-load Operating Pilot Circuit
1. Purpose:
Speed-up and Anticavitation when the arm is at
light loaded.
2. Principle:
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at arm 2
spool in C/V.
3. Operation:
1. When the arm in operation is performed, the
secondary pilot proportional pressure gets
out of port 4 of the left pilot valve (9) and acts
upon the low pressure sensor (SE-7).
At the same time, the pressure is branched
off in two flows, acts upon the PAa1 port and
the PLc2 port, changes over the arm spool
and the arm lock valve CRar releases.
2. The output voltage by the low pressure
sensor is input into mechatro controller, and
is pilot signal-processed, and is output to P1,
P2 pump proportional valve (PSV-P1), (PSV-
P2) and arm 2 inverse proportional valve
(PSV-A).
3. The secondary pressure from pilot
proportional valve, which is reduced by arm 2
inverse proportional valve (PSV-A) switches
arm 2 spool.
Arm In, Light-load Variable Normal Recirculation,
Internal Conflux Main Circuit
1. Operation:
1. The P2 pump delivery oil flows in travel left
section through P2 port of C/V (2) and is
branched off in bypass circuit and parallel
circuit, but because arm 1 spool is switched,
the delivery oil which goes through parallel
circuit opens load check valve LCa and is
flowed into arm 1 spool.
2. On the other hand, P1 pump delivery oil flows
in P1 port of C/V (2), and the flows in travel
straight section and travel right tandem path.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2,
goes through arm 2 spool, and confluences
with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
side through Aa port of C/V (2).
2-24
3. The return oil from arm cylinder (R) side flows
in Ba port of C/V (2) and passes through the
Ba port because the arm lock valve CRar is
open, and is flowed into arm 2 spool through
arm 1 spool.
4. Because arm 2 spool is switched to normal
recirculation position, causing restriction of
passage to tank, the return oil from arm
cylinder (R) side flows into arm cylinder (H)
side.
Because, at light load, the pressure in
cylinder rod (R) side is higher than that in the
head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated in
the head (H) side, resulting in the speed up of
arm-in operation at light load.
5. Cavitations prevention control in arm-in
operation.
Command current is output to arm 2
solenoid proportional valve by signal
processing of E/G speed and arm-in pilot
pressure, accordingly the arm 2 spool is
switched to neutral (cavitations
prevention) position, resulting in
cavitations prevention.
Position of arm 2 spool
Recirculation Normal recirculation position
From arm out P/V
From arm 2 inverse Neutral position
proportional valve
(Anticavitation position) SM1394
GRAPHIC_ID Figure 11
Reference:
I n l i g h t- l o a d a r m -i n op e r a ti o n ( n o rm a l
recirculation, conflux), when the attachment
to which the circuit in P1 pump side is applied
is operated, the meter-in path of arm 2 spool
is closed, resulting in single flow operation.
Spool position at arm in, light load and combined operation
(This position is not shown in hydraulic diagram)
Arm 2 spool Meter-in passage (Close)
Normal recirculation opsition Neutral position SM1395
GRAPHIC_ID Figure 12
Issued 02-2008 Bur 5-10680 NA
 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Arm Circuit: Arm In (Light Load) Operation, Arm Variable Recirculation and Cavitation Function

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GRAPHIC_1D
13 Figure 13

5-10680 NA Issued 02-2008 Bur 2-25

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

This section describes the following operations. 3. The return oil from arm cylinder (R) side flows
Arm in, heavy load operating pilot circuit in Ba port of C/V(2) and is flowed to arm lock
(recirculation cut) valve CRar, but because the arm lock valve
CRar is open, the return oil goes through arm
Arm in, heavy load operating sequence confluxed lock valve CRar and flows in arm 2 spool.
main circuit
4. The return oil returns directly into tank circuit
because arm 2 spool is switched to
Arm In, Heavy Load Operating Pilot Circuit recirculation cut position.

1. Operation: Position of arm 2 spool

1. 1)In arm-in operation, when the heavy
loading is applied to arm and the P2 pump Recirculation cut position From arm out P/V
pressure increases to the set pressure, the
voltage output by P2 pump pressure sensor
( S E - 23 ) i s c on v e r t e d to s i g n a l ( s i g n a l
processing) by mechatro controller,
consequently the current of arm 2 solenoid From arm 2 inverse Neutral position
proportional valve is controlled according to proportional valve SM1396
the load pressure and the arm variable GRAPHIC_ID Figure 14
recirculation is cut.
When th e recirculation is cut, intern al
confluence is held similarly to that in light load
operation.
2. Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.

Arm In, Heavy Load Operating Recirculation Cut

Main Circuit
1. Purpose:
Speed up for arm in operation
2. Principle:
Cut the recirculation and reduce rod pressure.
3. Operation:
1. P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in bypass circuit and parallel
circuit. Consequently the arm spool is
switched and pushes and opens load check
valve LCa through parallel circuit, and flows
in the arm spool.
2. On the other hand, P1 pump delivery oil flows
in P1 port of C/V (2), and flow in travel right
tandem passage through travel straight
section. Then because arm 2 spool was
switched, the delivery oil opens load check
valve LCAT2, and confluences with P2 pump
delivery oil in the valve section, and is flowed
into arm cylinder head (H) side through Aa
port of C/V(2).

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 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Arm Circuit: Arm In (Heavy Load) Operation, Arm Confluence And Recirculation Cut Function

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GRAPHIC_ID Figure 15

5-10680 NA Issued 02-2008 Bur 2-27

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

This section describes the following operations.
Arm out pilot circuit
Arm out 2 pumps conflux main circuit
Natural fall protection with arm lock valve
Arm Out Pilot Circuit
Natural Fall Protection With Arm Lock Valve
1. Purpose:
To prevent the arm from falling naturally by the
weight of the arm and bucket.
2. Principle:
Complete seat of the return circuit against the
arm spool of the arm cylinder (R) side circuit.

1. Operation: 3. Operation:

1. When the arm out operation is performed, the
secondary pilot proportional pressure gets
out of port 8 of the left pilot valve (9), and acts
upon the low pressure sensor (SE-8). At the
same time, the oil is branched off in two flows
and act upon the PBa1 and PBa2 ports of C/
V (2).
1. When the secondary pressure for arm
operation disappears and the arm cylinder
stops, the pressure on the rod (R) side
passes through the selector of the lock valve
from the Ba port of C/V, acts the back
pressure on the lock valve CRar and seats
the lock valve.

2. The operating proportional secondary 2. Since the oil flow into the arm spool from the
pressure flowed in PBa1 port of C/V (2) lock valve is shut off completely, natural fall of
switches the arm 1 spool. the arm due to oil leaks through the arm spool
is prevented.
3. Then, the operating secondary pressure
flowed in PBa2 port of C/V (2) switches the
arm 2 spool valve.

Arm Out 2 Pumps Conflux Main Circuit

1. Purpose:
Arm out operation speed up.
2. Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
3. Operation:
1. P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just short
of the arm lock valve.
2. And, P2 pump delivery oil flows through arm
1 spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRar with
free flow and is flowed into arm cylinder rod
(R) side through Ba port of C/V(2).
3. On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns
into tank circuit through arm 1 spool and arm
2 spool.
The return line which does not pass through
boost check valve is used for this return
circuit to reduce the pressure loss.

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 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Arm Circuit: Arm Out Operation, Confluence Function

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GRAPHIC_1D Figure 16

5-10680 NA Issued 02-2008 Bur 2-29

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

COMBINED CIRCUIT 3. The delivery oil flowed into P2 tandem circuit

This section describes only the difference in of P2 pump flows in left travel spool to travel
combined operation. leftward.
The delivery oil flowed into travel priority
Boom up / travel, pilot circuit spool of P2 pump flows in right travel spool
Boom up / travel, main circuit because the travel straight spool is shifted
and exerts on the right travel operation.
Boom Up / Travel, Pilot Circuit (In travel straight operation, P2 pump delivery
1. Operation: oil exerts on travel operation.)
<Operation: Different point of pilot circuit from 4. However, a portion of the flow is led to the
independent operation > spool of short-circuit valve notch restriction.
1. The mechatro controller outputs command The speed of attachments like travel, boom,
current to travel priority solenoid proportional etc. is adjusted by the circuit of restriction.
valve (PSV-C) and to short-circuit solenoid
proportional valve (PSV-R) after signal
processing.
And the solenoid proportional valve outputs
secondary pressure and acts on PTb port and
short-circuit valve.
2. Then the pressure of PTb port switches the
travel priority valve. And the secondary
pressure of solenoid valve in short-circuit
valve switches spool of short-circuit valve 1
step.

Boom Up / Travel, Main Circuit

1. Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
2. Principle:
The travel action and the attachment action are
actuated by separate pumps.
3. Operation:
1. P1 pump delivery oil flows through P1 port of
C/V(2) and branches off in P1 parallel circuit
and spool of short-circuit valve.
P2 pump delivery oil flows through P2 port of
C/V(2) and branches off in P2 tandem circuit
and spool of short-circuit valve.
2. The delivery oil flowed into P1 parallel circuit
of P1 pump opens check valve CT1 and LCb
and flows in boom spool, which exerts on
boom up operation.
The delivery oil flowed into travel priority
spool of P1 pump opens check valve CT2
because the travel priority spool is shifted,
and flows in boom conflux spool and exerts
on boom up operation with the internal oil
conflux.
(In travel straight operation, P1 pump delivery
oil exerts on operation of attachment.)

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 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Combined Circuit: Boom Up And Travel Forward 1st Speed Operation, Travel Priority Function.

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GRAPHIC_1D Figure 17

5-10680 NA Issued 02-2008 Bur 2-31

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

In this section, the independent operation is omitted Position of arm 2 spool

and describes difference in combined operation.
Position of forced recirculation
Swing / Arm in light load, pilot circuit
Meter-in passage
Swing / Arm in, swing priority main circuit Arm 2 spool
(Close)

Swing / Arm In Light Load, Pilot Circuit

1. Operation:
From arm 2 From
1. On operating swing (left) and arm in motions inverse Neutral position arm out
simultaneously, mechatro controller outputs proportional valve P/V
command current to travel priority solenoid Normal recirculation position
proportional valve (PSV-C) and arm 2 (PSV- SM1392
A) solenoid inverse proportional valve GRAPHIC_ID Figure 18
according to signal processing, and this
proportional valve outputs secondary
pressure, which acts on PTb port and PAa2
port of C/V(2).
2. PTb port pressure switches the travel priority
spool, and the PAa2 port pressure switches
the arm 2 spool to the forced recirculation
position.

Swing / Arm In, Swing Priority Main Circuit

1. Purpose:
Stable swing speed.
2. Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
3. Operation:
1. The swing main circuit operates with P2
pump flow. But on P2 pump circuit side, the
flow goes to the swing circuit and arm circuit
simultaneously because the swing circuit and
arm circuit are parallel. Then since the return
oil from arm cylinder rod (R) side is restricted
in the arm 2 spool because the arm 2 spool is
switched to forced recirculation position, the
pressure of return oil is raised, causing the
rise of circuit pressure on the arm cylinder
head (H) side.
2. At the same time meter-in of arm 2 spool
closes and arm in conflux is therefore
cancelled, and delivery oil from P2 pump and
P1 pump are combined in the parallel circuit
on P2 pump side because the travel straight
spool was switched.
The conflux oil of P1 and P2 delivery oil in
high pressure flows in swing side taking
priority over all others.
This operation is called SWING PRIORITY
CIRCUIT.

2-32 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Combined Circuit: Swing / Arm In Operation, Swing Priority Function

18

1 8

11

15 14

19
12

9
17

10
5

16
16

13
GRAPHIC_1D Figure 19

5-10680 NA Issued 02-2008 Bur 2-33

 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM
PRESSURE DRAINING (RELEASING) CIRCUIT
This section describes the following operations.
Pressure releasing pilot circuit
Pressure releasing main circuit
Pressure Releasing Pilot Circuit
1. Purpose:
To release the pressure in main circuit for piping
repair works.
2. Principle:
After the mode is switched to PRESSURE
RELIEF MODE with switch on gauge cluster,
mechatro controller outputs the following
commands.
1. Minimum tilting command value to pump
proportional valve (PSV-P1, PSV-P2).
2. Output PRESSURE RELIEF CONTROL
SPEED COMMAND VALUE at engine
governor motor (M2).
3. Stand-by command value to P1, P2
unloading proportional valves.
How to switch to PRESSURE RELEASE
MODE
1. Select the service diagnosis mode 1.
(Keeping pressing of the BUZZER STOP
SWITCH [ ] on gauge cluster, turn the
starter key ON.)
2. Select the service Adjustment Mode 1.
(Under the condition that Screen No.1 of
SERVICE DIAGNOSIS MODE 1 is
indicated, keeping pressing of the
BUZZER STOP SWITCH, press the
SELECT switch [ ] 3 times.
When LANGUAGE/LOGO, ADJUSTING
MODE 1 and PRESET BY FACTORY are
displayed, press [s] or [t] switch, and
highlight ADJUSTING MODE 1, and then
press SELECT Switch again.)
3. When ADJUSTING MODE 1 screen is
displayed, press [s] or [t] switch, several
times and DRAIN HYD. PRESS. OFF
screen appears.
4. Press SELECT Switch and highlight OFF,
and press [s] switch to change to DRAIN
HYD. PRESS. ON, and then press
SELECT Switch again.
3. Operation:
1. Pump proportional valve reduces the pump
flow rate to the minimum.
2-34
2. Unloading proportional valves (PSV-D, PSV-
B) output second ary pre ssure and the
secondary pressure flows in PCb, PCa ports
of C/V(2) and switches the P1, P2 unloading
valves to OPEN position.
Pressure Releasing Main Circuit
1. Operation:
CAUTION
Make sure to place bucket on the ground before
performing the hydraulic pressure release.
When the operating lever is shifted to neutral
during engine running, DRAINING HYD. PRESS.
is displayed on the gauge cluster while the mode
switch is changed to pressure relieving mode.
In this time the intermittent buzzer sounds
continuously. When right and left operating
levers are operated 4 or 5 times to their full
stroke, pressure is relieved.
After draining pressure is completed, turn off the
starter key and buzzer sound stops. If the pump
pressure is determined to be more than 1 MPa
(145 psi) by the output value of the high pressure
sensor (SE 22, SE 23) (or the high pressure
sensors are broken) FAIL DRAIN HYD. PRESS
is displayed and the buzzer sounds continuously.
In that case, also the buzzer is not stopped
unless the engine key is turned to OFF. Repeat
the pressure releasing procedure once again.
2. Hydraulics:
If the unloading valves are turned to the pressure
release position, the oil delivered by each pump
is unloaded to the tank passage. If the spools are
switched by pilot operation, the remaining
pressure from the actuators may be relieved to
the tank circuit, i.e. the main circuit pressure may
be released.
Issued 02-2008 Bur 5-10680 NA
 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM CHAPTER 2 - HYDRAULIC SYSTEM

Pressure Draining (Releasing ) Circuit: At Pressure Release Mode.

18

1 8

11

14
15

19
12

9
17

10
5

16
16

13
GRAPHIC_1D Figure 20
5-10680 NA Issued 02-2008 Bur 2-35
 SECTION 2 - SYSTEMS
CHAPTER 2 - HYDRAULIC SYSTEM

NOTES

2-36 Issued 02-2008 Bur 5-10680 NA

 SECTION 2 - SYSTEMS

CHAPTER 3

E175B
EXCAVATOR

ELECTRICAL SYSTEM

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

3-II Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS

CHAPTER 3
ELECTRICAL SYSTEM
TABLE OF CONTENTS

ELECTRICAL SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Electrical System (Overall System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cab Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cluster Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cluster Gauge Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Mechatro Controller and Fuses & Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Fuse & Relay box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
C - Batteries, Batteries Relay, Fuses Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
D – Hydraulic System Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
E – Engine Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
F – Electrical Components (Lights, Horns) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
ELECTRICAL SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Electrical System Diagram Reading Key (No. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Electrical System Diagram (No. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Electrical System Diagram Reading Key (No. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Electrical System Diagram (N0. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Electrical System Diagram Reading Key (N0. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Electrical System Diagram (No. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Electrical System Diaram Reading Key (No. 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Electrical System Diagram (No. 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Electrical System Diagram Reading Key (No. 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Electrical System Diagram (No. 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Cluster Guage Wiring Harness Assemby Reading Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Cluster Gauge Wiring Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Platform Wirng Harness Assembly Reading Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Platform Wiring Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Upper Frame Wiring Harness Assembly Reading Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Upper Frame Wiring Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Engine Wiring Harness (KSB and Stop) Reading Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Engine Wiring Harness (KSB and Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

NA Issued 10-2007 Bur 3-1

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

NOTES

3-2 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
ELECTRICAL SYSTEM MAIN COMPONENTS
ELECTRICAL SYSTEM (OVERALL SYSTEM)

2
6

3 4
SM1051
GRAPHIC_1D Figure 1

A. CAB CONTROL
B. MECHATRO CONTROLLER AND FUSE & RELAY BOX
C. BATTERIES, BATTERIES RELAY, FUSE LINK
D. HYDRAULIC SYSTEM ELECTRICAL COMPONENTS
E. ENGINE ELECTRICAL COMPONENTS
F. LIGHT, HORN, ETC.

NA Issued 10-2007 Bur 3-3

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
CAB CONTROL

Electrical Components

10 1

2
16

4
14

5
13

12 6

11 7

15
9

17

SM1252

GRAPHIC_1D Figure 2
1. CLUSTER GAUGE 10. HOUR METER
2. POWER BOOST SWITCH 11. CLIMATE CONTROLS PANEL
3. STARTER SWITCH 12. QUICK COUPLING SWITCH (OPT.)
4. ENGINE SPEED THROTTLE 13. TUNER
5. WORK LIGHTS SWITCH 14. CAB WORK LIGHTS SWITCH (OPT.)
6. SINGLE/DOUBLE FLOW SWITCH 15. PARKING BRAKE RELEASE SWITCH
7. HEAVY LIFT SWITCH (OPT.) 16. HORN SWITCH
8. LOAD MOMENTUM SWITCH (OPT.) 17. KPSS SWITCH
9. CIGARETTE LIGHTER

3-4 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
CLUSTER GAUGE

SM0003

GRAPHIC_1D Figure 3

1. COOLANT TEMPERATURE INDICATOR 7. WINDSHIELD WASHER BUTTON

2. FUEL LEVEL INDICATOR 8. WIPER BUTTON
3. SCREEN CHANGE BUTTON 9. BUZZER CUT-OFF BUTTON
4. SELECT BUTTON 10. TRAVEL SPEED BUTTON
5. AUTO-IDLE BUTTON 11. DISPLAY
6. WORK MODE BUTTON

NA Issued 10-2007 Bur 3-5

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
Cluster Gauge Wiring Harness

10

12
13
14
VIEW I
15
6 7 8 16

4 17
3 19
10
1 a-a
2 20
9

b-b
DETAIL a-a
c-c

11
I 2 3 4 5 6 7

1 E

8
8

W Br

18
VIEW E
DETAIL c-c
DETAIL b-b SM0098

GRAPHIC_1D Figure 4

1. STARTER SWITCH (SW-1) 11. WIPER MOTOR (M-3)

2. ENGINE SPEED THROTTLE (SE-16) 12. 12 V SOCKET (E-23)
3. WORK LIGHT SWITCH (SW-55) 13. SPEAKER RIGHT (E-9)
4. SINGLE/DOUBLE FLOW SWITCH (SW-15) 14. CONNECTOR FOR CAB WORK LIGHT (SW-26)
5. “HEAVY LIFT” SWITCH (SW-35) (OPT.) 15. CONNECTOR FOR ROOM LIGHT (L-5)
6. OVER LOAD ALARM SELECT SWITCH (SW-12) (OPT.) 16. CONNECTOR FOR WIPER INTERLOCK SWITCH (SW-19)
7. (OPT.) 17. SPEAKER LEFT (E-8)
8. CIGARETTE LIGHTER (E-14) 18. HOUR METER (E-3)
9. CLUSTER GAUGE (C-2) 19. CONNECTOR WITH “A” LABEL (CN-5F)
10. STARTER SWITCH (GND) (SW-1) 20. CONNECTOR WITH “B” LABEL (CN-6F)

3-6 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
MECHATRO CONTROLLER AND FUSES & RELAY BOX

SM1253

GRAPHIC_1D Figure 5

1. MECHATRO CONTROLLER UNIT (C-1)

2. FUSE & RELAY BOX (E-1)
3. DC-DC CONVERTER (E-22)

NA Issued 10-2007 Bur 3-7

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
FUSE & RELAY BOX

Fuses

SM0008

GRAPHIC_1D Figure 6

FUSES BOX FUSES BOX

FUSE No. PROTECTED CIRCUIT Rating(Amps) FUSE No. PROTECTED CIRCUIT Rating(Amps)
FUSE 1 Cab Work Light 20 FUSE 19 Air Conditioner 5
FUSE 2 Cab Work Light 20 FUSE 20 Work Light 20
FUSE 3 Monitor 5 FUSE 21 DC-DC Converter 10
FUSE 4 Wiper , Washer 20 FUSE 22 Opt.8 (Bucket Control) 5
FUSE 5 Option 1 20 FUSE 23 Opt.8 (Roof Wiper) 15
FUSE 6 Option 3 20 FUSE 24 Option 20
FUSE 7 Air Conditioner 15 FUSE 25 Safety Look Lever 10
FUSE 8 Air Conditioner 5 FUSE 26 Mechatro Controller 5
FUSE 9 Opt. (Hand Control) 5 FUSE 27 Mechatro Controller 20
FUSE 10 Relay, Hour Meter 5 FUSE 28 Engine Controller (ECU) 15
FUSE 11 Cigarette Lighter 10 FUSE 29 Engine Controller (ECU) 15
FUSE 12 Horn, Horn Relay 10 FUSE 30 Monitor (Back Up) 5
FUSE 13 Radio 10 FUSE 31 Fuel Supply Pump 15
FUSE 14 Starter Key Switch 20 FUSE 32 Mechatro Contr. (Back Up) 5
FUSE 15 Room Lamp, Tuner 5 FUSE 33 Spare 5
FUSE 16 Opt.2 (Auto Grease) 10 FUSE 34 Spare 10
FUSE 17 Option 4 10 FUSE 35 Spare 15
FUSE 18 Solenoid Valve 10 FUSE 36 Spare 20

3-8 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
Relays

SM0009

GRAPHIC_1D Figure 7

1. WINDOW WASHER MOTOR RELAY (RLY 32) 16. WIPER MOTOR RELAY (RLY 29)
2. WIPER MOTOR REVERSING RELAY (RLY 30) 17. DISCHARGE PRESSURE RELAY (RLY 17)
3. CAB WORKING LIGHT RELAY (RLY 9) 18. GREASE (FORWARD) RELAY (RLY 27)
4. CAB WORKING LIGHT RELAY (RLY 11) 19. GREASE (REVERSE) RELAY (RLY 35)
5. WORKING LIGHT RELAY (RLY 6) 20. SAFETY RELAY (RLY 4)
6. ALTERNATOR RELAY (RLY 28) 21. BUCKET CONTROL RELAY (RLY 10)
7. AUTO-IDLE STOP RELAY (RLY 24) 22. TRAVEL ALARM RELAY (RLY 8)
8. LEVER LOOK RELAY (RLY 26) 23. REVOLUTION RIGHT RELAY (RLY 12)
9. AUTO-IDLE STOP RELAY (RLY 23) 24. NIBBLER OPEN RELAY (RLY 15)
10. ENGINE EMERGENCY STOP RELAY (RLY 25) 25. REVOLUTION LEFT RELAY (RLY 13)
11. HORN RELAY (RLY 5) 26. RESERVE RELAY (RE-RLY 5)
12. NIBBLER CLOSE RELAY (RLY 16) 27. RESERVE RELAY (RE-RLY 6)
13. RESERVE RELAY (RE-RLY 1) 28. RESERVE RELAY (RE-RLY 4)
14. RESERVE RELAY (RE-RLY 2) 29. RESERVE RELAY (RE-RLY 3)
15. WIPER MOTOR RELAY (RLY 31)

NA Issued 10-2007 Bur 3-9

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
C - BATTERIES, BATTERIES RELAY, FUSES LINK

7 2

1
5

SM1254

GRAPHIC_1D Figure 8

1. BATTERY RELAY (R-1) 5. BATTERIES (E-12)

2. FUSE LINK 1, 2, 3, 4 (E-25) 6. PRE-HEATER RELAY (R-3)
3. STARTER MOTOR RELAY (R-2) 7. FUSE LINK 5 (E-26)
4. FUEL FILTER HEATER RELAY (R-40)

3-10 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

Fuses located into radiators compartment

Fuse No. Protected circuit Value (A)
FUSE 1 Fuses powering (1 – 6) 60
FUSE 2 Fuses powering (17 - 32) 60
FUSE 3 Alternator 100
FUSE 4 Starter relay, fuel heater filter relay 60
FUSE 5 Fuses powering (10 - 15) 60

NA Issued 10-2007 Bur 3-11

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
D – HYDRAULIC SYSTEM ELECTRICAL COMPONENTS

14 4 26 27 3

28
15

1 2

30 13
29

16

17

18

19

12 11 6 7 8 9

5 10

25 24 23 22 21 20
SM1255

GRAPHIC_1D Figure 9

1. EXTRA VALVE SELECTOR PRESS SENSOR (SE-29) (OPT.) 16. P1 OPT. SENSOR VALVE (SE-20)
2. POMP P2 PROPORTIONAL SOLENOID VALVE (PSV-P2) 17. TRAVEL RIGHT SENSOR (SE-9)
3. PUMP P1 PROPORTIONAL SOLENOID VALVE (PSV-P1) 18. TRAVEL LEFT SENSOR (SE-10)
4. SWING SENSOR (SE-5) 19. P2 OPT. SENSOR VALVE (SE-11)
5. LEVER LOCK SOLENOID VALVE (SV-4) 20. BUCKET DIGGING SENSOR (SE-1)
6. POWER BOOST SOLENOID VALVE (SV-2) 21. BUCKET DUMP SENSOR (SE-2)
7. P2 UNLOAD PROPORTIONAL SOLENOID VALVE (PSV-B) 22. BOOM RAISING SENSOR (SE-3)
8. TRAVEL PRIORITY PROP. SOLENOID VALVE (PSV-C) 23. BOOM LOWERING SENSOR (SE-4)
9. P1 UNLOAD PROPORTIONAL SOLENOID VALVE (PSV-D) 24. ARM IN SENSOR (SE-7)
10. ARM 2 INVERSE PROP. SOLENOID VALVE (PSV-A) 25. ARM OUT SENSOR (SE-8)
11. TWO SPEED SELECT SOLENOID VALVE (SV-3) 26. PUMP P1 SENSOR (SE-22)
12. SWING PARKING BRAKE SOLENOID VALVE (SV-1) 27. PUMP P2 SENSOR (SE-23)
13. SHORT-CIRCUIT PROPORTIONAL SOLENOID VALVE (PSV-R) 28. RELIEF ADJUSTMENT PROP. SOLENOID VALVE 1 (PSV-E)
14. EXTRA DIS-PRESS SOLENOID VALVE (SV-11) (OPT) 29. RELIEF ADJUSTMENT PROP. SOLENOID VALVE 2 (PSV-I)
15. EXTRA DIS-PRESS SENSOR (SE-28) (OPT) 30. SELECTOR E&N SOLENOID VALVE (SV-13)

3-12 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
E – ENGINE ELECTRICAL COMPONENTS

15

18

17
1

19

13

4
14

16
12
8
11
3

10 9 2 6-7 5 SM1257

GRAPHIC_1D Figure 10

1. AIR FILTER RESTRICTION SWITCH (SW-8) 11. AIR COMPRESSOR (E-21)

2. ENGINE COOLANT LEVEL SWITCH (SW-24) 12. COLD START AIR HEATER (E-12)
3. STEPPING MOTOR (M-2) 13. FUEL FILTER HEATER (E-20)
4. STARTER MOTOR ASSEMBLY (M-1) 14. ENGINE STOP SOLENOID (SV-15)
5. THERMO-SWITCH FOR HEATER (SW-52) 15. FUEL SENSOR (SE-15)
6. COOLANT THERMO SENSOR (SE-14) 16. ENGINE OIL LEVEL SENSOR (SE-12)
7. ENGINE COOLANT TEMPERATURE SWITCH (SW-6) 17. WATER SEPARATOR RESTRICTION SWITCH (SW-36)
8. ALTERNATOR ASSEMBLY (E-2) 18. WATER SEPARATOR HEATER (E19)
9. ENGINE REVOLUTION SENSOR (SE-13) 19. FUEL FILTER HEATER SWITCH (E-20)
10. ENGINE OIL PRESSURE SWITCH (SW-7)

NA Issued 10-2007 Bur 3-13

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
F – ELECTRICAL COMPONENTS (LIGHTS, HORNS)

4 5

SM1258

GRAPHIC_1D Figure 11

1. FRAME WORKING LIGHT (L-2 4. HORN HIGH (E5)

2. BOOM WORKING LIGHT LEFT (L-1) 5. HORN LOW (E6)
3. BOOM WORKING LIGHT RIGHT (L-6) 6. ENGINE ROOM LIGHT (L-11)

3-14 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
NOTES

NA Issued 10-2007 Bur 3-15

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM
ELECTRICAL SYSTEM DIAGRAMS
ELECTRICAL SYSTEM DIAGRAM READING KEY (NO. 1)

Item Description Code

1 Fuse box E-1
2 Key starter switch SW - 1
3 Fuse link box E - 25
4 Auto-Idle stop relay 1 R - 23
5 Starter motor M-1
6 Starter relay R-2
7 Safety relay R-4
8 Alternator relay R - 28
9 Battery relay R-1
10 Fuse link E - 26
11 Auto-Idle stop relay 2 R - 24
12 Alternator E-2
13 Reserve relay RY - 29
14 Battery E - 12
15 Engine emergency stop relay R - 25
16 Mega fuse E - 24
17 Fuel filter heater relay R - 40
18 Grid heater relay R-3
19 Water separator heater E - 19
20 Fuel filter heater E - 20
21 Grid heater E - 21
22 Engine stop solenoid SV - 15
23 Diode D - 21
24 Diode D - 30
25 Diode D - 20
26 Diode D - 19
27 Diode D - 13
28 Diode D - 14
29 Diode D-9
30 Diode D - 12
31 Diode D - 11
32 Diode D -18
33 Hour meter E-3
34 KSB solenoid ---
35 Mechatro Controller C-1

3-16 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

Electrical System Diagram (No. 1)

17
1

20

31

26
16 18
21

10

25

14
3

9 15 22 35

4
11 23
34
29
30
2 24

12

13

6
7

32
33
28

27 8
GRAPHIC_1D Figure 12

5-10690 NA Issued 02-2008 Bur 3-17

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (NO. 2)

ITEM DESCRIPTION CODE

35 Mechatro Controller C-1
36 Cluster gauge C-2
37 Water separator restriction switch SW - 36
38 Accel potentio pressure sensor SE -16
39 Bucket digging sensor SE - 1
40 Bucket dump sensor SE - 2
41 Boom raising sensor SE - 3
42 Boom lowering sensor SE - 4
43 Arm in sensor SE - 7
44 Arm out sensor SE - 8
45 Swing sensor SE - 5
46 Travel right sensor SE - 9
47 Travel left sensor SE - 10
48 Pump P1 sensor SE - 22
49 Pump P2 sensor SE - 23
50 P1 option sensor (2PB) SE - 20
51 P2 option sensor (Hammer) SE - 11
52 Engine coolant temperature switch SW - 6
53 Engine coolant thermo sensor SE - 14
54 Fuel level sensor SE - 15
55 Engine speed sensor SE - 55
56 Power boost switch right SW - 22
57 Power boost switch left (opt.) SW - 23
58 Swing parking release switch SW - 4
59 Swing parking brake solenoid valve SV - 1
60 Two-speed select solenoid valve SV - 3
61 Power boost solenoid valve SV - 2
62 P2 Unload proportional solenoid valve PSV - B
63 Travel priority proportional solenoid valve PSV - C
64 P1 Unload proportional solenoid valve PSV - D
65 Arm two-speed inverse proportional solenoid valve PSV - A
66 Pump P1 proportional solenoid valve PSV - P1
67 Pump P2 proportional solenoid valve PSV - P2
68 OPT. Relief adjustment proportional solenoid valve 1 PSV - E
69 OPT. Relief adjustment proportional solenoid valve 2 PSV - I
70 Short-circuit proportional solenoid valve PSV - R
71 Short-circuit proportional solenoid valve M-2

3-18 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM (N0. 2)

59

60
61
38 62
39
63
40
64
41
65
42
66
43

44 67

45

46

47

48

49

50

51

52
36 53

54 68

55 69

70

71
56

SM0094
GRAPHIC_1D Figure 13

5-10690 NA Issued 02-2008 Bur 3-19

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (N0. 3)

ITEM DESCRIPTION CODE

35 Mechatro Controller C-1
72 Engine oil pressure switch SW - 7
73 Air filter restriction switch SW - 8
74 Engine oil level sensor SE -12
75 Engine coolant level switch SW - 24
76 Conflux/single select switch SW - 15
77 Lever lock switch SW - 11
78 Lever lock relay R- 26
79 Operating lever lock solenoid valve SV - 4
80 Heavy lift switch SW - 35
81 Extra dis. Pressure relay opt. R - 17
82 Extra dis. Pressure solenoid valve opt. SV - 11
83 Extra dis. Pressure sensor opt. SE - 28
84 Prevent spark relay R - 31
85 Wiper motor relay R - 29
86 Wiper motor reversing relay R - 30
87 Window washer motor relay R - 32
88 Wiper motor M-3
89 Washer motor M-4
90 Wiper interlock switch SW - 19
91 Selector detect sensor opt. SE - 29
92 Selector solenoid opt. SV - 13
93 Air conditioner ampl. C-4
94 Receiver drier E - 10
95 Air compressor clutch E - 11
96 Cigarette lighter E - 14
97 Room light L-5
98 Horn relay R-5
99 Horn high E-5
100 Horn low E-6
101 Horn switch right opt. SW - 5
102 Horn switch left opt. SW - 10

3-20 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM (NO. 3)

93
72
94 95

73
82
74 81

83
75

96

76 88

84 85
97

86

78 79
77
89
87

80 90

98
99
100
91 101
102

92

SM1259

GRAPHIC_1D Figure 14

5-10690 NA Issued 02-2008 Bur 3-21

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIARAM READING KEY (NO. 4)

ITEM DESCRIPTION CODE

35 Mechatro Controller C-1
103 Revolution left nibbler relay R - 13
104 Revolution right nibbler relay R - 12
105 Diode D - 16
106 Diode D - 17
107 Revolution right nibbler switch SW - 33
108 Revolution left nibbler switch SW - 34
109 Revolution right nibbler solenoid valve SV - 6
110 Revolution left nibbler solenoid valve SV - 7
111 Pressure sensor boom head (for overload alarm) SE - 26
112 Overload alarm select switch SW - 12
113 Working light relay R-6
114 Working light switch SW - 55
115 Boom working light right L-6
116 Boom working light left L-1
117 Frame working light L-2
118 Engine room light switch SW - 16
119 Engine room light L - 11
120 Fuel supply pump (automatic fuel stop) M - 11
121 Auto grease motor opt. M-8
122 Fleet link opt. -
123 Antenna GPS -
124 Antenna GSM -

3-22 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM (NO. 4)

113
116

112 117

114

111

118 119

109
104 107
120
105

106
121
110
108
103

123 124

GRAPHIC_1D Figure 15

5-10690 NA Issued 02-2008 Bur 3-23

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM READING KEY (NO. 5)

ITEM DESCRIPTION CODE

35 Mechatro Controller C-1
125 12 V Socket E - 23
126 DC – DC converter E - 22
127 Tuner E-7
128 Antenna -
129 Speaker left E-8
130 Speaker right E-9
131 Quick coupler operation solenoid valve SV - 14
132 Quick coupler operation switch SW - 64
133 Diode D - 22
134 Thermo switch for heater SW - 52
135 Seat heater opt. E - 26
136 Cab working light relay 1 R-9
137 Cab working light relay 2 R - 11
138 Cab working light switch SW - 26
139 Cab working light front 1 L-7
140 Cab working light front 2 L-8
141 Cab working light front 3 L - 15
142 Cab working light front 4 L - 16
143 Cab working light back 1 L - 18
144 Cab working light back 2 L - 17
145 6P Connector -
146 Diode D - 23

3-24 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

ELECTRICAL SYSTEM DIAGRAM (NO. 5)

135

134

131
136
139

146 140
138

141
133
132
142

137 143

144

127
128

129
126

130

145

125

GRAPHIC_1D Figure 16

5-10690 NA Issued 02-2008 Bur 3-25

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

WIRING HARNESS
CLUSTER GUAGE WIRING HARNESS ASSEMBY READING KEY ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable

are from “X” side
SM0199

GRAPHIC_ID Figure 18

GRAPHIC_1D Figure 17

3-26 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

CLUSTER GAUGE WIRING HARNESS ASSEMBLY

SM0099
GRAPHIC_1D Figure 19

5-10690 NA Issued 02-2008 Bur 3-27

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

PLATFORM WIRNG HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable

are from “X” side
SM0199

GRAPHIC_ID Figure 21

3-28 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

PLATFORM WIRING HARNESS ASSEMBLY

SM0252

GRAPHIC_ID Figure 22

5-10690 NA Issued 02-2008 Bur 3-29

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

UPPER FRAME WIRING HARNESS ASSEMBLY READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable

are from “X” side
SM0199

GRAPHIC_ID Figure 24

SM0255

GRAPHIC_1D Figure 23

3-30 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

UPPER FRAME WIRING HARNESS ASSEMBLY

SM0254

GRAPHIC_1D Figure 25

5-10690 NA Issued 02-2008 Bur 3-31

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

ENGINE WIRING HARNESS (KSB AND STOP) READING KEY

ASSEMBLY CABLES ON THE CONNECTORS

- The connector view on the cable

are from “X” side
SM0199
SM0257

GRAPHIC_ID Figure 28
GRAPHIC_1D Figure 26

WIRING DIAGRAM

1 2

SM0258
GRAPHIC_1D Figure 27

1 To engine coolant temperature sensor (SE-14)

2 To opetator’s compartment wiring assembly, connector [CN-2M]
3 To KSB solenoid
4 To engine stop sloenoid (SV-15)

3-32 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM CHAPTER 3 - ELECTRICAL SYSTEM

ENGINE WIRING HARNESS (KSB AND STOP)

SM0256

GRAPHIC_1D

5-10690 NA Issued 02-2008 Bur 3-33

 SECTION 2 - SYSTEMS
CHAPTER 3 - ELECTRICAL SYSTEM

NOTES

3-34 Issued 02-2008 Bur 5-10690 NA

 SECTION 2 - SYSTEMS

CHAPTER 4

E175B
EXCAVATOR

COMPONENTS SYSTEM

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

4-II Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS

CHAPTER 4
COMPONENTS SYSTEM
TABLE OF CONTENTS

HYDRAULIC PUMP ASSEMBLY OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

General View and Hydraulic Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Gear Pump (For Pilot) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
PTO Gear Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Rotary Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Swash Plate Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Valve Block Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
PTO Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Positive Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Adjusting The Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Adjusting The Maximum Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Adjusting The Minimum Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Adjusting The Flow Control Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Causes Of Fault Resulting From Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Control Curve Of Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
PILOT VALVE (ATT) OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
PILOT VALVE (TRAVEL) OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Outside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
CONTROL VALVE OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Control Valve Outside View (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Control Valve Outside View (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Control Valve Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Control Valve (1/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Control Valve (2/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Control Valve (3/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Control Valve (4/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Control Valve (5/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Control Valve (6/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Main Relief Valve (601) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Over Load Relief Valve (602, 603, 606) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Arm 2 Spool (308) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Lock Valve Selector (211) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Bypass Cut Valve (605) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

NA Issued 10-2007 Bur 4-1

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

Swing Shuttle Valve Cover (204) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
In Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
Actuation In Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Left Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Actuation In Bucket Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51
Swing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55
Spool Actuation For Operation In Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56
Lock Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57
Bypass Cut Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
Boost Check Valve, Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61
Emergency Manual Valve For Lowering Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63
Emergency Manual Valve For Lowering Attachment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64
SWING DEVICE OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Swing Device General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68
Swing Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-71
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-71
Valve Casing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72
Operation of Anti-Cavitation Check Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72
Operation of Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72
Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75
Swing Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76
TRAVEL DEVICE OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-77
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78
Planetary Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78
Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-79
Costruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80
Track Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80
Hydraulic Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-82
Motor Drain Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-83
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-83
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84
SWIVEL JOINT OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-85
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-85
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-86
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-87
CYLINDERS OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
General View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-89
Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-89
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-90
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-91

4-2 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92
Hydraulic Cylinder Construction (For Boom, Arm and Bucket Cylinders) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93
Operation of Cylinder with Cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

NA Issued 10-2007 Bur 4-3

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

4-4 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
HYDRAULIC PUMP ASSEMBLY OUTLINE
GENERAL VIEW AND HYDRAULIC PORTS

5 Dr2 a3

A3

B3
Dr1
Psv1
a1 a2 Dr1

a5 A2

a4 A1

Dr1 PH1 PH2

Psv2

Dr1 B1

2 4 4 2
a4 Psv1 Psv2 a5
a5
Psv2 Psv1

1
A3
Dr1 (Dr1) Dr2
Dr1
a3

B1
B1 Dr3

B3

Dr1 PH2
3
(Dr1) a1 a2 Dr1

SM1013

GRAPHIC_1D Figure 1
1 - MAIN PUMP ASSY PSV2 - SERVO ASSIST PORT G 1/4-13
2 - REGULATOR ASSY (QTY 2) PH1 - PRESSURE SENSOR PORT G 3/8-17
3 - GEAR PUMP ASSY (FOR PILOT) PH2 - PRESSURE SENSOR PORT G 3/8-17
4 - SOLENOID PROPORTIONAL REDUCING VALVE (QTY 2) A1 - GAUGE PORT G 1/4-15
5 - PTO UNIT A2 - GAUGE PORT G 1/4-15
A1 - DELIVERY PORT SAE 6000 PSI 3/4 IN. A3 - GAUGE PORT G 1/4-14
A2 - DELIVERY PORT SAE 6000 PSI 3/4 IN. A4 - GAUGE PORT G 1/4-13
B1 - SUCTION PORT SAE 2500 PSI 2 1/2 IN. A5 - GAUGE PORT G 1/4-13
DR1 - DRAIN PORT G 1/2-19 A3 - GEAR PUMP DELIVERY PORT G 1/2-19
DR2 -DRAIN PORT G3/4-20 B3 - GEAR PUMP SUCTION PORT G 3/4-20.5
PSV1 - SERVO ASSIST PORT G 1/4-13 DR3 -GEAR PUMP DRAIN PORT G 3/8-15

NA Issued 10-2007 Bur 4-5

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
HYDRAULIC CIRCUIT DIAGRAM

4 4

2 2

SM1014

GRAPHIC_1D Figure 2

1 - MAIN PUMP ASSY

2 - REGULATOR ASSY (QTY 2)
3 - GEAR PUMP ASSY (FOR PILOT)
4 - SOLENOID PROPORTIONAL REDUCING VALVE (Q.TY 2)

4-6 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
SPECIFICATIONS

Item Main pump Gear pump for pilot

Pump K7V63DTP112R-V ZX10LPRZ2-07G
Variable displacement
Fixed displacement
Type plunger pump: regulator
type gear pump
attached type
Max. displacement capacity cm3 65.2 x 2 10
rpm
Revolution Rated (Clockwise seen from 2200 ¨
shaft end)
Rated 34.3
Pressure MPa 5.0
ATT boost 37.8
Max. flow L/min 143 x 2 at 7.8 MPa 22
Max. input Power
kW 78.3 3.4
(at 2000 rpm)
Max. input torque
Nm 340 14.7
(at 1200 rpm)
Model KR76-0E13-V
Electric flow control, positive flow control, total
Control function power control at emergency mode and power shift
Regulator
control
With solenoid proportional reducing valve
Others (KDRDE5K-31/30C50-123)
Mass kg 88

NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.

NA Issued 10-2007 Bur 4-7

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
HYDRAULIC PUMP

Main Pump
806 535 533 789 733 732 532 214 548 531 702 792 534 901 808 954 724 717 723 402 151 981 983
953 152

490 211
255
261
256
734
774 263
111
A A

127
710
406
123
415
824 251 212 271 153 468 156 157 313 124 711 116 312 886 314 401 141 272 113
727
05 04
Nm
401 M16 240
402 M16 240
406 M6 12
415 M8 29
468 G 1/2 110
490 NPTF1/16 8.8
A-A
531,532 M20X1.5 240
533 M30 220
806 M12 60
808 M16 130

GRAPHIC_1D Figure 3

111) DRIVE SHAFT (F)
113) DRIVE SHAFT (R)
116) GEAR #1
123) ROLLER BEARING (Q.TY 2)
124) NEEDLE BEARING (QTY 2)
127) BEARING SPACER (QTY 2)
141) CYLINDER BLOCK (QTY 2)
151) PISTON (QTY 18)
152) SHOE (QTY 18)
153) RETAINER PLATE (QTY 2)
156) SPHERICAL BUSHING (QTY 2)
157) CYLINDER SPRING (QTY 12)
211) SHOE PLATE (QTY 2)
212) SWASH PLATE (QTY 2)
214) TILTING BUSHING (QTY 2)
251) SWASH PLATE SUPPORT (QTY 2)
255) LOCK PIN (QTY 2)
256) SET SPRING (QTY 2)
261) SEAL COVER (F)
263) SEAL COVER (R)
271) PUMP CASING (F)
272) PUMP CASING (R)
312) VALVE BLOCK
313) VALVE PLATE (R)
314) VALVE PLATE (L)
401) SOCKET BOLT; M16X150 (QTY 2)
402) SOCKET BOLT; M16X190 (QTY 2)
406) SOCKET BOLT; M6X16 (QTY 4)
415) SOCKET BOLT; M8X20 (QTY 4)
468) PLUG; G1/2 (QTY 4)
490) PLUG; (QTY 9)
531) TILTING PIN; (QTY 2)
532) SERVO PISTON (QTY 2)
533) PLUG (QTY 2)
534) STOPPER (L) (QTY 2)
535) STOPPER (S) (QTY 2)
548) FEED BACK PIN (QTY 2)
702) O-RING; 1B G30 (QTY 2)
710) O-RING; 1B G80
711) O-RING; G95
717) O-RING; 1B G125 (QTY 2)
723) O-RING; 1B P11 (QTY 4)
724) O-RING; 1B P8 (QTY 12)
727) O-RING; 1B P18 (QTY 4)
732) O-RING; 1B P14 (QTY 2)
733) O-RING; P28 (QTY 2)
734) O-RING; G85
774) OIL SEAL
789) BACK UP RING; P14 (QTY 2)
792) BACK UP RING; G30 (QTY 2)
806) NUT; M12 (QTY 2)
808) NUT; M16 (QTY 2)
824) SNAP RING (QTY 2)
886) SPRING PIN (QTY 4)
901) EYE BOLT M10 (QTY 2)
953) SET SCREW; M12X23 (QTY 2)
954) SET SCREW; M16X34 (QTY 2)
981) PLATE
983) PIN (QTY 2)
04) GEAR PUMP
05) PTO UNIT

4-8 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Gear Pump (For Pilot)

16 700 433

354
434

15
B3
353 435

312
14

Dr4 a3 A3

710 11 850
732 10 12
355
13 434
466
725
Nm
312 M14 x 1.5 29
433 M8 17
434 M8 17
435 M10 33
466 G 1/4 16

SM1016
GRAPHIC_1D Figure 4

10 -POPPET 434 -FLANGE SOCKET; M8×55 (QTY 2)

11 -SEAT 435 -FLANGE SOCKET; M10×35 (QTY 2)
12 -RING 466 -VP PLUG; G1/4 (QTY 2)
13 -SPRING 700 -RING
14 -ADJUST SCREW 710 -O-RING
15 -GEAR CASE 725 -O-RING (QTY 2)
16 -FRONT CASE 732 -O-RING
312 -LOCK NUT; M14×1.5 850 -LOCKING RING
353 -DRIVE GEAR A3 -GAUGE PORT; G1/4 16 NM
354 -DRIVEN GEAR A3 -DELIVERY PORT; G3/8 34 NM
355 -FILTER B3 -SUCTION PORT; G3/4 74 NM
433 -FLANGE SOCKET; M8×40 (QTY 2) DR4 -DRAIN PORT; G3/8 34 NM

NA Issued 10-2007 Bur 4-9

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
PTO Gear Case

125 468
711
118
11 262
728
117
414
126 825

128
710
10 435
12 886
826

SM0749

GRAPHIC_1D Figure 5

10 -IDLE SHAFT 414 -SOCKET BOLT; M10X20 (QTY 2)

11 -GEAR CASE 435 -FLANGE SOCKET; M10×20 (QTY 4)
12 -PIN 468 -VP PLUG: G3/4
117 -2ND GEAR 710 -O-RING
118 -3RD GEAR 711 -O-RING
125 -BALL BEARING (QTY 2) 728 -O-RING
126 -ROLLER BEARING 825 -SNAP RING
128 -BEARING SPACER (QTY 2) 826 -SNAP RING
262 -COVER 886 -PIN (QTY 2)

4-10 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
OPERATION
The pump assembly is equipped with two pumps
arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the 111
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
116
gear pump arranged on another shaft.
The pump assembly consists largely of:
1. The rotary group, the main part of the pump that
makes rotary on;
2. The swash plate group that changes the delivery
rate;
3. The valve block group that selects between oil
suction and delivery;
4. The PTO group that transmits the drive power to
the gear pump. GRAPHIC_ID Figure 6

Rotary Group
The rotary group consists of shaft (111), cylinder
block (141), piston (151), shoe (152), plate (153),
spherical bushing (156), and cylinder spring (157).
The shaft is supported by bearings (123) and (124)
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of thrust
force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed against
the shoe plate by the cylinder spring, via the retainer
plate and the spherical bushing, so that it moves
smoothly over the shoe plate. The cylinder blocks
(141) are also pressed against valve plates (313) or
(314) by the action of cylinder spring (157).

312 313
124

116
124
314
141
157
156
153
151
211

GRAPHIC_1D Figure 7
NA Issued 10-2007 Bur 4-11
 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Swash Plate Group 532
The swash plate group consists of swash plate (212),
shoe plate (211), swash plate support (251), tilting 531
bushing (214), tilting pin (531),and servo piston 214
(532). The swash plate is the cylindrical part that is
formed on the opposite side of the shoe sliding
surface and is supported by the swash plate support.
The hydraulic force controlled by the regulator flows
into the hydraulic chamber that is provided on both 211
212
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 (a). GRAPHIC_ID Figure 8

Valve Block Group

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

116
314
GRAPHIC_ID Figure 9

PTO Group
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd
gear are supported by bearings (125) and (126)
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder 126
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with respect
to the cylinder while rotating with the cylinder block. If 118
we keep an eye on a single piston, it makes a motion 125
away from the valve plate (oil suction process) in the
first 180° and a motion toward the valve plate (oil 125
delivery process) in the remaining 180°. If the swash GRAPHIC_ID Figure 10
plate is not inclined (zero tilting angle), the piston
does not stroke i.e. delivers no oil.
The shaft rotation is taken up by the 1st gear (116)
and transmitted to the 2nd gear (117) and the 3rd gear
(118), in that order, to drive the gear pump that is
linked to the 3rd gear.

4-12 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
REGULATOR
CONSTRUCTION

B-B
541 543

755

545
496
325
624 627 466
755
631 897 496 418 601
643 CL P1
415 496
731 726 543
407 924
616 545
724 801
614 755
402
875 541
656
724 708
733
611
646
651 754
652 754 658 887

GRAPHIC_1D Figure 11

325 - VALVE CASING 646 - PILOT SPRING

402 - SCREW; M6X16 (QTY 4) 651 - SLEEVE
407 - SCREW; M6X30 (QTY 4) 652 - SPOOL
415 - SCREW; M8X40 (QTY 4) 656 - COVER
418 - SCREW; M5X12 (QTY 2) 658 - PLUG
466 - PLUG; G 1/4 708 - O-RING
496 - PLUG (QTY 9) 724 - O-RING (QTY 5)
541 - SEAT (QTY 2) 726 - O-RING
543 - STOPPER 1 (QTY 2) 731 - O-RING
545 - STEEL BALL (QTY 2) 733 - O-RING
601 - CASING 754 - O-RING (QTY 2)
611 - FEEDBACK LEVER 755 - O-RING (QTY 3)
614 - CENTER PLUG 801 - NUT; M10
616 - PREVENTION PLUG 875 - PIN; Ø5X10L
624 - SPRING SEAT 887 - PIN
627 - ADJUSTING STEM 897 - PIN
631 - SLEEVE 924 - SET SCREW; M10X20
643 - PILOT PISTON

The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

NA Issued 10-2007 Bur 4-13

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
OPERATION
Q
Summary
Regulator (KR76-0E13 for E175B ) for the inline axial
piston pump (K7V for E175B) series is of electric flow
control type that regulates the tilting angle (delivery
rate) of the pump as the command current I to the
solenoid proportional reducing valve is varied. This
regulator is of positive flow control type that
increases the delivery flow Q as the command
current I increases.
If an electric current is put in by this control according
to the flow needed for the operation, the pump I SM0250
delivers at a flow rate that is only required by the GRAPHIC_ID Figure 12
pump, consequently holding down unwanted power
consumption.

Positive Flow Control

As shown in the figure on the right, the regulator
regulates the delivery rate of the pump by command
current I.
Flow rate increase
As the command current I rises, the secondary pressure
of solenoid proportional reducing valve increases. This
causes spool (652) to move via pilot piston (643) and
stops where the hydraulic pressure pushing the spool
652 646
rightwards balances with the action of pilot spring (646).
If the spool (652) moves, port CL opens to the tank port.
This causes the pressure of the large diameter part of
servo piston (532) to go away. This causes the servo 643 611
CL
piston (532) to the left by delivery pressure P1 of the
small diameter part, resulting in an increase in the tilting 651
angle. Feedback lever (611) is linked with the servo A
piston and sleeve (651). As the servo piston moves to
532
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 P1
the sleeve to the right. The result is that the opening of
the spool sleeve begins to close gradually and the servo
piston settles down when the opening of the spool sleeve
closes completely.
Flow rate decrease
As the command current I decreases, the secondary
p r e s s u r e o f t h e s o l e n o i d p r o p o r t i o n a l va l ve
decreases. This causes the spool to move to the left. SM1018
When the spool (652) has moved, delivery pressure
P1 reaches port CL via spool and is admitted to the GRAPHIC_ID Figure 13
large diameter chamber of the servo piston. Delivery
pressure P1 is admitted to the small diameter part of
the servo piston at all times. The servo piston moves
rightward by areal difference to decrease tilting
angle. As the servo piston moves to the right, the
feedback lever rotates on point A to move the sleeve
to the left. The sleeve keeps moving till the opening
of the spool sleeve closes and settles down when the
spool sleeve closes completely.
4-14 Issued 10-2007 Bur NA
 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
ADJUSTING THE REGULATOR
The maximum flow, minimum flow and flow control
characteristics of the regulator may be controlled by
the adjust screw of the regulator.
Q
Adjusting The Maximum Flow
(See Hydraulic Pump-Construction)
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.

Adjust screw No 954

I (Pi)
No. of turns for tightening 1/4
Q
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 3.5

Adjusting The Minimum Flow

(See Hydraulic Pump-Construction)
For adjustment, loosen hex nut (808) and tighten (or
loosen) the set screw (953) on the small diameter
part of the servo piston. Tightening it increases the
flow and loosening it decreases the flow. Other
characteristics do not change the same way as the
adjustment of the maximum flow. Note that if the set I (Pi)
screw is tightened too much, the power requirement SM0996

at the maximum delivery pressure (at relieving) GRAPHIC_ID Figure 14

increases in some cases.

Adjust screw No 953

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 3.5

Adjusting The Flow Control Characteristics

(See Regulator-Construction)
For adjustment, loosen hex nut (801) and tighten
(loosen) the set screw (924). If the set screw is
tightened, the control curve moves rightwards.

Adjust screw No 924

No. of turns for tightening 1/4
Increase Pilot pressure Pi MPa 0.13
Decrease in delivery flow L/min 11.9

I (Pi)
SM0998
GRAPHIC_ID Figure 15

NA Issued 10-2007 Bur 4-15

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Causes Of Fault Resulting From Regulator
When trouble due to this regulator occurs,
disassemble and inspect it.

WHEN THE ENGINE IS OVERLOADED

Load every unit of pump, and check on pumps on the
right and left sides for possible damages. When
pumps on both sides are failed, check on them for
the following failures 1), 2). When pump on the one
side is failed, start checking from para. 3).
1. Check that the command current I of the
solenoid proportional reducing valve is normal.
2. The secondary pressure of solenoid proportional
reducing valve is high.
Check amplifier dither.
Replace solenoid proportional reducing valve.
3. Spool (652) and Sleeve (651) are stuck
Disassemble and clean.
4. Pilot piston (643) is stuck
Disassemble and clean.

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) is stuck
Disassemble and clean.
3. Spool (652) and sleeve (651) are stuck
Disassemble and clean.

NOTE: When the damage of part is severe, replace

the part with new one.

4-16 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONTROL CURVE OF PUMP

250

Q (L/min)
H Mode

200

150 Q (2200 min-1)

[2] [2] [1] [1] [2] [2] [1] [1]

100

50
min. Q (2200 min-1 )

0 5 10 15 20 25 30 35 40
Pd (MPa)
SM1022

GRAPHIC_1D Figure 16

250
Q (L/min)

S Mode

200

150
Q (2000 min-1)
[3] [3] [3] [3]

100

50
min. Q (2000 min-1 )

0 5 10 15 20 25 30 35 40
Pd (MPa)
SM1023

GRAPHIC_1D Figure 17
[1] 78 kW H mode at traveling or optional working
[2] 62 kW H mode at operating attachment
[3] 56 kW S mode at operating attachment and travelling

NA Issued 10-2007 Bur 4-17

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
PILOT VALVE (ATT) OUTLINE
GENERAL VIEW
g p g g T 49.0 (36.1)
(Port 2, 4) (Port 1, 3)

The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A

Model PV48K2004
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A

PORT 1, 3 PORT 2, 4

(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]

Secondary pressure [MPa (psi)]

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

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

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE

2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE

(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
1.17 (0.86) 1.17 (0.86)
0.98 (0.72) 0.98 (0.72)
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)

0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T

1 3 2 4

HYDRAULIC SYMBOL
SM0591

GRAPHIC_1D Figure 18

4-18 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONSTRUCTION

****312

302

501
***301

*212
213
151

211
214

216- 2 216- 1

241- 2 241- 1

201- 2
201- 1
**217

101 221

PORT 2,4 PORT 1,3

SM0592

GRAPHIC_1D Figure 19

Tightening torque Tightening torque

No. Parts Qty No. Parts Qty
Nm (pound-feet) Nm (pound-feet)
101 Casing 1 216-2 Spring seat 2
151 Plate 1 **217 Washer 2 (Shim) 4
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
*212 Push rod 4 ***301 Joint: M14 1 47.1 (34.7)
213 Seal 4 302 Circular plate 1
214 O-ring: 1B P20 4 ****312 Adjust nut: M14 1 68.6 (50.6)
216-1 Spring seat 2 501 Boots 1
Note: * apply grease on top section;
** secondary pressure adjusting shim
*** apply grease on rotating and sliding sections. Be careful of the assembling direction
**** apply Loctite #277

NA Issued 10-2007 Bur 4-19

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
OPERATION
1. Lever in neutral
The action of spr ing (509) (for secondar y
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201).
Therefore, spool (201) (for return) is pushed up
by spring (221) [spring seat (216)]. The output 216
ports (2, 4) connect with the T port. The result is
that the output pressure is equal to the tank 509
pressure.
221

GRAPHIC_ID 201 Figure 20

2. When the pilot lever is tilted.

When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)]
moves downward to make the port P to connect 511
with the port 2, 4, with the result that the oil of the
pilot pump flows to the port 2 ,4 to produce a
pressure.

216

201
GRAPHIC_ID Figure 21

3. Lever held
When the pressure at ports (2, 4) rises to a level
equivalent to the action of spring (509) that is set
by tilting the lever, the hydraulic pressure
balances the spring action.
When the pressure of ports (2, 4) rises above a
set value, ports (2, 4) and the P port close while
ports (2, 4) and the T port open. 509
When the pressure at ports (2, 4) falls below a
set value, ports (2, 4) and the P port open while
por ts (2, 4) and the T por t close. Thus the T PORT
secondary pressure is kept constant.
P PORT

GRAPHIC_ID Figure 22

4-20 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
4. Operation in the area where the tilting angle of
the lever is large. (varies with the model)
If the lever is inclined beyond a certain angle on
certain models, the top end of the spool contacts
the bottom of the bore of the push rod. This
keeps the output pressure connected with the P
port pressure.
Furthermore, on a model in which a spring seat
and a spring are built in the push rod, the bottom
of the bore of the push rod contacts the spring if
the lever is turned beyond a certain angle.
This causes the secondary pressure gradient to
change by the spring action. Thereafter, the
bottom of the bore of the push rod contacts the
top end of the spring seat, keeping the output
pressure connected with the P port.

