E135BSR

Repair Repair Manual

Manual

Printed No. 87743920A

English - Printed in Italy

E135BSR
PROVEN PERFORMANCE
 E135BSR

REPAIR MANUAL
ENGLISH

Print No. 87743920A

Edition 01/2008
English - Printed in Italy

Printed by Studio ti - 01708

 INTRODUCTION

TO THE READER
• This manual has been written for a skilled technician, For any question or comment, or in case you no-
in order to give him the information necessary to repair tice a mistake in this manual content, please con-
this machine. tact:
CNH ITALIA S.p.A.
Read this manual carefully for correct information Viale delle Nazioni, 55
41100 MODENA - Italia
about repair procedures.

ADDITIONAL REFERENCE MANUALS

• In addition to this Repair Manual, refer also to the fol-
lowing:
Operation and maintenance instruction manual
Spare parts catalog

DESCRIPTION OF THE REPAIR MANUAL
• This repair manual consists of one single volume,
identified with:
E235BSR - REPAIR MANUAL “Mini excavator”
• The “Mini excavator” Repair Manual contains the tech-
nical information necessary for machine service and
repair, the service equipment, the information on main-
tenance standards, the removal and installing proce-
dures, and the disassembly and assembly
procedures.

• The complete REPAIR MANUAL for the model

E135BSR consists of the following volume identified
by print number as shown herebelow:

VOLUME MACHINE TYPE PRINT No.

Repair Manual - “Hydraulic excavator” E135BSR
INTRODUCTION

AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of
some individuals to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS
CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs.
Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot
be completely safeguarded against without interfering with reasonable accessibility and efficient operation.
Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES” section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many thousand serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.

S ATTENTION
On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels,
loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjust-
ing and/or repairing.
If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the
equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.

COPYRIGHT BY CNH ITALIA S.p.A.

Viale delle Nazioni, 55
41100 MODENA - Italia

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

2) WARNING- Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury and is represented as
follows:

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

0-3
 INDEX E225BSR

Title Index
No.
MAINTENANCE SPECIFICATIONS

OUTLINE 1

SPECIFICATIONS 2

ATTACHMENT DIMENSIONS 3

TOOLS 11

STANDARD MAINTENANCE TIME SCHEDULE 12

MAINTENANCE STANDARD AND TEST PROCEDURE 13

MECHATRO CONTROL SYSTEM 21

HYDRAULIC SYSTEM 22
SYSTEM

ELECTRIC SYSTEM 23

COMPONENTS SYSTEM 24

AIR-CONDITIONER SYSTEM 25

DISASSEMBLING AND ASSEMBLING 31

DISASSEMBLING

ATTACHMENT 32

UPPER STRUCTURE 33

TRAVEL SYSTEM 34
TROUBLESHOOTING

BY ERROR CODES 46

BY TROUBLE 47

TROUBLE DIAGNOSIS MODE 48

E/G

ENGINE 51

APPLICABLE MACHINES

0-4
NOTE:
This Manual is prepared as a technical material in
which the information necessary for the maintenance
and repairing services of our hydraulic excavators are
collected, and is categorized into 7 Chapters, Specifica-
tion, Maintenance, System, Disassembly, Trouble-
shooting, Engine, and Installation Procedures for
Optional Attachment.
This Manual may be properly revised due to the im-
provement of products, modification of specifications,
etc. And there are cases where the system on actual
machine and a part of the contents of this manual may
differ due to the variations of specification by countries.
For the section in which the description is hardly under-
stood, contact our distributor.

• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.

0-5
0-6
 1

1. OUTLINE
TABLE OF CONTENTS

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-2

1.1.1 PREPARATION BEFORE DISASSEMBLING ..........................................................1-2
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-2
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-2
1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-3
1.1.5 HYDRAULIC PARTS ................................................................................................1-4
1.1.6 WELD REPAIR .........................................................................................................1-4
1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-4
1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-5

1-1
1. OUTLINE

1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
begin a meeting before starting the work.
MAKING REPAIRS
3) Before starting inspection and maintenance
1.1.1 PREPARATION BEFORE stop the engine.
DISASSEMBLING
4) Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact
Read Operator's Manual
for emergency measure and ambulance to
before disassembling

prepare for accidents and fire.

(1) Knowledge of operating procedure
Read Operator’s Manual carefully to understand
the operating procedure.
(2) Cleaning machines
Clean machines of soil, mud, and dust before
carrying into the service shop.
Carrying a soiled machine into the service shop,
causes making less efficient work and damage of
parts.
(3) Inspecting machines
Confirm the disassembling section before starting
work, determine the disassembly procedure taking
the conditions in work shop into account, and
request to procure necessary parts in advance.
(4) Recording
Record the following items to keep contact and
prevent malfunction from recurring.
1) Inspecting date, place
2) Model name, Serial number and Record on
hour meter
3) Trouble condition, place, cause
5) Choose a hard, lever and safe place, and put
attachment on the ground without fail.
6) Use hoist, etc. to remove parts of heavy weight
(23kg [50 lb] or more).
7) Use proper tools, and change or repair
defective tools.
8) Machine and attachment required to work in the
lifting condition should be supported with
supports or blocks securely.
1.1.3 DISASSEMBLING AND ASSEMBLING
HYDRAULIC EQUIPMENT
(1) Removing hydraulic equipment assy
1) 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.
2) Drain the oil in the removed pipes into pan to
prevent the oil from spilling on the ground.

4) Visible oil leak, water leak and damage
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness.
6) Examine the problems on the basis of monthly
operation rate with the last inspection date and
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Tools required for repair work.
2) Prepare the places to put the disassembled
parts.
3) Prepare oil pans for leaking oil, etc.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING
WARNING
(1) Safety
1) Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves.
3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
and gear oil before putting them on working
bench.
1) Since performance and function of hydraulic
equipment after disassembly and assembly
results in immunity from responsibility on the
manufacture’s side, disassembly, assembly
and modification without permission are strictly
prohibited.
2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
3) Make match mark on parts for reassembling.
4) Before disassembling, read Disassembling
Instruction in advance, and determine if the
disassembly and assembly are permitted or
not.

1-2

5) For parts which are required to use jig and
tools, don’t fail to use the specified jig and tools.
6) For parts which can not be removed in the
specified procedure, never force removal. First
check for the cause.
7) The removed parts should be put in order and
tagged so as to install on proper places without
confusion.
8) For common parts, pay attention to the quantity
and places.
(3) Inspecting parts
1) Check that the disassembled parts are free
from adherence, interference and uneven
working face.
2) Measure the wear of parts and clearance, and
record the measured values.
3) If an abnormality is detected, repair or replace
the parts.
(4) Reassembling hydraulic equipment
1) During the parts cleaning, ventilate the room.
2) Before assembly, clean parts roughly first, and
then completely.
3) Remove adhering oil by compressed air, and
apply hydraulic oil or gear oil, and then
assemble them.
4) Replace the removed O-ring, back-up rings and
oil seal with new ones, and apply grease oil on
them before assembling.


5) Removes dirt and water on the surface on
which liquid sealant are applied, decrease
them, and apply liquid sealant on them.
6) Before assembling, remove rust preventives on
new parts.
7) Use special tools to fit bearings, bushing and oil
seal.
8) Assemble parts matching to the marks.
9) After completion, check that there is no
omission of parts.
(5) Installing hydraulic equipment
1) Confirm hydraulic oil and lubrication oil.
2) 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
1-3
1. OUTLINE
If hydraulic oil and lubricating oil are not
filled and also air bleed is not performed,
the hydraulic equipment may be damaged.
3) For air bleed of hydraulic pump and swing
motor, loosen drain plug on the upper part, start
engine, and run in low idling, then bleed air until
hydraulic oil is comes out. After completion of
comes, tighten plug securely.
4) For air bleed of travel motor and hydraulic
cylinder, starts engine and operate it for 10
minutes or more at no-load and low speed.
For cylinder, don’t move it to the stroke end
at beginning.
5) Air in pilot circuit can be bleed out by only
operating digging, swing and traveling motions
thoroughly.
6) Check hydraulic oil level.
Move attachments to hydraulic oil check
position, and check hydraulic oil level of tank.
Refill oil if the oil level is lower than the specified
level.
How to check oil level of hydraulic oil tank

LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within
level marks, the oil quantity
is acceptable.
1.1.4 ELECTRICAL EQUIPMENT
(1) The disassembly of electrical equipment is not
allowed.
(2) Handle equipment with care so as not to drop it or
bump it.
(3) Connector should be removed by unlocking while
holding the connector.
Never stress in tension to the caulked section by
pulling wire.
(4) Check that connector is connected and locked
completely.
(5) Engine key off before removing and connecting
connector.
1. OUTLINE
(6) Engine key off before touching terminals of starter
and alternator.
(7) Remove battery grounding terminal before
beginning work close to battery and battery relay
with tools.
(8) Wash machine with care so as not to splash water
on electrical equipment and connector.
(9) When water has entered in the waterproofed
connector, the removing of water is not easy. So
check the removed waterproofed connector with
care to protect it from entry of water. If moisture
adheres on it, dry it completely before connecting.
Battery fluid is dangerous.
The battery fluid is dilute sulfuric acid, and causes
scald and loss of eyesight by adhering on eyes,
skin and clothes. When the fluid has adhered on
them, take an emergency measure immediately and
see a doctor for medical advice.
• When it has adhered on skin ;
Wash with soap and water.
• When it has got in eyes ;
Wash in water for 10 minutes or more
immediately.
• When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or wash
away with water.
• When it was swallowed ;
Drink milk or water.
• When it has adhered on clothes ;
Wash it immediately.
1.1.5 HYDRAULIC PARTS
(1) O-ring
• Check that O-ring is free from flaw and has
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-4
(2) Flexible hose (F hose)
• Even if the connector and length of hose are the
same, the parts differ according to the
withstanding pressure. Use proper parts.
• Tighten it to the specified torque, and check that
it is free from twist, over tension, interference,
and oil leak.
1.1.6 WELD REPAIR
(1) The weld repair should be carried out by qualified
personnel in the specified procedure after
disconnecting the grounding cable of battery. If the
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
entry of spark beforehand.
(3) Repair attachments which are damaged, giving
particular attention to the plated section of piston
rod to protect it from sparks, and don’t fail to cover
the section with flame-proof clothes.
1.1.7 ENVIRONMENTAL ISSUES
(1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
(2) Waste disposal
The following parts follows the regulation.
Waste oil, waste container and battery
(3) Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it was swallowed ;
Don’t force him to vomit it, but immediately
receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
For spare parts, grease and oil, use NEW HOL-
LAND genuine ones.
 1. OUTLINE

1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
° (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro μ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3

1-5
1. OUTLINE

(6) Unit Conversion Table

QUANTITIES JIS SI REMARKS

Mass kg kg
Force kgf N 1kgf=9.807N
Torque kgf•m N•m 1kgf•m=9.807N•m
Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Motive power PS kW 1PS=0.7355kW
Revolution r.p.m min –1 1r.p.m=1min–1

1-6
 2

2. SPECIFICATIONS
TABLE OF CONTENTS

2.1 NAME OF COMPONENTS................................................................................................2-2

2.2 GENERAL DIMENSIONS ..................................................................................................2-3
2.2.1 E135BSR/E135BSRLC
[4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.50m3 (0.65cu•yd) Bucket] ..........2-3
2.2.2 E135BSR/E135BSRLC
[4.68m (15ft-4in)+2.84m (9ft-4in) Long Arm+0.38m3 (0.50cu•yd) Bucket] ................2-3
2.3 WEIGHT OF COMPONENTS............................................................................................2-4
2.4 TRANSPOTATION ............................................................................................................2-5
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-5
2.4.2 DIMENSIONS OF ATTACHMENT ...........................................................................2-6
2.5 SPECIFICATIONS AND PERFORMANCE .......................................................................2-8
2.5.1 SPEED AND CLIMBING CAPABILITY .....................................................................2-8
2.5.2 ENGINE ....................................................................................................................2-8
2.5.3 HYDRAULIC COMPONENTS ..................................................................................2-8
2.5.4 WEIGHT ...................................................................................................................2-8
2.6 TYPE OF CRAWLER.........................................................................................................2-9
2.7 TYPE OF BUCKET ............................................................................................................2-9
2.8 COMBINATIONS OF ATTACHMENT................................................................................2-10
2.9 ENGINE SPECIFICATIONS ..............................................................................................2-11
2.9.1 SPECIFICATIONS....................................................................................................2-11
2.9.2 ENGINE CHARACTERISTIC CURVE ......................................................................2-12

2-1
2. SPECIFICATIONS

2.1 NAME OF COMPONENTS

  


  
  


  

 

 


  
 

    
   



   


  






  

 
 


   


    

  
 
   


2-2
 2. SPECIFICATIONS

2.2 GENERAL DIMENSIONS

2.2.1 E135BSR/E135BSRLC
[4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.50m3 (0.65cu•yd) Bucket]
Unit : mm (ft-in)
R14
60 (
4'9.
5")

190 (7.5")
")
0 (6'1
R185

R1
49
7110 (23'4")

0
2490 (8'2")

(4
'11
1490 (4'11")

")
2680 (8'10'')

2830 (9'3")
25 860 (33.9")

(17.5")
445
Lower roller Q'tys : 6 [7]
(0.984")
600
3600 (11'10") [3770 (12'4")] (23.6")
2590 (8'6")
7410 (24'4") [7500 (24'7")]

Dimensions marked * do not include the height of the shoe lug.

[ ] include LC specifications.

2.2.2 E135BSR/E135BSRLC
[4.68m (15ft-4in)+2.84m (9ft-4in) Long Arm+0.38m3 (0.50cu•yd) Bucket]
Unit : mm (ft-in)

7120 (23'4")
1490 (4'11")
3070 (10'1'')

2830 (9'3")
860 (33.9")

Lower roller Q'tys : 6 [7]

25
(0.984")

3600 (11'10") [3770 (12'4")]

7420 (24'4") [7510 (24'8")]

2-3
2. SPECIFICATIONS

2.3 WEIGHT OF COMPONENTS

Unit ; kg (lb)
Model
E135BSR E135BSRLC
Item
Fully equipped weight 14,200 (31,310) 14,500 (31,970)
1. Upper frame assy (Assembly of following :) 7,284 (16,060) ←
1.1 Upper frame 1,400 (3,087) ←
1.2 Counter weight 3,400 (7,500) ←
Counter weight (Semi-weighted) — —
Counter weight (weighted) — —
1.3 Cab 266 (587) ←
1.4 Engine *395 (871) ←
1.5 Hydraulic oil tank *112 (247) ←
1.6 Fuel tank *89 (196) ←
1.7 Slewing motor (including reduction unit) *109 (240) ←
1.8 Control valve *158 (348) ←
1.9 Boom cylinder *96 (212)×2 ←
1.10 Pin (for mounting boom) 66 (146) ←
1.11 Pump *89 (196) ←
1.12 Radiator (including intercooler) *77 (170) ←
2. Lower frame assy (Assembly of following :) 4,664 (10,284) 4,837 (10,666)
2.1 Lower frame 1,470 (3,241) 1,530 (3,374)
2.2 Slewing bearing 150 (330) ←
2.3 Travel motor (including reduction unit) 145 (320)× 2 ←
2.4 Upper roller 9 (20) 9 (20)× 2
2.5 Lower roller 25 (55) × 12 25 (55) × 14
2.6 Front idler 74 (163) × 2 ←
2.7 Idler adjuster 58 (128) × 2 ←
2.8 Sprocket 43 (95) × 2 ←
2.9 Swivel joint *24 (53) ←
2.10 Track link with 600mm (23.6in) shoes assy (HD) 1,016 (2,240) × 2 1,060 (2,337) × 2
Track link with 500mm (19.7in) shoes assy (HD) 908 (2,002) × 2 1,000 (2,205) × 2
3. Attachment (Assembly of following / STD :) 1,963 (4,328) —
{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + 0.50m (0.65cu•yd) Bucket}
3

Attachment (Assembly of following / LC :) — 2,013 (4,439)

{4.68m (15ft-4in) Boom + 2.84m (9ft-4in) Long Arm + 0.38m3 (0.50cu•yd) Bucket}
3.1 Bucket assy (STD / LC) 385 (849) 335 (739)
3.2 Arm assy (Assembly of following :) (STD / LC) 575 (1,268) 674 (1,486)
3.2.1 Arm 367 (809) 466 (1,028)
3.2.2 Bucket cylinder *82 (180) ←
3.2.3 Idler link 30 (66) ←
3.2.4 Bucket link 42 (93) ←
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 46 (101) ←
3.3 Boom assy (Assembly of following :) 1,256 (2,770) ←
3.3.1 Boom 844 (1,861) ←
3.3.2 Arm cylinder *138 (304) ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 29 (64) ←

2-4
 2. SPECIFICATIONS

Unit ; kg (lb)
Model
E135BSR E135BSRLC
Item
4. Lubricant and water (Assembly of following :) 334 (736) ←
4.1 Hydraulic oil 137 (302) ←
4.2 Engine oil 16 (35) ←
4.3 Fuel 167 (368) ←
4.4 Water 14 (31) ←

Marks * show dry weight.

2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 4.68m (15ft-4in) Boom+2.84m (9ft-4in) Long Arm+0.38m3 (0.50cu•yd) Bucket

Shoe type
600mm (23.6in) 600mm (23.6in) LC
Item
Width mm (ft-in) 2,590 (8'6") 2,590 (8'6")
Weight kg (lbs) 14,300kg (31,530 lbs) 14,400kg (31,750 lbs)

1100 (3'7") 7070 (23'2") 3480 (11'5")

3950 (12'12")
3210 (10'6")

3660 (12'0")
2910 (9'7")
150(5.9")

(29.5")
750

2-5
2. SPECIFICATIONS

2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM

Type
4.68m (15ft-4in) Boom
Item
Length×Height×Width 4.84 × 1.42 × 0.60
m (ft-in)
L×H×W (15'11"× 4'8"× 1'12")
Weight kg (lbs) 1,030 (2,271)

H
L

(2) ARM AND BUCKET

Type 2.38m (7ft-10in) Arm + 2.84m (9ft-4in) Arm +

0.50m 3 (0.65cu•yd) Bucket 0.38m 3(0.50cu•yd) Bucket
Item
Length×Height×Width 4.28 × 0.82 × 1.00 4.74 × 0.82 ×1.00
m (ft-in)
L×H×W (14'1"×2'8"×3'3") (15'7"×2'8"×3'3")
Weight kg (lbs) 1,000 (2,205) 1,100 (2,426)
H

(3) Arm

Type
2.38 m (7ft-10in) Arm 2.84 m (9ft-4in) Arm
Item
Length×Height×Width 3.13 × 0.65 × 0.53 3.59 × 0.66 × 0.56
m (ft-in)
L×H×W (10'3"×2'2"×1'9") (11'9"×2'2"×1'10")
Weight kg (lbs) 590 (1,300) 690 (1,521)
H

2-6
 2. SPECIFICATIONS

(4) Bucket

Type Hoe bucket

Length×Height×Width 1.19 × 1.07× 1.00 1.19 × 1.07× 0.70 1.19 × 1.07× 0.70 1.19 × 1.07× 0.80
m (ft-in)
L×H×W (3'11"×3'6"×3'3") (3'11"×3'6"×2'4") (3'11"×3'6"×2'4") (3'11"×3'6"×2'7")
Weight kg (lbs) 390 (860) 280 (620) 300 (660) 320 (706)
Bucket capacity m3 (cu•yd) STD 0.50 (0.65) 0.24 (0.31) 0.31 (0.41) 0.38 (0.50)

Type Hoe bucket

Length×Height×Width 1.19 × 1.07× 0.90 1.19 × 1.07× 1.10
m (ft-in)
L×H×W (3'11"×3'6"×2'11") (3'11"×3'6"×3'7")
Weight kg (lbs) 350 (770) 400 (880)
Bucket capacity m (cu•yd)
3
0.45 (0.59) 0.57 (0.75)

Hoe bucket

2-7
2. SPECIFICATIONS

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Model
E135BSR E135BSRLC
Item
Swing speed min-1 {rpm} 11.5 {11.5}
Travel speed (1-speed/2-
km/h (mile/h) 3.4 / 5.6 (2.1 / 3.5)
speed)
Gradeability % (degree) 70 (35)

2.5.2 ENGINE

Engine model MITSUBISHI HEAVY INDUSTRIES, Ltd. D04FR-74kW

Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine
Type
with inter cooler turbo-charger
4 -ø102 mm × 130 mm
Number of cylinders—Bore×Stroke
(4.02 in × 5.12 in)
Total displacement 4.249 L (259.27 cu•in)
Rated output / Engine speed 74 kW (101 PS) / 2,000 min-1
Maximum torque / Engine speed 375 N•m (277 lbf•ft)/ 1,600 min-1
Starter 24 V / 5.0kW
Alternator 24 V / 50A

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type

2.5.4 WEIGHT

Unit : kg (lbs)
Fully equipped weight 14,200 (31,310) 14,500 (31,970)
Upper structure 7,284 (16,060) ←
Lower machinery
4,664 (10,284) 4,837 (10,666)
(600mm grouser shoe)
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 1,963 (4,320) —
+0.50m3 (0.65cu•yd) Bucket
Attachment
4.68m (15 ft-4in) Boom+2.84m (9ft-4in) Long — 2,013 (4,439)
Arm+0.45m3 (0.59cu•yd) Bucket

2-8
 2. SPECIFICATIONS

2.6 TYPE OF CRAWLER

Overall width of crawler Ground pressure
Shape Shoe width mm (in)
mm (ft-in) kPa (psi)
Grouser shoe STD 2,590 (8'6") 37 (5.37)
600 (23.6)
LC 2,590 (8'6") 36 (5.22)

STD 2,690 (8'10") 32 (4.64)

700 (27.6)
LC 2,690 (8'10") 31 (4.50)

Use 600mm (23.6") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)

2.7 TYPE OF BUCKET

Heaped Outer width mm (ft-in) Availability
Struck Number W or W/O Weight
capacity With side Without side of face
m3(cu•yd) of tooth side cutter kg (lbs)
m3(cu•yd) cutter cutter shovel
0.20 280
0.24 (0.31) 590 (1'11") 500 (1'7.7") 3 W YES
Hoe bucket (0.26) (620)
0.23 300
0.31 (0.41) 700 (2'3.6") 600 (1'11.6") 3 W YES
(0.30) (660)
0.28 320
0.38 (0.50) 800 (2'7.5") 700 (2'3.6") 4 W YES
(0.37) (706)
0.35 350
0.45 (0.59) 910 (2'12") 810 (2'8") 4 W YES
(0.46) (770)
[STD] 0.38 390
1,000 (3'3") 900 (2'11.4") 5 W YES
0.50 (0.65) (0.50) (860)
0.43 400
1,100 (3'7") 1,000 (3'3") 5 W YES
0.57 (0.75) (0.56) (880)
0.50 410
0.70 (0.90) — 1,150 (3'9") 5 W YES
(0.65) (904)

2-9
2. SPECIFICATIONS

2.8 COMBINATIONS OF ATTACHMENT

Bucket Available Arm
Heaped capacity Struck 2.38m (7ft-10in) Arm 2.84m (9ft-4in)
Type
m3 (cu•yd) m3 (cu•yd) (STD) Arm (Long) Arm (Short)
0.24 (0.31) 0.20 (0.26) —
0.31 (0.41) 0.23 (0.30) —
0.38 (0.50) 0.28 (0.37) —

Hoe bucket 0.45 (0.59) 0.35 (0.46) —

STD
0.38 (0.50) —
0.50 (0.65)
0.57 (0.75) 0.43 (0.56) —
0.70 (0.90) 0.50 (0.65) —
Breaker — — —
Nibbler — — —

Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.