NA Issued 10-2007 Bur 4-21

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
PILOT VALVE (TRAVEL) OUTLINE
OUTSIDE VIEW

Tightening torque
Port size N.m (lbf.ft) Port name Function

1 LH travel forward port

2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port

GRAPHIC_1D Figure 23

Specifications

P T

Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol SM0597
GRAPHIC_1D Figure 24

4-22 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Performance Characteristics
Secondary pressure
[MPa (psi)] Secondary pressure

2.35 + 0.15
(340 + 22)

0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram SM0598
GRAPHIC_1D Figure 25

NA Issued 10-2007 Bur 4-23

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONSTRUCTION AND OPERATION
The hydraulic remote control valve in TH6NR type is
operated with directly-operated pressure-reducing
valve. The pilot control equipment TH6NR in double
foot pedal type is made up of the actuating section
which is equipped with 2 foot suppor ts (1), 4
pressure-reducing valves (11), 4 damper system (12)
and body (6).
Every pressure-reducing valve is made up of control
spool (2), control spring (3), return spring (4) and
plunger (5).
The damper system is made up of plunger (8), orifice
(9) and return spring (10).
In stationary condition, the pedal is held in neutral
position by return spring (10).
In operation, the foot pedal pushes the plunger (5)
used for pressure-reducing valve and plunger (8)
used for dumper system.
The hydraulic oil fed into damper chamber is
r e s t r i c t e d i n t h e o r i f i c e ( 9 ) by t h e p r e s s u r e
corresponding to the operating speed. [Similarly,
when the foot pedal returns to the neutral position
with the return spring, the hydraulic oil trapped in the
damper chamber is forced out. Consequently the
retur n speed is controlled by the flow rate of
hydraulic oil led through orifice (9).]
5
3
3
11
4
7 6
2
control ports 1-3
GRAPHIC_1D
4-24
Simultaneously, the plunger (5) is pushed against
return spring (4) and control spring (3). The control
s p r i n g ( 3 ) f i r s t m ove s t h e c o n t r o l s p o o l ( 2 )
downwards, and then closes the passage between
control port and the return pipe to tank port (T). At the
same time, the control port is connected to passage
(7). When the control spool reaches to the position
the force of control spring (3) balances the pressure
of control por t (1 or 2), it star ts retaining the
condition.
The pressure of control port is proportional to the
stroke of plunger (5) and the position of pedal (1)
according to the mutual relations between the control
spool (2) and control spring (3). The closed circuit
pressure control makes propor tional control of
selector valve and high responsibility of hydraulic
pump and motor possible in relation with the
characteristics of foot pedal (1) position and control
spring (3).
8 10
12
10
9
9
P line control ports 2-4
T line
SM0599
Figure 26
Issued 10-2007 Bur NA
 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONTROL VALVE OUTLINE
CONTROL VALVE OUTSIDE VIEW (1/2)

PAa2 PAo

PBa2 PBo

ARM2 OPTION
PAc PLC2
PBa1
BUCKET ARM1

PAb
PAs
BOOM SWING
(P3) (P4)
PBr PCa
T3
TRAVEL RIGHT P2 UNLOAD

PTb PBL
TRAVEL PRIORITY TRAVEL LEFT

PBa2 PBo

VIEW A
A

CT1
T2
PCb PAL
CMR1 CMR2
PTb TRAVEL PCb
STRAIGHT P1 UNLOAD
PAr CP1
PBL Br Ar PL
PBr PAr
TRAVEL RIGHT
PBb Ab
XAb PBs LCb (HEAD) PBb
PAb Bb (ROD)
CRb BOOM
PBc PSs PBc
LCc
PAa1
PAc PCc
Ac (HEAD) Bc(ROD) BUCKET
MU1 PAa2 PAo
PBa2 LCAT2 LCAP2 PAa2
ARM2

PBp1 PBp2

SM1294

GRAPHIC_1D Figure 27

NA Issued 10-2007 Bur 4-25

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONTROL VALVE OUTSIDE VIEW (2/2)

PTb PCa

PBL

(MU2)

P2

(P6) (P5)

P1

PCb PAL

T1 CT2 T2
PCb PAL
CP2
TRAVEL
PAL LEFT PBL
AL BL
DR PAr PB1
BOOM CCb P2
PB1 UNLOAD
CONFLUNCE
As LCs PBb
XAb PBs
PBs SWING PAs
Bs CRa
Aa (HEAD) PBc PSs
Pss PAa1
ARM 1
PAa1 PBa1
LCa PAa2 PAo
OPTION Ba
PAo Ao PBo MU1
(ROD)
LCo
Bo PBp1 PBp2

SM1295

GRAPHIC_1D Figure 28

4-26 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONTROL VALVE PORTS

Port size Tightening torque Ports Description

PF3/4 150~180 Nm (111~133 pound-ft) MU1 Plugged
MU2 Plugged
Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
Ao Optional pilot port
Bo Optional pilot port
(T3) Plugged
PF1/2 98~120 Nm (72~89 pound-ft) (P3) Plugged
(P4) Plugged
(P5) Plugged
(P6) Plugged
PF3/8 69~78 Nm (51~58 pound-ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port

NA Issued 10-2007 Bur 4-27

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Control Valve Ports (Cont.)

Port size Tightening torque Ports Description

PF1/4 34~39 Nm (25~29 pound-ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
PL Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel priority pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
XAb Lowering boom for emergency
M10 49~65 Nm (36~48 pound-ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
M12 83~110 Nm (61~81 pound-ft) T1 Tank port 1
T2 Tank port 2

SPECIFICATIONS

Item Specifications

Model KMX13YD/B44061

Maximum flow rate [L/min (gal/min)] 143 (37.78) × 2

Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)

Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 60× 2 L/min (15.95× 2gal/min)]
When power boost pressure 37.8 (5480) [at 55× 2 L/min (14.5× 2 gal/min)]

Overload relief valve set pressure 39.7 (5760) [at 30 L/min (8 gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]

Overload relief valve set pressure 37.8 (5480) [at 30 L/min (8 gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]

4-28 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONSTRUCTION

Control Valve (1/6)

PAa2 PAo

275 x 4

274 x 4
213

(P3) (P4)

212

PBa2 PBo

A
B
273 x 10 273 x 10

T2

PCb PAL
J P1 unload J
Travel left
(Travel priority)
C C
PAr PB1
Boom conflux
Travel right (P2 unload)

D D
PBb PBs
Boom Swing

E PBc Pss E
PCc PAa1
Bucket Arm 1

F F
PAa2 PAo
Arm 2 MU1 Option

G PBp1 G
PBp2

H H

B A
SM1288

GRAPHIC_1D Figure 29

NA Issued 10-2007 Bur 4-29

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Control Valve (2/6)

K
155 163 101
P2

T1
T2 CT2
K
PAL PBL

PB1 PCa

PBs PAs

Pss

PAa1 PBa1

PAo PBo

PBp2

SECTION A-A
(P4)
166 161 161 155 163 164

154 567 155 163 102

(MU2) (P6)
P1
973 973

CT1

PTb PCb

973 973
PBr PAr

PAb PBb

973 973
PBc
PAc PCc

973 973
PBa2 PAa2

973 PBp1

SECTION B-B
(P3)
161 164 163 155 161 161
SM1289

GRAPHIC_1D Figure 30

4-30 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Control Valve (3/6)

202 P1 unload 201

Travel left
333 333
PCb PAL
331 331
336 339
328
327
325
325
601 MR
331 331
261 261
309 306
PL
157
161 AL
161
512 511
522 521
CP2
CMR2
551
556
561 561
561 CMR1 BL
556
522
512
307
261 264
331 PBL
325 205
328
336 SECTION C-C
331 Travel priority
333 PTb
202

201 202
333 Travel right Travel left
Par
333
PB1
331 331
339 336
327 322
AbR
325 321
603
331 331
261 261
166 305
164
Dr 511
162
521
Ar CCb
306
511 551
521 561
CP1

551 551
561 561
166 Br
164 310
166
161 567
166 (T3) 154
264 261
PBr 331
205 325
328
336
SECTION D-D 331
PCa 333
P2 unload 202
SM1290

GRAPHIC_1D Figure 31

NA Issued 10-2007 Bur 4-31

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Control Valve (4/6)
203
333 Swing
331
PBs
339 Boom 204
320 PBb 333
Pss
319 331
279 x 3 336
211 322
331 321
216 266
261 331
266 XAb 261
266 x 4 166
160
301 303
561 CRb 161
Ab As
511
556
524 524
LCb
514 LCs
551 556
561 561
521
Bs
511 Bb
161

264
264
602
PAb
205 PAs 206
BbR

160 266 SECTION E-E

221 Bucket
561
PCc
218 201
209 Arm 1 333
333 331
PAa1
331 PBc 336
339 322
320 321
319 BcR 602
AaR
602
331 331
261
261

161
304

Bc Aa

511 511
521 521
LCc LCa 551
561
551
161
561
Ac 561
CRa 556
Ba
524
514
156
PLc2 167
264 160 x 2
603 302
PAc PBa1 264
205
AcR 211
SM1291
SECTION F-F 205

GRAPHIC_1D Figure 32

4-32 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Control Valve (5/6)

201 Arm 2 Option 201

333 333
PAa2 PAo
331 331
339 337
326 330
325 329
331 604
261 AoR 331
261
161
MU1 311
308
162
515
521 Ao

551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
Ba
511

162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 BaR

605 605

PBp1 PBp2

Bo

BoR
166 604
153 SECTION H-H
SM1292

GRAPHIC_1D Figure 33

NA Issued 10-2007 Bur 4-33

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Control Valve (6/6)

T2

P1
T1
511

521
CT1

551
561

511

P2
521
(MU2) CT2

551

561

162
SECTION J-J

278 x 5

160
266

207
267
267

528
527

T1

518
T2
517

SECTION K-K SM1293

GRAPHIC_1D Figure 34

4-34 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

Tightening torque Tightening torque

No. Parts Name Qty No. Parts Name Qty
Nm (pound-ft) Nm (pound-ft)
101 Casing A 1 309 P1 unload spool 1
102 Casing B 1 310 P2 unload spool 1
25~29 (19~21) 153 Plug 1 311 Option spool 1
220~250 (162~184) 154 Plug PF3/4 2 319 Spring 2
110~130 (81~96) 155 Plug PF1/2 4 320 Spring 2
13~17 (9~12) 156 Plug PF 1/8 1 321 Spring 3
20~24 (15~18) 159 Plug PT1/4 1 322 Spring 3
7.8~9.8 160 Plug PT1/16 5 325 Spring 6
161 O-ring 13 326 Spring 1
162 O-ring 6 327 Spring 2
163 O-ring 4 328 Spring 3
164 O-ring 4 329 Spring 1
166 O-ring 7 330 Spring 1
167 O-ring 1 331 Spring seat 24
16~18
201 Cover 5 333 Spacer bolt 12
Loctite #262
202 Cover 4 336 Stopper 6
203 Cover 1 337 Stopper 1
204 Cover 1 339 Stopper 5
205 Cover 7 511 Poppet 11
206 Cover 1 512 Poppet 2
Back pressure check
207 1 514 Poppet 2
valve cover
209 Cover 1 515 Poppet 1
9.8~14 (7.2~13) 211 Lock valve selector sub 2 517 Boost check valve 1
212 Plate 1 518 Poppet 1
213 Plate 1 521 Spring 11
216 Boom lowering valve 1 522 Spring 2
218 Piston 1 524 Spring 3
130~150 (96~111) 221 Plug 1 527 Spring 1
261 O-ring 12 528 Spring 1
264 O-ring 8 130~150 (96~111) 551 Plug 12
266 O-ring 8 130~150 (96~111) 556 Plug 5
267 O-ring 2 561 O-ring 18
25~34 (18~25) 273 Socket bolt 40 567 O-ring 2
98~120 (72~89) 274 Socket bolt 4 69~78 (51~58) 601 Main relief valve 1
98~120 (72~89 275 Socket bolt 4 69~78 (51~58) 602 Over load relief valve 3
9.8~14 (7.2~13) 278 Socket bolt 5 69~78 (51~58) 603 Over load relief valve 2
Plug assy for relief valve
9.8~14 (7.2~13) 279 Socket bolt 3 69~78 (51~58) 604 2
hole
301 Boom spool sub 1 98~120 (72~89) 605 Bypass cut valve 2
302 Arm 1 spool 1 69~78 (51~58) 606 Over load relief valve 1
303 Swing spool 1 140~180 (103~133) 973 Socket bolt 9
304 Bucket spool 1
305 Boom conflux spool 1
306 Travel spool 2
307 Travel priority spool 1
308 Arm 2 spool sub 1
NA Issued 10-2007 Bur 4-35
 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Main Relief Valve (601)

123 125 562 663 163 661

124 561 611 621 614 613

521 121 103 664 652

512 541 122 104 673 671
SM0827

GRAPHIC_1D Figure 35

Main Relief Valve (Two Step Relief)

Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (pound-ft) Nm (pound-ft)

69~78 (51~58) 103 Plug; M27 1 562 Back up ring 1

104 Adjust screw 1 611 Poppet 1

121 C-ring 1 613 Stopper 1

122 Spacer 1 614 Piston 1

123 C-ring 1 621 Spring 1

124 Filter stopper 1 652 Adjust screw 1

125 Filter 1 661 O-ring 1

163 O-ring 1 663 O-ring 1

512 Plunger 1 664 O-ring 1

521 Spring 1 28~31 (21~23) 671 Lock nut; M14 1

541 Seat 1 46~52 (34~38) 673 Lock nut; M24 1

561 O-ring 1 1

4-36 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Over Load Relief Valve (602, 603, 606)

564 521 124 561 611 661

301 563 123 125 562 621 612

511 522 101 102 671

161 541 162 651
SM0828
GRAPHIC_1D Figure 36

Over Load Relief Valve

Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (pound-ft) Nm (pound-ft)

69~78 (51~58) 101 Body; M27 1 541 Seat 1

69~78 (51~58) 102 Plug; M27 1 561 O-ring 1

161 O-ring 1 562 Backup ring 1

162 O-ring 1 563 O-ring 1

123 C-ring 1 564 Backup ring 1

124 Filter stopper 1 611 Poppet 1

125 Filter 1 612 Spring seat 1

301 Piston 1 621 Spring 1

511 Plunger 1 651 Adjust screw 1

521 Spring 1 661 O-ring 1

522 Spring 1 28~31 (21~23) 671 Lock nut; M14 1

NA Issued 10-2007 Bur 4-37

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Arm 2 Spool (308)

351 371 361 340 319 308 317 340 361 371 350
SM0829

GRAPHIC_1D Figure 37

Arm 2 Spool

Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (pound-ft) Nm (pound-ft)
16~18 (33~35)
308 Spool 1 350 Plug 1
Loctite #638

16~18 (33~35)
317 Plunger 1 351 Plug 1
Loctite #638

319 Plunger 1 361 O-ring 2

340 Spring 2 371 Backup ring 2

Boom spool (301)

301 317 340 361 371 350

SM0830
GRAPHIC_1D Figure 38

Boom Spool

Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (pound-ft) Nm (pound-ft)
16~18 (12~13)
301 Spool 1 350 Plug 1
Loctite #638

317 Plunger 1 361 O-ring 1

340 Spring 1 371 Backup ring 1

4-38 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Lock Valve Selector (211)

101

171 164

201

321
PLc A B Dr

166 541 167 511 161

SM0831

GRAPHIC_1D Figure 39

Lock Valve Selector

Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (pound-ft) Nm (pound-ft)

10~14
101 Casing 1 171 Socket bolt 3
(7.4~10.3)

161 O-ring 4 49~59 (36~44) 201 Plug 1

164 O-ring 1 321 Spring 1

166 O-ring 1 511 Spool 1

167 O-ring 1 541 Sleeve 1

NA Issued 10-2007 Bur 4-39

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Bypass Cut Valve (605)

302 301 402 401

P Pi

T Dr

201 202 102 101

SM0832

GRAPHIC_1D Figure 40

Bypass Cut Valve

Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (pound-ft) Nm (pound-ft)

98-120 (72-89) 101 Plug 1 301 Plunger 1

102 O-ring 1 302 Spring 1

201 Poppet 1 69-78 (51-58) 401 Plug 1

202 Spring 1 402 O-ring 1

4-40 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Swing Shuttle Valve Cover (204)

PBs
555

A
Pss

G1/4
A SECTION B-B

166 542 541 PBs G3/8

B B
Pss

554

202

PAs
SECTION A-A
SM0833

GRAPHIC_1D Figure 41

Swing Shuttle Valve Cover

Tightening Tightening
torque No. Parts Qty torque No. Parts Qty
Nm (pound-ft) Nm (pound-ft)

166 O-ring 1 542 Seat 1

202 Cover 1 25~29 (18~21) 554 Plug 1

7.9~9.8
541 Steel ball 1 555 Plug 1
(5.9~7.2)

NA Issued 10-2007 Bur 4-41

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
HYDRAULIC CIRCUIT DIAGRAM

GRAPHIC_1D Figure 42

1. TRAVEL PRIORITY 7. OPTION

2. P1 UNLOAD 8. ARM 1
3. TRAVEL RIGHT 9. SWING
4. BOOM 10. P2 UNLOAD
5. BUCKET 11. BOOM CONFLUX
6. ARM 2 12. TRAVEL LEFT

4-42 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
OPERATION

In Neutral Position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank
port T1. And when the operation of unloading valve is impossible due to failure of electric control system, because
the bypass cut valve (605) located on the downstream of center bypass passage (52) opens, the hydraulic oil
through hydraulic pump P1 port passes through travel priority spool (306), and then flows though the center bypass
passage (52) which passes through travel right, boom, bucket and arm 2 and the bypass cut valve (605) on P1
side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank
through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D)
and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from
hydraulic pump P1. And when the operation of unloading valve is impossible, because the bypass cut valve (605)
located on the downstream of center bypass passage (55) opens, the hydraulic oil through hydraulic pump P2 port
passes through main passage, and then flows though the center bypass passage (55) which passes through travel
left, swing, arm 1 and option and the bypass cut valve (605) on P2 side, and flows into low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.

(D)
605
517 52
306

T1

P2
P1

309

55 310 605

(D)(*)

SM1297

GRAPHIC_1D Figure 43
IN NEUTRAL POSITION
(*) CONNECTED TO LOW PRESSURE CIRCUIT OF P2 SIDE CASING

NA Issued 10-2007 Bur 4-43

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Actuation In Travel Operation
A. In travel independent operation
On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into
travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot
pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of
springs (325) (327) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports
PCb and PCa and switches unloading spools (309) (310).
The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into
main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into A
side of right travel motor through port AR. The hydraulic oil delivered by hydraulic pump P2 flows through
between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through
port AL similarly to the stream of hydraulic oil delivered by hydraulic pump P1.
But in the meantime, the return oil from the B sides of left and right travel operations passes through
between the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into
low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port
T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control
valve), the actuation is similar to that in forward travel operation.

Left Travel Motor

A B

AL BL

CP2
327 325 306

PBL
PAL

SM1298
GRAPHIC_1D Figure 44
IN LEFT REVERSE TRAVEL (AT PBL IS PRESSURIZED)

4-44 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

B. In travel priority operation

When actuator other than travel operation and the travel operation are operated simultaneously in the said
item a) IN TRAVEL INDEPENDENT OPERATION the pilot signal from the outside acts on port PTb and the
travel straight spool (307) moves upward.
With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used
for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into
main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel
simultaneous operation. (Travel priority function) At circuit (I) position, a part of hydraulic oil delivered by
hydraulic oil P1 passes through circular notch on travel priority spool (307) and enters from P1 to B enabling
the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch
on travel priority spool (307) closes and the pump line on the travel sides is independent from pump line on
actuator.

CMR2 CMR2
P2 P2
B B
CMR1 CMR1
P1 P1
A A

307 307

325 325

328 328

PTb PTb

P2 P1 P2 P1

PTb PTb
Dr Dr Dr Dr
A
B A
B
SM1299

GRAPHIC_1D Figure 45

CIRCUIT (I) CIRCUIT (II)

A - TO EACH ACTUATOR
B - TO TRAVEL RIGHT
MOVEMENT OF TRAVEL PRIORITY SPOOL

NA Issued 10-2007 Bur 4-45

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Actuation In Bucket Operation
A. In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward
the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional valve
[XI] acts on port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of
bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.
And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is
low, the pilot signal from the outside enters port PCc and piston (218) moves rightward. With this actuation,
the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the
perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket
cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may
be occurred on bucket cylinder head side (H). (Stroke limiter ON).

53
218

PCc PAc

PBc

(D) Bc Ac
LCc
304 511
319
320

(R) (H) SM1300

GRAPHIC_1D Figure 46
IN BUCKET DIGGING OPERATION (STROKE LIMITER ON)

4-46 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

B. In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (319) (320), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by
hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and
flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and
supplied to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of
bucket spool (304) and casing and flows through low pressure circuit (D), and returns to the hydraulic tank
through tank port T1. The return oil does not pass through boost check valve (517).
Downstream of boost check valve.

(D*)
53
218

PCc PAc

PBc

Bc Ac
LCc
304 511
319
320

(R) (H) SM1301

GRAPHIC_1D Figure 47

(D*) DOWNSTREAM OF BOOST CHECK VALVE

IN BUCKET DUMPING OPERATION

NA Issued 10-2007 Bur 4-47

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Boom
A. In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward
against the force of springs (319) (320), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCb and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs
(321) (322) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches
unloading spools (310).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through
U-shaped passage, and supplied to the both boom cylinders head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of
boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.

(R) (R)

(H) (H)

301 (D) 53 511 514 (A) 319 320

Bb LCb CRb
Ab

PAb PBb

SM1302

GRAPHIC_1D Figure 48
(A): BH CHAMBER

IN BOOM UP OPERATION (BOOM SPOOL)

4-48 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

B. In boom up conflux operation

The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel
passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of
boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux
check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the
hydraulic oil from the hydraulic pump P1 side.

PB1

322

321

511

CCb

(B)

305 56 SM1303

GRAPHIC_1D Figure 49

(B): CONFLUX PASSAGE TO AB PORT OF P1 CASING

IN BOOM UP CONFLUX OPERATION (BOOM CONFLUX SPOOL)

NA Issued 10-2007 Bur 4-49

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

C. In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward
against the force of springs (319) (320) and the secondary pressure of solenoid proportional valve [X1] acts
on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is
switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is
connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab).
Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is
released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and
passes through between the perimeter of boom spool (301) and casing, and flows through low pressure
circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a
part of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301).
Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes
through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the
figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through
port Bb. (Boom recirculation function)

(R) (R)

(H) (H)

301 317 53 511 514 (A) 319 320

LCb CRb
Bb Ab

PAb PBb

(D) SM1304

GRAPHIC_1D Figure 50

(A): BH CHAMBER

IN BOOM DOWN OPERATION

4-50 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Arm Operation
A. In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves
leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches
unloading spools (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load
check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center bypass passage (52)
and pushes and opens load check valve LCAP2 (515) and enters U-shaped passage, and pushes and
opens load check valve LCAT2 (511) provided with orifice, and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber
through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm
1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and
then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).

(H) (R)

322 321 302 514 211

Aa 511 LCa (AR) CRar Ba

56 P1 LCAT2
PAa1 PBa1 (D')
LCAP2
(D)
Arm 1 P1
(D') RH PAa2
HH 52 RR PBa2
(D') Dr Dr
Arm 2

PBa2 (F)
PAa2 Ba
(ROD) Aa (HEAD)
53
(G)
MU1

326 325 308 515 LCAP2 LCAT2 511

SM1308

GRAPHIC_1D Figure 51
(F): TO ARM 1 SPOOL
(G): TO PILOT CUT VALVE

IN ARM OUT OPERATION

NA Issued 10-2007 Bur 4-51

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

B. In arm in operation (At light load: arm recirculation function)

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

4-52 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

(H) (R)

322 321 302 514 211

511 (AR) CRar Ba
Aa LCa

56
PAa1
PBa1

Arm 1
(D') (D)
HH RH 52 RR
Arm 2

PAa2
PBa2
[XR] 53

MU1

LCAP2 LCAT2
326 325 308 319 515 511

P1
(D') LCAT2
LCAP2
(D)
P1
PAa2 PBa2
Dr Dr

(F)
Aa (Head)
Ba
Circuit (I) (Rod)

(G) SM1309
GRAPHIC_1D Figure 52

(F): TO ARM 1 SPOOL

(G): TO PILOT CUT VALVE

IN ARM IN OPERATION (AT LIGHT LOAD: ARM RECIRCULATION FUNCTION)

NA Issued 10-2007 Bur 4-53

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

C. In arm in operation (In heavy load operation)

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

(H) (R)

322 321 302 514 211

511 (AR) CRar Ba
Aa LCa
Circuit (II)

P1 LCAT2
56 (D') LCAP2
PAa1
PBa1 (D)
P1
Arm 1
PAa2 PBa2
Dr Dr
(D') (D)
HH RH 52 RR
(F)
Arm 2 Aa(Head)
Ba
PAa2 (Rod)
PBa2
[XR] 53
(G)
MU1

LCAP2 LCAT2
326 325 308 319 515 511 SM1310

GRAPHIC_1D Figure 53

(F): TO ARM 1 SPOOL

(G): TO PILOT CUT VALVE

IN ARM IN OPERATION (IN HEAVY LOAD OPERATION)

4-54 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Swing Operation
On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle
valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on
port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check
valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped
passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing
spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve
(517), and then returns to the hydraulic tank through tank port T1.

204

PAs
PBs

Pss

Bs As
LCs

(D) 56 511 (D) 303 321 322

B A
Swing motor
SM0847

GRAPHIC_1D Figure 54
SWING OPERATION

NA Issued 10-2007 Bur 4-55

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Spool Actuation For Operation In Option
This spool is used to control the attachment in option like Nibbler (Crusher), etc.
When the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports
PAo, and option spool (311) moves against the force of springs (329) (330), and simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load
check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through U-
shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option
spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517),
and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to
port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil
passage is used as passage to connect to N&B selector valve.

511
604 311

Ao LCo Bo

329
330
AoR (O)
BaR

56
PAo PBo

(D) SM1305

GRAPHIC_1D Figure 55
SPOOL ACTUATION FOR OPERATION IN OPTION

4-56 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Lock Valve Operation
The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm
cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused
by each cylinder.
A. At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side as
shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of bushing
(541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the
holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541)
spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed
the lower side as shown in the figure and restricts the leaking to the minimum.

1 RH 514 BH Sb PLc Dr 2 541 511

CRb
Ab
(a) (b)
321
PLc Sa Sb Dr
A A
SECTION A-A
Sa

319 320

PBb

SM1306
Dr 301 (D)
GRAPHIC_1D Figure 56
1. RETURN OIL FROM BOOM CYLINDER HEAD
2. LOCK VALVE SELECTOR

LOCK VALVE OPERATION (AT BOOM SPOOL NEUTRAL POSITION)

NA Issued 10-2007 Bur 4-57

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

B. In boom down operation (In arm in operation)

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

RH 514 BH Sb PLc Dr 2 541 511

1

CRb
(a) (b)
Ab
321
PLc Sa Sb Dr
A A SECTION A-A
Sa

319 320

PBb

Dr 301 (D) SM1307

GRAPHIC_1D Figure 57
1. RETURN OIL FROM BOOM CYLINDER HEAD

2. LOCK VALVE SELECTOR

LOCK VALVE SELECTOR OPERATION (AT BOOM DOWN OPERATION)

4-58 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Bypass Cut Valve
This bypass cut valve is located on the most downstream of center bypass passage (52) on P1 side and center
bypass passage (55) on P2 side. And this bypass cut valve controls the flow rate of hydraulic oil from each center
bypass passage to low pressure passage (D).
A. In normal operation
On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot
ports PBp1 and PBp2 of bypass cut valve (605). This secondary pressure is the same as that acting on pilot
port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310).
The following explains the bypass cut valve on P1 side, the operation of bypass cut valve on P2 side is the
same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves
downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on
the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101).
The hydraulic oil from center bypass passage (52) passes through the orifice of poppet (201) and enters
spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of
plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center bypass
passage (52) and poppet (201) is pushed the seat section of casing shutting off center bypass passage (52)
and low pressure passage (D).
Consequently, in normal operation, center bypass passage (52) is always disconnected from low pressure
passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center bypass
passage (52), but returns to the hydraulic tank through P1 unloading spool (309).

[X1]

PBp1

301 302

(C) (b)

Dr 101

201 (a)

(D)

52

SM0969
GRAPHIC_1D Figure 58
BYPASS CUT VALVE (IN NORMAL OPERATION)

NA Issued 10-2007 Bur 4-59

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

B. At the time when failure occurred

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

PBp1

301 302

(C) (b)

Dr 101

201 (a)

(D) 202

52

SM0970

GRAPHIC_1D Figure 59
BYPASS CUT VALVE (IN CONDITION OF FAILURE)

4-60 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Boost Check Valve, Bypass Check Valve
1. Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost
pressure necessary for the low pressure passage.
A. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the
force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure
generated by spring (527) is used as the boost pressure for the low pressure passage.
But the return oil used for the arm out and bucket dumping operation does not pass through boost check
valve (517), but returns from low pressure passage (D’) to hydraulic tank through tank port T1.
B. In make up operation
When supplying to make up the flow rate through low pressure passage (D) after the swing operation is
suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic oil
is made up from hydraulic tank into low pressure passage (D).
When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure
passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port
T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving
section in ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed
upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make
up the deficient flow rate.

527

528
(D') T2
518
T1

102

1
517 (D) 528
527
T2 518
102
T1
517

(D) 2
SM0971

GRAPHIC_1D Figure 60

1. IN NORMAL OPERATION

2. IN MAKE UP OPERATION

BOOST CHECK VALVE OPERATION

NA Issued 10-2007 Bur 4-61

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

2. bypass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the bypass check valve
actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and
consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from
possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), bypass check valve (518) is
pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the
hydraulic tank through tank port T2.

527

528

(D')
T2
518
T1
102

517 (D)
SM0992

GRAPHIC_1D Figure 61

BYPASS CHECK VALVE OPERATION

4-62 Issued 10-2007 Bur NA

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

NA Issued 10-2007 Bur 4-63

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Emergency Manual Valve For Lowering Attachment Operation

(R)

1
(H)
2
Ab

XAb 5

9
SM0993

GRAPHIC_1D Figure 62

1. BOOM CYLINDER HEAD SIDE 6. LOCK NUT

2. CONTROL VALVE 7. SHUTTLE VALVE
3. HYDRAULIC OIL TANK 8. TO LEVER LOCK SOLENOID VALVE
4. DRAIN PASSAGE 9. TO CONTROL PILOT VALVE
5. NEEDLE VALVE

4-64 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
SWING DEVICE OUTLINE
SWING DEVICE GENERAL VIEW

712

702
712 743

702 742

111 301

743 742 301 101

SM0588

GRAPHIC_1D Figure 63

Tightening torque
Symbol Port name Port size
Nm (pound-feet)
A, B Main port PF 3/4 167 (123)
DB Drain port PF 3/8 74 (55)
M Make-up port PF 3/4 167 (123)
PA, PB Pressure measuring port PF 1/4 36 (27)
PG Parking brake release port PF 1/4 36 (27)
L Gear oil level gauge PF 1/2 65 (48)
IP Gear oil filling port PF 3/4 98 (72)

NA Issued 10-2007 Bur 4-65

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

ANTI-REACTION
PB PA VALVE BLOCK

M DB
A,(B)

PG
IP
FILLING PORT
PT3/4

Grease
fitting

SM0571

GRAPHIC_1D Figure 64

PG

DB

PA PB

A B
Hydraulic diagram SM0572
GRAPHIC_1D Figure 65

4-66 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
SPECIFICATIONS

Specification
Model M5X130CHB–10A–598/285-122
Type Swash-plate type, fixed-displacement plunger motor
3 121.6
Displacement cm
Hydraulic motor

Working pressure MPa (psi) 34,3 (4974)

L/min
Max. flow 143 (37.8)
(US gpm)
Braking torque Nm (lbf·ft) 583÷818 (430÷603)
Release pressure MPa (psi) 2.3~5.0 (333~725)
Relief set pressure MPa (psi) 28 (4060)
Mass kg (lbs) 49 (108)

Antireaction Type 2KAR6P72/240-712

valve block Mass kg (lbs) 2.5 (5.5)
Hydraulic motor assy mass kg (lbs) 5.5 (114)
Speed reduction type Planetary 2-stage
Reduction ratio 15.38
Reduction unit

Lubicate oil Gear oil SAE90 (API class GL–4 grade)

Lubicate oil volume L (US gal) 3.0 (0.8)
Grease Extreme pressure lithium base # 2 grease
Grease volume kg (lbs) Approx. 1.0 (2.2)
Mass kg (lbs) 144.2 (318.0)
Total mass kg (lbs) 196 (432)

NA Issued 10-2007 Bur 4-67

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONSTRUCTION

Swing Motor

993

VALVE CASING SECTION

702 712

ANTI
CAVITATION
PLUNGER
351 Arrangement of brake spring

355
051 RELIEF VALVE

469
051-1
488 ANTI-REACTION
VALVE BLOCK 401
052 151
303 162 171 161
985
163 985 444 984 131 451
712 A A
472 390 391
VIEW I
702

707

706
100

980
743

742
400-1
111
400-2 052
121
400
123 994 SECTION A-A

122
114 301
124 443 491 101
SM0573
GRAPHIC_1D Figure 66

4-68 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM

Tightening torque Tightening torque

No. Parts Qty No. Parts Qty
Nm (pound-feet) Nm (pound-feet)
Relief valve; Anti-reaction
051 2 177 (130) 400 2 69 (51)
M33x1.5 valve; M22x1.5
051-1 O-ring; 1B G30 2 400-1 O-ring; 1B P20 2

Anti-reaction
052 1 400-2 Backup ring 2
valve sub
Casing for anti- Socket bolt;
100 1 401 4 430 (318)
reaction valve M20×45
101 Drive shaft 1 443 Roller bearing 1

111 Cylinder 1 444 Roller bearing 1

114 Spring plate 1 451 Pin 2

ROMH plug;
121 Piston 9 469 2 334 (246)
M30x1.5
O-ring;
122 Shoe 9 472 1
W1516,WG40
123 Set place 1 488 O-ring; 1B P28 2

124 Shoe plate 1 491 Oil seal 1

131 Valve plate 1 702 Brake piston 1

O-ring;
151 Plug; PF1/4 2 36 (27) 706 1
W1516,WG38
O-ring;
161 O-ring; 1B P11 2 707 1
W1516,WG41
162 O-ring; 1B P12 2 712 Brake spring 16

163 O-ring; 1B P6 2 742 Friction plate 3

Socket bolt;
171 4 29 (21) 743 Separator plate 4
M8×55
301 Casing 1 980 Plug; PF1/4 1 0.9 (0.66)

303 Valve casing 1 984 Plug; PF3/8 1 1.7 (1.2)

351 Plunger 2 985 Plug; PF3/4 3 4.4 (3.2)

355 Spring 2 993 Plug; PT1/2 1 65 (48)

390 Name plate 1 994 Plug; PT3/4 1 98 (72)

391 Rivet 2

NA Issued 10-2007 Bur 4-69

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Swing Reduction Unit

Be careful about installation

direction of retaining ring. Caulk these 2 places
Apply Three Bond #1360 with punch.
or equivalent. 23
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
Apply Loctite #515. 19 2 28 15 16 3

6 SURFACE OF Be careful about

LUBE OIL
7 15 installation direction
of spring pin.
4 18
5 VIEW (II) (4 places)
8
Apply Loctite #515. 17
Be careful about 18
installation direction 20 Drive this spring pin
of retaining ring. 22 into 1mm lower than
10 the surface of spider.
9
Apply Loctite #515. 25
12 26

31
Install the filling port 27 Apply seal tape or
of this fitting toward Loctite #577.
motor side. 24
13
32
Fill up this space
with grease.
11
30
21

1
SM0574
GRAPHIC_1D Figure 67

Tightening torque Tightening torque

No. Parts Qty No. Parts Qty
Nm (pound-feet) Nm (pound-feet)
1 Pinion shaft 1 17 Needle bearing 4
2 #1 sungear 1 18 Washer 8
3 #1 pinion 3 19 Retaining ring 1
4 #2 sungear 1 20 Retaining ring 1
5 #2 pinion 4 21 Sleeve 1
6 Ring gear 1 22 Spring pin Ø 8x25 4
Capscrew;
7 Spider assy 1 23 11 181 (134)
M14X135
8 Spider 1 24 Cap 2
9 Shaft 4 25 Tube L=112 1
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 27 Plug 1 69.1 (51)
12 Oil seal 1 28 Retaining ring 3
13 Housing 1 30 Oil seal 1
Grease fitting; PT
15 Thrust washer 6 31 1
1/8
Relief fitting; PT
16 Needle bearing 3 32 1
1/8

4-70 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
HYDRAULIC MOTOR

Operation
If the high pressure oil flows into the cylinder through Cylinder block (111)
the inlet port (a) of valve plate (131), as shown on the
figure on the right, the hydraulic pressure acts upon
F2
piston (121) and creates force F in the axial direction. F1
The force F may be divided into force F1 vertical to F
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 Drive shaft (101)
pistons (121) and causes drive shaft to turn so as to
produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of Valve
plate
high pressure oil. (131)
Shoe Shoe Piston
If the oil supply and discharge directions are plate (122) (121)
reversed, the drive shaft rotates in the opposite (122)
SM0575
direction. GRAPHIC_ID Figure 68
Theoretical output torque T can be given by the
following equation.

PXq
T= Low pressure oil High pressure oil
2X

p: Effective differential pressure MPa

q: Displacement per revolution cc/rev OUTLET INLET (a)

SM0576

GRAPHIC_ID Figure 69

NA Issued 10-2007 Bur 4-71

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
VALVE CASING SECTION
351
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 M port
deficient oil, in order to prevent cavitation from (Make-up port)
occurring due to oil deficiency.

GRAPHIC_ID Figure 70

Operation of Relief Valve

1. Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the Chamber h
tank pressure at the beginning, as shown in Fig. Orifice m Spring (321) Piston 1 (302)
71.
The relief valve begins to operates when the
hydraulic pressure that is determined by the P
product of the pressure-receiving area A1 of
plunger (301) and the pressure P balances the
R
hydraulic pressure that is determined by the Pressure Chamber g
receiving A3 A2
product of the pressure-receiving area A2 of the area A1 Plunger (301) A4
Orifice n
plunger (301) and the pressure Pg of chamber g.
SM0578
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to GRAPHIC_ID Figure 71
spring (321) increases by this movement of the
piston.
As the result, the relief pressure P is raised and
controlled in the pressure boost time t1 from P1
till Ps.
This process is explained in the following in the
relationships between the movements of the
components and the relief pressure:

A. Condition shown in Fig. 72.

If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the
Chamber h
restrictor m of plunger (301). Orifice m Spring (321)
Pin (303) Piston 1 (302)
The hydraulic pressure acting on plunger
(301) increases and when it balances the load
Fsp of spring (321), the relief valve performs
relieving action by the pressure P1. P
This relationship is expressed as:
R
P1×A1=Fsp1+Pg1×A2 Orifice n
Plunger (301) Chamber g

where Fsp1: SM0579

primary set load value of spring (321). GRAPHIC_ID Figure 72

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 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
B. Condition shown in Fig. 73.
The pressure of chamber g acts upon the
pressure-receiving area A3-A4 of piston 1
Chamber h
(302). When the hydraulic pressure rises Orifice m Spring (321)
Pin (303) Piston 1 (302)
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to
the left while discharging the oil of chamber h P
arranged between piston 1 and adjust plug
(401) into chamber g via orifice n provided in R
pisto n 1 (30 2), ch ambe r h ser ves as a Orifice n
Plunger (301) Chamber g
dumping chamber.
The load of the spring increases slowly till SM0580

piston 1 reaches the end of the adjust plug. GRAPHIC_ID Figure 73

The relief pressure P rises smoothly.

C. Condition shown in Fig. 74.

The machine does not travel to the left further
when piston 1 (302) arrives at the end of
adjust plug (401). Therefore, the relief valve Orifice m Spring (321) Pin (303) Piston 1 (302)
keeps its normal relieving action whereby the
relief pressure is held at P2.
In the processes a. to c. above, the relief
pressure changes as shown in Fig. 75. P

R
Plunger (301) Orifice n
Chamber g

SM0581

GRAPHIC_ID Figure 74

2. Function when the relief valve pressure is

reduced.
Let us consider the pressure of the P port is
reduced.
When the pressure at port P is reduced to zero,
the pressure of chamber g falls to the tank
pressure level. The result is that the plunger
(301) which is now open moves to the left and is
seated on seat (341). At the same time, the
piston 1 (302) moves to the right by the action of
spring (321) and returns to the condition of Fig.
73.
SM0582

GRAPHIC_ID Figure 75

NA Issued 10-2007 Bur 4-73

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
3. Operation of anti-reacation valve
A. Neutral condition
The coresponding figure illlustrates the
relationship between the neutral condition of the
ani-reaction valve and the hydraulic circuits.
Now, let us consider a braking condition in which
brake pressure generates on the AM port side.
B. When brake pressure occurs: ANTI REACTION
VALVE
If pressure P generates at the AM port, it passes
ANTI REACTION
through the passage L, the hole on the shaft of VALVE
seat (313) and the passage m of the plunger GRAPHIC_ID Figure 76
(311) and is led to the n chamber.
When the pressure P rises above a vlaue (Ps)
set by spring (321), plunger (311) compresses
spring (321) and shifts it to the left. L
Seat (313) compresses weak spring (322) as
pushed by plunger (311) and moves to the left.
C. at anti-reaction k
322 313 321 311
When inertia load stops moving (point Y), brake GRAPHIC_ID
SM0584
Figure 77
pressure P tries to fall.
m n
When P<Ps, plunger (311) moves toward the
right return side by the action of spring (321).
Seat (313) tries to move to the right by the action P=PS
of spring (322), but since chamberp provides
damping action by orific g, the reurn of the seat L
makes a time delay with regard to the reurn of
the plunger.
Consequently, seat t opens. This makes a 322 313 321 311
SM0585
GRAPHIC_ID Figure 78
passage connecting the AM port and BM ports or
both por ts of the hydraulic motor by way of
p t
t r k. The result is that the
pressures at the AM and BM ports become
equal (Pb), falling into the conditon at point Z.
P<PS
This prevents the hydraulic motor from swing
shick by the closing pressure of the AM port. L

k
322 313 g r 321 311
SM0586

GRAPHIC_ID Figure 79

P Y
PS

PB
X
Z
T
SM0587

GRAPHIC_ID Figure 80

4-74 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
BRAKE SECTION
712
Operation
The cylinder (111) is jointed by drive shaft (101) and
a spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves provided 702
in casing (301). 712 743
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against 702 742
casing (301) via separator plate (743) and brake
piston (702) by the action of brake spring (712), 111 301
frictional force is created between friction plate (742)
and casing (301) and between separator plate (743) 743 742 301 101
SM0588
and brake piston (702). The frictional force bounds GRAPHIC_ID Figure 81
the drive shaft to brake the motor.
In the meantime, when brake release pressure
applied to the oil chamber formed between brake
piston (702) and casing (301) overcomes the spring
force, the brake is released as brake piston (702)
moves till friction plate (742) is separated from casing
(301).

NA Issued 10-2007 Bur 4-75

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
SWING REDUCTION UNIT

Operation
Ring gear (Fixed) Planetary shaft
The swing reduction unit is used to reduce the
rotating speed which is transmitted by the hydraulic
motor and to convert it to the strong turning force
(torque).
Spider
This swing speed reduction unit is equipped with
planetary speed reducing mechanism. Sun
The planetary mechanism is made up of sun gear, gear
planetary pinion, planetary shaft, spider and ring
gear, as shown in Fig.82.
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (2). Sun gear (2)
is engaged with planetary pinion (3) and rotates, but
since ring gear (6) is fixed, planetary pinion (3)
Planetary pinion
revolves about sun gear (2) with the planetary shaft GRAPHIC_ID Figure 82
and spider (7).
The role of spider is to hold the planetary pinion and
planetary shaft and transmits the power from the Swing motor
planetary pinion to the spider through the planetary
shaft. 3 2
6
The #1 spider (7) is linked with #2 sun gear (4) by the
involute spline, and transmits the power to the 2nd
stage planetary mechanism. 7
For the operation of the 2nd stage planetary, the 4
power is transmitted to sun gear (4) →planetary
pinion (5) →spider (8) similarly to the 1st stage. 8
The #2 spider (8) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with 13
the swing gear fixed on the undercarriage (lower
frame) and rotates. 5
10

11 1

SM0590
GRAPHIC_ID Figure 83

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 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
TRAVEL DEVICE OUTLINE
CHARACTERISTICS

Reduction gear unit Epicycloidal, three-stage planetary type

Model 710 C3 K
Gearbox ratio 1 : 63.1
Travel motor Two speed, axial piston swash plate type
Model MAG 85 VP 17
high speed 50.4 cm3/rev
Displacement
low speed 87.3 cm3/rev
Max. flow 130.4 L/min
high speed 17368 Nm
Max. gearbox output torque
low speed 30087 Nm
static 234 Nm
Parking brake torque
dynamic 194 Nm
Min. pressure parking brake release 14 bar
cracking 311 bar at 1.1 L/min
Relief valve set pressure
total flow 353 bar at 37 L/min
Mass 262 kg

NA Issued 10-2007 Bur 4-77

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Hydraulic Motor
Two speed hydraulic motor (axial piston swash plate
type) containing:
Integrated counterbalance valve;
Crossover relief valve which contains a shock
absorber to smooth acceleration and stopping;
Negative multidisc parking brake built-in directly
driven from the motor oil pressure (no additional
hose is required);
Double speed function, allowing the motor to be
set to a fast or slow speed.

Planetary Gearbox
Planetary gearbox, 3 stages, rotating housing type.
The track drive is suitable to be used as track drive
for crawled machines equipped with open loop
hydraulic circuit.

Ports

7 7
3P
3 3
3V 3V
3 3
3P
7 7

60

GRAPHIC_1D Figure 84

P1 PF 3/4in.
Service ports
P2 PF 3/4in.
T1 PF 1/2in.
Drain ports
T2 PF 1/2in.
Ps PF 1/4in. 2 speed control port
Pm1 PF 1/4in.
Pressure gauge ports
Pm2 PF 1/4in.

4-78 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Hydraulic Circuit

3P

3
5*
3

77

3V 3P
60

GRAPHIC_1D Figure 85

NA Issued 10-2007 Bur 4-79

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
COSTRUCTION

Track Drive



 
 
 












60

GRAPHIC_1D Figure 86

1. SOCKET SCREW M10X25 (QTY 10) 75 NM 12. SOCKET SCREW M20X100 (QTY 4) 585 NM
2. END COVER 13. 3RD REDUCTION PLANET CARRIER
3. PLUG M22X1.5 (QTY 2) 65 ± 5 NM 14. BUSH (QTY 4)
4. WASHER 15. SCREW (QTY 16)
5. O-RING 16. WASHER (QTY 16)
6. PLUG 17. SPROCKET
7. 1ST STAGE SUN GEAR 18. GEARBOX HOUSING
8. 1ST STAGE REDUCTION ASSEMBLY 19. LIFETIME SEAL
9. 2ND STAGE SUN GEAR 20. CENTERING RING
10. 2ND STAGE REDUCTION ASSEMBLY 21. HYDRAULIC MOTOR
11. 3RD STAGE SUN GEAR

4-80 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
NOTES

NA Issued 10-2007 Bur 4-81

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Hydraulic Motor Components





 




 

















  
  
  
 
 

  
  

 



 
 
  

  
  
 
 
 
  
    



60
GRAPHIC_1D Figure 87

4-82 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
1. FLANGED HUB 37. O-RING (QTY 2)
2. O-RING 38. SOCKET HEAD SCREW M10X35 (QTY 4)
3. ORIFICE 39. FLANGED PLUG
4. O-RING (QTY 4) 40. BALL (QTY 2)
5. SEAL RING 41. SPRING (QTY 2)
6. BEARING 42. O-RING (QTY 2)
7. MOTOR SHAFT 43. PLUG
8. STEEL BALL (QTY 2) 44. FLANGED PLUG (QTY 2)
9. TWO SPEED CONTROL SPRING (QTY 2) 45. RELIEF VALVE (QTY 2)
10. TWO SPEED CONTROL PISTON (QTY 2) 46. BACKUP RING (QTY 4)
11. SWASH PLATE 47. O-RING (QTY 2)
12. PISTON (QTY 9) 48. BACKUP RING (QTY 4)
13. RETAINER PLATE 49. O-RING (QTY 2)
14. SPHERICAL RETAINER PLATE HOLDER 50. O-RING (QTY 2)
15. PIN (QTY 3) 51. O-RING (QTY 2)
16. CYLINDER BLOCK 52. TWO SPEED SPOOL
17. SPRING HOLDER 53. SPRING
18. SPRING 54. SPRING SEAT
19. COLLAR WASHER 55. SPRING SEAT
20. CIRCLIP 56. O-RING (QTY 2)
21. VALVE PLATE 57. PLUG
22. BEARING 58. PLUG
23. BRAKE DISK 59. BACKUP RING
24. BACKUP RING 60. O-RING
25. O-RING 61. BACKUP RING
26. O-RING 62. BACKUP RING
27. BACKUP RING 63. CONICAL PLUG (QTY 11)
28. BRAKE PISTON 64. ORIFICE (QTY 2)
29. PIN (QTY 2) 65. ORIFICE (QTY 2)
30. SPRING (QTY 8) 66. BASE PLATE
31. PIN (QTY 2) 67. PLUG (QTY 3)
32. O-RING (QTY 2) 68. O-RING (QTY 3)
33. COUNTERBALANCE VALVE SPOOL 69. ORIFICE (QTY 2)
34. SPRING SEAT (QTY 2) 70. O-RING (QTY 2)
35. SPRING (QTY 2) 71. PLUG (QTY 2)
36. SPRING SEAT (QTY 2) 72. SOCKET HEAD SCREW M14X40 (QTY 9)

Motor Drain Pressure

Continuous running Less than 2 bar

Max. intermittent Less than 5 bar

Brake
The track drive is supplied with a safety negative disc
brake fitted into the hydraulic motor (parking brake).
Parking brake release is automatically operated
when high pressure oil is supplied to one of the two
ports of the hydraulic motor.
For this reason, there is no need of brake external
pilot.
The brake technical data are shown on the track
drive installation drawing.

NA Issued 10-2007 Bur 4-83

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Direction of Rotation
When assembling the track drive on the machine and connecting the hoses, follow instructions shown in below
sketch for proper direction of rotation.

SM0555

GRAPHIC_1D Figure 88

Oil inlet port Oil outlet port Direction of rotation

P1 P2 Clockwise
P2 P1 Counterclockwise

4-84 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
SWIVEL JOINT OUTLINE
GENERAL VIEW

E
A

F B

D
VIEW Y

GRAPHIC_1D VIEW Z Figure 89

SPECIFICATIONS

Working pressure 34.3 MPa

High pressure ports 51.5 MPa
Max. impact pressure
A,B,C,D
Rated flow 255 L/min

Working pressure 0.49 MPa

Low pressure ports E
Rated flow 50 L/min

Working pressure 5 MPa

Low pressure ports F
Rated flow 30 L/min

Revolution 15 min-1
A,B,C,D (body) PF 1
A,B,C,D (stem) PF 3/4
Ports size
E PF 1/2
F PF 1/4

Length (height) 368 mm

Weight 24.5 kg

NA Issued 10-2007 Bur 4-85

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONSTRUCTION

E
2

H
C

13
D
H
6 E
A
1

B
D

VIEW Y
C

B 12
F
A

5
7
9 SECTION HH
3
E E 8

SM0569

GRAPHIC_1D Figure 90

1. BODY 7. O-RING
2. STEM 8. CAPSCREW; M8X20 (QTY 2) 30.4 NM
3. THRUST PLATE 9. CAPSCREW; M8X30 (QTY 3) 30.4 NM
4. COVER 12. PLUG
5. SEAL (QTY 5) 13. O-RING (QTY 2)
6. SEAL

4-86 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem
(2) or body (1) past the circumferential groove between body (1) and stem (2); the oil flow is never shut off because
of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the
body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.

NA Issued 10-2007 Bur 4-87

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CYLINDERS OUTLINE
GENERAL VIEW

B
gth
en
dl A
de gth
x ten en
l ly e te dl
Fu rac
et
lly r
Fu

Part No. and Manufacturing No.

Stamp position

SM0560
GRAPHIC_1D Figure 91

SPECIFICATIONS

Center distance of
Cylinder bore/ pins
Stroke Dry weight
Use Rod Dia. Full extend B / Cushion
Full retract A
mm (in.) mm (in.) mm (in.) kg (lbs)
110 / 80 1150 2815 / 1665 With cushion
Boom 149 (329)
(4.33 / 3.15) (45.28) (110.83 / 65.55) on rod side
125 / 90 1290 3060 / 1770 With cushion
Arm 194 (428)
(4.92 / 3.54) (50.79) (120.47 / 46.06) on both sides
105 / 75 1025 2565 / 1540 With cushion
Bucket 128 (282)
(4.13 / 2.95) (40.35) (100.98 / 60.63) on rod side
135 / 85 1012 2555 / 1543
Positioning Without cushion 196 (432)
(5.13 / 3.35) (39.84) (100.59 / 60.75)

4-88 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CONSTRUCTION

Boom Cylinder


      


 3)   





60
GRAPHIC_1D Figure 92

1- ROD ASSEMBLY 9- SEALS PISTON

2- TUBE ASSEMBLY 10- PISTON
3- SEALS ROD 11- NUT; M58X3 3790 NM (2795 POUND-FEET)
4- HEAD ASSEMBLY 12- SHIM
5- BACKUP RING + O-RING 13- SCREW; M12X1.75 56.9±10.7 NM (42.0±7.9 POUND-FEET)
6- SEAL CUSHION 14- BALL STEEL
7- SCREW; M14X2 171 NM (126 POUND-FEET) (QTY 12) 15- GREASE FITTING; M10X1
8- RING CUSHION 30- WIPER; (QTY 4)

NA Issued 10-2007 Bur 4-89

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Arm Cylinder

   

  
        

 



60

GRAPHIC_1D Figure 93

1- ROD ASSEMBLY 12- SHIM

2- TUBE ASSEMBLY 13- SCREW; M12X1.75 56.9±10.7 NM (42.0±7.9POUND-FEET)
3- SEALS ROD 14- BALL STEEL
4- HEAD ASSEMBLY 15- GREASE FITTING
5- BACKUP RING + O-RING 17- RING CUSHION
6- SEAL CUSHION 18- SEAL CUSHION
7- SCREW; M16X2 267 NM (197 POUND-FEET) (QTY 12) 19- STOPPER
8- RING CUSHION 20- COLLAR; (QTY 2)
9- SEALS PISTON 30- KIT SEALS; (QTY 4)
10- PISTON; M65X3 8200 NM (6048 POUND-FEET)

4-90 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Bucket Cylinder

 
     


  


 



60

GRAPHIC_1D Figure 94

1- ROD ASSEMBLY 10- PISTON

2- TUBE ASSEMBLY 11- NUT; M52X3 4810 NM (3547 POUND-FEET)
3- SEALS ROD 12- SHIM
4- HEAD ASSEMBLY 13- SCREW; M12X1.75 56.9±10.7 NM (42.0±7.9 POUND-FEET)
5- BACKUP RING + O-RING 14- BALL STEEL
6- SEAL CUSHION 15- GREASE FITTING M10X1
7- SCREW; M14X2.5 171 NM (126 POUND-FEET) (QTY 12) 16- GREASE FITTING M10X1
8- RING CUSHION 30- KIT SEALS: (QTY 4)
9- SEALS PISTON

NA Issued 10-2007 Bur 4-91

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
Positioning

     
    

3)



60
GRAPHIC_1D Figure 95

1- ROD ASSEMBLY 10- PISTON

2- TUBE ASSEMBLY 11- NUT; M70X3 10280 NM (7582 POUND-FEET)
3- SEALS ROD 12- SHIM
4- HEAD ASSEMBLY 13- SCREW; M12X1.75 56.9±10.7 NM (42.0±7.9 POUND-FEET)
5- BACKUP RING + O-RING 14- BALL STEEL
7- SCREW; M18X2.5 367 NM (271 POUND-FEET) (QTY 12) 15- GREASE FITTING
9- SEALS PISTON 30- KIT SEALS; (QTY 4)

4-92 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
HYDRAULIC CYLINDER CONSTRUCTION (FOR BOOM, ARM AND BUCKET CYLINDERS)
By construction the hydraulic cylinder consists mainly
of cylinder tube assembly (1), piston rod assembly
(2) that takes out the motion of pistons reciprocating
in the cylinder tube assembly, and cylinder head (3)
that serves as both a lid and a guide. Cylinder tube
assembly (1) is equipped with a pin mount (clevis)
that connects piston rod assembly (2) with other
parts.
In addition to these main components, seal ring (16)
and back-up ring (17) are located between cylinder
tube assembly (1) and piston rod assembly (2);
buffer ring (6), U ring (7) back-up ring (8) and wiper
ring (9) are located between piston rod assembly (2)
and cylinder head (3); and an O-ring (10) and a back-
up ring (11) are placed between cylinder tube
assembly (1) and cylinder head (3).

Operation
If pressurized oil is fed alternatively to the oil inlet and CUSHION RING (13) CHAMBER “A” PATH (B)
outlet provided in the cylinder, force acts on the TANK
piston which in turn causes the piston rod (2) to PISTON (15)
extend and retract. ROD (2)

Operation of Cylinder with Cushion HEAD ROD

SIDE SIDE
CUSHION ON ROD SIDE
The cushion mechanism is provided to prevent the CYLINDER HEAD (3)
generation of shock when the moving speed of piston CUSHION STROKE
(15) is not reduced and strikes cylinder head (3).
An oil in chamber A returns to the tank by passing
SM0565
through paths B at a fixed flow rate in a intermediate GRAPHIC_ID Figure 96
stroke state of pressing bottom side.

Next, in a state of just before stroke end, cushion ring

(13) plunges into path B. TANK
CLEARANCE “D”
At this time, an oil in chamber A passes clearance D
and mouth gap C, an oil flow volume returning to tank
suddenly drops and the piston part movement slows
down.
MOUTH GAP “C”

SM0566
GRAPHIC_ID Figure 97

NA Issued 10-2007 Bur 4-93

 SECTION 2 - SYSTEMS
CHAPTER 4 - COMPONENTS SYSTEM
CUSHION ON HEAD SIDE
CUSHION SEAL (24)
This construction is similar to the one of cushion on
rod side. In a state of intermediate stroke pressing PATH “B” CUSHION BEARING (23)
TANK
rod side, an oil in chamber A returns to tank by
passing through path B at a fixed flow rate.
Next, in a state of just before stroke end, cushion
bearing (23) plunges into path B. At this time, an oil
in chamber A path clearance D and cushion seal (24)
are mouth gap C, an oil flow volume returning to tank
suddenly drops and the piston part movement slows
down. CLEARANCE “D”
CHAMBER “A”

SM0567
GRAPHIC_ID Figure 98

4-94 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS

CHAPTER 5

E175B
EXCAVATOR

AIR CONDITIONING SYSTEM

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783-NA
 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

5-II Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

CHAPTER 5
AIR CONDITIONING SYSTEM
TABLE OF CONTENTS

BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Air Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Auto Air Conditioner System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Component and Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Mechanism of Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Characteristics of Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Precautions to be Exercised in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Removing Inner Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Removing Selector Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Removing Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Removing Upper Unit Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Replacing Blower Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Removing Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Replacing Evaporator and Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Replacing Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
CHARGING REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Precautions to be Exercised In Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Procedure for the Generation of Vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Procedure for the Charging of the Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
ELECTRIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Wiring Diagram and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Structure and Operation of Each Functional Parts and the Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Self Diagnosis Function On Display Of Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Position of Indication for Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Explanation of Indication for Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Failure of Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Failures of Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Communication Error of Control Amplifier and Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Explanation of Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Position of Monitor Mode Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Operation of Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Contents of Monitor Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

NA Issued 10-2007 Bur 5-1

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

NOTES

5-2 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)
Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside
/outside air switching unit. And this unit changes hot air to cool air.

AIR CYCLE
Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.

Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air blows
off from grille through duct.
Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows in
the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation
is controlled by air mixing damper on the air-con unit.

NA Issued 10-2007 Bur 5-3

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
AUTO AIR CONDITIONER SYSTEM OUTLINE

25.0℃ COMPRESSOR

SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE

REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH

AIR-CON BLOWER REVOLUTION SIGNAL

AIR OUTLET SWITCHING SIGNAL CONTROLLER

INNER AIR SENSOR

EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL

OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR

AIR CONDITIONER UNIT FACE

FOOT MOTOR BLOWER

ACTUATOR CONTROLLER

GRAPHIC_1D Figure 1

5-4 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
COMPONENT AND CONSTRUCTION

Component
27

33 30
27-1

40

32

39
27-6
27-3 27-5

27-2
35

35-7 35-6

35-1

35-2 35-5

34 35-8

35-10 35-9

GRAPHIC_1D Figure 2

AIR CONDITIONER GROUP

No. Parts Q.ty No. Parts Q.ty No. Parts Q.ty

Air conditioner
27 1 32 Compressor 1 35-6 D hose 1
assy
Air conditioner
27-1 1 33 Pulley 1 35-7 L hose 1
unit
27-2 Hose 2 34 Condenser 1 35-8 L hose: Ø 15.5 1
27-3 Clamp 2 35 Air dryer assy 1 35-9 S tube: Ø 16 1
27-5 Filter 1 35-1 Receiver dryer 1 35-10 L tube: Ø 8.5 1
27-6 Tube assy 1 35-2 Bracket 1 39 Filter 1
Solar radiation
30 Panel assy 1 35-5 S hose: Ø 24.5 1 40 1
sensor

NA Issued 10-2007 Bur 5-5

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Construction
(1) Air conditioner unit
48
6
47
46
44

31
42 31
41
50 F
3 1

45 1

43
32 G
1

1
28 1
39

37
38
B
36
27
H

9
40

A I

2
33

GRAPHIC_1D Figure 3
AIR CONDITIONER UNIT (1/2)

5-6 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

14
1 1 31 16

1 5
15
31
1
3
1 61

F 1
C 1
D
4
7
G

1 1
1

26 20 13

59

29
11

21 23
22

H
24 1

B
1
8 60

D
17
18 A
I
C
10
31
19
12
1
3
31 25

52

SM0021

GRAPHIC_1D Figure 4
AIR CONDITIONER UNIT (2/2)

NA Issued 10-2007 Bur 5-7

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

No. Parts Q.ty No. Parts Q.ty No. Parts Q.ty

1 Screw M5×16 23 19 Relay 2 40 KK-box lower packing 1
2 Main harness 1 20 Evaporator 1 41 Vent lever 1
3 MA air mix 3 21 Expansion valve 1 42 Face lever 1
4 Blower controller 1 22 O-ring 1 43 Foot joint lever 1
5 Upper casing 1 23 O-ring 1 44 MA mode lever 1
6 Air mix door 1 24 Screw M5×40 2 45 Foot lever 1
7 Air mix lever 1 25 Thermistor 1 46 Face lever cam 1
8 Lower casing 1 26 Thermistor holder 1 47 Vent lever cam 1
9 Air mix door sub 1 27 Heater core 1 48 Face rod 1
10 Air mix lever sub 1 28 Pipe holder 1 49 Vent rod 1
11 Blower 1 29 Thermistor 1 50 Foot rod 1
12 Lever MA air mix 1 31 Screw M4×30 9 52 Inner air filter 1
13 Intake door 1 32 Upper casing 1 55 Screw M6×25 10
14 MA intake lever 1 33 Lower casing 1 56 Screw M8×25 10
15 Intake lever 1 36 Foot door 1 59 Evaporator packing 1
16 Intake rod 1 37 Vent door 1 60 Casing packing A 1
17 Air mix rod 1 38 Face door 1 61 Casing packing B 1
18 Air mix rod sub 1 39 KK box upper packing 1

Receiver Dryer
1. PRESSURE SWITCH
2. SIGHT GLASS
3. DESICCANT
4. SUCTION PIPE
5. FILTER 2 -M6
6. RECEIVER TANK
A. A - REFRIGERANT INLET
1
B. B - REFRIGERANT OUTLET

3
4

SM0037
GRAPHIC_ID Figure 5

5-8 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
FUNCTION
HFC-134a (R134a)
Mechanism of Cooling Circuit Chemical formula CH2FCF3
MECHANISM OF COOLING Molecular weight 102.03
In the cooling process, the refrigerant that flows Boiling point –26.19 °C
through the cooling circuit changes its phases from
Critical temperature 101.14 °C
liquid to gas and vice versa during which process
heat is transferred from the low temperature part Critical pressure 4.065 MPa
(compartment) to the high temperature part (outside Critical density 511 kg/m3
of the vehicle).
Density of saturated liquid (25 °C) 1206 kg/m3
Kind of Refrigerant
Specific volume of saturated vapor
Many kinds of refrigerants that change in that way 0.0310 m3/kg
(25 °C)
are available, but the following requirements are
Latent heat of vaporization (0 °C) 197.5 kJ/kg
needed for use in such applications:
Flammability Non flammable
1. Latent heat of vaporization (heat of vaporization)
is large. Ozone destruction coefficient 0

2. It is easy to liquify (condense). (It does not

require very high pressure for condensation.)
3. It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
4. It has small specific heat. (Since the refrigerant
itself is cooled by the expansion valve, the loss
r e s u lt i n g f r o m i t mu s t b e h e l d d ow n t o a
minimum.)
5. It has a high critical temperature and a low
solidification point.
6. It is stable chemically and does not corrode and
permeate into the circuit parts.
7. It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
8. It has small specific volume.
9. 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
br oken. Th e re fo re, a l way s use a d esignated
refrigerant for the cooling unit.
Table shows the principal characteristics of the
R134a refrigerant that is used in this machine.