• Use the attachments recommended by manufacturer.

The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility

When the only 2.38m (7ft-10in) arm is using, do not turn the bucket back to front to use as a shovel.

2-10
 2. SPECIFICATIONS

2.9 ENGINE SPECIFICATIONS

2.9.1 SPECIFICATIONS

Applicable machine E135BSR, E135BSRLC

Engine model MITSUBISHI HEAVY INDUSTRIES, Ltd. D04FR-74kW
Water-cooled, 4 cycle 4 cylinder direct injection type
Type
diesel engine with inter cooler turbo-charger
Number of cylinder×Bore×Stroke mm (in) 4 × 102 × 130 (4.02 × 5.12)
Total displacement cc (cu•in) 4,249 (259.27)
Compression ratio 17.8
Rated output kW (PS) at min -1
74 (101) at 2,000
N•m (lb•ft) at
Maximum torque 375 (277) at 1,600
min-1
High idling min-1 2,240 ± 20
Low idling min -1
1,015 ± 20
Injection starting pressure MPa (psi) —
Start/Full open
Thermostat action 344 (160) / 358 (185)
K (°F)
Firing order 1-3-4-2
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 50
ø600 (23.6") × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.9
Full level 17.5 (4.62)
Engine oil quantity L (gal) Low level 14.5 (3.83)
Total 18.5 (4.89)
Dry weight kg (lbs) 395 (871)
Fuel consumption ratio
g/kW•h (g/ps•h) 233 (171)
(At rated output)
Allowable inclination Front / Rear and Right / Left : 35°
Dimension (L×W×H) mm (in) 911 × 719 × 940 (35.9in × 28.3in × 37.0in)
Rotating direction Counterclockwise seeing from flywheel side

2-11
2. SPECIFICATIONS

2.9.2 ENGINE CHARACTERISTIC CURVE

Condition to be measured: The net value is indicated, measuring without cooling fan.
TORQUE Nm
OUTPUT kW

ENGINE SPEED (min-1)

Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
233g/kW.h
X 74kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
20.65
Fuel consumption in regular operation
(load factor 0.70~0.80)
14.5 L/h~16.5 L/h

2-12
 3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS

3.1 BOOM ................................................................................................................................3-2

3.1.1 BOOM DIMENSIONAL DRAWING...........................................................................3-2
3.1.2 BOOM MAINTENANCE STANDARD .......................................................................3-3
3.2 ARM ...................................................................................................................................3-5
3.2.1 ARM DIMENSIONAL DRAWING..............................................................................3-5
3.2.2 ARM MAINTENANCE STANDARD ..........................................................................3-6
3.3 BUCKET ............................................................................................................................3-9
3.3.1 BUCKET DIMENSIONAL DRAWING .......................................................................3-9
3.3.2 BUCKET DIMENSIONAL TABLE .............................................................................3-9
3.3.3 LUG SECTION DIMENSIONAL DRAWING .............................................................3-10
3.3.4 BOSS SECTION DIMENSIONAL DRAWING...........................................................3-11

3-1
3. ATTACHMENT DIMENSIONS

3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING

d2
J

X-X

Fig. 3-1 Boom dimensional drawing

Unit : mm (ft-in)
STD —
4.68M (15ft-4in) BOOM

No NAME DIMENSION
A Boom length 4,680 (15'4") —
B Boom foot width 575 (22.6") —
C Boom end inner width 274 (10.8") —
D Boom end outer width 386 (15.2") —
E Height of boom cylinder rod pin 952 (37.5") —
F Height of arm cylinder (head side) pin 1,079 (3'6") —
G Distance between pins of boss R2,110 (6'11") —
H Distance between pins of bracket R2,293 (7'6") —
I Arm cylinder (head side) inner width 111 (4.4") —
J Outer width of bracket on the arm cylinder (rod side) 399 (15.7") —
mounting
d1 Boom foot pin dia. ø 70 (2.76") —
d2 Boom cylinder (rod side) pin dia. ø 80 (3.15") —
d3 Pin dia. of boom end. ø 70 (2.76") —
d4 Arm cylinder (head side) pin dia. ø 70 (2.76") —

3-2
 3. ATTACHMENT DIMENSIONS

3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section

A
C

Fig. 3-2 Clearance of pin and bushing on boom section

Unit : mm (in)
Standard value Clearance
Bushing
Symbol Item Pin dia. Standard Repairable Service Remedy
Pin dia. i.d.
tolerance value level limit
tolerance
+ 0.223 + 0.243
(+0.0088) (+0.0096)
A Boom foot
+ 0.081 + 0.061
ø 70 (+0.0032) (+0.0024)
(2.7559) + 0.237 + 0.257
Boom cylinder (+0.0093) (0.0101)
B
(Head side) + 0.020 + 0.101 + 0.081
More than Replace
(+0.0008) (+0.0040) (+0.0032) 2.0
1.2 bushing
- 0.020 + 0.229 + 0.249 (0.079)
(0.047) or pin
Boom cylinder ø 80 (-0.0008) (+0.0090) (+0.0098)
C
(Rod side) (3.1496) + 0.089 + 0.069
(+0.0035) (+0.0027)
+ 0.231 + 0.251
Arm cylinder ø 70 (+0.0091) (+0.0099)
D
(Head side) (2.7559) + 0.091 + 0.071
(+0.0036) (+0.0028)

3-3
3. ATTACHMENT DIMENSIONS

(2) Clearance in thrust direction on the boom cylinder installation section

D
D C

B A

SECTION C-C

SECTION D-D

SECTION A-A

SECTION B-B

Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section

Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
575
Boom
(22.6) 0.5 (0.02) 1.0 1.5 732
A-A Boom foot L1 PL1
581 or less (0.04) (0.06) (28.8)
Upper frame
(22.9)
90
Boom cylinder
Boom cylinder (3.54) 0.6~1.0 2.0 2.5 185
B-B L2 PL2
(Head side) 96 (0.02~0.04) (0.08) (0.10) (7.28)
Upper frame Shim
(3.78)
adjust
80
Boom cylinder L3 ment
Boom cylinder (3.15) 0.6~2.0 2.5 3.0 597
C-C PL3
(Rod side) 399 (0.02~0.08) (0.10) (0.12) (23.5)
Boom L3'
(15.7)
105
Arm cylinder
Arm cylinder (4.13) 0.6~1.0 2.0 2.5 222
D-D L4 PL4
(Head side) 111 (0.02~0.04) (0.08) (0.10) (8.74)
Boom
(4.37)

3-4
 3. ATTACHMENT DIMENSIONS

3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
Z

E
Z Y
F X G
X H
R D
Y
C

VIEW J

SECTION X-X

SECTION Y-Y SECTION Z-Z

Fig. 3-4 ARM DIMENSIONAL DRAWING

2.84m (9ft-4in) ARM Unit : mm (ft-in)

Code NAME DIMENSION Code NAME DIMENSION
C Arm length 2,840 (9'4") N Bracket inner width 110 (4.33")
Distance between pins of boss
D R641.5 (25.3") O Bracket inner width 91 (3.58")
and bracket
D1 I.D of boss ø95 (3.74") P Idler link dimension 514 (20.2")
D2 I.D of boss ø75 (2.95") Q Bucket link dimension 492 (19.4")
Height between pins of boss and
D4 I.D of boss ø85 (3.35") R 20 (0.79")
center
Distance between pins of boss
E R1,862.8 (6'1") d1 Pin dia. ø65 (2.56")
and bracket
Distance between pins of boss
F R350 (13.8") d2 Pin dia. ø60 (2.36")
and boss
Height between pins of boss and
G 462.3 (18.2") d3 Pin dia. ø70 (2.76")
bracket
Height between pins of boss and
H 238.7 (9.4") d4 Pin dia. ø70 (2.76")
bracket
K Arm top end boss width 249 (9.8") d5 Pin dia. ø60 (2.36")
L Arm link section boss width 254 (10.0")
M Boss width 269 (10.6")

3-5
3. ATTACHMENT DIMENSIONS

3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing

E F
D, D'
B

C
G

Fig. 3-5 Clearance of pin and bushing on arm section

Unit : mm (in)
Standard dimensions Clearance
No. Item Pin dia. Bushing i.d. Standard Repairable Remedy
Pin dia. Service limit
tolerance tolerance value level
+0.267 +0.327
(+0.0105) (+0.0129)
A Arm point
–0.020 +0.090 +0.110
ø65 (-0.0008) (+0.0035) (+0.0043)
(2.5591) –0.060 +0.225 +0.258
Bucket link (-0.0024) (+0.0089) (+0.0102)
B
(Bucket side) +0.089 +0.105
(+0.0035) (+0.0041)
+0.203 +0.243
Idler link
ø60 (+0.0080) (+0.0096)
C (Connected part of
(2.3622) +0.093 +0.093
arm) (+0.0037) (+0.0037)
0 +0.198 +0.238
Bucket link (0) (+0.0078) (+0.0094)
D
(Idler link side) –0.040 +0.085 +0.085
Replace
ø65 (-0.0016) (+0.0033) (+0.0033) 1.2 2.0
bushing or
(2.5591) +0.198 +0.238 (0.05) (0.008)
pin
Bucket cylinder (+0.0078) (+0.0094)
D'
(Rod side) +0.085 +0.085
(+0.0033) (+0.0033)
+0.195 +0.215
Bucket cylinder ø60 (+0.0077) (+0.0085)
E
(Head side) (2.3622) +0.081 +0.061
(+0.0032) (+0.0024)
+0.020 +0.231 +0.251
Arm cylinder (+0.0008) (+0.0091) (+0.0085)
F
(Rod side) –0.020 +0.091 +0.071
ø70 (-0.0008) (+0.0036) (+0.0024)
(2.7559) +0.226 +0.246
Arm foot
(+0.0089) (+0.0097)
G (Connected part of
+0.085 +0.065
boom) (+0.0033) (+0.0026)

3-6
 3. ATTACHMENT DIMENSIONS

(2) Clearance of arm and cylinder installing sections in thrust direction

E
D, D'
B
F
E
B C
D, D' F
A A

C G
G
X1 L1
X L3 PL5
X L6
X L5

PL1 PL3 PL6

SECTION A-A SECTION C-C SECTION E-E SECTION F-F
PL7
X2 L2 X7 L7
X L4

X4' L4'
PL2 PL4
SECTION B-B SECTION D-D
SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction

3-7
3. ATTACHMENT DIMENSIONS

Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
294
Arm
(11.6)
A-A Arm point L1 PL1
251
Bucket
(9.88) 0.6~1.0 1.2 391
250 (0.024~0.04) (0.05) (15.4)
Link side
(9.84)
B-B Bucket link L2 PL2
252
Bucket
(9.92)
254 0.5 2.0
Idler link Arm 1.0
C-C L3 (10.0) (0.02) (0.08) PL3
(Arm connection) (0.04)
Link side - or less
Bucket link Rod side -
D-D (Idler link L4 254 336
Link side
connection) (10.0) (13.2)
0.6~1.0 1.2 Shim
85 PL4
Rod side (0.024~0.04) (0.05) adjust
Bucket link (3.35)
D’-D’ L4’ -ment
(Rod side) 90
Link side
(3.54)
85
Head side
Bucket cylinder (3.35) 190
E-E L5 PL5
(Head side) 91 (7.48)
Arm
(3.58) 0.6~2.0 2.0 2.5
105 (0.024~0.08) (0.08) (0.10)
Rod side
Arm cylinder (4.13) 222
F-F L6 PL6
(Rod side) 110 (8.74)
Arm
(4.33)
269
Arm 0.5
(10.59) 1.0 2.0 399
G-G Arm foot L7 (0.02) PL7
274 (0.04) (0.08) (15.7)
Boom or less
(10.79)

3-8
 3. ATTACHMENT DIMENSIONS

3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket

Fig. 3-7 Bucket dimensional drawing

No. NAME No. NAME

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

3.3.2 BUCKET DIMENSIONAL TABLE

Unit : mm (ft-in)
Type Normal digging
[STD]
0.24 0.31 0.38 0.45 0.57 0.70
Capacity 0.50
(0.22) m3 (0.27) m3 (0.33) m3 (0.40) m3 (0.50) m3 (0.60) m3
(0.45) m3
A R376 (14.8") ← ← ← ← ← ←
B R1,225 (4'0.23") ← ← ← ← ← ←
C 863 (34.0") 462 (18.2") 562 (22.1") 662 (26.1") 772 (30.4") 962 (37.9") 1,112 (3'7.8")
D 324 (12.8") ← ← ← ← ← ←
E 252 (9.9") ← ← ← ← ← ←
F 1,000 (3'3.37") 593 (23.3") 700 (27.6") 800 (31.5") 910 (35.8") 1,100 (3'3.7") —
G 739 (29.1") 383 (15.1") 439 (17.3") 539 (21.2") 649 (25.6") 839 (33.0") 989 (39.0")
H 903 (35.6") 500 (19.7") 600 (23.6") 700 (27.6") 772 (30.4") 1,000 (3'3.37") 1,150 (3'9.3")
I 192.5 (7.6") 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 218.5 (8.6") 256 (10.1")
IO 192.5 (7.6") 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 218.5 (8.6") 256 (10.1")
d1 ø 80 (3.2") ← ← ← ← ← ←
d2 ø 65 (2.6") ← ← ← ← ← ←
Bucket capacity : SAE heaped (Stuck)

3-9
3. ATTACHMENT DIMENSIONS

3.3.3 LUG SECTION DIMENSIONAL DRAWING

X B

J
A

Roughness of counterbore bottom X

surface is to be 100S or less in
range of diameter 39mm. BOSS
And M16 bolt is to be installed. (3 places) M
28 2418P26832
(1.10) Apply rust prevention oil
19
(0.748)
3-G

B
F
N
D E

H
BOSS
SHIM 1 Insert this pin flush with surface YY61B01005P1
Five shims are installed
at shipping SECTION X-X
DETAIL B

Fig. 3-8 Dimension of lug section

Unit : mm (ft-in)
Lug plate thickness

Screw hole P.C.D

Boss outer dia.

Boss outer dia.

Spring pin dia.
Pin hole dia.

Boss width.

Boss width.

Capacityof
Screw dia.

bucket
Hole dia.

Type of
bucket (SAE heaped)
m3 (cu.yd)

A B D E F G H J M N
[STD]
0.50 (0.45)
0.24 (0.22)
Normal 0.31 (0.27) 65 22 80 10 146 22 138 36 115
digging (2.56") (0.866") (3.14") (0.394") (5.75") M14 (0.866") (5.43") (1.42") (4.53")
0.38 (0.33)
0.45 (0.40)
0.57 (0.50)
0.70 (0.60)

Bucket capacity : SAE heaped (Struck)

3-10
 3. ATTACHMENT DIMENSIONS

3.3.4 BOSS SECTION DIMENSIONAL DRAWING

H 5
(0.197")
oG

oC

oD
oA

oB

15 (0.591")

DETAIL A
E

Fig. 3-9 Dimension of boss section

Unit : mm (ft-in)
Capacity of
Type of
bucket øA øB øC øD E F øG H I
bucket
m3 (cu•yd)
[STD]
0.50 (0.45) 101.6 69 94.5 99.5 15 30 15 13 2.5
0.24 (0.22) (4.0") (2.72") (3.72") (3.92") (0.591") (1.18") (0.591") (0.512") (0.098")

Normal 0.31 (0.27)

digging 0.38 (0.33)
0.45 (0.40) 101.6 69 94.5 99.5 19 34 15 13 2.5
0.57 (0.50) (4.0") (2.72") (3.72") (3.92") (0.748") (1.34") (0.591") (0.512") (0.098")

0.70 (0.60)
Bucket capacity : SAE heaped (Struck)

3-11
3. ATTACHMENT DIMENSIONS

3-12
 11. TOOLS
11
TABLE OF CONTENTS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ............................................11-2

11.2 SCREW SIZE...................................................................................................................11-4
11.2.1 CAPSCREW (BOLT) ..............................................................................................11-4
11.2.2 CAPSCREW (SOCKET BOLT) ..............................................................................11-4
11.2.3 SOCKET SET SCREW...........................................................................................11-4
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-5
11.3.1 JOINT (O-RING TYPE)...........................................................................................11-5
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-5
11.3.3 JOINT (ORS TYPE) ................................................................................................11-5
11.3.4 SPLIT FLANGE ......................................................................................................11-5
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-6
11.5 PLUG ...............................................................................................................................11-7
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-7
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-8
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-10
11.7 SPECIAL TOOLS.............................................................................................................11-11
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......11-13
11.9 SUCTION STOPPER.......................................................................................................11-14
11.9.1 COMPONENTS ......................................................................................................11-14
11.9.2 DIMENSION ...........................................................................................................11-14
11.9.3 APPLICABLE MODEL ............................................................................................11-14
11.10 COUNTERWEIGHT LIFTING JIG ...................................................................................11-15
11.11 UPPER FRAME LIFTING JIG..........................................................................................11-16
11.12 ENGINE MOUNTING PEDESTAL ...................................................................................11-17
11.13 TRACK SPRING SET JIG ...............................................................................................11-18

11-1
11. TOOLS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

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

11-2
 11. TOOLS

Table11-2 Tightening torques for metric fine threads (not plated)

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

11-3
11. TOOLS

11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)

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

11.2.2 CAPSCREW (SOCKET BOLT)

Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36

11.2.3 SOCKET SET SCREW

Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10

11-4
 11. TOOLS

11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)

Size Wrench Tightening torque

(PF) (mm) N•m (lbf•ft) O-RING O-RING
1/8 14 17±2 (13±1.5)
1/4 19 36±2 (27±1.5)
3/8 22 74±5 (55±4)
1/2 27 108±9.8 (80.0±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)

11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)

Size Tightening torque

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

11.3.3 JOINT (ORS TYPE)

Tightening Torque CONNECTOR O-RING FITTING

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

11.3.4 SPLIT FLANGE

Tightening torque N•m (lbf•ft)  

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

11-5
11. TOOLS

11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

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

SLEEVE NUT
B

d
d

Tube size Tube size Opposing

ød ød flats
(HEX) mm
6 6 14
8 8 17
10 10 19
12 12 22
15 15 27
18 18 32
22 22 36
28 28 41
32 32 50
35 35 55
38 38 60

11-6
 11. TOOLS

11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)

Applicable Opposing flats

tube T screw
A
O. D : A H1 H
6 M12 X 1.5 14 14
8 M14 X 1.5 17 17
10 M16 X 1.5 17 19
12 M18 X 1.5 19 22
H1 T screw H 15 M22 X 1.5 24 27
18 M26 X 1.5 27 32
22 M30 X 1.5 32 36
28 M36 X 1.5 38 41

(2) Plug (Tube plug)

Applicable
tube
O. D : A
A

6
8
10
12
Sleeve Nut
Type 15
joint body 18
22
28

(3) Nut

Applicable
A

d screw tube d screw Opposing flats

O. D : A
6 M12 X 1.5 14
8 M14 X 1.5 17
10 M16 X 1.5 19
12 M18 X 1.5 22
15 M22 X 1.5 27
18 M26 X 1.5 32
22 M30 X 1.5 36
28 M36 X 1.5 41
32 M42 X 1.5 50
35 M45 X 1.5 55
38 M48 X 1.5 60

11-7
11. TOOLS

11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw

B
O-ring
PF screw B mm O-ring parts No. Nominal O-ring
PF1/4 19 ZD12P01100 1B P11
PF3/8 22 ZD12P01400 1B P14
PF1/2 27 ZD12P01800 1B P18
PF3/4 36 ZD12P02400 1B P24
PF screw PF1 41 ZD12P02900 1B P29

(2) PT screw

B
PT screw
PT screw B mm
PT1/8 5
PT1/4 6
PT3/8 8
PT1/2 10
PT3/4 14
PT1 17
PT1 1/4 22
PT1 1/2 22

(3) Plug for (F) flare hose

 PF screw

PF screw B mm
PF1/4 14
60

PF3/8 17
PF1/2 22
PF3/4 27
Opposing flats B PF1 36

PF screw E mm F mm
PF PF1/4 14 19
60

screw
PF3/8 17 22
PF1/2 23 27
PF3/4 27 36
Opposing PF1 36 41
Opposing
flats F PF1 1/4 40 50
flats E

11-8
 11. TOOLS

(4) Plug for ORS joints

Male

O-RING

Screw size Applicable Opposing Nominal

A hose O.D flats (HEX) O-ring
A 1-14UNS o21.7 27 1B A16
1 3/16-12UN o27.2 36 1B A18
1 7/16-12UN o34.0 41 1B A21

Female

Screw size Applicable Opposing

A tube O.D flats (HEX)

A 1-14UNS o21.7 32
1 3/16-12UN o27.2 36
1 7/16-12UN o34.0 41

(5) Plug for half clamp

4-oH For standard pressure : 20.6 MPa (2990 psi)

Size C mm D mm G mm H mm
25.53~
1/2 38.10 17.48 25.40
9
31.88~
3/4 47.63 22.23 31.75 11
39.75~
1 52.37 26.19 39.62 11
44.58~
D 1 1/4 58.72 30.18 44.45 11

For high pressure : 41.2 MPa (5970 psi)

G Size C mm D mm G mm H mm
25.53~
1/2 40.49 18.24 9
25.40
31.88~
3/4 50.80 23.80 11
31.75
39.75~
1 57.15 27.76 39.62 13
44.58~
1 1/4 66.68 31.75 44.45 15

11-9
11. TOOLS

11.6 SPECIAL SPANNER FOR TUBE

Applicable tube diameter
HEX (mm) Drawing of a special spanner mm (in)
mm (in)

70(2.76)

16 22
15 (0.591) 27 (0.630) (0.315) (0.866)

40(1.57) 12.7 (0.500 )

70(2.76)
42(1.65)

19 22
18 (0.709) 32 (0.748) (0.866)

12.7 (0.500 )
22(0.866)

70(2.76)
48(1.89) 11.5(0.453)

23 22
22 (0.866) 36 (0.906) (0.866)

12.7 (0.500 )

109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 41 (1.142) (0.866)

12.7 (0.500 )

   
 


28 (1.10) 46    



    

  



  
32 (1.26) 50    

  

81(3.19) 90(3.54)
20.5(0.807)

35 (1.38) 55 41 PART-No. 45
(1.61) (1.77)

HEX55 19.05 (0.750 )

11-10
 11. TOOLS

11.7 SPECIAL TOOLS

Table11-4
No. Tools name Shape Applicable

Allen wrench
Pump
1 Nominal
suction
B : 10, C : 11.3

Commercial tool length (L1) - cut length = Required length

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

Spanner Swing motor

3
Nominal S : 36 A,B port

Commercial tool outer width (D) - cut length = Required length

81 (3.19") - 16 (0.63") = 65 (2.56")

M10 Eye bolt

For slinging the

Eye bolt
swing motor
4 M10×18
&
Flare hose
18

M10

M8 Eye bolt

Plug
(Nominal
tube dia. 22)
5 Reference nut Flare hose
Reference
Eye bolt
M8 X 18
Nut Addtional
threading for
M8 Eye bolt

11-11
11. TOOLS

Table11-4

M8 Eye bolt

M8 X 18
Plug Additional
threading
Nominal
6 1-14UNS HEX 27 Flare hose

Eye bolt
1-14UNS

M8 Eye bolt
M8 X 18
Additional
Plug threading
Nominal
7 1 3/16-12UN HEX 36 Flare hose

Eye bolt
1 3/16-12UN

M12 Eye nut

Plug
PF1/2 For slinging the
8 Weld
swivel joint
Coupling half

PF 1/2

5.49
TORX driver
(with tamper proof) For instrument
9 Point shape
T30 panel cover (RH)
(For M6)

11-12
 11. TOOLS

11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING

COMPOUND
(1) For general use

Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound

(2) For specific location

No. Use Manufacturer Name Equivalent Applicable

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

11-13
11. TOOLS

11.9 SUCTION STOPPER

11.9.1 COMPONENTS

No. NAME Q'TY

SUCTION STOPPER ASSY
1 ROD 1
1 Rod
2 NUT 1
3 COVER 1
4 O-RING 1

2 Nut
3 Cover

4 O-ring

Fig. 11-1 Components of suction stopper

11.9.2 DIMENSION

50
(1.97")

R
(1 8 O113 (4.45")
.3
15" 2
) M8 NUT (0.08")

O8 (1.315")
600 (23.6")

+0.5
M8 O100 0
(0.787")

(3.94 +0.0197
0 )
O108
20

(4.25")
ROD COVER
Fig. 11-2 Dimension of suction stopper

11-14
 11. TOOLS

11.10 COUNTERWEIGHT LIFTING JIG

(1) Two lifting jigs (YY60C01111P1, YY60C01112P1)

180 (7.09")

(1.18")
80 4
(3.15") (0 -C1

30
.5 5
9"
)

(2.36") (2.44")
42 ")

(1.10")
62

28
65
(1.