NA Issued 10-2007 Bur 5-9

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Characteristics of Refrigerant
P (MPa)
In general, the fluid (general term of gas and liquid) 4 R134a
has the following qualities:
1. As a gas under certain pressure is cooled down, 3
it begins to condensate at a certain temperature
to take a liquid state. The temperature at which
LIQUID
condensation begins is unique to each 2
substance (fluid) at a given pressure. The GAS
temperature determined by a given pressure is 1
called saturation temperature.

0 15 18 35 50 T (°C)
GRAPHIC_ID Figure 6

2. Inversely to 1. above, the pressure at which a

gas condenses for a temperature is determined.
1
This pressure is called saturation pressure.
Figure beside illustrates the relationships 2
between the saturation temperature and the
saturation pressure in the case of refrigerant
R134a used in the air-conditioner. At the
3 9
temperature and the pressure on the lower right-
hand side of the curve in figure, the refrigerant
take a gaseous state, while at the temperature
and the pressure on the upper leviathan side of 6
the curve, the refrigerant takes a liquid state.
Let us think of a case where an air-conditioner is 4 5
o p e ra t e d i n t h e m id s t o f s u m m e r. A s th e
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order to 7 8
cool the inside of the compartment down to 25
°C, the refrigerant must transform (evaporate)
from a liquid to a gaseous state at a lower GRAPHIC_ID Figure 7
temperature. It can be seen from the figure that
1. INSIDE OF THE COMPARTMENT (CAB)
R134a under a pressure above the atmospheric
2. EVAPORATOR
pressure is capable of cooling the inside of the
3. BLOWER
compartment sufficiently. (If a refrigerant that 4. COMPRESSOR
requires a pressure below the atmospheric 5. COOLING FAN
pressure to cool it to a required temperature is 6. INSIDE OF ENGINE ROOM
used, air is mixed into the circuits, thereby 7. CONDENSER
deteriorating the performance of the cooling 8. RECEIVER DRYER
unit.) In the process in which gaseous refrigerant 9. EXPANSION VALVE
is brought back to a liquid state, the refrigerant is
cooled and condensed by the outer air
exceeding 35 °C.
A c c or d i n g l y th e re f r i g e ra n t i s c a pa ble o f
condensing at a pressure exceeding 1 Mpa, as
seen from the figure.

5-10 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Cooling circuit
The figure illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant
takes heat off the surrounding area as evaporation
heat as it evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant takes
place is the evaporator, cooled air is constantly
delivered to the circumference of the evaporator by
the blower fan. In the meantime, liquid refrigerant
(slightly wet vaporized refrigerant) is fed into the
evaporator, when cooling effect is attained. For
instance, in order to cool the air to 15 °C, the
refrigerant can not absorb evaporation heat from the
air unless it evaporates at a temperature lower that
15 °C. For that purpose, it can be seen from the
figure that the pressure of the refrigerant in the
evaporator must be less than 0.51 MPa.
Furthermore, the cooling effect deteriorates unless
the feed rate of the refrigerant is controlled so that all
of the refr ige ran t supp lied to the evapo rator
vaporizes and turns into dry vapor.
Consequently, the cooling circuit is so constructed
that the evaporator can cool down an object (air in
this case) sufficiently (i.e. so as to decrease the
pressure in the evaporator) and that an adequate
amount of refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator
is held low by the throttling action of the expansion
valve and the suction action of the compressor. The
c o m p r e s s o r a c t s a s a p u m p t h a t a l l ow s t h e
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.

NA Issued 10-2007 Bur 5-11

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
COMPONENT PARTS 1

Evaporator
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
r e f r i g e r a n t . T h e r e fo r e , i t i s n e c e s s a r y t h a t
satisfactory heat transfer between the object and the 2
refrigerant take place in the evaporator.
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer area
of the air side and thereby perform excellent thermal
transfer between the refrigerant and the air.
3
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if the
water drops freeze. Therefore, how to discharge 4
GRAPHIC_ID Figure 8
water is an important point.
1. EVAPORATOR
The amount of refrigerant supplied to the evaporator 2. O-RING
is controlled by the expansion valve which is 3. EXPANSION VALVE
described in the following. In order to attain proper 4. SOCKET BOLT M5 X 40
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.
Expansion Valve
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature 1
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 2
too high, non-vaporized liquid refrigerant returns to
t h e c o m p r e s s o r ( l i q u i d b a ck ) . T h i s n o t o n l y 3
deteriorates the cooling effect, but also damages the
compressor valves. 4
The expansion valve feeds the flowing high-pressure
high-temperature liquid refrigerant to the evaporator
as low-pressure low-temperature liquid refrigerant
(damp vapor of low dryness). The expansion valve
controls the feed rate of the refrigerant at the same
time. 5
Th e figu re b eside s hows how th e block type
expansion valve is constructed. The temperature 6
sensing part is provided in the shaft of the expansion
valve to directly detect the refrigerant temperature at 7
the outlet of the evaporator. GRAPHIC_ID Figure 9
The diaphragm contains R134a in saturated state. 1. DIAPHRAGM
The pressure in the diaphragm changes according to 2. EVAPORATOR SIDE
the temperature detected by the sensor. The change 3. REFRIGERANT OUTLET
in the pressure causes the force acting upon the 4. SHAFT
diaphragm to vary accordingly. 5. REFRIGERANT INLET
6. BALL VALVE
7. SPRING

5-12 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
The high pressure high temperature liquid refrigerant
that is fed from the receiver side reduces the
pressure abruptly as it passes through the valve
(throttling action). On that occasion, part of the
refrigerant evaporates by the ver y 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
s e n s e d by t h e th e r m owe l l ). T h e fe e d ra te i s GRAPHIC_ID Figure 10
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
t h e i n l e t p r e s s u r e o f t h e ev a p o r a t o r a n d
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure drop in the
evaporator is excessive, it is difficult to control the
overheating or the feed rate of the refrigerant. For
this reason, the smaller the pressure drop of the
evaporator, the better.
The expansion valve senses the pressure and the
temperature at the outlet of the evaporator and
controls the overheating of the refrigerant and the
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block
type expansion valve.

NA Issued 10-2007 Bur 5-13

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Compressor
The compressor perfor ms the following three
functions in the cooling circuit: 1

1. SUCTION ACTION
2. PUMPING ACTION
3. COMPRESSIVE ACTION
2
1. The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
per mits the refr igerant to vapor ize 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 continuous cooling. 3
3. The compressive action, as combined with the
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant back
to a liquid state again.
SM0042
The saturation temperature gets higher as the GRAPHIC_ID Figure 11
pressure increases. For instance, it becomes
1. D HOSE
possible to cool down the refrigerant by the use
2. S HOSE
of an outer air of 35 °C and liquify it. The
3. COMPRESSOR
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only for
a short period, the refrigerant hardly exchanges
heat with outer air. That is to say, it takes a near
form of thermally insulated compression, so that
the refrigerant discharged by the compressor
turns into high-temperature high-pressure vapor
and is delivered to the condenser.
Condenser
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by
the use of outer air and condenses the refrigerant.
The direction in which heat moves is from the
refrigerant to air, the opposite to the case of the
evaporator. Fins are equipped on the outer air side to
improve thermal transfer. If the refrigerant is not
c o o l e d we l l by t h e c o n d e n s e r, t h e a ir i n t h e
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.
SM0023
GRAPHIC_ID Figure 12

5-14 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Receiver Dryer
1. Receiver Tank 3
On the air-conditioner, the revolution of the
compressor varies greatly which causes the
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores 4
extra refrigerant temporarily and supplies it when
the cooling circuit needs much refrigerant. The
receiver tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2. Dryer 5
If wate r is mixe d in th e co olin g circu it, it
deteriorates the compressor valves and oil, 6
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion
valve. It is desirable that the amount of water 7
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner uses
a molecular sieve as desiccant suited for the
circuit, in order to absorb water content that
intr udes into the circuit when the dr yer is
installed or when refrigerant is charged. 8

3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the
only means of confirming the inside of the circuit
visually. GRAPHIC_ID Figure 13
1. REFRIGERANT INLET
4. Filter
2. SIGHT GLASS
5. Pressure Switch 3. REFRIGERANT OUTLET
4. PRESSURE SWITCH
This machine employs pressure switches of
5. DESICCANT
high/low pressure type.
6. SUCTION PIPE
The pressure switch protects the circuit by 7. FILTER
cutting off the power supply to the compressor 8. RECEIVER TANK
when high pressure increases abnormally high
(more than 3.14 MPa).
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit falls
below 0.196 MPa.

NA Issued 10-2007 Bur 5-15

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
DISASSEMBLY AND ASSEMBLY
TIGHTENING
PIPE FASTENING PART
Precautions to be Exercised in Operation TORQUE

1. Special Refrigerator Oil Unit: Nm (pound-ft)

This air-conditioner uses special refrigerator oil D hose and compressor (M8 19.6~24.5 (14~18)
SP20 for use with new refrigerant R134a. Oils
D hose and condenser 19.6~24.5 (14~18)
other than SP20 may not be used. Since SP20
tends to absorb moisture and may corrode paint L hose and condenser 11.8~14.7 (8.7~11)
and resin, the following points must be noted: 7.8~11.8 (5.8~8.7)
L hose and receiver dyer (M6
A. Do not keep open all pipe connections on a
L hose and air-conditioner unit 11.8~14.7 (8.7~11)
new compressor and the component parts of
the installed refrigeration circuit S hose and air-conditioner unit 29.4~34.3 (22~25)
( R e m o ve va l ve s a n d c a p s a t t h e p i p e Expansion valve 1.96~2.45
openings of the compressor, just before
connecting pipes. If you have removed a pipe
joint for repair, put a cap to both por ts TIGHTENING
SCREW SIZE
immediately.) TORQUE
B. Use care so SP20 does not adhere to the Unit: Nm (pound-ft)
painted surface and resin parts. In case SP20 N4, T4 machine screw, M4 0.78~1.18
has adhered to such surfaces, wipe it off
immediately. N5, T5 machine screw, M5 1.96~2.45

2. The receiver dryer is filled with desiccant to M6 (mounting part of L hose 7.85~11.8
absorb moisture in the circuit. Therefore, remove joint) (5.8~8.7)
the valve at the pipe port immediately before M6 (except mounting part of L 9.8~11.8 (7.2~8.7)
connecting pipes. hose joint)
3. Tightening Torque M8 (mounting part of S,D hose 19.6~24.5 (14~18)
joints)
A. Pipe Joints
When connecting pipe joints, coat the O-ring M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
with special oil (SP20) and fasten to the M8 (other than those mentioned 11.8~15.7 (8.7~12)
tightening torque indicated in the table, using above)
a double spanner. M10 39.2~53.9 (29~40)
B. Screws and Bolts
Fasten to the tightening torque indicated in the
table REPLACED PARTS AMOUNT TO BE

4. Amount of Oil for Compressor EVAPORATOR 40 cc (2.4cu·in)

The compressor SD7H (HD type) is filled with
CONDENSER 40 cc (2.4cu·in)
135cc (8.2cu•in) of oil. If the oil volume is small,
seizure at high revolution and shortening of Drain out the
service life will occur. If the oil volume is large, volume of oil left in
the cooling ability will be deteriorated. COMPRESSOR the compressor to
Once the air-conditioner is operated, part of the be replaced, from
the new
oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right RECEIVER DRYER 20 cc (1.2cu·in)
Table, adjust the oil level to that of table. HOSES 20 cc (1.2cu·in)
5. Before performing operation, stop the engine
and turn off all power supplies to the equipment
related to the air-conditioner.
6. After the operation is over, confirm that all faults
have been repaired completely, by operating the
air-conditioner.

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 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Removing Inner Air Filter
7 2
Slide the inner air filter (1) leftward and remove it
from the unit (2).

GRAPHIC_ID Figure 14

Removing Selector Box

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

Removing Main Harness

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

SM0028

GRAPHIC_ID Figure 15

Removing Upper Unit Case

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

GRAPHIC_ID Figure 16

NA Issued 10-2007 Bur 5-17

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Replacing Blower Controller
1. Remove 2 plus screws (14) and remove the 2b
blower controller (15) from the upper unit casing
(2b).
2. Install new blower controller by the reverse
procedure of removal.

NOTE: Do not disassemble the blower controller.

14 15
SM0030
GRAPHIC_ID Figure 17

Removing Heater Core 20

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

NOTE: * Do not remove the fan from the blower

motor. 2a SM0031

2. Install it by the reverse procedure of removal. GRAPHIC_ID Figure 18

Replacing Evaporator and Expansion Valve

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

GRAPHIC_ID Figure 19

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 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
4. Remove 2 socket bolts M5×40 (23) with Allen
wrench (4 mm) and remove the expansion valve A
from the evaporator (20).
5. Fit O-ring (24) (NF O-ring 5/8 and 1/2 one each)
to new evaporator.
24
NOTE: When assembling again, fit O-ring paying
attention so as not to be caught with others. (Socket
bolt M5×40 (2 pcs.) Tightening torque: 6.9 Nm
(5.1pound-ft).

NOTE: Do not apply undue force to pipe of

25
evaporator outlet. This undue stress causes the leak
of refrigerant from A part of evaporator. GRAPHIC_ID Figure 20
Moreover, when tube assembly (27-6) (see
Page. T3-8-3 Fig. SM0025) connected with
expansion valve (25) is disconnected from
ex p a n s i o n va l ve, s i m i l a r c a r e f u l wo r k i s
necessary.
Replacing Motor Actuator
1. Replacing mode actuator 28
A. Remove connector (26) connected to the 30 26
motor actuator (27).
B. Remove FACE rod (28) and VENT rod (29) 31
which is used to connect MA mode lever (30)
and mode cam from the holder. 27
C. Remove 3 plus screws (31) and remove the
motor actuator (27) with lever MA mode from
the unit.
D. Remove the lever MA mode from the removed
motor actuator, and install it on new motor
actuator by the reverse procedure of removal. GRAPHIC_ID Figure 21

33
2. Replacing air mixing actuator 36
A. Remove connector (32) connected to the
motor actuator.
32
B. Remove rod air MIX (33) which is used to
connect the motor actuator (27) and the lever
MA air MIX.
C. Remove 3 plus screws (34) and remove the
motor actuator (35) with MA lever air MIX (36)
from the unit.
D. Remove the MA lever air MIX from the
removed motor actuator, and install it on new
34
motor actuator by the reverse procedure of 35 SM0035
GRAPHIC_ID Figure 22
removal.

NA Issued 10-2007 Bur 5-19

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
3. Replacing inner and outer air switching actuator
A. Disconnect connector (37) connected to the 39
motor actuator (38). 41
B. Remove intake rod (39) from MA intake lever
(40).
C. Remove 3 plus screws and remove the motor 37
actuator (38) with MA intake lever (40) from
the unit.
D. Remove the MA intake lever (40) from the
removed motor actuator, and install it on new
motor actuator by the reverse procedure of
removal.
GRAPHIC_ID Figure 23

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 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
CHARGING REFRIGERANT
PRECAUTIONS TO BE EXERCISED IN OPERATION
1. Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person
familiar with how work is done for handling refrigerant.

WARNING
Wear protective goggles. (You may lose your sight if
the refrigerant gets in your eyes.)
The refrigerant in liquid state is at very low
temperature [approx. -26°C (-15°F)]. Therefore, handle
it with care. (You may get a frostbite if the refrigerant
is sprayed over your skin.)

2. Storage and Transportation

A. Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is
filled in the can in a saturated liquified state, the pressure in the can increases sharply as temperature rises.
The can may blast as the result.
It is for this reason why the can temperature must be kept below 40°C (104°F).
B. For storage, choose a cold dark place not exposed to direct sunlight.
C. If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside
pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
D. The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the
compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous
temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to
a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above
into account.
E. Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
F. Do not drop or knock on the can.
G. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
H. Store cans beyond the reach of children.
3. Charging
A. When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low
pressure valve of the gauge manifold and warm the can in warm water of 40°C (104 °F) or below (to an
extent that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated
by a direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
B. When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge
manifold in any case.
4. Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the air-
conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the
air-conditioner correctly and speedily. Pay full attention to the entry of water and dust.

CAUTION
Be careful about overcharge of gas
Fasten pipes to a specified torque

NA Issued 10-2007 Bur 5-21

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
OPERATING PROCEDURE
The change of refrigerant in the air conditioner
requires a vacuum generation procedure and a gas
charging procedure.
1. The VACUUM GENERATION PROCEDURE
consists in removing moisture from the air
conditioner circuit. In the event even a small
quantity of moisture remains in the system, it
wo u l d f r e e ze i n t h e s m a l l o r i f i c e s o f t h e
expansion valve when in operation. This causes
a clogging of the circuit or the formation of rust,
with a series of operational troubles. prior to
filling the circuit with refrigerant, apply the
vacuum and cause the boiling and vaporization
of the moisture. In this manner, moisture is
eliminated from the system.
2. The GAS CHARGING PROCEDURE consists in
the filing the circuit with refrigerant, after applying
a vacuum. the filling of the gas is not only
depending upon the cooling performance of the
air conditioner, but it influences also the useful
wor king life of the circuit components. An
excessive overloading increases considerably
the pressure of the system and damages the
cooling performance. On the contrary, a too low
charging, results in an insufficient circulation of
lubricant oil in the compressor, causing the wear
of the moving parts of the compressor.
WARNING
The gas filling operation involves the handling of
highly compressed gases; it is dangerous to handle
the gas without complying strictly with the relevant
procedures. The procedures and the protections
described in this manual for the filling of refrigerant
gas must be strictly adhered to.

Vacuum making operation Refrigerant filling operation

More than Leave it as it is

30 min. for five minutes

Begin vacuum Stop vacuum Check air Fill in Check for Fill in
making making tightness refrigerant gas leak refrigerant

Gauge indicates
abnormality

Check and correct joints

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 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
PROCEDURE FOR THE GENERATION OF VACUUM
1. Close high pressure valve (3) and low pressure
valve (1) on gauge manifold (2). 2
2. Connect the red charging pipe (5) and the blue 1 3
one (6) to compressor service valves (8) D and S
as described in the figure. 6 5

WARNING 4
D
Never exchange by mistake the high pressure pipe
with the low pressure pipe when connecting them.
Install the pipe firmly until a click noise is heard.
Connect the quick release joint of the charging pipe S
with the service valve of the compressor. If the
charging pipe is connected in the opposite direction, GRAPHIC_ID Figure 24
mini-valve (9) of the compressor fails to open.

3. Connect the central valve of the gauge manifold

with charging pipe (4) of the vacuum pump (7).

NOTE: Some types of manifold are not equipped

with an open/close valve in the central part.
4. Open high pressure valve (3) and low pressure
valve (1) of gauge manifold (2).
5. Start the vacuum pump and let it operate 30
minutes to generate the vacuum.
6. At the end of the vacuum phase for the D S
prescribed time (vacuum value: lower than 750
mm Hg) close the high pressure valve (3) and
the low pressure valve (1) of the gauge manifold
(2). 9
8
7. Cut-off the vacuum pump.
SM0017
8. With the high pressure valve (3) and the low GRAPHIC_ID Figure 25
pressure valve (1) closed, check, after five
minutes, that the pressure gauge dial does not
return to zero.

NOTE: In the event the pressure gauge moves

toward zero, this indicates the presence of a leakage.
Tighten again the connecting joints and apply the
vacuum again, verifying that there are no further
leakages.

NA Issued 10-2007 Bur 5-23

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
PROCEDURE FOR THE CHARGING OF THE GAS
2
1. After applying the vacuum repeatedly, exchange
charging pipe (4) of the gauge manifold (2), from 11
the vacuum pump to the service can (9).
2. Open the valve of service can (10). Close the
high and low pressure valves of the gauge 4
manifold. Press central bleeding valve (11) of the
side service opening on the low pressure side of
the gauge manifold using a screwdriver in order 10
to let out the air in the charging pipe by the
pressure of the refrigerant. Proceed with this
9
operation until a whistle is heard coming from the
bleeder.
SM0018
GRAPHIC_ID Figure 26

3. Open high pressure valve (3) of the gauge

manifold and charge the refrigerant to a pressure
of 0.1 MPa. 3
1
Once the charge is completed, close high
pressure valve (3) of the gauge manifold and
service valve (10).
D
WARNING
Never start operating the compressor during this
work. The starting of the compressor causes the 10
blowing of the service can.
S
4. Check that there are no leakages of gas in the GRAPHIC_ID Figure 27
cycle, using a gas leakage tester. Retighten and
eliminate all points of leakage.

NOTE: To check for gas leakages, always use a

tester for R134a.
5. Make sure that high pressure valve (3) and low
pressure valve (1) of the manifold and service
valve can (10) are closed.
6. Start the engine running it at 1500 ± 100 rpm and
open fully the door and windows of the cab.
7. Activate the air conditioner, setting it at maximum
ventilation speed and at lowest temperature.
8. During the charging of the gas, set the discharge
pressure of the compressor to 1.4 ~ 1.6 MPa.

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 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
9. Open low pressure valve (1) of the gauge
manifold and service valve can (10) and fill with
refrigerant until all air bubbles in sight window
(12) of the dryer disappear.
Total quantity of gas to be charged: 900 ± 50 g.
10. Once the refrigerant change operation is
terminated, close low pressure valve (1) of the
gauge manifold and the service valve can (10).

WARNING
Do not open the high pressure valve of the manifold
under any circumstance nor place the service can
upside down. GRAPHIC_ID Figure 28

11. The level of refrigerant is correct only once the

air conditioner is activated and through the
inspection sight window, just a few air bubbles
are seen and, afterward, a white color slightly
milky is seen.
IMPORTANT: When the air conditioner operates
with an insufficient quantity of refrigerant, this has a
negative effect on the compressor; on the contrary,
when the refrigerant is charged with an excessive
quantity, the cooling performance is lost. Also, the
pressure of the system increases abnormally.
12. Disassemble the manifold disconnecting the
c h a r g i n g p i p e s f r o m t h e c o m p r e s s o r, a s
indicated here below.
A. Press the quick release coupling of the
charging pipe on the low pressure side
against the service valve of the compressor so
that the refrigerant doers not escape leaking
when loosening the connection. As soon as
the nut has been removed, disconnect the
charging pipe from the service valve.
B. Wait for the pressure in the high pressure site
to decrease, indicated on the pressure gauge,
to a value of 1.0 MPa.
C. Disconnect the red charging pipe from the
high pressure side, in the same manner as
described for the low pressure.
GRAPHIC_ID Figure 29
A. APPROPRIATE QUANTITY OF REFRIGERANT
B. THE SYSTEM IS OVERLOADED
C. INSUFFICIENT QUANTITY OF REFRIGERANT

NA Issued 10-2007 Bur 5-25

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
ELECTRIC CIRCUIT
WIRING DIAGRAM AND CONNECTORS
Wiring Diagram

(A)(B)

2
(C)

12 3
(N)
(R) (D)
155(BR) 150(BP)
4
FUSE 20A 15 85E(WB)
18(RG) (E)
25(WG)
FUSE 5A
13 26(RL)
FUSE 15A
E24(B) 5
FUSE 5A

(Q) (M)
FUSE BOX

(L) (F)
6
(P) 11

(K)

10 (G)
14
7
9

(J) (H)

8
SM0044
(I)
GRAPHIC_1D Figure 30

1. CCU(OPERATION PANEL + CONTROLLER) 9. BLOWER AMP

2. EVAPORATOR SENSOR 10. BLOWER MOTOR
3. AIR INLET SENSOR 11. BLOWER OFF RELAY
4. SOLAR RADIATION SENSOR 12. PRESSURE SWITCH
5. MOTOR ACTUATOR (FOR AIR MIX) 13. MAIN KEY SWITCH
6. MOTOR ACTUATOR (FOR MODE) 14. COMPRESSOR
7. MOTOR ACTUATOR (REC/FRESH) 15. LIGHT SWITCH
8. COMPRESSOR RELAY

5-26 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
CONNECTORS

(A) JAE (B) JAE

HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000

(C) MAKER : YAZAKI CORP.

HOUSING No. : 7123-2228
(D) MAKER : YAZAKI CORP. (E) NIPPON AMP KK 174056-2
HOUSING No. : 7123-2228 TERMINAL : 175062-1
TERMINAL : 17111 TERMINAL : 17111

(F) JAE IL-AG5-7S-S3C1 (G) JAE IL-AG5-7S-S3C1 (H) JAE IL-AG5-7S-S3C1

TERMINAL : AG5-C1-5000 TERMINAL : AG5-C1-5000 TERMINAL : AG5-C1-5000

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

(M) MAKER : YAZAKI CORP. (N) MAKER : YAZAKI CORP.

(L) MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40
HOUSING No. : 7123-2249 REAR HOLDER : 7157-6260-30
TERMINAL : 17111 TERMINAL : 7114-2871 TERMINAL : 7116-2871

26 25 85E
150 E24 18

(P) (R) MAKER : SUMITOMO

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

150 155

SM0045

JAE : JAPAN AVIATION ELECTRONICS

INDUSTRY, LTD.

P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE

GRAPHIC_1D Figure 31

NA Issued 10-2007 Bur 5-27

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
1. Control panel and control unit
The control unit is integrated into control panel,
and processes the signal input by each sensor,
etc. and the signal input by each switch through
control panel with the function of the built-in
micro computer, and comprehensively controls
each actuator (Inner and outer air flow select, air
mix), fan motor and compressor on the output
side. And the self-diagnosis performance is
provided to facilitate the trouble shooting.
2. Blower controller (TKS-B215A1)
The power transistor shifts the fan motor into
variable speed with base current from the control
SM0047
unit. GRAPHIC_ID Figure 32

TERMINAL CONTINUITY 1 2 3
NO.

CONTINUED
+ -
(4.7 k ±5%)
- + NOT CONTINUED
TESTER CONTINUED (DIODE
PARALLEL AND
+ -
FORWARD DIRECTION Lg L
FLOW)

In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the 㨫 㨫
blower amplifier side.
NOTE: The installing position is provided on the left GRAPHIC_ID Figure 33
side of air conditioning unit.

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 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
3. Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
A. Blower OFF relay
The blower OFF relay turns on after receiving
the signal from the control amplifier. A
When the blower OFF relay turns on, the
source voltage is supplied to the blower motor A
and the blower motor starts running.
B. Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control.
C. Relay inspecting items GRAPHIC_ID Figure 34
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4.Be careful about the coil side of relay
because this relay has polarity.
5. Inspection: Inspect the continuity between
3 an d 4 a ccor din g to t he co nd ition s
mentioned below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2:
Not continued
4. Air mix actuator
Air mix actuator is installed at the center of air-
con unit, and opens and closes air mix damper
through the link.
The air mix actuator contains potentiometer
which is switched by being coupled to the shaft
of actuator.
CONTROL AMPLIFIER MOTOR ACTUATOR
When the target air mix door position is LIMITER
determined through the temperature control COOL
POTENTIO 5V
switch, the control unit reads the level of POTENTIO

potentiometer of the actuator, and determines POTENTIO GND

the rotating direction of motor in either normal

rotation or reverse rotation. Then as the motor GRAPHIC_ID
HOT
Figure 35
rotates, the contact point is moved, and when the
contact point is detached or the output signal of
control unit turns OFF, the motor stops rotating.

NA Issued 10-2007 Bur 5-29

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
5. The actuator for inner and outer
The actuator for inner and outer air flow select is
installed on the blower intake unit, and opens
and closes inner and outer air damper through
the link. The actuator for inner and outer air flow
select contains position detection switch which is
switched with the movement of shaft of the
actuator. AMPLIFIER MOTOR ACTUATOR

When the inner and outer damper position is set

by the inner and outer switch on the control
panel, the control unit reads the signal of the
position detection switch in the actuator and
determines the rotation direction of motor in INNER AIR SIDE

either normal rotation or reverse rotation. Then GRAPHIC_ID

OUTER AIR SIDE
Figure 36
as the motor rotates, the position detection
switch also rotates and makes it stop at the set
position of the inner and outer air damper.
6. Evaporator sensor
This sensor is used to control the evaporator
outlet temperature with the compressor ON-OFF
to protect the evaporator from freezing, and this
evaporator sensor functions as a sensor of this
control.
Evaporator sensor inspecting items
(Specification)
Terminal resistance:
at 0 degree C: 7.2 k
at 25 degree C: 2.2k
SM0052

GRAPHIC_ID Figure 37

7. Dual pressure switch

This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was
generated on the high pressure side.
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)

ON SM0053

OFF
0.20MPa 3.14MPa
GRAPHIC_ID

(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)

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 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
8. Solar radiation sensor
This solar radiation sensor, which is used to
correct the solar radiation to the auto air
conditioner detects the strength and solar
orientation of sunbeam after transforming them
into current by means of photo diode.
Inspection: Check for the continuity between
terminals.

SM0054
GRAPHIC_ID Figure 38

NA Issued 10-2007 Bur 5-31

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
TROUBLESHOOTING

Air temperature does not fall

If AUTO switch or A/C switch is pushed, HL.E is indicated on the set temperature
display of the panel
NO YES
Connector for air mix M/A is disconnected or in poor
HL.* is shown on the set temperature display of the contact.
panel. Air mix M/A has failed.
Main harness shows poor continuity.
NO YES

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

Inspect and correct or replace parts. A

NO YES

Blowout temp. falls if temp. is set at 18.0 ºC Evaporation sensor connector is disconnected or in
(64.4 ºC) (COOLMAX) and the blowout mode is poor condition.
changed to vent mode. Evaporation sensor is disconnected or shorted.

NO YES Inspect and correct or replace parts.

Air mix damper is in Cool air flowing into

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

Refer to troubleshooting for

refrigeration cycle. Inspect and replace.

NO YES
Inspect, correct or replace M/A M/A failed or controller is out of order.
lever link.
After cleaning lever link, apply
grease. Replace.

NOTE: M/A is motor actuator. * is any numbers 0 - 9.

5-32 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

Air temperature does not rise.

HL.E is shown on the set temp. display on the panel.

NO YES
Connector for air mix M/A is disconnected or
HL.* is shown on the set temp. display of the in poor contact.
panel. Air mix M/A has failed.
Main harness shows poor continuity.
NO YES
Inner air sensor or harness is Inspect and correct or replace parts.
disconnected or shorted.
Inner air sensor connector is
disconnected or in poor contact.

Inspect and correct or replace parts.

Blowout temp. rises at blowout mode if temp. is set at

HOT MAX 32.0 ºC (89.6 ºF)
NO YES
Air mix damper is in HOT Warm air is flowing into inner air
MAX. sensor.
NO YES NO YES
If M/A action is at Controller or
Inspect or eliminate causes for
stop, eliminate Inspect warm inner air sensor
warm air entry.
cause, correct and water piping. is out of order.
measure operating
force. (less than
14.7N: OK) Inspect and replace.

NO YES

Inspect, correct or replace M/A lever M/A failed or controller is

link. out of order.
Clean lever link and apply grease.

Replace.

NOTE: * is any of the numbers 0 - 9.

NA Issued 10-2007 Bur 5-33

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

Blower motor does not run.

At air flow HI, battery voltage acts across both

Note 1)
terminals (+) and (-) of blower motor.

NO YES

Battery voltage acts across red Blower motor fails

(+) and body of blower motor.

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

Eliminate cause and

Inspect and
Battery voltage acts across white/red replace blower
repair harness.
wire and body of blower motor relay. amplifier.

NO YES
Inspect and repair harness Blower turns if orange wire of blower
or replace. motor relay is connected with ground.
NO YES
Replace relay. Inspect and correct harness
or replace controller.

Note 1) Measure with connector set.

Note 2) Before beginning work always turn off air
conditioner, starter key switch, and light switch.

5-34 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

Blower motor speed does not change .

Case (1) HL. * is shown on the set temp. display of the

panel.
NO YES
Replace blower amplifier Inner air sensor or harness is disconnected or
controller. shorted.
Inner air sensor connector is disconnected or in
poor contact.
See section monitor mode

Inspect and correct or replace parts.

Case (2)
Blower motor does not change speed.

NO Yes
Is door or front window open? See case (1).
NO Yes
The limiting or control See case (1).
operation is actuated by the
door switch or front window
switch.

NOTE: * is any of the numbers 0 - 9.

NA Issued 10-2007 Bur 5-35

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

Magnetic clutch does not engage.

Snow mark lights if A/C switch is pressed.

NO YES

Snow mark flickers and E is Voltage acts upon the clutch.

shown on the panel display. NO Yes
Voltage is applied to Clutch is faulty.
Refer to "A" on page 32. pressure switch harness.
NO YES
Voltage acts across white/green wire and ground Pressure switch is faulty or refrigerant
(black) connector connected to excavator. gas is under charged or overcharged.
NO YES
Inspect clutch fuses. Inspect air conditioner Refer to troubleshooting for
harness. No fault. refrigeration cycle.
NO YES
Replace harness. Replace controller.

Inner air and outer air does not change.

Inner / outer air mode display on

operation panel is flickering.
NO YES
M/A lever contains foreign matter Connector of inner/outer air M/A is dis-
or is broken. connected or in poor contact. Or M/A
failed or main harness failed.
No YES
M/A failed.
Remove foreign
matter and replace Inspect or replace.
Replace. parts.

5-36 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

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
NO YES in poor contact or M/A failed or main
Repair. harness is faulty.
Each damper lever
does not disengage.
Inspect or replace.
NO YES
Repair When the rod is removed and cam is operated
by hand, it is heavy. ( more than 19.6N)

NO YES
M/A is controller is out of order. Cam or damper shaft contains
foreign matter or is broken.
Erroneous motion occurs die to
Replace. dirty grease.

Remove foreign matter or replace parts.

Clean cam and apply new grease.

NA Issued 10-2007 Bur 5-37

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM

Trouble with refrigeration cycle.

Both high and low pressures are lower.

Air bubbles are seen in sight glass.

NO YES
Cooling does not work if run at high speed. Oil comes out from piping and parts.
NO YES NO Yes
Expansion valve is
Expansion valve is clogged Natural leak from Gas leaks from pipe
frozen or intruded by
or needs adjusted. hose. joint and parts.
water.

Adjust or replace expansion After making Change gas Tighten pr replace

valve. vacuum, refill parts.
refrigerant and
replace receiver.

Low pressure is higher.

NO YES
Air bubbles are seen in sight glass. High pressure is lower

Compressor cylinder does not get hot. Compressor cylinder gets very hot.

Expansion valve needs adjusted. (open too much). Compressor does not discharge well.

Replace expansion valve. Replace compressor.

High pressure is lower.

Air bubbles are seen in sight glass

NO YES
High pressure gets lower slowly. Condenser is fouled or clogged.
NO Yes

High pressure circuit before Air bubbles are hard Clean condenser
receiver is clogged up. to get out even if
water is poured on
condenser.
Remove clogging or replace parts
Air is mixed. Create a
vacuum and refill
refrigerant.

5-38 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL
The failure of motor actuator and each sensor can be identified on the display of panel.

POSITION OF INDICATION FOR FAILURE.

SM0055

GRAPHIC_1D Figure 39
EXPLANATION OF INDICATION FOR FAILURE.

Failure of Motor Actuator

1. HL.E is indicated on 3 digits segment.

Check harness or connector to motor actuator for the air

mix damper for disconnection.

SM0056

GRAPHIC_ID Figure 40

2. MODE is flickering.

Check harness or connector to motor actuator for the air

outlet damper for disconnection.

SM0057

GRAPHIC_ID Figure 41

3. R/F is flickering.

Check harness or connector to motor actuator for the inner

and outer air damper for disconnection.
Note:The above indication and flickering does not function
if the harness and connector were disconnected under the
condition the panel ON/OFF switch is ON.
After the failure was occurred, if the panel ON/OFF switch
is turned ON, it functions.
After correction of failure, if the starter switch is not switched
from OFF to ON the error indication and flickering are not
released.
GRAPHIC_ID Figure 42
NA Issued 10-2007 Bur 5-39
 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Failures of Sensors
1. HL.* is indicated on 3 digits segment.

Check the inner air sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

SM0059

GRAPHIC_ID Figure 43

2. **E and mark are flickering.

Check evaporator sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

SM0060
GRAPHIC_ID Figure 44
Note:The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition the
panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is released.

Communication Error of Control Amplifier and

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

Check the harness of control amplifier and panel for

disconnection, and connectors for poor connection.

SM0061

GRAPHIC_ID Figure 45

5-40 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
EXPLANATION OF MONITOR MODE
When error FAILURE OF SENSORS is displayed, the monitor mode is available to identify the sensor condition
(disconnection, short circuit).
Position of Monitor Mode Indication

SM0062

GRAPHIC_1D Figure 46

Operation of Monitor Mode

A B E

SM0063
C D
GRAPHIC_1D Figure 47
1. Press inner and outer air flow select switch (A) and ON/OFF switch (D) simultaneously for 1 second.
2. Press AUTO switch (E).
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3. Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd
digit of segment in three digits. The 1st digit is indicated by H.
4. Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing UP
or DOWN of blower switch (B) or (C), and the required sensor is selected from the list below.

GRAPHIC_1D Figure 48
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5. The monitor display is terminated by pressing the inner and outer air flow select switch (A) and ON/OFF switch
(D) for 1 second again, or turning off the main switch of excavator.

NOTE: The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.

NOTE: Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch (D) again, and the error display is disappeared.

NA Issued 10-2007 Bur 5-41

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
Contents of Monitor Mode Display
Refer to the list of segment display exclusively used for monitor and the list of segments in three digits.
1. Example 1

When the segment exclusively used for monitor indicates 0

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

GRAPHIC_ID Figure 49

2. Example 2

When the segment exclusively used for monitor indicates 1

(displays the evaporator sensor condition), since the
segment indicates 00, the sensor is in disconnection
condition according to the list of 3 segments.
--> The evaporator sensor is in disconnection condition.
SM0066

GRAPHIC_ID Figure 50

3. Example 3

When the segment exclusively used for monitor

indicates 2 (displays the solar radiation sensor
condition), since the segment indicates FF, the
sensor is in short-circuiting condition according to the
list of 3 segments.
SM0067
-->The solar radiation sensor is in short-circuiting
condition.

GRAPHIC_ID Figure 51

5-42 Issued 10-2007 Bur NA

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
4. List of 3 segments
SECOND SEGMENT

INNER AIR SENSOR DISCONNECTION

EVAPORATOR SENSOR DISCONNECTION
SOLAR RADIATION SENSOR SHORT-CIRCUITING
THIRD SEGMENT

EACH SENSOR IS NORMAL

SOLAR RADIATION SENSOR 5V SIDE SHORT-CIRCUITING

INNER AIR SENSOR SHORT-CIRCUITING

EVAPORATOR SENSOR SHORT-CIRCUITING
SM0068
GRAPHIC_1D Figure 52

NA Issued 10-2007 Bur 5-43

 SECTION 2 - SYSTEMS
CHAPTER 5 - AIR CONDITIONING SYSTEM
NOTES

5-44 Issued 10-2007 Bur NA

REPAIR MANUAL - SECTION 3

E175B
EXCAVATOR

GENERAL REMOVAL/
INSTALLATION AND
DISASSEMBLY/ASSEMBLY

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783-NA
 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B
 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

SECTION 3
GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
SECTION TABLE OF CONTENTS
CHAPTER 1
ATTACHMENTS
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FRONT ATTACHMENT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
BOOM AND ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
CHAPTER 2
UPPER STRUCTURE
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
REMOVAL AND INSTALLION OF UPPER STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
DISASSEMBLY AND ASSEMBLY OF REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
REMOVAL AND INSTALLATION OF CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
REMOVAL AND INSTALLATION OF SWING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
DISASSEMBLY AND ASSEMBLY OF SWING REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
DISASSEMBLY RIGHT AND LEFT PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
DISASSEMBLY AND ASSEMBLY OF THE TRAVEL PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
CHAPTER 3
UNDERCARRIAGE (TRAVEL SYSTEM)
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
REMOVAL AND INSTALLATION OF SWING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
REMOVAL AND INSTALLATION OF TRAVEL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
DISASSEMBLY TRAVEL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
ASSEMBLY TRAVEL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
REMOVAL AND INSTALLATION OF SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
SWIVEL JOINT DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
REMOVAL AND INSTALLATION OF TRACK ADJUSTER (WITH FRONT IDLER) . . . . . . . . . . . . . . . . . 3-79
DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
DISASSEMBLY AND ASSEMBLY FRONT IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
REMOVAL AND INSTALLATION OF UPPER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
UPPER ROLLER DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
REMOVAL AND INSTALLATION OF LOWER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
LOWER ROLLER DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
REMOVAL AND INSTALLATION OF TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109

NA I
 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

NOTES

II Issued 10-2007 Bur NA

SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

CHAPTER 1

E175B
EXCAVATOR

ATTACHMENTS

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

1-II Issued 05-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

CHAPTER 1
ATTACHMENTS
TABLE OF CONTENTS

FRONT ATTACHMENT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

BOOM AND ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Monoblock version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Maintenance: Monoblock Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Triple Articulation Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Maintenance: Triple Articulation Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Standard Dimensions For Arm and Bucket Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Replacement of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Removing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Installing the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Bucket Play Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Bucket Teeth Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Bucket Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Bucket Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Arm Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Arm Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Boom Cylinders Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Boom Cylinders Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Positioner Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Positioner Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Cylinders Assembly and Disassembly (Bucket Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Bucket Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Bucket Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Arm Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
Arm Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Positioner Cylinder (Triple Articulation Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Positioner Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Positioner Cylinder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Boom Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Boom Cylinders Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
Boom Cylinders Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
Maintenance Standard: Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

NA Issued 10-2007 Bur 1-1

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS

NOTES

1-2 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
FRONT ATTACHMENT REMOVAL AND INSTALLATION

BOOM AND ARM

MONOBLOCK VERSION

WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent these dangers
by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the valve located on
the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before
starting any intervention, make sure that oil and components have cooled off.
Always make sure that hooks and chains used for lifting are in good condition and adequate to the expected load.
Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.
Removal
1. Park the machine on firm, level ground. Position
the front attachment as illustrated and lower the
bucket to the ground.
2. Disconnect lubrication hoses (1) from boom
cylinder rod end.

3. Loosen lock nuts (2), remove bolt (3) and

stopper (4) from boom cylinder rod end.
Carry out the same procedure for the other boom
cylinder.

GRAPHIC_ID S
Figure 1

1
3

4
2

SM0201
GRAPHIC_ID Figure 2
4. Attach each boom cylinder to a crane.
3
NOTE: Boom cylinder weight: 149 kg (328 lbs)
Remove cylinder rod end pin (5) and shims (6) using
a hammer and bar. 5 4 2

4 3
GRAPHIC_ID SM0202
Figure 3
NA Issued 10-2007 Bur 1-3
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
5. Slowly lower the boom cylinder using the crane
onto the wooden block.
6. Press the valve located on the hydraulic oil tank
to bleed the residual pressure inside the tank
itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
PROCEDURE FOR THE BLEEDING OF THE
P R E S S U R E F R O M T H E H Y D R AU L I C
SYSTEM.

SM0203
GRAPHIC_ID Figure 4

7. Disconnect hoses (7) and (8) of bucket cylinder

and arm cylinder.

NOTE: If the machine is equipped with the hammer/ 10 10

crusher, bucket rotation or anti-drop valves variants,
9 9
disconnect the relevant hoses (9), (10) and (11).
Bucket (7) and arm (8) cylinder hoses: 7 7
Hammer/crusher hoses (9):
Bucket rotation hoses (10):
8 8
Anti-drop valves hoses (11): 11 11
Close all openings with plugs to keep clean.
SM1000
GRAPHIC_ID Figure 5

8. Disconnect centralized lubrication hoses (12)

located between the boom cylinders.

12

GRAPHIC_ID SM1001

1-4 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
9. Loosen lock nuts (13) and remove bolt (14).
14
10. Sling the boom to a hoist. Slightly lift the boom.

NOTE: Approximate mass of the front equipment:

2700 kg (5952 lbs).

13

SM1002
GRAPHIC_ID Figure 6

11. Pull out the boom lower pivot pin (15) to the
frame using the appropriate puller.

SM0208
GRAPHIC_ID Figure 7

12. Lift the front attachment. Move the machine

away from the front attachment and the hoist.

15

SM1003
GRAPHIC_ID Figure 8

NA Issued 10-2007 Bur 1-5

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Installation
1. Lift the front attachment. 14

NOTE: Approximate mass of the front equipment:

2700 kg (5952 lbs) 15
Install dust seals to boom foot. Align the boom
foot boss with the main frame boss. Insert a
thrust plate to both right and left sides of the 13
boom foot boss to take out clearance between
the boom foot boss and the main frame boss.
2. Install boom foot pin (15) using a hammer and
bar.
SM1004
GRAPHIC_ID Figure 9

3. Install bolt (14) and tighten lock nuts (13).

Tightening torque: 200 Nm (148 pound-feet)
4. Connect hoses (7) and (8) of bucket cylinder and 10 10
arm cylinder.
9 9
NOTE: If the machine is equipped with the hammer/
crusher, bucket rotation or anti-drop valves variants, 7 7
connect the relevant hoses (9), (10) and (11).
Bucket (7) and arm (8) cylinder hoses:
8 8
Tightening torque: 177 ± 18 Nm (130 ± 13 11 11
pound-feet)
Hammer/crusher hoses (9):
SM1000
GRAPHIC_ID Figure 10
Tightening torque: 177 ± 18 Nm (130 ± 13
pound-feet)
Bucket rotation hoses (10):
Tightening torque: 78 ± 5 Nm (57.5 ± 3.7 pound-
feet)
Anti-drop valves hoses (11):
Tightening torque: 49 ± 5 Nm (36 ± 3.7 pound-
feet)

1-6 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
5. Attach the boom cylinder to a crane.

NOTE: Boom cylinder weight: 149 kg (328 lbs)

Lift the boom cylinder and align the boom
cylinder rod with the pin hole on the boom.

NOTE: For easy alignment, start the engine and use

the boom control lever.

SM0211
GRAPHIC_ID Figure 11

6. Install shims (6) and insert pin (5).

7. Install stopper (4), tighten bolts (3) and lock nuts 3
(2):
Tightening torque: 147 Nm (108 pound-feet)
5 4 2

4 3
GRAPHIC_ID SM0202
Figure 12

8. Connect lubrication hoses (1) to boom cylinder

rod.
5
Tightening torque: 20 Nm (14.8 pound-feet)
1
3

4
2

SM0201
GRAPHIC_ID Figure 13

NA Issued 10-2007 Bur 1-7

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
9. Connect centralized lubrication hoses (12)
located between the boom cylinders.
Tightening torque: 20 Nm (14.8 pound-feet)
12
Using a grease gun, inject grease via nipples
(16) (boom) and (17) (boom cylinders).

NOTE: Fill the hydraulic oil tank with hydraulic oil to

17 16 17
the specified level. Run the engine at idle. Check
hose connections for any oil leakage.
IMPORTANT: Bleed air from hydraulic circuit.

SM1005
GRAPHIC_ID Figure 14

1-8 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Maintenance: Monoblock Version

F E G H

A B C J K

D I

SM0213

GRAPHIC_1D Figure 15

Parts name Standard Allowable limit Remedy

Pin 85 84
A
Bushing 85 86.5
Pin 85 84
B Boss (Main Frame) 85 86,5
Bushing (Boom Cylinder) 85 86,5
Pin 85 84
C Bushing (Boom Cylinder) 85 86,5
Foro (Boom) 85 86,5
Pin 80 79
D
Bushing 80 85.5
Pin 80 79
E Boss (Arm) 80 81.5
Bushing (Arm Cylinder) 80 81.5
Pin 80 79
Replace
F Boss (Arm) 80 81.5
Bushing (Arm Cylinder) 80 81.5
Pin 70 69
G Boss (Arm) 70 71.5
Bushing ( Bucket Cylinder) 70 71.5
Pin 70 69
H Boss 70 71.5
Bushing ( Bucket Cylinder) 70 71.5
Pin 65 64
I
Bushing 65 66.5
Pin 80 79
J
Bushing 80 81.5
Pin 80 79
K
Bushing 80 81.5

IMPORTANT: Be sure to install front attachment bushings using a press.

NA Issued 10-2007 Bur 1-9
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
TRIPLE ARTICULATION VERSION

WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this dangers
by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the valve located on
the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before
starting any intervention, make sure that oil and components have cooled off.
Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load.
Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.

Removal
1. Park the machine on firm, level ground. Position
the front attachment as illustrated and lower the
bucket to the ground.
2. Disconnect lubrication pipes (1) from boom
cylinder rod end.

3. Loosen lock nuts (2), remove bolt (3) and

stopper (4) from boom cylinder rod end.
Carry out the same procedure for the other boom
cylinder.

SM0215
GRAPHIC_ID Figure 16
4. Attach each boom cylinder to a crane.

NOTE: Boom cylinder weight: 149 kg (328 lbs) 3

Remove cylinder rod end pin (5) and shims (6)
using a hammer and bar. 5 1

4
2
SM1006
GRAPHIC_ID Figure 17

5 4 2

4 3
GRAPHIC_ID SM0217
Figure 18

1-10 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
5. Slowly lower the boom cylinder using the crane
onto the wooden block.
6. Press the valve located on the hydraulic oil tank
to bleed the residual pressure inside the tank
itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
PROCEDURE FOR THE BLEEDING OF THE
P R E S S U R E F R O M T H E H Y D R AU L I C
SYSTEM.
7. Disconnect hoses (12), (7) and (8) of positioner
cylinder, bucket cylinder and arm cylinder.
SM0218
GRAPHIC_ID Figure 19

NOTE: If the machine is equipped with the hammer/

crusher, bucket rotation or anti-drop valves variants,
disconnect the relevant hoses (9), (10) and (11). 10
Positioner cylinder hoses (12) (from the control
valve):
9 9 7 7
Bucket (7) and arm (8) cylinder hoses:
Hammer/crusher hoses (9):
Bucket rotation hoses (10): 8 8
12 12
Anti-drop valves hoses (11):
11 11
Close all openings with plugs to keep clean.
SM1007
GRAPHIC_ID Figure 20

8. Disconnect centralized lubrication hoses (13)

located between the boom cylinders.

13

SM1008
GRAPHIC_ID Figure 21

NA Issued 10-2007 Bur 1-11

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
9. Loosen lock nuts (14) and remove bolt (15).
10. Sling the boom to a hoist. Slightly lift the boom. 15

NOTE: Approximate mass of the front equipment:

3200 kg (7055 lbs).

14

SM1009
GRAPHIC_ID Figure 22

11. Pull out the boom lower pivot pin (16) to the
frame using the appropriate puller.

16

SM1010
GRAPHIC_ID Figure 23

12. Lift the front attachment. Move the machine

away from the front attachment and the hoist.

SM0223
GRAPHIC_ID Figure 24

1-12 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Installation
1. Lift the front attachment. 15

NOTE: Approximate mass of the front equipment:

3200 kg (7055 lbs) 16
Install dust seals to boom foot. Align the boom foot
boss with the main frame boss. Insert a thrust plate
to both right and left sides of the boom foot boss to 14
take out clearance between the boom foot boss and
the main frame boss.
2. Install boom foot pin (16) using a hammer and
bar.
SM1011
GRAPHIC_ID Figure 25

3. Install bolt (15) and tighten lock nuts (14).

Tightening torque: 200 Nm (147 pound-feet)
10

4. Connect bucket cylinder hoses (7), positioner

cylinder hoses (12) and arm cylinder hoses (8). 9 9 7 7

NOTE: If the machine is equipped with the hammer/ 8 8

crusher, bucket rotation or anti-drop valves variants, 12 12
connect the relevant hoses (9), (10) and (11). 11 11
Positioner cylinder hoses (12) (from the control
valve):
SM1007
GRAPHIC_ID Figure 26
Tightening torque: 83 ± 5 Nm (61 ± 3.7 pound-
feet)
Bucket (7) and arm (8) cylinder hoses:
Tightening torque: 177 ± 18 Nm (130 ± 13
pound-feet)
Hammer/crusher hoses (9):
Tightening torque: 177 ± 18 Nm (130 ± 13
pound-feet)
Bucket rotation hoses (10):
Tightening torque: 78 ± 5 Nm (57.5 ± 3.7 pound-
feet)
Anti-drop valves hoses (11):
Tightening torque: 49 ± 5 Nm (36 ± 3.7 pound-
feet)

NA Issued 10-2007 Bur 1-13

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
5. Attach the boom cylinder to a crane.

NOTE: Boom cylinder weight: 149 kg (328 lbs)

Lift the boom cylinder and align the boom cylinder
rod with the pin hole on the boom.

NOTE: For easy alignment, start the engine and use

the boom control lever.
6. Install shims (6) and insert pin (5).
7. Install stopper (4), tighten bolts (3) and lock nuts
(2): 3
Tightening torque: 147 Nm (108 pound-feet)
8. Connect lubrication hoses (1) to boom cylinder
5 4 2
rod.
Tightening torque: 20 Nm (14.8 pound-feet)
2

4 3
GRAPHIC_ID SM0217
Figure 27
9. Connect centralized lubrication hoses (13)
located between the boom cylinders.
Tightening torque: 20 Nm (14.8 pound-feet) 3
Using a grease gun, inject grease via nipples (17) 1
(boom) and (18) (boom cylinders). 5

NOTE: Fill the hydraulic oil tank with hydraulic oil to

the specified level. Run the engine at idle.
Check hose connections for any oil leakage.
IMPORTANT: Bleed air from hydraulic circuit. 4
2
SM1006
GRAPHIC_ID Figure 28

13

18 17 18

SM1012
GRAPHIC_ID Figure 29

1-14 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Maintenance: Triple Articulation Version

F E L M G

A B C D H J K

N I

GRAPHIC_1D Figure 30

Unit: mm
Parts name Standard Allowable limit Remedy
Pin 85 84
A-D-N
Bushing 85 86.5
Pin 85 84
B Boss (Main Frame) 85 86.5
Bushing (Boom Cylinder) 85 86.5
Pin 85 84
C Bushing (Boom Cylinder) 85 86.5
Boss (Boom) 85 86.5
Pin 85 84
E Boss (Positioner) 85 86.5
Bushing (Positioner Cylinder) 85 86.5
Pin 85 84
F Boss (Boom) 85 86.5
Bushing (Positioner Cylinder) 85 86.5
Pin 70 69
Replace
G Boss (Arm) 70 71.5
Bushing (Bucket Cylinder) 70 71.5
Pin 70 69
H Bushing 70 71.5
Bushing (Bucket Cylinder) 70 71.5
Pin 65 64
I
Bushing 65 66.5
Pin 80 79
J-K
Bushing 80 81.5
Pin 80 79
L Boss (Positioner) 80 81.5
Bushing (Arm Cylinder) 80 81.5
Pin 80 79
M Boss (Arm) 80 81.5
Bushing (Arm Cylinder)

IMPORTANT: Be sure to install front attachment bushings using a press.

NA Issued 10-2007 Bur 1-15
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION

o p q
g
h
k

A i
j

d
l
m
B
f
c
B n
e

a b

A
SM0214
GRAPHIC_1D Figure 31

E175B
a (*) 326
b (*) 50
c 580
d 525
e 400.1
f 1369
g 433
h 326
i 80
j 399
k 30
l 433
m 307
n 80
o 45°
p 0°
q 449
(*) Arm: 2600 mm

1-16 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
BUCKET
REPLACEMENT OF BUCKET

CAUTION
1. Place the bucket on firm level ground. Pay
close attention to safety.
2. When aligning the pin bores, DO NOT
INSERT YOUR HAND OR FINGERS into the
bores. It may cause severe injury. Align the
bores visually or using a tool.
3. Hold the removed bucket in the stable
condition.
GRAPHIC_ID Figure 32
Removing the Bucket
Place the machine on a firm and flat surface and rest
the bucket on the ground in a stable position.
Place O-rings (1) out of the relevant seats. Remove
the pins and the retaining rings of the pins.
Remove pin (E) and pin (B); then remove the bucket.

INSTALLING THE BUCKET

Using a suitable hoist, place the bucket on the same
level as the tracks.
Position the O-Rings (1)outside their seats.
Using the arm cylinder control and boom cylinder GRAPHIC_ID Figure 33
control make small ver tical and hor izontal
movements to insert pivot pin (B) connecting the
bucket to the arm into hole (A).
U s e t h e bu cke t c y l i n d e r c o n t r o l t o a l i g n t h e
connecting rod (C) to hole (D) and insert pivot pin
(E).
Secure pivot pins using lock pins and retaining rings
and reposition the O rings into their seats.
IMPORTANT: During the removal of the bucket, take
care that the pin are not contaminated by dirt, sand
etc. After the reinstallation of the bucket, provide
grease to the pins through the appropriate fittings.
BUCKET PLAY ADJUSTMENT
Bucket play (g) is adjusted by opportunely changing
total shims installed.

NOTE: Bucket play (g) should be 0.5 to 1.5 mm.

If bucket play (g) exceeds the specified value,
increase adjust shims as follows:
1. Loosen the three bolts (2) taking care to retrieve
the washers. Slide out the ring (1);
2. Add adjust shims (3) until compensating the play
(g);
3. Install the ring (1), and tighten securing bolts (2).
GRAPHIC_ID Figure 34

NA Issued 10-2007 Bur 1-17

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
BUCKET TEETH REPLACEMENT

WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.

Make sure the machine is parked on a level surface.

Rest the bucket to the ground.
Switch off the Auto-Idle, fully turn the engine speed
manual control counterclockwise, stop the engine,
remove the ignition key and move the safety lever in
the locked position (LOCK).
Use a hammer and punch to push lock pin (1) out of
its seat and remove the tip of bucket tooth (2). GRAPHIC_ID Figure 35

NOTE: To push lock pin (1) out of its seat, strike it

with a punch on its upper side.
Install a new rubber insert (3) inside lock pin (1).
Clean the surface of bucket tooth (4) and insert a
new tip.
Insert lock pin (1) into its seat using a punch and
hammer, until it is fully mounted.

GRAPHIC_ID Figure 36

1-18 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
CYLINDERS
REMOVAL AND INSTALLATION

WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries. Prevent this dangers
by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes. Press the valve located on
the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before
starting any intervention, make sure that oil and components have cooled off.
Always ensure that hooks and chains used for lifting are in good condition and adequate to the expected load.
Metal fragments may fly off when a hammer is used to remove pins. Be sure to wear necessary protection.

Bucket Cylinder Removal

1. Park the machine on firm, level ground. Position
the front attachment as illustrated and lower the
bucket to the ground.
2. Press the valve located on the hydraulic oil tank
to bleed the residual pressure inside the tank
itself.
3. Insert wooden block (3) between bucket cylinder
(1) and arm (2).

GRAPHIC_ID S
Figure 37
4. Complete the bleeding of the residual pressure
from the hydraulic system, making reference to 1
PROCEDURE FOR THE BLEEDING OF THE
P R E S S U R E F R O M T H E H Y D R AU L I C
SYSTEM.
IMPORTANT: Pin (6) end of the link will drop when 3
pin is removed, possibly resulting in personal injury.
Be sure to secure the link using a wire before
removing pin (6).
2
5. Loosen lock nuts (4) and remove bolt (5).
Pull-out pin (6) with the help of a mallet and a bar
so that the end of the cylinder is free, then
remove adjusting shims (7). SM0226
GRAPHIC_ID Figure 38

6
7 4

GRAPHIC_ID Figure 39

NA Issued 10-2007 Bur 1-19

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
6. Disconnected hoses (8) from bucket cylinder (1).

9
12
Put plugs on cylinder pipes and hoses. 11

NOTE: Bucket cylinder weight: 128 kg (282 lbs)

10
7. Using a hoist, slightly lift bucket cylinder (1).
Loosen locking nuts (9) remove screw (10) and
pull-out pin (11) with the help of a mallet and a 1
bar so that the end of the cylinder is free, then
remove adjusting shims (12).

8
8. Remove bucket cylinder (1).

SM0228

GRAPHIC_ID Figure 40

1-20 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Bucket Cylinder Installation 12
11
NOTE: Bucket cylinder weight: 128 kg (282 lbs)
1. Connect bucket cylinder (1) to a crane using a
10
sling belt.
Align the hole of the bucket cylinder with the pin
hole on the arm-tip bracket. 1
2. Install adjusting shims (12) and insert pin (11).
Install screw (10) and tighten lock-nuts (1).
Tightening torque: 120 ± 12 Nm (88.5 ± 8.9 8
pound-feet)
3. Connect two hoses (8) to bucket cylinder (1).
10 mm
8
Tightening torque: 83 ± 5 Nm (61 ± 3.7 pound-
feet)
36 mm
Tightening torque: 177 Nm (130 pound-feet)

NOTE: Fill the hydraulic oil tank with hydraulic oil to

the specified level. Run the engine at idle. Check
hose connections for any oil leakage.

GRAPHIC_ID Figure 41
4. Align the bucket cylinder rod with bucket links
(13) and (14). 6
7 4
Install shims (7) and pin (6).
NOTE: For easy alignment, start the engine and use
the arm control lever.
5. Install bolt (5) onto pin (6) then tighten lock nuts 5
(4).
14
Tightening torque: 103 ± 10 Nm (76 ± 7.4 pound-
13
feet)
IMPORTANT: If link (13) has been disconnected
from the arm, be sure to insert shims (7) when
connecting it. Bleed air from hydraulic circuit.
GRAPHIC_ID Figure 42

NA Issued 10-2007 Bur 1-21

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Arm Cylinder Removal
1. Insert a wooden block (3) between arm cylinder
(1) and boom (2). 1
2. Press the valve located on the hydraulic oil tank
to bleed the residual pressure inside the tank
itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to 3
PROCEDURE FOR THE BLEEDING OF THE
P R E S S U R E F R O M T H E H Y D R AU L I C
SYSTEM. 2

SM0230
GRAPHIC_ID Figure 43

3. Loosen lock nuts (4), remove bolt (5) and pull-out 6

pin (6) with the help of a mallet and a bar so that 7 4
the end of the cylinder is free, then remove
adjusting shims (7).

SM0231
GRAPHIC_ID Figure 44

4. Disconnected hoses (8) and (9) from arm

cylinder.
Put plugs on cylinder pipes and hoses. 8
5. Disconnect lubrication hose (10).

NOTE: Arm cylinder weight: 194 kg (428 lbs) 10

SM0232
GRAPHIC_ID Figure 45

1-22 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
6. Using a hoist, slightly lift arm cylinder (1). 13
Loosen locking nuts (11) remove screw (12) and 14 11
pull-out pin (13) with the help of a mallet and a
bar so that the end of the cylinder is free, then
remove adjusting shims (14).
7. Remove arm cylinder (1).
12

SM0233
GRAPHIC_ID Figure 46

NA Issued 10-2007 Bur 1-23

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Arm Cylinder Installation

NOTE: Arm cylinder weight: 194 kg (428 lbs)

1. Using a crane, align the hole of the arm cylinder
with the pin hole on the boom-tip bracket.
2. Install adjusting shims (14), pin (13), install screw 13
14 11
(12) onto pin (13) and tighten lock-nuts (11).
Tightening torque: 147 Nm (108 pound-feet)
3. Connect lubrication hoses (10) and hoses (8)
and (9) to the arm cylinder.
12
10 mm
Tightening torque: 83 ± 5 Nm (61 ± 3.7 pound-
feet)
36 mm
Tightening torque: 177 Nm (130 pound-feet)
SM0233
GRAPHIC_ID Figure 47
NOTE: Fill the hydraulic oil tank with hydraulic oil to
the specified level. Run the engine at idle. Check
hose connections for any oil leakage. 8
4. Slightly lift arm cylinder and align the arm
cylinder rod with the pin hole on the arm.
NOTE: For easy alignment, start the engine and use
the arm control lever. 10

SM0232
GRAPHIC_ID Figure 48

5. Install adjusting shims (7), pin (6), install screw 6

(5) onto pin (6) and tighten lock-nuts (4). 7 4
Tightening torque: 103 ± 10 Nm (76 ± 7.4 pound-
feet)
IMPORTANT: Bleed air from hydraulic circuit.
5

SM0231
GRAPHIC_ID Figure 49

1-24 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Boom Cylinders Removal
1. Park the machine on firm, level surface and
5
lower the bucket teeth and arm top to the ground
with the arm and bucket cylinders fully retracted.
1
2. Disconnect lubrication hoses (1). 3

3. Loosen lock nuts (2), remove bolt (3) and

stopper (4) from boom cylinder rod end.
4
2
NOTE: Boom cylinder weight: 149 kg (328 Lbs).

SM0201
GRAPHIC_ID Figure 50

4. Attach boom cylinder to a crane.

5. Slowly lower the boom cylinder using the crane 3
onto the wooden block.
6. Press the valve located on the hydraulic oil tank
to bleed the residual pressure inside the tank 5 4 2
itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to 2
PROCEDURE FOR THE BLEEDING OF THE
P R E S S U R E F R O M T H E H Y D R AU L I C 6
SYSTEM.

4 3
GRAPHIC_ID SM0202
Figure 51

7. Disconnect hoses (7) of boom cylinder. Put plugs

on cylinder pipes and hoses.

8. Disconnect centralized lubrication hoses (10)

located between the boom cylinders. 7

9. Remove securing screws (8) complete with

washers, then remove pin (9) and adjusting
shims (10). 9
8

SM0234
GRAPHIC_ID Figure 52

NA Issued 10-2007 Bur 1-25

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
10. Using a hoist, lift boom cylinder. Remove the
o t h e r b o o m c y l i n d e r fo l l o w i n g t h e s a m e
10 10
procedure.

SM0235
GRAPHIC_ID Figure 53

1-26 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Boom Cylinders Installation

NOTE: Boom cylinder weight: 149 kg (328 lbs)

1. Using a crane, install the boom cylinders to the
main frame. 7
2. Install adjusting shims and pin (9), then tighten
securing screws (8) complete with washers.
Tightening torque: 220 ± 22 Nm (162 ± 16.2
pound-feet)
9
3. Connect hoses (7) to boom cylinder.
8
Tightening torque: 137 Nm (101 pound-feet)
SM0234
GRAPHIC_ID Figure 54

4. Connect centralized lubrication hoses (10)

located between the boom cylinders.
10 10
Tightening torque: 20 Nm (14.8 pound-feet)

SM0235
GRAPHIC_ID Figure 55

5. Install shims (6) and insert pin (5).

6. Install stopper (4), tighten bolts (3) and lock nuts 3
(2):
Tightening torque: 147 Nm (108 pound-feet)
7. Connect lubrication hoses (1) to boom cylinder 5 4 2
rod.
Tightening torque: 20 Nm (14.8 pound-feet) 2

4 3
GRAPHIC_ID SM0202
Figure 56

NA Issued 10-2007 Bur 1-27

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
8. Using a grease gun, inject grease via nipples
(10).
10 10
Install the other boom cylinder following the same
procedure.

NOTE: Fill the hydraulic oil tank with hydraulic oil to

the specified level. Run the engine at idle. Check
hose connections for any oil leakage.
IMPORTANT: Bleed air from hydraulic circuit.

SM0235
GRAPHIC_ID Figure 57

1-28 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Positioner Cylinder Removal
1. Insert a wooden block (3) between positioner
cylinder (1) and boom (2).
2. Press the valve located on the hydraulic oil tank
to bleed the residual pressure inside the tank 1
itself.
Complete the bleeding of the residual pressure
from the hydraulic system, making reference to
PROCEDURE FOR THE BLEEDING OF THE
P R E S S U R E F R O M T H E H Y D R AU L I C 3
SYSTEM.

2
SM0236
GRAPHIC_ID Figure 58

3. Loosen lock nuts (4), remove bolt (5) and pull-out 6

pin (6) with the help of a mallet and a bar so that 7 4
the end of the cylinder is free, then remove
adjusting shims (7).

SM0237
GRAPHIC_ID Figure 59

4. Disconnect hoses (8) and (9) from arm cylinder.

Put plugs on cylinder pipes and hoses.
8
5. Disconnect lubrication hose (10).

NOTE: Positioner cylinder weight: 220 kg (485 lbs).

10

SM0232
GRAPHIC_ID Figure 60

NA Issued 10-2007 Bur 1-29

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
6. Using a hoist, slightly lift positioner cylinder (1). 13
Loosen locking nuts (11) remove screw (12) and 14 11
pull-out pin (13) with the help of a mallet and a
bar so that the end of the cylinder is free, then
remove adjusting shims (14).

12
7. Remove positioner cylinder (1).

SM0233
GRAPHIC_ID Figure 61

1-30 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Positioner Cylinder Installation 13
14 11
NOTE: Positioner cylinder weight: 220 kg (485 lbs)
1. Using a crane, align the hole of the positioner
cylinder with the pin hole on the boom-tip
bracket.
12
2. Install adjusting shims (14), pin (13), install screw
(12) onto pin (13) and tighten lock-nuts (11).
Tightening torque: 147 Nm (108 pound-feet)

SM0233
GRAPHIC_ID Figure 62

3. Connect lubrication hoses (10) and hoses (8)

and (9) to positioner cylinder.
10 mm
8

Tightening torque: 83 ± 5 Nm (61 ± 3.7 pound-

feet)
36 mm
10
Tightening torque: 177 Nm (130 pound-feet)

SM0232
GRAPHIC_ID Figure 63

NOTE: Fill the hydraulic oil tank with hydraulic oil to

the specified level. Run the engine at idle. Check
hose connections for any oil leakage.
4. Slightly lift positioner cylinder and align the
positioner cylinder rod with the pin hole on the
arm.

NOTE: For easy alignment, start the engine and use

the arm control lever.

NA Issued 10-2007 Bur 1-31

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
5. Install adjusting shims (7), pin (6), install screw 6
(5) onto pin (6) and tighten lock-nuts (4). 7 4
Tightening torque: 147 Nm (108 pound-feet)
IMPORTANT: Bleed air from hydraulic circuit.
5

SM0237
GRAPHIC_ID Figure 64

1-32 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
CYLINDERS ASSEMBLY AND DISASSEMBLY (BUCKET CYLINDER)

13
19
20
15

16
17
18
16
19
20
21
24
23 22

11

12

1
2
3
8 4

5
6
9
10

GRAPHIC_1D Figure 65

1. WIPER RING 9. BACKUP RING 18. O-RING

2. BACKUP RING 10. O-RING 19. SLIDE RING (QTY 2)
3. SEAL 11. CYLINDER ROD 20. SLIDE RING (QTY 2)
4. SEAL 12. CYLINDER TUBE 21. SHIM
5. BUSHING 13. CUSHION BEARING 22. SET SCREW
6. SNAP RING 14. PISTON 23. STEEL BALL
7. CYLINDER HEAD 16. BACKUP RING (QTY 2) 24. NUT
8. SOCKET BOLT (QTY 12) 17. SEAL RING

NA Issued 10-2007 Bur 1-33

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Bucket Cylinder Disassembly
Be sure to read all the precautions for disassembly/
assembly work before star ting the disassembly
procedure.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.

NOTE: Bucket cylinder mass: 128 kg (282 lbs)

1. Lift and securely place the cylinder on a

workbench using a crane.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
2. Fully extend cylinder rod (11). Secure the rod
end using a crane. Remove socket bolts (8) from
cylinder head (7).
IMPORTANT: Be sure to pull cylinder rod (11)
straight so as not to damage the sliding surfaces.
3. Pull out cylinder head (7) from cylinder tube (12)
by tapping with a plastic hammer.
4. Secure cylinder rod (11). Put matching marks
between cylinder rod (11) and nut (24).
5. Remove set screw (22) and steel ball (23).

NOTE: Cut away its mushroomed portion using a

drill first, as set screw was mushroomed with a punch
and hammer at two places after it had been screwed
in.
6. Loosen nut (24).
Remove piston (15), shim (21) cushion bearing.
Socket to loosen nut (24):

7. Remove seal ring (17), slide rings (19) and (20),

O-ring (18) and backup rings (16) from piston
(15).
8. Remove cylinder head (7) from cylinder rod (11).
9. Remove O-Rings (10), backup rings (9) and (2)
from cylinder head (7), then remove wiper ring
(1), seal (3), buffer ring (4), snap ring (6), and
bushing (5).

1-34 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Bucket Cylinder Assembly
1. Install bushing (5) to cylinder head (7) using a
press.

IMPORTANT: Be sure that the rings are installed

correctly.
2. Install seal (3), back-up ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
4. Install O-Rings (10) and backup ring (9) to
cylinder head (7).
5. Install O-Ring (18), backup ring (16) (Qty 2), seal
ring (17), slide ring (19) (Qty 2), (20) (Qty 2) to
piston (15).

6. Install cylinder head (7) to cylinder rod (11).

IMPORTANT: Be sure that the cushion seal slit faces

toward the piston and that the cushion bearing oil
groove faces the correct direction.
7. Install cushion bearing (13) to cylinder rod (11).
Install piston (15) to cylinder rod (11).
8. Install shim (21) to cylinder rod (11).
Tighten nut (24).
Be sure to align the machine mark on the rod
with that on the nut.
Socket to tighten nut (24):
Tightening torque: 4810 Nm (3548 pound-feet)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two
places using a punch and hammer.
Tightening torque: 56.9 ± 10.7 Nm (42 ± 7.9
pound-feet)
IMPORTANT: Be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in
order to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a
work bench.
Insert cylinder rod (11) into cylinder tube (12).
11. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
Tightening torque: 171 Nm (126 pound-feet)

NA Issued 10-2007 Bur 1-35

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
ARM CYLINDER

14
13
19
20

15

23 22
16
17
18
16
20 11
19 25
26
27
28

12
1
2
3
8 4

5
6
9
10

SM0241
GRAPHIC_1D Figure 66

1. WIPER RING 10. O -RING 19. SLIDE RING (QTY 2)

2. BACKUP RING 11. CYLINDER ROD 20. SLIDE RING (QTY 2)
3. SEAL 12. CYLINDER TUBE 22. SET SCREW
4. SEAL 13. CUSHION BEARING 23. STEEL BALL
5. BUSHING 14. CUSHION SEAL 25. SNAP RING
6. SNAP RING 15. PISTON 26. CUSHION SEAL
7. CYLINDER HEAD 16. BACKUP RING (QTY 2) 27. CUSHION BEARING
8. SOCKET BOLT (QTY 12) 17. SEAL RING 28. STOPPER
9. BACKUP RING 18. O -RING
1-36 Issued 10-2007 Bur NA
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Arm Cylinder Disassembly
Be sure to read all the precautions for disassembly/
assembly work before star ting the disassembly
procedure.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.
NOTE: Arm cylinder mass: 194 kg (428 lbs)
1. Lift and securely place the cylinder on a
workbench using a crane. Be sure that the
cylinder is placed horizontally. Drain hydraulic oil
from the cylinder.
2. Fully extend cylinder rod (11). Secure the rod
end using a crane. Remove socket bolts (8) from
cylinder head (7).

IMPORTANT: Be sure to pull cylinder rod (11)

straight so as not to damage the sliding surfaces.
3. Pull out cylinder head (7) from cylinder tube (12)
by tapping with a plastic hammer.Secure cylinder
rod (11). Put matching marks between cylinder
rod (11) and piston nut (15).
4. Remove set screw (22) and steel ball (23).

NOTE: Cut away its mushroomed portion using a

drill first, as set screw was mushroomed with a punch
and hammer at two places after it had been screwed
in.
5. Loosen piston (15).
Remove shim (21) cushion bearing (13) and
cushion seal (14).
6. Remove seal ring (17), slide rings (19) and (20),
O-ring (18) and backup rings (16) from piston
(15).
7. Remove cylinder head (7) from cylinder rod (11).
8. Remove O-Rings (10), backup rings (9) and (2)
from cylinder head (7), then remove wiper ring
(1), seal (3), buffer ring (4), snap ring (6), and
bushing (5).
9. Remove stopper (28) from cylinder rod (11)
using a screw driver. Remove cushion bearing
(27), cushion seal (26), and snap ring (25).

NA Issued 10-2007 Bur 1-37

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Arm Cylinder Assembly
1. Install bushing (5) to cylinder head (7) using a
press.
Be sure that the rings are installed correctly.
2. Install seal (3), backup ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer.
4. Install O-Rings (10) and backup ring (9) to
cylinder head (7).
5. Install O-Ring (18), backup ring (16) (Qty 2), seal
ring (17), slide ring (19) (Qty 2) and (20) (Qty 2)
to piston (15).

6. Install cylinder head (7) to cylinder rod (11).

IMPORTANT: Be sure that the cushion seal slit faces

toward the piston and that the cushion bearing oil
groove faces the correct direction.
7. Install cushion seal (14) to cylinder rod (11).
Install cushion bearing (13) and piston (15) to
cylinder rod (11).
8. Install shim (21) to cylinder rod (11). Tighten
piston nut (15).
Be sure to align the machine mark on the rod
with that on the nut.
Tightening torque: 8200 Nm (6048 pound-feet)
9. Align the holes on cylinder rod (11) and piston
nut (15). Insert steel ball (23) into the hole, and
tighten set screw (22) into the hole.
Mushroom the head of set screw (22) at two
places using a punch and hammer.
Tightening torque: 56.9 ± 10.7 Nm (42 ± 7.9
pound-feet)
IMPORTANT: Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
groove faces the correct direction.
10. Install snap ring (25) and cushion seal (26) to
cylinder rod (11). Install cushion bearing (27) and
stopper (28) to cylinder rod (11).
IMPORTANT: Be sure to keep cylinder rod (11)
aligned with the center of cylinder tube (12) when
inserting, in order to avoid damaging the rings.
11. Secure cylinder tube (12) horizontally using a
vise.
Insert cylinder rod (11) into cylinder tube (12).
12. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
Tightening torque: 267 Nm (197 pound-feet)

1-38 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
POSITIONER CYLINDER (TRIPLE ARTICULATION VERSION)

19
20
15

16
17
18
16
19
20
21
24
23 22

11

12

1
2
3
8 4

5
6
9
10

SM0242
GRAPHIC_1D Figure 67

1. WIPER RING 9. BACKUP RING 19. SLIDE RING (QTY 2)

2. BACKUP RING 10. O -RING 20. SLIDE RING (QTY 2)
3. SEAL 11. CYLINDER ROD 21. SHIM
4. SEAL 12. CYLINDER TUBE 22. SET SCREW
5. BUSHING 15. PISTON 23. STEEL BALL
6. SNAP RING 16. BACKUP RING (QTY 2) 24. NUT
7. CYLINDER HEAD 17. SEAL RING
8. SOCKET BOLT (QTY 12) 18. O -RING

NA Issued 10-2007 Bur 1-39

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Positioner Cylinder Disassembly
Be sure to read all the precautions for disassembly/
assembly work before star ting the disassembly
procedure.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.

NOTE: Positioner cylinder mass: 196 kg (432 lbs)

1. Lift and securely place the cylinder on a
workbench using a crane. Be sure that the
cylinder is placed horizontally. Drain hydraulic oil
from the cylinder.
2. Fully extend cylinder rod (11). Secure the rod
end using a crane. Remove socket bolts (8) from
cylinder head (7).

IMPORTANT: Be sure to pull cylinder rod (11)

straight so as not to damage the sliding surfaces.
3. Pull out cylinder head (7) from cylinder tube (12)
by tapping with a plastic hammer.
4. Secure cylinder rod (11). Put matching marks
between cylinder rod (11) and nut (24).
5. Remove set screw (22) and steel ball (23).

NOTE: Cut away its mushroomed portion using a

drill first, as set screw was mushroomed with a punch
and hammer at two places after it had been screwed
in.
6. Loosen nut (24).
Remove piston (15) and shim (21).
Socket to loosen nut (24)
7. Remove seal ring (17), slide rings (19) and (20),
O-ring (18) and backup rings (16) from piston
(15).
8. Remove cylinder head (7) from cylinder rod (11).
9. Remove O-Rings (10), backup rings (9) and (2)
from cylinder head (7), then remove wiper ring
(1), seal (3), buffer ring (4), snap ring (6), and
bushing (5).

1-40 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Positioner Cylinder Assembly
1. Install bushing (5) to cylinder head (7) using a
press.
IMPORTANT: Be sure that the rings are installed
correctly.
2. Install seal (3), backup ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer (7).
4. Install O-Rings (10) and backup ring (9) to
cylinder head (7).
5. Install O-Ring (18), backup ring (16) (Qty 2), seal
ring (17), slide ring (19) (Qty 2), (20) (Qty 2) to
piston (15).
6. Install cylinder head (7) to cylinder rod (11).

7. Install piston (15) to cylinder rod (11).

8. Install shim (21) to cylinder rod (11). Tighten nut
(24) using appropriate tool .
Be sure to align the machine mark on the rod
with that on the nut.
Tightening torque: 10280 Nm (7582 pound-feet)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two
places using a punch and hammer.
Tightening torque: 56.9 ± 10.7 Nm (42 ± 7.9
pound-feet)
IMPORTANT: Be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in
order to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a
work bench.
Insert cylinder rod (11) into cylinder tube (12).
11. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
Tightening torque: 367 Nm (270 pound-feet)

NA Issued 10-2007 Bur 1-41

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
BOOM CYLINDERS

13
19
20
15

16
17
18
16
19
20
21
24
23 22

11

12

1
2
3
8 4

5
6
9
10

GRAPHIC_1D Figure 68

1. WIPER RING 9. BACKUP RING 18. O-RING

2. BACKUP RING 10. O-RING 19. SLIDE RING (QTY 2)
3. SEAL 11. CYLINDER ROD 20. SLIDE RING (QTY 2)
4. SEAL 12. CYLINDER TUBE 21. SHIM
5. BUSHING 13. CUSHION BEARING 22. SET SCREW
6. SNAP RING 15. PISTON 23. STEEL BALL
7. CYLINDER HEAD 16. BACKUP RING (QTY 2) 24. NUT
8. SOCKET BOLT (QTY 12) 17. SEAL RING 25.

1-42 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Boom Cylinders Disassembly
Be sure to read all the precautions for disassembly/
assembly work before star ting the disassembly
procedure.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed.

NOTE: Boom cylinder mass: 149 kg (328 lbs).

1. Lift and securely place the cylinder on a
workbench using a crane.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
2. Fully extend cylinder rod (11). Secure the rod
end using a crane. Remove socket bolts (8) from
cylinder head (7).
IMPORTANT: Be sure to pull cylinder rod (11)
straight so as not to damage the sliding surfaces.
3. Pull out cylinder head (7) from cylinder tube (12)
by tapping with a plastic hammer.
4. Secure cylinder rod (11). Put matching marks
between cylinder rod (11) and nut (24).
5. Remove set screw (22) and steel ball (23).

NOTE: Cut away its mushroomed portion using a

drill first, as set screw was mushroomed with a punch
and hammer at two places after it had been screwed
in.
6. Loosen nut (24) using appropriate tool . Remove
piston (15), shim (21) cushion bearing (13).
Socket to loosen nut (24):
7. Remove seal ring (17), slide rings (19) and (20),
O-ring (18) and backup rings (16) from piston
(15).
8. Remove cylinder head (7) from cylinder rod (11).
9. Remove O-Rings (10), backup rings (9) and (2)
from cylinder head (7), then remove wiper ring
(1), seal (3), buffer ring (4), snap ring (6), and
bushing (5).

NA Issued 10-2007 Bur 1-43

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
Boom Cylinders Assembly
1. Install bushing (5) to cylinder head (7) using a
press.
Use appropriate tools for bushing installation (5):
IMPORTANT: Be sure that the rings are installed
correctly.
2. Install seal (3), backup ring (2), elastic ring (6)
and seal (4) on the cylinder front sleeve (7).
3. Install wiper ring (1) to cylinder head (7) using a
plastic hammer (7).
4. Install O-Rings (10) and backup ring (9) to
cylinder head (7).
5. Install O-Ring (18), backup ring (16) (Qty 2), seal
ring (17), slide ring (19) (Qty 2), (20) (Qty 2) to
piston (15).
Use appropriate tools for seals assembly:

6. Install cylinder head (7) to cylinder rod (11).

IMPORTANT: Be sure that the cushion seal slit faces

toward the piston and that the cushion bearing oil
groove faces the correct direction.
7. Install cushion bearing (13) to cylinder rod (11).
Install piston (15) to cylinder rod (11).
8. Install shim (21) to cylinder rod (11).
Tighten nut (24) using appropriate tool.
Be sure to align the machine mark on the rod
with that on the nut.
Socket to tighten nut (24):
Tightening torque: 3790 Nm (2795 pound-feet)
9. Align the holes on cylinder rod (11) and nut (24).
Insert steel ball (23) into the hole, and tighten set
screw (22) into the hole.
Mushroom the head of set screw (22) at two
places using a punch and hammer.
Tightening torque: 56.9 ± 10.7 Nm (42 ± 7.9
pound-feet)
IMPORTANT: Be sure to align cylinder rod (11) with
the center of cylinder tube (12) when inserting, in
order to avoid damaging the rings.
10. Secure cylinder tube (12) horizontally using a
work bench.
Insert cylinder rod (11) into cylinder tube (12).
11. Install cylinder head (7) to cylinder tube (12).
Tighten socket bolts (8).
Tightening torque: 171 Nm (126 pound-feet)

1-44 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
MAINTENANCE STANDARD: ROD

SM0243

GRAPHIC_1D Figure 69

Cylinders STANDARD (A) Remedy

Boom 80 ± 0.03

Arm 90 ± 0.03
Replace or plate with chromium
Bucket 75 ± 0.03

Positioning (*) 85 ± 0.03

(*) Triple articulation version Unit: mm

NA Issued 10-2007 Bur 1-45

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 1 - ATTACHMENTS
NOTES

1-46 Issued 10-2007 Bur NA

SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

CHAPTER 2

E175B
EXCAVATOR

UPPER STRUCTURE

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

2-II Issued 05-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

CHAPTER 2
UPPER STRUCTURE
TABLE OF CONTENTS

REMOVAL AND INSTALLION OF UPPER STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Removal of Upper Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Removal and Installation of the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Removal and Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Disconnecting Hoses of Swivel Joint Lower Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Removal and Installation of Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Repair Standards for Cylinder, Valve Plate and Swash Plate (Shoe Plate Face) . . . . . . . . . . . . . . . . . . . . . 2-25
DISASSEMBLY AND ASSEMBLY OF REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Air Pulling Out Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
REMOVAL AND INSTALLATION OF CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Removal of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Control Valve Ports (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Control Valve Ports (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Control Valve (1/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Control Valve (2/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Control Valve (3/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Control Valve (4/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Control Valve (5/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Control Valve (6/6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Assembly and Disassembly of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Preparation For Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
REMOVAL AND INSTALLATION OF SWING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

NA Issued 10-2007 Bur 2-1

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51

Preliminary Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54
DISASSEMBLY AND ASSEMBLY OF SWING REDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Preliminary Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61
Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
Standard For Correcting Sliding Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
Swing Reduction Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72
DISASSEMBLY RIGHT AND LEFT PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74
Cleaning Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-78
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-84
DISASSEMBLY AND ASSEMBLY OF THE TRAVEL PILOT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Pilot Valve (For Travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-85
Boot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86
Switch Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86
Switch Plate Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87
Retaining Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-87
Damping Plunger Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-88
Guide/Plunger and Regulation Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
Throttle Kit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-90
Shuttle Valve Kit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-91
Check Valve Kit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-92
Bleeding of the Hydraulic Pilot Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-93

2-2 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLION OF UPPER STRUCTURE

WARNING
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior
to beginning an intervention, make sure that the oil and components are cooled off.
the hydraulic oil tank ca[ can be ejected, if the pressure is mot released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and
appropriate to hold the weight of the load.

PREPARATION
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the
hy d r a u l i c s y s t e m , r e fe r t o p r o c e d u r e
RELEASING THE HYDRAULIC PRESSURE.
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual
pressure that may be present in the tank itself.
Remove hydraulic oil tank cap. Connect a
vacuum pump to maintain negative pressure in
the hydraulic oil tank.

NOTE: Be sure to run the vacuum pump

continuously while working.

REMOVAL OF UPPER STRUCTURE

1. Remove the front equipment and the boom
cylinders, performing the operations described in
the procedure in section FRONT
ATTACHMENT.
2. Remove the cab, refer to cab removal in this
section.
3. Remove the counterweight, refer to
counterweight removal in this section.
4. Disconnect the hoses of the swivel joint lower
side, refer to swivel joint removal in this section.
5. Remove the main frame, refer to frame removal
in this section.

NA Issued 10-2007 Bur 2-3

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF THE CAB

Removal
1. Remove floor mat
1
2. Remove cover (1).
Lift cover (1) upwards and remove it. (Fixed with
two clips)
3. Remove cover assembly (2).
Loosen 4 sems bolts (3) M6X16 and lift cover
assembly (2) up.
Disconnect each connector for both speakers.
Then remove cover assembly (3). 3
4. Remove the harness connector. 2
Disconnect connectors of cluster gauge harness:
(CN-5F), (CN-6F), (CN-61F), (CN-62F), and
earth wire (P-1) at rear right of cab.
SM0259
Disconnect antenna cable coming in from
backside of tuner at rear left of cab. GRAPHIC_ID Figure 1
5. Remove the plastic tube for the window washer
from the rear left of the cab.
6. Remove the right panel of the cab.
Remove 2 caps (4), loosen 2 sems bolts (5)
M6X25 and 1 sems bolt (6) M6X16, and right
panels (7) and (8) are freed. 9
Lift cover (9) upwards and remove it. (Fixed with
3 clows and 2 clips.)
Unfix 3 harness clips (10) of inside on right panel
(8). Free the harnesses connected to key switch.
3
With harnesses still connected, install key switch
cover (9) to bracket (11) of rear cab temporarily 10
5
(see figure 3).
4 7
Disconnect harness connectors of work light
switch on right panel (7), air conditioner panel 10 6
and cigarette lighter, and remove panel (7) and 5
(8).
10
Loosen sems bolts (12) M6X16 and (13) M6X40,
one each, and remove front panel (14) with air 4 8
conditioner duct.

12

14

13 SM0261

GRAPHIC_ID Figure 2

2-4 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE

11

GRAPHIC_ID Figure 3

7. Remove cab attaching bolt. 17 15

5 capscrew (15) M12X65 and 1 capscrew (16)
M12X30.
2 nuts (17) M16
15

16

15
15
15 SM0262
GRAPHIC_ID Figure 4

8. Slinging the cab.

Remove two plastic plugs at the front of the 18
ceiling of the cab. Then place a wire sling with
eye bolts (18) and a hook around the cab as
shown. 18
Then lift up slowly avoiding interference with
surroundings.

NOTE: Weight of cab: Approx. 250 kg (550 lbs.).

GRAPHIC_ID Figure 5

NA Issued 10-2007 Bur 2-5

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Installation
Allen Tightening
Install cab in the reverse order of removing according Tightening position Wrench torque
to the Tightening Torque Table. Hex Nm (pound-feet)
Nut M16 (17) 24 191 (140)
Capscrew (2) (9) 19 79.4 (60)
Sems bolt M6 torxdriver
8.5 (6.3)
(5), (6) T30
Sems bolt M6 Plus
5.0 (3.7)
(12), (13) driver

2-6 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF COUNTERWEIGHT

Removal
1. Remove plugs (1) from the counterweight and 1
attach two M36 eyebolts to the counterweight.

NOTE: Approximate mass of counterweight: 3300

kg (7273 lbs)

SM1321
GRAPHIC_ID Figure 6

2. Attach wire rope (2) to eyebolts (3) using

appropriate tools.
2
Take out slack of wire rope by applying tension
slowly with a crane or hoist.
3. Remove 4 bolts (4) M27.
3
Lift counterweight using a crane or hoist.
4. Remove shims (5), (6), (7) from the frame when
present.

5
6
7
4
SM1322
GRAPHIC_ID Figure 7

5. Lower the counterweight on proper stand.

SM1323

GRAPHIC_ID Figure 8
NA Issued 10-2007 Bur 2-7
 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Installation
2
NOTE: Approx. mass of counterweight 3300 kg
(7273 lbs).
1. Attach lifting tools (2) to eyebolts (3) of
counterweight. 3
2. Install shims (5), (6), (7).
3. Lift counterweight and install it onto the frame.
4. Install bolt M27 (4) and washers to counterweight
and tighten temporarily.

5
6
7
4
SM1322
GRAPHIC_ID Figure 9
5. Remove lifting device.
Tighten the bolt (4) with appropriate wrench.
1
NOTE: Torque bolt (4) to 1150 ± 150 Nm (850 ± 110
pound-feet)
6. Remove eyebolts (3) and install plugs (1) onto
the counterweight.

4
SM1324

GRAPHIC_ID Figure 10

2-8 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISCONNECTING HOSES OF SWIVEL JOINT LOWER SIDE
Disconnect the hose on the lower side of the swivel
joint.

NOTE: Close all openings with plugs to keep them

clean.
1. Disconnect the two hose (1). (E Port: PF1/2)
Tightening torque: 78.5 Nm (58.1 pound-feet)
2. Disconnect the hose (2) and (3).
(A and B Port:PF1).
Tightening torque: 177 Nm (131 pound-feet)
3. Disconnect the hose (4) and (5).
(C and D Port: PF1)
Tightening torque: 177 Nm (131 pound-feet)
4. Disconnect the two hose (6). (F Port: PF1/4)
Tightening torque: 29.4 Nm (21.7 pound-feet)

A B B

C D E
D

F F F

F F D

C
B
A

E E

SM1
GRAPHIC_1D Figure 11

NA Issued 10-2007 Bur 2-9

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Swivel Joint lower side hoses.

2 3 5
4

4 6 6 5

2 3

SM1326

GRAPHIC_1D Figure 12

2-10 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF MAIN FRAME

Removal 3

NOTE: Approx. mass of main frame: 4000 kg (8816 4

lbs).
1. Insert two upper swing body lifting jigs (2) and
two counterweight fastening screws M27 (1) into
the counterweight mounting holes from above. 2
2. Attach two chain blocks (4) to the boom foot side.
3. Attach appropriate lifting device (3).
Use chain blocks (4) for easy adjustment of wire
rope lengths and to level the frame. 1

IMPORTANT: Make sure rear slings do not touch the

engine.

NOTE: Chain blocks (Qty. 2)should be rated for

2,000 kg (4408 lbs).

NOTE: Special tool (Qty 2) required for lifting.

GRAPHIC_ID Figure 13

4. Put matching marks (M) on swing bearing and

main frame. M

SM0271

GRAPHIC_ID Figure 14

NA Issued 10-2007 Bur 2-11

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
5. remove the bolts (5) M20 (Qty 30), the reamer
bolt (6) M20X15 and the relevant gaskets from
the swing bearing. A

6. Lift main frame slightly from undercarriage.

Level main frame by adjusting the chain blocks
(4).

GRAPHIC_ID Figure 15

Installation

NOTE: Approx. mass of main frame: 4000 kg (8816

lbs).
Installing is done in the reverse order of removing.
1. Clean mating surfaces of upper frame and swing
bearing
2. Apply Loctite #515 to the side of the capscrews
on the contact surface (A).
3. Slinging upper frame.
Match marks and install it with a reamer bolt (6)
and a washer temporarily.
GRAPHIC_ID Figure 16

IMPORTANT: Confirm the reamer bolt position (X),

refer to figure. OUTER (S) ZONE POSITION
4. Apply loctite #262 onto the threads of bolts (5),
then install bolts.
Tightening torque: 392 ± 39 Nm (290 ± 28.8
pound-feet).
X

(*) SM1328

GRAPHIC_ID Figure 17

2-12 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
5. Apply Loctite #262 onto threads of reamer bolt
(6), then install reamer bolt. OUTER (S) ZONE POSITION
Tightening torque: 392 ± 39 Nm (290 ± 28.8
pound-feet).

(*) SM1329

GRAPHIC_ID Figure 18

NA Issued 10-2007 Bur 2-13

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers
by discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components have cooled off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and
appropriate ho hold the weight of the load.

PREPARATION
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the
hy d r a u l i c s y s t e m r e fe r t o t h e p r o c e d u r e
RELEASING THE HYDRAULIC PRESSURE.
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual
pressure present in the tank itself. Remove
hydraulic oil tank cap. Connect a vacuum pump
to maintain negative pressure in the hydraulic oil
tank.

NOTE: Be sure to run the vacuum pump

continuously while working.

REMOVAL
1. Remove all protection panels and doors to give
access to the Hydraulic Pump Device.
2. Disconnect all electrical connectors.
3. Remove all hoses and collector from hydraulic
pump device.
4. Fasten the hydraulic pump device by means of a
hoist and lifting ropes.

NOTE: Hydraulic pump device weight: 88 kg (194

lbs)
5. Remove the fixing bolts of hydraulic pump device
and draw it from engine.

INSTALLATION
1. Lift the hydraulic pump device by means of hoist
and ropes.

NOTE: Hydraulic pump device weight:88 kg (194

lbs)
2. Install the hydraulic pump device to the engine
by means of related bolts.
3. Install all hoses and collector to the hydraulic
pump device.
4. Connect all electrical connectors.
5. Install all protection panels and doors.
2-14 Issued 10-2007 Bur NA
 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC PUMP DEVICE

GRAPHIC_1D Figure 19
NOTE: The number in a rectangle represent adjust screws. DO NOT tamper with the adjust screws as much as
possible.
1)HYDRAULIC PUMP 255)LOCK PIN (QTY 2) 535)STOPPER (S) (QTY 2)
2)REGULATOR 256)SET SPRING (QTY2) 702)O-RING;1B G30 (QTY 2)
3)REGULATOR 261)SEAL COVER (F) 710)O-RING; 1B G80
4)SOLENOID VALVE 263)SEAL COVER (R) 711)O-RING; G95
5)GEAR PUMP 271)PUMP CASING (F) 717)O-RING; 1B G125 (QTY 2)
6)PTO UNIT 272)PUMP CASING (R) 723)O-RING; 1B P11 (QTY 4)
111)DRIVE SHAFT (F) 312)VALVE BLOCK 724)O-RING; 1B P8 (QTY 12)
113)DRIVE SHAFT (R) 313)VALVE PLATE (R) 727)O-RING; 1B P18 (QTY 4)
116)GEAR #1 314)VALVE PLATE (L) 732)O-RING; 1B P14 (QTY 2)
123)ROLLER BEARING (QTY 2) 401)SOCKET BOLT; M16X150 (QTY 2) 733)O-RING; P28 (QTY 2)
124)NEEDLE BEARING (QTY 2) 402)SOCKET BOLT; M16X190 (QTY 2) 734)O-RING; G85
127)BEARING SPACER (QTY 2) 406)SOCKET BOLT; M6X16 (QTY 4) 774)OIL SEAL
141)CYLINDER BLOCK (QTY 2) 415)SOCKET BOLT; M8X20 (QTY 4) 789)BACK UP RING; P14 (QTY 2)
151)PISTON (QTY 18) 468)PLUG; G1/2 (QTY 4) 792)BACK UP RING; G30 (QTY 2)
153)RETAINER PLATE (QTY 2) 490)PLUG (QTY 9) 806)NUT; M12 (QTY 2)
156)SPHERICAL BUSHING (QTY 2) 531)TILTING PIN (QTY 2) 808)NUT; M16 (QTY 2)
157)CYLINDER SPRING (QTY 12) 532)SERVO PISTON (QTY 2) 824)SNAP RING (QTY 2)
211)SHOE PLATE (QTY 2) 533)PLUG (QTY 2) 886)SPRING PIN (QTY 4)
212)SWASH PLATE (QTY 2) 534)STOPPER (L) (QTY 2) 901)EYEBOLT M10 (QTY 2)
251)SWASH PLATE SUPPORT (QTY 2) 953)SET SCREW; M12X23 (QTY2)

NA Issued 10-2007 Bur 2-15

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY
Proceed with disassembly operations in a clean
place.
Spread rubber sheet of cloth on work bench to 435
435
protect parts from damaging.
Clean the parts removing duct and rust, etc. on pump 467
surface with appropriate cleaner.
Drain out the oil in the pump casing by removing
drain port plugs (466 and 468). 311

312
466 SM1331
GRAPHIC_ID Figure 20

1. Removing pilot pump.

Remove the socket bolts (435), then remove pilot
pump (4).
2. Remove PTO gear casing.
Remove the socket bolts (435), then remove
PTO gear casing (5).
5
435

GRAPHIC_ID Figure 21

3. Removing regulator.
Remove the 4 socket bolts (415), then remove
the regulator (2), (3).

SM1332
GRAPHIC_ID Figure 22

2-16 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
4. Loosen socket bolts (401 and 402) that fasten
swash plate support (251), pump casing (271 402
and 272) and valve block (312).

401 SM1333
GRAPHIC_ID Figure 23

5. Place the pump level on a work bench with its

mounting surface of the regulator facing down. 312 271
Then separate pump casing (271) and valve
block (312).

NOTE: When facing the mounting surface of the

regulator down, place a rubber board on a work
bench so as not to score the mounting surface.
When the pump casing has been separated from the
valve block, draw out the 1st gear (116) at the same
time.

GRAPHIC_ID Figure 24

6. Draw out cylinder (141) out of pump casing (271) 271

in parallel to shaft (111). At the same time draw
141 (151) (157)
out piston (151), plate (153), spherical bushing
(156) and cylinder spring (157) 153

NOTE: Use care so as not to score the sliding 156

surface of the cylinder, spherical bushing, shoe and
the swash plate.

SM1334
GRAPHIC_ID Figure 25

NA Issued 10-2007 Bur 2-17

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
7. Remove socket bolt (406) and seal cover (261)
406
NOTE: The seal cover may be drawn out with ease
if it is taken out by tightening bolts in the tapped 261
holes of the seal cover. An oil seal is fitted to seal
cover. Therefore, use care so as not to score the oil
seal.

SM1335
GRAPHIC_ID Figure 26

8. Knock lightly on the mounting flange of swash

271
plate support (251) from the pump casing (271)
side and separate the swash plate support from
the pump casing.
251

SM1336
GRAPHIC_ID Figure 27

9. Draw out shoe plate (211) and swash plate (212)

from pump casing.
271

212
(211)

GRAPHIC_ID Figure 28

2-18 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
10. Tap lightly the shaft end (111 and 113) by means
251
of a plastic hammer and draw out the shaft from
the swash plate support.

111
(113)

SM1337
SM1337
GRAPHIC_ID Figure 29

11. Remove valve plate (313 and 314) from valve

block (312)

NOTE: The valve plate may come off during the

separation of pump casing from valve block. 312

314
(313)

GRAPHIC_ID Figure 30

12. If necessary, remove stoppers (534 and 535)

servo piston (532) and tilting pin (531) from
pump casing (271) and remove needle bearing 535 532 531 534
(124) from valve block(312). 806 808
312

NOTE: When removing the tilting pin, use care so as 271

not to score the head of the tilting pin, using 251
124
appropriate jig.
It is hard to separate the tilting pin from the servo
piston in some cases Loctite is coated on the mating
part between them. Use care so as not to score the
servo piston by applying unreasonable force.
Do not draw out needle bearings except when their SM1338
service life has ended. GRAPHIC_ID Figure 31
Do not loosen hex nuts (806 and 808) of valve block
(312) and swash plate support (251). A set flow rate
changes.

NA Issued 10-2007 Bur 2-19

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
ASSEMBLY
1. Assembly is a reverse order of disassembly but
notice the following.
A. Repair scored parts at disassembly. Get
replacements ready beforehand.
B. Wash parts in cleaning oil and dry them.
C. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
D. In principle, replace sealing parts such as O-
rings and oil seals.
E. Tighten socket bolts and plugs to specified
torques in this manual using a torque wrench.
F. Do not mix up front pump parts with rear pump
parts.

2. Attach swash plate support (251) to pump casing

(271) by tapping the swash plate support lightly 271
with a plastic hammer.

NOTE: When the servo piston, the tilting pin, the

stoppers have been removed, install them to the
pump casing beforehand.
When tightening servo piston and tilting pin, use an
appropriate jig so as not to damage the head of the
tilting pin and feedback pin.
Coat the screwed part with Loctite 262. 251

SM1339
GRAPHIC_ID Figure 32

3. Install swash plate placing pump casing with its 251

mounting surface of the regulator facing down. 271 (531)
Insert the tilting bushing of the swash plate into
tilting pin (531) and fit swash plate (212) to
swash plate support (251) properly.

NOTE: Confirm by your both hands that swash plate

moves smoothly.
212
The shaft can be installed easily if grease is applied to
the sliding parts of swash plate and swash plate
support.
Do not damage the sliding surfaces of shoe plate.
SM1340
GRAPHIC_ID Figure 33

2-20 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
4. Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824) to
swash plate support (251).
251
NOTE: Do not knock on the shaft with a hammer or
anything.
Fix the bearing by lightly tapping on the outer race of 123
it by means of a plastic hammer and set it exactly to
127,824
the end by using a steel rod and others.

111
SM1341
GRAPHIC_ID Figure 34

5. Install seal cover (261) to pump casing (271) and

fix it with socket bolts (406).
271
Tightening torque: 12 Nm (8.9 pound-feet)

NOTE: Coat the oil seal in seal cover with a thin film 261
of grease.
Handle the oil seal with sufficient care so it is not 406
scored.

SM1342
GRAPHIC_ID Figure 35

6. Assemble the piston cylinder sub compound to

the cylinder block (141), piston (151), shoe (152),
plate (153), spherical bushing (156) and cylinder 141(151,152,157)
spring (157).
156
Align the spherical bushing with the cylinder
spline and insert them into the pump casing.
153

SM1343
GRAPHIC_ID Figure 36

NA Issued 10-2007 Bur 2-21

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
7. Install valve plate (313 and 314) to valve block
(312) by aligning pin.

NOTE: Do not mistake the suction and delivery

sides of the valve plate. 312

314
(313)

GRAPHIC_ID Figure 37

8. Install valve block (312)to pump casing (271 and

272) and fasten them together with socket bolts 402
(401 and 402).
Tightening torque: 240 Nm (177 pound-feet)

NOTE: Work will be furthered if assembly is started

from the rear pump.
Exercise care so as not to mistake the direction of the
valve block (312). Install it so the regulator comes up
as seen from the front side and the suction flange
comes on the right.
Insert 1st gear into the valve block beforehand and
connect it with the spline of the shaft. 401 SM1333
GRAPHIC_ID Figure 38

9. Install regulator (9) pinching feedback pin of

tilting pin in feedback lever of the regulator, them 9
install the regulator and fasten 4 socket bolt
(415).
Tightening torque: 29 Nm (21.4 pound-feet)
IMPORTANT: Do not mistake the front regulator for
the rear regulator.

GRAPHIC_ID Figure 39

2-22 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
10. Install gear casing (5) and fasten it with socket
bolts (435).
Tightening torque: 33.3 Nm (24.6 pound-feet)

5
435

GRAPHIC_ID Figure 40

11. Install pilot pump (4) and fasten it with socket

bolts (435).
Tightening torque: 33.3 NM (pound-feet).
435
435

467

311

312
466 SM1331
GRAPHIC_ID Figure 41

NA Issued 10-2007 Bur 2-23

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
MAINTENANCE STANDARD

Recommended
Standard
value for
Part name and inspection item dimension Remedy
replacement
mm (in.)
mm (in.)
Clarence between piston and cylinder
bore (D-d)

0.039 0.067
Replace piston or cylinder.
(0.0015) (0.0026)

SM0520

GRAPHIC_ID Figure 42
Gap between piston and caulked part
of shoe (d)

0 ~ 0.1 0.3
Replace piston shoe assembly.
(0 ~ 0.0039) (0 ~ 0.0118)

SM0521

GRAPHIC_ID Figure 43
Thickness of shoe (t)

4.9 4.7
Replace piston shoe.
t (0.1930) (0.1851)

SM0522

GRAPHIC_ID Figure 44
Free height of cylinder spring (L)

41.1 40.3
Replace cylinder spring.
(1.6193) (1.5878)

L
SM0523

GRAPHIC_ID Figure 45
Combined height of retainer plate and
spherical bushing (H-h)

23.0 22.0 Replace a set of spherical bushing or

(0.9062) (0.8668) retainer plate.
SM0524

GRAPHIC_ID Figure 46

2-24 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REPAIR STANDARDS FOR CYLINDER, VALVE PLATE AND SWASH PLATE (SHOE PLATE FACE)

Valve plate (sliding section) Surface roughness requiring correction 3Z

Swash plate (shoe plate face)
standard surface roughness
Cylinder (sliding section) Less than 0.4Z (lapping)
Roughness of each surface (correction value)

NA Issued 10-2007 Bur 2-25

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY AND ASSEMBLY OF REGULATOR

651

418 643

079
466 496 (X9)

755

543
545
541
631
755
731

041
402
466

656 924
407 755

325

733
601 646
624
415

041 801
627

543
545
541
755

726
614
875
724 724 754
754 887
652
616
658
708

897
611

GRAPHIC_1D Figure 47
NOTE: The number in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as
possible.

2-26 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE

041)VALVE 643)PILOT PISTON

079)PROPORTIONAL SOLENOID VALVE 646)PILOT SPRING
325)VALVE CASING 651)SLEEVE
402)SCREW; M6X16 (QTY 4) 652)SPOOL
407)SCREW; M6X30 (QTY 4) 656)COVER
415)SCREW; M8X40 (QTY 4) 658)PLUG
418)SCREW; M5X12 (QTY 2) 708)O-RING
466)PLUG; G 1/4 724)O-RING (QTY 5)
496)PLUG (QTY 9) 726)O-RING
541)SEAT (QTY 2) 731)O-RING
543)STOPPER 1 (QTY 2) 733)O-RING
545)STEEL BALL (QTY 2) 754)O-RING (QTY 2)
601)CASING 755)O-RING (QTY 3)
611)FEEDBACK LEVER 801)NUT; M10
614)CENTER PLUG 875)PIN; 05X10L
616)PREVENTION PLUG 887)PIN
624)SEAT ADJUSTMENT 897)PIN
627)ADJUSTMENT STEM 924)SET SCREW; M10X20
631)SLEEVE

Tightening torque of bolt, plug and nut

Tightening
No. Thread size torque
Nm (pound-feet)
402,407 M6 12 (8.9)
415 M8 29 (21)
418 M5 6.9 (5)
466 G 1/4 16 (12)
496 NPTF 1/16 8.8 (6.5)
614 M14X1.5 27 (20)
801 M10 29 (21)

NA Issued 10-2007 Bur 2-27

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY 415
1. Proceed with disassembly operations in a clean 415
place
Spread rubber sheet or cloth on work bench to
protect parts from damaging.
2. Clean the parts removing dust and rust, etc. on
regulator surface wit appropriate cleaner.
3. Remove regulator (2 or 3).
Remove the 4 socket bolts (415) and separate
the regulator from the pump body.

NOTE: Be careful not to loose the O-rings and the SM1345

valve parts (541, 543, and 545). GRAPHIC_ID Figure 48

4. Remove the socket bolts (402) and separate the

port plate (656).
5. After removal of the plate (656) , extract the
adjustment stem (627) and the O-ring (733).
627
NOTE: The cover is equipped with lock nut (924) 656
hex nut (801) and set screw (924). Do not loosen
these parts. If they are loosened, pre adjusted se 801 402
pressure and flow values change.

733
924 SM1346
GRAPHIC_ID Figure 49

NOTE: The adjust stem comes out easily if a M4 bolt

is used.
6. Take out the pilot spring (646) and the spring
seat (624).

646

624 SM1347
GRAPHIC_ID Figure 50

2-28 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
7. remove socket bolts (407) and pilot cover (325)
with O-ring (731).
325

407

731

SM1348
GRAPHIC_ID Figure 51

8. Take out prevention plug (616), fulcrum plug 614 616

(614) with O-ring (726) and draw out the pin 875 726
(875).

897
611
SM1349
GRAPHIC_ID Figure 52

9. Remove the feedback lever (611) with pin (897).

631
643
651
652

SM1350
GRAPHIC_ID Figure 53

NA Issued 10-2007 Bur 2-29

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
10. Remove the sleeve (631), the pilot piston (643),
the spool (652) and the sleeve (651).
651

652

643
631

SM1351
GRAPHIC_ID Figure 54

11. Remove plug (466), or plugs depending on the

regulator, with O-ring (755) in order to access the
internal area.

466
755 755

466

325
SM1352
GRAPHIC_ID Figure 55

2-30 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
ASSEMBLY 652
1. Assembly is the reverse order of disassembly.
Do the work paying attention to the following:
Repair those parts that were damaged during
disassembly and prepare replacement parts
beforehand.
Clean parts in appropriate cleaning solution, dry
them and assemble part in a clean place.
Always tighten screws and plugs to the specified
torque. Tolerance of torque should be within
10%.
601 897
Do not fail to coat moving par ts with clean 611 SM1353
hydraulic oil before assembly. GRAPHIC_ID Figure 56

Replace seals and O-rings.

2. Insert the spool (652) in the spool hole.

3. Assemble on the spool (652) the feedback lever

(611) with the pin (496) put in it, operating on the
lever and the spool so that the pin enters the
hole in the spool 496

NOTE: The work is eased if the pin is put in the

feedback lever a little beforehand.
Take care so as not to mistake the direction of the
feedback lever. 611

652

SM1355
GRAPHIC_ID Figure 57

4. Place pin (875) in the hole of the feedback lever

and in the corresponding hole of the casing. 616
614
5. Insert adjust plug (614) and O-ring (726) and the 875 726
the prevention plug (616).
Tightening torque: 27Nm (19.9 pound-feet).

SM1354
GRAPHIC_ID Figure 58

NA Issued 10-2007 Bur 2-31

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
6. Assemble the sleeve (651) on the spool (652).

NOTE: Make sure that the spool and the sleeve

move smoothly in the casing.
Beware of the direction of the spool.
7. Insert into the spool (652) the pilot piston (643) 651
and assemble on it the sleeve (631).

NOTE: Before assembling the sleeve, make sure 643

631
that the pilot piston moves smoothly.

SM1356
GRAPHIC_ID Figure 59

8. Assemble on the pilot cover (325) the plug (466)

and the relevant O-ring; depending on the
regulator, 1or 2 plugs are present.
Tightening torque:16 Nm (11.8 pound-feet)
466
755 755

466

325
SM1352
GRAPHIC_ID Figure 60

9. Assemble the pilot cover (325) and the relevant

O-ring (731) on casing (601) and fasten it with 4
socket bolts (407) 325
Tightening torque: 12 Nm (8.85 pound-feet)

407

731

SM1348
GRAPHIC_ID Figure 61

2-32 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
10. Put spring seat (624) and pilot spring (646) into
the pilot hole.

646

624 SM1347
GRAPHIC_ID Figure 62

11. Put the adjust stem (627) with O-ring (733) on

the spring and fasten the port plate (656) by 4
socket bolts (402).
Tightening torque: 12 Nm (8.85 pound-feet)
627
NOTE: The cover is equipped with set screw (924) 656
and hex hut (801).
801 402

733
924 SM1346
GRAPHIC_ID Figure 63

12. Assemble the regulator on the pump and fasten 415

it by 4 socket bolts (415). 415
Tightening torque: 29 Nm (21.4 pound-feet)

SM1345
GRAPHIC_ID Figure 64

NA Issued 10-2007 Bur 2-33

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY AND ASSEMBLY OF PTO GEAR CASING

128 435 711 262 414

117

126
886

826

128

12

886 728

10

468

11
435
710
125
118
825 125 SM1357

GRAPHIC_1D Figure 65

10)IDLE SHAFT 414)SOCKET BOLT; M10X20 (QTY 20)

11)GEAR CASING 435)FLANGE SOCKET M10X20 (QTY 4)
12)SPRING PIN 468)VP PLUG PF3/4
117) 2ND GEAR 710)O-RING
118)3RD GEAR 711)O-RING
125)BALL BEARING (QTY 2) 728)O-RING
126)ROLLER BEARING 825)SNAP RING
128)BEARING SPACER (QTY 2) 826)SNAP RING
262)COVER 886)PIN (QTY 2)

2-34 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY

NOTE: If gear and bearings show damage that need

replacement, check first the availability of the parts
before disassembling the PTO assembly. If parts are
414
not available for service, replace the PTO as an
assembly.
1. Proceed with disassembly operations in a clean 262
place.
Spread rubber sheet or cloth on work bench to
468
protect parts from damaging.
2. Remove dust and rust, etc. on pump surface with
appropriate cleaner.
GRAPHIC_ID Figure 66
3. Remove plug (468) and O-ring (728).

NOTE: For assembly, tightening torque:73.5 Nm

(53.4 pound-feet).

4. Remove the socket bolts (414). Then remove the

cover (262).
10
NOTE: For assembly, tightening torque: 33.3 Nm
(24.6 pound-feet).
5. Remove spring pin (12) and idle shaft (10). Then 117
draw out 2nd gear (117), roller bearing (126), (126, 128)
and bearing spacer (128).

NOTE: Roller bearing (126) can not be separated

from 2nd gear (117).

SM1358
GRAPHIC_ID Figure 67

6. Remove snap ring (825) and draw out 3rd gear

(118) and ball bearing (125).

NOTE: Ball bearing (125) can not be separated from

3rd gear (118). 125

118

GRAPHIC_ID Figure 68

NA Issued 10-2007 Bur 2-35

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
ASSEMBLY
Assembly is a reverse order of disassembly but
notice the following:
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash all parts sufficiently in appropriate cleaner
and dry them.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. Replace parts such as O-rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques.

MAINTENANCE STANDARD
In case a pitching (1 pit is more than 1 mm, 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.
AIR PULLING OUT POINT
1. After the relief valve installation, start the engine.
2. Loosen the air pulling out plug (1) until O-ring (2) 1
comes off to allow the air to flow out.
3. Air pulling out operation is completed when, for
two seconds, only hydraulic oil flows out from
plug (1).
4. Tighten the plug (1) to specified torque: 23 Nm 2
(17 pound-feet).

SM1251

GRAPHIC_ID Figure 69

2-36 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF CONTROL VALVE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers
by discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components have cooled off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and
appropriate ho hold the weight of the load.

PREPARATION
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the
hy d r a u l i c s y s t e m r e fe r t o t h e p r o c e d u r e
RELEASING THE HYDRAULIC PRESSURE.
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual
pressure present in the tank itself. Remove
hydraulic oil tank cap. Connect a vacuum pump
to maintain negative pressure in the hydraulic oil
tank.

NOTE: Be sure to run the vacuum pump

continuously while working.
REMOVAL OF CONTROL VALVE
1. Remove the panel protecting the control valve,
removing the securing screws.
2. Disconnect all hoses, pipes and connectors from
the control valve (1).
1
NOTE: Attach caps to hoses and pipes. Attach
labels or tags to hoses and pipes to aid in assembly.
3. Remove the control valve securing screws (2)

NOTE: Control valve assembly mass: 155 kg (342

lbs)
4. Remove the control valve.

2
SM1277
GRAPHIC_ID Figure 70

NA Issued 10-2007 Bur 2-37

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
INSTALLATION OF CONTROL VALVE
1. Install the control valve (1) to frame and tighten
bolts (2).
Tightening torque: 110 Nm (81 pound-feet).
2. Connect all hoses, pipes, and connectors to the
control valve.

2
SM1277

GRAPHIC_ID Figure 71

Connector / Bolt Hose Nut Remarks

Tread Tightening Tightening
Ports Opposing Opposing
size Name torque torque
flats flats
Nm (pound-ft) Nm (pound-ft)
Pss, Plc2, PBp1, PBp2, PL, PB1, PTb,
PF 1/4 19 36 (27) 19 29 (21)
PCa, PCb, PCc, XAb
PAa1, PBa1,PAb, PBb, PAc, PBc, PAL, ORS
PF 3/8 PBL, PAr, PBr, PAs, PBs, PAa2, PBa2, 22 74 (55) 22 49 (36)
Joint
Pao, Pbo, DR
MU1, MU2, T3, Ar, Br, AL, BL, As,Bs,
PF3/4 36 162 (119) 36 118 (87)
Aa, Ba, Ac, Bc, Ab, Bb, Ao, Bo
M10 P1, P2 Sems 14 57 (42) - -
M12 T1, T2 bolt 17 96 (70) - -

3. Install the panel protecting the control valve

using the securing screws.
Tightening torque: 108 Nm (80 pound-feet).