180 (7.09")
180 (7.09")

(2.44") (2.36")
60
60
(1.10")

(1 42
28

62
.6
5"
)
(1.18")

4
30

(0 -C1
.5 5 80
9"
) (3.15")180 (7.09")

225 (8.86") 225 (8.86")

R R
(1 50 (1 50
.9 .9
7" 7"
) )

)
4"
(3 100

.9
)
4"

(3
200 (7.87")

200 (7.87")
R
.9

40 ")

00
40 ")
58

R1
(1. 58
(1.
0 )
(1 R50

R5 97"
)
7"

120 (4.72")
.9

18 1 . 120 (4.72")
( 18
(0.71") (0.71")
(1.10")

(1.10")
28

28
155 (6.10") 155 (6.10")

Q'ty : Each one

Material : Mild steel
Fig. 11-3 Counterweight lifting jig

11-15
11. TOOLS

11.11 TOOL FOR PULLING OUT OF BOOM MOUNTING PIN

Fig. 11-4 Slide hammer for boom foot pin

Tool accesories assy

No. TOOLS NAME SHAPE APPLICATION

ROD

(0.16")
A 4
80 6
(3.15") (0.24") For boom
1 M24 mounting pin.
HOLE 35 (1.38")

(3.94")
100
ITEM A
26 (1.02")
34 (1.34")

100 14 16 50 10
Preheating 300~350 4 (3.94") (0.55") 1350 (4'5") (0.63") (1.97") (0.39")
(0.16") 4
1416 (4'8") (0.16")

4
(0. -R5
(2.36")

20 10 )
R 9"
60

")
2- (0.3
(1.41")

(0 2-C
(3.94")
100
36

.3 8
2" For boom
)
2 HAMMER mounting pin.

25 (0.98") 25 (0.98")
30 100 (3.94") 30
(1.18") 160 (6.30") (1.18")

11-16
 11. TOOLS

11.12 UPPER FRAME LIFTING JIG

(2.36")
(4.92")

(1.18")
7

(4'1.7")
5 (5.04")

(3.47")

4
(0.47")
(4.49")
(0.35")

(9.96")

6X12 piece 7X22 piece t9 (0.35")

)
7"
.9
(1
(1.38")

(1.97")

(0.8
7")

(1.77")

8X12 piece
(1.34")

(1.34")

(1.97")

(6.50") (0.59") Q'ty : 2 sets

Material : Mild steel
(13.0")

Fig. 11-5 Upper frame lifting jig (1/2)

11-17
11. TOOLS

1X1 piece t6 (0.24") 2X1 piece t9 (0.35")

(4.21")
(2.36")
(0.35")

(1.18")
7")
(0.8

(31.3")
(3.34")

(11.3")
(0
.
35
(1.97")

")
(7.05")
(4.21")

(2.01")

(3.82")
(0
.7
1"
) (5.39")
(3.94")
(2.80")
(1.58")

(1
.1
")

8"
39

(6.46") )
(0.

(9.61")

3X1 piece t9 (0.35") 4X1 piece t12 (0.47")

(2.36")
(0.35") (3.94")

(1.39
")

(3.47")

(5.04")
(3'3.8")

5X2 piece t12 (0.47")

(2.76")

(4.72")
(1.53")

(6.46")
)
9"
.8
)
39"

(1
(0

.18
")
(0.

(3.47")

(9.96") (5.04")
Q'ty : 2 sets
Material : Mild steel
Fig. 11-6 Upper frame lifting jig (2/2)

11-18
 11. TOOLS

11.13 ENGINE MOUNTING PEDESTAL

Material : Wood
Unit : mm (inch)

(8.07")
(12.2")

(28.3")
3 3
(10.6")

(8.07")

2
(11.8") (0.83")
(11.8")

(0.79") (0.79")

(3.15") (17.2") (3.15")

(23.5")

1X1 piece 3X2 piece

(20.3") (12.2")

(6.50")
(11.8")
(6.30")

(0.83")
(11.8")

(0.83")

2X1 piece 5X2 piece

(3.15")

(20.3") (0.83")
(11.8")

(28.3")

(0.83")

Fig. 11-7 Engine stand

11-19
11. TOOLS

11.14 TRACK SPRING SET JIG

M30
Retainer nut

Retainer plate
)
.6"
(12

(27.6")

Stand
(15.0")

Hydraulic jack

Base
Fig. 11-8 Track spring set jigS

11-20
 12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-3
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST ........................................12-14

12-1
12. STANDARD MAINTENANCE TIME TABLE

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

12-2
 12. STANDARD MAINTENANCE TIME TABLE

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF

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

A/C : Air conditioner C/V : Control valve O/H : Over haul

ASSY : Assembly Cyl : Cylinder SOL : Solenoid
ATT : Attachment E/G : Engine SW : Switch
BRG : Bearing F hose : Flexible hose V : Valve

(2) Classification of working code

No. Group Remarks

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

(3) Conditions for standard service time of the engine

1) Tools designated by E/G maker are used
2) Genuine parts are changed
3) Correct working procedures are observed.
• The time required for works specified in this Chapter shows the total time for maintenance.

12-3
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.5
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.1
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 2.0
07 • Tooth Replace 1 pc. 0.5
08 • Side cutter Replace 1 pc. 1.0
09 • Bushing Replace 1 pc. 0.5

10 Arm relation See 32.1.3

11 Arm ASSY Detach/attach 1 pc. 1.0
12 • Bucket cylinder attaching and Preparation 1 pc. 0.3
detaching position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.1
17 • Boom top pin Detach/attach 1 pc. 0.1
01 Attachment

18 • Arm sling and movement Detach/attach 1 pc. 0.1

30 Boom relation See 32.1.4

31 Boom ASSY Detach/attach 1 pc. 1.0
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.2
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.2
35 • Boom cylinder piping Detach/attach 2 pc. 0.2
36 • Arm & bucket piping Detach/attach 1 pc. 0.2
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.2
39 • Boom assy slinging Detach/attach 1 pc. 0.1
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.3
41 • Arm cylinder piping Detach/attach 1 pc. 0.1
42 • Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.1
43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.6
51 • Boom cylinder piping Detach/attach 2 0.2
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.2
53 • Boom cylinder slinging Detach/attach 2 0.2
60 Bucket cylinder O/H 1 3.0
61 • Pin bushing Replace 1 Include seal. 1.0
70 Arm cylinder O/H 1 3.0

12-4
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.0
80 Boom cylinder O/H 2 6.0
01

81 • Pin bushing Replace 1 set Include seal. 1.0

10 Cab relation See 33.1.2

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

20 Guard relation See 33.1.4

21 Bonnet (H1) Detach/attach 1 pc. 0.2
22 Bonnet assy (H3) Detach/attach 1 pc. 0.2
23 Bonnet assy (H2) Detach/attach 1 pc. 0.2
24 Bracket (5) Detach/attach 1 pc. 0.2
02 Cab & Guard

25 Bracket assy (3) Detach/attach 1 pc. 0.2

26 Cover assy (1,2,4,9) Detach/attach 1 pc. 0.5
27 Bracket (7,8) Detach/attach 1 pc. 0.4
28 Bracket (20,22) Detach/attach 1 pc. 0.3
29 Cover assy (21) Detach/attach 1 pc. 0.2
30 Cover assy (A1,A3,A4) Detach/attach 1 pc. 0.3
31 Panel assy (B1) Detach/attach 1 pc. 0.2
32 Guard assy (33,34) Detach/attach 1 pc. 0.3
33 Cover assy (C4) Detach/attach 1 pc. 0.2
34 Panel assy (C1) Detach/attach 1 pc. 0.2
35 Panel assy (C3) Detach/attach 1 pc. 0.2
36 Stay (D1) Detach/attach 1 pc. 0.2
37 Panel assy (C2) Detach/attach 1 pc. 0.2
38 Bracket (32) Detach/attach 1 pc. 0.2
39 Box (29) Detach/attach 1 pc. 0.2
40 Bracket assy (27) Detach/attach 1 pc. 0.2
41 Cover (E1,E2) Detach/attach 1 pc. 0.3
42 Cover assy (36) Detach/attach 1 pc. 0.2
43 Duct (F1) Detach/attach 1 pc. After removing counterweight 1.0
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.

12-5
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
52 Cover (2) Detach/attach 1 pc. 0.1
53 Cover (3) Detach/attach 1 pc. 0.1
54 Cover (4) Detach/attach 1 pc. 0.1
02 Cab & Guard

55 Cover (5) Detach/attach 1 pc. 0.1

56 Cover (6) Detach/attach 1 pc. 0.1
57 Cover (9) Detach/attach 1 pc. 0.1
60 Counterweight relation See 33.1.11
61 Counterweight ASSY Detach/attach 1 pc. 0.4
62 • Counterweight lifting jig Detach/attach 1 set 0.1
63 • Counterweight temporary slinging Preparation 1 pc. 0.1
64 • Counterweight mounting bolt Detach/attach 1 pc. 0.1
65 • Counterweight slinging Detach/attach 1 pc. 0.1

10 Intake relation See 33.1.9

11 Air cleaner ASSY Detach/attach 1 pc. 0.5
12 • Hose (2) Detach/attach 1 0.1
13 • Hose (4) Detach/attach 1 0.1
14 • Air cleaner mounting bolt Detach/attach 1 set 0.1
15 • Element Replace 1 0.1
20 Exhaust relation See 33.1.10
21 Muffler ASSY Detach/attach 1 pc. 0.4
22 • U bolt Detach/attach 1 pc. 0.2
23 • Clamp ASSY Detach/attach 1 pc. 0.2
03 Swing frame

30 Radiator relation See 33.1.12

31 Radiator ASSY Detach/attach 1 pc. 5.0
32 • Coolant (LLC) Replace 1 pc. 0.2
33 • • Concentration of coolant Measuring 1 pc. 0.2
34 • A/C condenser Detach/attach 1 pc. 0.2
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.2
37 • Sub tank hose Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.2
39 • Water hose (radiator to E/G) Detach/attach 2 0.4
40 • Radiator mounting bolts removing Detach/attach 1 set 0.2
41 • Under cover Detach/attach 3 pc. 0.3
42 • Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
43 • Hydraulic oil piping Detach/attach 1 pc. 0.6
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.

12-6
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.4
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 0.8
Other necessary works Detach/attach 1 pc. 1.0
50 Fuel relation See 33.1.6
51 Fuel tank ASSY Detach/attach 1 pc. 1.0
52 • Fuel Replace 1 pc. 0.2
53 • Hose (tank side) Detach/attach 2 0.1
54 • Fuel filter Detach/attach 1 pc. 0.1
55 • Fuel tank installing bolts Detach/attach 1 set 0.2
56 • Tank slinging Detach/attach 1 pc. 0.2
Other necessary works Detach/attach 1 pc. Guard 0.6

60 Hydraulic oil tank relation See 33.1.7

61 Hydraulic oil tank ASSY Detach/attach 1 pc. 2.5
62 • Cover Detach/attach 1 pc. 0.2
63 • Hydraulic oil Replace 1 pc. 0.4
03 Swing frame

64 • Main line return hose Detach/attach 2 pc. 0.4

65 • Pilot drain hose Detach/attach 1 pc. 0.2
66 • Pump suction hose Detach/attach 1 pc. 0.4
67 • Mounting bolt Detach/attach 1 pc. 0.2
68 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.2
69 • Return filter Replace 1 0.2
70 • Suction filter Cleaning 1 0.2
Other necessary works Detach/attach 1 pc. Guard 1.0
80 Pump relation See 33.1.8
81 Pump ASSY Detach/attach 1 pc. 2.0
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.2
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 0.8
85 • Pump slinging Detach/attach 1 pc. 0.4
86 • Cleaning Cleaning 1 pc. 0.1
87 • Vent air Adjust 1 pc. 0.1
88 Pump ASSY O/H 1 pc. 3.0
Other necessary works Detach/attach 1 pc. Guard, Counterweight 1.0
90 Swing motor unit relation See 33.1.18
91 Swing motor ASSY Detach/attach 1 pc. 2.2
92 • Piping Detach/attach 1 set 0.8
93 • Mounting bolt Detach/attach 1 set 0.6
94 • Unit slinging Detach/attach 1 pc. 0.4
95 • Cleaning and sealant Cleaning 1 set 0.2
96 Swing motor O/H 1 pc. 3.0
97 Swing reduction gear O/H 1 pc. 3.5

12-7
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
100 Swivel joint relation See 33.1.19
101 Swivel joint ASSY Detach/attach 1 2.2
102 • Piping (Top part only) Detach/attach 1 set 0.4
103 • Whirl stop bolt Detach/attach 1 0.2
104 • Cover Detach/attach 1 0.3
105 • Joint & elbow Detach/attach 1 set 0.3
106 • Mounting bolts Detach/attach 1 set 0.3
107 • Swivel joint slinging Detach/attach 1 0.3
108 • Cleaning Cleaning 1 set 0.2
109 Swivel joint O/H 1 set 3.0
Other necessary works Detach/attach 1 set Lower piping 0.5

120 Main control valve See 33.1.15

121 Main control valve ASSY Detach/attach 1 pc. 2.0
122 • Attach tag to port name of pipe Preparation 1 pc. 0.5
123 • Piping Detach/attach 1 set 1.2
124 • Bracket mounting bolts Detach/attach 1 set 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 5.0
Other necessary works Detach/attach 1 set Guard 1.0
03 Swing frame

130 Valve relation

131 Solenoid valve ASSY (7-section) Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
133 • Piping Detach/attach 1 set 0.5
134 • Mounting bolts Detach/attach 1 set 0.3
Other necessary works Detach/attach 1 set Guard 0.6
135 Hydro valve assy (Swing pilot line) Detach/attach 1 set 0.3

140 Engine (E/G) mounting relation See 33.1.13

141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.5
142 • Harness connector & grounding & Detach/attach 1 set 0.2
cable connection
143 • Fuel hose Detach/attach 1 set 0.1
144 • Others Detach/attach 1 set 0.4
145 • Mounting bolt Detach/attach 1 pc. 0.4
146 • Engine slinging Detach/attach 1 set 0.2
147 • Cleaning Cleaning 1 pc. 0.2
148 Engine O/H 1 set Reference for engine (Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
Detach/attach 1 set Removing and installing Counterweight 0.4
Detach/attach 1 set Removing and installing pump 2.0
Detach/attach 1 set Removing and installing air cleaner 0.4
Detach/attach 1 set Removing and installing muffler 0.4
Detach/attach 1 set Removing and installing radiator 2.5

12-8
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
150 Upper frame See 33.1.20
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.0
152 • Mounting bolts Detach/attach 1 set 0.3
153 • Upper frame slinging Detach/attach 1 pc. 0.3
03 Swing frame

154 • Cleaning Cleaning 1 set 0.2

155 • Sealant Apply 1 set 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.3
Detach/attach 1 set Counterweight 0.4
Detach/attach 1 set Boom 1.4

00 Travel relation See 34.1.2

01 Track link ASSY Detach/attach One side Include adjustment of tension 1.0
02 • Track link attaching and detaching position Preparation One side 0.1
03 • Master pin Detach/attach One side 0.4
04 • Track link extending and winding Detach/attach One side 0.4
05 Shoe plate Replace 1 pc. 0.4

10 Upper roller relation See 34.1.3

11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0

20 Lower roller relation See 34.1.4

21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.0
04 Travel system

30 Front idler relation See 34.1.5

31 Front idler ASSY Detach/attach One side After removing track link 0.5
32 Front idler ASSY slinging Detach/attach One side 0.2
33 Front idler ASSY Detaching One side 0.2
34 Idler ASSY O/H One side 1.0
35 Idler adjuster ASSY O/H One side Replace spring 2.0
36 • Grease cylinder O/H One side 0.5

40 Sprocket See 34.1.6

41 Sprocket Replace One side After removing track link 0.5

50 Travel motor relation See 34.1.7

51 Travel motor ASSY Detach/attach One side After removing track link 1.4
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 0.7
54 • Motor mounting bolts Detach/attach One side 0.4
55 • Motor slinging Detach/attach One side 0.1
56 Motor cleaning Cleaning One side 0.1
57 Travel motor O/H One side 3.0

12-9
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
58 Travel reduction gear O/H One side 3.0

60 Swivel joint relation

04 Travel system

61 Pipe on swivel joint travel side Detach/attach 1 pc. See 33.1.19 0.5
62 Swivel joint O/H 1 pc. See 33.2.6 3.0

70 Swing bearing See 34.1.8

71 Swing bearing ASSY Detach/attach 1 pc. After removing upper frame 0.6
72 Swing bearing mounting bolts Detach/attach 1 set 0.4
73 Swing bearing slinging Detach/attach 1 pc. 0.2

Controller
C-1 Controller (KPSS)
C-2 Gauge cluster
C-4 Air conditioner Amplifier
C-8 Engine controller
Replace 1 0.5
Replace 1 1.0
Replace 1 2.0
Replace 1 0.5

Diode
D-4 Diode Replace 1 0.3
D-5 Diode Replace 1 0.3
D-6 Diode Replace 1 0.3
D-9 Diode Replace 1 0.3
06 Electric equipments

D-10 Diode Replace 1 0.3

D-11 Diode Replace 1 0.3
D-12 Diode Replace 1 0.3
D-13 Diode Replace 1 0.3
D-14 Diode Replace 1 0.3
D-15 Diode Replace 1 0.3
D-16 Diode Replace 1 0.3
D-17 Diode Replace 1 0.3

Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0

12-10
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
E-11 Air-con compressor Replace 1 0.4
E-12 Battery Replace 2 0.4
E-13 Travel alarm Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3
E-15 Fusible link Replace 1 0.2
E-22 DC-DC controller Replace 1 0.2
E-23 12V socket Replace 1 0.3
E-40 Tuner AM & FM (12V) Replace 1 0.3
E-41 Speaker (LH) (12V) Replace 1 0.3
E-42 Speaker (RH) (12V) Replace 1 0.3

Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-5 Room light Replace 1 0.2
L-6 Boom work light (right) Replace 1 0.2
06 Electric equipments

L-7 Cab work light front 1 Replace 1 0.4

L-8 Cab work light front 2 Replace 1 0.4
L-11 Eng. room light Replace 1 0.2

Motor
M-1 Starter motor Replace 1 Include Counterweight removing and installing. 1.0
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor Replace 1 0.5

Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.3
PSV-B P2 unload proportional valve Replace 1 0.3
PSV-C Travel straight proportional valve Replace 1 0.3
PSV-D P1 unload proportional valve Replace 1 0.3
Opt. relief adjustment proportional
PSV-E Replace 1 0.3
valve 1
Opt. relief adjustment proportional
PSV-I Replace 1 0.3
valve 2
PSV-S Boom electric cushion proportional valve Replace 1 0.3
PSV-P1 P1 pump proportional valve Replace 1 0.3
PSV-P2 P2 pump proportional valve Replace 1 0.3

12-11
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-8 Travel alarm relay Replace 1 0.1
R-9 Cab work light relay 1 Replace 1 0.1
R-11 Cab work light relay 2 Replace 1 0.1
R-17 Extra dis-pressure relay Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
06 Electric equipments

R-31 Wiper motor arc prevention relay Replace 1 0.1

R-32 Washer motor relay Replace 1 0.1

Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.3
SE-15 Fuel level sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-17 Boom potentio Replace 1 0.5
SE-19 Arm potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.3
SE-23 Pressure sensor : P2 pump Replace 1 0.3
SE-26 Pressure sensor : Boom head over load alarm Replace 1 0.3
SE-28 Extra pressure Replace 1 0.3
SE-29 Opt. selector detect sensor Replace 1 0.3

12-12
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
Solenoid
SV-1 Swing parking SOL Replace 1 0.3
SV-3 2-speed travel SOL Replace 1 0.3
SV-4 Safety lock lever SOL Replace 1 0.3

Switch
SW-1 Key switch
SW-4 Swing parking release switch
SW-7 Engine oil pressure switch
06 Electric equipments
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3

SW-8 Clogged air filter switch Replace 1 0.3

SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lock lever switch Replace 1 0.3
SW-12 Over load alarm select switch Replace 1 0.3
SW-13 Travel alarm switch Replace 1 0.3
SW-15 Conflux/single select switch Replace 1 0.3
SW-16 Eng. room light switch Replace 1 0.3
SW-17 Skylight wiper switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-22 KPSS release switch Replace 1 0.3
SW-26 Cab work light switch Replace 1 0.3
SW-55 Boom work light switch Replace 1 0.3
SW-56 Fuel supply auto stop switch Replace 1 0.3

12-13
12. STANDARD MAINTENANCE TIME TABLE

12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

This page is left blank because we had not received related infomation from "Engineerring Division".

12-14
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED13-2
13.2 PERFORMANCE INSPECTION STANDARD TABLE .....................................................13-3
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-5
13.3.1 MEASUREMENT OF ENGINE SPEED ..................................................................13-5
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-6
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-6
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-6
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-7
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-9
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-10
13.5.1 TRAVEL SPEED.....................................................................................................13-10
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-10
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-11
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-12
13.6 MEASURING SWING PERFORMANCES.......................................................................13-13
13.6.1 SWING SPEED ......................................................................................................13-13
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-13
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-14
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-15
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-16
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-16
13.7.2 OIL TIGHTNESS OF CYLINDERS .........................................................................13-17
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-18
13.9 MECHATRO CONTROLLER...........................................................................................13-19
13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................................13-19
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT) 13-19

13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

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

13-2
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2 PERFORMANCE INSPECTION STANDARD TABLE

Unless otherwise specified, measure it on "H" mode.

Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition

Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition

or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 30 - 30 LOW throttle
Measure the engine
Engine speed

H mode Hi idle 2000 + 30 - 30 Full throttle (HI idle)

not required
Adjustment
speed at multi display on
B mode Hi idle 2000 + 30 - 30 Perform all
the gauge cluster, or min-1
A mode Hi idle 2000 + 30 - 30 measurement with
measure with diesel
Decel 1050 + 30 - 30 the air-conditioner
speed meter.
S mode Hi idle 1900 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure

P1 a1
Main relief

ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

P2 a2
P1 a1
Boost — — — MR1 —
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit

H 37.8 (5480) 0 - 4.0 (-580) OR3 Boom up

Over load relief valve pressure

R 37.8 (5480) 0 - 4.0 (-580) OR8 Arm out

Main pump

Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 37.8 (5480) 0 - 4.0 (-580) OR1 Bucket digging
RH 28.0 (4060) + 3.4 (+493) + 0.5 (+73) OR6 Swing RH
Swing a2
LH 28.0 (4060) + 3.4 (+493) + 0.5 (+73) OR5 Swing LH
FW —
RH a1 34.3 (4970) + 1.7 (+240) - 0.5 (-73) Simultaneous
Travel

RV —
operation of travel
FW —
LH a2 34.3 (4970) + 1.7 (+240) - 0.5 (-73) RH and LH
RV —

13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE

Standard
Inspection item Unit
value
Sprocket revolution 1st speed 30.4 ~ 33.6
min-1
(RH,LH) 2nd speed 50.6 ~ 56.0
Up 3.0 ~ 3.6
Boom
Down 2.7 ~ 3.3
Operating speed

Operating time of In 2.8 ~ 3.4

Arm sec (At no load)
cylinder Out 2.4 ~ 3.0
Digging 2.2 ~ 2.8
Bucket
Dumping 2.1 ~ 2.7
RH
Swing speed 4.7 ~ 5.9 sec / 1 rev
LH
1st speed Iron shoe 20.6 ~ 22.8
Travel speed sec / 20 m
2nd speed Iron shoe 12.8 ~ 14.0
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance

55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 90
ATT amount of drift Boom cylinder 3 mm / 5min (At no load)
Arm cylinder 4
Amount of horizontal play at the bucket tooth 30 ~ 50 mm

The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out











 
  

13-4
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine
Start engine to raise the coolant temperature of
engine to 60 to 90°C (140 to 194°F) at surface of
radiator upper tank.
The E/G coolant tem-perature gauge is used to
measure. The range in white color shows the
temperature of approx. 65 to 105°C (149 to 221°F),
so confirm that the pointer indicates the
temperature within the white range.

RED WHITE

BLUE

(2) Engine speed measured value through service

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

time the "Wiper switch" on the gauge cluster is  

pushed.

4) The screen returns like No.45, No.44....each  
time the "Washer switch" is pushed.
5) The display does not disappear unless the 
  
starter switch is turned to"OFF".
    
Fig. 13-1 Switch for E/G speed indication

NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V

Fig. 13-2 Service diagnosis for E/G speed

measuring (Example)

13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4 MEASUREMENT OF HYDRAULIC PRESSURE

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

After releasing air in the hydraulic oil tank, open the

cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit =" 258 258 =#
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). ,H
,H *!
(2) Pilot circuit
Replace pilot gauge plug (a3) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi). ,H ,H

=!
= =
Fig. 13-3 Gauge port on main pump

13-6
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
PLUG FOR
OR7 : ARM (H) OPTIONAL RELIEF

MACHINE
TOP

MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R)

(ATT & TRAVEL)

VIEW FROM RIGHT FRONT OF MACHINE

OR4 : BOOM (R) OR1 : BUCKET (H)

MACHINE
TOP

OR8 : ARM (R) PLUG FOR OPTIONAL RELIEF

VIEW FROM LEFT REAR OF MACHINE

Fig. 13-4 Relief valve position on main control valve

13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(2) Pilot relief valve

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

A3

a3

Dr3

B3
PR1 ADJUST SCREW
FOR PILOT RELIEF

Fig. 13-5 Pilot relief valve position

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

PA PB

SWING RIGHT SWING LEFT

OVERLOAD RELIEF OVERLOAD RELIEF
OR6 OR5

Fig. 13-6 Swing over load relief position

13-8
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).

: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)

: 6 mm

No. of turns of adjust screw Pressure change MPa (psi)

 

1 turn Approx. 2.1 (305) 
Fig. 13-7 Pilot relief valve
(2) Main relief valve
(Common for travel and ATT sections) %
Loosen lock nut (7) and adjust the pressure with
adjust screw (6). $
Tightening torque : 27~31 N•m (20~23 lbf•ft)

: 19 mm, Adjust screw

: 4 mm Fig. 13-8 Main relief valve

(Travel section, ATT common section)
No. of turns of adjust screw Pressure change MPa (psi)
1 turn Approx. 17.7 (2560)

(3) Over load relief valve

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

: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)

: 6 mm 0-:
Fig. 13-9 Over load relief valve
No. of turns of adjust screw Pressure change MPa (psi) (Boom, bucket, arm sections)

1 turn Approx. 17.7 (2560)

(4) Over load relief valve (Swing) 0-:!& 0-:!

When the pressure adjustment is required, loosen 
lock nut (1) and adjust the pressure with cap (2).

: 30, 38mm,
Tightening torque :118 N•m (87 lbf•ft)

: 12 mm 4 !
Fig. 13-10 Swing over load relief valve
No. of turns of adjust screw Pressure change MPa (psi)
1 turn Approx. 10 (1450)

(5) Travel over load relief valve #

This valve was adjusted by manufacturer and
shipped. Do not replace the parts except O-ring.
Loosen cap (205) and adjust the pressure with shim
(213).
!
: 10 mm Fig. 13-11 Travel over load relief valve

13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation
Attach the reflection panel with a magnet to the Fig. 13-12 One side lifted position
travel motor cover.
Swing the swing frame through 90°as shown in Fig.
13-12 and make the crawler on one side take off the REFLECTION
ground, using the attachment. PANEL
(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd speed
Measuring points ; Right and left
Method, example 1 ;
Measure revolution with a stroboscope
Fig. 13-13 Adhering position of reflection panel
Method, example 2 ;
Measure the revolutions per minute visually. Sprocket revolution Unit min-1
Measurement item Standard Reference value Service
value for remedy limit
RH H mode 1st speed 30.4~33.6 23.7~26.2 21.4 or less
&
LH H mode 2nd speed 50.6~56.0 39.5~43.7 35.7 or less

13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m (66ft) BOOM FOOT PIN
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the
travel drive system.
(2) Condition
Hydraulic oil temperature ; ARM TOP PIN
45~55°C (113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Fig. 13-14 Travel position
Engine revolution; Hi idle

13-10
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)

1) Measure the max. deviation distance of the

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

13.5.3 PERFORMANCES OF PARKING BRAKE

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

C
GUIDE FRAME
Fig. 13-17 Method of measurement

Parking brake Unit : mm(in)/5min

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

13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD 90 o 10
To measure the drain rate of the travel motor and to (3.54") (0.394")

confirm the performances of the travel motor. o 22 PIPE 40

(0.866") (1.57")
(2) Conditions
Hydraulic oil temperature ; RIB "A" STOPPER
150
(5.91")
45~55°C (113~131°F) "B"
Engine revolution; Hi idle
(3) Preparation o 80
(3.15")
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel
sprockets. Fig. 13-18 Location of stopper applied to travel
2) Stop the engine and release pressure from the sprocket
hydraulic circuit.
3) Connect a hose with the drain port of the travel
motor and take drain in a container.
(4) Measurement ; at Travel Lock

Unless you observe the rotary force direction at

travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Fig. 13-18)

1) Start the engine and relieve pressure at the full

stroke of the travel lever. Fig. 13-19 Method of measuring the drain rate of
2) Measure the drain rate for 30 seconds of travel motor
relieving.
Drain rate of motor Unit : L(gal)/30sec
Measuring Reference value
position Standard value for remedy Service limit
Drain rate 5 (1.3) 13 (3.4) 15~ (4.0~)

13-12
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump and the
swing motor of the swing drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
Put the bucket empty and extend the boom, arm
and bucket cylinder fully. Fig. 13-20 Swing speed measuring position (at the
And the machine becomes a position of minimum min. reach)
reach.
Swing speed Unit : sec/rev
(4) Measurement Measuring Reference value
position Standard value for remedy Service limit
Swing the machine by bringing the swing lever to its
Swing speed at
full stroke. Measure the time required to make two min. reach 4.7~5.9 6.0~7.6 8.0~

turns after one turn of preliminary run and calculate

the time required for one turn.

13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by the ARM TOP BOOM FOOT
swing relief valve. PIN PIN

(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation Fig. 13-21 Swing brake performance measuring
1) Put the bucket empty, retract the arm cylinder position
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
2) Put a matching mark on the outer circumference
of the swing bearing of the upper frame side and
of the track frame side. Place two poles (flags)
on the front and back of the extended line of the
matching mark.

13-13
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(4) Measurement MEASURING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
1) When operating in regular swing speed, by
MATCHING MARKS ON
shifting lever to neutral position at pole position
OUTER RACE
the swing operation stops.
2) Calculate the swing drift angle by the following
equation, after the upper swing body stops,
using the amount of deflection (m) of the
matching marks on the swing race and the length
MATCHING MARKS
(m) of the circumference of the swing race : ON INNER RACE

 

   Fig. 13-22 Measuring position of swing brake
         

    

  
    performances

  
   Swing brake performance Unit : degree
Measuring Reference value
position Standard value for remedy Service limit
Swing 180 75 83 90 ~

13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.
(2) Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the
boom so that the arm top pin is positioned at same
height with boom foot pin.
Fig. 13-23 Swing parking brake performance
measuring position
(3) Preparation MEASUREING THE LENGTH OF THE ARC OVER
Put the angle meter on the shoe plate and make THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
sure that the angle is more than 15 degree. OUTER RACE
Put a matching mark on the outer race side and on
the inner race side.
(4) Measurement
When five minutes has passed after the engine
stops, measure the length of the movement of the
MATCHING MARKS
matching marks. ON INNER RACE

Fig. 13-24 Measuring position of swing parking

brake performances

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

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

13-14
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
(2) Conditions
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take
oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock Fig. 13-25
1) Start the engine and put the side faces of bucket
Travel deviation Unit : L(gal)/30sec
against the inside of the right or left shoe plates. Measuring Reference value
position Standard value for remedy Service limit
2) Relieve the swing motor at full stroke of the
swing motion. Drain rate 5.0 (1.3) 8.0 (2.1) 11~ (2.9~)

3) Collect the amount of drained oil in a container

for 30 seconds.

13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm and
bucket and confirm the performances between the
hydraulic pump and the cylinder of the attachment
drive system.
(2) Condition  

Hydraulic oil temperature ; 45~55°C (113~131°F) Fig. 13-26 Measuring position for bucket digging
Engine revolution; Hi idle and dump
Operating time excluding the cushion stroke
 
(3) Preparation
  


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

When lowering the boom, allow the bucket onto a

soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other
solid material.
30cm (1ft)
Measurement 2 ; Arm in and out, bucket digging
and dump Fig. 13-28 Measuring position for arm in and out
In a position in which the tooth of the bucket rises to motions
a level of about 30cm (1ft) above ground, measure
Cylinder Operating time Unit : sec
the full stroke operating time required with the arm Measuring Reference value
and bucket operating levers at full stroke. position Standard value for remedy Service limit
2.2~2.8 2.8~3.6 3.8~
2.1~2.7 2.7~3.5 3.6~
3.0~3.6 3.8~4.6 5.0~
2.7~3.3 3.5~4.2 4.5~
2.8~3.4 3.6~4.4 4.7~
2.4~3.0 3.1~3.8 4.1~

13-16
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose B
Confirm that the cylinder oil tight by checking the BOOM FOOT PIN
moving length of the cylinder rods. C
(2) Condition A
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground ARM TOP PIN D
After cylinders are replaced, bleed off air from the
cylinders, before checking for oil tightness. Fig. 13-29
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range Oil tightness of cylinder Unit : mm(in)/5min
of the cushioning mechanism. Measuring
Standard value
Reference value
Service limit
position for remedy
(3) Preparation A 3 (0.12) 6 (0.24) 9~ (0.35~)
Put the bucket empty. Extend the arm cylinder rod B 4 (0.16) 8 (0.32) 12~ (0.47~)
50mm (2in) from the most retracted position. And C - - -
extend the bucket cylinders fully. Then hold the D 90 (3.54) 115 (4.53) 150~ (5.91~)
boom so that the arm top pin is positioned at same
height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is
turned off.

13-17
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.8 MEASURING PERFORMANCES OF SWING BEARING

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

abnormal sound during turning.

Fig. 13-30 How to measure the axial play of swing
bearing
(3) Preparation
1) Install a dial indicator to the magnetic base and
fix it to the lower frame.
90 ~100
2) Direct the upper swing body and the lower frame
toward the travel direction, bring the probe of the
dial indicator in contact with the bottom surface
30cm (1ft)
of the outer race on the swing body side and set
the reading at zero. Fig. 13-31 Measuring position 1
(4) Measurement 1 (Measuring position 1 and 2)
1) Measure the displacement of the outer race in ARM TOP BOOM FOOT
PIN PIN
the axial direction in position 1 [The arm at
90°~110° and the crawler front is lifted by
attachment about 30cm (1ft)] and in position 2,
using a dial indicator.

Fig. 13-32 Measuring position 2

Axial play of swing bearing Unit : mm (in)

Measuring Reference value
position Standard value for remedy Service limit
0.5~1.5 1.9~2.9 3.0~
A (0.02~0.06) (0.08~0.11) (0.12~)

(5) Measurement 2 (Measuring position 3)

1) Retract the arm cylinder fully and extend the ARM TOP BOOM FOOT
PIN PIN
bucket cylinder fully. And move the boom so that
the arm top pin is positioned at same height with
boom foot pin. Then swing the bucket right and
left by man power.
But in this case, the gap of the attachment is
included.
Fig. 13-33 Measuring position 3

Right and left movement of the tip of bucket Unit : mm (in)

Measuring Reference value
position Standard value for remedy Service limit
Bucket 30~50 (1.18~1.97) 80 (3.15) 120 (4.72)

13-18
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

INJECTOR
C-8:
ENGINE CONTROLLER
E-1:
C-2: FUSE&RELAY (ECU)
GAUGE CLUSTER BOX

ENGINE
ENGINE SPEED
SENSOR

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

Fig. 13-34 INPUT / OUTPUT

13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (B-C ADJUSTMENT)

13.9.2.1 PURPOSE OF THE ADJUSTMENT

There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function
to ensure performance of machine.
(1) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
engine rated output.
(2) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the operability further.

13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

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

13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the air-conditioner 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.

13-20
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.2.4 ADJUSTING PROCEDURE

MULTI DISPLAY

BUZZER STOP SWITCH WORK MODE SELECT SWITCH

WASHER SWITCH

WIPER SWITCH
SELECT SWITCH

Fig. 13-35 Gauge cluster

(1) Adjustment of pump ("B" adjustment)
Procedure
1) Turn starter key switch ON keeping the work mode selector switch on the 


gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If 
the engine is started, the following indication is not displayed. Therefore do not
start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
it and the screen for selecting adjustment is displayed. When adjustment data
ADJUST
READY
is not entered in mechatro controller, "READY" is indicated. If the adjustment FEED
operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Press selector switch on gauge cluster to display "START ENG".
 
"Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration  

 
command voltage) are indicated.


 
     




4) The adjustment automatically shifts from engine starting to pump, the speed
   
shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. 
  

And the unloading proportional valve and pump proportional valve actuate,   
   

accordingly the loading of pump is increased.    
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are indicated.
5) After detection of the engine rated speed, the adjustment of pump is
FINISH PUMP
automatically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M

and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA

not performed, and default value is written.)

13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(2) Adjustment of unloading valve ("C" adjustment)

Procedure
1) The adjustment shifts from pump to unloading, and the unloading valve
MEMORY UNLOAD
actuates, accordingly the pump pressure is detected. And "MEMORY ENGINE SPEED
2000rpm
UNLOAD" is displayed. PUMP PRESSURE
C-1 2.0M C-2 2.0M

The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPO- PROPO-VALVE
D-1 300mA D-2 300mA

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 current of P1, P2

unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically stored.)

(3) Corrective actions taken when the adjustment can not be performed;

1) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve
current reaches to the specified value.

The P1 and P2 pump pressures usually increase to 33~38MPa.

When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally.
And so on.

13-22
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

2) In cases where unloading valve can not be performed; And "ERROR

ERROR UNLOAD
UNLOAD" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The pump pressure does not increase up to the pressure in the range of the D-1 300mA D-2 300mA
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.

Normally the pump pressures of P1 and p2 pumps gradually increase to

10~25MPa.
(It may be affected by operating oil temperature.)

When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
(4) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be
performed normally.
First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the
adjustment could not be performed normally.

13-23
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(5) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge 


cluster pressed, 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"
ADJUST
READY
is displayed. FEED
When adjustment data is not entered in mechatro controller, "READY" is
indicated. If the adjustment operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and
 

select "ADJUST UNLOAD". (See Fig. 13-35)  
Like the output adjustment, when adjustment data is not entered in mechatro 
controller, "READY" is indicated. If the adjustment operation is once
performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".
 
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration  

 
command voltage) are indicated.


 
     




5) After starting engine, press selector switch on gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is indicated, the engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M

"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" PROPO-VALVE

D-1 300mA D-2 300mA

(acceleration command current) are indicated.

6) When the unloading proportional valve operates to the specified value, the
 

adjustment of unloading proportional valve automatically completes. "FINISH   

UNLOAD" is indicated.  
   
  

The speed is shifted to the speed corresponding to acceleration potentiometer.  
 

The value of adjusting current is indicated on the display of current of P1 and

P2 unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically stored.)

13-24
 21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM.........................................................21-3

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..................................................21-3
21.1.2 UNLOAD VALVE CONTROL..................................................................................21-5
21
21.1.3 POSITIVE CONTROL & P-Q CONTROL ...............................................................21-6
21.1.4 BOOM UP CONFLUX CONTROL ..........................................................................21-8
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-9
21.1.6 ARM-IN ANTI-CAVITATION CONTROL ................................................................21-11
21.1.7 ARM-OUT CONFLUX CONTROL ..........................................................................21-12
21.1.8 BUCKET DIGGING (DUMP) CONTROL ................................................................21-13
21.1.9 SWING PRIORITY CONTROL ...............................................................................21-14
21.1.10 TRAVEL STRAIGHT CONTROL ............................................................................21-15
21.1.11 PRESSURE RELEASE CONTROL (INCLUDE EXTRA PRESSURE RELEASE) .21-17
21.1.12 N&B SWITCH CONTROL (OPTION) .....................................................................21-19
21.1.13 OPTION CONFLUX CONTROL (OPTION) ............................................................21-20
21.1.14 N&B SOLENOID RELIEF VALVE CONTROL ........................................................21-21
21.2 MECHATRO CONTROLLER...........................................................................................21-22
21.2.1 SUMMARY OF MULTI DISPLAY ...........................................................................21-22
21.2.2 SELF DIAGNOSIS DISPLAY..................................................................................21-33
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-36
21.2.4 TROUBLE HISTORY DIAGNOSIS .........................................................................21-46
21.2.5 TROUBLE DIAGNOSIS MODE ..............................................................................21-47
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-48
21.2.7 ADJUSTING PROCEDURE OF DISPLAY .............................................................21-49
21.2.8 MECHATRO CONTROL EQUIPMENT ..................................................................21-52

21-1
21. MECHATRO CONTROL SYSTEM

PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the
conditions before and after each conversion, refer to the hydraulic system and the electric system.

21-2
 21. MECHATRO CONTROL SYSTEM

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL
ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC
PILOT SECONDARY PRESSURE VOLTAGE OUTPUT L1
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT
L2

LH RH LH RH
OPTION PILOT VALVE

PILOT VALVE
PILOT VALVE FOR TRAVEL
FOR ATT

SE-9
SE-10

SE-11
MULTI CONTROL VALVE OR SENSOR BLOCK

LOW PRESSURE SENSOR

SE-4
(4)
L3
SE-3
(3) L4
GAUGE CLUSTER
SE-2 L5
(2)
LCD DISPLAY
FOR SELECTION SE-1
(1)
FUEL GAUGE
COOLANT TEMP. GAUGE SE-8
(8)
LOWER SW.
SCREEN CHANGE SE-7
(7)
BUZZER STOP L6
MODE (6)
WASHER
WIPER SE-5
(5)
OUTPUT VOLTAGE

TRAVEL
DECEL
SERIAL COMMUNICATION

SERIAL COMMUNICATION

ACCEL DIAL

SE-16
SE-23
PROPORTIONAL VOLTAGE

HIGH PRESSURE SENSOR

C-1 SE-22 L7
MECHATRO CONTROLLER A1 A2
ENGINE A3
INJECTOR SPEED SENSOR
SE-13

KPSS
RELEASE SWITCH PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
: INJECTOR P2 PUMP PROPORTIONAL VALVE

: E/G SPEED SENSOR CAN COMMUNICATION L8

C-8
: LOW PRESSURE SENSOR ENGINE CONTROLLER
(ATT : 7pcs, TRAVEL : 2pcs) ENGINE SPEED L9
COMMAND CURRENT
VOLTAGE 24V
PROPORTIONAL COMMAND CURRENT

21-3
21. MECHATRO CONTROL SYSTEM

MAIN CONTROL VALVE

L1

SE-29
L2

ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

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

P1 UNLOAD

SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED

TRAVEL RIGHT
ARM 2 SPEED

ARM 1 SPEED
TRAVEL LEFT

N&B
BUCKET

P2 UNLOAD

OPTION
STRAIGHT

SWING
TRAVEL SOL

P1 P2
(1) (3) (5) (7) PSV-I
L3 DIGGING UP REVERSE REVERSE RIGHT ARM IN
L4 SOLENOID VALVE
L5

L6

SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE

SAFETY LOCK LEVER

TRAVEL 1,2 SPEED
TRAVEL STRAIGHT
ARM IN 2 SPEED

L7
P1 UNLOAD

P2 UNLOAD

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

(7)
ARM IN
L8 BUCKET CYLINDER
DIGGING / DUMP CONFLUX

L9
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK

21-4
 21. MECHATRO CONTROL SYSTEM

21.1.2 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

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

21-5
21. MECHATRO CONTROL SYSTEM

21.1.3 POSITIVE CONTROL & P-Q CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
OPTIONAL
PILOT VALVE
P2 P1

SE-23 SE-22

SE-11

(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE

PILOT VALVE
FOR TRAVEL

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

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

PILOT SECONDARY PRESSURE

pi

pi

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

21-6
 21. MECHATRO CONTROL SYSTEM

(1) Positive control

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

POSITIVE CONTROL P-Q CONTROL

PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE

SECONDARY PRESSURE
PUMP PROPORTIONAL

PUMP PROPORTIONAL

PILOT PRESSURE PUMP DELIVERY PRESSURE

21-7
21. MECHATRO CONTROL SYSTEM

21.1.4 BOOM UP CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

LOW
PRESSURE
SENSOR
SE-3

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

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

(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 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 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.

21-8
 21. MECHATRO CONTROL SYSTEM

21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED

ARM 2 SPEED
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
PILOT
VALVE
P2 P1

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

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

ARM IN PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT 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

21-9
21. MECHATRO CONTROL SYSTEM

(1) Recirculation and conflux (Low loading)

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

21-10
 21. MECHATRO CONTROL SYSTEM

21.1.6 ARM-IN ANTI-CAVITATION CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE

P2 P1

LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7

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

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

(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 valves output pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump
delivery rate is low due to low engine speed.

21-11
21. MECHATRO CONTROL SYSTEM

21.1.7 ARM-OUT CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

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

ARM OUT PILOT SECONDARY PRESSURE

pi

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

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

(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 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 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.

21-12
 21. MECHATRO CONTROL SYSTEM

21.1.8 BUCKET DIGGING (DUMP) CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE P2 P1

LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
(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 pump proportional valve, and P1 unload
proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 pump delivery rate and switches P1 unload valve.

21-13
21. MECHATRO CONTROL SYSTEM

21.1.9 SWING PRIORITY CONTROL

BOOM UP CONFLUX

P1 UNLOAD
PILOT

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
VALVE

TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

LOW
PRESSURE
SENSOR
SE-5 SE-7
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
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

(1) During arm-in operation, arm operating pilot secondary pressure switches arm 1 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 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 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 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.

21-14
 21. MECHATRO CONTROL SYSTEM

21.1.10 TRAVEL STRAIGHT CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
OPTIONAL

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

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

TRAVEL STRAIGHT SIGNAL

pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT 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
MECHATRO
pi : PROPORTIONAL VALVE
PILOT SECONDARY PRESSURE CONTROLLER
SECONDARY PRESSURE

21-15
21. MECHATRO CONTROL SYSTEM

(1) Judgment travel straight

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

 
       
 
 
 
 
 
 

21-16
 21. MECHATRO CONTROL SYSTEM

21.1.11 PRESSURE RELEASE CONTROL (INCLUDE EXTRA PRESSURE RELEASE)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1

SE-23 SE-22

ENGINE
EXTRA
P4

SE-28 UNLOAD VALVE

PRESSURE
RELEASE
CONTROL

pi

SOLENOID

pi
ENGINE SPEED
CONTROL

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER SECONDARY PRESSURE

(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot,
accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum
tilt angle.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes
engine speed to pressure release control speed.
3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and
P2 unload valves to the maximum opening.

21-17
21. MECHATRO CONTROL SYSTEM

(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to
be released by operating each control lever and switching spool with the unload valve opened.
(5) In case of EXTRA pressure release specification, switch mechatro controller to pressure release control mode
in a similar way of above mentioned (1). And in similar way of usual pressure release control, pump delivery oil
is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating
each control lever and switching spool.

21-18
 21. MECHATRO CONTROL SYSTEM

21.1.12 N&B SWITCH CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

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

BUCKET
OPTION
SE-29

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

A MODE

B MODE

GAUGE CLUSTER

pi

B MODE SWITCH MECHATRO

CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

(1) Nibbler circuit

1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display
is output to gauge cluster.
(2) Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display
is output to gauge cluster.

21-19
21. MECHATRO CONTROL SYSTEM

21.1.13 OPTION CONFLUX CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD
PILOT VALVE

TRAVEL
P2 P1

SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

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
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE

(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting option operation, option operating pilot pressure switches option spool and is input to low pressure
sensor.
(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.

21-20
 21. MECHATRO CONTROL SYSTEM

21.1.14 N&B SOLENOID RELIEF VALVE CONTROL

SOLENOID RELIEF
PSV-E

BOOM UP CONFLUX
VALVE

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
SOLENOID RELIEF

PILOT P2 P1
VALVE
VALVE

PSV-I

RELIEF VALVE
SOLENOID
OUTPUT
LOW
PRESSURE
SENSOR
SE-11

OPTION PILOT
SECONDARY PRESSURE

(1) Solenoid relief valve

Using solenoid relief valve, relief pressure is able to set in advance.
1) Using gauge cluster, setting pressure of A and B mode is selectable individually.
2) When optional operation is done, command value according to setting pressure which is selected with
solenoid relief valve is output from mechatro controller.
3) Each proportional valve outputs pilot proportional secondary pressure according to command value from
mechatro controller, and the pressure switches relief pressure.

21-21
21. MECHATRO CONTROL SYSTEM

21.2 MECHATRO CONTROLLER

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

GAUGE
CLUSTER

SAFETY
LOCK
LEVER

RIGHT
CONTROL
LEVER

STARTER SWITCH

ACCEL DIAL

KPSS WORK MODE

RELEASE SWITCH

SWING PARKING
BRAKE RELEASE
SWITCH

ENGINE
FUSE & ECU
MECHATRO RELAY BOX
CONTROLLER
A DETAIL A

(2) Gauge cluster

No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)

21-22
 21. MECHATRO CONTROL SYSTEM

(3) KPSS work mode switch

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

• S mode: For standard excavating work

• H mode: For heavy duty excavating work
• B mode: For works with breaker
• A mode: For demolition works with crusher
(Nibbler)
10:25
S
• The initial setting (default) of work mode had been set
to "S" mode at factory.
As for the work mode after the engine starts, the
mode that was used the last time engine was stopped
is automatically set.
Check that the selected mode conforms to the work
before starting work.
• Check that the attachment in use conforms to the
work mode before starting work. If not conformed,
select proper mode with the work mode select switch.
• The operation under improper work mode may cause
damage to machine.

Work mode Display Contents

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

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

B mode
10:25 For the work with breaker, select "B mode" without fail.

A mode
10:25 For the work with crusher (nibbler), select "A mode".

For the work with breaker, select "B mode" without fail.
The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and
breaker.

21-23
21. MECHATRO CONTROL SYSTEM

(4) Procedure of setting a flow rate and a option relief pressure at A/B mode

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch 5
8 Select Switch 8 7 6
Fig. 21-1

According to some kind of attachment, it is required to change the flow rate and relief pressure for service circuit.
Regarding the adjustment of flow rate and relief pressure for Nibbler (Crusher) and Breaker, the settings of 9
patterns are available.

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9

Flow rate L/min 130 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet
Nibbler
Pressure A MPa 25 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet
(Crusher)
Pressure B MPa 25 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9

Flow rate L/min 130 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet
Breaker
Pressure B MPa 34 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet

Both Nibbler (Crusher) and Breaker are set in conditions "SET 1" as factory default in the above table at
shipping.
* The meaning of "Not set yet" shows that 130L/min as flow rate is initial value and 50MPa as pressure is
temporary value.

Set the flow rate and relief pressure in accordance with next procedure.
And these setting values in above adjustment are selectable by using after-mentioned "Flow rate and Relief
pressure Selection".

21-24
 21. MECHATRO CONTROL SYSTEM

1) When using Nibbler (Crusher)

NO.1 (a)
MAIN CONT. P/N
YY22E00100F1
PROGRAM VERSION

1-VER 01.00
2-VER 00.00
SERVICE DIAG 1

+ X3
(b) (c) (d) (e)
LANGUAGE/LOGO LANGUAGE / LOGO 69 ADJ OPT
RISE-UP WIPER
ADJUSTING MODE 1 ADJUSTING MODE 1
ON
18
PRESET BY FACTORY PRESET BY FACTORY FEED FEED

(f)

SET 1 SET SET SET

(g)
L/ L/ L/ L/
Flow rate 120 min Flow rate 100 min Flow rate 130 min Flow rate 110 min

PressureA 25 MPa PressureA 15 MPa PressureA 15 MPa PressureA 15 MPa

. During setting, the pressure

indicates P2 pump's pressure
always.
(h)
L/ L/ L/ L/
Flow rate 120 min Flow rate 100 min Flow rate 130 min Flow rate 110 min

PressureA 33 MPa PressureA 32 MPa PressureA 32 MPa PressureA 30 MPa

Fig.PressB2 Fig.PressB2 Fig.PressB2 Fig.PressB2

(i)
L/ L/ L/ L/
Flow rate 120 min Flow rate 100 min Flow rate 130 min Flow rate 110 min

PressureB 33 MPa PressureB 32 MPa PressureB 32 MPa PressureB 30 MPa

. During setting, the pressure

indicates P2 pump's pressure
always.

1. Hold buzzer stop switch down and turn starter key switch on, and the service diagnosis mode screen (a) is
displayed.
2. Start engine and select work mode "A".
3. Hold buzzer stop switch down and press select switch 3 times, and the adjusting mode screen (b) is displayed.
4. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to
"ADJUSTING MODE 1" screen (c) and then press select switch and the "ADJUSTING MODE 1" (RISE-UP
WIPER) screen (d) is displayed.
5. In operations of UP ARROW and DOWN ARROW, move cursor to "ADJ OPT (Nibbler)" screen (c) and then
press select switch and the "Nibbler operation relief pressure adjustment (SET 1)" screen (g) is displayed.
6. Select the desired setting number (The available setting range is 9 steps from 1 to 9.) and then press select
switch and the "Flow rate adjust screen" (g) is displayed.
7. In operations of UP ARROW and DOWN ARROW, set the flow rate. And press the select switch and then the
"Pressure (A) adjusting screen" (h) is displayed.
8. While depressing the heel of optional right pedal (P2 pump side optional operation), using UP ARROW and
DOWN ARROW and adjust the pressure. When desired pressure is indicated, press the select switch to set.
(*When the select switch is pressed, be careful that 0MPa is usually displayed at time if you do not depress
the heel side of right pedal down.)
9. Then "Pressure (B) adjusting screen" (i) is indicated, and while depressing the toe of optional right pedal,
using UP ARROW and DOWN ARROW and adjust the pressure. When desired pressure is indicated, press
the select switch to set.
(*When the select switch is pressed, be careful that 0MPa is usually displayed at time if you do not depress
the toe side of right pedal down.)
10.Then the screen returns to "ADJ OPT (Nibbler)" (e) select screen.

21-25
21. MECHATRO CONTROL SYSTEM

2) When using Breaker

NO.1 (a)
MAIN CONT. P/N
YY22E00100F1
PROGRAM VERSION

1-VER 01.00
2-VER 00.00
SERVICE DIAG 1

+ X3
(b) (c) (d) (j)
LANGUAGE/LOGO LANGUAGE / LOGO 69 ADJ OPT
RISE-UP WIPER
ADJUSTING MODE 1 ADJUSTING MODE 1
ON
18
PRESET BY FACTORY PRESET BY FACTORY FEED FEED

(k)

SET 1 SET SET SET

. During setting, the pressure

indicates P2 pump's pressure
always.

(m)
L/ L/ L/ L/
Flow rate 120 min Flow rate 100 min Flow rate 130 min Flow rate 110 min

PressureB 34 MPa PressureB 15 MPa PressureB 15 MPa PressureB 15 MPa

. During setting, the pressure

indicates P2 pump's pressure
always.

(n)
L/ L/ L/ L/
Flow rate 120 min Flow rate 100 min Flow rate 130 min Flow rate 110 min

PressureB 30 MPa PressureB 28 MPa PressureB 25 MPa PressureB 25 MPa

1. Hold buzzer stop switch down and turn starter key switch on, and the service diagnosis mode screen (a) is
displayed.
2. Start engine and select work mode "B".
3. Hold buzzer stop switch down and press select switch 3 times, and the adjusting mode screen (b) is displayed.
4. In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to
"ADJUSTING MODE 1" screen (c) and then press select switch and the "ADJUSTING MODE 1" (RISE-UP
WIPER) screen (d) is displayed.
5. In operations of UP ARROW and DOWN ARROW, move cursor to "ADJ OPT (Breaker)" screen (c) and then
press select switch and the "Breaker operation relief pressure adjustment (SET 1)" screen (j) is displayed.
6. Select the desired setting number (The available setting range is 9 steps from 1 to 9.) and then press select
switch and the "Flow rate adjust screen" (m) is displayed.
7. In operations of UP ARROW and DOWN ARROW, set the flow rate. And press the select switch and then the
"Pressure (B) adjusting screen" (n) is displayed.
8. While depressing the toe of optional right pedal (P2 pump side optional operation), using UP ARROW and
DOWN ARROW and adjust the pressure. When desired pressure is indicated, press the select switch to set.
(*When the select switch is pressed, be careful that 0MPa is usually displayed at time if you do not depress
the toe side of right pedal down.)
9. Then the screen returns to "ADJ OPT (Breaker)" select screen.

21-26
 21. MECHATRO CONTROL SYSTEM

(5) Pump Flow Rate and Relief Pressure Selection (A mode/ B mode)
Flow rate and Relief pressure Selection
Above-mentioned setting values are selectable from desired combination of flow rate and relief pressure.

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9

Flow rate L/min 130 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet
Nibbler
Pressure A MPa 25 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet
(Crusher)
Pressure B MPa 25 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9

Flow rate L/min 130 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet
Breaker
Pressure B MPa 34 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet

Both Nibbler (Crusher) and Breaker are set in conditions "SET 1" as factory default in the above table at
shipping.
If you select a "Not set yet" from among "SET 2" to "SET 9", pay attention to the relief pressure, because the
pressure is about 20MPa.

Example :
When the upper table is set and the "SET 1" is selected, the values in lower table are applied.

Flow rate 130 L/min

Pressure A 25 MPa
Pressure B 25 MPa

When you need the setting of "SET 2" thru "SET 9", set the values in accordance with above-mentioned "Flow
rate and Relief pressure Adjustment". Select the combination of flow rate and relief pressure in accordance with
next procedure.

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch 5
8 Select Switch 8 7 6
Fig. 21-2

21-27
21. MECHATRO CONTROL SYSTEM

Main screen Attachment mode (A mode)

(a) (b) (b')
These displays are
10:25 Flow rate 130 min Flow rate 130 min
switched automatically
every about 5 sec.
PressureA 25 MPa PressureB 25 MPa alternately
S A A
Selected "SET number" is displayed.
(d)
These arrows are used
for increasing/decreasing
Select suitable mode SET 1 SET 9 "SET number".
for specification
of attachment.

Flow rate 130 min

Screen in Attachment/Breaker mode PressureA 30 MPa

Enter
A mode B mode A
In Breaker mode (B mode)
Flow rate 130 min Flow rate 130 min (c)
PressureA 25 MPa PressureB 25 MPa
Flow rate 130 min
A B
PressureB 25 MPa
(b) (c)
B
Flow rate 130 min
Selected "SET number" is displayed.
PressureB 25 MPa
(d)
These arrows are used
A for increasing/decreasing
SET 1 SET 9 "SET number".
(b')

Flow rate 130 min

PressureB 25 MPa
Enter
B

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. Refer to (b)
(b') and (c).
4. Press select switch (8) in A/B mode display screens (b)/(c)/(b') and the press "SET" number screen (d) is
displayed. This "SET" number contains set flow rate and relief pressure which are selected now. In this
condition, press FEED (4)/FEED (5), and "SET number" is changeable.
5. Select the suitable "SET number" from among the desired setting flow rate and relief pressure, then press
select switch (8) to set the desired condition.

When the switch of conflux flow is selected, the double volume of oil flows.
Check the flow rate and the position of switch before operation whether they are in the best condition for the
attachment. Also check the relief pressure, whether the pressure is suitable for the attachment.
If these flow rate or pressure is unsuitable for the specification of attachment, the attachment and machine may
cause damaging.

21-28
 21. MECHATRO CONTROL SYSTEM

(6) Overload alarm pressure adjustment

If the overload pressure exerts on head side of boom cylinder, the overload alarm sounds. At that time, adjust
the pressure according to the following procedure.

NO.1
MAIN CONT. P/N
(a)
YY22E00100F1
PROGRAM VERSION

1-VER 01.00
2-VER 00.00
SERVICE DIAG 1

+ X3

LANGUAGE / LOGO LANGUAGE / LOGO

ADJUSTING MODE 1 ADJUSTING MODE 1

PRESET BY FACTORY PRESET BY FACTORY

(b) (c)

ADJ OVERLOAD PRESS. RISE-UP WIPER

18 ON
FEED FEED
(e) (d)

ADJ OVERLOAD PRESS. ADJ OVERLOAD PRESS.

18 16
FEED
(f) (e)
Range of adjustment
10~27 MPa
(Default is 18)

1. 1.Hold buzzer stop switch down and turn starter key switch on, and the service diagnosis mode screen (a) is
displayed.
2. 2.Hold buzzer stop switch down and press select switch 3 times, and the adjusting mode screen (b) is
displayed.
3. 3.In operations of UP ARROW (washer switch) and DOWN ARROW (wiper switch), move cursor to
"ADJUSTING MODE 1" screen (c) and then press select switch and the "ADJUSTING MODE 1" (RISE-UP
WIPER) screen (d) is displayed.
4. 4.In operations of UP ARROW and DOWN ARROW, move cursor to "ADJ OVERLOAD PRESS." screen (e)
and then press select switch and the "ADJ OVERLOAD PRESS." screen (f) is displayed.
5. 5.Vary the values by pressing the desired figure in operations UP ARROW and DOWN ARROW. The
available setting range is 18 steps from 10 to 27MPa.
(Example) 18: If the pressure of boom cylinder head exceeds 18MPa, alarm sounds.
* Initial setting value is 18 (MPa).
6. Press select switch and the adjusted values are stored as a memory and "The adjusting overload pressure"
is completed, and then the screen returns to "ADJ OVERLOAD PRESS." select screen (e).
7. Turn starter key switch OFF to finish the adjustment.

21-29
21. MECHATRO CONTROL SYSTEM

(7) Maintenance screen displays

This screen displays the remaining time to the end of recommended replacement/change interval specified for
filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 5,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.

1. Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change. 492Hr
ENGINE OIL
H

2. Remaining time display to the coming fuel filter replacement

This display shows the remaining time to the coming engine fuel filter 492Hr
replacement. FUEL FILTER
H

3. Remaining time display to the coming hydraulic oil filter replacement

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

4. Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil 4992Hr
change. HYD. OIL
H

• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.

21-30
 21. MECHATRO CONTROL SYSTEM

(8) 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.

   

 
  


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

21-31
21. MECHATRO CONTROL SYSTEM

. Warning Error codes.

SELECTOR VALVE
FAILURE
W009 WARM AUTO WARMING UP DRAIN WATER SEPA W010

CHANGE ENG OIL WARM FINISH WARM-UP CLOGGED AIR FLTR W008

HYDRAULIC SYSTEM DATA

CPU BACK UP MODE CPU COMMUNICATION ENGINE STOP
ERROR

ATTACHMENT SWING BRAKE

W001 HEAVY LIFT
OVER LOAD DISENGAGED
(EU ONLY)
TRAVEL HIGH ENG
CHARGE ERROR INDEP, MODE WATER TEMP.
W006
(USA ONLY)

LOW FUEL LEVEL

SUPPLEMENTARY EXPLANATION:
1. Error code is stored as trouble history, and it can be displayed on multi display by indication system of trouble
history.
2. These displays are indicated "Pictogram" in EU, but are indicated "Pictogram and comment" in USA.

21-32
 21. MECHATRO CONTROL SYSTEM

21.2.2 SELF DIAGNOSIS DISPLAY

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

!"
    
 

  

   
   

  

    

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.
Alphabet: Decide system failure occurred.
10:25 B 01 3 Last 2nd and 3rd digits: Specifies failed section.
B013
Last 1 digit: Specifies failure type.
This failure symbol is displayed simultaneously with error code during failure diagnosis.
ERROR CODE
A B C D E F G H I K P R
Last 2,3 Controller Low pressure High pressure Proportional Proportional Solenoid Speed sensor Potentiometer Communication Battery relay Engine ECU Relay output
digits memory sensor sensor valve for valves valve for pumps valve etc
Boom up P1 pump P1 unload P1 pump Acceleration Battery relay Wiper ark
01 prevention relay
Torque Boom down P2 pump P2 unload P2 pump Swing parking Wiper ark forward
02 adjust data rotation relay
Unload Arm out Boom head Travel straight Relief adjust 1 Travel 1,2 Angle sensor Wiper ark reverse
03 adjust data speed for shovel rotation relay
Arm in Relief adjust 2 Option Angle sensors for Washer motor
04 selector shovel & ECU
Bucket Bucket stroke
05 digging limit
Bucket Arm 2 spool
06 dump for arm in
Swing
07
Engine coolant
08 temp. sensor
Travel right Fuel sensor
09

Refer to next page (Engine)

Travel left
10
Selector position CAN
11 detection communication

12
Swing flasher
13 right relay
Swing flasher
14 left relay
Travel alarm
15 relay
P1 side option AIS relay 2
16
P2 side option Engine stop
17 relay
Safety lock
18 lever relay

19
Adjustment
21 data sector 1
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust data
Cluster
31 communication
Refer to next page (Engine)

Larger than Larger than

0 normal range normal range
Transistor OFF CAN error
failure / Grounding
1 - short circuit
Wrong output Wrong output Transistor Transistor Over run
2 - ON failure ON failure
Disconnection Disconnection Disconnection Disconnection Transistor ON Disconnection Disconnection Time is over
failure /
3 - Disconnection
Power source Power source Power source Contact point is Power source
4 - short circuit short circuit short circuit melted and adhered short circuit
Wrong value
5

21-33
21. MECHATRO CONTROL SYSTEM

ECU failure code list

Failure Code Malfunctioned component Content of Failure [Class]/Limitation of output when failure occurs
20081 ADC monitoring ECU failure [1]
20082 Dfp_ADCMon A/D converter is abnormal in ECU. Engine is shut down
20084
20088
00291 Accelerator sensor 1 Analog signal input is defective. [5]
00292 SRC Defective analog input signal from controller is detected. -
Dfp_APP1
03838 Accelerator sensor Accelerator signal mutual comparison is defective. [5]
mutual diagnosis When there is deflection of 20% or more between CAN signal and analog signal, sensor detects it. -
Dfp_APPSync
01081 Atmospheric pressure sensor Atmospheric pressure sensor fails [4]
01082 Dfp_APSCD Defective operation of atmospheric pressure sensor in ECU (Disconnection, short circuit and characteristic defect) is detected. Engine power down
01021 Boost pressure sensor Boost pressure sensor failure [4]
01022 Dfp_BPSCD Defective operation of boost pressure sensor attached to engine (Disconnection, short circuit and characteristic defect) is detected. Engine power down
01101 Coolant temperature sensor Coolant temperature sensor failure [5]
01102 Dfp_CTSCD Defective operation of coolant temperature sensor attached to engine (Disconnection, short circuit and characteristic defect) is detected. Engine power down
05181 Q tune resistance Q tune resistance failure [8]
05182 SRCDfp_EngCD_TrqAdj Input failure of Q tune resistance is detected. -
06351 Cam single operation warning Crank sensor failure [3]
Dfp_EngMBackUp It is detected that crank sensor fails and engine is operated with the cam sensor. Engine power down
06361 Cam sensor Cam sensor failure [5]
06362 Dfp_EngMCaS1 Failure of cam sensor (Disconnection, short circuit, and damaged tooth) is detected. -
06371 Crank sensor Crank sensor failure [3]
06372 Dfp_EngMCrS1 Failure of crank sensor (Disconnection, short circuit, and damaged tooth) is detected. Engine power down
02281 Misalignment between cam and crank Misalignment between cam and crank [3]
Dfp_EngMOfsCaSCrS Misalignment between cam and crank is detected. Engine power down
00914 CAN accelerator CAN communication failure [7]
Dfp_FrmMngCANAPP It is detected that accelerator opening (APPREQ) received with CAN is defective. -