2-38 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
CONTROL VALVE PORTS (1/2)

Functions Ports Ports on upper sides Ports Functions

LEFT RIGHT PBp1 P1 bypass cut
P2 bypass cut PBp2 PAa2 Arm 2 in
Option PAo MU1 Make-up line
Arm (H) relief valve - - Bucket (R)relief valve

Arm 1 in PAa1 XAb Boom lowering valve

PBb Boom down
Swing (LH) PBs
- Boom (H) relief valve
Boom conflux PB1
PAr Travel right forward
Travel left forward PAL
- Main relief valve
Tank return T2 PCb P1 unload
Ports on rear sides (on machine)
LEFT RIGHT

P1 P1 pump

P2 P2 pump

Ports on right sides (on machine)

UPPER SIDE LOWER SIDE
Bucket dump Bc

Bucket dump PBc

Bucket (H) stroke limit PCc Ac Bucket digging

Boom up Ab Bb Boom down

Br Travel right reverse

Travel right forward Ar

ATT power boost PL

SM1278

GRAPHIC_1D Figure 72

NA Issued 10-2007 Bur 2-39

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
CONTROL VALVE PORTS (2/2)

Function Ports Ports on left side (on machine) Ports Function

LOWER UPPER
SIDE SIDE Ao Option
Option Bo

Aa Arm 1 out

Arm 2 in Ba Pss Swing low pressure sensor

Swing left Bs As Swing right

Travel left reverse BL Dr Drain

AL Travel left forward

T1 Tank return

Ports on lower side (on machine)

LEFT SIDE RIGHT SIDE
Travel left reverse PBL
PTb Travel priority

P2 unload PCa
PBr Travel right reverse

Swing right PAs

PAb Boom up

Arm 1 out PBa1

- Boom (R) relief valve

Arm out lock release PLc2

- Bucket (H) relief valve

Arm (R) relief valve -

PAc Bucket digging

Option PBo
PBa2 Arm 2 out
SM1279

GRAPHIC_1D Figure 73

2-40 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Control Valve (1/6)

PAa2 PAo

275 x 4

274 x 4
213

(P3) (P4)

212

PBa2 PBo

A
B
273 x 10 273 x 10

T2

PCb PAL
J P1 unload J
Travel left
(Travel priority)
C C
PAr PB1
Boom conflux
Travel right (P2 unload)

D D
PBb PBs
Boom Swing

E PBc Pss E
PCc PAa1
Bucket Arm 1

F F
PAa2 PAo
Arm 2 MU1 Option

G PBp1 G
PBp2

H H

B A
SM1288

GRAPHIC_1D Figure 74

NA Issued 10-2007 Bur 2-41

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Control Valve (2/6)

K
155 163 101
P2

T1
T2 CT2
K
PAL PBL

PB1 PCa

PBs PAs

Pss

PAa1 PBa1

PAo PBo

PBp2

SECTION A-A
(P4)
166 161 161 155 163 164

154 567 155 163 102

(MU2) (P6)
P1
973 973

CT1

PTb PCb

973 973
PBr PAr

PAb PBb

973 973
PBc
PAc PCc

973 973
PBa2 PAa2

973 PBp1

SECTION B-B
(P3)
161 164 163 155 161 161
SM1289

GRAPHIC_1D Figure 75

2-42 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Control Valve (3/6)

202 P1 unload 201

Travel left
333 333
PCb PAL
331 331
336 339
328
327
325
325
601 MR
331 331
261 261
309 306
PL
157
161 AL
161
512 511
522 521
CP2
CMR2
551
556
561 561
561 CMR1 BL
556
522
512
307
261 264
331 PBL
325 205
328
336 SECTION C-C
331 Travel priority
333 PTb
202

201 202
333 Travel right Travel left
Par
333
PB1
331 331
339 336
327 322
AbR
325 321
603
331 331
261 261
166 305
164
Dr 511
162
521
Ar CCb
306
511 551
521 561
CP1

551 551
561 561
166 Br
164 310
166
161 567
166 (T3) 154
264 261
PBr 331
205 325
328
336
SECTION D-D 331
PCa 333
P2 unload 202
SM1290

GRAPHIC_1D Figure 76

NA Issued 10-2007 Bur 2-43

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Control Valve (4/6)

203
333 Swing
331
PBs
339 Boom 204
320 PBb 333
Pss
319 331
279 x 3 336
211 322
331 321
216 266
261 331
266 XAb 261
266 x 4 166
160
301 303
561 CRb 161
Ab As
511
556
524 524
LCb
514 LCs
551 556
561 561
521
Bs
511 Bb
161

264
264
602
PAb
205 PAs 206
BbR

160 266 SECTION E-E

221 Bucket
561
PCc
218 201
209 Arm 1 333
333 331
PAa1
331 PBc 336
339 322
320 321
319 BcR 602
AaR
602
331 331
261
261

161
304

Bc Aa

511 511
521 521
LCc LCa 551
561
551
161
561
Ac 561
CRa 556
Ba
524
514
156
PLc2 167
264 160 x 2
603 302
PAc PBa1 264
205
AcR 211
SM1291
SECTION F-F 205

GRAPHIC_1D Figure 77

2-44 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Control Valve (5/6)

201 Arm 2 Option 201

333 333
PAa2 PAo
331 331
339 337
326 330
325 329
331 604
261 AoR 331
261
161
MU1 311
308
162
515
521 Ao

551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
Ba
511

162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 BaR

605 605

PBp1 PBp2

Bo

BoR
166 604
153 SECTION H-H
SM1292

GRAPHIC_1D Figure 78

NA Issued 10-2007 Bur 2-45

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Control Valve (6/6)

T2

P1
T1
511

521
CT1

551
561

511

P2
521
(MU2) CT2

551

561

162
SECTION J-J

278 x 5

160
266

207
267
267

528
527

T1

518
T2
517

SECTION K-K SM1293

GRAPHIC_1D Figure 79

2-46 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Components

Tightening torque Tightening torque

No. Parts Name Qty No. Parts Name Qty
Nm (pound-feet) Nm (pound-feet)
101 Casing A 1 309 P1 unload spool 1
102 Casing B 1 310 P2 unload spool 1
25 -29 (19-21) 153 Plug 1 311 Option spool 1
220-250(162-184) 154 Plug PF 3/4 2 319 Spring 2
110-130 (81-96) 155 Plug PF1/2 4 320 Spring 2
13 -17 (9-12) 156 Plug PF 1/8 1 321 Spring 3
20 24 (15-18) 159 Plug PT1/4 1 322 Spring 3
7.8-9.8 (5.7-7.2) 160 Plug PT 1/16 5 325 Spring 6
161 O-ring 13 326 Spring 1
162 O-ring 6 327 Spring 2
163 O-ring 4 328 Spring 3
164 O-ring 4 329 Spring 1
166 O-ring 7 330 Spring 1
167 O-ring 1 331 Spring seat 24
201 Cover 5 16-18 (11.5-13) 333 Spacer bolt 12
Loctite #262
202 Cover 4 336 Stopper 6
203 Cover 1 337 Stopper 1
204 Cover 1 339 Stopper 5
205 Cover 7 511 Poppet 11
206 Cover 1 512 Poppet 2
207 Back pressure check valve 514 Poppet 2
1
Cover
1
209 Cover 515 Poppet 1
2
9.8-14 (7.2-13) 211 Lock valve selector sub 517 Boost check valve 1
1
212 Plate 518 Poppet 1
1
213 Plate 521 Spring 11
216 Boom lowering valve 1 522 Spring 2
218 Piston 1 524 Spring 3
130-150 (96-111) 221 Plug 1 527 Spring 1
261 O-ring 12 528 Spring 1
264 O-ring 8 130-150 (96-111) 551 Plug 12
266 O-ring 8 130-150 (96-111) 556 Plug 5
267 O-ring 2 561 O-ring 18
25-34 (18-25) 273 Socket bolt 40 567 O-ring 2
98-120 (72-89) 274 Socket bolt 4 69-78 (51-58) 601 Main relief valve 1
98-120 (72-89) 275 Socket bolt 4 69-78 (51-58) 602 Over load relief valve 3
9.8-14 (7.2-13) 278 Socket bolt 5 69-78 (51-58) 603 Over load relief valve 2
9.8-14 (7.2-13) 279 Socket bolt 3 69-78 (51-58) 604 Plug assembly for relief 2
valve hole
301 Boom spool sub 1 98-120 (72-89) 605 Bypass cut valve 2
302 Arm 1 spool 1 69-78 (51-58) 606 Over load relief valve 12
303 Swing spool 1 140-180 (103-133) 973 Socket bolt 9
304 Bucket spool 1
305 Boom conflux spool 1
306 Travel spool 2
307 Travel priority Spool 1
308 Arm 2 spool sub 1

NA Issued 10-2007 Bur 2-47

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
ASSEMBLY AND DISASSEMBLY OF CONTROL
VALVE

Preparation For Disassembly

General precautions:
1. As well the hydraulic components are precisely
machined, it is essential to carry out disassembly
and assembly in a clean location.
2. When handling the control valve, take special
care to prevent the entry of foreign matter, such
as sand or dust.
3. Cap each port of the control valve before
removing the valve from the machine. Before
disassembly, confirm that each cap is in place
and then clean the exterior of the assembly.
4. Use a workbench. Lay a clean sheet of paper or
rubber mat over the workbench
5. When carrying or moving control valve, hold the
body. Never put pressure on a lever, an exposed
spool, or the end cover. Handle the valve with
care.
6. Tests (for relief characteristics, leaks, overload
valve settings, flow resistance, etc.) that are
desired after disassembly and assembly require
hydraulic testing apparatus. For this reason, do
not disassemble hydraulic units that cannot be
tested or adjusted.
7. Prepare beforehand washing fluid, hydraulic oil,
grease. etc.

2-48 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF SWING DEVICE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers
by discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components have cooled off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and
appropriate ho hold the weight of the load.

PREPARATION
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the
hy d r a u l i c s y s t e m r e fe r t o t h e p r o c e d u r e
RELEASING THE HYDRAULIC PRESSURE.
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual
pressure present in the tank itself. Remove
hydraulic oil tank cap. Connect a vacuum pump
to maintain negative pressure in the hydraulic oil
tank.

NOTE: Be sure to run the vacuum pump

continuously while working.
REMOVAL
1. Remove hose (1) from the Tee in the makeup
port M
2. Remove the hoses (2 and 3) from the Tee in the 6
drain port Dr. 5 4
3. Remove the hoses (4 and 5) from the elbows of
the A and B port. 1
4. Remove the hose (6) from the elbow of the PG
port.
2
3
SM0701
GRAPHIC_ID Figure 80

5. Put in plugs into the opened ports on the swing

motor unit. 8 8
6. Remove the swing motor unit by loosening the
screw (7) (Qty 13).
7. Remove the plastic cap (8) M12 at the top of the
swing motor and install the lifting eyebolts. 7
8. Sling and remove the swing unit.

NOTE: Swing unit weight: approx. 202 kg (445 lbs).

SM0702
GRAPHIC_ID Figure 81

NA Issued 10-2007 Bur 2-49

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
INSTALLATION
8 8
1. Clean mating surfaces of swing motor unit and
upper frame.
2. Apply Loctite #515 on entire mounting surface of
swing motor unit.
7
3. Place the swing unit on the upper frame.

NOTE: Swing unit weight: approx. 202 kg (445 lbs).

4. Remove the lifting eyebolts and insert in the
holes the plastics caps (8) M12 previously
removed.

SM0702
GRAPHIC_ID Figure 82

5. Fix the swing unit to the frame by tightening the

screws (7) (Qty 13). Apply loctite #262 to screws.
Tightening torque: 539 ± 54 Nm (400 ± pound-
feet). 6
6. Install the hoses (4and 5) on the elbows of port A 5 4
and B.
Tightening torque: 167 Nm (123 pound-feet) 1
7. Install the hose (6) on the elbow of port PG.
Tightening torque: 36 Nm (26.6 pound-feet) 2
8. Install the hoses (2 and 3) on the tee in the drain
3
port Dr.
Tightening torque: 74 Nm (55 pound-feet). GRAPHIC_ID SM0701
Figure 83
9. Install the hose (1) on the make up port M.
Tightening torque: 167 Nm (123 pound-feet).

2-50 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
27 44

20 1
21

31

2
15 3 17 13-14

16 43 29 42 12 30
19 A A
43 32
38
37
35
36
4

41
6
25 40
26 8
24 9

7
A-A
45

18
GRAPHIC_1D Figure 84

1. RELIEF VALVE (QTY 2) 16. O-RING (QTY 2) 33. O-RING (QTY 2)

2. O-RING (QTY 2) 17. SOCKT BOLT (QTY 4) 34. OIL SEAL
3. SWING SHOCKLESS VALVE 18. SWING MOTOR CASING 35. BRAKE PISTON
4. SHOCKLESS VALVE CASING 19. VALVE CASING 36. O-RING
5. DRIVE SHAFT 20. PLUNGER (QTY 2) 37. O-RING
6. CYLINDER 21. SPRING (QTY 2) 38. BRAKE SPRING (QTY 16)
7. SPRING 24. SWING SHOCKLESS VALVE (QTY 2) 39. FRICTION PLATE (QTY 3)
8. PISTON (QTY 9) 25. O-RING (QTY 2) 40. SEPARATION PLATE (QTY 4)
9. SHOE 26. BACKUP RING (QTY 2) 41. PLUG (G 1/4)
10. SET PLATE 27. SOCKET BOLT (QTY 4) 42. ROLLER BEARING
11. SHOE PLATE 28. ROLLER BEARING 43. PLUG (G 3/4) (QTY 3)
12. VALVE PLATE 29. PLUG (G 3/8) 44. PLUG (PT 1/2)
13. PLUG (QTY 2) 30. PIN (QTY 2) 45. PLUG (PT 3/4)
14. O-RING (QTY 2) 31. PLUG (QTY 2) 46.
15. O-RING (QTY 2) 32. O-RING 47.

NA Issued 10-2007 Bur 2-51

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
PRELIMINARY OPERATIONS
1. Hydraulic components are precision products
and have small clearance. Assemble and
disassemble in a less dusty, clean place. Use
cleaned tools and cleaning oil. Handle
components with full care.
2. If a component is removed from the main body,
clean the area around the port and plug them up
so nothing will enter them. When fitting them
back to the body, do not remove the plugs until
piping is completed.
3. Study the structural drawing before the work
begins and prepare the necessar y par ts
beforehand. Seals and O-rings can not be
reused and must be replaced.
4. The piston and the cylinder block ar shop fitted
when new. If you intend to reuse them, put a
matching mark on the piston and cylinder block.
DISASSEMBLY 3
1. Remove the drain plug and drain hydraulic oil 17 12
from casing (18). 19 1
2. Fix the motor on a work bench so the drive shaft
(5) end comes down. On that occasion, put a 38
matching mark on the mating parts of casing (18)
and valve casing (19).

NOTE: Choose a clean place. Lay down a rubber

sheet or cloth on a work bench. Handle the valve
casing with care so parts do not have dents. 18
3. Loosen relief valve (1) and separate it from valve
casing (19).
4. Loosen ant-reaction valve sub assembly (3) and
remove from valve casing (17)

5 SM0704
GRAPHIC_ID Figure 85
5. Separate plugs (31) from valve casing (19) and
draw out springs (21) and plungers (20).
6. Loosen socket bolts (27) and separate valve 27
casing (19) from casing (18).

NOTE: If the socket bolts (27) are loosened, the

valve casing (19) floats off casing (18) by the force of
brake springs (38).
7. Separate valve plate (12) from valve casing (19).

20

21

31
S
GRAPHIC_ID Figure 86

2-52 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
8. Draw out brake spring (38) from brake piston 38
(35). (A)
9. Draw out the brake piston (35) using appropriate
tool.
35

SM0706
GRAPHIC_ID Figure 87
10. Lay the motor on its side again and draw out
cylinder block (6) from drive shaft (5), draw out
piston (8), set spring (7), plate (10), and shoe 11 7 8
plate (11).
11. Draw out friction plate (39) and separator plate
(40) from casing.
12. Draw out drive shaft (5) using a plastic mallet.

10 39 40 6

GRAPHIC_ID Figure 88

Perform the following operations as required:

A. Drawing the inner race of roller bearing (28)
from drive shaft (5) using a press.
B. Drawing out the outer race of roller bearing
(28) from casing (18) by lightly tapping the
steel rod from the oil seal (34) housing side.
C. Separate the outer race of roller bearing (42)
from valve casing (19) using a slide hammer
bearing puller.
IMPORTANT: Do not reuse the bearing, replace it.
5

34
28
18
S
GRAPHIC_ID Figure 89

NA Issued 10-2007 Bur 2-53

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
ASSEMBLY
1. Place casing (18) on a proper bench facing
upward.
The following operations are necessary only when
the roller bearings (28) and (42) are removed.
A. Shrinkage fit the inner race of roller bearing
(28) into drive shaft (5).
B. Shrinkage fit the inner race of roller bearing
(42) to drive shaft.
C. Fit oil seal (34) to casing (18).
D. Assemble the outer race of roller bearing (28)
into casing (18) by lightly tapping the steel rod. GRAPHIC_ID Figure 90
2. Attach drive shaft (5) to casing (18).

3. Inset shoe plate (11).

4. Set the set plate (10) and spring (7), then set 9 7
piston sub assembly (8 and 9).
5. Assemble piston sub assembly (8 and 9) fixed in
retainer plate (10) into cylinder (6), match it to the
spline of drive shaft (5) and insert into place.
11
10

GRAPHIC_ID Figure 91

6. Place casing (18) with oil seal facing downward

and assemble separator plate (40) and friction 39
plate (39) into casing (18).

40

GRAPHIC_ID Figure 92

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 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
7. Fit O-ring (36 and 37) to casing (18) 36 37
8. Assemble brake piston (35) into casing (18).
9. Assemble brake spring (38) into brake piston
(35). Make sure that a spring is placed securely
in the spot faced part of the brake piston.

NOTE: This operation is necessary only where roller

bearing (42) is removed.

GRAPHIC_ID Figure 93

10. Insert the outer race of roller bearing (42) into 3

valve casing (190 while lightly tapping the steel 17 42 12
rod with a hammer.
19 1
11. Assemble the valve plate (12) into valve casing
(19) and fit O-ring (32) in it. 38
12. Install valve casing (19) to casing (18) and fasten 35
them with socket bolts (27).
32
Tightening torque: 430 Nm (318 pound-feet).

18

GRAPHIC_ID 5 Figure 94

13. Fit plunger (20) and spring (21) to valve casing

(19). Then tighten plug (31) fitted with O-ring (33)
27
against valve casing (19).
Tightening torque: 334 Nm (274 pound-feet).
14. Fit relief valve (1) to valve casing (19).
Tightening torque: 177 Nm (131 pound-feet).
15. Fit anti-reaction sub assembly (3) to valve casing
(19).
Tightening torque: 69 Nm (51 pound-feet). 20

21

31
SM0705
GRAPHIC_ID Figure 95

NA Issued 10-2007 Bur 2-55

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY AND ASSEMBLY OF SWING REDUCER

8 7 4 19 2 28 16

6
20
3
10 15

12 18
17
5
9
23 22

31

32
25 26

13

24

27

21

11 1

30

SM0714
GRAPHIC_1D Figure 96

1. PINION SHAFT 11. SPHERICAL BEARING 22. SPRING PIN (QTY 4)

2. #1 SUN GEAR 12. OIL SEAL 23. SOCKET BOLT (QTY 11)
3. #1 PINION (QTY 3) 13. HOUSING 24. CAP (QTY 2)
4. #2 SUN GEAR 15. THRUST WASHER (QTY 6) 25. TUBE
5. #2 PINION (QTY 4) 16. NEEDLE BEARING (QTY 3) 26. ELBOW
6. RING GEAR 17. NEEDLE BEARING (QTY 4) 27. PLUG
7. #1 SPIDER ASSEMBLY 18. THRUST WASHER (QTY 4) 28. SNAP RING (QTY 3)
8. #2 SPIDER ASSEMBLY 19. SNAP RING 30. OIL SEAL
9. SHAFT (QTY 4) 20. SNAP RING 31. GREASE FITTING
10. SPHERICAL BEARING 21. SLEEVE 32. RELIEF FITTING

2-56 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
PRELIMINARY OPERATIONS
1. Before disassembly, clean the swing reduction 23
unit outer, checking for no damage or scratches.
2. Drain out the gear oil from reduction unit.
3. Remove the draining pipe.
4. Before disassembly put a matching mark (X) on
the par ts to be connected on the reduction x
casings to help alignment upon assembly.
x
27
DISASSEMBLY
1. Place the reduction unit assembly on a stable
work bench as shown, remove plug (27) and
SM0715
drain out oil. Put a matching mark (X), if not GRAPHIC_ID Figure 97
already done, on the matching surfaces.

2. Loosen all socket bolts (18) M14. Attach eyebolts

(M10) in the lifting bolt holes in the top surface of 7 2
the swing motor and lift the assembly by crane or
hoist.
If it is hard to remove the swing motor assembly
from the reduction unit, float it by inserting a flat
screwdriver blade in the groove of the flange.
3. Remove #1 spider gear (2).
4. The spider assembly (7) [consisting of thrust
washers (15), #1 pinions (3), needle bearings
(16), and snap rings (28)] can be removed from
the spline easily if it is lifted up in that condition.
SM0716
GRAPHIC_ID Figure 98

5. Attach eyebolts (M10) to the top surface of ring

rear (6) and lift the ring gear lightly by a sling.
Put a flat blade screwdriver into the matching
surface of ring gear (6) and housing (13) and 6
remove ring gear (6) by lightly tapping the outer
circumference of the ring gear with a plastic 13
mallet.

SM0717
GRAPHIC_ID Figure 99

NA Issued 10-2007 Bur 2-57

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
6. Draw out #2 sun gear (4) and remove the #2
spider assembly (8). 4 8

SM0718
GRAPHIC_ID Figure 100

NOTE: Particularly in no failure is found, the further

disassembly is not allowed
Check on parts for possible failure according to the
inspection procedure shown in maintenance
standards.
It is recommended that the pinion shaft and housing
assembly are replaced together as one set. But if it is
unavoidably necessary to replace a part of them,
follow the procedure shown below.

GRAPHIC_ID Figure 101

7. Remove retaining ring (20) from pinion shaft (1).

20 1
8. Pull pinion shaft (1), sleeve (21), oil seal (30),
and spherical bearing (lower)(11) out by means
of a press while supporting the housing (13) with
appropriate tool.

NOTE: Spherical bearing (upper) (10) and oil seal

(12) are left in the housing.

GRAPHIC_ID
(B) Figure 102

2-58 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
9. Pull oil seal (30), sleeve (21) and spherical
bearing (lower) (11) out by means of appropriate 21
tools while supporting pinion shaft assembly .
30
NOTE: Press force: 30 t.
11 (D)
NOTE: Do not reuse the removed oil seal and
bearing, replace them.

GRAPHIC_ID Figure 103

10. Set housing (13) as shown, insert appropriate

tool between bearing (10) and oil seal (12) and
remove bearing (10) by striking from the upper
side. 13
11. Remove oil seal (12) from housing (13).

NOTE: Do not reuse the removed oil seal and

bearing, replace.

12
10

GRAPHIC_ID Figure 104

12. Disassemble #1 spider assembly performing the 15

3 16 28
following procedures.
A. Remove retaining rings (28) with a plier.
B. Remove thrust washers (15), pinions (3) and
needle bearings (16).

NOTE: The shaft attached to spider assembly (17) is

caulked. When replacing parts, replace the spider
assembly as a set. Pinions (3) can not be replaced
singularly. Replace them in a set of three.
17 15

GRAPHIC_ID Figure 105

NA Issued 10-2007 Bur 2-59

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
13. Disassembling #2 spider assembly performing 18
the following steps.
A. Draw out spring pin (22). 5
B. Draw out shafts (9) from spider (8) and
remove thrust washers (18), pinions (5), and
needle bearings (24).

NOTE: Pinions (5) can not be replaced singularly.

Replace them is a set of four.

24

18
GRAPHIC_ID Figure 106

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 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
ASSEMBLY
1. Clean every part with cleaner and dry with
compressed air. (F)
2. Check on every part for failure. 30
3. Attach oil seal (30) to sleeve (21) by means of
appropriate tool.

21

GRAPHIC_ID Figure 107

4. Insert sleeve (21) and oil seal assembly (30) in

pinion shaft (1).
5. Apply gear oil to the perimeter of axis of pinion
shaft (1) lightly to prevent seizure.

21 30

GRAPHIC_ID Figure 108

6. Seal sufficient grease in spherical bearing

(lower) (11) and force it in pinion shaft (1) by
means of appropriate tool.
Press force: 4 - 5 t. 1 11

NOTE: Since the bearing is formed with a partition at

the center section, seal grease in it from both sides.

GRAPHIC_ID Figure 109

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 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
7. Apply sufficient grease to the pinion shaft
assembly.
Grease: lithium extreme-pressure grease
(Shell Albania EP2 or equivalent)

GRAPHIC_ID Figure 110

8. Place housing (13) on level bench and attach

eyebolt to screw (M10) at the axis end of pinion
shaft assembly and perpendicularly hang up
pinion shaft assembly and place it in the housing.

NOTE: Horizontally orient the outer race of spherical 13

bearing and insert it by striking lightly. If the outer
race is tilted, it is hard to insert even if striking.
Then do not force to inset it in, but take it away once
and horizontally orient the outer race again and insert
it in

GRAPHIC_ID Figure 111

9. Set housing assembly so that the pinion directs

downward and fit oil seal (12) in housing (13) by
means of appropriate tool.
12
NOTE: Apply Loctite #515 to the perimeter of oil
seal. Fill one third (1/3) of the space of the groove
shaped section provided on the oil seal (12) lip with
grease. Insert it horizontally giving attention to the lip
of oil seal so as not to be damaged.

13

GRAPHIC_ID Figure 112

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 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
10. Press fit spherical bearing (upper) (10) pinion
shaft (1) and housing (13) at the same time by
means of appropriate tool.

13

GRAPHIC_ID Figure 113

11. Attach retaining ring (20).

GRAPHIC_ID Figure 114

12. Assemble #1 spider assembly performing the 15

3 16 28
following operations.
A. Coat the bore surface of pinion (3) with
grease. Put pinion (3) on thrust washer (15)
and assemble needle bearings (16) into the
bore surface.
B. Fit thrust washers (15), pinions (3) and fit snap
rings(28) by means of pliers.

15

GRAPHIC_ID Figure 115

NA Issued 10-2007 Bur 2-63

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
13. Assemble #2 spider assembly performing the
A
following operations.
A. Coat the bore surface of pinion (5) with
grease. Put pinion (5) on thrust washer (180
and fit needle bearing (17) to the bore surface.
B. Fit thrust washer (18) and pinion (5), insert
shaft (9) into spider (8) and drive spring pin
(22).
6 - 7 mm 6 - 7 mm

8 9 18
5

17

22
GRAPHIC_ID Figure 116
14. Insert #2 spider assembly (8) in spline axis of
pinion shaft. 8

SM0735
GRAPHIC_ID Figure 117
15. Install #2 sun gear (4) directing the spline
upward. 4

SM0736
GRAPHIC_ID Figure 118

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 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
16. Apply a thin film of sealant Loctite #515 to the
matching surface of housing (13) and ring gear
(6) and assemble them, aligning the gear teeth
and according to the matching marks given. 6

13

SM0737
GRAPHIC_ID Figure 119

17. Mesh the #1 spider assembly (7) with ring gear

7 2 3
(6) and set them in place.
18. Mesh #1 sun gear (2) with #1 pinions (3) and set
them in place.
6

SM0738
GRAPHIC_ID Figure 120

19. Fit drain tube (250 and plug (27).

Tightening torque: 69.1 ± 4.4 Nm (51.5 ± 3.2 23
pound-feet)
20. Fill in 3 L (0.8 gal) of gear oil (API GL-4)
21. Attach eyebolts (M10) in the tapped holes of the
swing motor and put a sling in them. Coat the
matching surface of ring gear (6) with sealant 25
x
Loctite #515.
Insert the spline joint of the swing motor and x
27
match the matching marks. Coat socket bolts
(23) with sealant Three-Bond 1360K and fasten
them.
SM0739
Tightening torque: 181 ± 18 Nm (134 ± 13 GRAPHIC_ID Figure 121
pound-feet).

NA Issued 10-2007 Bur 2-65

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
MAINTENANCE STANDARDS

Swing Motor

Recommended
Standard
value for
Item dimension Remedy
replacement
mm (in.)
mm (in.)
Clearance between piston and cylinder
bore (D-d)

D 0.027 0.052
Replace piston or cylinder
d (0.0010) (0.0020)

GRAPHIC_ID Figure 122

Gap between piston and caulked part of
shoe (d)

0 0.3
Replace piston and shoe assembly
(0) (0.0118)

GRAPHIC_ID Figure 123

Thickness of shoe (t)

5.5 5.3
Replace piston and shoe assembly
(0.2167) (0.2088)

GRAPHIC_ID Figure 124

Thickness of friction plate

2.0 1.8
Replace
(0.0788) (0.0709)

GRAPHIC_ID Figure 125

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 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Standard For Correcting Sliding Surfaces.
If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the
parts.

Standard for correcting sliding surfaces

Surface roughness
Name of parts Standard surface roughness
requiring correction
Shoe 0.8 - Z (Ra= 0.2)(lapping) 3-Z (Ra=0.8)
Shoe plate 0.4 - Z (Ra=0.1)(lapping) 3-Z (Ra=0.8)
Cylinder 1.6 - Z (Ra=0.4)(lapping) 12.5 - Z (Ra=3.2)
Valve plate 0.8 - Z (Ra= 0.2)(lapping) 6.3 - Z (Ra=1.6)

NOTE: Lap each sliding surface to a standard

roughness level or finer. If the spherical sliding
surface of the spring (7) and cylinder (6) are
roughened, replace parts in pairs.

NA Issued 10-2007 Bur 2-67

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Swing Reduction Gear

A D

C
D

C
B

SM0740

GRAPHIC_1D Figure 126

Repairable Level
Code Item Service Limit Remedy
(mm)
Replace entire
A Wear in #1 planetary shaft ø 39
spider assembly
No flaking
Replace four shafts
B Wear in #2 planetary shaft ø 29
as a set
There should be no pitting exceeding 1.6 mm. in
Condition of Replace (planetary
diameter, abnormal wear or seizure.
tooth flank pinion should be
C Gears
replaced in a
Condition of set of four.
There should be no cracks
tooth flank
D Thickness of thrust washer 1.6 1.3 Replace
E Thickness of thrust washer 2.0 1.6 Replace
Wear in shaft (diameter of
F part coming in contact with ø 95 ø 94.9 Replace
oil seal

2-68 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
SPECIAL TOOLS
Dimension: mm (in.)

Item Descrption Note

14 (0.551")

85 (3.35")
75 (2.95")
30 (1.18")
15 (0.591")

35 (1.38")
5
2. 2")
R1 .49
(0
M16
(A) Piston brake puller

100 (3.94")
44 (1.73")
8 (0.315") 4 M18
(0.158")

o 8 (0.315")

o 412 (16.23”)
Material : mild steel
o 270 (10.64”)

230 (9.06”)
(B) Support
190(7.48”) 22(0.86”)

o 162(6.38”)
Material : mild steel

n.13-o 16
(C) Bearing (10) removing jig n.13-(o .06”)

P.C.D 146 (5.75”)

VIEW X
X

SM1359
GRAPHIC_1D Figure 127

NA Issued 10-2007 Bur 2-69

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
Dimension: mm (in.)

100 (3.94”)
(D) Bearing (11) removing jig

Material : mild steel ) t=4.5

5”
.3
(3
(E) 85
Bearing (10) removing jig o

9 (0.35”)
Material : mild steel o 150 (5.91”)
o 125 (4.95”)
(F) Oil seal (30) installing jig

Material : mild steel o 105 (4.14”) t=10 or more

160 (6.3”) or more

(G) Bearing (11) press-fit jig

9 (0.35”)
Material : mild steel o 140 (5.51”)
o 95 (3.74”)
(H) Oil seal (12) intalling jig

(1.97”)
Material : mild steel

60 (2.36”)
50

(L) Bearing (10) press-fit jig

o 91(3.58”)
o 158 (6.22”)

GRAPHIC_1D Figure 128

2-70 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers
by discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components have cooled off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and
appropriate ho hold the weight of the load.

PREPARATION
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the
hy d r a u l i c s y s t e m r e fe r t o t h e p r o c e d u r e
RELEASING THE HYDRAULIC PRESSURE.
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual
pressure present in the tank itself.
REMOVAL
1. Free and lift rubber cap (5) complete with plate
(4)unlocking its hooks using a screwdriver.
2. Remove side panels (2) and (3) removing
securing screw.
3. Remove the hand grip (1) removing lock-nut (6)
disconnecting the relevant electric connection. 

IMPORTANT: Attach an identification tag on each
hose to aid in assembly. 




GRAPHIC_ID Figure 129

4. Disconnect hoses for port connector PF 3/8 (7)
and PF 1/4 (8) of pilot valve body.

NOTE: Attach a cap on each of the disconnected
hose ends.
5. Remove pilot valve (9) removing securing
screws (10)M6X25 complete with washers.


60

GRAPHIC_ID Figure 130

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 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
INSTALLATION
1. Install pilot valve (9) on the frame tightening
securing screws (10) M6X25 complete with 7
washers. 7 

2. Connect hoses to pilot valve body (9). 
Tightening torque: 
Port P: 29.4 Nm (22 pound-feet) 
Port 1to 8, T: 49 Nm (36 pound-feet)  3
 3
 60

GRAPHIC_ID Figure 131

3. Tighten the hand grip on the pilot valve (9),

tighten lock-nut (6) and connect the electrical LEFT SIDE RIGHT SIDE
connector. BUCKET
5 SWING(L) GRAY 1 RED
(H)
BUCKET
6 SWING(R) RED 2 BLUE
(R)
7 ARM (H) BLUE 3 BOOM (H) GREEN
8 ARM (R) GREEN 4 BOOM (R) GRAY

4. Install side panels (2 and 3) tightening securing

screws
5. Arrange rubber cap (5)complete with plate (4)
locking the hooks on side panel (2).









GRAPHIC_ID Figure 132

2-72 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY RIGHT AND LEFT PILOT VALVE

60

GRAPHIC_1D Figure 133

33. ADJUSTING NUT (M14) 39. PLUG (QTY 4) 17. SPRING (QTY 2)
34. BOOTS 40. O-RING (QTY 4) 18. SPRING (QTY 2)
35. CIRCULAR PLATE 41. PUSH ROD (QTY 4) 19. WASHER 2 (SHIM) (QTY 4)
36. JOINT (M14) 12. SPRING SEAT 1 (QTY 2) 20. SPOOL (QTY 2)
37. PLATE 14. SPRING SEAT 1 (QTY 2) 21. SPOOL (QTY 2)
38. SEAL (QTY 4) 15. SPRING (QTY 4) 22. CASING

NA Issued 10-2007 Bur 2-73

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY 
Be sure to read PRECAUTIONS FOR DISASSEMBY
AND ASSEMBLY before starting the disassembly
work.

NOTE: Replace O-ring every disassembly

operation.
1. Plug each port of pilot valve and clean it.
P port: PF 1/4 in.
1 - 4 port and T: PF 3/8

GRAPHIC_ID Figure 134

2. Fix pilot valve in a vise, via a protective plate

(aluminum plate etc.) and remove boot (2).
3. Remove adjusting nut (1) applying spanners to
circular plate (3). 
4. Remove circular plate (3).


60
GRAPHIC_ID Figure 135

5. Turn joint (4) in counter clockwise with jig (E)

(380001055) to remove it.

WARNING (
When the force of return springs (15) is high, never
loosen joint (4). If loosened, it might result in jumping

out of plate (5) plug (7) and push rod (9). Remove joint
(4) pressing plate (5) downward with two fingers.

60

GRAPHIC_ID Figure 136

2-74 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
6. Remove plate (5). 

NOTE: When the force of return spring (15) is high,

press plate to let it come up slowly.
When the force of the return spring (15) is low, plug
(7) is left in casing (22) die to sliding resistance of O-
ring (8).

60
GRAPHIC_ID Figure 137



60
GRAPHIC_ID Figure 138

7. Pull plug (7) out with a screwdriver.

WARNING
To prevent personal injury, plug (7) must be removed
slowly and evenly until the return spring (15) force is
completely released.


60
GRAPHIC_ID Figure 139

NA Issued 10-2007 Bur 2-75

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
8. Remove push rod (9), plug (7), pressure
reducing valve assembly (spool) and the return
springs (15) from casing (22) 

NOTE: Record combination of port holes on casing

and the pulled out parts. The stroke differs according 
to direction.



60

GRAPHIC_ID Figure 140

9. Press springs seats (12 and 14) so that the

movement is 7 mm (max) (0.275 in.), then
remove spools (20 and 21) through the larger
hole of the seat.

IMPORTANT: Never push down spring seat (12) in 7
mm (0.275 in.) or more. (For port 1 and 3).
Never push down spring seat (14) in 9.4 mm (0
.375 in) or more. (For port 2 and 4).


60
GRAPHIC_ID Figure 141

10. Remove spool (20 and 21), spring seats(12 and

14), springs (17 and 18) and washer (19).


 


60
GRAPHIC_ID Figure 142

2-76 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
11. Pull out push rod (9) from plug (7).
12. Remove O-ring (8) from plug (7). 

 
60
GRAPHIC_ID Figure 143

13. Remove inside seal (6) from plug (70 with small
screwdriver.

 60
GRAPHIC_ID Figure 144

Cleaning Parts
1. Clean parts with appropriate cleaner.
2. Dry parts by swabbing with a clean cloth.
3. Apply rust preventatives on parts.

NA Issued 10-2007 Bur 2-77

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
ASSEMBLY











 

 




 

 

60

GRAPHIC_1D Figure 145

1. ADJUSTING NUT (M14) 9. PUSH ROD (QTY 4) 18. SPRING (QTY 2)

2. BOOTS 10. SPRING (QTY 4) 19. WASHER 2 (SHIM) (QTY 4)
3. CIRCULAR PLATE 11. SPRING SEAT 2 (QTY 2) 20. SPOOL (QTY 2)
4. JOINT M14 12. SPRING SEAT 1 (QTY 2) 21. SPOOL (QTY 2)
5. PLATE 13. APRING SEAT 2 (QTY 2) 22. CASING
6. SEAL (QTY 4) 14. SPRING SEAT 1 (QTY 2) 23. 2E4 PORT
7. PLUG 15. SPRING (QTY 2) 24. 1E3 PORT
8. O-RING (QTY 4) 17. SPRING (QTY 2)

2-78 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
1. Fit washer 2 (19), springs (17 and 18), spring
seats (12 and 14) to spools (20 and 21).





60
GRAPHIC_ID Figure 146

2. Push spring seat 1 (12) so that the movement is

7 mm (0.275 in.) or less and install spool (20)
through the large hole of spring seat 1.
For spring seat 1 (14), push spring seat (14) in 
9.4 mm (0.375 in.) or less and install spool (21).
IMPORTANT: Never push down spring seat (12) in 7
mm (0.275 in.)or more. (For port 1 and 3).
Never push down spring seat (14) in 9.4 mm (0.375
in.) or more. (For port 2 and 4).


60
GRAPHIC_ID Figure 147

3. Place springs (15) into ports 1 of casing (22) and

then install pressure reducing valve assembly in
it. 
Place spring (16) in to ports 2 and 4 and then
install pressure reducing valve assembly in it.

NOTE: Install the remove respective assembly into
respective holes. 

60
GRAPHIC_ID Figure 148

NA Issued 10-2007 Bur 2-79

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
4. Fit O-ring (8) and seal (6) into plug (7).
  

60
GRAPHIC_ID Figure 149

5. Apply hydraulic oil on surface of push rod (9).

 

60

GRAPHIC_ID Figure 150

6. Insert push rod (9) in plug (7).

 
60
GRAPHIC_ID Figure 151

2-80 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
7. Fit plug (7) assembly to casing (22)

GRAPHIC_ID Figure 152

NOTE: When the force of spring (15) is low , it stops

at the position where it is pushed in by the sliding 
resistance of O-ring (8).
When the force of the spring (15) is high, attach plate
(5) and press 4 push rods by hand at the same time
and tighten joint (4) temporarily.
Install spools (20 and 21) straight and evenly into the
hole of casing.


60
GRAPHIC_ID Figure 153

8. Install joint (4) on casing (22) with special tool (E)

(380001055) securely.
Tightening torque;47.1 ± 2.9 Nm (34.8 ± 2.1
pound-feet)


(

60
GRAPHIC_ID Figure 154

NA Issued 10-2007 Bur 2-81

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
9. Install circular plate (3) to joint (4).
IMPORTANT: Screw it in until it comes in contact
with 4 push rods (9) equally.
The screwing in too far may cause malfunction of

machine.
10. Screw adjusting nut (1) applying Loctite #277 to
thread of joint, until it touches circular plate (3)
and tighten it applying spanner to stop circular 
plate returning.
Tightening torque: 68.6 ± 4.9 Nm (50 ± 3.6
pound-feet).

60
GRAPHIC_ID Figure 155

11. Apply heat-resisting grease (G) to joint (4)

rotating section and the top of push rod (9).
*



60
GRAPHIC_ID Figure 156

12. Cover it with boots (2).


13. Spray rust preventatives through each port an
attach plug respectively.

GRAPHIC_ID Figure 157

2-82 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries. Prevent these dangers
by discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components have cooled off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and
appropriate ho hold the weight of the load.

PREPARATION
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the
hy d r a u l i c s y s t e m r e fe r t o t h e p r o c e d u r e
RELEASING THE HYDRAULIC PRESSURE.
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual
pressure present in the tank itself. Remove
hydraulic oil tank cap.

REMOVAL
1. Remove the cover under the cab.
2. Remove the floor mats in the cab.
3. Remove the pedal removing the securing screws
(1) (Qty 4) then remove the levers, removing
securing screws (2) (Qty 4).
4. Disconnect pressure sensors (7) from body (8).
IMPORTANT: Attach an identification tag on each
hose to aid in assembly.
5. Disconnect pipes (from 3 through 6) of body (8).

NOTE: Attach a cap on each of the disconnected

hose ends.
6. Remove body (8) removing securing screws (9)
complete with washers. 





 


 60

GRAPHIC_ID Figure 158

NA Issued 10-2007 Bur 2-83

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
INSTALLATION
1. Install body (8) on the frame tightening securing
screw (9) complete with washers.
Tightening torque: 37 Nm (27.4 pound-feet)
2. Connect pipes (from 2 through 6) to body (8).
Tightening torque:(19 mm) 16.7 Nm (12.3
pound-feet)
Tightening torque: (22 mm) 30 Nm (22 pound-
feet)
3. Connect pressure sensors (7) to body (8).
Tightening torque: 16.7 Nm (12.3 pound-feet
4. Install the levers tightening securing screws (2)
and the pedals, tightening securing screws (1).
Tightening torque: (17 mm) 46.1 Nm (34.1
pound-feet) 

Tightening torque:(13 mm) 23.5 Nm (17.4
pound-feet)
5. Install the cover under the cab.
Tightening torque: 108 Nm (80.0 pound-feet) 




 


 60

GRAPHIC_ID Figure 159

2-84 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
DISASSEMBLY AND ASSEMBLY OF THE TRAVEL PILOT VALVE
PILOT VALVE (FOR TRAVEL)

R

R

K
R
\
 \
[ [



 
I

G
/RFWLWH 
J
7 
J
O 
T 
7  U 
X
 W 7 
L 7 

N 7 
K X
 W 7 
M W 
X
U
T
  7 
/RFWLWH 

]
U 
Z
7 aa
GRAPHIC_1D Figure 160
NOTE: T= tightening torque Nm (pound-feet).

No. Parts Qty No. Parts Qty

5 Rubber Boots 2 12-x Seal Ø14x20x3 6
6 Foot Pedal (Switch Plate) (2) 12-y Wiper Ring 6
6-d Switch Plate 2 13 Damper Spring 4
6-f Regulation Screw M8x28 4 14 Check Valve Kit (2)
6-g Set Screw M5x8 4 14-q Plug M8 2
6-l Damping Screw 4 14-r Ball M6, 35 2
7 Retaining Plate Kit (1) 15 Orifice (4)
7-h Plate 1 15-u Plug M6 4
7-i Capscrew M10x20 2 15-t Orifice M6, Ø0.6 4
7-j Shaft 2 17 Shuttle Valve Kit (2)
7-k Set Screw M4x10 2 17-w Shuttle Valve And Orifice 2
8 Flange Kit 4 17-r Ball M6, 35 2
10 Control Spool 4 17-z Orifice M5, Ø0.8 2
11 Return Spring 4 21 Plug 4
12 Damper Flange Kit (4) 22 Valve Body 1
12-o Damper Plunger Ø14 4

NA Issued 10-2007 Bur 2-85

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
BOOT REPLACEMENT

NOTE: The pilot control unit does not need to be 

removed from the machine to perform this operation. 
1. Remove both faulty boots (using a flat
screwdriver if necessary).
2. Replace both boots with a new one.
Assembly:
1. First fit the lower part of the rubber boot (5) on
the retaining plate (7-h) between the 2 switch
K
plate (6).
2. Then put the lower part in the external groove of
the retaining plate.
3. Finish by fitting the upper part of the rubber boot
on the switch plate.

60
GRAPHIC_ID Figure 161
SWITCH PLATE REMOVAL %
1. Remove:
The pilot control unit from the machine
Both rubber boots.
2. Remove the screw (7-k) locking the axis using a
2 mm socket wrench.
Assembly:
$
Apply a droplet of Loctite #262 on the locking N
screw thread. &
I
Tightening torque:1.2 Nm (0.89 pound-feet).
3. Fit a M3 screw on the switch plate axis (7-j) in
order to remove it, (using pliers if necessary.)
4. Position the axis so that the hole (f) is aligned
with the locking screw (7-k) as shown. M
5. Mark out the position of the switch plate before
removing it.
6. Repeat the operation for the second switch plate.
7. Assemble parts in reverse order. ' (
GRAPHIC_ID Figure 162

2-86 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
SWITCH PLATE ADJUSTMENT
I
NOTE: If the switch plate (6) is replaced, it is
necessary to adjust the regulations screws (65-f).
1. Unscrew the 2 licking screws (6-g) using a 2.5
mm socket.
Assembly:
Apply a droplet of Loctite #262 on the locking
screw thread.
Tightening torque:3 Nm (2.2 pound-feet)
2. Set the switch plate (6) horizontally.
3. Screw on simultaneously both regulation screws
(6-g) using a flat screwdriver until feeling some J
resistance.


GRAPHIC_ID Figure 163
NOTE: Do not misadjust the two damping screws
(6-l)
4. tighten the locking screws (6-g) to hold the
regulation screws (6-f) in position.
5. Repeat the operation for the second switchplate
making sure both switch plates ar parallel.
I O


GRAPHIC_ID Figure 164

RETAINING PLATE REMOVAL

1. Remove:
The pilot control unit from the machine
Both rubber boots
Both switch plates
2. Drain the oil by loosening the check valve plug
(14-q). 
3. Unscrew simultaneously both screw (7-i) holding
the retaining plate using a 8 mm socket wrench. L
Assembly:
Apply a droplet of Loctite #262 o the screw K
thread. GRAPHIC_ID Figure 165

Tightening torque: 30 Nm (22 pound-feet)

NA Issued 10-2007 Bur 2-87

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
4. Lift the retaining plate (7-h) to remove it.
Assembly: Using the retaining plate (7-h) to
insert the 4 guides into the body simultaneously  K
and perpendicularly (22).
5. Assemble parts in reverse order

60

GRAPHIC_ID Figure 166

DAMPING PLUNGER SEALS REPLACEMENT .

1. Remove:
The pilot control unit from the machine
Both rubber boots
Both switch plates the retaining ring
2. Remove the wiper ring (12-y).
Assembly:
Replace with a new wiper ring (12-y).
\ R
$ %
60

GRAPHIC_ID Figure 167

WARNING K
Always place the damping plunger (12-o) prior to the
wiper ring (12-y) and make sure that it correctly
\
positioned.
[

R




GRAPHIC_ID Figure 168

2-88 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
3. Remove the damping plunger (12-o).
4. Using a needle, remove the seal (12-x) placed
inside the body (22).
Assembly: [
1. Replace with a new seal and grease it.

$ % 
60

GRAPHIC_ID Figure 169

2. (A) Squeeze the seal (12-x) between you fingers
to obtain a 8-shape.
3. (B,C) Insert the seal (12-x) within the groove with
your fingers (lip in bottom position).
4. (D) Push the seal (12-x) against the side using $ %
the round head of a small socket wrench.
IMPORTANT: During the assembly, make sure the
seal (12-x) is correctly positioned and pay attention [
not to damage of twist it.
5. Repeat the operation for the other 3 assemblies.
6. Extract the damping springs (13) from the body
(22) (using flat nose pliers).
GRAPHIC_ID Figure 170
7. Inspect the damping springs (13). if defects are
detected, replace the 4 springs.
8. Assemble parts in reverse order.
GUIDE/PLUNGER AND REGULATION UNIT
REPLACEMENT
1. Remove:
The pilot control from the machine
Both rubber boots
Both switch plates
The retaining ring
2. Guide/ plunger replacement
Insert the end of a tin screwdriver between the
guide and the body (22), carefully lift the guide to
remove it from the body.

NOTE: Hold the guides with the other hand during


the extraction operation to limit the effect of the 
return spring.
3. Remove the guide/plunger assembly.
4. Repeat the operation for the other 3 assemblies.
5. Visually check that the guides/plungers are in
good condition. If defects are present, replace
the 4 sub-assemblies.

GRAPHIC_ID Figure 171

NA Issued 10-2007 Bur 2-89

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
6. Guide/plunger and regulation unit replacement.
Extract the regulation units from the body (22)
(using flat nose pliers).
Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.




60
GRAPHIC_ID Figure 172

7. Return spring replacement (11):

Extract the return springs (11) from the body (22)

(using flat nosed pliers.)
Inspect the return springs (11). If defects are found,
replace the 4 springs.
8. Assemble parts in reverse order.



60
GRAPHIC_ID Figure 173

THROTTLE KIT REPLACEMENT

X
1. Remove:
The pilot control unit from machine
Both rubber boots
Both switch plated
The retaining plate
The damping plungers and springs
2. Drain the oil by loosening the check valve plug
(14-q).
3. Unscrew the screw (15-u) using a 3 mm socket

wrench. 60
GRAPHIC_ID Figure 174
Assembly:
1. Apply a droplet of Loctite #262 on the screw
thread.
2. Screw on until it sets just above the body (22).

2-90 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
3. Unscrew the Throttle (15-t) using a 3 mm socket
wrench.
4. Repeat the operation for the other 3 assemblies.
Assembly
1. Replace with new screws (15-u) and new
throttles (15-t).
2. Assemble in reverse order.
3. Tightening torque: 4 Nm (3 pound-feet).

X

GRAPHIC_ID Figure 175

SHUTTLE VALVE KIT REMOVAL

1. Remove the pilot control unit from the machine.
2. Drain the oil by loosening the check valve plug
(14-q).

NOTE: The pilot control unit does not need to be

disassembled to perform this operation.
3. Unscrew the shuttle valve (17-w) using a 4 mm
socket wrench.

GRAPHIC_ID Figure 176

4. Put the body upside down to remove the shuttle

valve (17-w) and the ball (17-r).

Z

GRAPHIC_ID Figure 177

NA Issued 10-2007 Bur 2-91

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
5. Unscrew the throttle (17-z) using a 2.5 mm
socket wrench.
6. Repeat the operation for the subassemblies.

GRAPHIC_ID Figure 178

7. Clean the body to remove any trace of old

Loctite.
8. Inspect the shuttle valves (17-w), balls (17-r) and
throttles (17-z). If defected are found, replace all
of the assemblies. W
Z ]
Assembly
1. Assemble parts in reverse order
2. Hand tighten the throttles (17-z).
60
3. Insert ball (17-r)
4. Apply a droplet of Loctite #262 on the shuttle
valve thread (17-w).
IMPORTANT: Wait for 8 hours before using the GRAPHIC_ID Figure 179
machine to let the loctite #262 dry completely.
Tightening torque: 4 Nm (3 pound-feet)

CHECK VALVE KIT REMOVAL

1. Remove the pilot control unit from the machine. T
2. Drain the oil by loosening the check valve plug
(14-q).

NOTE: The pilot control unit does not need to be

disassembled to perform this operation.
3. Unscrew the check valve (14-q) using a 4 mm
socket wrench.

GRAPHIC_ID Figure 180

2-92 Issued 10-2007 Bur NA

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
4. Put the body (22) upside down to remove the ball
(14-r).
5. Repeat the operation for the second valve kit.
6. Inspect the check valve plugs (14-q), O-rings and
ball (14-r). I f defects are found, replace all the
assemblies.
7. Assemble in reverse order.

8. Tightening torque: 5 Nm (3.7 pound-feet).

T

GRAPHIC_ID Figure 181

BLEEDING OF THE HYDRAULIC PILOT

CONTROL UNIT
T
NOTE: When removing the retaining plate, the
throttle kit or shuttle valve kit, it is necessary to drain
the pilot unit.
1. Assemble the pilot control unit completely.
2. Install the pilot control unit in the machine.
3. Slightly unscrew the check valve plug (14-q)
using a 4 mm socket wrench.
4. Switch on the machine.
5. Operate gently the pedal until the bubbles
disappear. GRAPHIC_ID Figure 182
6. Tighten the check valve plug (14-q).
7. Tightening torque: 5 Nm (3.7 pound-feet).
8. Repeat the operation for the other check valve
plug.

NA Issued 10-2007 Bur 2-93

 SECTION 3 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 2 - UPPER STRUCTURE
NOTES

2-94 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

CHAPTER 3

E175B
EXCAVATOR

UNDERCARRIAGE (TRAVEL
SYSTEM)

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

3-II Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY

CHAPTER 3
UNDERCARRIAGE (TRAVEL SYSTEM)
TABLE OF CONTENTS

REMOVAL AND INSTALLATION OF SWING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
REMOVAL AND INSTALLATION OF TRAVEL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
DISASSEMBLY TRAVEL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Preliminary Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Disassembly of the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Disassembly of the Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Disassembly of the Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Disassembly of the Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Disassembly of the Flanged Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Disassembly of the Base Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Disassembly of the Motor Shaft and Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
ASSEMBLY TRAVEL DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Preliminary Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Assembly of the Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Assembly of the Base Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Assembly of the Flanged Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Assembly of the Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53
Assembly of the Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Assembly of the Two Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
Assembly of the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
REMOVAL AND INSTALLATION OF SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
SWIVEL JOINT DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Inspection After Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
REMOVAL AND INSTALLATION OF TRACK ADJUSTER (WITH FRONT IDLER) . . . . . . . . . . . . . . . . . . . . . 3-79
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Tool Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
DISASSEMBLY AND ASSEMBLY FRONT IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Front Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Axle and Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Tool Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
REMOVAL AND INSTALLATION OF UPPER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
NA Issued 10-2007 Bur 3-1
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-92
UPPER ROLLER DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-96
REMOVAL AND INSTALLATION OF LOWER ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-100
LOWER ROLLER DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-105
Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107
Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107
Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107
Upper Roller Axle and Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
Lower Roller Axle and Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
Tool Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
REMOVAL AND INSTALLATION OF TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-109
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112
Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115
Link Pin and Track Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115
Master Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115
Master Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-115
Tool Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-116

3-2 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
REMOVAL AND INSTALLATION OF SWING BEARING

WARNING
Wear close-fitting clothing and safety equipment
appropriate to the job. Use tools appropriate for the
job to be performed. Always make sure that slings
and chains used for lifting are adequate to the load
and in good condition.

B e fo r e r e m o v i n g t h e sw i n g b e a r i n g , t h e
upperstruture must be removed first. For removal
and installation of the upperstructure, refer to
REMOVE AND INSTALL MAIN FRAME section. In
this section, the procedure starts on the premise that
the upperstructure has already been removed.

REMOVAL
1. Put alignment marks on (A) swing bearing (1)
and track frame (2). $
2. Remove screws M20 (3) (Qty 36) and the
relevant washers (Qty 36).

NOTE: Swing bearing weight: 212 kg (467 lbs.).

 
60
GRAPHIC_ID Figure 1

3. Attach lifting tools (380001026), hoist swing

bearing (4) and remove it.


60
GRAPHIC_ID Figure 2

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
INSTALLATION
Clean the matching surfaces of swing bearing and
the frame.
1. Apply THREEBOND 1102 to the matching
surfaces of swing bearing and track frame.
NOTE: Swing bearing weight: 212 kg (467 lbs.).

60
GRAPHIC_ID Figure 3

NOTE: Inner race soft zone (S) and the ball filler port
should be placed on the same position (right side of $
the frame).
6
1. Hoist the swing bearing.
Align the swing bearing with the alignment mark
on the track frame and install the swing bearing.
Apply Loctite #262 on the thread of the screws (3)
before assembling.
%

60
GRAPHIC_ID Figure 4

2. Install screws M20 (3) (Qty 36) with the relevant

washers (Qty 36) and tighten them to the
prescribed torque.
Tightening torque: 563 ± 56 Nm (415 ± 41pound-
feet)
NOTE: Fill in grease bath with 8.6 ± 0.86 kg (19 ± 2
lbs.)of IP BIMOL 481 or equivalent grease.


60
GRAPHIC_ID Figure 5

3-4 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
REMOVAL AND INSTALLATION OF TRAVEL DEVICE

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns. Prior
to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.
Check that the lifting devices (hooks, chains, etc.) are in perfect conditions without any sign of excessive wear and
appropriate to hold the weight of load.

PREPARATION
1. Park the machine on a firm, level surface.
2. To drain the hydraulic pressure from the
H y d r a u l i c S y s t e m , r e fe r t o p r o c e d u r e
RELEASING THE HYDRAULIC PRESSURE.
3. Cut-off the engine. Press the valve located on
the hydraulic oil cap to release any residual
pressure present in the tank itself. Remove
hydraulic oil tank cap. Connect a vacuum pump
to maintain negative pressure in the hydraulic oil
tank.

NOTE: Be sure to run the vacuum pump

continuously while working.

REMOVAL
The procedure starts on the premise that the track 4 5
link has already been removed.
1. Loosen bolts M12 (7) to remove cover (6).
Disconnect hoses (2), (3), (4) and (5).
3
19 mm: 29.4 ±5 Nm (21.7 ± 3.7 pound-feet)
27 mm: 78.5 ±5 Nm (57.9 ± 3.7 pound-feet) 2
36 mm: 177 ±18 Nm (130.5 ± 13 pound-feet)

NOTE: Install caps on all disconnected hose and

line ends.

8
1
7 6

9 SM0300

GRAPHIC_ID Figure 6

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
2. Attach the travel device to a crane using a wire
rope. Remove any slack from the wire rope so as
to secure the travel device when the mounting
bolts are removed.

NOTE: Travel device weight: Approx. 300 kg (661.5

lbs).
3. Remove bolts M16 (1). Remove the travel device
using the crane.
Tightening torque: 320 ± 32 Nm (236 ± 23
pound-feet)

INSTALLATION
1. Install the travel device using bolts (1). 4 5
2. Connect hoses (2), (3), (4) and (5).
3. Install cover (6) and fix it with screws (7) and
washers (8) and (9). 3
Tightening torque: 83.4 ± 8.4 Nm (61.5 ± 6.2
pound-feet)
2

8
1
7 6

9 SM0300

GRAPHIC_ID Figure 7

After completing travel motor installation, be sure to

fill the travel motor with hydraulic oil. After completing
installation of the travel motor or the travel device, be
sure to perform test driving to prevent motor seizure.
Test drive as follows:
1. Run the engine with the engine control dial in the
slow idle position.
2. Turn the travel speed mode switch to the slow
speed position.
3. Test drive the machine back-and-forth for 0.5 m
to 1 m in each direction five times or more.

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY TRAVEL DEVICE
PRELIMINARY OPERATIONS
In the case that it was necessary to undergo a
(partial or total) revision, it will be necessary to
dismount the gearmotor from the machine. As this is
known as an out of the ordinar y maintenance
procedure, it is important that only personnel with
specific skills and experience undertake it.
It is also important that this procedure is undertaken
in a workshop that is adequately tooled. As well as
normal workshop tools it will be necessary to use
special tools.
In the following pages all the procedures for
disassembling and assembling the gearmotor are
given, it is important to strictly adhere to them.
P r o c e e d w i t h t h e s e o p e ra t i o n s u si n g a l l t h e
necessary safety measures, like for example:
1. Cutting off all the hydraulic system connections
on the gearmotor to avoid the introduction of any
foreign parts in the circuit and the gearmotor.
2. Making sure that the coupling surfaces are not
damaged.
3. Following the handling so as to be sure that there
are no risks for human safety and to guarantee
the reliability of the gearmotor.
4. Making available a work area that is in line with
wo r k a n d h e a l t h s a fe t y i n t h e wo r k p l a c e
guidelines.
NOTE: Initial inspection of hydraulic motor and
gears, can be made without disassembling the track
drive from the machine.
Initial inspection of the gears, can be made without
disassembling the track and the track drive from the
machine. Before track drive disassembling, make
sure that the oil is discharged.

NA Issued 10-2007 Bur 3-7

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY OF THE GEARBOX

1. Make sure that the oil is discharged.
2. Unscrew the socket bolts (1) (Qty 10) which fix
the end cover (2) to the gearbox housing (3).


60
GRAPHIC_ID Figure 8

3. Remove the end cover (2) by using screws (4)

screwed into the oil plugs holes.


60
GRAPHIC_ID Figure 9

4. Remove the O-Ring seal (1) from the end cover 

(2).


60
GRAPHIC_ID Figure 10

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
5. Take out 1st stage sun gear (3).

60
GRAPHIC_ID Figure 11

6. Remove the 1st reduction assembly (4). 

60
GRAPHIC_ID Figure 12

7. Take out 2nd stage sun gear (5).

60
GRAPHIC_ID Figure 13

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
8. Remove the 2nd reduction assembly (1).


60
GRAPHIC_ID Figure 14

9. Take out 3rd stage sun gear (2).

60
GRAPHIC_ID Figure 15

10. Unscrew the socket bolts (3) (Qty 4), which fix 
the 3rd reduction assembly to the hydraulic
motor.

60
GRAPHIC_ID Figure 16

3-10 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
11. By using a puller, remove the 3rd reduction
planet carrier (4) from the hydraulic motor (5).




GRAPHIC_ID Figure 17

12. By using the puller (A) (380001076), remove the

bushes (1) (Qty 4) from the hydraulic motor or
from the 3rd reduction planet carrier (2).


$ 

60
GRAPHIC_ID Figure 18

13. By using the puller remove the planet assemblies

of the 3rd reduction (2).

60
GRAPHIC_ID Figure 19

NA Issued 10-2007 Bur 3-11

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
14. Lift the gearbox housing (3) positioning it on 2
spacers. By using a press and a metal stopper,
remove the hydraulic motor (4) from the gearbox
housing (3) paying attention to the eventual 
falling down of the main bearing's balls.

60
GRAPHIC_ID Figure 20

15. Use a screwdriver to remove the 1st half-seal (5)

from the hydraulic motor (4).

60
GRAPHIC_ID Figure 21

16. Use a screwdriver to remove the 2nd half-seal

(1) from the gearbox housing (2).



60
GRAPHIC_ID Figure 22

3-12 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
17. Use a puller to remove the bearing inner race
remaining on the hydraulic motor (3).

60
GRAPHIC_ID Figure 23

18. Remove the bearing balls from the gearbox

housing (4).

60
GRAPHIC_ID Figure 24

NA Issued 10-2007 Bur 3-13

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY OF THE HYDRAULIC MOTOR
Disassembly Of The Two Speed Control Assembly.

1. Unscrew the plug (1) from the base plate (2).

60
GRAPHIC_ID Figure 25

2. Remove the O-Ring seal (3) from its seat in the

plug (1).

 
60
GRAPHIC_ID Figure 26

3. Remove the O-Ring seal (4) from its seat in the

plug (2).

 
60
GRAPHIC_ID Figure 27

3-14 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Take out the spring (1).


60
GRAPHIC_ID Figure 28

5. Unscrew the plug (2) from the base plate.


60
GRAPHIC_ID Figure 29

6. Remove the O-Ring seal (3) from its seat in the

plug (2).



60
GRAPHIC_ID Figure 30

NA Issued 10-2007 Bur 3-15

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
7. Take out the two speed spool (4).

 60
GRAPHIC_ID Figure 31

3-16 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY OF THE RELIEF VALVE
1. Unscrew the relief valve (1) from the base plate
(2). 


60
GRAPHIC_ID Figure 32

2. Take out the free piston (3) from the relief valve
(1).


60
GRAPHIC_ID Figure 33

3. Remove the O-Ring seal (4) and the backup

rings (5) from their seats in the free piston (3).

  60
GRAPHIC_ID Figure 34

NA Issued 10-2007 Bur 3-17

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Remove the O-Ring seal (6) from relief valve (1).
Repeat the same steps for the 2nd relief valve
disassembly (1).

 
GRAPHIC_ID Figure 35

3-18 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY OF THE COUNTERBALANCE
VALVE
1. Unscrew the socket bolts (1) (Qty 4), of the 1st
flanged plug assembly (2).


60
GRAPHIC_ID Figure 36

2. Take out the 1st flanged plug (2) and the spring
seat.


60
GRAPHIC_ID Figure 37

3. Remove the 1st spring (3).

60
GRAPHIC_ID Figure 38

NA Issued 10-2007 Bur 3-19

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Take out the 1st spring seat (4) from the
counterbalance valve spool (5).


60
GRAPHIC_ID Figure 39

5. Unscrew the socket bolts (1) (Qty 4), of the 2nd

flanged plug assembly (2).


60
GRAPHIC_ID Figure 40

6. Take out the 2nd flanged plug (2) and the spring
seat.

60
GRAPHIC_ID Figure 41

3-20 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
7. Remove the 2nd spring (3).


60
GRAPHIC_ID Figure 42

8. Take out the 2nd spring seat (1) from the

 
counterbalance valve spool (2).

60
GRAPHIC_ID Figure 43

9. Take out the counterbalance valve spool (3).

60
GRAPHIC_ID Figure 44

NA Issued 10-2007 Bur 3-21

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY OF THE FLANGED PLUG
1. Remove the O-Ring seal (2) from the flanged 
plug (4).

60
GRAPHIC_ID Figure 45

2. Unscrew the plug (5) from the flanged plug (6).


60
GRAPHIC_ID Figure 46

3. Take out the spring (1) from the plug (2).


60
GRAPHIC_ID Figure 47

3-22 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Remove the O-Ring seal (3) from the plug (2).

 
60
GRAPHIC_ID Figure 48

5. Take out the ball (4) from the flanged plug (5).
Repeat the same steps for the 2nd flanged plug
disassembly.

 60
GRAPHIC_ID Figure 49

NA Issued 10-2007 Bur 3-23

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY OF THE BASE PLATE.
1. Unscrew the plugs (1) from the base plate (2). 

 60
GRAPHIC_ID Figure 50

2. Remove the O-Ring seal (3) from the plug (4).


60
GRAPHIC_ID Figure 51

3. Unscrew the conical plugs (5) from the base

plate (2).

60
GRAPHIC_ID Figure 52

3-24 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Unscrew the conical plugs (5) from the base
plate (2).

 60
GRAPHIC_ID Figure 53

5. Unscrew the orifices (1) from the base plate.

 60
GRAPHIC_ID Figure 54

6. Remove the caulking with a M5 tap before

unscrewing the orifices (2).

60
GRAPHIC_ID Figure 55

NA Issued 10-2007 Bur 3-25

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
7. Unscrew the orifices (2) from the base plate.

60
GRAPHIC_ID Figure 56

8. Unscrew the plug (3) from the base plate.

60
GRAPHIC_ID Figure 57

9. Remove the O-Ring seal (1) from its seat in the

plug (2).
 

60
GRAPHIC_ID Figure 58

3-26 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
10. Unscrew the socket bolts (3) (Qty 9), of the base
plate.

60
GRAPHIC_ID Figure 59

11. Remove carefully the base plate (4) until pins are
completely out. 

60
GRAPHIC_ID Figure 60

12. Remove the caulking in the brake pilot hole in the

base plate (4) with a M5 tap.


60
GRAPHIC_ID Figure 61

NA Issued 10-2007 Bur 3-27

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
13. Unscrew the orifice (1) from the base plate.

60
GRAPHIC_ID Figure 62

14. Take out the pins (2).

60
GRAPHIC_ID Figure 63

15. Remove the valve plate (3).

60
GRAPHIC_ID Figure 64

3-28 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
16. By using a puller, remove the bearing (4) from
the base plate (5). 


60
GRAPHIC_ID Figure 65

NA Issued 10-2007 Bur 3-29

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY OF THE MOTOR SHAFT AND
CYLINDER BLOCK  
1. Remove the O-Ring seal (1) from its seat in the
flanged hub (2).

60
GRAPHIC_ID Figure 66

2. Remove the O-Ring seal (3) from its seat of the

brake pilot hole in the flanged hub (2).




60
GRAPHIC_ID Figure 67

3. Remove the O-Ring seals (3) from their seat of

the two speed control holes in the flanged hub
(2). 


60
GRAPHIC_ID Figure 68

3-30 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Remove the springs (4) from the brake piston.

60
GRAPHIC_ID Figure 69

5. Mark the position of the brake piston (1) as a

reference for the reassembling step.

60
GRAPHIC_ID Figure 70

6. Remove the brake piston (1).

60
GRAPHIC_ID Figure 71

NA Issued 10-2007 Bur 3-31

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
7. Remove the O-Ring seals (2) and the backup
rings from their seats in the brake piston (1).



60
GRAPHIC_ID Figure 72

8. Take out the brake disc (3).

60
GRAPHIC_ID Figure 73

9. Remove the cylinder block (1).

60
GRAPHIC_ID Figure 74

3-32 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
10. Take out the spherical retainer plate holder (2).

60
GRAPHIC_ID Figure 75

11. Take out the pins (3) (Qty 3) from their seats in
the cylinder block (1). 

60
GRAPHIC_ID Figure 76

12. Disassemble the pistons and the retainer plate

(1). 

60
GRAPHIC_ID Figure 77

NA Issued 10-2007 Bur 3-33

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
13. Take out the pistons (2) from the retainer plate
(3).


60
GRAPHIC_ID Figure 78

14. Remove the swash plate (4) from the flanged

hub (5). 

60
GRAPHIC_ID Figure 79

15. Take out the steel balls (6) (Qty 2) from their 
seats in the flanged hub (5).


60
GRAPHIC_ID Figure 80

3-34 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
16. Take out the two speed control pistons (1) (Qty
2). 

60
GRAPHIC_ID Figure 81

17. Take out the two speed control springs (2) (Qty
2).

60
GRAPHIC_ID Figure 82

18. By using a punch, take out the motor shaft and

the bearing from the flanged hub.

60
GRAPHIC_ID Figure 83

NA Issued 10-2007 Bur 3-35

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
19. By using a puller, take out the bearing (3) from
the motor shaft (4).



60
GRAPHIC_ID Figure 84

20. By using a screwdriver remove the seal ring (1)

from its seat in the flanged hub.

60
GRAPHIC_ID Figure 85

NOTE: Disassemble the seal ring only in case of

replacement, because this will damage it.

3-36 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY TRAVEL DEVICE
PRELIMINARY OPERATIONS
When proceeding with the gearbox assembly, it is
necessary to follow the rules listed below:
1. In case of damaged gears, for example a planet,
do not replace the single gear, but the whole
reduction stage.
2. Replace always the O-Rings and seal rings of
the part to be assembled after having carefully
cleaned the seats and having buttered some
grease on the seats themselves and on the O-
Rings to make easier the assembly.
3. Always replace all the components that seems to
be damaged or with excessive wear, with original
spare parts.

ASSEMBLY OF THE HYDRAULIC MOTOR  

Assembly of Motor Shaft and Cylinder Block
1. Place the seal ring (1) into its seat in the flanged
hub (2).

60
GRAPHIC_ID Figure 86

2. Using appropriate tool and a rubber hammer

push the seal ring against the seat shoulder.
%

60
GRAPHIC_ID Figure 87

NA Issued 10-2007 Bur 3-37

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
3. Place the bearing (1) on the motor shaft (2).



60
GRAPHIC_ID Figure 88

4. Using appropriate tool and a rubber hammer

push the bearing (1) against the motor shaft
shoulder (2).
&


60
GRAPHIC_ID Figure 89

5. Place the bearing-motor shaft unit (4) in the seat 

inside the flanged hub (5).
NOTE: Be careful when inserting the shaft inside the
motor seal, that must be greased. 

60
GRAPHIC_ID Figure 90

3-38 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
6. By using appropriate tool and hammer push the
bearing-motor shaft unit (4) against the flanged '
hub shoulder (5).

60
GRAPHIC_ID Figure 91

7. Assemble the steel balls (1) (Qty 2) into their

seats (2) in the flanged hub.


60
GRAPHIC_ID Figure 92

8. Assemble the two speed springs (3) into their

seats in the two speed pistons (4).

60
GRAPHIC_ID Figure 93

NA Issued 10-2007 Bur 3-39

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
9. Assemble the two speed pistons (4) (Qty 2) into
their seats inside the flanged hub.

NOTE: Be sure that the pistons can move freely into

the seats. 

60
GRAPHIC_ID Figure 94

10. Insert the swash plate (5) inside the flanged hub
being careful tha t spher ical housings (2 ) 
matches with the steel balls (1).

60
GRAPHIC_ID Figure 95

11. Assemble the pins (1) (Qty 3) in their seats in the

cylinder block (2). 

 60
GRAPHIC_ID Figure 96

3-40 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
12. Assemble the spherical retainer holder (3) on the
cylinder block (2).

NOTE: The two splines must be aligned together 


60
GRAPHIC_ID Figure 97

13. Piston orifice (4) must be open and free of dust

or dirt.

60
GRAPHIC_ID Figure 98

14. Assemble correctly the pistons (4) (Qty 9) in the

retainer plate (5).

60
GRAPHIC_ID Figure 99

NA Issued 10-2007 Bur 3-41

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
15. Assemble the pistons-retainer plate unit (1) in the
cylinder block (2).


60
GRAPHIC_ID Figure 101

60
GRAPHIC_ID Figure 100

16. Assemble the cylinder block unit (2) into the


flanged hub (3) on the motor shaft spline (4).




60
GRAPHIC_ID Figure 102

17. Insert the brake disc (5) in the cylinder block (2).
 

60
GRAPHIC_ID Figure 103

3-42 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
18. Assemble the backup ring (6) into its seat in the
brake piston (7). 

60
GRAPHIC_ID Figure 104

19. Assemble the O-Ring seals (1) into their seats in

the brake piston (2). 
Assemble the backup ring (3) into its seat as
shown on the sketch below.


60
GRAPHIC_ID Figure 106

60
GRAPHIC_ID Figure 105

20. Assemble the brake piston (2) respecting the 

markings set out previously and being careful not
to damage the seals already fitted.

60
GRAPHIC_ID Figure 107

NA Issued 10-2007 Bur 3-43

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
21. Assemble the O-Ring seal (4) into its seat in the
flanged hub (5). 


60
GRAPHIC_ID Figure 108

22. Assemble the O-Ring seal (6) into the brake pilot
hole of the flanged hub (5).

60
GRAPHIC_ID Figure 109

23. Assemble the O-Ring seals (1) into their seats in

the two speed control holes in the flanged hub. 

60
GRAPHIC_ID Figure 110

3-44 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
24. Insert the springs (2) in their seats in the brake
piston (3). 

60
GRAPHIC_ID Figure 111

NA Issued 10-2007 Bur 3-45

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY OF THE BASE PLATE
1. Tighten the orifice (1) in the base plate (2)
Tightening torque 2.5 ± 0.5 Nm (1.8 ± 0.35
pound-feet).


60
GRAPHIC_ID Figure 112

2. By using a punch (3) and an hammer deform the

thread hole.

60
GRAPHIC_ID Figure 113

3. Assemble the bearing (4) into its seat in the base

plate (2). 


60
GRAPHIC_ID Figure 114

3-46 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. By using appropriate tool and a rubber hammer
push the bearing (4) against the base plate seat
shoulder (2).
(

GRAPHIC_ID  60
Figure 115

5. Place the valve plate (1) on the base plate (2). 

NOTE: Bronze layer surface must be upwards.


60
GRAPHIC_ID Figure 116

6. Insert the pins (2).

60
60
GRAPHIC_ID Figure 117

NA Issued 10-2007 Bur 3-47

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
7. Place the base plate (3) on the flanged hub (4).

NOTE: The base plate is centered by two pins and

the second speed oil passages must match together.

60
60
GRAPHIC_ID Figure 118

8. Fix the base plate (2) to flanged hub (4) by using

socket head bolts (5) (Qty 9). 
:Tightening torque: 205 ± 10 Nm (151 ± 7.3
pound-feet)


60
GRAPHIC_ID Figure 119

9. By using the appropriate tool assemble the

O-Ring seals (1) in their seats in the plugs (2).


)

60
GRAPHIC_ID Figure 120

3-48 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
10. Tighten the plugs (2).
:Tightening torque: 36.8 ± 2.5 Nm (27.2 ± 1.85
pound-feet)

60
GRAPHIC_ID Figure 121

11. Tighten the orifices (3) in the base plate.

:Tightening torque: 2.5 ± 0.5 Nm (1.85 ± 0.35
pound-feet)

 60
GRAPHIC_ID Figure 122

12. Seal the thread of the plugs (4) with Teflon tape.
Tighten the plugs in the base plate.
:Tightening torque: 10 ± 1 Nm (7.4 ± 0.75 pound-
feet)


60
GRAPHIC_ID Figure 123

NA Issued 10-2007 Bur 3-49

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
13. Tighten the orifices (1) in the base plate.
:Tightening torque: 2.5 ± 0.5 Nm (1.85 ± 0.35
pound-feet) 

60
GRAPHIC_ID Figure 124

14. By using a punch and an hammer deform the

thread hole.

60
GRAPHIC_ID Figure 125

3-50 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY OF THE FLANGED PLUG. 
1. Insert the ball (2) in the flanged plug (3).

60
GRAPHIC_ID Figure 126

2. By using the appropriate tool assemble the O-

Ring (4) in its seat in the plug (5).

60
GRAPHIC_ID Figure 127

3. Insert the spring (1) into the plug (2).

60
GRAPHIC_ID Figure 128

NA Issued 10-2007 Bur 3-51

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Tighten the plug (2).

:Tightening torque: 20.6 ± 1.0 Nm (15.25 ± 0.75
pound-feet).

60
GRAPHIC_ID Figure 129

5. Assemble the O-Ring (3) in its seat in the flanged

plug (4). 

60
GRAPHIC_ID Figure 130

3-52 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY OF THE COUNTERBALANCE VALVE
1. Insert the counterbalance valve spool (5).

60
GRAPHIC_ID Figure 131

2. Insert the 1st spring seat (1) on the 

counterbalance valve spool (2).


60
GRAPHIC_ID Figure 132

3. Insert the 1st spring (3) on the counterbalance 

valve spool (2).


60
GRAPHIC_ID Figure 133

NA Issued 10-2007 Bur 3-53

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Assemble the 1st flanged plug (1) with proper
spring seat.

60
GRAPHIC_ID Figure 134

5. Tighten the socket bolts (2) (Qty 4), of the 1st

flanged plug (1). 
Tightening torque: 59 ± 5 Nm (43.7 ± 3.7 pound- 
feet)

60
GRAPHIC_ID Figure 135

6. Insert the 2nd spring seat (3) on the

counterbalance valve spool (4).

 
60
GRAPHIC_ID Figure 136

3-54 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
7. Insert the 2nd spring (5) on the counterbalance
valve spool (4).


60
GRAPHIC_ID Figure 137

8. Assemble the 2nd flanged plug (1) with proper

spring seat.

60
GRAPHIC_ID Figure 138

9. Tighten the socket bolts (2) (Qty 4), of the 1st


flanged plug (1).
Tightening torque: 59 ± 5 Nm (43.7 ± 3.7 pound-
feet)


60
GRAPHIC_ID Figure 139

NA Issued 10-2007 Bur 3-55

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY OF THE RELIEF VALVE
1. By using the appropriate tool assemble the O- +
Ring seal (3) in its seat in the relief valve (4).

60
GRAPHIC_ID Figure 140

2. Assemble the 1st backup-ring (1) into its seat in

the free piston (2). 


60
GRAPHIC_ID Figure 141

3. Assemble the O-ring seal (3) into its seat in the

free piston. After this step assemble the 2nd
backup ring as shown on sketch below.


60
GRAPHIC_ID Figure 143

60
GRAPHIC_ID Figure 142

3-56 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Insert the free piston (2) in the relief valve (4) 

checking that the groove side is toward inside of
the motor.

60
GRAPHIC_ID Figure 144

5. Insert the relief valve (1) inside the base plate

(2).


60
GRAPHIC_ID Figure 145

6. Tighten the relief valve (1).

Tightening torque: 373 ± 20 Nm (276 ± 14.8
pound-feet)


60
GRAPHIC_ID Figure 146

NA Issued 10-2007 Bur 3-57

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY OF THE TWO SPEED CONTROL
1. By using the appropriate tool assemble the O-
ring (3) in its seat in the plug (4).

60
GRAPHIC_ID Figure 147

2. Tighten the plug (4).

Tightening torque: 120 ± 5 Nm (88.8 ± 3.7
pound-feet)

60
GRAPHIC_ID Figure 148

3. Insert the two speed spool (1) in the base plate 

(2).

NOTE: Two speed spool have to move smoothly

inside its seat in the base plate.


60
GRAPHIC_ID Figure 149

3-58 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Insert the spring (3) in the two speed spool (1). 


60
GRAPHIC_ID Figure 150

5. Insert the spring seat (4) and the washer.


60
GRAPHIC_ID Figure 151

6. By using the appropriate tool assemble the O-

ring seal (1) in its seat in the plug (2).

60
GRAPHIC_ID Figure 152

NA Issued 10-2007 Bur 3-59

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
7. Tighten the plug (3).
Tightening torque: 120 ± 5 Nm (88.8 ± 3.7
pound-feet)


60
GRAPHIC_ID Figure 153

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY OF THE GEARBOX
1. Make ready of the lifetime seal.
Instructions to properly assemble the lifetime  
seal:
A. Carefully clean the seats (1 and 2) using, if
 
necessary, metal brushes or solvent (surfaces
in contact with or (3) must be perfectly clean
and dry).
 
B. Make sure that sealing surfaces (4) of metal
rings (5) are free from scratches, dings or  
foreign substances; metal ring surfaces must
be perfectly clean and dry. 

60
C. Carefully clean the lapped surface (4) of metal GRAPHIC_ID Figure 154
rings (5) and remove dust or fingerprints.
Then lubricate them with a thin oil film, taking
care not to oil the other components.

2. Assemble an half seal (7) on the tool.

60
GRAPHIC_ID Figure 155

3. Assemble an half seal (8) on the hydraulic motor.


60
GRAPHIC_ID Figure 156

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Clean carefully the metallic faces of the lifetime
seal (1), and lube them with a thin oil film.


60
GRAPHIC_ID Figure 157
5. Fit the lower ball row (d), into the gearbox
housing (2) holding the inner raceway (c) with
spacers (a) and the tube (F) (380001081).

D
.



60
GRAPHIC_ID Figure 158
6. Remove the spacer (a).
7. Drop the upper ball row (e).
8. Assemble the inner raceway (f). I

D .

60
GRAPHIC_ID Figure 159
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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
9. By using the appropriate tool, assemble the half
seal on the gearbox housing. -
Clean carefully the metal faces of the half-seals.

60
GRAPHIC_ID Figure 160

10. By using a tackle, position the hydraulic motor

(2) inside the gearbox housing (1).

60

GRAPHIC_ID Figure 161

11. By using a press and the appropriate tool, push

the hydraulic motor (2) against the shoulder of
the gearbox housing (1) until assembly of the
unit is complete.
/

60
GRAPHIC_ID Figure 162

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
12. Screw the safety bush (M) (380001083) in one of
the four holes in the hydraulic motor by using the
socket bolts (3), and turn the unit upside down.
At the end of above step disassemble the safety
bush.


60
GRAPHIC_ID Figure 163

13. Place the bushes (1) (Qty 4) into their seats in

the hydraulic motor (2) and by using a press,
push them against the shoulder inside their seats
until assembly is complete.


60
GRAPHIC_ID Figure 164

14. Place the planet assemblies of the 3rd reduction

(3) (Qty 4) into their seats in the hydraulic motor
(2), and by using a press, push them against the 
shoulder until assembly is complete.

60
GRAPHIC_ID Figure 165

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
15. Position the 3rd reduction planet carrier (4) on
the hydraulic motor (2) and by using a press
push it against the shoulder.


60
GRAPHIC_ID Figure 166

16. Apply Loctite 243 on the socket bolts (5) (Qty 4),
and inser t them in the thread holes in the 
hydraulic motor (2).


60
GRAPHIC_ID Figure 167

17. Tighten the socket bolts (1) (Qty 4).

Tightening torque:585 Nm torque (432.98 pound-
feet)

60
GRAPHIC_ID Figure 168

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
18. Insert the 3rd stage sun gear (2).


60
GRAPHIC_ID Figure 169

19. Assemble the 2nd reduction assembly (3).

 60
GRAPHIC_ID Figure 170

20. Insert the 2nd stage sun gear (4).

60
GRAPHIC_ID Figure 171

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
21. Assemble the 1st reduction assembly (1).

60
GRAPHIC_ID Figure 172

22. Insert the 1st stage sun gear (2).

60
GRAPHIC_ID Figure 173

23. Assemble the O-Ring seal (3) into its seat in the
end cover (4). 

60
GRAPHIC_ID Figure 174

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
24. Assemble the end cover (4) on the gearbox
housing (5).


60
GRAPHIC_ID Figure 175

25. Fix the cover (1) to the gearbox housing (2) by 

using socket bolts (3) (Qty 10).
Tightening torque: 75 Nm (55.5 pound-feet)

60
GRAPHIC_ID Figure 176

26. Fill the gearbox with the lubricant oil. Tighten the
plugs (4) into the oil draining-filling holes of the
end cover (1).
Tightening torque: 65 ± 5 Nm (48.1 ± 3.7 pound-
feet)


60
GRAPHIC_ID Figure 177

3-68 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
REMOVAL AND INSTALLATION OF SWIVEL JOINT

WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located on the
hydraulic oil tank to release any residual pressure present in the tank itself.

PREPARATION
1. Park the machine on a firm, level surface.
2. Cut-off the engine. Actuate the manual and pedal
pilot valves to release any residual pressure from
inside the hydraulic system. Press the valve
located on the hydraulic oil tank to release any
residual pressure present inside the tank itself.
3. Remove hydraulic oil tank cap. Connect a
vacuum pump to maintain negative pressure in
the hydraulic oil tank.

NOTE: Be sure to run the vacuum pump

continuously while working.
REMOVAL 3. Remove tubes (2 and 8) (PF1).
NOTE: Attach labels or tags to hoses and adapters, Tightening torque: 177 ±18 Nm (130.5 ± 13
to aid in assembly. pound-feet)
1. Remove tube (5 and 6) (PF1/2). 4. Remove tubes (3 and 4) (PF1/4).
Tightening torque: 78.5 ±5 Nm (57.9 ± 3.7 Tightening torque : 29.4 ±5 Nm (21.7 ± 3.7
pound-feet) pound-feet)
2. Remove tubes (1 and 7) (PF1).
Tightening torque: 177 ±18 Nm (130.5 ± 13
pound-feet)

60
GRAPHIC_1D Figure 178

NA Issued 10-2007 Bur 3-69

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
5. Remove drain hose (2).

: 78.5 ±5 Nm (57.9 ± 3.7 pound-feet)
6. Remove hoses (4 and 6).

: 177 ±18 Nm (130.5 ± 13 pound-feet)

7. Remove hoses (1 and 3).

: 177 ±18 Nm (130.5 ± 13 pound-feet)

8. Remove hose (5).

: 29.4 ±5 Nm (21.7 ± 3.7 pound-feet)




60

GRAPHIC_ID Figure 179

9. Loosen the stop nut (7) M20 of swivel joint and

remove the screw (8) M20x120.
 

: 157 Nm (115.8 pound-feet)

60
GRAPHIC_ID Figure 180

10. Remove two adapters (9 and 10).

: 36 Nm (26.6 pound-feet) 

60

GRAPHIC_ID Figure 181

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
11. Remove six screws (2) M10x25.

: 14.7 Nm (10.8 pound-feet)
12. Remove clip (1). 

: 6.8 Nm (5.0 pound-feet)

13. Remove seal (4)



60
GRAPHIC_ID Figure 182

14. Attach eye bolt (5), lift it up temporarily, and

remove three screws (6) M12x35.

: 108 Nm (79.7 pound-feet)

NOTE: Swivel joint weight: 31 kg (68.4 lbs). 

60

GRAPHIC_ID Figure 183

INSTALLATION

NOTE: Refer to REMOVAL section above for

tightening torques.
Proceed with the installation of the center joint
following the operation in reversed order with respect
to the removal.
IMPORTANT: Swivel joint weight: 31 kg (68.4 lbs).

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
SWIVEL JOINT DISASSEMBLY AND ASSEMBLY

60

GRAPHIC_1D Figure 184

1. BODY 7. O-RING
2. STEM 8. SOCKET BOLT (M8 X 20)
3. THRUST PLATE 9. SOCKET BOLT (M8 X 30)
4. COVER 12. PLUG
5. SEAL ASSY 13. O-RING
6. SEAL ASSY

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY 
T h e p a r t nu m b e r s u s e d i n t h i s d i s a s s e m bl y 

procedure correspond to those of a construction
drawing on the previous page. 
1. Mark cover (4) and body (1) with matching marks
for convenient assembly.
2. Place a V (A) block on a work bench, place a 
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and wrench.
Alternately, the swivel joint may be fixed by
$
holding stem (2) in a vise.

GRAPHIC_ID Figure 185

3. Remove cover (4) from body (1) and draw out O-

Ring (7) from cover (4).

60

GRAPHIC_ID Figure 186

4. Loosen socket bolt (8) fastening thrust plate (3), 

in the same manner as the removing of the 
above mentioned cover (4). 
When removing thrust plate (3) by fixing body
(1), support stem (2) so it may not fall down.

60

GRAPHIC_ID Figure 187

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
5. Place body (1) on a V (A) block. Put a wooden
block against stem (2) via the body so about half % 
of the stem is covered by the wooden block (B)

and knock it out using a mallet.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand.

$ 60

GRAPHIC_ID Figure 188

6. Remove the backup ring of the seals assemblies

(5 and 6) by means of a spatula (E). (

NOTE: Make sure the body (1) is not scored from

the tip of the spatula (E).


60
GRAPHIC_ID Figure 189

7. Take off the slip ring (B) of the seals assemblies

(5 and 6) by means of pin of screwdriver (A) and &
remove them from the O-Ring grooves (D). The
figure on side shows the use of only one pin of
screwdriver, but by using two screwdriver pins,
these can be extracted with more sureness.
%
NOTE: Make sure the body (1) is not scored from
the screwdriver (A).



$


'

60
GRAPHIC_ID Figure 190

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY %
Prior to assembly, clean parts (excluding the O- ring
and slipper ring), and arrange in the sequence of
assembly.
1. Make sure that oil and grease remains have
been completely removed.
2. Apply grease on the groove where are seated
the O-Ring (6).
3. Apply hydraulic oil to O-ring (13) thinly and insert
it into O-ring groove. Check the twist of O-ring.
4. Slipper ring (B) is assembled, after first inserting
the backup ring, by slightly distorting the shape
60
as shown in figure. Also after inserting all of the GRAPHIC_ID Figure 191
seals, be certain that these are installed in the
seal groove by use of the spatula.
5. Assemble seal (5) by the same procedure above
mentioned, after removing grease, hydraulic oil
and vaseline from the groove of the seal. Seals
(5) have no backup ring.

6. Lightly coat the outer circumference of stem (2)
and the inner surface of body (1) with grease or
vaseline and slowly insert stem (2) into body (1).

NOTE: If stem (2) is pressed in too fast, the seal
may be damaged. Do it slowly. The clearance 
between body (1) and stem (2) is about 0.1mm. Push
stem straight along the shaft center.


60

GRAPHIC_ID Figure 192

7. While holding stem (2) and body (1), match the
hole of thrust plate (3) and the stem (2) hole.
8. Next, after removing any oil from the thread of   
socket bolt (8), coat it with Loctite 242 and
tighten to stem (2).

Tightening torque: 30.4 Nm (22.4 pound-feet)

60
GRAPHIC_ID Figure 193

NA Issued 10-2007 Bur 3-75

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
9. After installing O-Ring (7) to cover (4) and $
aligning the matching marks of the cover (4) and
body (1), coat socket bolt (9) with Loctite 242 and 
tighten it which will then complete assembly.

Tightening torque: 30.4 Nm (22.4 pound-feet)

GRAPHIC_ID Figure 194

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
MAINTENANCE STANDARD

Allowable Limit
Item Remedy
(basis of judgment)

Sliding surface and sealed Scored or something hurt it. Replace

parts

Sliding surface exception Scored more than 0.1 mm. Replace

sealed parts Scored less than 0.1 mm. Repair with oil stone
Body, Stem
Wear more than 0.5 mm deep. Replace
Wear less than 0.5 mm deep. Repair
Sliding surface ring
Scored less than 0.5 mm and able to
Repair
repair.
Wear more than 0.5 mm. Replace
Wear less than 0.5 mm. Repair
Cover Sliding surface ring
Scored less than 0.5 mm and able to
Repair
repair.
Protruded excessively from seal groove.

Replace
(with back-up ring)

60
GRAPHIC_ID Figure 195

Slipper ring narrower than 1.5 mm of seal

groove, or narrower than back-up ring.

Slipper ring Replace (with

back-up ring)
PPPD[

60
GRAPHIC_ID Figure 196

Worn unevenly more than 0.5 mm.

PPPD[

Replace (with
back-up ring)

60
GRAPHIC_ID Figure 197

NA Issued 10-2007 Bur 3-77

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
INSPECTION AFTER ASSEMBLY

After completion of assembly, inspection for oil
leakage, pressure resistance, etc., using a device as
shown in the figure on right.
1. High pressure port (A, B, C, D and F port). 
Install a directional valve (8) and pressure gauge
(1) to the stem side port and body side port
respectively, and while watching the pressure

gauge (for high pressure) installed on the body
side and also by regulating high pressure relief
valve (7), gradually increase the pressure. When
the pressure has reached 1.5 times the
maximum working pressure, close stop valve (3) 
and lock in the hydraulic oil in the swivel.
At this time, keep stop valve (6) on the low 
pressure relief valve side closed for, at least, 3
minutes and check for any distortions, breakages
or loosening.

During the first minute, check for oil leakages
and, in case of pressure drop, this should be the
10% of the pressure trapped. This check should
be performed on each circuit.
2. Low pressure port (E port).
Similar to the high pressure por t, install a
directional valve and pressure gauge on each
port of the stem side and body side.   
Open stop valve (6) on the side of low pressure 60
GRAPHIC_ID Figure 198
relief valve (5) and while watching the pressure
gauge (for low pressure) connected to the body 1 -PRESSURE GAUGE
side and also by regulating low pressure relief 2 - SWIVEL JOINT
valve (5), gradually increase the pressure and 3 - STOP VALVE
check for outside leakage with a color check at a
4 -HYDRAULIC SOURCE
pressure of 0.49 MPa.
5 -RELIEF VALVE FOR LOW PRESSURE
6 - STOP VALVE
7 -RELIEF VALVE FOR HIGH PRESSURE
8 -DIRECTIONAL VALVE
9 - PIPING, ETC.

3-78 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
REMOVAL AND INSTALLATION OF TRACK ADJUSTER (WITH FRONT IDLER)
Before removing the track adjuster, the tracks and
the front idler must be removed first. For removal and
installation of the tracks and the front idler, refer to
applicable removal/installation sections. In this
section, the procedure starts on the premise that the
tra cks a nd the fr ont idler have a lr ead y b een
removed.

REMOVAL

NOTE: Track adjuster assembly weight:

202 kg (445 lbs).

WARNING
Be sure cables are anchored and the anchor point is
strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.

1. After swinging superstructure to 90° related to

machine longitudinal centerline for easier access
to track components, remove the front idler and
track adjuster assembly from track frame by
prying it out, using a pry bar shown in figure.

60
GRAPHIC_ID Figure 199

INSTALLATION

WARNING
Be sure cables are anchored and the anchor point is
strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.

1. As shown in figure, install the front idler and track

adjuster into spring guide on track frame.

60
GRAPHIC_ID Figure 200

NA Issued 10-2007 Bur 3-79

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY AND ASSEMBLY TRACK ADJUSTER
DISASSEMBLY
B e s u r e t o r e a d P R E C AU T I O N S F O R
DISASSEMBLY AND ASSEMBLY before starting the
disassembly work.

Be sure to use appropriate tool for assembly / disas- $

sembly of the track adjuster.

WARNING
Prevent personal injury. The spring force of the track
adjuster is extremely large. Inspect the special tool
for any damage. Carefully perform assembly work
referring to the procedure below. GRAPHIC_ID Figure 201

NOTE: Approximate weight of the track spring

holder assembly:
217 kg (478 lbs).
$
1. Place a jack on the bottom of the track spring
holder assembly (380001029).
2. Loosen four nuts to remove the plate (A).
NOTE: Track adjuster weight: 90.1 kg (199 lbs).

GRAPHIC_ID Figure 202

3. Connect the track adjuster to a hoist using a

lifting strap.
Put the track adjuster in the track spring holder
assembly (380001029).
Remove the lifting strap.
NOTE: Track adjuster weight: 90.1 kg (199 lbs).

9
60
GRAPHIC_ID Figure 203

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Draw out piston (6) from grease cylinder (1) of
the idler adjuster assembly.
5. Removing oil seal (9), O-Ring (8) from grease         
cylinder (1).
6. Set the idler adjuster assembly on the stand of
the jig, with its bracket side facing up.

 

GRAPHIC_ID Figure 204

7. Fit retainer plate (A) to bracket (2), tighten

holding-down nuts alternately, and secure idler
adjuster assembly. 

 $

60
GRAPHIC_ID Figure 205

8. Remove spring pin (4), press spring (5) lifting it

with jack so that nut (3) can be turned freely, and 
remove nut.

60
GRAPHIC_ID Figure 206

NA Issued 10-2007 Bur 3-81

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
9. Allow the hydraulic jack to retract slowly till the
spring is extended to its free length. Remove the
retainer plate and take off bracket (2) and cover
(11).



60
GRAPHIC_ID Figure 207

10. Hook lifting eye nut (W) to screw M48 on grease

cylinder (1) top end and hoist it. Then, remove
the set of grease cylinder (1) and spring (5) using :
crane from the jig. 
Remove spring (5), collar (7), grease cylinder (1),
in that order.


60
GRAPHIC_ID Figure 208

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 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY
1. Insert grease cylinder (1) and collar (7) into
spring (5) and attach lifting eye nut (W) to screw         
M48 at the tip of the grease cylinder. Lift the
grease cylinder by crane and erect it in the
center of the jig stand upright (380001029).

 

GRAPHIC_ID Figure 209

:

60
GRAPHIC_ID Figure 210
2. Install bracket (2) and cover (11) on top of spring
(5).
Center the rod of grease cylinder (1) and the 
holes in bracket (2). Attach the retainer plate (13)
and four holding-down nuts (12). Fasten the nuts 
evenly all round and fix the idler adjuster
assembly to the jig body (380001029).
3. Extend the hydraulic jack, compress spring (5) to
a set length and screw in nut (3) to the screwed 
part at the tip of grease cylinder (1). 
Set length of the spring: 432 mm (17.0 in.) 

4. Tighten nut (3) till the holes for locking spring  

pins (4) are aligned. Then fit spring pin (4).


60
GRAPHIC_ID Figure 211

NA Issued 10-2007 Bur 3-83

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
5. Remove idler adjuster assembly from jig
(380001029).

NOTE: Track adjuster weight: 90.1 kg (199 lbs).

GRAPHIC_ID Figure 212

6. Apply grease on the oil seal (9) and O-Ring (8)

then fit them to grease cylinder (1).
7. Fill up grease in cylinder (1), remove the grease   
nipple from piston (6) in order to discharge the 
inside air, and press in the piston by hand.
8. Direct grease nipple hole downward to make air
discharge easier.
9. Tighten grease nipple (X) to piston (6).
Tightening torque: 59 Nm (43.5 pound-feet)
; 60

GRAPHIC_ID Figure 213

TOOL TABLE

TOOL NO. DESCRIPTION

380001029 Jig stand track adjuster

3-84 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
DISASSEMBLY AND ASSEMBLY FRONT IDLER ASSEMBLY
DISASSEMBLY
1. Remove plug (8) on the side of collar (3) to drain
oil.










60

GRAPHIC_ID Figure 214

2. To remove pin (5) apply pin push bar (A) striking bar lightly by hammer.
(380001051) to the top of pin, and push out

3. Put idler on repair stand. Apply push-out jig on

shaft (B) (380001052), push out shaft (6) with
 collar (3), then remove collar (3).
$

60

GRAPHIC_ID Figure 215

4. If removal of collar (3) on the opposite side is

required, turn over front idler and proceed with
 the procedure described in the previous step.


%




60

GRAPHIC_ID Figure 216

NA Issued 10-2007 Bur 3-85

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
5. With idler (1) mounted on the stand, tap bushing
(C) (380001053) lightly by hammer, while placing
the bushing drawing rod against the end face of
%
bushing (2) evenly all round, till it comes out.

 6. Take out floating seals (4) from idler (1), collar
(3). If you intend to reuse floating seals (4),
confirm that there is no scoring and rusting on
the contact surface and store the floating seals in
pairs by placing card board between the sealing
faces.
7. Separate O-Ring from shaft.

GRAPHIC_ID Figure 217

& 


60
GRAPHIC_ID Figure 218

3-86 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY
1. Align inner hole of idler (1) and bushing (2) and

press fit it vertically with press so that jig (D)  '


(380001054) for bushing press-fitting is inserted 
into bushing.

60

GRAPHIC_ID Figure 219

2. Fit O-Ring (7) to O-Ring groove on shaft (6).

3. Press fit the O-Ring installed side of shaft (6) into
collar (3), and drive pin (5). 
4. Fit the half of floating seal (4) on each side of
collar (3) and idler (1).




60
GRAPHIC_ID Figure 220

5. Install idler (1) on the shaft (6) with the floating

seal (4) fitted into shaft (6) with the toward collar 
(3). 
6. Fit floating seal (4) on the other side of idler (1).


60
GRAPHIC_ID Figure 221
7. Fit the half of floating seal (4) on the other collar 8. Fill in 265 cm³ of engine oil AGIP SAE40RCL
(3), press fit it in shaft (6), and drive pin (5) in through the plug hole of collar (3), wind seal tape
with hammer. and tighten plug (8).

NA Issued 10-2007 Bur 3-87

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
NOTE: After installing the idler assembly to the idler
adjuster assembly, make certain that no oil leaks  
from floating seal and plug (8) and that idler (1)
rotates smoothly. 

60
GRAPHIC_ID Figure 222

3-88 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
MAINTENANCE STANDARD

Front Idler

& '

$
%
60

GRAPHIC_1D Figure 223

Standard (mm) Allowable (mm) Remedy

A 84 66
B 159 -
C 500 482 Buildup weld and finishing
D 540 -
E 20 -

Axle and Bushing

STANDARD (mm) ALLOWABLE (mm) REMEDY

Axle Outside Diameter 75 74.2
Bushing Inside Diameter 75 76 Replace
Bushing Flange thickness 2 1.2

TOOL TABLE

TOOL NO. DESCRIPTION

380001051 Pin push bar
380001052 Push-out jig
380001053 Punch for upper roller bushes
380001054 Bushing press-fitting jig

NA Issued 10-2007 Bur 3-89

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
REMOVAL AND INSTALLATION OF UPPER ROLLER
REMOVAL

WARNING
Do not loosen valve (1) quickly or loosen it too much
as high-pressure grease in the adjusting cylinder may
spout out. Loosen carefully, keeping body parts and
face away from valve (1).
Never loosen grease fitting (2).

60
GRAPHIC_ID Figure 224

IMPORTANT: When gravel or mud is packed

between sprockets and tracks, remove it before
loosening.
1. Loosen valve (1) to drain grease.


 60
GRAPHIC_ID Figure 225

WARNING 

Insert a piece of non-sliding rag between track frame

(5) and hydraulic jack to prevent that the latter slides.

2. Lift track chains (3) with the hydraulic jack to a

height sufficient to remove upper roller (4).


60
GRAPHIC_ID Figure 226

3-90 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
3. Insert a wooden block between tracks (3) and
track frame (5). 

 60
GRAPHIC_ID Figure 227

4. Remove screws (2) from the support roller (1).

NOTE: Support roller mass 16.5 kg (36.4 lbs).




60
GRAPHIC_ID Figure 228

5. Remove the upper roller (1) from the track frame

(3).

NOTE: Support roller mass 16.5 kg (36.4 lbs).

 60
GRAPHIC_ID Figure 229

NA Issued 10-2007 Bur 3-91

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
INSTALLATION
1. Install the support roller (1) and, after coating
with Loctite #232, tighten screws (2).

Tightening torque: 265 Nm (195.4 pound-feet)

2. Remove the wooden blocks and the hydraulic
jack.

60
GRAPHIC_ID Figure 230

3. Supply grease to valve (3) through nipple (4) to

adjust tracks tension.
Track sag specifications (A): 320 - 350 mm (12.6
- 13.7 in.)
Tightening torque: 59 Nm (43.5 pound-feet)

NOTE: Check the track sag after removing soil stuck

on the track area by washing.


 60
GRAPHIC_ID Figure 231

60
GRAPHIC_ID Figure 232

3-92 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Add engine oil via plug (3) hole on cover (4).
Apply sealant (Loctite 503 or equivalent) to plug
(3). Tighten plug (3).
Engine oil quantity: 0.2 kg
Tightening torque: 23 Nm (17.0 pound-feet)



60
GRAPHIC_ID Figure 233

NA Issued 10-2007 Bur 3-93

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
UPPER ROLLER DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
1. Remove plug (3) and drain out oil.            $

2. Mount the end face inside upper roller (1) on

stand jig (A) (XXXXXXXXX) and loosen bolts
(12). 
3. Take off cover (9). 

4. Separate O-Ring (11) from cover (9). 

5. Loosen two trust-washer bolts (13) and draw out
trust-washer (10) from roller (1).

60
GRAPHIC_ID Figure 234

6. Put the extrusion jig (B) (XXXXXXXXX) against

the end face of shaft (2) and push shaft with %
collar (8) to floating seals (6, 7) using a press or
a hammer.











$

60

GRAPHIC_ID Figure 235

7. Take out floating seals (6, 7) from roller (1).




60

GRAPHIC_ID Figure 236

3-94 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
8. Remove from collar (8) another floating seal (6)
that is located on the side on which shaft (2) was
disparted.
IMPORTANT: Collar (8) is press fitted into shaft (2)
means of a press. Therefore DO NOT disassemble it.

GRAPHIC_ID Figure 237

9. Since the bushings (4, 5) are thin, machine them

on a lathe or scrape them off, exercise care so
as not to damage the bore of roller (1).
If the bushings are not worn much, mount upper
roller (1) on jig (A) (XXXXXXXXX), and push out
the bushings (4, 5) with punch (380001053) and 
hammer.
IMPORTANT: Hammer the surface of roller lightly so
as not to damage the surface. Put the extrusion
punch (380001053) uniformly over the circumference
of bushings and extrude them perpendicularly little
by little.





60
GRAPHIC_ID Figure 238

NA Issued 10-2007 Bur 3-95

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY
&
1. Assembly of the upper roller is done in the
reverse order of disassembly.
2. Place upper roller (1) on the top end face of jig
(A) (XXXXXXXXX), with its floating seal setting
side facing down.

3. Confirm that the outer surface of bushing (5) is
not seized and coat the outer surface of the 
inserting side of the bushing, with Molybdenum

Disulfide grease.

4. Put jig (C) (XXXXXXXXX) into bushing (5) and
press it in, using the bore of the bushing and the
bore of the roller as guides.
IMPORTANT: If you fail in this operation by pressing
the bushing unevenly, the bushing is distorted and
gets unserviceable. In that case, do not reuse the $
bushing as it may develop mechanical problems after
assembly.

GRAPHIC_ID Figure 239

5. Two floating seals (6) make a pair.
Attach one floating seal to retainer fixed in shaft
(2), and another to the inside of upper roller (1),
placing O-Rings (7).
Prior to placing floating seals (6), apply engine oil
lightly to seal surface.


GRAPHIC_ID Figure 240




60
GRAPHIC_ID Figure 241
3-96 Issued 10-2007 Bur NA
 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
6. Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).

GRAPHIC_ID Figure 242

7. Mount upper roller (1) on the stand jig (A)
(XXXXXXXXX) and attach thrust-washer to the            $
end face of the shaft (10) with bolt (13).
Tightening torque: 114.7 Nm (84.6 pound-feet)
8. Fit O-Ring (9) to the groove of cover (11).

NOTE: Apply grease to O-Ring. 
9. Fit cover (9) to upper roller (1) and fix it with bolts
(12). 

10. Fill in 0.2 cm3 of engine oil SAE40 through the

plug hole in cover (3).
11. Wind seal tape around plug (3) and screw it into 60
the plug hole of the upper roller (1). GRAPHIC_ID Figure 243

Tightening torque: 23 Nm (17.0 pound-feet)

After assembling the upper roller, confirm that oil
is not leaking from it and that it rotates smoothly
by.

NA Issued 10-2007 Bur 3-97

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
REMOVAL AND INSTALLATION OF LOWER ROLLER
REMOVAL
1. Remove the roller guard and loosen bolts M18
(5).

60
GRAPHIC_ID Figure 244
2. Lift the one side of the track frame high enough
to remove the lower roller.
Insert wooden blocks under track frame (2).


60
GRAPHIC_ID Figure 245

WARNING
Do not loosen valve (3) quickly or loosen it too much
as high-pressure grease in the adjusting cylinder may
spout out. Loosen carefully, keeping body parts and
face away from valve (3).
Never loosen grease fitting (4).

60
GRAPHIC_ID Figure 246

3-98 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
3. Loosen valve (3) to drain grease enough to
permit the roller removal.


 60
GRAPHIC_ID Figure 247

4. Securely hold the lower roller using a fork lift.

Remove lower roller (1).

NOTE: Lower roller weight: 36.43 kg (80.3 lbs).


60
GRAPHIC_ID Figure 248

NA Issued 10-2007 Bur 3-99

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
INSTALLATION
 
1. Securely hold the lower roller using a fork lift.
Put lower rollers (1) on the tracks as illustration.

60
GRAPHIC_ID Figure 249

2. Lower track frame (2) enough to allow bolts (4) to

be installed into track frame (2).  

60
GRAPHIC_ID Figure 250

3-100 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
3. Align tapped holes in track frame (2).
Tighten bolts M18 (5).
Tightening torque: 397 ± 39 Nm (293 ± 29
pound-feet)


60
GRAPHIC_ID Figure 251

4. Supply grease to valve (3) through nipple (4) to

adjust tracks tension.
Track sag specifications (A): 320 - 350 mm (12.6
- 13.7 in)
Tightening torque: 59 Nm (43.5 pound-feet)


 60

GRAPHIC_ID Figure 252

NA Issued 10-2007 Bur 3-101

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
NOTE: Check track sag after removing soil stuck on
the track area by washing.

60
GRAPHIC_ID Figure 253

3-102 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
LOWER ROLLER DISASSEMBLY AND ASSEMBLY
DISASSEMBLY

 







 



60

GRAPHIC_1D Figure 254

1. PLUG (QTY 2) 5. FLOATING SEAL (QTY 2)

2. COLLAR (QTY 2) 6. BUSHING (QTY 2)
3. ELASTIC PIN (QTY 2) 7. ROLLER
4. O-RING (QTY 2) 8. AXLE

NA Issued 10-2007 Bur 3-103

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
B e s u r e t o r e a d P R E C AU T I O N S F O R
DISASSEMBLY AND ASSEMBLY before starting the    
disassembly work.
1. Remove plug (1) and elastic pins (3) from collars
(2), and drain oil.




60
GRAPHIC_ID Figure 255

2. Press down axle (8) until O-Ring (4) comes out 

of collar (2). 
Remove collar (2) from axle (8).
3. Remove O-Ring (4) from axle (8).
Remove axle (8) from roller (7).
4. Remove floating seal (5) from roller (7) and collar
(2).
5. Press out axle (8), and remove collar (2) and O- 
Ring (4) from axle (8).

60
GRAPHIC_ID Figure 256

6. In case of replacing bushings (6), remove the

bushings using a press and the special tool.

Special Tool (380001030) (9).

GRAPHIC_ID Figure 257

3-104 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
ASSEMBLY

    
 

60
GRAPHIC_1D Figure 258

1. PLUG (QTY 2)) 5. FLOATING SEAL (QTY 2)

2. COLLAR (QTY 2) 6. BUSHING (QTY 2)
3. ELASTIC PIN (QTY 2) 7. ROLLER
4. O-RING (QTY 2) 8. AXLE

1. Install bushings (6) (Qty 2) onto roller (7) using a

press. Take care not to dent the flange surface of   
bushings. Apply a coat of grease to O-Ring (4)
and install onto axle (8). 
2. Install collar (2) onto axle (8), aligning the pin
holes. Secure them using elastic pin (3). Take
care not to damage O-Ring (4).

60
GRAPHIC_ID Figure 259

NA Issued 10-2007 Bur 3-105

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)

IMPORTANT: The elastic pin (3) has to be fitted with  

the slit oriented to the internal side of the roller.

IMPORTANT: For handling of floating seal (4), refer

 
to the section PRECAUTIONS FOR FLOATING
SEAL HANDLING.

60
GRAPHIC_ID Figure 260

3. Install floating seal (5) to roller (7) and to collar

(2).
   
Insert axle (8) into roller (7). Install the other
floating seal (5) to roller (7) and to collar (2).
Install O-Ring (4) the other collar (2). Secure
them using elastic pin (3).
IMPORTANT: The elastic pin (3) has to be fitted with
the slit oriented to the internal side of the roller.


60
GRAPHIC_ID Figure 261

4. Add engine oil through plug (1) hole on collar (2).

Apply sealant (Loctite 503 or equivalent) to plug  
(1).
Tighten plug (1).
Engine oil quantity: 211 cm3 

Tightening torque: 9.8 Nm (7.2 pound-feet)


60
GRAPHIC_ID Figure 262

3-106 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
MAINTENANCE STANDARD

Upper Roller

&

$
% 60

GRAPHIC_1D Figure 263

Standard (mm) Allowable Limit (mm) Remedy

A 84 -
B 150 - Replace
C 140 130

Lower Roller

'

& $ &
%

60

GRAPHIC_1D Figure 264

Standard (mm) Allowable Limit (mm) Remedy

A 172 181.5
B 218 - Buildup
weld and
C 23 11.5 finishing
D 150 132

NA Issued 10-2007 Bur 3-107

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
Upper Roller Axle and Bushing

Standard (mm) Allowable Limit (mm) Remedy

Axle Outside Diameter 45 44.7
Replace
Bushing Inside Diameter 45 45.3

Lower Roller Axle and Bushing

Standard (mm) Allowable Limit (mm) Remedy

Axle Outside Diameter 65 64.2
Bushing Inside Diameter 65 66 Replace
Bushing Flange Thickness 2 1.2

TOOL TABLE

TOOL NO. DESCRIPTION

380001053 Punch for upper roller bushings
XXXXXXXXX Stand jig upper roller
XXXXXXXXX Stopper shaft upper roller
XXXXXXXXX Stopper bushings upper roller
380001030 Push-out jig bushings lower roller

3-108 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
REMOVAL AND INSTALLATION OF TRACKS
REMOVAL

WARNING
Do not loosen valve (1) quickly since high-pressure
grease in the adjusting cylinder may spout out.
Loosen carefully, keeping body parts and face away
from valve (1).
Never loosen grease fitting (2).

60
GRAPHIC_ID Figure 265

5. Move the tracks so that master pin (3) is

positioned over front idler (4). 
Put a wooden block under track shoes (5), as
shown.


60
GRAPHIC_ID Figure 266

6. To loosen the track tension, slowly turn valve (1)

counterclockwise one turn; grease will escape
from grease outlet.


 60
GRAPHIC_ID Figure 267

NA Issued 10-2007 Bur 3-109

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)

WARNING
The front idler may jump out of position due to strong
spring force when the track is disconnected.
Especially, the strong spring force is always applied
to the bolt part of the rod. If the rod and/or the bolt are
damaged, metal fragments may fly off when the
tracks is disconnected.

60

GRAPHIC_ID Figure 268

7. Remove master pin (5) by using a appropriate

tool.

60

GRAPHIC_ID Figure 269

A: 380001008
B: 380001009
C: 380001013 ' &  (

D: 380001012
E: 380001015
G: 380001019
5: MASTER PIN

* % $
60

GRAPHIC_ID Figure 270

3-110 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
8. Slowly drive the machine in reverse until the
whole length of the removing track comes on the
ground.

60

GRAPHIC_ID Figure 271

9. Rotate the upperstructure 90 degrees toward the

removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
between them is 90 to 110 degrees.
Lower the boom with the bucket rolled-in to jack
up the machine as illustrated.
ƒƒ

60

GRAPHIC_ID Figure 272

NA Issued 10-2007 Bur 3-111

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
INSTALLATION

 
1. Jack up the machine and put the track under the
lower roller.
Be sure to position the track in correct direction,
as illustrated.
A. Sprocket side
B. Idler side

GRAPHIC_ID Figure 273

2. Lift the track, and place it on sprocket (1).

60
GRAPHIC_ID Figure 274

3. Slowly turn the sprocket in forward direction.

60
GRAPHIC_ID Figure 275

3-112 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
4. Turn sprocket (1) until end of track (4) comes on
front idler (3). 
Lower the machine and put a wooden block as
illustrated.

60
GRAPHIC_ID Figure 276

NOTE: Hole surfaces, link holes and counterbore

surfaces, bushing ends, shall be free from dust and
rust.
5. Install master pin (5), using a hammer and
special tool.

60

GRAPHIC_ID Figure 277

A: 380001008
B: 380001009
C: 380001013 ' &  (

D: 380001012
E: 380001015
G: 380001019
5: MASTER PIN

* % $
60

GRAPHIC_ID Figure 278

NA Issued 10-2007 Bur 3-113

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)

IMPORTANT: Inject rust preventive protective (ex.

TECTYL165 G) between pin and bushing clearance.
IMPORTANT: If any links have been removed from
the track, be sure to charge the grease into the
clearance between the pin and bushing when
reconnecting the links. Also, apply a coat of grease
to the ends of the bushing.
Grease Charging Method:
Stand the bushing on a flat plate.
Fill the bushing bore with the grease.
Insert the pin into the bushing while pushing the 60
GRAPHIC_ID Figure 279
bushing onto the plate (so that the bushing end
stays on the plate).
Wipe off excess grease.

6. Supply grease to the cylinder through the grease

fitting to adjust the track tension.
When proper track sag is obtained, turn value
clockwise and tighten.
Track sag specifications (A): 320 to 350 mm
(12.6 - 13.8 in.)

Tightening torque: 59 Nm (43.5 pound-feet)

IMPORTANT: Check track sag after removing soil
stuck on the track area by washing.

60
GRAPHIC_ID Figure 280

3-114 Issued 10-2007 Bur NA

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
MAINTENANCE STANDARD
Link Pin and Track Bushing
Measure the length of four links, as illustrated, with the tension on the track.
Do not measure the master-pin included in part of the track.

GRAPHIC_1D Figure 281

Standard Allowable Limit Remedy

A 761 (mm) 774 (mm) Replace

Master Pin
%

$
60

GRAPHIC_ID Figure 282

Standard Allowable Limit Remedy

A 212 (mm) 205 (mm)
Replace
B 38 (mm) 36.5 (mm)

Master Bushing

% &

$
60
GRAPHIC_1D Figure 283

Standard Allowable Limit Remedy

A 129.2 (mm) -
B 38.7 (mm) 40.2 (mm) Replace
C 59 (mm) 54.4 (mm)

NA Issued 10-2007 Bur 3-115

 SECTION 2 - GENERAL REMOVAL/INSTALLATION AND DISASSEMBLY/ASSEMBLY
CHAPTER 3 - UNDERCARRIAGE (TRAVEL SYSTEM)
TOOL TABLE

TOOL NO. DESCRIPTION

380001008 Tool fitting/pushing-out master pin
380001009 Tool fitting/pushing-out master pin
380001012 Tool fitting/pushing-out master pin
380001013 Tool fitting/pushing-out master pin
380001015 Tool fitting/pushing-out master pin

3-116 Issued 10-2007 Bur NA

REPAIR MANUAL - SECTION 4

E175B
EXCAVATOR

TROUBLESHOOTING

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783-NA
 SECTION 4 - TROUBLESHOOTING

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B
 SECTION 4 - TROUBLESHOOTING

SECTION 4
TROUBLESHOOTING
SECTION TABLE OF CONTENTS
CHAPTER 1
TROUBLESHOOTING BY ERROR CODES
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TROUBLESHOOTING OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
TROUBLESHOOTING BY ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CHAPTER 2
TROUBLESHOOTING BY TROUBLE
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
TROUBLESHOOTING BY TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
CHAPTER 3
TROUBLESHOOTING BY DIAGNOSIS MODE
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
TROUBLE DIAGNOSIS MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

NA I
 SECTION 4 - TROUBLESHOOTING

NOTES

II Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING

CHAPTER 1

E175B
EXCAVATOR

TROUBLESHOOTING BY ERROR
CODES

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

1-II Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING

CHAPTER 1
TROUBLESHOOTING BY ERROR CODES
TABLE OF CONTENTS

TROUBLESHOOTING OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Judgment of Actual Thing at Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Get to the Site as Quickly as Possible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Verify Background of Trouble Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
How to Diagnose Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Explanation of the Cause of Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Classification of Failure and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
The Blown Fuse of Mechatro Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
TROUBLESHOOTING BY ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

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 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES

NOTES

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 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
TROUBLESHOOTING 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,
r e fe r t o t r o u bl e s h o o t i n g fo r e a c h m a n u a l o f
equipment.

JUDGMENT OF ACTUAL THING AT SITE

Get to the Site as Quickly as Possible SM0100

Verify model, serial number, situation of trouble and

field, and notify person of arrival time. GRAPHIC_ID Figure 1
ATTENDING THE FIELD TO VERIFY ACTUAL THING

Verify Background of Trouble Occurred

1. Model name and serial number
2. Kind of attachment.
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3. Operating time by hour-meter
4. History of trouble occurred and additional works.
5. Recurrence of past trouble, or problems on the
additional works.

SM0101
GRAPHIC_ID Figure 2
VERIFYING BACKGROUND OF TROUBLE OCCURRED

How to Diagnose Trouble

1. Verify defective part
2. Make the condition of trouble again
3. Where defective parts can not be verified,
surmise causes systematically.
4. Verify reasons for surmise
5. Report methods, procedure, and period for
repairing to user.

SM0102

GRAPHIC_ID Figure 3
CONFIRM THE SYMPTOMS OF THE TROUBLE

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 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
Explanation of the Cause of Trouble
1. Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2. Treatment of damaged parts.
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them. SM0103
And also use care not to flaw and damage those
surfaces. GRAPHIC_ID Figure 4
DIAGNOSING FAIL BY MEANS TROUBLESHOOTING

Classification of Failure and Troubleshooting

Classify failures into the following 3 types and carry out the troubleshooting.

No. Classes of failure Troubleshooting

When error code after self-diagnosis is displayed on

A Carry out troubleshooting according to the error code.
gauge cluster
When it is hard to recreate the failure situation, cancel
When no failure is detected currently but error code after the data in the history and reproduce the failed situation
B
self diagnosis is remained in trouble history or suppose the cause according to the troubleshooting
by error code, and then repair it.
Carry out troubleshooting according to instructions in
When error code after self diagnosis is not displayed or TROUBLESHOOTING BY TROUBLE.
C
is not remained in the history Carry out troubleshooting according to instructions in
TROUBLE DIAGNOSIS MODE.

THE BLOWN FUSE OF MECHATRO

CONTROLLER
If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
1. The blown fuse of mechatro controller
A. Blown fuse 5A of mechatro controller :
DATA COMMUNICATION ERROR is displayed
on the gauge cluster in the condition where the
controller program is not executed.
B. Blown fuse 20A of mechatro controller
The controller functions normally but the power
supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge
cluster.
D013, D023, D033, D063,
E013, E023, F021

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 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
TROUBLESHOOTING BY ERROR CODE
When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the
troubleshooting referring to applicable page in the contents of error codes.