16744 APPREQ message time-out CAN communication failure [7]

Dfp_FrmMngTOAPPREQ Accelerator opening (APPREQ) signal is received by CAN. But it detects that the CAN -
cannot receive the signal.
20284 CAN transmission time-out CAN communication failure [7]
Dfp_FrmMngTxTO The transmission of CAN message is defective. -
06771 Glow relay power stage Glow relay failure [5]
06772 Dfp_GlwCD_Actr Failure of glow relay or wiring harness is detected. -
06774
06778
12311 SPI communication error ECU failure [1]
Dfp_HWEMonCom SPI (Serial peripheral interface): Serial communication malfunction between CPU and each internal IC occurs. Engine is shut down
12352 EEPROM ECU failure [5]
12354 Dfp_HWEMonEEPROM Defective reading and writing to EEPROM are detected. -
12358
16688 Recovery occurrence ECU failure [5]
Dfp_HWEMonRcyLocked Recovery (partial reset) occurred by ECU internal malfunction. -
16698 Recovery generation ECU failure [5]
Dfp_HWEMonRcySuppressed Recovery (partial reset) occurred by ECU internal malfunction. -
16708 Recovery generation ECU failure [5]
Dfp_HWEMonRcyVisible Recovery (partial reset) occurred by ECU internal malfunction. -
15421 CJ940 excessive voltage ECU failure [1]
Dfp_HWEMonUMaxSupply The supply voltage is excessive for power stage control IC. Engine is shut down
15432 CJ940 voltage is too low ECU failure [1]
Dfp_HWEMonUMinSupply The supply voltage is too low for power stage control IC. Engine is shut down
6511 Injector drive bank 1 Injector failure (ECU internal circuit) [1]
6512 Dfp_InjVlvBnk1A The injector drive circuit detected short circuit. Engine is shut down
6518
6524 Injector drive bank 1 Injector failure (ECU internal circuit) [1]
Dfp_InjVlvBnk1B The injector drive circuit detected disconnection. Engine is shut down
6531 Injector drive bank 2 Injector failure (ECU internal circuit) [1]
6532 Dfp_InjVlvBnk2A The injector drive circuit detected short circuit. Engine is shut down
6538
6544 Injector drive bank 2 Injector failure (ECU internal circuit) [1]
Dfp_InjVlvBnk2B The injector drive circuit detected disconnection. Engine is shut down
6551 Injector drive IC ECU failure [1]
6552 Dfp_InjVlvChipA IC which controls injector is malfunctioned. Engine is shut down
6554
6558
6561 Injector drive IC ECU failure [1]
6562 Dfp_InjVlvChipB IC which controls injector is malfunctioned. Engine is shut down
6564
6568
6571 Injector #1 Injector failure [1]
6574 Dfp_InjVlvCyl1A Short circuit is detected in injector or harness. Engine is shut down
6578
6584 Injector #1 Injector failure [5]
Dfp_InjVlvCyl1B Disconnection is detected in injector or harness. -
6591 Injector #2 Injector failure [1]
6594 Dfp_InjVlvCyl2A Short circuit is detected in injector or harness. Engine is shut down
6598

Note) For detail of engine error code refer to "Section 51 ENGINE CHAPTER"

21-34
 21. MECHATRO CONTROL SYSTEM

Failure Code Malfunctioned component Content of Failure [Class]/Limitation of output when failure occurs
6604 Injector #2 Injector failure [5]
Dfp_InjVlvCyl2B Disconnection is detected in injector or harness. -
6611 Injector #3 Injector failure [1]
6614 Dfp_InjVlvCyl3A Short circuit is detected in injector or harness. Engine is shut down
6618
6624 Injector #3 Injector failure [5]
Dfp_InjVlvCyl3B Disconnection is detected in injector or harness. -

6631 Injector #4 Injector failure [1]

6634 Dfp_InjVlvCyl4A Short circuit is detected in injector or harness. Engine is shut down
6638
6644 Injector #4 Injector failure [5]
Dfp_InjVlvCyl4B Disconnection is detected in injector or harness. -
20004 MPROP power stage MPROP failure [2]
20008 Disconnection and excessive load Disconnection or short circuit of MPROP or harness. Engine power down
Dfp_MeUnCDNoLoad
20011 MPROP power stage MPROP failure [2]
VB short Battery short circuit of MPROP or harness Engine power down
Dfp_MeUnCDSCBat
20022 MPROP power stage MPROP failure [2]
GND short circuit GND short circuit of MPROP or harness Engine power down
Dfp_MeUnCDSCGnd
14848 Supervision ECU failure [1]
Dfp_Montr Malfunction judgment by self-diagnosis function in ECU. Engine is shut down
16711 CAN A Pass off CAN communication failure [7]
Dfp_NetMngCANAOff Disconnection and short circuit of CAN communication line -
16731 CAN C Pass off CAN communication failure [7]
Dfp_NetMngCANCOff Disconnection and short circuit of CAN communication line -
198 Oil pressure switch Oil pressure switch failure [8]
Dfp_OPSCDPlaus1 Engine speed is high but sensor is OFF status. LOW IDLE
1008 Oil pressure switch Oil pressure switch failure [1]
Dfp_OPSCDPlaus2 Engine speed is high but sensor is OFF status. Engine is shut down
20051 Engine speed ECU failure [5]
Dfp_OvRMonSigA Recognized engine speed is defective. -
20411 DBV valve opening DBV valve opening [2]
Dfp_PRVMonMax It is recognized that DBV opened. Engine power down
20422 DBV kick off DBV valve is opened forcibly. [2]
Dfp_PRVMonMin Open valve forcible command is ordered for entering into Limp-home mode. Engine power down
20434 DBV valve is seized in closed position DBV valve is seized in closed position [1]
Dfp_PRVMonSig If you try to open valve forcibly, valve doesn't open. Engine is shut down
20441 Holding pressure of DBV Holding pressure of DBV is abnormal [1]
2-step is too high Holding pressure of DBV 2-step is higher than standard level. Engine is shut down
Dfp_PRVPresHi
20452 Holding pressure of DBV Holding pressure of DBV is abnormal [1]
2-step is too low Holding pressure of DBV 2-step is lower than standard level. Engine is shut down
Dfp_PRVPresLo
281 PTO accelerator sensor PTO failure for backup [2]
282 Dfp_PTOCD_APP Disconnection and short circuit of PTO or harness are detected. Engine power down
20111 Rail pressure sensor SRC Rail pressure sensor failure [2]
20112 Dfp_RailCD Disconnection and short circuit of rail pressure sensor or harness are detected. Engine power down

20121 Rail pressure sensor offset Rail pressure sensor failure [2]
20122 monitoring Zero-adjustment failure of rail pressure sensor. Engine power down
Dfp_RailCDOfsTst
20131 Rail pressure governor has deviation Rail pressure control failure [4]
(Nonattainment of target value) Rail pressure doesn't achieve target value. Engine power down
Dfp_RailMeUn0
20141 Rail pressure governor has deviation Rail pressure control failure [1]
(Nonattainment of target value & Despite fully pressurized feed of pump, rail pressure doesn't achieve target value. Engine is shut down
Fully pressurized feed of pump)
Dfp_RailMeUn1
20151 Rail pressure governor has deviation Rail pressure control failure [2]
(Pressure exceeds target value Despite fully closed pump, rail pressure is higher than target value. Engine power down
& Pump doesn't inject)
Dfp_RailMeUn2
20161 Rail pressure governor Rail pressure control failure [1]
(Real pressure is too low) Rail pressure is lower than standard value. Engine is shut down
Dfp_RailMeUn3
20171 Rail pressure governor Rail pressure control failure [2]
(Real pressure is too high) Rail pressure is higher than standard value. Engine power down
Dfp_RailMeUn4
11102 Shut-off pass test ECU failure [5]
11104 Dfp_SOPTst Emergency injection stop circuit doesn't operate. -
11108
10791 Sensor supply voltage monitor1 ECU failure [5]
10792 Dfp_SSpMon1 Failure of 5V power line which supplies power to sensor. -
10801 Sensor supply voltage monitor 2 ECU failure [5]
10802 Dfp_SSpMon2 Failure of 5V power line which supplies power to sensor. -
6201 Sensor supply voltage monitor 3 ECU failure [5]
6202 Dfp_SSpMon3 Failure of 5V power line which supplies power to sensor. -
20098 TPU monitoring ECU failure [1]
Dfp_TPUMon Failure of TPU in ECU Failure of Engine is shut down
Arithmetic circuit of rotational pulse
20108 SPIDfp_WdCom ECU failure [1]
Judgment of malfunction by self-diagnosis for ECU Error of watch dog Engine is shut down

Note) For detail of engine error code refer to "Section 51 ENGINE CHAPTER"

21-35
21. MECHATRO CONTROL SYSTEM

21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This
section explains the operating procedure and examples of each screen. The values in display changes according to
the conditions like engine speed, attachment position, etc.
(1) Service diagnosis display screen operating procedure

1) Turn starter switch ON keeping buzzer stop switch pressed.

2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
• Mode No.1 : Screen No.1~No.30
• Mode No.2 : Screen No.1, Screen No.31~No.40
• Mode No.3 : Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)
Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1.
(No.1→No.2→No.3→No.1→...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to
No.3. (No.3→No.2→No.1→No.3→...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.

21-36
 21. 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.)
1) Service diagnosis mode No.1
No. Displays Contents No. Displays Contents
1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YY22E00100F1 P/No. indication K-1 AIS RELAY 2 ON Indicated value
PROGRAM VERSION K-2 SAFETY RLY - Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH ON Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER ON Indicated value
SWITCH OFF Switch

2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 1000 No load setting rpm B-1 BOOM RAISE
MEAS1 1000 Actual rpm 1 0.5V 0.0M Sensor voltage / Pressure converted value
MEAS2 1000 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 0.5V 0.0M Sensor voltage / Pressure converted value
WATER TEMP 20 Coolant temperaturre sensor B-3 ARM OUT
MODE H Work mode 0.5V 0.0M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 0.5V Potentiometer voltage B-4 ARM IN
POS. 0% Voltage % indication 0.5V 0.0M Sensor voltage / Pressure converted value
ECU OUTPUT 1.4V Accel output voltage to engine B-5 BUCKET DIG
controller 0.5V 0.0M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
0.5V 0.0M Sensor voltage / Pressure converted value

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

21-37
21. MECHATRO CONTROL SYSTEM

7 NO.7 P.SENSOR PROPO-V 16

NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11 Option selector detect
0.5V 0.3M Sensor voltage / Pressure converted value 0.3V 0.0M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
0.5V 0.3M Sensor voltage / Pressure converted value 0.0V 0.0M Sensor voltage / Pressure converted value
C-3 BOOM-HEAD (Over load alarm) B-13
0.0V 0.0M Sensor voltage / Pressure converted value 0.0V 0.0M Sensor voltage / Pressure converted value
C-4 BOOM-ROD
B-14
0.0V 0.0M
PROPO-VALVE Sensor voltage / Pressure converted value 0.0V 0.0M Sensor voltage / Pressure converted value
E-3 OPT RELIEF 1 B-15
COMP. 0mA 0.0M Set value in computer / Converted value from pressure 0.0V 0.0M Sensor voltage / Pressure converted value
MEAS. 0mA 0.0M Measured value / Converted value from pressure B-20
E-4 OPT RELIEF 2 0.0V 0.0M Sensor voltage / Pressure converted value
COMP. 0mA 0.0M Set value in computer / Converted value from pressure
MEAS. 0mA 0.0M Measured value / Converted value from pressure

8 NO.8 PROPO-VALVE
18
NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 750mA 3.0M Set value in computer / Converted value from pressure DI2 ON ON/OFF indication
MEAS. 750mA 3.0M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 750mA 3.0M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 750mA 3.0M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
COMP. 350mA 0.6M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 350mA 0.6M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 750mA 0.0M Set value in computer / Converted value from pressure DI11 OFF ON/OFF indication
MEAS. 750mA 0.0M Measured value / Converted value from pressure DI12 OFF ON/OFF indication
DI13 OFF ON/OFF indication
DI14 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 417mA 1.0M Set value in computer / Converted value from pressure DI16 ON ON/OFF indication
MEAS. 417mA 1.0M Measured value / Converted value from pressure DI17 ON ON/OFF indication
POWER SHIFT 0mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 20L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 ON ON/OFF indication
COMP. 417mA 1.0M Set value in computer / Converted value from pressure DI21 OFF ON/OFF indication
MEAS. 417mA 1.0M Measured value / Converted value from pressure DI22 OFF ON/OFF indication
POWER SHIFT 0mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 20L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 OFF ON/OFF indication
DI26 OFF ON/OFF indication
DI27 OFF ON/OFF indication
DI28 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
0.7V 97% Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
0.0V 0 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW - Glow switch DI33 ON ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER - Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW OFF Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER - Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL OK Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL - Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH - Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. - Set value in computer MEAS. OFF Measured value
MEAS. - Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. - Set value in computer DO6 COMP. OFF Set value in computer
MEAS. - Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. ON Set value in computer
2.5V 90 Sent value from sensor / Converted value from angle MEAS. ON Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
2.5V 90 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
DO10 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO11 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO12 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO13 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO14 COMP. OFF Set value in computer
MEAS. OFF Measured value

21-38
 21. MECHATRO CONTROL SYSTEM

No. Displays Contents No. Displays Contents

23 27
NO.23 DIGITAL OUTPUT NO.27 MERIT SYSTEM
DO15 COMP. OFF Set value in computer
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT controller
DO16 COMP. ON Set value in computer 0
MEAS. ON Measured value
DO17 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO18 COMP. ON Set value in computer 000000000
MEAS. ON Measured value
DO19 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO20 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO21 COMP. ON Set value in computer
MEAS. ON Measured value
24 28
NO.24 DIGITAL OUTPUT NO.28 ENG CONT.
DO22 COMP. OFF Set value in computer TRANS.COUNT. 0 Counted number of transmission error
MEAS. OFF Measured value RECEIVE COUNT. 0 Counted number of reception error
DO23 COMP. OFF Set value in computer DIAG STATUS 0 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 0 Numbers of error
DO24 COMP. OFF Set value in computer BOOST PRESS. 0 Boost pressure
MEAS. OFF Measured value BOOST TEMP. 0 Boost temperature
DO25 COMP. OFF Set value in computer BAROMETRIC P. 0 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. 0 Fuel temperature
DO26 COMP. OFF Set value in computer FUEL CONS. 0 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. 0 Intake air temperature
DO27 COMP. OFF Set value in computer ENG PRESS. 0 Engine oil pressure
MEAS. OFF Measured value GLOW - Glow output from ECU
DO28 COMP. OFF Set value in computer ENG STOP - Engine stop command from ECU
MEAS. OFF Measured value TORQUE 500 Calculated torque of ECU
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW OFF Wiper rise-up switch
REVERSE SW OFF 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

2) 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-PRES 0.3M Pump pressure sensor
YY22E00100F1 P/No. indication C-2 P2-PRES 0.3M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 417mA Command current
1-VER 12.34 Program version indication E-2 P2-PSV 417mA Command current
2-VER 11.11 MERIT controller program version D-1 P1-UL(BPC) 750mA Command current
D-2 P2-UL(BPC) 750mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 350mA Command current
B-5 BUCKET DIG 0.0M Bucket digging pressure sensor
B-6 BUCKET DUMP 0.0M Bucket dump pressure sensor
G-3 ENG SPEED 1000 Engine actual speed
POWER SHIFT 0mA Power shift current

31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 0.3M Pump pressure sensor C-1 P1-PRES 0.3M Pump pressure sensor
C-2 P2-PRES 0.3M Pump pressure sensor C-2 P2-PRES 0.3M Pump pressure sensor
E-1 P1-PSV 417mA Command current E-1 P1-PSV 417mA Command current
E-2 P2-PSV 417mA Command current E-2 P2-PSV 417mA Command current
D-1 P1-UL(BPC) 750mA Command current D-1 P1-UL(BPC) 750mA Command current
D-2 P2-UL(BPC) 750mA Command current D-2 P2-UL(BPC) 750mA Command current
B-1 BOOM RAISE 0.0M Boom up pressure sensor D-3 S-TRAVEL 350mA Command current
B-2 BOOM LOWER 0.0M Boom down pressure sensor B-9 TRAVEL(R) 0.0M Travel right pressure sensor
G-3 ENG SPEED 1000 Engine actual speed B-10 TRAVEL(L) 0.0M Travel left pressure sensor
POWER SHIFT 0mA Power shift current Pi-P1 0.0M Pilot pressure at travel straight (P1 side)
Pi-P2 0.0M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 1000 Engine actual rpm
POWER SHIFT 0mA Power shift current

32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1-PRES 0.3M Pump pressure sensor C-1 P1-PRES 0.3M Pump pressure sensor
C-2 P2-PRES 0.3M Pump pressure sensor C-2 P2-PRES 0.3M Pump pressure sensor
E-1 P1-PSV 417mA Command current E-1 P1-PSV 417mA Command current
E-2 P2-PSV 417mA Command current E-2 P2-PSV 417mA Command current
D-1 P1-UL(BPC) 750mA Command current D-1 P1-UL(BPC) 750mA Command current
D-2 P2-UL(BPC) 750mA Command current D-2 P2-UL(BPC) 750mA Command current
D-3 S-TRAVEL 350mA Command current D-3 S-TRAVEL 350mA Command current
D-6 ARM-IN-2 750mA Command current E-3 OPT RELIEF 0mA Command current
B-3 ARM OUT 0.0M Arm out pressure sensor B-16 P1 OPT 0.0M P1 side option pressure sensor
B-4 ARM IN 0.0M Arm in pressure sensor B-17 P2 OPT 0.0M P2 side option pressure sensor
B-1 BOOM RAISE 0.0M Boom up pressure sensor F-4 OPT SELECT - Optional selector SOL (Nibbler line)
B-7 SWING 0.0M 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 0mA Power shift current POWER SHIFT 0mA Power shift current

21-39
21. MECHATRO CONTROL SYSTEM

3) 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
YY22E00100F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 12.34 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 11.11 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode 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 2450 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 519mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
9mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 34.6M 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 580mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 590mA 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

21-40
 21. MECHATRO CONTROL SYSTEM

(3) Service diagnosis data list

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

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

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
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
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle

No.31 BOOM No.31 BOOM

C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 450~550 mA
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 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-41
21. MECHATRO CONTROL SYSTEM

Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 549 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA

Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~16.5 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~16.5 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 550~700 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 550~750 mA
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-2 200 mA D-6 ARM-IN-2 370 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-42
 21. MECHATRO CONTROL SYSTEM

Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~18.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~18.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 606~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 606~750 mA
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-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Operation No.10 : Operation No.11 :

Swing in full lever operation & relief Swing in full lever operation & in operation
H mode Hi idle H 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 28.0~35.8 M C-2 P2-PRES 8.0~13.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 500~610 mA E-2 P2-PSV 642 mA
D-1 P1-UL(BPC) 750 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 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 3.0 M B-7 SWING 3.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-43
21. MECHATRO CONTROL SYSTEM

Operation No.12 : Operation No.13 :

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 750 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 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
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.14 : Operation No.15 :

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 650 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 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
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-44
 21. MECHATRO CONTROL SYSTEM

Operation No.16 : Operation No.17 :

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 480~590 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 480~590 mA E-2 P2-PSV 665~750 mA
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 720 mA D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

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 TRAVLE
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 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-45
21. MECHATRO CONTROL SYSTEM

21.2.4 TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one
of history. And the errors are able to be indicated on the multi display.
The warning content is stored partially in "Travel history screen".
The error code for self diagnosis is stored.

(1) How to display

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR

Error detected in the past

3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)

• Press washer switch ( ), and the item moves upward.

• Press wiper switch ( ), and the item moves downward.

5) Turn starter switch off, and the display is disappeared.

(2) How to delete contents of trouble history

1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.

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

21-46
 21. MECHATRO CONTROL SYSTEM

21.2.5 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code) like
disconnection and abnormal output. This is useful to save the time for troubleshooting.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are automatically
actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition
or failed condition of the system.

For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

21-47
21. MECHATRO CONTROL SYSTEM

21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/
change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches
to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the initial setting
by the following order.

Screen change Buzzer stop KPSS work mode

switch switch select switch

Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 5,000 Hr switch select switch

Procedure Operating Procedure Display on Multidisplay

After several seconds,

display is changed to 10:25
1 Turn starter key switch on. (Logo mark) 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 increased 10 hours with each 500 Hr
and the time to the coming engine oil change is ENGINE OIL ENGINE OIL
pressing of switch.
added. Press " " switch and the time to the
coming engine oil change is reduced.

When desired to return to the initial set time,

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

time is stored. H

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

21-48
 21. MECHATRO CONTROL SYSTEM

21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator

1) Clock Adjustment Switches

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

Main screen (a)

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

(c) (d) (e)

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

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

1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).

2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.

3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.

4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).

21-49
21. MECHATRO CONTROL SYSTEM

2) Contrast Adjustment Switches

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

Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST

H
(a) (b)

(c) (d) (a)

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

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

Adjustable range
11111~99999 Increase/Decrease
(Default 55555)

1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).

2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.

3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.

5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).

21-50
 21. MECHATRO CONTROL SYSTEM

(2) Function for service

Following items are provided for adjustment of service function.

Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
Over load alarm Adjustment of boom head pressure for over load alarm

21-51
21. MECHATRO CONTROL SYSTEM

21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view

2 1 6 2 1 4 2 1 8 2 1
10
16
26
34

27 22 18 16 12 28 22
CN101 CN102 CN103 CN104

CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21

21

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

2) List of connectors

Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
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 GND / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output GND / OPEN
30 DO 21 - Output GND / OPEN
31 DO 22 Spare Output GND / OPEN
32 DO 23 Rotary light (yellow) Output GND / OPEN
33 DO 24 Rotary light (green) Output GND / OPEN
34 DI 36 - Input GND / OPEN

21-52
 21. 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

21-53
21. MECHATRO CONTROL SYSTEM

Connector No. Pin No. Port name Function Input/putput Signal level
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Boom rod Input 0.5 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 Spare Input 0.5~4.5V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
17 A23 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Spare 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 - Input GND / OPEN

Connector No. Pin No. Port name Function Input/putput Signal level
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
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 - 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+ - Output +0~800mA
26 D7- -0~800mA
27 D8+ - Output +0~800mA
28 D8- -0~800mA
29 D9+ - Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V

21-54
 21. 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+ - Output +24V 1.5A
4 F1- Output +24V 1.5A
5 F2+ Output +24V 1.5A
6 F2- Output +24V 1.5A
7 OIL - 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+ Spare 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 - CAN communication
24 CANL2 CAN communication

Connector No. Pin No. Port name Function Input/putput Signal level
CN107 1 DI 3 - Input +24V/OPEN
2 DI 8 Water separetor Input GND / OPEN
3 DI 9 - Input GND / OPEN
4 DI 10 Air filter Input GND / OPEN
5 DI 11 Stroke end check Input GND / OPEN
6 DI 12 KPSS release Input GND / OPEN
7 DI 13 - Input GND / OPEN
8 DI 14 Spare Input GND / OPEN
9 DI 15 Spare Input GND / OPEN
10 DI 20 ECU main relay Input GND / OPEN
11 DI 28 Spare Input GND / OPEN
12 DI 32 Hand control nibbler Input GND / OPEN
13 DI 38 Quick coupler Input GND / OPEN
14 DI 39 Extra pressure Input GND / OPEN
15 DI 40 Spare Input GND / OPEN
16 DI 41 Spare Input GND / OPEN
17 Reserved

21-55
21. 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 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 High reach hoisting at fixed position Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 - Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 - 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
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 High reach (hoist at travel) 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 Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 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 Bucket move limitation Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
18 RXD2 Reception RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 - SV 24V/OPEN

21-56
 21. MECHATRO CONTROL SYSTEM

(2) Gauge cluster (symbol C-2)

1) General view

MULTI
DISPLAY LCD

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

BUZZER STOP SWITCH WORK MODE SWIHCH

2) Connector CN-600 (Harness side)

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

3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.