Described
Error Code Trouble
on page
A015 Engine adjustment (A adjustment) is not adjusted yet or is failed. 1-8
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed. 1-8
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. 1-9
A215 Written data of ROM adjustment data is incorrect. 1-9
A225 Writing of ROM adjustment data is incorrect. 1-10
A235 Written data of ROM hour meter data is incorrect. 1-10
A245 Writing of ROM hour meter data is incorrect. 1-11
A255 Writing of proportional valve adjustment data is incorrect. 1-11
B012 Incorrect output of boom up pressure sensor 1-12
B013 Disconnection of boom up pressure sensor 1-12
B014 Short-circuit of boom up pressure sensor 1-13
B022 Incorrect output of boom down pressure sensor 1-13
B023 Disconnection of boom down pressure sensor 1-14
B024 Short-circuit of boom down pressure sensor 1-14
B032 Incorrect output of arm out pressure sensor 1-15
B033 Disconnection of arm out pressure sensor 1-15
B034 Short-circuit of arm out pressure sensor 1-16
B042 Incorrect output of arm in pressure sensor 1-16
B043 Disconnection of arm in pressure sensor 1-17
B044 Short-circuit of arm in pressure sensor 1-18
B052 Incorrect output of bucket digging pressure sensor 1-18
B053 Disconnection of bucket digging pressure sensor 1-19
B054 Short-circuit of bucket digging pressure sensor 1-19
B062 Incorrect output of bucket dump pressure sensor 1-20
B063 Disconnection of bucket dump pressure sensor 1-20
B064 Short-circuit of bucket dump pressure sensor 1-21
B072 Incorrect output of swing pressure sensor 1-21
B073 Disconnection of swing pressure sensor 1-22
B074 Short-circuit of swing pressure sensor 1-22
B092 Incorrect output of travel right pressure sensor 1-23
B093 Disconnection of travel right pressure sensor 1-23
B094 Short-circuit of travel right pressure sensor 1-24
B102 Incorrect output of travel left pressure sensor 1-24
B103 Disconnection of travel left pressure sensor 1-25
B104 Short-circuit of travel left pressure sensor 1-25
B113 Disconnection of pressure sensor of optional selector positioning 1-26

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 SECTION 2 - TROUBLESHOOTING
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Described
Error Code Trouble
on page
B114 Short-circuit of pressure sensor of optional selector positioning 1-26
B162 Incorrect output of P1 optional side pressure sensor 1-27
B163 Disconnection of P1 side optional pressure sensor 1-27
B164 Short-circuit of P1 side optional pressure sensor 1-28
B172 Incorrect output of P2 optional side pressure sensor 1-28
B173 Disconnection of P2 side optional pressure sensor 1-29
B174 Short-circuit of P2 side optional pressure sensor 1-29
C012 Incorrect output of P1 pump pressure sensor 1-30
C013 Disconnection of P1 pump pressure sensor 1-30
C014 Short-circuit of P1 pump pressure sensor 1-31
C022 Incorrect output of P2 pump pressure sensor 1-31
C023 Disconnection of P2 pump pressure sensor 1-32
C024 Short-circuit of P2 pump pressure sensor 1-32
C033 Disconnection of boom head pressure sensor 1-33
C034 Short-circuit of boom head pressure sensor 1-33
D012 Failure of output transistor ON at P1 unload proportional valve 1-34
D013 Disconnection of P1 unload proportional valve 1-34
D022 Failure of output transistor ON at P2 unload proportional valve 1-35
D023 Disconnection of P2 unload proportional valve 1-35
D032 Failure of output transistor ON at travel straight proportional valve 1-36
D033 Disconnection of travel straight proportional valve 1-36
D062 Failure of output transistor ON at arm in high speed proportional valve 1-37
D063 Disconnection of arm in high speed proportional valve 1-37
D152 Failure of output transistor ON at short-circuit valve 1-38
D153 Disconnection of short-circuit valve 1-38
E012 Failure of output transistor ON at P1 pump proportional valve 1-39
E013 Disconnection of P1pump proportional valve 1-39
E022 Failure of output transistor ON at P2 pump proportional valve 1-40
E023 Disconnection of P2 pump proportional valve 1-40
F011 Failure of output transistor OFF and GND short of attachment boost SOL valve 1-41
F013 Failure of output transistor ON and disconnection of attachment boost SOL valve 1-41
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 1-42
F023 Failure of output transistor ON and disconnection of swing parking SOL valve 1-42
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve 1-43
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve 1-43
F041 Failure of output transistor OFF and GND short of optional selector SOL valve 1-44
F043 Failure of output transistor ON and disconnection of optional selector SOL valve 1-44
G011 Failure of output transistor ON at governor motor 1-45
G013 Disconnection of governor motor 1-45

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 SECTION 2 - TROUBLESHOOTING
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Described
Error Code Trouble
on page
G023 Starting point indexing is impossible 1-46
G032 Overrun of speed sensor of direct input Mechatro controller 1-46
G033 Disconnection of speed sensor of direct input Mechatro controller 1-47
H013 Disconnection of acceleration potentio 1-47
H014 Power short-circuit of acceleration potentiometer 1-48
H023 Disconnection of boom angle potentiometer 1-48
H024 Power short-circuit of boom angle potentiometer 1-49
H033 Disconnection of arm angle potentiometer 1-49
H034 Power short-circuit of arm angle potentiometer 1-50
H091 Failure of GND short-circuit of fuel sensor 1-50
H093 Disconnection of fuel sensor 1-51
I313 Received error of cluster communication (time-out error) 1-51
K014 Adhesion of battery relay terminal 1-52
R014 Failure of arc prevention relay of wiper motor 1-53
R024 Failure of normal rotation relay of wiper motor 1-53
R034 Failure of reverse rotation relay of wiper motor 1-54
R044 Failure of washer motor relay 1-54
R134 Failure of swing flasher relay 1-55
R144 Failure of swing flasher relay 1-55
R154 Failure of travel alarm relay 1-56
R164 Failure of auto idling stop relay 2 1-56
R174 Failure of engine forcible stop relay 1-57
R184 Failure of lever lock relay 1-57
R214 Failure of safety relay 1-58

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 SECTION 2 - TROUBLESHOOTING
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Error Codes
Table 1

Error code A015

Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)

Judging condition Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Symptom Deviated from the required value, but no problem in normal operations.
Control in the
Rotate with the default engine.
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Screen No. 2 G-3 SPEED SET
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Carry out engine adjustment (A adjustment). When ERROR ENG was
displayed during adjustment, refer to the section ADJUSTMENT
1 Checking
PROCEDURE - MEASURES TO BE TAKEN WITH THE ADJUSTMENT
FAILED
2 Mechatro controller Check that the error is corrected after replacement of controller.
3

Table 2

Error code A025

Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the
Judging condition
adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation.
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Screen No. 9 E-1 P1 PUMP
Service
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen
Screen No.
Checking object Checking contents and remedy
Carry out pump adjustment (B adjustment).
When ERROR PUMP was displayed during adjustment, refer to the section
1 Checking
ADJUSTMENT PROCEDURE - MEASURES TO BE TAKEN WITH THE
ADJUSTMENT FAILED
2 Mechatro controller Check that the error is corrected after replacement of controller.
3

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 SECTION 2 - TROUBLESHOOTING
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Table 3

Error code A035

Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging condition The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting range.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
Service
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen
Screen No.
Checking object Checking contents and remedy
Carry out adjustment of unload valve (C adjustment).
When ERROR PUMP was displayed during adjustment, refer to the section
1 Checking
ADJUSTMENT PROCEDURE - MEASURES TO BE TAKEN WITH THE
ADJUSTMENT FAILED
2 Mechatro controller Check that the error is corrected after replacement of controller.
3

Table 4

Error code A215

Trouble The data of ROM adjustment is written incorrectly.

Judging condition Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen No.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

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 SECTION 2 - TROUBLESHOOTING
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Table 5

Error code A225

Trouble The data of ROM adjustment is written incorrectly.

Judging condition Check adjustment data, and judge the data is correct or not.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen No.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Table 6

Error code A235

Trouble The data of ROM adjustment is written incorrectly.

Judging condition Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen No.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

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 SECTION 2 - TROUBLESHOOTING
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Table 7

Error code A245

Trouble The data of ROM hourmeter is written incorrectly.

Judging condition Check hourmeter memory, and judge the data is incorrect.
Symptom The hourmeter data which was judged as error is taken as 0 Hr. No problem in normal operation.
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen No.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Table 8

Error code A255

Trouble The data of proportional valve adjustment is written incorrectly.

Judging condition Check proportional valve adjustment data, and judge the data is incorrect.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Screen No.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

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 SECTION 2 - TROUBLESHOOTING
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Table 9

Error code B012

Trouble Boom up pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter
Judging condition
switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The boom up operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 5 B-1 BOOM RAISE
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B012 is cancelled and other error occurs by turning starter switch on
1 Boom up pressure sensor SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom up pressure When B012 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 10

Error code B013

Trouble Boom up pressure sensor’s wiring disconnects.

Judging condition The input voltage from boom up pressure sensor is less than 0.1 V.
Symptom The boom up speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-1 BOOM RAISE
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B013 is cancelled and other error occurs after exchanging the connector
1 Boom up pressure sensor SE-3 with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom up pressure
When B013 is displayed after the connector is exchanged with other sensor.
sensor and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-126F
and repair it if necessary.
CN-101F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 11

Error code B014

Trouble Boom up pressure sensor’s power source is shortcut.

Judging condition The input voltage from boom up pressure sensor is 4.7 V or more.
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-1 BOOM RAISE
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B014 is cancelled and other error occurs after exchanging the connector
1 Boom up pressure sensor SE-3 with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom up pressure
When B014 is displayed after the connector is exchanged with other sensor.
sensor and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-126F
and repair it if necessary.
CN-101F
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 12

Error code B022

Trouble Boom down pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter
Judging condition
switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The boom down operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 5 B-2 BOOM LOWER
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B022 is cancelled and other error occurs by turning starter switch on
1 Boom down pressure sensor SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom down pressure When B022 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 13

Error code B023

Trouble Boom down pressure sensor’s wiring is disconnecting.

Judging condition The input voltage from boom down pressure sensor is 0.1 V or less.
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-2 BOOM LOWER
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B023 is cancelled and other error occurs after exchanging the connector
1 Boom down pressure sensor SE-4 with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom down
When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-127F
and repair it if necessary.
CN-101F
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 14

Error code B024

Trouble Boom down pressure sensor’s power source is shortcut.

Judging condition The input voltage from boom down pressure sensor is 4.7 V or more.
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-2 BOOM LOWER
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B024 is cancelled and other error occurs by turning starter switch on
1 Boom down pressure sensor SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom down pressure When B024 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 15

Error code B032

Trouble Arm-in pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter
Judging condition
switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 5 B-3 ARM OUT
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B032 is cancelled and other error occurs by turning starter switch on
1 Arm-out pressure sensor SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between arm-out pressure When B032 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 16

Error code B033

Trouble Arm-out pressure sensor’s wiring is disconnecting.

Judging condition The input voltage from arm-out pressure sensor is 0.1 V or less.
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-3 ARM OUT
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B033 is cancelled and other error occurs after exchanging the connector
1 Arm-out pressure sensor SE-8 with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between arm-out pressure
When B033 is displayed after the connector is exchanged with other sensor.
sensor and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-131F
and repair it if necessary.
CN-101F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 17

Error code B034

Trouble Arm-out pressure sensor’s power source is shortcut.

Judging condition The input voltage from arm-out pressure sensor is 4.7 V or more.
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-3 ARM OUT
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B034 is cancelled and other error occurs by turning starter switch on after
1 Arm-out pressure sensor SE-8 exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Wiring between arm-out pressure When B034 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 18

Error code B042

Trouble Arm-in pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure
Judging condition
sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 5 B-4 ARM IN
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B042 is cancelled and other error occurs by turning starter switch on after
Arm-in pressure sensor
1 exchanging the connector with other sensor.
SE-7
Check sensor unit for possible failure. If failure found, replace it.
Wiring between arm-in pressure When B042 is displayed after turning the starter switch on after the connector is
sensor and controller exchanged with other sensor.
2
CN-130F Check wiring for possible failure according to the wiring checking procedure and
CN-101F repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-16 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
Table 19
Error code B043

Trouble Arm-in pressure sensor’s wiring is disconnecting.

Judging condition The input voltage from arm-in pressure sensor is 0.1 V or less.
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if
Symptom attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom
put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-4 ARM IN
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B043 is cancelled and other error occurs after exchanging the connector
Arm-in pressure sensor
1 with other sensor.
SE-7
Check sensor unit for possible failure. If failure found, replace it.
Wiring between arm-in pressure
When B043 is displayed after the connector is exchanged with other sensor.
sensor and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-130F
and repair it if necessary.
CN-101F
3 Mechatro controller Check that the error is corrected after replacement of controller.

NA Issued 10-2007 Bur 1-17

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES

Table 20
Error code B044

Trouble Arm-in pressure sensor’s power source is shortcut.

Judging condition The input voltage from arm-in pressure sensor is 4.7 V or more.
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if
Symptom attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom
put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0 mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0 mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200 mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-4 ARM IN
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B044 is cancelled and other error occurs by turning starter switch on after
Arm-in pressure sensor
1 exchanging the connector with other sensor.
SE-7
Check sensor unit for possible failure. If failure found, replace it.
Wiring between arm-in pressure When B044 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-130F Check wiring for possible failure according to the wiring checking procedure and
CN-101F repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 21

Error code B052

Trouble Bucket digging pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the bucket digging
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 5 B-5 BUCKET DIG
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B052 is cancelled and other error occurs by turning starter switch on
Bucket digging pressure sensor
1 after exchanging the connector with other sensor.
SE-1
Check sensor unit for possible failure. If failure found, replace it.
Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-18 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
Table 22

Error code B053

Trouble Bucket digging pressure sensor’s wiring is disconnected.

Judging condition The input voltage from bucket digging pressure sensor is 0.1 V or less.
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-5 BUCKET DIG
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B053 is cancelled and other error occurs by turning starter switch on
Bucket digging pressure sensor
1 after exchanging the connector with other sensor.
SE-1
Check sensor unit for possible failure. If failure found, replace it.
Wiring between bucket digging When B053 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 23

Error code B054

Trouble Bucket digging pressure sensor’s power source is shortcut.

Judging condition The input voltage from bucket digging pressure sensor is 4.7 V or more.
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-5 BUCKET DIG
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B054 is cancelled and other error occurs by turning starter switch on
Bucket digging pressure sensor
1 after exchanging the connector with other sensor.
SE-1
Check sensor unit for possible failure. If failure found, replace it.
Wiring between bucket digging When B054 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

NA Issued 10-2007 Bur 1-19

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES

Table 24

Error code B062

Trouble Bucket dump pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the bucket dump pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 5 B-6 BUCKET DUMP
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B062 is cancelled and other error occurs by turning starter switch on
Bucket digging pressure sensor
1 after exchanging the connector with other sensor.
SE-2
Check sensor unit for possible failure. If failure found, replace it.
Wiring between bucket digging When B062 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 25

Error code B063

Trouble Bucket dump pressure sensor’s wiring is disconnected.

Judging condition The input voltage from bucket dump pressure sensor is 0.1 V or less.
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-6 BUCKET DUMP
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B063 is cancelled and other error occurs by turning starter switch on
Bucket digging pressure sensor
1 after exchanging the connector with other sensor.
SE-2
Check sensor unit for possible failure. If failure found, replace it.
Wiring between bucket digging When B063 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-20 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
Table 26

Error code B064

Trouble Bucket dump pressure sensor’s power source is shortcut.

Judging condition The input voltage from bucket dump pressure sensor is 4.7 V or more.
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-6 BUCKET DUMP
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B064 is cancelled and other error occurs by turning starter switch on
Bucket digging pressure sensor
1 after exchanging the connector with other sensor.
SE-2
Check sensor unit for possible failure. If failure found, replace it.
Wiring between bucket digging When B064 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 27

Error code B072

Trouble Swing pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the swing pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The swing operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 6 B-7 SWING
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B072 is cancelled and other error occurs by turning starter switch on after
Swing pressure sensor
1 exchanging the connector with other sensor.
SE-5
Check sensor unit for possible failure. If failure found, replace it.
Wiring between swing pressure When B072 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

NA Issued 10-2007 Bur 1-21

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES

Table 28

Error code B073

Trouble Swing pressure sensor’s wiring is disconnected.

Judging condition The input voltage from swing pressure sensor is 0.1 V or less.
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-7 SWING
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B073 is cancelled and other error occurs by turning starter switch on
Swing pressure sensor
1 after exchanging the connector with other sensor.
SE-5
Check sensor unit for possible failure. If failure found, replace it.
Wiring between swing pressure sensor When B073 is displayed after turning the starter switch on after the connector
and controller is exchanged with other sensor.
2
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 29

Error code B074

Trouble Swing pressure sensor’s power source is shortcut.

Judging condition The input voltage from swing pressure sensor is 4.7 V or more.
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-7 SWING
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B074 is cancelled and other error occurs by turning starter switch on
Swing pressure sensor
1 after exchanging the connector with other sensor.
SE-5
Check sensor unit for possible failure. If failure found, replace it.
Wiring between swing pressure sensor When B074 is displayed after turning the starter switch on after the connector
and controller is exchanged with other sensor.
2
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-22 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
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Table 30

Error code B092

Trouble Travel right pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the travel right pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The travel right operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 6 B-9 TRAVEL (R)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B092 is cancelled and other error occurs by turning starter switch on
Travel right pressure sensor
1 after exchanging the connector with other sensor.
SE-9
Check sensor unit for possible failure. If failure found, replace it.
Wiring between travel right pressure When B092 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 31

Error code B093

Trouble Travel right pressure sensor’s wiring is disconnected.

Judging condition The input voltage from Travel right pressure sensor is 0.1 V or less.
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-9 TRAVEL (R)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B093 is cancelled and other error occurs by turning starter switch on after
Travel right pressure sensor
1 exchanging the connector with other sensor.
SE-9
Check sensor unit for possible failure. If failure found, replace it.
Wiring between travel right pressure When B093 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

NA Issued 10-2007 Bur 1-23

 SECTION 2 - TROUBLESHOOTING
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Table 32

Error code B094

Trouble Travel right pressure sensor’s power source is shortcut.

Judging condition The input voltage from Travel right pressure sensor is 4.7 V or more.
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-9 TRAVEL (R)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B094 is cancelled and other error occurs by turning starter switch on after
Travel right pressure sensor
1 exchanging the connector with other sensor.
SE-9
Check sensor unit for possible failure. If failure found, replace it.
Wiring between travel right pressure When B094 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 33

Error code B102

Trouble Travel left pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the travel left pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The travel left operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 6 B-10 TRAVEL (L)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B102 is cancelled and other error occurs by turning starter switch on after
Travel left pressure sensor
1 exchanging the connector with other sensor.
SE-10
Check sensor unit for possible failure. If failure found, replace it.
Wiring between travel left pressure When B102 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-24 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
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Table 34

Error code B103

Trouble Travel left pressure sensor’s wiring is disconnected.

Judging condition The input voltage from Travel left pressure sensor is 0.1 V or less.
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-10 TRAVEL (L)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B103 is cancelled and other error occurs by turning starter switch on after
Travel left pressure sensor
1 exchanging the connector with other sensor.
SE-10
Check sensor unit for possible failure. If failure found, replace it.
Wiring between travel left pressure When B103 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 35

Error code B104

Trouble Travel left pressure sensor’s power source is shortcut.

Judging condition The input voltage from Travel left pressure sensor is 4.7 V or more.
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-10 TRAVEL (L)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B104 is cancelled and other error occurs by turning starter switch on after
Travel left pressure sensor
1 exchanging the connector with other sensor.
SE-10
Check sensor unit for possible failure. If failure found, replace it.
Wiring between travel left pressure When B104 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

NA Issued 10-2007 Bur 1-25

 SECTION 2 - TROUBLESHOOTING
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Table 36

Error code B113

Trouble Option selector position detect pressure sensor’s wiring is disconnected.

Judging condition The input voltage from option selector position detect pressure sensor is 0.1 V or less.
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 16 B-11
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Option selector position detect When B113 is cancelled and other error occurs by turning starter switch on
1 pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
Wiring between option selector
When B113 is displayed after turning the starter switch on after the connector
position detect pressure sensor and
is exchanged with other sensor.
2 controller
Check wiring for possible failure according to the wiring checking procedure
CN-162F
and repair it if necessary.
CN-104F
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 37

Error code B114

Trouble Option selector position detect pressure sensor’s wiring is disconnected.

Judging condition The input voltage from selector position detect pressure sensor is 4.7 V or more.
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 16 B-11
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Option selector position detect When B114 is cancelled and other error occurs by turning starter switch on
1 pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
Wiring between option selector
When B114 is displayed after turning the starter switch on after the connector
position detect pressure sensor and
is exchanged with other sensor.
2 controller
Check wiring for possible failure according to the wiring checking procedure
CN-162F
and repair it if necessary.
CN-104F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 38

Error code B162

Trouble P1 side option pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the P1 side option
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 6 B-16 P1 OPT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B162 is cancelled and other error occurs by turning starter switch on
P1 side option pressure sensor
1 after exchanging the connector with other sensor.
SE-20
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 39

Error code B163

Trouble P1 side option pressure sensor’s wiring is disconnected.

Judging condition The input voltage from P1 side option pressure sensor is 0.1 V or less.
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-16 P1 OPT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B163 is cancelled and other error occurs by turning starter switch on after
P1 side option pressure sensor
1 exchanging the connector with other sensor.
SE-20
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

NA Issued 10-2007 Bur 1-27

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES

Table 40

Error code B164

Trouble P1 side option pressure sensor’s wiring is disconnected.

Judging condition The input voltage from P1 side option pressure sensor is 4.7 or more.
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-16 P1 OPT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B164 is cancelled and other error occurs by turning starter switch on after
P1 side option pressure sensor
1 exchanging the connector with other sensor.
SE-20
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 41

Error code B172

Trouble P2 side option pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the P2 side option
Judging condition
pressure sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 6 B-17 P2 OPT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B172 is cancelled and other error occurs by turning starter switch on
P2 side option pressure sensor
1 after exchanging the connector with other sensor.
SE-11
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 side option When B172 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-28 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
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Table 42

Error code B173

Trouble P2 side option pressure sensor’s wiring is disconnected.

Judging condition The input voltage from P2 side option pressure sensor is 0.1 V or less.
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-17 P2 OPT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B173 is cancelled and other error occurs by turning starter switch on
P2 side option pressure sensor
1 after exchanging the connector with other sensor.
SE-11
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 side option When B173 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 43

Error code B174

Trouble P2 side option pressure sensor’s wiring is disconnected.

Judging condition The input voltage from P2 side option pressure sensor is 4.7 V or more.
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0 mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode).
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-17 P2 OPT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B174 is cancelled and other error occurs by turning starter switch on
P2 side option pressure sensor
1 after exchanging the connector with other sensor.
SE-11
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 side option When B174 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
2
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 44

Error code C012

Trouble P1 pump pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the P1 pump pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 7 C-1 PUMP P1
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C012 is cancelled and other error occurs by turning starter switch on
P1 pump pressure sensor
1 after exchanging the connector with other sensor.
SE-22
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 pump pressure When C012 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 45

Error code C013

Trouble P1 pump pressure sensor’s wiring is disconnected.

Judging condition The input voltage from P1 pump pressure sensor is 0.1 V or less.
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 C-1 PUMP P1
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C013 is cancelled and other error occurs by turning starter switch on
P1 pump pressure sensor
1 after exchanging the connector with other sensor.
SE-22
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 pump pressure When C013 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 46

Error code C014

Trouble P1 pump pressure sensor’s power source is shortcut.

Judging condition The input voltage from P1 pump pressure sensor is 4.7 V or more.
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 C-1 PUMP P1
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C014 is cancelled and other error occurs by turning starter switch on
P1 pump pressure sensor
1 after exchanging the connector with other sensor.
SE-22
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 pump pressure When C014 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 47

Error code C022

Trouble P2 pump pressure sensor outputs error.

After starter switch ON and engine does not start yet. And the input voltage from the P2 pump pressure
Judging condition
sensor after starter switch ON is in the range of 1.4 V or more to less than 4.7 V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control.
event of failure
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turns on it again.
normal condition
Screen No. 7 C-2 PUMP P2
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C022 is cancelled and other error occurs by turning starter switch on
P2 pump pressure sensor
1 after exchanging the connector with other sensor.
SE-23
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 pump pressure When C022 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 48

Error code C023

Trouble P2 pump pressure sensor’s wiring is disconnected.

Judging condition The input voltage from P2 pump pressure sensor is 0.1 V or less.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 C-2 PUMP P2
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C023 is cancelled and other error occurs by turning starter switch on
P2 pump pressure sensor
1 after exchanging the connector with other sensor.
SE-23
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 pump pressure When C023 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 49

Error code C024

Trouble P2 pump pressure sensor’s power source is shortcut.

Judging condition The input voltage from P2 pump pressure sensor is 4.7 V or more.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 C-2 PUMP P2
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C024 is cancelled and other error occurs by turning starter switch on
P2 pump pressure sensor
1 after exchanging the connector with other sensor.
SE-23
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 pump pressure When C024 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 50

Error code C033

Trouble Boom head pressure sensor’s wiring is disconnected.

Judging condition The input voltage from boom head pressure sensor is 0.1 V or less.
Symptom Overload detection is not available.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 C-3 BOOM-HEAD
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C033 is cancelled and other error occurs by turning starter switch on
Boom head pressure sensor
1 after exchanging the connector with other sensor.
SE-24
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom head pressure When C033 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 51

Error code C034

Trouble Boom head pressure sensor’s power source is shortcut.

Judging condition The input voltage from boom head pressure sensor is 4.7 V or more.
Symptom Then overload detection switch is ON, overload alarm sounds constantly.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 C-3 BOOM-HEAD
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When C034 is cancelled and other error occurs by turning starter switch on
Boom head pressure sensor
1 after exchanging the connector with other sensor.
SE-24
Check sensor unit for possible failure. If failure found, replace it.
Wiring between boom head pressure When C034 is displayed after turning the starter switch on after the connector
sensor and controller is exchanged with other sensor.
2
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 52

Error code D012

Trouble P1 unload proportional valve and output transistor ON are failure.

Judging condition The feedback value from proportional valve is 1000 mA or more.
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0 mA. (Valve emergency mode).
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D012 is cancelled and other error occurs by turning starter switch on
P1 unload proportional valve
1 after exchanging the connector with other sensor.
PSV-D
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 53

Error code D013

Trouble P1 unload proportional valve’s wiring is disconnected.

The feedback value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode).
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D013 is cancelled and other error occurs by turning starter switch on
P1 unload proportional valve
1 after exchanging the connector with other sensor.
PSV-D
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P1 unload When D013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 54

Error code D022

Trouble P2 unload proportional valve and output transistor ON are failure.

Judging condition The feedback value from proportional valve is 1000 mA or more.
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D022 is cancelled and other error occurs by turning starter switch on
P2 unload proportional valve
1 after exchanging the connector with other sensor.
PSV-B
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 unload When D022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 55

Error code D023

Trouble P2 unload proportional valve’s wiring is disconnected.

The feedback value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0 mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D023 is cancelled and other error occurs by turning starter switch on
P2 unload proportional valve
1 after exchanging the connector with other sensor.
PSV-B
Check sensor unit for possible failure. If failure found, replace it.
Wiring between P2 unload When D023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 56

Error code D032

Trouble Travel straight proportional valve and output transistor ON are failure.
Judging condition The feedback value from proportional valve is 1000 mA or more
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0 mA
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-3 S-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D032 is cancelled and other error occurs by turning starter switch on
Travel straight proportional valve
1 after exchanging the connector with other sensor.
PSV-C
Check sensor unit for possible failure. If failure found, replace it.
Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 57

Error code D033

Trouble Travel straight proportional valve’s wiring is disconnected.

The feedback value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0 mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-3 S-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D033 is cancelled and other error occurs by turning starter switch on after
Travel straight proportional valve
1 exchanging the connector with other sensor.
PSV-C
Check sensor unit for possible failure. If failure found, replace it.
Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 58

Error code D062

Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition The feedback value from proportional valve is 1000 mA or more
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-4 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D062 is cancelled and other error occurs by turning starter switch on
Arm-in spool 2 proportional valve
1 after exchanging the connector with other sensor.
PSV-A
Check sensor unit for possible failure. If failure found, replace it.
Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 59

Error code D063

Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.

The feedback value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0 mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-4 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When D063 is cancelled and other error occurs by turning starter switch on
Arm-in spool 2 proportional valve
1 after exchanging the connector with other sensor.
PSV-A
Check sensor unit for possible failure. If failure found, replace it.
Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
2
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 60

Error code D152

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1
2
3

Table 61

Error code D153

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1
2
3

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Table 62

Error code E012

Trouble P1 pump proportional valve and output transistor ON are failure.

Judging condition The feedback value from proportional valve is 1000 mA or more.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turn on again.
normal condition
Screen No. 9 E-1 PUMP P1
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When E012 is cancelled and other error occurs by turning starter switch on after
P1 pump proportional valve exchanging the connector with other sensor.
1
PSV-P1 Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
When E012 is displayed after turning the starter switch on after the connector
Wiring between P1 pump proportional
is exchanged with other sensor.
valve and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-141F
and repair it if necessary.
CN-105F
When replacing of connector is executed, turn off power source once.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 63

Error code E013

Trouble P1 pump proportional valve’s wiring is disconnected.
The feedback value from proportional valve is 100 mA or less.
Judging condition
(If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turn on again.
normal condition
Screen No. 9 E-1 PUMP P1
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When E013 is cancelled and other error occurs by turning starter switch on
P1 pump proportional valve after exchanging the connector with other sensor.
1
PSV-P1 Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
When E013 is displayed after turning the starter switch on after the connector
Wiring between P1 pump proportional
is exchanged with other sensor.
valve and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-141F
and repair it if necessary.
CN-105F
When replacing of connector is executed, turn off power source once.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 64

Error code E022

Trouble P2 pump proportional valve and output transistor ON are failure.

Judging condition The feedback value from proportional valve is 1000 mA or more.
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turn on again.
normal condition
Screen No. 9 E-2 PUMP P2
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When E022 is cancelled and other error occurs by turning starter switch on
P2 pump proportional valve after exchanging the connector with other sensor.
1
PSV-P2 Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
When E022 is displayed after turning the starter switch on after the connector
Wiring between P2 pump proportional
is exchanged with other sensor.
valve and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-142F
and repair it if necessary.
CN-105F
When replacing of connector is executed, turn off power source once.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 65

Error code E023

Trouble P2 pump proportional valve’s wiring is disconnected.
The feedback value from proportional valve is 100 mA or less.
Judging condition
(If output is 100 mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0 mA.
event of failure (Hydraulic pump emergency mode)
Returned in
Not returned automatically under normal condition. Switch the power OFF once and turn on again.
normal condition
Screen No. 9 E-2 PUMP P2
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When E023 is cancelled and other error occurs by turning starter switch on
P2 pump proportional valve after exchanging the connector with other sensor.
1
PSV-P2 Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
When E023 is displayed after turning the starter switch on after the connector
Wiring between P2 pump proportional
is exchanged with other sensor.
valve and controller
2 Check wiring for possible failure according to the wiring checking procedure
CN-142F
and repair it if necessary.
CN-105F
When replacing of connector is executed, turn off power source once.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 66

Error code F011

Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feedback signal is grounding level while exciting command is output.
Symptom ATT boost is not available.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is 24V level while exciting command is output.
normal condition
Screen No. 3 F-1 POWER BOOST
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F011 is cancelled and other error occurs by exchanging the connector
ATT boost solenoid valve
1 for other solenoid valve.
SV-2
Check solenoid valve unit for possible failure. If failure found, replace it.
Wiring between ATT boost solenoid When F011 is displayed after the connector is exchanged with other solenoid
valve and controller valve.
2
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 67

Error code F013

Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feedback signal is 24 V level while exciting command is not output.
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is grounding level while exciting command is not output.
normal condition
Screen No. 3 F-1 POWER BOOST
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F013 is cancelled and other error occurs by exchanging the connector
ATT boost solenoid valve
1 for other solenoid valve.
SV-2
Check solenoid valve unit for possible failure. If failure found, replace it.
Wiring between ATT boost solenoid When F013 is displayed after the connector is exchanged with other solenoid
valve and controller valve.
2
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 68

Error code F021

Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feedback signal is grounding level while exciting command is output.
Symptom Swing parking is not available.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is 24 V level while exciting command is output.
normal condition
Screen No. 3 F-2 SWING-BRAKE
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F021 is cancelled and other error occurs by exchanging the connector
Swing parking solenoid valve
1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure
SV-1
found, replace it.
Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
2
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 69

Error code F023

Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feedback signal is 24 V level while exciting command is not output.
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is grounding level while exciting command is output.
normal condition
Screen No. 3 F-1 POWER BOOST
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F023 is cancelled and other error occurs by exchanging the connector
Swing parking solenoid valve
1 for other solenoid valve.
SV-1
Check solenoid valve unit for possible failure. If failure found, replace it.
Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
2
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 70

Error code F031

Trouble Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feedback signal is grounding level while exciting command is output.
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is 24 V level while exciting command is output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F031 is cancelled and other error occurs by exchanging the connector
Travel 1, 2 speed solenoid valve
1 for other solenoid valve.
SV-3
Check solenoid valve unit for possible failure. If failure found, replace it.
Wiring between travel 1, 2 speed When F031 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
2
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 71

Error code F033

Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feedback signal is 24 V level while exciting command is not output.
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is grounding level while exciting command is not output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F033 is cancelled and other error occurs by exchanging the connector
Travel 1, 2 speed solenoid valve
1 for other solenoid valve.
SV-3
Check solenoid valve unit for possible failure. If failure found, replace it.
Wiring between travel 1, 2 speed When F033 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
2
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 72

Error code F041

Trouble Option selector solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition The feedback signal is grounding level while exciting command is output.
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is ground level while exciting command is output.
normal condition
Screen No. 11 F-4 OPT SELECT
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F041 is cancelled and other error occurs by exchanging the connector
Option selector solenoid valve
1 for other solenoid valve.
SV-13
Check solenoid valve unit for possible failure. If failure found, replace it.
Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
2
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 73

Error code F043

Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feedback signal is 24 V level while exciting command is not output.
Symptom Option selector valve does not change to breaker side or it does not change from breaker to nibbler.
Control in the
Normal control.
event of failure
Returned in
The feedback signal is ground level while exciting command is not output.
normal condition
Screen No. 11 F-4 OPT SELECT
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When F043 is cancelled and other error occurs by exchanging the connector
Option selector solenoid valve
1 for other solenoid valve.
SV-13
Check solenoid valve unit for possible failure. If failure found, replace it.
Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
2
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 74

Error code G011

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1
2
3

Table 75

Error code G013

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1
2
3

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 SECTION 2 - TROUBLESHOOTING
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Table 76

Error code G023

Trouble
Judging condition
Symptom
Control in the
event of failure
Returned in
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1
2
3

Table 77

Error code G032

Trouble Mechatro controller direct input speed sensor is overrun.

Judging condition Engine rpm input is 3000 rpm or more. (Only trouble history).
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service diagnosis
Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen
Screen No.
Checking object Checking contents and remedy

Engine speed sensor Measure the resistance between terminals of speed sensor.
1
SV-13 Normal value: 1.6~2.0k Ω.
Wiring between option selector
Check wiring for possible failure according to the wiring checking
solenoid valve and controller
2 procedure and repair it if necessary.
CN-251F
Especially check wiring for false disconnection and noise included.
CN-105F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 78

Error code G033

Trouble Mechatro controller direct input speed sensor, Disconnection.

Judging condition Voltage of alternator is 12 V or more, and speed sensor indicates excess low engine rpm.
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service diagnosis
Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen
Screen No.
Checking object Checking contents and remedy
Engine speed sensor Measure the resistance between terminals of speed sensor.
1
SE-13 Normal value: 1.6~2.0k Ω.
Wiring between engine speed sensor
and controller Check wiring for possible failure according to the wiring checking procedure
2
CN-136F and repair it if necessary.
CN-106F
Check that the error is corrected after replacement of controller.
3 Mechatro controller
(Controller is broken by only applying power to grounding of signal.).

Table 79

Error code H013

Trouble Accel potentiometer is disconnected.

Judging condition The input voltage from accel potentiometer is 0.1 V or less.
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 2 H-1 ACCEL VOLT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k Ω
1
SE-16 Turn the potentiometer and measure resistance between signal and GND.
Wiring between accel potentiometer
and controller Check wiring for possible failure according to the wiring checking procedure
2
CN-402F and repair it if necessary.
CN-102F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 80

Error code H014

Trouble Accel potentiometer’s power source is shortcut.

Judging condition The input voltage from accel potentiometer is 4.7 V or more.
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 2 H-1 ACCEL VOLT.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Measure the resistance between terminals of accel potentiometer.
Accel potentiometer
1 1.6~2.0k Ω.
SE-16
Turn the potentiometer and measure resistance between signal and GND.
Wiring between accel potentiometer
and controller Check wiring for possible failure according to the wiring checking procedure
2
CN-402F and repair it if necessary.
CN-102F
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 81

Error code H023

Trouble Boom angle potentiometer’s wiring is disconnected.

Judging condition The input voltage from boom angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 12 H-2 BOOM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Measure the resistance between terminals of boom angle potentiometer.
Boom angle potentiometer 4.0~6.0k Ω.
1
SE-17 Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k Ω
Wiring between boom angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
2
CN-702F and repair it if necessary.
CN-103F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 82

Error code H024

Trouble Boom angle potentiometer’s power source is shortcut.

Judging condition The input voltage from boom angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 12 H-2 BOOM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Measure the resistance between terminals of boom angle potentiometer.
Boom angle potentiometer 4.0~6.0k 087.
1
SE-17 Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k Ω
Wiring between boom angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
2
CN-702F and repair it if necessary.
CN-103F
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 83

Error code H033

Trouble Arm angle potentiometer’s wiring is disconnected.

Judging condition The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 12 H-3 ARM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Measure the resistance between terminals of arm angle potentiometer.
Arm angle potentiometer 4.0~6.0k Ω.
1
SE-18 Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k Ω.
Wiring between arm angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
2
CN-703F and repair it if necessary.
CN-103F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 84

Error code H034

Trouble Arm angle potentiometer’s power source is shortcut.

Judging condition The input voltage from arm angle potentiometer is 0.1 V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 12 H-3 ARM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Measure the resistance between terminals of arm angle potentiometer.
Arm angle potentiometer 4.0~6.0k Ω.
1
SE-18 Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k Ω.
Wiring between arm angle
potentiometer and controller Check wiring for possible failure according to the wiring checking procedure
2
CN-703F and repair it if necessary.
CN-103F
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 85

Error code H091

Trouble Fuel sensor grounding is short-circuited.

Judging condition The input voltage from fuel sensor is 0.1 V or less.
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 10 H-9 FUEL LEVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Move fuel sensor and measure the resistance between terminals of fuel
Fuel sensor potentiometer
1 sensor.
SE-15
EMPTY 95. Ω~ FULL 5 Ω.
Wiring between fuel sensor and
controller Check wiring for possible failure according to the wiring checking procedure
2
CN-152F and repair it if necessary.
CN-104F
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 86

Error code H093

Trouble Fuel sensor’s wiring is disconnection.

Judging condition The input voltage from fuel sensor is 4.7 V or more.
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 10 H-9 FUEL LEVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Move fuel sensor and measure the resistance between terminals of fuel
Fuel sensor potentiometer
1 sensor.
SE-15
EMPTY 95. Ω~ FULL 5 Ω.
Wiring between fuel sensor and
controller Check wiring for possible failure according to the wiring checking procedure
2
CN-152F and repair it if necessary.
CN-104F
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 87

Error code I313

Trouble Reception of cluster communication is abnormal. (Time-out error)

Judging condition Reception from gauge cluster can not receive correctly.
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No.
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
Wiring between gauge cluster and
controller Check wiring for possible failure according to the wiring checking procedure
1
CN-600F and repair it if necessary.
CN-101F
2 Mechatro controller Check that the error is corrected after replacement of controller.

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 SECTION 2 - TROUBLESHOOTING
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Table 88

Error code K014

Trouble Battery relay contact welded.

The power 24 V is continuously supplied to controller for 40 seconds or more while the key switch ON
Judging condition
signal turned OFF.
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Control in the
Normal control with key switch OFF.
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24 V to mechatro controller is stopped.
Screen No. 4 K-1 AIS RELAY 2
Service diagnosis
Screen No. 4 K-3 KEY SWITCH OFF
checking screen
Screen No.
Checking object Checking contents and remedy
Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
1 R-1 relay coil. If 24 V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
Wiring between auto idle stop relay/ When K014 is left displayed with the relay removed.
alternator relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
3 CN-109F, CN2-1 checking procedure and replace it if necessary.
Fuse& relay box When no failure found after checking on wiring and K014 is left displayed
E-1 Replace fuse/relay box.
4 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 89

Error code R014

Trouble Wiper motor arc prevention relay error.

The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power
Judging condition
source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 25 PREVENT ARC
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing wiper motor arc prevention relay, check
Wiper motor arc prevention relay
1 relay unit for failure, replace it with new one if failed.
R-31
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between wiper motor arc When R014 is left displayed with the relay removed.
prevention relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-1 checking procedure and replace it if necessary.
Fuse& relay box When no failure found after checking on wiring and R014 is left displayed.
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 90

Error code R024

Trouble Wiper motor forward rotation relay error.
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the power
Judging condition
source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 25 CW MOTOR RLY
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing wiper motor forward rotation relay,
Wiper motor forward rotation relay
1 check relay unit for failure, replace it with new one if failed.
R-29
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between wiper motor forward When R024 is left displayed with the relay removed.
rotation relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-1 checking procedure and replace it if necessary.
Fuse& relay box When no failure found after checking on wiring and R024 is left displayed.
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 91

Error code R034

Trouble Wiper motor reverse rotation relay error.

The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power
Judging condition
source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 25 CCW MOTOR RLY
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing wiper motor reverse rotation relay,
Wiper motor reverse rotation relay
1 check relay unit for failure, replace it with new one if failed.
R-30
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between wiper motor forward When R034 is left displayed with the relay removed
rotation relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-1 checking procedure and replace it if necessary.
Fuse& relay box When no failure found after checking on wiring and R034 is left displayed
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 92

Error code R044

Trouble Washer motor relay error.
Judging condition The mechatro controller output line to washer motor relay is short-circuited with the power source.
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 25 MOTOR RELAY
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing washer motor relay, check relay unit for
Washer motor relay
1 failure, replace it with new one if failed.
R-32
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between washer motor relay When R044 is left displayed with the relay removed
and controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-112F, CN2-1 checking procedure and replace it if necessary.
Fuse& relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 93

Error code R134

Trouble Swing flasher relay error.

Judging condition The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 22 D13
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing connector (CN-74F) of swing flasher
Swing flasher relay relay, check relay unit for failure, replace it with new one if failed.
1
R-19 When resistance between relays (HB) and (HC) is 0 Ω, it is in abnormal
condition.
Wiring between swing flasher relay
When R134 is left displayed with the relay removed
and controller
2 Check that no power 24 V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F
figure C) according to the wiring checking procedure and replace it if necessary.

3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 94

Error code R144

Trouble Swing flasher relay error.

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

3 Mechatro controller Check that the error is corrected after replacement of controller.

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Table 95

Error code R154

Trouble Travel alarm relay error.

Judging condition The mechatro controller output line to travel alarm relay is short-circuited with the power source.
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 23 D15
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing of travel alarm relay, check relay unit
Travel alarm relay
1 for failure, replace it with new one if failed.
R-8
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between travel alarm relay and When R154 is left displayed with the relay removed
controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-2 checking procedure and replace it if necessary.
Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 96

Error code R164

Trouble Auto idle stop relay 2 relay error.
Judging condition The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 4 K-1 AIS RELAY 2
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing of auto idle stop relay 2, check relay unit
Auto idle stop relay 2 relay
1 for failure, replace it with new one if failed.
R-24
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between auto idle stop relay 2 When R164 is left displayed with the relay removed
and controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-2 checking procedure and replace it if necessary.
Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-56 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES
Table 97

Error code R174

Trouble Engine forcibly stop relay error.

Judging condition The mechatro controller output line to engine forcibly stop is short-circuited with the power source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 4 K-3 ENG STOP
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error is cancelled after removing of engine forcibly stop relay, check relay
Engine forcibly stop relay
1 unit for failure, replace it with new one if failed.
R-25
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between engine forcibly stop When R174 is left displayed with the relay removed
relay and controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-2 checking procedure and replace it if necessary.
Fuse & relay box When no failure found after checking on wiring and R174 is left displayed.
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

Table 98

Error code R184

Trouble Safety lock lever relay error.
Judging condition The mechatro controller output line to safety lock lever relay is short-circuited with the power source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 4 K-4 LOCK LEVER
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error R184 is cancelled after removing of safety lock lever relay, check
Safety lock lever relay
1 relay unit for failure, replace it with new one if failed.
R-26
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between safety lock lever relay When R184 is left displayed with the relay removed
and controller Check that no power 24 V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-2 checking procedure and replace it if necessary.
Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

NA Issued 10-2007 Bur 1-57

 SECTION 2 - TROUBLESHOOTING
CHAPTER 1 - TROUBLESHOOTING BY ERROR CODES

Table 99

Error code R214

Trouble Safety relay error.

Judging condition The mechatro controller output line to safety relay is short-circuited with the power source.
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF.
normal condition
Screen No. 4 K-2 SAFETY RLY
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When error R214 is cancelled after removing of safety relay, check relay unit
Safety lock lever relay
1 for failure, replace it with new one if failed.
R-26
When resistance between relays (1) and (2) is 0 Ω, it is in abnormal condition.
Wiring between safety lock lever relay When R214 is left displayed with the relay removed
and controller Check that no power 24V is produced on relay (-) line according to the wiring
2 CN-109F, CN2-2 checking procedure and replace it if necessary.
Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
E-1 Replace fuse/relay box.
3 Mechatro controller Check that the error is corrected after replacement of controller.

1-58 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING

CHAPTER 2

E175B
EXCAVATOR

TROUBLESHOOTING BY
TROUBLE

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 B95, B95TC, B95LR, B110, B115

2-II Issued 05-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING

CHAPTER 2
TROUBLESHOOTING BY TROUBLE
TABLE OF CONTENTS

TROUBLESHOOTING BY TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
1. All Controls Do Not Function/Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2. Engine Down/Stalled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3. Move at Lever Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
4. Poor Fine Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
5. Slow Boom Up, Insufficient Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
6. Slow Boom Down, Insufficient Power For Lifting Up Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
7. Slow Arm In, Insufficient Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
8. Slow Independent Arm Out (In The Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
9. Slow Bucket Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
10. Slow Bucket Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
11. Swing Operation Not Functioned/Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
12. Noise During Swing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
13. Swing on a Slope Drifts When Control Lever is in Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
14. Swing Drifts When Swing Operation is Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
15. Slow Travel Speed/Weak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
16. Travel Deviation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
17. Travel 1st/2nd Speed Not Changed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
18. Travel Parking on a Slope is Not Held . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
19. Travel Does Not Run Straightly When Both Crawlers and Attachment Operated Simultaneously . . . 2-31
20. Slow Breaker (Crusher) Operation, Weak Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
21. Option Selector Valve Malfunction: Not Switched To Breaker Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 2-34
22. Option Selector Valve Malfunction: Not Switched To Nibbler Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Electric Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Wiring Checking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Engine Does Not Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
CPU Data Communication Error is Displayed on Multi Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Auto Accel Does Not Actuate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Auto Accel Does Not Actuate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Wiper Does Not Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

NA Issued 10-2007 Bur 2-1

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

2-2 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
TROUBLESHOOTING BY TROUBLE
HYDRAULIC SYSTEM
Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
1. All controls do not function/slow
2. Engine down/stalled
3. Move at lever neutral position
4. Poor fine operability
5. Slow boom up, insufficient power
6. Slow boom down, insufficient power for lifting up
body
7. Slow arm in, insufficient power
8. Slow independent arm out (in the air)
9. Slow bucket digging
10. Slow bucket dumping
11. Swing operation not functioned/slow
12. Noise during swing operation
13. Swing on a slope drifts when control lever is in
neutral position
14. Swing drifts when swing operation is stopped
15. Slow travel speed/weak
16. Travel deviation
17. Travel 1st/2nd speed not changed
18. Travel parking on a slope is not held
19. Travel does not run straightly when both crawlers
and attachment operated simultaneously.
20. Slow breaker (crusher) operation, weak power
21. Option selector valve malfunction: not switched
to breaker circuit
22. Option selector valve malfunction: not switched
to nibbler circuit

NA Issued 10-2007 Bur 2-3

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
1. All Controls Do Not Function/Slow

No. Sections Contents/normal value Corrective action, others

Check fuse No.4 If the fuse is blown out, check

1 Fuse
(10 A) on the short-circuited section.

Check action of switch by

No.4 K-4 switch:
Safety lever lock Carry out service tester, or check that the power
2 Push down the lever and it turns on, push
switch diagnosis voltage is lowered by pushing
up and it turns off.
the lever down.

Check solenoid unit for

Check that the Measure both terminals of solenoid
Safety lever lock possible failure.
3 solenoid is switched connector. 24 V by pushing the lever
switching Check harness for possible
correctly down, 0 V by pushing it up
failure.

No.4 K-4 lock lever:

Safety lever lock Carry out service
4 Push down the lever and it turns off, push Check action of relay by tester
relay diagnosis
up and it turns on.

Stop engine stop and key is on position.

5 Pilot pressure sensor All pilot low pressure sensors are 0 MPa Check 5 V power for controller
to 0.1 MPa.

Solenoid valve for Measure pressure About 0 MPa by pushing the lever up, and
6 Replace solenoid valve
safety lock lever of solenoid A1 port 4 MPa or more by push it down.

Disassemble and
7 Pilot line filter Check filter for clogging Clean filter
check it visually

8 Pilot gear pump
Measure pilot
Check that it is 4 MPa or more in high Check gear pump and the relief
primary pressure at
idling valve for possible failure
gear pump

Since all are blocked due to poor

Multi control valve (in
switching performance, check that the
9 case that travel is Change position
lever select pattern is set to the proper
operable)
position.

In case where the reading is

Actual measuring No.8 D-1 P1 unload valve (cut valve)
largely differed from the
current value of P1/ Carry out service D-1 P2 unload valve (cut valve)
10 actually measured value,
P2 unload diagnosis See Service Diagnosis Data List
check proportional valve and
proportional valve Operation No.3 Boom up full lever & relief
controller for possible failure.

Measure the
proportional valve
Check that P1/P2 unload secondary
Secondary pressure secondary pressure
pressures are within the range of 0.5 to
11 of P1, P2 unload directly at the ports Replace proportional valve
1.2 MPa in boom up full lever and high
proportional valve A7 and A5 of 8
idling operation
sections solenoid
block

No.9 E-1 P1 pump

E-2 P2 pump In case where the reading is
Actual measuring
See Service Diagnosis Data List largely differed from the
current value of P1/ Carry out service
12 Operation No.18 Travel right full lever & actually measured value,
P2 pump diagnosis.
idling check proportional valve and
proportional valve
Operation No.19 Travel left full lever & controller for possible failure.
idling

2-4 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
No. Sections Contents/normal value Corrective action, others

Measure the pump Check that pump proportional valve

proportional valve secondary pressure is 2.7 MPa or more in
Secondary pressure
secondary pressure right (left) travel full lever and high idling
13 of pump proportional Replace proportional valve
directly in idling operation
valve
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve

Carry out service See Service Diagnosis Data List Measure the relief pressure
14
diagnosis Operation No.3 Boom up full lever & relief actually
Main relief pressure Check that P1 and P2 pump pressures
15 Check set pressure are 32 MPa in boom up full lever, high Reset or replace
idling and H mode operation.

When removing, free from abnormal

resistance against sliding.
16 Pump regulator Visual check Free from abnormal damage, etc. on Replace
outside surface
Spring free from breakage, damage, etc.

When removing, inside parts (cylinder

block, piston, valve plate, shaft, etc.) are
17 Pump Visual check Replace
free from abnormal resistance against
sliding, abnormal damage, etc.

NA Issued 10-2007 Bur 2-5

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
2. Engine Down/Stalled

No. Sections Contents/normal value Corrective action, others

In case where the reading is

Actual measuring No.9 E-1 P1 pump
largely differed from the
current value of P1/ Carry out service E-2 P2 pump
1 actually measured value,
P2 pump diagnosis See Service Diagnosis Data List
check proportional valve and
proportional valve Operation No. 1 Operation is nil
controller for possible failure.

Measure the pump

Check that P1/P2 pump proportional
Secondary pressure proportional valve
valve pressures are within the range of
2 of P1, P2 pump secondary pressure Replace proportional valve
0.5 to 1.0 MPa in control lever neutral and
proportional valve directly (Ports a3,
high idling operation.
a4)

See Service Diagnosis Data List

Pressure sensor of Check pressure sensor and
3 Check pressure Operation No. 1 Operation is nil
P1, P2 pump replace it if necessary
Operation No.3 Boom up full lever & relief

When removing, free from abnormal

resistance against sliding
4 Pump regulator Visual check Free from abnormal damage, etc. on Replace
outside surface
Spring free from breakage, damage, etc.

When removing, inside parts (cylinder

block, piston, valve plate, shaft, etc.) are
5 Pump Visual check Replace
free from abnormal resistance against
sliding, abnormal damage, etc.

2-6 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
3. Move at Lever Neutral Position

No. Sections Contents/normal value Corrective action, others

Pilot pressure Carry out service Check that targeted pilot pressure of
1 Check remote control valve
sensor diagnosis sensor is 0MPa in high idling

Check targeted
Remote control Check that spool is free from abnormal
2 remote control Replace
valve damage and spring is free from breakage
valve

Check targeted Check that spool is free from abnormal

3 Main spool Replace
spool visually damage and spring is free from breakage

Over load relief Check targeted Free from dust entered in port relief
4 Replace
valve spool visually valve. Seat is free from abnormality

Lock valve poppet

Check targeted
5 (in case of boom and Seat is free from abnormality Replace
poppet visually
arm)

Exchange lock
Lock valve selector
valve selector of
6 (in case of boom and Check that the trouble is reversed Replace
boom/arm and
arm)
boom/arm

Holding valve spool Check that smooth Replace

Free from abnormal resistance against
7 for boom sliding of spool in Do not pull spool out of sleeve
sliding
(in case of boom) sleeve forcibly.

Holding valve relief

Check targeted
8 valve for boom Filter free from abnormal contamination Replace
spool visually
(in case of boom)

Check targeted Make sure of no problem of seals by

9 Cylinder Replace cylinder or seals
cylinder visually disassembling and investigation

NA Issued 10-2007 Bur 2-7

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
4. Poor Fine Operability

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List

Carry out service Operation No. 1 Operation is nil
1 Pressure sensor Replace pressure sensor
diagnosis All low pressure sensors are 0MPa to 0.1
MPa

In case where the reading is

Actual measuring No.8 D-1 P1 unload valve (cut valve)
largely differed from the
current value of P1/ Carry out service D-1 P2 unload valve (cut valve)
2 actually measured value,
P2 unload diagnosis See Service Diagnosis Data List
check proportional valve and
proportional valve Operation No. 1 Operation is nil
controller for possible failure.

Measure the
proportional valve
Check that P1/P2 unloads secondary
Secondary pressure secondary pressure
pressures is within the range of 2.7 MPa
3 of unload directly at the ports Replace proportional valve
or more in control lever neutral and high
proportional valve A7 and A8 of 8
idling operation
sections solenoid
block

In case where the reading is

Actual measuring No.9 E-1 P1 pump
largely differed from the
current value of P1/ Carry out service E-2 P2 pump
4 actually measured value,
P2 pump diagnosis See Service Diagnosis Data List
check proportional valve and
proportional valve Operation No. 1 Operation is nil
controller for possible failure.

Measure the pump

Check that P1/P2 pump proportional
Secondary pressure proportional valve
valve pressures are within the range of Replace proportional valve
5 of P1, P2 pump secondary pressure
0.5 to 1.0 MPa in control lever neutral and Check regulator
proportional valve directly. (Ports a3,
high idling operation
a4)

In case where the reading is

No.15 D-15 largely differed from the
Command current Carry out service
6 See Service Diagnosis Data List actually measured value,
value of short-circuit diagnosis.
Operation No. 1 Operation is nil. check proportional valve and
controller for possible failure.

Measure the
secondary pressure
Secondary pressure Control lever is neutral, high idling and
of proportional
7 of proportional valve secondary pressure is within the range of Replace proportional valve.
valve in short-circuit
in short-circuit valve. 0.5 -1.0 MPa.
valve directly. (G
Port)

Slow return check

Check that slow return check valve
valve of pilot line
8 Visual check installed on pilot line is free from dust Clean and replace
(in case of boom up
entered
or arm out)

When removing, free from abnormal

Short-circuit valve resistance against free from abnormal Replace (Check on the casing
9 Visual check
spool. damage, etc. on outside surface Spring is site for damage).
free from breakage, damage, etc.

2-8 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
5. Slow Boom Up, Insufficient Power

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List Check and replace pressure

Boom up pressure Carry out service
1 Operation No.3 boom up full lever and sensor
sensor diagnosis
relief Check remote control valve

Measure directly Check remote control valve

Check that pressure is 3.0 MPa or more
Remote control remote control When equipped with multi
2 in boom up full lever and high idling
valve pressure of boom control valve, check it while
operation
up changing lever pattern

Carry out service When there is difference

See Service Diagnosis Data List
Pump pressure diagnosis for P1, P2 between P1 and P2 pump
3 Operation No.4 boom up full lever and in
sensor pump pressures in pressures, check high
operation
operation. pressure sensor.

In case where the reading is

Actual measuring No.8 D-1 P1 unload valve (cut valve)
largely differed from the
current value of P1/ Carry out service D-1 P2 unload valve (cut valve)
4 actually measured value,
P2 unload diagnosis See Service Diagnosis Data List
check proportional valve and
proportional valve Operation No.3 Boom up full lever & relief
controller for possible failure.

Measure the
proportional valve
Check that P1/P2 unload secondary
Secondary pressure secondary pressure
pressures are within the range of 0.5~1.2
5 of P1, P2 unload directly at the ports Replace proportional valve
MPa in boom up full lever and high idling
proportional valve A7 and A5 of 8
operation
sections solenoid
block

No.9 E-1 P1 pump In case where the reading is

Actual measuring
E-2 P2 pump largely differed from the
current value of P1/ Carry out service
6 See Service Diagnosis Data List actually measured value,
P2 pump diagnosis
Operation No.4 boom up full lever & in check proportional valve and
proportional valve
operation controller for possible failure.

Measure the pump

Check that P1/P2 pump proportional
Secondary pressure proportional valve
valve pressures are within the range of
7 of P1, P2 pump secondary pressure Replace proportional valve
1.8 to 3.0 MPa in boom up full lever and
proportional valve directly (Ports a3,
high idling operation
a4)

P2 by-pass cut valve No problem for sliding ability of main

<Trouble> poppet and no contamination on orifice
8 Visual check Clean and replace
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)

Check targeted
Remote control Check that spool is free from abnormal
9 remote control Replace
valve damage and spring is free from breakage
valve

Lock valve poppet When removing, free from abnormal

Replace
<Trouble> resistance against sliding
10 Visual check (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc. on
damage)
pressures are low. outside surface

Conflux check valve When removing, free from abnormal

Replace
<Trouble> resistance against sliding
11 Visual check (Check on the casing side for
Only P2 pressure is Free from abnormal damage, etc. on
damage)
high. outside surface

NA Issued 10-2007 Bur 2-9

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

No. Sections Contents/normal value Corrective action, others

Holding valve for

When removing, free from abnormal
boom (poppet) Replace
resistance against sliding
12 <Trouble> Visual check (Check on the casing side for
Free from abnormal damage, etc. on
Both P1 and P2 damage)
outside surface
pressures are high.

Boom spool
When removing, free from abnormal Replace
<Trouble>
13 Visual check resistance against sliding (Check on the casing side for
Only P1 pressure is
Spring is free from breakage. damage)
high.

Check boom spool

and recirculation Free from abnormal resistance against
Disassembly and
14 <Trouble> sliding Replace spool assembly
investigation
Only P1 pressure is Spring is free from breakage.
low.

When removing, free from abnormal

Conflux spool
resistance against sliding Replace
<Trouble>
15 Visual check Spring is free from breakage. (Check on the casing side for
Only P2 pressure is
Free from abnormal damage, etc. on damage)
high.
outside surface

Main relief valve

See Service Diagnosis Data List
<Trouble>
16 Check set pressure Operation No.3 boom up full lever and Reset or replace
Relief pressure is
relief
low.

Over load relief

Pressure is 32 MPa or more in boom up
valve
Visual check (Head full lever and high idling. Free from dust When only relief pressure of
17 <Trouble>
side) entered in over load relief valve. Seat is boom up is low, replace valve
Relief pressure is
free from abnormality
low.

2-10 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
6. Slow Boom Down, Insufficient Power For Lifting Up Body

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List Check and replace pressure

Boom down Carry out service
1 Operation No.5 boom down full lever & in sensor.
pressure sensor diagnosis
operation Check remote control valve.

Check remote control valve

Measure remote Check that pressure is 3.0 MPa or more
Remote control When equipped with multi
2 control pressure of in boom down full lever and high idling
valve control valve, check it while
boom down directly operation
changing lever pattern.

In case where the reading is

Actual measuring P1 unload valve (cut valve)
largely differed from the
current value of P1 Carry out service See Service Diagnosis Data List
3 actually measured value,
unload proportional diagnosis Operation No.5 boom down full lever & in
check proportional valve and
valve operation
controller for possible failure.

Measure the
proportional valve Check that P1 unload secondary
Secondary pressure
secondary pressure pressures are within the range of 0.8 to
4 of P1 unload Replace proportional valve
directly at the ports 1.2 MPa in boom down full lever and high
proportional valve
A7 of 8 sections idling operation
solenoid block.

In case where the reading is

Actual measuring No.9 E-1 P1 pump
largely differed from the
current value of P1 Carry out service See Service Diagnosis Data List
5 actually measured value,
pump proportional diagnosis Operation No.5 boom down full lever & in
check proportional valve and
valve operation
controller for possible failure.

Measure the pump

Check that P1 pump proportional valve
Secondary pressure proportional valve
pressures are within the range of 2.0 to
6 of P1 pump secondary pressure Replace proportional valve
2.5 MPa in boom down full lever and high
proportional valve directly (Ports a3,
idling operation
a4)

Check that the value is not change

Check pressure sensor of
regardless of operation
travel
Actual measuring See Service Diagnosis Data List
In case where the reading is
current value of Carry out service Operation No. 1 Operation is nil
7 largely differed from the
travel straight diagnosis Operation No.18 Travel right full lever &
actually measured value,
proportional valve idling
check proportional valve and
Operation No.19 Travel left full lever &
controller for possible failure.
idling

Measure directly
Travel straight the travel straight
High idling pressure is 0.8 MPa or less
8 proportional valve proportional valve Replace proportional valve
regardless neutral/operation
secondary pressure secondary
pressure.

Check that the value is not change Check pressure sensor of

regardless of operation No 15 D-15
Actual measuring See Service Diagnosis Data List
Carry out service
9 current value of Operation No. 1 Operation is nil.
diagnosis
short-circuit valve. Operation No.18 travel right full lever &
idling. Operation No.19 travel left full
lever & idling
travel.
In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

NA Issued 10-2007 Bur 2-11

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

No. Sections Contents/normal value Corrective action, others

Measure directly
Secondary pressure the travel straight
High idling pressure is 0.8 MPa or less
10 of proportional valve proportional valve Replace proportional valve
regardless neutral/operation
in short-circuit valve secondary
pressure. (G Port)

Check targeted
Remote control Check that spool is free from abnormal
11 remote control Replace
valve damage and spring is free from breakage
valve

When removing, free from abnormal

Lock valve poppet Replace
resistance against sliding
12 <Trouble> Visual check (Check on the casing side for
Free from abnormal damage, etc. on
Boom down is low. damage)
outside surface

Holding valve When removing, free from abnormal

Replace
(poppet) resistance against sliding free from
13 Visual check (Check on the casing side for
<Trouble> abnormal damage, etc. on outside
damage)
Boom down is slow. surface

When removing, free from abnormal

Boom spool resistance against sliding Replace
14 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
Boom down is slow. outside surface damage)
Spring is free from breakage.

Check boom spool

and recirculation
Free from abnormal resistance against
<Trouble> Disassembly and
15 sliding Replace spool assembly
Machine can not be investigation
Spring is free from breakage.
lifted by supporting
with boom.

When removing, free from abnormal

short-circuit valve resistance against free from abnormal Replace (Check on the casing
16 Visual check.
spool. damage, etc. on outside surface Spring is site for damage).
free from breakage.

Main relief valve

See Service Diagnosis Data List
<Trouble>
17 Check set pressure Operation No.3 boom up full lever and Reset or replace
Relief pressure is
relief
low.

Over load relief

valve
Free from dust entered in port relief
<Trouble>
18 Visual check valve. Replace
Machine can not be
Seat is free from abnormality
lifted by supporting
with boom.

2-12 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
7. Slow Arm In, Insufficient Power

No. Sections Contents/normal value Corrective action, others

Check and replace pressure

Arm in pressure Carry out service See Service Diagnosis Data List
1 sensor
sensor diagnosis Operation No.6 arm in full lever and relief
Check remote control valve

Check remote control valve

Measure directly Check that pressure is 3.0 MPa or more
Remote control When equipped with multi
2 remote control in arm in full lever and high idling
valve pressure control valve, check it while
pressure of arm in operation
changing lever pattern

Carry out service When there is difference

See Service Diagnosis Data List
Pump pressure diagnosis for P1, P2 between P1 and P2 pump
3 Operation No.7 arm in full lever and in
sensor pump pressures in pressures, check high
operation
operation. pressure sensor

In case where the reading is

Actual measuring No.8 D-1 P1 unload valve (cut valve)
largely differed from the
current value of P1/ Carry out service D-1 P2 unload valve (cut valve)
4 actually measured value,
P2 unload diagnosis See Service Diagnosis Data List
check proportional valve and
proportional valve Operation No.6 Arm in full lever & relief
controller for possible failure.

Measure the
proportional valve
Check that P1/P2 unload secondary
Secondary pressure secondary pressure
pressures are within the range of 0.5 to
5 of P1, P2 unload directly at the ports Replace proportional valve
1.2 MPa in arm in full lever and high idling
proportional valve A7 and A5 of 8
operation.
sections solenoid
block.

No.9 E-1 P1 pump In case where the reading is

Actual measuring
E-2 P2 pump largely differed from the
current value of P1/ Carry out service
6 See Service Diagnosis Data List actually measured value,
P2 pump diagnosis
Operation No.7 Arm in full lever & in check proportional valve and
proportional valve
operation controller for possible failure.

Measure the pump Check that P1/P2 pump proportional

Secondary pressure proportional valve valve pressures are 2.0 MPa or more in
7 of P1, P2 pump secondary pressure arm in full lever and high idling operation. Replace proportional valve
proportional valve directly. (Ports a3, (Secondary pressure is affected by oil
a4) temperature and attachment weight)

See Service Diagnosis Data List In case where the reading is

Actual measuring
Operation No. 1 Operation is nil largely differed from the
current value of arm Carry out service
8 Operation No.6 Arm in full lever & relief actually measured value,
in spool 2 diagnosis
Operation No.7 Arm in full lever & in check proportional valve and
proportional valve
operation controller for possible failure.

Measure directly
Check that secondary pressure of
the proportional
proportional valve secondary pressures
Secondary pressure valve secondary
are within the range of following
9 of arm in spool 2 pressure at the Replace proportional valve
Lever neutral: 0 MPa
proportional valve ports A8 (arm 2
Motion in the air: 1.7 to 2.2 MPa
spool) of 8 sections
Arm in relief: 2.5 MPa or more
solenoid block.

NA Issued 10-2007 Bur 2-13

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
No. Sections Contents/normal value Corrective action, others

Check that the value is not change

Check pressure sensor of
regardless of operation
travel
Actual measuring See Service Diagnosis Data List
In case where the reading is
current value of Carry out service Operation No. 1 Operation is nil
10 largely differed from the
travel straight diagnosis Operation No.18 Travel right full lever &
actually measured value,
proportional valve idling
check proportional valve and
Operation No.19 Travel left full lever &
controller for possible failure.
idling

Measure directly
the proportional
valve secondary
Secondary pressure
pressure at the 0.8 MPa or less in high idling operation
11 of travel straight Replace proportional valve
ports A6 (travel regardless of neutral/operation
proportional valve
straight) of 8
sections solenoid
block

Check targeted
Remote control Check that spool is free from abnormal
12 remote control Replace
valve damage and spring is free from breakage
valve

Main relief valve

See Service Diagnosis Data List
<Trouble>
13 Check set pressure Operation No.3 boom up full lever and Reset or replace
Relief pressure is
relief
low.

Over load relief Pressure is 32 MPa or more in arm in and

valve relief.
Visual check (Head When only relief pressure of
14 <Trouble> Free from dust entered in over load relief
side) arm in is low, replace valve
P1, P2 pressure is valve.
low. Seat is free from abnormality

Over load relief Pressure is 32 MPa or more in arm out

valve and relief.
Visual check (Rod When only relief pressure of
15 <Trouble> Free from dust entered in over load relief
side) arm out is low, replace valve
P1, P2 pressure is valve.
low. Seat is free from abnormality.

When removing, free from abnormal

Arm 1 spool
resistance against sliding Replace
<Trouble>
16 Visual check Free from abnormal damage, etc. on (Check on the casing side for
P1, P2 pressure is
outside surface damage)
high.
Spring is free from breakage.

When removing, free from abnormal

Arm 2 spool
resistance against sliding Replace
<Trouble>
17 Visual check Free from abnormal damage, etc. on (Check on the casing side for
P1, P2 pressure is
outside surface damage)
high or low.
Spring is free from breakage.

Check arm 2 spool

and recirculation Free from abnormal resistance against
Disassembly and
18 <Trouble> sliding Replace spool assembly
investigation
Arm in power is Spring is free from breakage.
poor.

Check lock valve

Free from abnormal resistance against
poppet Replace
sliding
19 <Trouble> Visual check (Check on the casing side for
Free from abnormal damage, etc. on
Both P1, P2 damage)
outside surface
pressures are high.

2-14 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
8. Slow Independent Arm Out (In The Air)

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List Check and replace pressure

Arm out pressure Carry out service
1 Operation No.8 arm out full lever and sensor
sensor diagnosis
relief Check remote control valve

Check remote control valve

Measure directly Check that pressure is 3.0 MPa or more
Remote control When equipped with multi
2 remote control in arm out full lever and high idling
valve control valve, check it while
pressure of arm out operation
changing lever pattern

Carry out service When there is difference

See Service Diagnosis Data List
Pump pressure diagnosis for P1, P2 between P1 and P2 pump
3 Operation No.9 arm out full lever and in
sensor pump pressures in pressures, check high
operation
operation. pressure sensor

In case where the reading is

Actual measuring No.8 D-1 P1 unload valve (cut valve)
largely differed from the
current value of P1/ Carry out service D-1 P2 unload valve (cut valve)
4 actually measured value,
P2 unload diagnosis See Service Diagnosis Data List
check proportional valve and
proportional valve Operation No.8 Arm out full lever & relief
controller for possible failure.

Measure the
proportional valve
Check that P1/P2 unload secondary
Secondary pressure secondary pressure
pressures are within the range of 0.5 to
5 of P1, P2 unload directly at the ports Replace proportional valve
1.2 MPa in arm out full lever and high
proportional valve A7 and A5 of 8
idling operation
sections solenoid
block

No.9 E-1 P1 pump In case where the reading is

Actual measuring
E-2 P2 pump largely differed from the
current value of P1/ Carry out service
6 See Service Diagnosis Data List actually measured value,
P2 pump diagnosis
Operation No.9 Arm out full lever & in check proportional valve and
proportional valve
operation controller for possible failure.

Check that P1/P2 pump proportional

Measure the pump
valve pressures are within the range of
Secondary pressure proportional valve
1.5 to 2.7 MPa in arm out full lever and
7 of P1, P2 pump secondary pressure Replace proportional valve
high idling operation
proportional valve directly (Ports a3,
(Secondary pressure is affected by oil
a4)
temperature and attachment weight)

Check that the value is not change

Check pressure sensor of
regardless of operation
travel
Actual measuring See Service Diagnosis Data List
In case where the reading is
current value of Carry out service Operation No. 1 Operation is nil
8 largely differed from the
travel straight diagnosis Operation No.18 Travel right full lever &
actually measured value,
proportional valve idling
check proportional valve and
Operation No.19 Travel left full lever &
controller for possible failure.
idling

Measure directly
the proportional
valve secondary
Secondary pressure
pressure at the 0.8 MPa or less in high idling operation
9 of travel straight Replace proportional valve
ports A6 (travel regardless of neutral/operation
proportional valve
straight) of 8
sections solenoid
block

NA Issued 10-2007 Bur 2-15

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

No. Sections Contents/normal value Corrective action, others

Check targeted
Remote control Check that spool is free from abnormal
10 remote control Replace
valve damage and spring is free from breakage
valve

Main relief valve

See Service Diagnosis Data List
<Trouble>
11 Check set pressure Operation No.3 boom up full lever and Reset or replace
Relief pressure is
relief
low.

Over load relief

Pressure is 32 MPa or more in arm out
valve
Visual check (Rod and relief. When only relief pressure of
12 <Trouble>
side) Free from dust entered in over load relief arm out is low, replace valve
P1, P2 pressure is
valve. Seat is free from abnormality
low.

When removing, free from abnormal

Arm 1 spool resistance against sliding Replace
13 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P2 pressure is high. outside surface damage)
Spring is free from breakage.

When removing, free from abnormal

Arm 2 spool resistance against sliding Replace
14 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P1 pressure is high. outside surface damage)
Spring is free from breakage.

Check arm 2 spool

and recirculation Disassembly and Free from abnormal resistance against
15 <Trouble> investigation sliding Replace spool assembly
Both P1, P2 (spring side) Spring is free from breakage.
pressures are low.

Check lock valve

Free from abnormal resistance against
poppet Replace
sliding
16 <Trouble> Visual check (Check on the casing side for
Free from abnormal damage, etc.etc. on
Both P1, P2 damage)
outside surface
pressures are high.

2-16 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
9. Slow Bucket Digging

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List Check and replace pressure

Bucket digging Carry out service
1 Operation No.12 bucket digging full lever sensor
pressure sensor diagnosis
and relief Check remote control valve

Measure directly Check remote control valve

Check that pressure is 3.0M Pa or more
Remote control remote control When equipped with multi
2 in bucket digging full lever and high idling
valve pressure of bucket control valve, check it while
operation
digging changing lever pattern

Carry out service When there is difference

See Service Diagnosis Data List
Pump pressure diagnosis for P1, P2 between P1 and P2 pump
3 Operation No.13 Bucket digging full lever
sensor pump pressures in pressures, check high
and in operation
operation. pressure sensor

No.8 D-1 P1 unload valve (cut valve) In case where the reading is
Actual measuring
D-1 P2 unload valve (cut valve) largely differed from the
current value of P1/ Carry out service
4 See Service Diagnosis Data List actually measured value,
P2 unload diagnosis
Operation No.12 Bucket digging full lever check proportional valve and
proportional valve
& relief controller for possible failure.

Measure the
proportional valve
Check that P1/P2 unload secondary
Secondary pressure secondary pressure
pressures are within the range of 0.5 to
5 of P1, P2 unload directly at the ports Replace proportional valve
1.2 MPa in bucket digging full lever and
proportional valve A7 and A5 of 8
high idling operation
sections solenoid
block

No.9 E-1 P1 pump In case where the reading is

Actual measuring
E-2 P2 pump largely differed from the
current value of P1/ Carry out service
6 See Service Diagnosis Data List actually measured value,
P2 pump diagnosis
Operation No.13 Bucket digging full lever check proportional valve and
proportional valve
& in operation controller for possible failure.

Measure the pump Check that P1 pump proportional valve

Secondary pressure proportional valve pressures is 2.7 MPa or more and P2
7 of P1, P2 pump secondary pressure pump proportional valve pressure is 1.6 Replace proportional valve
proportional valve directly (Ports a3, to 2.2 MPa in bucket digging full lever and
a4) high idling operation.

Attachment boost Carry out service No.3 POWER BOOST Check harness
8
solenoid command diagnosis Bucket digging COMP OFF, MEAS OFF Replace solenoid valve

Attachment boost Measure switching

Check that pressure is 0 MPa in bucket
9 solenoid secondary valve secondary Replace solenoid valve
digging full lever and high idling operation
pressure pressure

In case where the reading is

Actual measuring
See Service Diagnosis Data List largely differed from the
current value of Carry out service
10 Operation No.12 Bucket digging full lever actually measured value,
travel straight diagnosis
& relief check proportional valve and
proportional valve
controller for possible failure.

NA Issued 10-2007 Bur 2-17

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

No. Sections Contents/normal value Corrective action, others

Measure directly
the proportional
valve secondary
Secondary pressure Check that travel straight secondary
pressure at the
11 of travel straight pressure is 2.7 MPa or more in bucket Replace proportional valve
ports A6 (travel
proportional valve digging full lever and high idling operation
straight) of 8
sections solenoid
block

P2 by-pass cut valve No problem for sliding ability of main

<Trouble> poppet and no contamination on orifice
12 Visual check Clean or replace
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)

When piston is removed from cover, it is

Check stroke limiter
free from abnormal resistance against Replace
<Trouble>
13 Visual check sliding (Check on the casing side for
Both P1, P2
Free from abnormal damage, etc. on damage.)
pressures are high.
outside surface

Check targeted
Remote control Check that spool is free from abnormal
14 remote control Replace
valve damage and spring is free from breakage
valve

See Service Diagnosis Data List

15 Main relief valve Check set pressure Operation No.3 Boom up full lever and Reset or replace
relief

When removing, free from abnormal

Travel straight spool resistance against sliding Replace
16 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P2 pressure is high. outside surface damage)
Spring is free from breakage.

When removing, free from abnormal

Bucket spool
resistance against sliding Replace
<Trouble>
17 Visual check Free from abnormal damage, etc. on (Check on the casing side for
Both P1, P2
outside surface damage)
pressures are high.
Spring is free from breakage.

Free from dust entered in over load relief

Over load relief Check targeted
18 valve. Replace
valve spool visually
Seat is free from abnormality.

2-18 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
10. Slow Bucket Dump

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List Check and replace pressure

Bucket dump Carry out service
1 Operation No.14 Bucket dump full lever sensor
pressure sensor diagnosis
and relief Check remote control valve

Measure directly Check remote control valve

Check that pressure is 3.0 MPa or more
Remote control remote control When equipped with multi
2 in bucket dump full lever and high idling
valve pressure of bucket control valve, check it while
operation
dump changing lever pattern

Carry out service When there is difference

See Service Diagnosis Data List
Pump pressure diagnosis for P1, P2 between P1 and P2 pump
3 Operation No.15 Bucket dump full lever
sensor pump pressures in pressures, check high
and in operation
operation. pressure sensor

No.8 D-1 P1 unload valve (cut valve) In case where the reading is
Actual measuring
D-1 P2 unload valve (cut valve) largely differed from the
current value of P1/ Carry out service
4 See Service Diagnosis Data List actually measured value,
P2 unload diagnosis
Operation No.14 Bucket dump full lever & check proportional valve and
proportional valve
relief controller for possible failure.

Measure the
proportional valve Check that P1/P2 unload secondary
Secondary pressure secondary pressure pressures are within the range of 0.5~1.2
5 of P1, P2 unload directly at the ports MPa in bucket dump full lever and high Replace proportional valve
proportional valve A7 and A5 of 8 idling operation. Replace proportional
sections solenoid valve
block

No.9 E-1 P1 pump In case where the reading is

Actual measuring
E-2 P2 pump largely differed from the
current value of P1/ Carry out service
6 See Service Diagnosis Data List actually measured value,
P2 pump diagnosis
Operation No.15 Bucket dump full lever & check proportional valve and
proportional valve.
in operation controller for possible failure.

Measure the pump Check that P1 pump proportional valve

Secondary pressure proportional valve pressures is 2.7 MPa or more and P2
7 of P1, P2 pump secondary pressure pump proportional valve pressure is 0.9 Replace proportional valve
proportional valve directly (Ports a3, to 1.4 MPa in bucket dump full lever and
a4) high idling operation.

In case where the reading is

Actual measuring
See Service Diagnosis Data List largely differed from the
current value of Carry out service
8 Operation No.14 Bucket dump full lever & actually measured value,
travel straight diagnosis
relief check proportional valve and
proportional valve
controller for possible failure.

Measure directly
the proportional
valve secondary
Secondary pressure Check that travel straight secondary
pressure at the
9 of travel straight pressure is 2.7 MPa or more in bucket Replace proportional valve
ports A6 (travel
proportional valve dump full lever and high idling operation
straight) of 8
sections solenoid
block

P2 by-pass cut valve No problem for sliding ability of main

<Trouble> poppet and no contamination on orifice
10 Visual check Clean and replace
Only P2 pressure is No problem for sliding ability of internal
low. piston (Check it through PBP2 port.)

NA Issued 10-2007 Bur 2-19

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

No. Sections Contents/normal value Corrective action, others

Check stroke limiter Replace

Free from abnormal damage and wear
11 <Trouble> Visual check (Check on the casing side for
on outside of piston inside cover
Pilot pressure is low. damage.)

Check targeted
Remote control Check that spool is free from abnormal
12 remote control Replace
valve damage and spring is free from breakage
valve

Main relief valve

See Service Diagnosis Data List
<Trouble>
13 Check set pressure Operation No.3 Boom up full lever and Reset or replace
Relief pressure is
relief
low.

When removing, free from abnormal

Travel straight spool Replace
resistance against sliding
14 <Trouble> Visual check (Check on the casing side for
Free from abnormal damage, etc. on
P2 pressure is high. damage)
outside surface

When removing, free from abnormal

Bucket spool
resistance against sliding Replace
<Trouble>
15 Visual check Free from abnormal damage, etc. on (Check on the casing side for
Both P1, P2
outside surface damage)
pressures are high.
Spring is free from breakage.

Free from dust entered in over load relief

Over load relief Check targeted
16 valve. Replace
valve spool visually
Seat is free from abnormality.

2-20 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
11. Swing Operation Not Functioned/Slow

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List Check and replace pressure

Swing pressure Carry out service
1 Operation No.11 Swing full lever and in sensor
sensor diagnosis
operation Check remote control valve

Check remote control valve

Measure directly Check that pressure is 3.0 MPa or more
Remote control When equipped with multi
2 remote control in boom up full lever and high idling
valve control valve, check it while
pressure of swing operation
changing lever pattern

No.3 F-2 SWING-BRAKE

Swing parking brake Carry out service Check swing pressure sensor
3 Lever neutral: COMP ON, MEAS ON
solenoid diagnosis Check harness
Swing: COMP OFF, MEAS OFF

Measurement of
Swing parking brake Lever neutral: 0 MPa
4 solenoid valve A2 Replace solenoid valve
solenoid In operation: 4 MPa or more
port

No contamination on spool cover (short

Shuttle valve
side) and orifice
5 <Trouble> Visual check Clean or replace
No damage on spool cover (long side)
Pilot pressure is low.
and shuttle

Carry out service

See Service Diagnosis Data List
Pump pressure diagnosis for P2
6 Operation No.11 Swing full lever and in Check high pressure sensor
sensor pump pressures in
operation
operation

In case where the reading is

Actual measuring No.8 D-2 P2 unload valve (cut valve)
largely differed from the
current value of P2 Carry out service See Service Diagnosis Data List
7 actually measured value,
unload proportional diagnosis Operation No.11 Swing full lever & in
check proportional valve and
valve operation
controller for possible failure.

Measure the
proportional valve Check that P2 unload secondary
Secondary pressure
secondary pressure pressures are within the range of 0.5 to
8 of P2 unload Replace proportional valve
directly at the ports 1.2 MPa in swing full lever and high idling
proportional valve
A5 of 8 sections operation
solenoid block

In case where the reading is

Actual measuring No.9 E-2 P2 pump
largely differed from the
current value of P2 Carry out service See Service Diagnosis Data List
9 actually measured value,
pump proportional diagnosis Operation No.11 Swing full lever & in
check proportional valve and
valve operation
controller for possible failure.

Measure the pump

Secondary pressure proportional valve Check that P2 pump proportional valve
10 of P2 pump secondary pressure pressure is 2.7 MPa or more in swing full Replace proportional valve
proportional valve directly (Ports a3, lever and high idling operation
a4)

Check that the value is not change

Actual measuring Check pressure sensor of
regardless of operation
current value of travel
See Service Diagnosis Data List
travel straight In case where the reading is
Carry out service Operation No. 1 Operation is nil
11 proportional valve largely differed from the
diagnosis Operation No.18 Travel right full lever &
(Check this trouble actually measured value,
idling
by only swing check proportional valve and
Operation No.19 Travel left full lever &
operation) controller for possible failure.
idling

NA Issued 10-2007 Bur 2-21

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE

No. Sections Contents/normal value Corrective action, others

Measure directly
Secondary pressure the proportional
of travel straight valve secondary
proportional valve pressure at the 0.8 MPa or less in high idling operation
12 Replace proportional valve
(Check this trouble ports A6 (travel regardless of neutral/operation
by only swing straight) of 8
operation) sections solenoid
block

Check that the value is not change Check pressure sensor of

regardless of operation No 15 D-15
See Service Diagnosis Data List
Command current Carry out service
13 Operation No. 1 Operation is nil.
value of short-circuit. diagnosis
Operation No.18 travel right full lever &
idling. Operation No.19 travel left full
lever & idling
travel.
In case where the reading is
largely differed from the
actually measured value,
check proportional valve and
controller for possible failure.

Measure directly
Secondary pressure the secondary
of proportional valve pressure of the 0.8 MPa or less in high idling operation
14 Replace proportional valve.
in short-circuit valve. proportional valve regardless of neutral/operation.
in short-circuit
valve. (G Port)

Check targeted
Remote control Check that spool is free from abnormal
15 remote control Replace
valve damage and spring is free from breakage
valve

When removing, free from abnormal

Travel straight spool resistance against sliding Replace
16 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P2 pressure is low. outside surface damage)
Spring is free from breakage.

When removing, free from abnormal

Swing spool resistance against sliding Replace
17 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P2 pressure is high. outside surface damage)
Spring is free from breakage.

When removing, free from abnormal

Short-circuit valve resistance against free from abnormal Replace (Check on the casing
18 Visual check.
spool. damage, etc. on outside surface Spring is site for damage).
free from breakage.

Swing relief valve

See Service Diagnosis Data List
<Trouble>
19 Check set pressure Operation No.10 Swing full lever and Reset or replace
Relief pressure is
relief
low.

Inner parts (cylinder block, piston, valve

brake etc.) are to be free from abnormal
20 Swing motor Visual check resistance against sliding. Replace
Free from abnormal damage, etc. on
outside surface (brake plate etc.)

Take sample oil

Swing reduction Sampling oil does not include a lot of Disassemble and inspect
21 from swing
gear oil metal powder. reduction gear
reduction gear drain

Tooth surface is not worn abnormally and

22 Swing reduction Visual check Replace
is not chipped.

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 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
12. Noise During Swing Operation

No. Sections Contents/normal value Corrective action, others

No.3 F-2 SWING-BRAKE

Swing parking brake Carry out service Check swing pressure sensor
1 Lever neutral: COMP ON, MEAS ON
solenoid diagnosis Check harness
Swing: COMP OFF, MEAS OFF

Measurement of
Lever neutral: 0 MPa
2 solenoid valve A2 Replace solenoid valve
In operation: 4 MPa or more
port

Boost check valve When removing, free from abnormal

3 (Sound of cavitation Visual check resistance against sliding Replace
at stopping) Spring is free from breakage.

By-pass check valve When removing, free from abnormal

4 (Sound of cavitation Visual check resistance against sliding Replace
at stopping) Spring is free from breakage.

Swing motor
Disassemble and inspect abnormal wear
5 (Brake valve/friction Visual check Replace
and scuffing
plate)

When removing, free from abnormal

6 Swing motor piston Visual check resistance against sliding Replace
Spring is free from breakage.

Take sample oil

Swing reduction from swing Sampling oil does not include a lot of Disassemble and inspect
7
gear oil reduction gear metal powder. reduction gear
drain.

Tooth surface has no abnormally worn

8 Swing reduction Visual check Replace
and chipped.

NA Issued 10-2007 Bur 2-23

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
13. Swing on a Slope Drifts When Control Lever is in Neutral Position

No. Sections Contents/normal value Corrective action, others

•Engine stop & starter key ON

Swing pressure Carry out service Check and replace pressure
1 All pilot low pressure sensors are within
sensor diagnosis sensor
range of 0 to 0.1 MPa.

Check targeted
Remote control Check that spool is free from abnormal
2 remote control Replace
valve damage and spring is free from breakage
valve

Check swing pressure sensor

No.3 F-2 SWING-BRAKE
Swing parking brake Carry out service Check harness
3 Lever neutral: COMP ON, MEAS ON
solenoid diagnosis Check parking brake release
Swing: COMP OFF, MEAS OFF
switch

Measurement of
Lever neutral: 0 MPa
4 solenoid valve A2 Replace solenoid valve
In operation: 4 MPa or more
port

Swing motor
Disassemble and inspect abnormal wear
5 (Brake valve/friction Visual check Replace
and scuffing
plate)

Piston and friction plate do not have

6 Parking brake Visual check abnormal resistance against sliding Replace
Free from spring damage

2-24 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
14. Swing Drifts When Swing Operation is Stopped

No. Sections Contents/normal value Corrective action, others

Shuttle valve No contamination on spool cover (short

1 <Trouble> Visual check side) and orifice. No damage on spool Clean or replace
Pilot pressure is low cover (long side) and shuttle.

Engine stop & starter key ON

Swing pressure Carry out service
2 All pilot low pressure sensors are within Replace pressure sensor
sensor diagnosis
range of 0 to 0.1 MPa.

Swing relief valve

See Service Diagnosis Data List
<Trouble>
3 Check set pressure Operation No.10 Swing full lever and Reset or replace
Relief pressure is
relief
low.

Free from dirt entering

Sliding part should be free from foreign
4 Anti-reaction valve Visual check Clean or replace
matter entering, abnormal damage and
wear.

Check targeted
Remote control Check that spool is free from abnormal
5 remote control Replace
valve damage and spring is free from breakage
valve

Inner parts (cylinder block, piston, valve

brake etc.) are to be free from abnormal
6 Swing motor Visual check resistance against sliding. Replace
Free from abnormal damage, etc. on
outside surface (brake plate etc.)

NA Issued 10-2007 Bur 2-25

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
15. Slow Travel Speed/Weak

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List

Operation No.18 Travel right full lever Check and replace pressure
Travel right and left Carry out service
1 and idling sensor
pressure sensor diagnosis
Operation No.19 Travel left full lever and Check remote control valve
idling

Measure directly
Check that pressure is 2.1 MPa or more
Remote control remote control
2 in travel right (left), forward (reverse) full Check remote control valve
valve pressure of travel
lever and high idling operation
right and left

No.9 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve) In case where the reading is
Actual measuring
See Service Diagnosis Data List largely differed from the
current value of P1/ Carry out service
3 Operation No.18 Travel right full lever & actually measured value,
P2 unload diagnosis
idling check proportional valve and
proportional valve
Operation No.19 Travel left full lever & controller for possible failure.
idling

Measure the Check that P1/P2 unload secondary

proportional valve pressures are within the range of
Secondary pressure secondary pressure followings in travel right (left), forward
4 of P1, P2 unload directly at the ports (reverse) full lever and high idling Replace proportional valve
proportional valve A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa

No.9 E-1 P1 pump

E-2 P2 pump In case where the reading is
Actual measuring
See Service Diagnosis Data List largely differed from the
current value of P1/ Carry out service
5 Operation No.18 Travel right full lever & actually measured value,
P2 pump diagnosis
idling check proportional valve and
proportional valve
Operation No.19 Travel left full lever & controller for possible failure.
idling

Check that P1/P2 unload secondary

Measure the pump pressures are within the range of
Secondary pressure proportional valve followings in travel right (left), forward
6 of P1, P2 pump secondary pressure (reverse) full lever and high idling Replace proportional valve
proportional valve directly (Ports a3, operation
a4) Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more

Check that the value is not change Check voltage of low pressure
regardless of operation sensor other than sensor for
Actual measuring See Service Diagnosis Data List travel
current value of Carry out service Operation No. 1 Operation is nil In case where the reading is
7
travel straight diagnosis Operation No.18 Travel right full lever & largely differed from the
proportional valve idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve and
idling controller for possible failure

Measure directly
Secondary pressure
the proportional 0.8 MPa or less in high idling operation
8 of travel straight Replace proportional valve
valve secondary regardless of neutral/operation
proportional valve
pressure

2-26 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
No. Sections Contents/normal value Corrective action, others

Check that the value is not change Check pressure sensor of

regardless of operation No 15 D-15 travel.
See Service Diagnosis Data List In case where the reading is
Command current Carry out service
9 Operation No. 1 Operation is nil. largely differed from the
value of short-circuit diagnosis
Operation No.18 travel right full lever & actually measured value,
idling. Operation No.19 travel left full check proportional valve and
lever & idling controller for possible failure.

Measure directly
the secondary
Secondary pressure
pressure of the 0.8 MPa or less in high idling operation
10 of proportional valve Replace proportional valve.
proportional valve regardless of neutral/operation.
in short-circuit valve.
in short-circuit
valve. (G Port)

Check that spool is free from abnormal

Check targeted
Remote control damage and spring is free from breakage
11 remote control Replace
valve Check sealing ability of shuttle valve and
valve
entry of dust in orifice

When removing, free from abnormal

Travel straight spool resistance against sliding Replace
12 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P1 pressure is high. outside surface damage)
Spring is free from breakage.

When removing, free from abnormal

Travel spool
resistance against sliding Replace
<Trouble> Visual check of
13 Free from abnormal damage, etc. on (Check on the casing side for
Pump pressure is targeted spool
outside surface damage)
high.
Spring is free from breakage.

When removing, free from abnormal

short-circuit valve resistance against free from abnormal Replace (Check on the casing
14 Visual check.
spool. damage, etc. on outside surface Spring is site for damage).
free from breakage

Check P1 and P2 pump pressures are 32 If P1 is low, right travel motor

Travel motor relief MPa or more in right and left travel levers relief valve is failed.
15 Check set pressure
valve full lever (relief operation at locked If P2 is low, left travel motor
crawler belt) and high idling relief valve is failed.

Inner parts (piston, cylinder block, valve

plate, brake valve spool) are to be free
16 Travel motor Visual check from abnormal resistance against sliding. Replace
Free from abnormal damage, etc. on
outside surface (brake plate etc.)

When removing, free from abnormal

Parking brake in resistance against sliding
17 Visual check Replace
travel motor No sticking on friction plate and separator
plate

Take sample oil

Travel reduction Sampling oil does not include a lot of Disassemble and inspect
18 from travel
gear oil metal powder. reduction gear
reduction gear drain

Tooth surface is not worn abnormally and

19 Travel reduction Visual check Replace
is not chipped.

NA Issued 10-2007 Bur 2-27

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
16. Travel Deviation

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List

Operation No.18 Travel right full lever Check and replace pressure
Travel right and left Carry out service
1 and idling sensor
pressure sensor diagnosis
Operation No.19 Travel left full lever and Check remote control valve
idling

Measure directly
Check that pressure is 2.1 MPa or more
Remote control remote control
2 in travel right (left), forward (reverse) full Check remote control valve
valve pressure of travel
lever and high idling operation
right and left

Check that the value is not change Check voltage of low pressure
regardless of operation sensor other than sensor for
Actual measuring See Service Diagnosis Data List travel
current value of Carry out service Operation No. 1 Operation is nil In case where the reading is
3
travel straight diagnosis Operation No.18 Travel right full lever & largely differed from the
proportional valve idling actually measured value,
Operation No.19 Travel left full lever & check proportional valve and
idling controller for possible failure.

Measure directly
Secondary pressure
the proportional 0.8 MPa or less in high idling operation
4 of travel straight Replace proportional valve
valve secondary regardless of neutral/operation
proportional valve
pressure

No.8 D-1 P1 unload valve (cut valve)

D-1 P2 unload valve (cut valve) In case where the reading is
Actual measuring
See Service Diagnosis Data List largely differed from the
current value of P1/ Carry out service
5 Operation No.18 Travel right full lever & actually measured value,
P2 unload diagnosis
idling check proportional valve and
proportional valve
Operation No.19 Travel left full lever & controller for possible failure.
idling

Measure the Check that P1/P2 unload secondary

proportional valve pressures are within the range of
Secondary pressure secondary pressure followings in travel right (left), forward
6 of P1, P2 unload directly at the ports (reverse) full lever and high idling Replace proportional valve
proportional valve A7 and A5 of 8 operation
sections solenoid Travel right (P1 unload): 0.5 to 1.0 MPa
block Travel left (P2 unload): 0.5 to 1.0 MPa

No.9 E-1 P1 pump

E-2 P2 pump In case where the reading is
Actual measuring
See Service Diagnosis Data List largely differed from the
current value of P1/ Carry out service
7 Operation No.18 Travel right full lever & actually measured value,
P2 pump diagnosis
idling check proportional valve and
proportional valve
Operation No.19 Travel left full lever & controller for possible failure.
idling

Check that P1/P2 unload secondary

Measure the pump pressures are within the range of
Secondary pressure proportional valve followings in travel right (left), forward
8 of P1, P2 pump secondary pressure (reverse) full lever and high idling Replace proportional valve
proportional valve directly (Ports a3, operation
a4) Travel right (P1 pump): 2.7 MPa or more
Travel left (P2 pump): 2.7 MPa or more

2-28 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
No. Sections Contents/normal value Corrective action, others

If the direction is changed,

Exchange delivery inspect a pump. If the direction
9 Exchange P1 for P2 Check the direction of deviation
pipe of P1 for P2 is not changed, inspect a valve
and travel unit.

Check that spool is free from abnormal

Check targeted
Remote control damage and spring is free from breakage
10 remote control Replace
valve Check sealing ability of shuttle valve and
valve
entry of dust in orifice

When removing, free from abnormal

Travel straight spool resistance against sliding Replace
11 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P1 pressure is high. outside surface damage)
Spring is free from breakage

When removing, free from abnormal

Travel spool
resistance against sliding Replace
<Trouble> Visual check of
12 Free from abnormal damage, etc. on (Check on the casing side for
Pump pressure is targeted spool
outside surface damage)
high.
Spring is free from breakage

If P1 is low, right travel

Check P1 and P2 pump pressures are 32
motorÅfs relief valve is failed.
Travel motor relief MPa or more in right and left travel levers
13 Check set pressure If P2 is low, left travel motorÅfs
valve full lever (relief operation at locked
relief valve is failed.
crawler belt) and high idling
Replace as necessary

Inner parts (piston, cylinder block, valve

plate, brake valve spool) are to be free
14 Travel motor Visual check from abnormal resistance against sliding. Replace
Free from abnormal damage, etc. on
outside surface (brake plate etc.)

Take sample oil

Travel reduction Sampling oil does not include a lot of Disassemble and inspect
15 from travel
gear oil metal powder. reduction gear
reduction gear drain

Tooth surface is not worn abnormally and

16 Travel reduction Visual check Replace
is not chipped.

When removing, free from abnormal

resistance against sliding
17 Pump regulator Visual check Free from abnormal damage, etc. on Replace
outside surface
Spring free from breakage, damage, etc.

When removing, inside parts (cylinder

block, piston, valve plate, shaft, etc.) are
18 Pump Visual check Replace
free from abnormal resistance against
sliding, abnormal damage, etc.

NA Issued 10-2007 Bur 2-29

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
17. Travel 1st/2nd Speed Not Changed
(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the
speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic
speed change.)

No. Sections Contents/normal value Corrective action, others

Switch travel 1/2 speed to 2nd speed Check pressure sensor

Travel 1/2 speed Carry out service No.3 F-3 1/2-TRAVEL Check harness
1
switching solenoid diagnosis Lever neutral COMP OFF, MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON, MEAS ON on gauge cluster

Measure A3 port
Travel 1/2 speed Lever neutral: 0 MPa
2 pressure on Replace solenoid valve
switching solenoid In operation: 4 MPa or more
solenoid valve

Replace
1/2 speed switching Check that spool is free from abnormal
3 Visual check (Check on the casing side for
spool in travel motor damage and spring is free from breakage
damage)

1/2 speed switching

4 Visual check Free from entry of dust Remove dust or replace
orifice in travel motor

Replace
Tilting piston in Free from abnormal wear on piston and
5 Visual check (Check on the casing side for
travel motor seal
damage)

18. Travel Parking on a Slope is Not Held

No. Sections Contents/normal value Corrective action, others

Engine stop & starter key switch is ON Check pressure sensor and
Pilot pressure Carry out service
1 Targeted pilot low pressure sensor is in replace as necessary
sensor diagnosis
range of 0 to 0.1 MPa Check remote control valve

Check targeted
Remote control Check that spool is free from abnormal
2 remote control Replace
valve damage and spring is free from breakage
valve

When removing, free from abnormal

Parking brake in
3 Visual check resistance against sliding Replace
travel motor
Spring free from breakage, damage, etc.

Orifice of passage
4 for parking brake in Visual check Free from entry of dust Remove dust or replace
travel motor

2-30 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
19. Travel Does Not Run Straightly When Both Crawlers and Attachment Operated Simultaneously
.

No. Sections Contents/normal value Corrective action, others

No. 8 D-3 S-TRAVEL is should be COMP Check voltage of low pressure

557 mA and MEAS 557±30 mA in both sensor other than travel
Actual measuring travel full lever and in boom-up full lever sensor
current value of Carry out service at high idling (Command value is In case where the reading is
1
travel straight diagnosis changed according to operation. Above largely differed from the
proportional valve mentioned values indicate while boom- actually measured value,
up and full lever operation are check proportional valve and
performed). controller for possible failure.

Check secondary pressure is within

range of 1.7 to 2.1 MPa in both travel full
Measure directly
Secondary pressure lever and in boom-up full lever at high
the proportional
2 of travel straight idling. (Command value is changed Replace proportional valve
valve secondary
proportional valve according to operation. Above mentioned
pressure
values indicate while boom-up and full
lever operation are performed).

Check voltage of low pressure

sensor other than travel
No 15 D-15 is should be COMP 530 mA sensor.
Command current
Carry out service and MEAS 530±30 mA in both travel full In case where the reading is
3 value short-circuit
diagnosis. lever and in boom-up full lever at high largely differed from the
valve
idling actually measured value,
check proportional valve and
controller for possible failure.

Measure directly
the secondary Check secondary pressure is within
Secondary pressure
pressure of the range of 1.5 to 1.9 MPa in both travel full
4 of proportional valve Replace proportional valve.
proportional valve lever and in boom-up full lever at high
in short-circuit valve.
in short-circuit idling.
valve. (G Port)

When removing, free from abnormal

resistance against sliding Replace
5 Travel straight spool Visual check Free from abnormal damage, etc. on (Check on the casing side for
outside surface damage)
Spring is free from breakage.

When removing, free from abnormal

Short-circuit valve resistance against free from abnormal Replace (Check on the casing
6 Visual check.
spool. damage, etc. on outside surface Spring is site for damage).
free from breakage.

NA Issued 10-2007 Bur 2-31

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
20. Slow Breaker (Crusher) Operation, Weak Power
(In case of conflux, check p1 unload/pump and travel straight)

No. Sections Contents/normal value Corrective action, others

See Service Diagnosis Data List Check and replace pressure

Pressure sensor for Carry out service
1 Operation No.16 P2 side OPT full lever sensor
optional attachment diagnosis
and relief Check remote control valve

Measure directly
Check that pressure is 2.1 MPa or more
Remote control remote control
2 in optional attachment full lever and high Check remote control valve
valve pressure of travel
idling operation
right and left

•In case where the reading is

Actual measuring
See Service Diagnosis Data List largely differed from the
current value of P1/ Carry out service
3 Operation No.16 P2 side OPT full lever actually measured value,
P2 unload diagnosis
and relief check proportional valve and
proportional valve
controller for possible failure.

Measure the
proportional valve
Secondary pressure secondary pressure Check that P1/P2 unload secondary
4 of P1, P2 unload directly at the ports pressures are within the range of 0.5 to Replace proportional valve
proportional valve A7 and A5 of 8 1.2 MPa
sections solenoid
block

Check voltage of low pressure

sensor other than sensor for
Actual measuring optional attachment
See Service Diagnosis Data List
current value of Carry out service In case where the reading is
5 Operation No.16 P2 side OPT full lever &
travel straight diagnosis largely differed from the
relief
proportional valve actually measured value,
check proportional valve and
controller for possible failure.

Measure directly
the proportional
valve secondary Check that travel straight secondary
Secondary pressure
pressure at the pressure is 2.7 MPa or more in optional
6 of travel straight Replace proportional valve
ports A6 (travel attachment full lever and high idling
proportional valve
straight) of 8 operation
sections solenoid
block

P1 by-pass cut valve No problem for sliding ability of main

<Trouble> poppet and no contamination on orifice
7 Visual check Clean or replace
Only P1 pressure is No problem for sliding ability of internal
low. piston (Check it through PBp2 port.)

See Service Diagnosis Data List

Operation No.16 P2 side OPT full lever
8 Relief pressure Check set pressure and relief Reset or replace
(Set value of factory shipment is 24.5
MPa.)

Check targeted
Remote control Check sealing ability of shuttle valve and
9 remote control Replace
valve entry of dust in orifice.
valve

2-32 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
No. Sections Contents/normal value Corrective action, others

When removing, free from abnormal

Travel straight spool resistance against sliding Replace
10 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P1 pressure is high. outside surface damage)
Spring is free from breakage.

Spool for optional When removing, free from abnormal

attachment resistance against sliding Replace
11 <Trouble> Visual check Free from abnormal damage, etc. on (Check on the casing side for
P1, P2 pressures outside surface damage)
are high. Spring is free from breakage.

Free from dust entered in over load relief

Over load relief Check targeted
12 valve Replace
valve spool visually
Seat is free from abnormality.

NA Issued 10-2007 Bur 2-33

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
21. Option Selector Valve Malfunction: Not Switched To Breaker Circuit.
(Indication of failure is displayed. For reference, see ACTION OF OPTIONAL SELECTOR SOLENOID VALVE)

No. Sections Contents/normal value Corrective action, others

When removing, free from abnormal

resistance against sliding Replace
1 N&B selector spool Visual check Free from abnormal damage, etc. on (Check on the casing side for
outside surface damage)
Spring is free from breakage

N&B selector Screw for Check that the error indication is

2 Replace solenoid valve
solenoid emergency disappeared by turning emergency screw

No.11 F-4 Option selector is B mode

N&B selector Carry out service COMP ON, MEAS ON Check solenoid valve
3
solenoid diagnosis Spool position BRK Check harness
Selector switch BRK

No.16 B-11
N&B selector Carry out service Data List Check pressure sensor
4
pressure sensor diagnosis 3.0 MPa at B mode and 0.0 MPa at A Check harness
mode

22. Option Selector Valve Malfunction: Not Switched To Nibbler Circuit.

(Indication of failure is displayed. For reference, see Action of optional selector solenoid valve)

No. Sections Contents/normal value Corrective action, others

When removing, free from abnormal

resistance against sliding Replace
1 N&B selector spool Visual check Free from abnormal damage, etc. on (Check on the casing side for
outside surface damage)
Spring is free from breakage.

No.11 F-4 Option selector is A mode

N&B selector Carry out service COMP OFF, MEAS OFF Check solenoid valve
2
solenoid diagnosis Spool position NIB Check harness
Selector switch NIB

2-34 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
Table 1 - Action Of Optional Selector Solenoid Valve

Safety Safety Optional Selector

lock lock selector valve Failure
Engine Work Spool
No. lever lever valve detecting Warning display diagnosis
condition mode position
SW's relay's COMP. pressure display
input output MEAS. sensor

1 Running ON OFF A OFF Nibbler Normal — —

SELECTOR VALVE [F042] displayed
2 Running ON OFF A ON Breaker Normal
FAILURE simultaneously
SELECTOR VALVE
3 Running ON OFF A OFF Breaker Normal —
FAILURE

4 Running ON OFF A ON Nibbler Normal — [F042] displayed

5 Running ON OFF B ON Breaker Normal — —

SELECTOR VALVE [F043] displayed
6 Running ON OFF B OFF Nibbler Normal
FAILURE simultaneously
SELECTOR VALVE
7 Running ON OFF B ON N&B Normal —
FAILURE

8 Running ON OFF B OFF Breaker Normal — [F043] displayed

SELECTOR VALVE
9 Running ON OFF — — — Failure [B113] displayed
FAILURE

10 Stopping — — — — — — — —

11 — OFF — — — — — — —

12 — — ON — — — — — —

NA Issued 10-2007 Bur 2-35

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
ELECTRIC SYSTEMS

Wiring Checking Procedure

Check for continuity between connector terminals, CONNECTOR
presence or absences of short-circuit with other
wires, and presence or absences of short-circuit with
machine body grounding.
WIRE
1. Checking for disconnection between connectors.
(When both ends measurement is easy because
TESTER
of short distance between connectors) SM0104

Measure the resistance using tester.

Pull out opposite connector first.
GRAPHIC_ID Figure 1
When the resistance is zero (0), it is in normal
condition.

(When both ends measurement is difficult because of

long distance between connectors)
Measure the resistance using tester.
Pull out opposite connector first.
JUMPER
Where the resistance is zero (0), if the terminal on WIRE
one side is connected to frame body grounding with
jumper wire, it is in normal condition.
The resistance is 1 M or more when the terminal TESTER
o n o n e s i d e i s n o t c o n n e c t e d t o fra m e b o d y FRAME BODY GROUNDING
grounding with jumper wire, it is in normal condition. SM0105

GRAPHIC_ID Figure 2

2. Checking for presence or absence of short-

circuit with machine body
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1 M or more, it is in
normal condition.

TESTER
FRAME BODY GROUNDING
SM0106

GRAPHIC_ID Figure 3

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 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
3. Checking for presence or absence of short-
circuit between wirings.
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1 M or more, it is in
normal condition.

TESTER
SM0107

GRAPHIC_ID Figure 4

4. Checking connector terminal for contact

Insert male terminal into female terminal unit,
and then check that the inser ting force is
equivalent to other female terminals.
If looseness is there, replace the female terminal INSERT
with new one.
Clean the dirt terminal.
MALE TERMINAL FEMALE TERMINAL

SM0108

GRAPHIC_ID Figure 5

NOTE: Do not insert the male terminal if the

thickness differs. It may cause a loose connection.
5. Caution which should be paid in measuring
voltage
When measuring the power supply to electric
equipment at connector position with the
grounding ter minal contained inside of
con ne cto r, me asu re th e vo lt ag e be twe en
grounding inside of connector and power
terminal.
When measuring the voltage between frame
body grounding and power source, the
disconnection of wiring to grounding inside of
connector cannot be identified.
Since the voltage may var y between with
connector connected and with connector not
connected. Measure the voltage with each
connector connected whenever possible.
NA Issued 10-2007 Bur 2-37
 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
6. Checking the general view of connector When water intruding is found, check rubber plug
A. Check the terminal crimped condition. for damage and also that the sealing is fitted
properly.
Pull one electric cable with the about 3kg force, CRIMPED
PART
and make sure that the cable does not come out
of the terminal.
When came out, replace the terminal and crimp it RUBBER
PLUG
again. RECEPTACLE.
CONTACT
B. Check connector for imperfect insertion PLUG
SEALING
Check that all top ends form a line on the same (is housed in plug)
position as seen from the connector engaged DOUBLE LOCK
PLATE FOR PLUG
side.
DOUBLE LOCK
When moved along, push it in further through PLATE FOR CAP

wire inserting hole. CAP

C. Check connector for intruding of water. TAB.CONTACT

SM0109
Pull out the connector and check that the inside GRAPHIC_ID Figure 6
is free from intruding of water.

7. When abnormality occurs at intervals.

When the abnormality situation can not be
reoccurred during checking operation, try the
following operations.
A. Check that variable of display exists or not on
the service diagnosis screen while shaking the
harness or giving shock by operating the
machine.
B. Check that variables of resistance and voltage
exist or not using tester while shaking the
harness.
C. Turn starter switch on and apply electricity
continuously, and check it again after the
temperature of wiring and equipment was
raised.

8. Checking on body grounding

Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose connection
due to corrosion.

There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding
fixed together with horn, body grounding placed
on attaching section of boom working light.
Block of grounding is located
under floor plate of cab.
SM0110
GRAPHIC_ID Figure 7

2-38 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
Trouble
1. Engine does not stop.
2. CPU DATA COMMUNICATION ERROR is displayed on multi display.
3. Auto accel does not actuate. (The engine speed does not automatically slow down.)
4. Auto accel does not actuate. (The engine speed does not automatically speed up.)
5. Wiper does not function.

Engine Does Not Stop

No. Sections Contents/normal value Corrective action, others

Check signal of
No.4 K-3 Key switch Check continuity between
starter key switch
1 Starter key switch OFF at starter key switch OFF position terminals of starter switch
ON by carrying out
ON at starter key switch ON position using tester
service diagnosis.

When ON is
displayed with the
starter switch OFF,
No.4 K-3 Key switch
Engine forcible stop then pull out R-25 Check on engine forcible stop
2 OFF at starter key switch OFF position
relay engine forcible stop relay
ON at starter key switch ON position
relay and carry out
the service
diagnosis.

Voltage between
line No.62 among
Check harness
starter switch,
Check diode D-9 between
3 Wiring engine forcible stop 0 V when starter switch is OFF
starter switch and auto idling
relay, engine stop
stop relay 1
solenoid and the
body grounding

CPU Data Communication Error is Displayed on Multi Display

No. Sections Contents/normal value Corrective action, others

Check harness
1 Fuse No.1 fuse (5 A) Not blown fuse
Replace fuse

Engine speed varies according to accel

potentiometer operation. Check mechatro controller
2 Mechatro controller Accel control
(Use remote control because the auto and replace as necessary
accel function is working.)

Transmission circuit
line No.770 from
3 Wiring See WIRING CHECKING PROCEDURE Repair wiring
mechatro controller
to gauge cluster

4 Gauge cluster Gauge cluster Replace gauge cluster

NA Issued 10-2007 Bur 2-39

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
Auto Accel Does Not Actuate.
(The engine speed does not automatically slow down.)

No. Sections Contents/normal value Corrective action, others

Check engine No.2 G-5 WATER TEMP

coolant Auto accel does not work in the
Engine coolant Replace engine coolant
1 temperature by temperature -15 °C or less.
temperature sensor
carrying out service Warm up and raise the coolant
diagnosis. temperature to – 15 °C or more

Mark DISPLAY/NOT DISPLAY for auto

Indication of auto
2 Gauge cluster accel switches by auto accel switch Replace gauge cluster
accel
operation on gauge cluster.

Each control pressure of No.5 and No.6

Low pressure
3 Service diagnosis is in the range of 0~0.1 MPa at control Check low pressure sensor
sensor
lever neutral position.

Auto Accel Does Not Actuate.

(The engine speed does not automatically speed up.

No. Sections Contents/normal value Corrective action, others

Low pressure Each control pressure of No.5 and No.6

1 Service diagnosis Check low pressure sensor
sensor is raised with control lever operated.

2-40 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
Wiper Does Not Function.

Wiping range of
forward and
reverse movements

Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position

SM0111

GRAPHIC_1D Figure 8

No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.20 Replace fuse

Check wiper interlock switch

SW-19: Service diagnosis No.19 D125 and repair it if necessary
2 Wiper interlock Wiper switch display (D125) is OFF with front window closed. Check according to WIRING
switch CHECKING PROCEDURE
and repair it if necessary

Check according to WIRING

Service diagnosis No.25 Wiper system
CHECKING PROCEDURE

Switch action in operation

Rise up limit switch
3 built-in wiper motor
Normal condition
Reverse limit switch
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF

GRAPHIC_ID Figure 9

4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
relay Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
R-30: Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
f th
GRAPHIC_ID i t t t OFF ll l ' t t if Figure 10
relay

NA Issued 10-2007 Bur 2-41

 SECTION 2 - TROUBLESHOOTING
CHAPTER 2 - TROUBLESHOOTING BY TROUBLE
NOTES

2-42 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING

CHAPTER 3

E175B
EXCAVATOR

TROUBLESHOOTING BY
DIAGNOSIS MODE

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

3-II Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING

CHAPTER 3
TROUBLESHOOTING BY DIAGNOSIS MODE
TABLE OF CONTENTS

TROUBLE DIAGNOSIS MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

How To Use and Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Table 1 - Failure Diagnosis Mode-1/ Diagnosis Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Table 2 - Failure Diagnosis Mode-1/ Diagnosis and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

NA Issued 10-2007 Bur 3-1

 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE

NOTES

3-2 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE
TROUBLE DIAGNOSIS MODE
The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be
detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal
output.
Function: There are two types of trouble diagnosis mode.
1. Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine
system.
2. Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are automatically
actuated, the sensor detects the machine condition and the mechatro controller identifies the normal condition or
failed condition of the system.

HOW TO USE AND FLOW CHART

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

NA Issued 10-2007 Bur 3-3

 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE

No.1 No.2 No.3

SELECT SWITCH
LANGUAGE/LOGO 8 FAULT DIAG MODE DIAG MODE 1
BUZZER STOP SWITCH
ADJUSTING MODE 1 DIAG MODE 2
PRESET BY FACTORY
FEED SCREEN CHANGE SWITCH

CASE OF DIAG MODE 1

SENSOR CHECK START ENG LOWER BOOM DIAG MODE 1

ENGINE SPEED
RELEASE LOCK In diagnosis
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND LEVER START operation
PROPO-VALVE About 15 minutes
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA

For
Forthe
tthediagnosing
diagnosingitems,
items,see
seeTable
Table 48-1.
1.
When
Whenrequired
requiredto
tostop
stopin indiagnosis
diagnosis
Turn engine on operation,press
operation, pressthe
thebuzzer
buzzerstop
stopswitch
switch
manually. BACK TO No.3 and
andthetheoperation
operationisisforcedly
forcedlystopped.
stopped.

The data at the time of judgment

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

The other judgments can be

Engine stops confirmed with the feed button.
automatically. RESULT OF DIAGNOSIS

When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm

P1 UN-LOAD SPOOL NG NG PRESSURE

C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA

The suspected trouble sections are displayed in order of

possibility. The suspected three sections in maximum are
BACK TO No.3 displayed. When desired to see other suspected trouble sections,
press feed " " button. For diagnosis results and corrective
actions to be taken, see Table 2.

SM0114

GRAPHIC_1D Figure 1
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the
machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death.
Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start
operating the trouble diagnosis mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve
for possible abnormality.
3. Check that the commands of proportional valve and select valve do not largely differ from the actually
measured values through the service diagnosis.
4. The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
5. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an
example. When multiple troubles are occurred at the same time, there is a case no accordance of diagnosis
obtained. In this case, contact our dealer/distributor.
6. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.

3-4 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE

No.4 CASE OF DIAG MODE 2

SENSOR CHECK START ENG

ENGINE SPEED
LOWER BOOM DIAG MODE 2
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND START
PROPO-VALVE
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA

Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP

OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa

In the normal condition, OK is

displayed when the control
lever is moved to stroke end.

SM0115

GRAPHIC_1D Figure 2

SEARCHABLE OPERATION

Boom up
Boom down
Bucket digging
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P2 side option

Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the
machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death.
Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start
operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place the bucket on
the ground between both crawlers.
2. In the case of DIAG MODE2, pump pressure is unloaded with unload valve in order not to actuate attachment.
3. When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and UNLOAD PSV
NG is displayed. Check the troubled section according to indication.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not
appear. If necessary, examine the presence or absence of trouble referring to the trouble history.

NA Issued 10-2007 Bur 3-5

 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE
TABLE 1 - FAILURE DIAGNOSIS MODE-1/ DIAGNOSIS ITEM

Table 1 - Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis

Is normal pressure generated in the condition that the flow rate at P1 side is minimum and the
1 1 P1 UNLOAD
unloading valve is in the emergency position?
2 2 P1 UNLOAD Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P1 side
3 3 P1 UNLOAD
flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position, and
4 1 P2 UNLOAD
P2 side flow rate is minimum?
5 2 P2 UNLOAD Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P2 side
6 3 P2 UNLOAD
flow rate is minimum?
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the
7 1 P1 PUMP
unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and P1 side flow
8 2 P1 PUMP
rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position, and
9 3 P1 PUMP
P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the
10 1 P2 PUMP
unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and P2 side flow
11 2 P2 PUMP
rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position, and
12 3 P2 PUMP
P2 side flow rate is maximum?
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload valve is
13 1 TRAVEL-S
emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload valve is
14 2 TRAVEL-S
emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when
15 1 P1 ENGINE
P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when
16 2 P2 ENGINE
P2 side flow rate is relieved?

3-6 Issued 10-2007 Bur NA

 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE
TABLE 2 - FAILURE DIAGNOSIS MODE-1/ DIAGNOSIS AND REMEDY

Table 2 - Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy

SENSOR CHECK Disconnection of pressure sensor, Short circuit, Check each pressure sensor by service
NG Abnormal output diagnosis and replace it if necessary
Secondary pressure is excessive high against the
command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low against the and replace it if necessary
command
Stuck at full-stroke side Check P1 unload spool and replace it if
P1 UN-LOAD SPOOL NG
Stuck at neutral side necessary
Secondary pressure is excessive high against the
command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
Secondary pressure is excessive low against the and replace it if necessary
command
Stuck at full-stroke side Check P2 unload spool and replace it if
P2 UN-LOAD SPOOL NG
Stuck at neutral side necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
Stuck at neutral side replace it if necessary
Secondary pressure is excessive high against the
command Check P1 pump proportional valve and
P1 PUMP PSV NG
Secondary pressure is excessive low against the replace it if necessary
command
Delivery rate is excessive large against the Check P1 pump regulator and replace
command it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.
Secondary pressure is excessive high against the
command Check P2 pump proportional valve and
P2 PUMP PSV NG
Secondary pressure is excessive low against the replace it if necessary
command
Delivery rate is excessive large against the Check P2 pump regulator and replace
command it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.
Secondary pressure is excessive high against the
command Check travel straight proportional valve
S-TRAVEL PSV NG
Secondary pressure is excessive low against the and replace it if necessary
command
Stuck at full-stroke side Check travel straight spool and replace
S-TRAVEL SPOOL NG
Stuck at neutral side it if necessary
Check P1 high pressure sensor and
PUMP 1 PRESS. SENSOR NG Pressure is recognized lower than it is
replace it if necessary
Check P2 high pressure sensor and
PUMP 2 PRESS. SENSOR NG Pressure is recognized lower than it is
replace it if necessary
Set pressure decreases Check main relief valve and replace it if
MAIN RELIEF NG
Set pressure increases necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary
NA Issued 10-2007 Bur 3-7
 SECTION 2 - TROUBLESHOOTING
CHAPTER 3 - TROUBLESHOOTING BY DIAGNOSIS MODE
NOTES

3-8 Issued 10-2007 Bur NA

REPAIR MANUAL - SECTION 5

E175B
EXCAVATOR

ENGINE

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 5 - ENGINE

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B
 SECTION 5 - ENGINE

SECTION 5
ENGINE
SECTION TABLE OF CONTENTS
CHAPTER 1
ENGINE
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ENGINE- REFER TO NEW HOLLAND ENGINE REPAIR MANUAL SOURCE CODE NO. 87630274 NA 1-3

NA I
 SECTION 5 - ENGINE

II Issued 10-2007 Bur NA

 SECTION 5 - ENGINE

CHAPTER 1

E175B
EXCAVATOR

ENGINE

Issued 10-2007
Book/Form Number NA
Copyright © 2007. CNH America LLC. All Rights Reserved.
Printed in U.S.A. • Bur
Source Code No. 87634783
 SECTION 5 - ENGINE
CHAPTER 1 - ENGINE

CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do
not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer

Revision History
Issue Issue Date Applicable Machines Form Number Remarks
First Edition 10-2007 E175B

1-II Issued 10-2007 Bur NA

 SECTION 5 - ENGINE

CHAPTER 1
ENGINE
TABLE OF CONTENTS

ENGINE- REFER TO NEW HOLLAND ENGINE REPAIR MANUAL SOURCE CODE NO. 87630274 NA . . . . . 1-3

NA Issued 10-2007 Bur 1-1

 SECTION 5 - ENGINE
CHAPTER 1 - ENGINE

NOTES

1-2 Issued 10-2007 Bur NA

 SECTION 5 - ENGINE
CHAPTER 1 - ENGINE
ENGINE- REFER TO NEW HOLLAND ENGINE REPAIR MANUAL SOURCE CODE NO.
87630274 NA

NA Issued 10-2007 Bur 1-3

 SECTION 5 - ENGINE
CHAPTER 1 - ENGINE
NOTES

1-4 Issued 10-2007 Bur NA