4) Summary of display and drive item

No. Item Remarks

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

21-57
21. MECHATRO CONTROL SYSTEM

(3) Relay & fuse box (symbol E-1)

1) General view

(Overhead view of box)

LABEL INSIDE

Note) These circles indicate the parts

which are used in standard specification

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

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

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

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

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME

21-58
 21. MECHATRO CONTROL SYSTEM

2) Circuit diagram

21-59
21. MECHATRO CONTROL SYSTEM

21-60
 21. MECHATRO CONTROL SYSTEM

21-61
21. MECHATRO CONTROL SYSTEM

(4) High pressure sensor

ECONOSEAL SERIES MARK (+)> SPECIFICATION :

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

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

O-RING P14 PIPE

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

(5) Low pressure sensor

Tightening torgue
Vout
29.4 34.3N.m (21.7 25.3lbf.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 CASING AND EACH TERMINAL AT
50V DC MEGGER)

21-62
 22. HYDRAULIC SYSTEM
TABLE OF CONTENTS

22.1 SUMMARY.......................................................................................................................22-2
22.2 HYDRAULIC CIRCUITS AND COMPONENTS ...............................................................22-3
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-6
22.4 NEUTRAL CIRCUIT.........................................................................................................22-6 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-8
22.6 BUCKET CIRCUIT...........................................................................................................22-10
22.7 BOOM CIRCUIT ..............................................................................................................22-12
22.8 SWING CIRCUIT .............................................................................................................22-16
22.9 ARM CIRCUIT .................................................................................................................22-18
22.10 COMBINED CIRCUIT ......................................................................................................22-24
22.11 PRESSURE DRAINING (RELEASING) CIRCUIT ...........................................................22-28

22-1
22. HYDRAULIC SYSTEM

22.1 SUMMARY operability, safety, mass volume handling and low fuel
consumption.
The hydraulic circuits are built up with the following
functions and features in order to achieve easy
Table22-1

Perfor- Device
mance Function Features

Travel straight Travel straight at combined operation

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

Auto parking brake Automatic braking when parking

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

(simultaneous operation of arm in and swing motions) swing press digging

Automatic swing parking brake Swing parking brake when operating at on a slope
AB bypass valve function Improvement of swing stop feeling
Hydraulic pilot control system Light action with operating lever
Easy operability and safety

Attachment

Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Boom/Arm safety valve (Option) Prevention of boom and arm falling when boom head side
and arm rod side pipings break
Lowering boom to the ground in case of emergency When engine is stalled, the boom is lowered to
the ground safely.
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others

Return circuit To prevent hydraulic oil from contamination

Cooling hydraulic oil by oil cooler
Pressure draining circuit
Main control valve with optional valve
Switching of return line for N&B machine in the cab
(Option)
Extra circuit (Option)
consumption Mass handling capability
To prevent hydraulic oil from being deteriorated.
To release the main circuit pressure for piping repair work.
Optional piping and additional work are easy
Switching of return line for N&B machine is able to
change with a switch in the cab
Installation of optional piping is easy after shipping

Electric flow controlled variable displacement pump Pump delivery rate control by a current command to the
Pump

solenoid proportional valve of the variable displacement pump

Positive flow rate control Flow control by positive pilot control pressure
Boom up conflux circuit Speed up of boom up operation
Attachment

Arm conflux circuit Speed up of arm operation

Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes

Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel

speed when control lever is in neutral position.

Micro

22-2
 22. HYDRAULIC SYSTEM

22.2 HYDRAULIC CIRCUITS AND

COMPONENTS
STD. SCHEMATIC HYD. LINES
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 Restrictor
17 Shuttle valve
18 Valve assy, Hyd.
19 Check valve

22-3
22. HYDRAULIC SYSTEM

22-4
 22. HYDRAULIC SYSTEM

22.2.1 STANDARD

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

22-1
22. HYDRAULIC SYSTEM

22.2.2 N&B SPECIFICATION (OPTION)

NIBBLER & BREAKER

SPECIFICATION
NO. PARTS
50 SELECTOR VALVE
51 STOP VALVE
52 PILOT VALVE
53 RELIEF VALVE ASSY
NOTE 1:This hydraulic circuit is used to add to standard circuit.
2:For using of nibbler confluence/single flow or breaker,
choosed condition and an order.
CHOOSED CONDITION
AN ORDER OF OUTPUT FOR
AN ORDER OF OUTPUT FOR PROPORTIONAL SOLENOID VALVE (W:٤ , W/O:-)
CONFLUENCE/SINGLE FLOW PROPORTIONAL SOLENOID VALVE
CHANGEOVER SWITCH IN VALVE SELECTOR(ITEM 50) TRAVEL P1 P2
(W:٤ , W/O:-) P1 PUMP P2 PUMP
STRAIGHT UNLOAD UNLOAD
CONFLUENCE FLOW OF NIBBLER CONFLUENCE ON
SINGLE FLOW OF NIBBLER CONFLUENCE OFF
BREAKER CONFLUENCE OFF

3:When using nibbler, according to specification of nibbler

installed, choose confluence or single flow by
"confluence/single flow changeover switch"

51

52

53

50

22-2
 22. HYDRAULIC SYSTEM

22.2.3 BOOM & ARM SAFETY SPECIFICATION

BOOM & ARM SAFETY SPECIFICATION

NO. PARTS
50 HOLDING VALVE
51 HOLDING VALVE

NOTE 1: This hydraulic circuit is used to add to standard

circuit.

51

50

50

22-3
22. HYDRAULIC SYSTEM

22.2.4 EXTRA SPECIFICATION / EXTRA PRESSURE DRAINING SPEC.

This page is left blank because we had not received related information from "Engineering Division".

22-4
 22. HYDRAULIC SYSTEM

This page is blank for editing convenience.

22-5
22. HYDRAULIC SYSTEM

22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly,
FOR HYDRAULIC CIRCUITS (1) Type : when the servo piston moves rightward, the
This section describes the following.
Electric flow controlled variable displacement spool (652) is moved leftward by the feedback
Blue (1) Bypass cut valve and unload valve control
pump. lever.
Feed, drain circuit (2) Safety lock lever and pilot circuit The operation is maintained until the opening of
less than 0.44 MPa (64 psi) (2) Principle :
(3) Pump positive flow control spool sleeve is closed.
Green The current command I to the pump’s solenoid
(4) Pump P-Q (Pressure-Quantity) curve control proportional valve controls the delivery rate of the
Return, make up circuit, 22.4.4 PUMP P-Q CURVE CONTROL
0.44~0.59 MPa (64~86 psi) pump. OPERATION
22.4.1 OPERATION OF BY-PASS CUT VALVE
Purple AND UNLOADING VALVE HOUSED IN (3) Operation : (1) Type :
Secondary pilot pressure, CONTROL VALVE 1) Flow rate rise operation (Eg. P1 pump) Electrical flow control type variable pump
(including proportional vlave) By operating any of control levers, the
(1) By-pass cut valve (2) Principle :
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve
On starting engine, P1 and P2 unloading Perform an operation of the value from pump high
Red rises, and the rising pressure is transformed to
proportional valves (PSV-D, PSV-B) output pressure sensor to P-Q curve control value, and
Primary pilot pressure, the rise of output voltage corresponding to the
secondary pressure according to the command send a command to the pump solenoid proportional
(including proportional vlave) pressure input by the low pressure sensor.
output by mechatro controller, and this pressure valve.
5 MPa (725 psi) Mechatro controller signal-processes this
exerts on PBp1 and PBp2 ports, and consequently (3) Operation :
Orange change of voltage, resulting in rise of command
the by-pass cut spool is switched to CLOSE side. The pump high pressure sensor converts the
Main pump drive pressure, current value I to the pump proportional
The by-pass cut spool is usually held on CLOSE pressure to the output voltage corresponding to the
5~34.3 MPa (725~4970 psi) solenoid valve and consequently the pump flow
side after the engine started. And it is switched to pump delivery pressure.
Blue tone rate rises. This is called "Positive Control
OPEN side only when failure occurred on pump The mechatro controller converts the voltage output
At valve operation System".
proportional valve and mechatro controller. by the high pressure sensor to the P-Q curve
Red valve As the pump command current value rises, the
(2) Unloading valve control value. On the other hand, select the pump
When solenoid proportional valve (reducing) secondary pressure of proportional solenoid
On starting engine, like by-pass cut valve, the positive control command current value from the
is operating valve also rises. On the regulator attached on
secondary pressures output by P1 and P2 low pressure sensor in lower order, and the values
Red solenoid the pump, the spool (652) through piston (643)
unloading proportional valves (PSV-D, PSV-B) are output to respective pump proportional valve as
In active and exciting is pushed leftward, and stops at the position
exert on PCb and PCa ports, consequently the P1 a command current.
Displaying the flow circuit and standby circuit when where being in proportion to the force of pilot
and P2 unloading valves are switched to OPEN With this operation, the pump power is controlled so
operating. spring (646).
side. as not to be exceed the engine power, therefore
Regarding the electrical symbols in this manual, refer to The tank port connected to the large bore of
engine dose not stall.
the electric circuit diagram. 22.4.2 SAFETY LOCK LEVER AND PILOT servo piston (532) opens, and the piston
CIRCUIT moves leftward by delivery pressure P1 of the
(1) Purpose : small bore resulting in the increase of tilt angle
To protect attachment from unexpected movement ( ).
for safety. The servo piston and spool (652) are
connected to feedback lever (611). Therefore
(2) Principle :
when servo piston moves leftward, the spool
Cut pressure source of pilot valve for operation.
(652) also moves rightward by means of
(3) Operation :
feedback lever. With this movement, the
If the safety lock lever (red) is pushed forward after
opening of spool sleeve closes gradually, and
the engine starts, the limit switch (SW-11) is turned
the servo piston stops at the position the
on. The timer relay is actuated one second later
opening closed completely.
which causes the solenoid (SV-4) of the solenoid
2) Flow rate reduction operation
valve block (13) to be energized and makes the
As the current value I of mechtro controller
pilot operating circuit to stand by.
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the delivery
pressure P1 usually flows into the 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,

22-6
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
643 646 646 643 PG
REV. REV.
4 DB
611 A B
3
652 A
A
652
1 8 C
611 B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP ǩ ǩ TRAVEL RIGHT TRAVEL LEFT P D
532 532
Dr1 Pi1

5.0MPa
69kw M
/2000min-1 a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5 8 7 6 5 4 3 2 1
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)

22-7
22. HYDRAULIC SYSTEM

22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
(1) Travel forward pilot simultaneous operation circuit
(1) Purpose :
(2) 2 speed travel solenoid command circuit and auto
Change travel motor speed with switch.
1-speed return function
(2) Principle :
(3) Travel main circuit
If the switch is turned, an electric signal is issued. It
(4) Travel motor function excites the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
22.5.1 TRAVEL FORWARD PILOT
pressure to a tilting angle of the variable
SIMULTANEOUS OPERATION CIRCUIT
displacement motor.
(1) Purpose :
(3) Operation :
Light operating force and shockless operation
If the rabbit marked switch on the gauge cluster is
(2) Mechatronics :
pressed, the solenoid (SV-3) of the proportional
1) If the travel lever with damping mechanism is valve block (13) is excited and changes the
operated for travel right, left and forward proportional valve. Then the solenoid command
motions, the secondary pilot proportional pressure is issued from port A3, enters the P port of
pressure comes out of the 3, 1 ports of P/V (10). the travel motor (4), opens the oil passage to the
The higher of the pressures is selected, comes 2nd speed select piston, and causes the motor to
out of the 6, 5 ports and acts upon the low run in the 2nd speed tilting mode by its self
pressure sensors (SE9) (SE-10). pressure. However, when the main circuit pressure
2) The pilot secondary pressure flows to PBr and rises above 27.3 MPa (3960 psi), the motor’s self
PBL ports of the control valve (2), moves the pressure pushes the 2nd speed select piston back
travel spool, and switches the main circuit. to the 1st speed.
3) The low pressure sensor output voltage is input
22.5.3 TRAVEL MAIN CIRCUIT
into mechatro controller. The mechatro
(1) Operation :
controller performs signal processing and
The delivery oil from Pump A1 and A2 ports by
outputs current corresponding to the increase
changing the travel spool with the operation of
of flow rate to P1 pump proportional valve
travel pilot flows in each A, B port on the left side of
(PSV-P1) and P2 pump proportional valve
travel motor (4) through C,D ports of swivel joint (8)
(PSV-P2), and at the same time the command
from BL, BR ports of C/V, and rotates the travel
current is output to P1 unloading valve (PSV-D)
motor.
and P2 unloading valve (PSV-B).
4) The secondary pressures output by P1 pump 22.5.4 TRAVEL MOTOR FUNCTION
proportional valve (PSV-P1) and P2 pump (1) Function :
proportional valve (PSV-P2) exert on pump
1) Prevents the motor from over running on a
regulator, actuating the pump on the delivery
slope.
flow rate increase side.
2) Check valve that prevents cavitation of the
5) The secondary pressure delivered in P1
hydraulic motor.
unloading valve (PSV-D) and P2 unloading
3) Shockless relief valve and anti cavitation valve
valve (PSV-B) is fed to PBp1, Pcb, PBp2 and
when inertia force stops.
PCa ports provided in control valve (2).
The secondary pressure from proportional 4) High/Low 2 step speed change mechanism and
valve which has exerted on PBp1 and PBp2 auto 1st speed return at high load.
ports holds the by-pass cut spool on CLOSE 5) Travel parking brake.
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.

22-8
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.

22-9
22. HYDRAULIC SYSTEM

22.6 BUCKET CIRCUIT 22.6.2 AUTO ACCELERATION OPERATION

This section describes the following. (1) Principle :
Auto acceleration actuates according to signals
(1) Bucket digging pilot circuit
from low pressure sensor.
(2) Auto accel operation
(2) Operation :
(3) Flow control in the work mode
<When lever is set to neutral position>
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING In the event where the sensor does not receive
signal for 4 seconds or more even though the
(1) Mechatronics :
acceleration dial is set to MAX position, the engine
1) When the operation for bucket digging is
speed should be raised to 1000rpm.
performed, the pilot proportional secondary
<When lever is operated>
pressure is delivered through port 1 of the right
When the pressure 0.6MPa (87psi) is input to low
pilot V (9), flows to PAc port, and acts on the low
pressure sensor in STD specification (travel,
pressure sensor (SE-1), and at the same time
bucket, swing, arm), proportional voltage from low
the bucket spool is switched.
pressure sensor inputs in mechatro controller, and
2) The voltage output by low pressure sensor then the engine speed returns to the dial set
inputs in mechatro controller. The mechatro position corresponding to the lever operation.
controller performs signal processing and
outputs current corresponding to the increase 22.6.3 STAND-BY CURRENT CONSTANT
of pump flow rate to pump proportional valve CONTROL
(PSV-P1) on the P1 pump side, and at the (1) Principle :
same time the command current is output to P1 When the engine speed is intermediate speed or
unloading valve (PSV-D). lower, command current value to have the pump
In the following pages, the relation of operation delivery rate constant is output.
of low pressure sensor to both the increase of (2) Operation :
pump flow rate and unloading proportional Even if the engine speed specified by acceleration
valve is the same. Therefore the explanation is potentiometer is low speed, as the delivery rate
omitted. corresponds to the intermediate speed, the
3) The secondary pressure output by P1 pump actuator moves earlier than the movement
proportional valve (PSV-P1) exerts on pump equivalent to the control lever angle rate in light
regulator, actuating the pump onto the delivery load operation.
flow increase side.
4) The secondary pressure delivered in P1
unloading valve (PSV-D) is led to PBp1 and
PCb ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 port holds the
by-pass cut spool on CLOSE side, like the
operation in the lever neutral position.
The secondary pressure from proportional
valve which has exerted on PCb port switches
the unloading spool in CLOSE side.

22-10
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb K
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-3 BUCKET CIRCUIT : Bucket digging, Auto-accelation and Standby flow rate constant control

22-11
22. HYDRAULIC SYSTEM

22.7 BOOM CIRCUIT

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

22.7.1 BOOM RAISE PILOT CIRCUIT

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

22.7.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
(1) Purpose :
Boom up speed up
(2) Principle :
Confluxing oil from 2 pumps
(3) Operation :
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since 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.

22-12
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.

22-13
22. HYDRAULIC SYSTEM

This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of portáC of the right pilot valve (9) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
PBb port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the Bb port.
3) Then, the proportionl 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 boom
lines and switches boom spool and releases
spool, pushes the check valve in the spool open, is
boom lock valve.
recirculated to the Bb port and is supplied to the rod
22.7.4 PREVENTION OF NATURAL FALL BY (R). When the (R) pressure is larger than the head
LOCK VALVE AND ACTUATION AT (H) pressure, the check valve in spool closes.
LOWERING Thereupon, 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.

22-14
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.

22-15
22. HYDRAULIC SYSTEM
22.8 SWING CIRCUIT
This section describes the following operations.
(1) Swing left pilot circuit
(2) Swing auto parking brake
(3) Swing main circuit
(4) Swing motor circuit
(5) Pilot line air bleeding circuit
22.8.1 PILOT CIRCUIT FOR LEFT SWING
(1) Operation :
1) When lowering safety lock lever, pilot circuit
becomes standby status (see 22.4.2), the pilot
circuit pressure acts upon B port on hydro valve
assy (18) and the valve is closed.
2) When the left swing operation is performed, the
pilot proportional secondary pressure is
delivered through port (5) of left pilot V (9), and
the secondary pressure acts on PAs port of C/V
(2), and simultaneously flows out from Pss port
of C/V and acts on low pressure sensor (SE-5).
Simultaneously, the pilot proportional
secondary pressure acts upon pi2 port on
swing motor and closes the bypass valve.
3) The voltage output by the low pressure sensor
is input in the mechatro controller, and is signal-
processed.
4) Then, the secondary pressure led into PAs port
of C/V (2) switches the swing spool.
22.8.2 SWING AUTO PARKING BRAKE
(1) Purpose :
Swing lock in neutral position and parking
(2) Principle :
Release mechanical brake only when required to
operate swing and arm in.
(3) Operation :
1) The swing parking system excites the swing
parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
mechanical brake.
2) The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing and
arm in actions acts upon any of the low
pressure sensors (SE-5, 7).
22-16
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.
22.8.3 SWING MAIN CIRCUIT
(1) Operation :
The oil delivered from the A2 port of the P2 pump
enters the P2 port of C/V (2) and is branched off into
the bypass line and the parallel circuit. However,
since the bypass line is closed as the swing spool
is shifted, the oil pushes the load check valve LCs
open through the parallel circuit, enters the B port
of the swing motor via the As port of C/V (2), and
rotates the swing motor counterclockwise.
22.8.4 SWING MOTOR CIRCUIT
(1) Anti cavitation circuit at swing deceleration
(2) Shockless relief valve that prevents the swing
motor from being reversed.
22.8.5 PILOT LINE AIR BLEEDING CIRCUIT
(1) Purpose :
Air bleeding for piping work of pilot line.
(2) Principle :
The back pressure from T3 port on C/V flows back
to swing pilot line by opening hydro valve assy (18).
(3) Operation :
When the safety lock lever is pulled up during
engine running, hydro valve assy (18) is open
constantly. Consequently, the back pressure from
T3 port on C/V (2) flows back in swing pilot line, and
the air is released.
After maintaining swing pilot line, be sure to run the
engine for 5 minutes or more in the condition of
pulling up safety lock lever, and the air is released.
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P
19
P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-6 SWING CIRCUIT : Swing operation (LH)

22-17
22. HYDRAULIC SYSTEM
22.9 ARM CIRCUIT
This section describes the following operations.
(1) Arm in, light-load operating pilot circuit
(2) Arm in, light-load variable normal recirculation main
circuit / internal conflux main circuit
22.9.1 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 7 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 CRa. 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.
22.9.2 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 by-pass 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
22-18
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).
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 CRa 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
Neutral position
(Anticavitation position)
Normal recirculation position
Recirculation
From arm out
P/V
From arm 2 inverse
proportional valve
Reference :
In light-load arm-in operation (normal 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)
Meter-in passage (Close)
Neutral position
Normal recirculation position
Arm 2 spool
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function

22-19
22. HYDRAULIC SYSTEM

This section describes the following operations. 4) The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
(4) Arm in, heavy load operating sequence confluxed
Position of arm 2 spool
main circuit
Recirculation cut position Neutral position
22.9.3 ARM IN, HEAVY LOAD OPERATING
PILOT CIRCUIT
(1) Operation : From arm out
P/V
1) In arm-in operation, when the heavy loading is
From arm 2 inverse
applied to arm and the P2 pump pressure proportional valve
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.

22.9.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose :
Speed up for arm in operation
(2) Principle :
Cut the recirculation and reduce rod pressure.
(3) Operation :
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is switched
and pushes and opens load check valve LCa
through parallel circuit, and flows in the arm
spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the
valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side flows
in Ba port of C/V(2) and is flowed to arm lock
valve CRa, but because the arm lock valve CRa
is open, the return oil goes through arm lock
valve CRa and flows in arm 2 spool.

22-20
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function

22-21
22. HYDRAULIC SYSTEM

This section describes the following operations.
(5) Arm out pilot circuit
(6) Arm out 2 pumps conflux main circuit
(7) Natural fall protection with arm lock valve
22.9.5 ARM OUT PILOT CIRCUIT
(1) 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).
2) The operating proportional secondary pressure
flowed in PBa1 port of C/V (2) switches the arm
1 spool.
3) Then, the operating secondary pressure flowed
in PBa2 port of C/V (2) switches the arm 2 spool
valve.
22.9.7 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.
(3) Operation :
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) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall of
the arm due to oil leaks through the arm spool
is prevented.

22.9.6 ARM OUT 2 PUMPS CONFLUX MAIN

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

22-22
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function

22-23
22. HYDRAULIC SYSTEM
22.10 COMBINED CIRCUIT
This section describes only the difference in combined
operation.
(1) Boom up / travel, pilot circuit
(2) Boom up / travel, main circit
22.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT
(1) Operation :
<Operation: Different point of pilot circuit from
independent operation >
1) The mechatro controller outputs command
current to travel straight solenoid proportional
valve after signal processing, and the solenoid
valve outputs secondary pressure and acts on
PTb port of C/V (2).
2) Then the pressure of PTb port switches the
travel straight valve one step.
22-24
22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT
(1) Purpose :
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle :
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation :
1) P1 pump delivery oil flows through P1 port of C/
V(2) and branches off in P1 parallel circuit and
travel straight spool.
P2 pump delivery oil flows through P2 port of C/
V(2) and branches off in P2 tandem circuit and
travel straight spool.
2) The delivery oil flowed into P1 parallel circuit of
P1 pump opens check valve CT1 and LCb and
flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool
of P1 pump opens check valve CT2 because
the travel straight spool is shifted, and flows in
boom conflux spool and exerts on boom up
operation with the internal oil conflux.
(In travel straight operation, P1 pump delivery
oil exerts on swing operation of attachment.)
3) The delivery oil flowed into P2 tandem circuit of
P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel straight spool
of P2 pump flows in right travel spool because
the travel straight spool is shifted and exerts on
the right travel operation.
(In travel straight operation, P2 pump delivery
oil exerts on travel operation.)
4) However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted
by the circuit of restriction.
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.

22-25
22. HYDRAULIC SYSTEM
In this section, the independent operation is omitted
and describes difference in combined operation.
(3) Swing / Arm in light load, pilot circuit
(4) Swing / Arm in, swing priority main circuit
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
CIRCUIT
(1) Operation :
1) On operating swing (left) and arm in motions
simultaneously, mechatro controller outputs
command current to travel straight solenoid
proportional valve (PSV-C) and arm 2 solenoid
inverse proportional valve (PSV-A) according to
signal processing, and this proportional valve
outputs secondary pressure, which acts on PTb
port and PAa2 port of C/V(2).
2) PTb port pressure switches the travel straight
spool 2 steps, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
22-26
22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
CIRCUIT
(1) Purpose :
Stable swing speed.
(2) Principle :
Raise the oil pressure flowing to arm cylinder, and
give a priority of the delivery of P2 pump to swing
operation.
(3) Operation :
1) The swing main circuit operates with P2 pump
flow. But on P2 pump circuit side, the flow goes
to the swing circuit and arm circuit
simultaneously because the swing circuit and
arm circuit are parallel. Then since the return oil
from arm cylinder rod (R) side is restricted in
the arm 2 spool because the arm 2 spool is
switched to forced recirculation position, the
pressure of return oil is raised, causing the rise
of circuit pressure on the arm cylinder head (H)
side.
2) At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".
Position of arm 2 spool
Position of forced recirculation
Meter-in passage (Close)
Neutral position
From
From arm out
arm 2 inverse P/V
proportional valve
Normal recirculation position
Arm 2 spool
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa SENSOR P P P P P P
BLOCK
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
Dr 8 7 6 5 4 3 2 1
PBr CCb
HYD. TANK PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function

22-27
22. HYDRAULIC SYSTEM
22.11 PRESSURE DRAINING
(RELEASING) CIRCUIT
This section describes the following operations.
(1) Pressure drain (releasing) pilot circuit
(2) Pressure drain (releasing) main circuit
22.11.1 PRESSURE RELIEVING 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 ECU. (Electric system)
3) Stand-by command value to P1, P2 unloading
proportional valves
How to switch to "Pressure release mode"
1) Select the service diagnosis mode.
(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 selector switch [ ] 3
times. When "LANGUAGE/LOGO",
"ADJUSTING MODE 1" and "PRESET BY
FACTORY" are displayed, press [ ] or [ ]
switch, and highlight "ADJUSTING MODE 1",
and then press "Selector Switch" again.)
3) When "ADJUSTING MODE 1" screen is
displayed, press [ ] or [ ] switch, and "DRAIN
HYD. OFF" screen appears.
4) Press "Selector Switch" and highlight "OFF",
and press [ ] switch to change to "DRAIN
HYD. ON", and then press "Selector Switch"
again.
22-28
(3) Operation :
1) Pump proportional valve reduces the pump flow
rate to the minimum.
2) Unloading proportional valves (PSV-D, PSV-B)
output secondary pressure and the secondary
pressure flows in PCb, PCa ports of C/V(2) and
switches the P1, P2 unloading valves to OPEN
position.
22.11.2 PRESSURE RELEASE MAIN CIRCUIT
(1) Operation :
When the hydraulic pressure releasing is
performed, make sure to place bucket on the
ground.
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
or the high pressure sensors (SE-22,23) 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 :
Unload spool is switched to open position, and 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.
 22. HYDRAULIC SYSTEM

D P

PSV1
SE-22
P
A1a1 a2
SE-23
A1
P PSV2
4
PH1 PH2
PSV-P1 PSV-P2
a3 a4 SWING
B FOR. FOR. A
PG
REV. REV.
4 DB
A B
3
1 8 C
B DEE I HAC
PA
28.0MPa 18
PB
MAIN PUMP TRAVEL RIGHT TRAVEL LEFT P D
Dr1 Pi1

69kw 5.0MPa
/2000min-1 M
a3
B1
Pi2
B3 Dr3 A3 11

2 RIGHT
A B
MU2 MAIN CONTROL VALVE P1 (P6) T1 (P5) T2 P2 LEFT
34.3MPa
15 12 CMR1
PTb CMR2 PBL
BUCKET DUMP
TRAVEL BUCKET DIGGING
P1 UNLOARD STRAIGHT TRAVEL LEFT SWING LEFT
PCb PAL SWING RIGHT

AL
19 ARM OUT
ARM IN
BOOM UP
BOOM UP
14 CT2 CP2 BL

SE-8
SE-7

SE-4
SE-3
SE-2
SE-1
T3
TRAVEL RIGHT P2 UNLOAD
PAr CT1 PCa P P P P P P
CP1 BOOM 8 7 6 5 4 3 2 1
Br CONFLUX PB1
Ar
CCb Dr
HYD. TANK PBr PBs
Pss SE-5
LCs
SOL/V
17 PAb
BOOM LCb SWING
PAs
P

P1 BLOCK LEVER
A1 LOCK B A As
SV-4 37.8MPa Bs
(ROD)Bb PBa1
C
CRb
SWING
SV-1
A2 P/B
(HEAD)Ab
LCa
16 ATT. Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
PILOT
TRAVEL ARM 1 PAa1 VALVE
1/2 SPEED
A3 CHANGEOVER
BUCKET 9
SV-3
PBb
37.8MPa CYLINDER
9
XAb 37.8MPa
LCc Aa (HEAD)
A4 PAc
BUCKET
7
CRa ARM
PLc2 CYLINDER P T P T
37.8MPa BOOM ARM
A5 P2 UNLOAD (ROD)Bc & BUCKET & SWING
Ba (ROD)
PSV-B (HEAD)Ac
37.8MPa
37.8MPa
6
TRAVEL
TRAVEL PBc PILOT VALVE P T
A6 STRAIGHT LCAT2
PSV-C
PAa2
ARM 2
LCAP2 OPTION
10
LCo
PAo
5
A7 P1 UNLOAD BOOM
PSV-D CYLINDER
PBa2
Ao
Bo 3 6 4 1 5 2
A8 ARM 2
PSV-A RIGHT TRAVEL FORWARD P P
16 PBo
RIGHT TRAVEL REVERSE
LEFT TRAVEL FORWARD
SE-9 SE-10

13 MU1
PBp1 P1 BY PASS
CUT
P2 BY PASS
CUT
PBp2 LEFT TRAVEL REVERSE

T2 P2

(P3) (P4)

16

Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.

22-29
22. HYDRAULIC SYSTEM

[MEMO]

22-30
 23. ELECTRIC SYSTEM
TABLE OF CONTENTS

23.1 ELECTRIC CIRCUIT DIAGRAM ......................................................................................23-3

23.2 ELECTRICAL EQUIPMENT LIST....................................................................................23-9
23.3 HARNESS........................................................................................................................23-10
23.3.1 HARNESS LIST ......................................................................................................23-10
23.3.2 INSTRUMENT PANEL ASSY.................................................................................23-11
23.3.3 CONTROLLER INSTALL........................................................................................23-12 23
23.3.4 OPERATOR'S CONTROL (SWITCH INSTALL).....................................................23-13
23.3.5 UPPER ELECTRIC ASSY ......................................................................................23-14
23.3.6 UPPER HARNESS ASSY (1/8) ..............................................................................23-15
23.3.7 UPPER HARNESS ASSY (FLOOR) (1/3) ..............................................................23-30
23.3.8 ENGINE HARNESS ASSY .....................................................................................23-37
23.3.9 CAB INSTALL.........................................................................................................23-38
23.3.10 WASHER TANK ASSY...........................................................................................23-39
23.3.11 CAB HARNESS ASSY ...........................................................................................23-40
23.3.12 BOOM HARNESS ASSY........................................................................................23-43
23.3.13 BOOM LIGHT INSTALL..........................................................................................23-43
23.3.14 UPPER LIGHT INSTALL ........................................................................................23-44

23-1
23. ELECTRIC SYSTEM

23-2
 23. ELECTRIC SYSTEM

23.1 ELECTRIC CIRCUIT DIAGRAM

HORN,HORN RELAY
ENG.CONTROLLER

KEY SW.STARTER RELAY

GAUGE CLUSTER
DC-DC CONVERTER,
ROOM LIGHT TUNER

IT CONTROLLER
ENG.CONTROLLER
LUBRICATION OIL

AUTO GREASE
CONTROLLER

CONTROLLER

CONTROLLER

FUEL SUPPLY
PRESS.SENSOR
RELAY,HOUR

LEVER LOCK

BATTERY RELAY
MECHATRO

MECHATRO

CIGARETTE

GLOW RELAY
BACK UP
LIGHTER

BACK UP
METER

TUNER

PUMP
C-8:ENG.CONTROLLER ENG.HARNESS

E-1:FUSE & RELAY BOX

RDS/RAIL PRESS.

R-26: (NONUSE) BOOST PRESS.

LEVER LOCK RELAY SENSOR

WATER TEMP
SENSOR

CRANK SENSOR

LIGHT,TRAVEL ALARM,
OPT.HAND
CONTROL
OPT.4
AIR CON.(AMP.)

GAUGE CLUSTER

WIPER,WASHER
SOLENOID,
HIGH REACH,LMN/BH
WORK LIGHT

CAB WORK LIGHT

CAB WORK LIGHT

AIR CON.

AIR CON.

ROOF WIPER

OPT.BACKET
CONTROL
OPT.1

OPT.3
FLASHER,REARWORK
RELEASE SW.(KPSS)

LEVEL CONTROLLER,
DC-DC CONVERTER
RADIATOR COOLANT
SH2 SHEILD

ONE WAY CALL

CAM SENSOR

SH3 SHEILD

E-12: E-12: INJECTOR 1

BATTERY BATTERY
STARTER CABLE
INJECTOR 2

INJECTOR 3

R-1: ACCEL REDUNDANT

BATTERY REAY POTENTIO
E-15: INJECTOR 4
FUSIBLE LINK
75A

R-23: MPROP
AUTO IDLE STOP RELAY 1 R-24: R-25:
AUTO IDLE STOP ENG.EMERGENCY STOP
RELAY 2 RELAY LUBRICATION OIL
KEY ON PRESS. SENSOR
G
N TIN
IO EA
SIT EH
PO PR
TERMINAL

O A O S
T
F C A
F C N R TERMINAL FOR SERVICE
T

R-3:
GLOW RELAY GLOW

R-53:
GLOW RELAY
SW-1: KEY SW. (ECU)

M-1:
STARTER MOTOR

C-1:
MECHATRO CONTROLLER(TCO-60-2)
R-2:
STARTER RELAY

R-4: SAFETY RELAY C-6:

AUTO GREASE
CONTROLLER
SH8 SHIELD
E-3:
HOUR METER
CHARGE
KEY ON

CONTROL:
(SENSOR,5V,CPU)
(PULL UP)
OUT SOURCE:
(PSV.SOL.MOTOR)

R-28:ALTERNATOR RELAY

TO(2/6)
(1/6)

23-3
23. ELECTRIC SYSTEM

C-1: MECHATRO CONTROLLER(TCO-60-2)

FROM (1/6)

SE-16:ACCEL POTENTIO

N
IO AL ASE
PRESS.SENSOR SIT ORM ELE
PO N R

TERMINAL
SW-4:
SE-1:BUCKET DIGGING SWING PARKING RELEASE SW.

SE-2:BUCKET DUMP SV-1:SWING PARKING BRAKE SOL.

SV-3:TWO-SPEED SELECT SOL.

SE-3:BOOM RAISING

PSV-B:P2 UNLOAD PROPORTIONAL SOL.

SE-4:BOOM LOWERING

PSV-C:TRAVEL PRIORITY PROPORTIONAL SOL.

SE-7:ARM IN

PSV-D:P1 UNLOAD PROPORTIONAL SOL.

SE-8:ARM OUT
PSV-A:ARM TWO-SPEED INVERSE PROPORTIONAL SOL.

SE-5:SWING

SE-9:TRAVEL RIGHT PSV-E:OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 1

SE-10:TRAVEL LEFT PSV-I:OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 2

SE-22:PUMP P1
N
IO AL ASE
SIT ORM ELE
PO N R SW-22:

TERMINAL
SE-23:PUMP P2 RELEASE SW. (KPSS)
E-38: RESISTOR

SE-20:P1 OPT.
C-2:GAUGE CLUSTER
PSV-P1:PUMP P1 PROPORTIONAL SOL.
SE-11:P2 OPT.

ENG.WATER TEMP METER

PSV-P2:PUMP P2 PROPORTIONAL SOL.

FUEL METER SE-15:FUEL SENSOR

SE-32:DOZER

SE-33:SEPARATE

SE-13:ENG.REVOLUTION SENSOR
SHIELD

SHIELD

DISPLAY BUZZER STOP MODE WASHER

SELECT SW.

ENTER DECEL TRAVEL WIPER TO(3/6)

2-SPEED

(2/6)

23-4
 23. ELECTRIC SYSTEM

C-1:MECHATRO CONTROLLER(TCO-60-2)

FROM 2/6

SW-8:AIR FILTER RESTRICTION SW. R-5:HORN RELAY

E-5:HORN HIGH
E-6:HORN LOW
SW-36:WATER SEPARATOR
RESTRICTION SW. SW-10:HORN SW. LEFT

SW-5:HORN SW. RIGHT

(WIPER RELAY)

SW-15:
CONFLUX/SINGLE SELECT SW. R-31: R-29:
PREVENT SPARK WIPER MOTOR RELAY
RELAY L-5:ROOM LIGHT
M-3:
WIPER MOTOR

R-30:
WIPER MOTOR
REVERSING RELAY

R-32: E-14:CIGARETTE LIGHTER

M-4:
WINDOW WASHER WASHER MOTOR
MOTOR RELAY
E-1:
FUSE & RELAY BOX
R-26: E-11:
SW-11: LEVER LOCK SV-4:OPERATING E-10:
LEVER LOCK SOL. AIR COMPRESSOR
LEVER LOCK SW. RELAY RECEIVER DRIER CLUTCH
STOP R-6:
REVERSE WORK LIGHT RELAY

AIR CON.AMP.
(GROUND OUTPUT)

SW-19:WIPER INTERLOCK SW.

R-8:TRAVEL ALARM RELAY

E-13: COOLING
TRAVEL ALARM UNIT
SE-29:OPT.SELECT
DETECT SENSOR
SW-13:
TRAVEL ALARM SW

DOMESTIC,AUSTRALIA
SV-13:OPT.SELECTOR SOL. DOMESTIC OPT.
KCMA KCMA STD.
AUSTRALIA STD.

SW-12:
OVER LOAD SELECT SW.
SW-17:ROOF WIPER SW.
POSITION
TERMINAL

SE-26: M-9:ROOF WIPER MOTOR

PRESS. SENSOR:BOOM HEAD
EU (FOR OVER LOAD ALARM)

EU

ROOF WIPER

TO 4/6

(3/6)

23-5
23. ELECTRIC SYSTEM

C-1:MECHATRO CONTROLLER

FROM 3/6

C-6:AUTO GREASE
CONTROLLER

SE-26:
PRESS.SENSOR:BOOM HEAD M-8:GREASE MOTOR

SE-25:
PRESS. SENSOR:BOOM ROD E-2:
ALTERNATOR

OPT.
AUTO GREASE
SE-17:BOOM POTENTIO

SE-19:ARM POTENTIO

R-6:WORK LIGHT RELAY L-6:BOOM WORKING LIGHT RIGHT OFFSET

L-1:BOOM WORKING LIGHT LEFT

L-2:FRAME WORKING LIGHT RIGHT

R-36:ROTARY C-4:AIR-CON AMP
LIGHT RELAY (RED) L-19:
HIGH REACH THREE
COLORS ROTARY LIGHT SW-55:
BOOM,DECK WORKING LIGHT SW.

R-37:ROTARY LIGHT R-19:

RELAY (YELLOW) FLASHER RELAY
L-3:
SWING FLASHER LEFT

R-38:ROTARY LIGHT
RELAY (GREEN) L-4:
SWING FLASHER RIGHT

L-10:
HIGH REACH ROTARY LIGHT

SV-5:
BUCKET DUMP CUT SOL.
N RY
IO NA L
SIT TIO AVE
PO STA TR
TERMINAL

SW-41:
HIGH REACH
CRANE SW.
(STATIONARY)
SWING FLASHER & WORKING LIGHT
(TRAVEL)

OPT.
HIGH REACH CRANE

SW-37:
TRAVEL INDEPENDENT
SW.

KCMA

TO 5/6

(4/6)

23-6
 23. ELECTRIC SYSTEM

C-1:MECHATRO CONTROLLER (TCO-60-2)

FROM 4/6

M-11:FUEL SUPPLY PUMP

SW-69:P.D.C RELEASE SW. (GRIP)

SW-68:P.D.C RELEASE SW. SW-56:FUEL SUPPLY AUTO SW.

EU

E-7:TUNER AM & FM

PRESS. SENSOR
E-8:SPEAKER LEFT
SE-35:OFFSET RIGHT FM / AM

E-9:SPEAKER RIGHT

SE-36:OFFSET LEFT (BACK UP)

SE-37:OFFSET POTENTIO
WITH OUT EU

E-22:DC-DC CONVERTER

PSV-T:BOOM RAISING CUSHION E-23:12V SOCKET

PROPORTIONAL SOL.

PSV-U:BOOM LOWERUNG CUSHION

PROPORTIONAL SOL.
E-40:TUNER AM & FM(12V)

PSV-V:ARM IN CUSHION
PROPORTIONAL SOL. E-41:SPEAKER
LEFT(12V)

PSV-W:ARM OUT CUSHION E-42:SPEAKER

PROPORTIONAL SOL. RIGHT(12V)
(BACK UP)
PSV-W:OFFSET LEFT CUSHION
PROPORTIONAL SOL.

EU

OFFSET

SW-16:ENG. ROOM LIGHT SW. R-11:ENG. ROOM LIGHT

R-9:CAB WORKING
LIGHT RELAY 1
EU
L-7:CAB WORKING
LIGHT FRONT 1
L-8:CAB WORKING
LIGHT FRONT 2
SW-26:CAB WORKING L-15:CAB WORKING
LIGHT SW. LIGHT FRONT 3

L-16:CAB WORKING SW-40:ROTARY LIGHT SW.

LIGHT FRONT 4
L-18:CAB WORKING
LIGHT REAR L-20:ROTARY LIGHT
R-11:CAB WORKING L-17:BACK LIGHT
LIGHT RELAY 2
(5/6)
EU

23-7
23. ELECTRIC SYSTEM

C-1:MECHATRO CONTROLLER (TCO-60-2)

9P CONNECTOR
C-1:MECHATRO CONTROLLER (TCO-60-2)

DOWNLOAD

R-26:
LEVER LOCK RELAY SV-6:
SW-33: REVOLUTION
R-12: REVOLUTION RIGHT SOL.
REVOLUTION RIGHT SW.
SW-62: SV-18:
RIGHT RELAY EXTRA(B)SOL
EXTRA(B)SW.
R-42: C-1:MECHATRO CONTROLLER (TCO-60-2)
EXTRA(B)RELAY

SV-7:
SW-34: REVOLUTION
R-13: REVOLUTION LEFT SOL.
REVOLUTION LEFT SW. SV-17: E-25:PDC ANTENNA
C-7:IT CONTROLLER
LEFT RELAY SW-63: EXTRA(A)SOL
REVOLUTION N&B R-43: EXTRA(A)SW.
EXTRA(A)RELAY

E-24:GPS ANTENNA

SW-29: SV-9:
NIBBLER NIBBLER OPEN SOL.
R-15:
NIBBLER OPEN SW. SHIELD
OPEN RELAY
(CASE OF HAND CONTROL
NIBBLER CONNECT WITH 571)

(CASE OF HAND CONTROL

BRAKER CONNECT WITH 572)

SV-10: E-16:ONE WAY CALL AMP

SW-30: NIBBLER
NIBBLER CLOSE SOL.
EASY OPERATING R-16: CLOSE SW.
NIBBLER NIBBLER
CLOSE RELAY

E-17:
ONE WAY CALL SPEAKER

OPT.
MIC ONE WAY CALL

(6/6)

23-8
 23. ELECTRIC SYSTEM

23.2 ELECTRICAL EQUIPMENT LIST

GROUP CODE NAME GROUP CODE NAME GROUP CODE NAME GROUP CODE NAME
MECHATRO CONTROLLER L-1 BOOM WORK LIGHT (LH) R-1 BATTERY RELAY SWING PARKING
(C) CONTROLLER

C-1 SV-1
(TCO-60-2) L-2 FRAME WORK LIGHT (RH) R-2 STARTER RELAY BRAKE SOL.
(YY35V00013F1)
C-2 GAUGE CLUSTER L-3 SWING FLASHER (LH) R-3 GLOW RELAY TWO SPEED
SV-3 SOLENOID
AIR-CON CONTROLLER L-4 SWING FLASHER (RH) R-4 SAFETY RELAY SELECT SOL
C-4 VALVE ASSY
(INCLUDING PANEL) L-5 ROOM LIGHT R-5 HORN RELAY SAFETY LOCK
SV-4

(SV) SOLENOID
C-8 ENGINE CONTROLLER L-6 BOOM WORK LIGHT (RH) R-6 WORKING LIGHT RELAY LEVER SOL
L-7 CAB WORK LIGHT (FRONT 1) R-8 TRAVEL ALARM RELAY SV-6 REVOLUTION RIGHT SOLENOID

(L) LIGHT
D-4 DIODE L-8 CAB WORK LIGHT (FRONT 2) R-9 CAB WORKING LIGHT RELAY SV-7 REVOLUTION LEFT SOLENOID
D-5 DIODE L-15 CAB WORK LIGHT (FRONT 3) R-11 CAB WORKING LIGHT RELAY SV-9 NIBBLER OPEN SOLENOID
D-6 DIODE L-16 CAB WORK LIGHT (FRONT 4) R-12 REVOLUTION RIGHT RELAY SV-10 NIBBLER CLOSE SOLENOID
D-9 DIODE R-13 REVOLUTION LEFT RELAY SV-11 EXTRA DIS-PRESS SOLENOID
D-10 DIODE R-15 NIBBLER OPEN RELAY SV-13 OPT. SELECTOR SOLENOID

(R) RELAY
D-11 DIODE R-16 NIBBLER CLOSE RELAY SV-17 EXTRA (A) SOLENOID
D-12 DIODE R-17 EXTRA DIS-PRESS RELAY SV-18 EXTRA (B) SOLENOID
(D) DIODE

D-13 DIODE R-19 FLASHER RELAY

D-14 DIODE R-23 AUTO IDLE STOP RELAY 1
D-15 DIODE M-1 STARTER MOTOR R-24 AUTO IDLE STOP RELAY 2 SW-1 KEY SWITCH
D-16 DIODE M-3 WIPER MOTOR R-25 ENGINE EMERGENCY STOP RELAY SWING PARKING BRAKE RELEASE
SW-4

(M) MOTOR
D-17 DIODE M-4 WASHER MOTOR (TANK ASSY) R-26 LEVER LOCK RELAY SWITCH
D-18 DIODE M-8 GREASE MOTOR R-28 ALTERNATOR RELAY SW-5 HORN SWITCH (RH)
D-19 DIODE M-9 ROOF WIPER MOTOR WIPER MOTOR RELAY SW-7 E/G OIL PRESSURE SWITCH
R-29
M-10 WIPER MOTOR (NORMAL ROTATION) SW-8 AIR FILTER CLOGGING SWITCH
WIPER MOTOR RELAY SW-10 HORN SWITCH (LH)
R-30
(REVERSE ROTATION) SW-11 SAFETY LOCK LEVER SWITCH
ARM 2 SPEED R-31 PREVENT SPARK RELAY SW-12 OVER LOAD ALARM SELECT SWITCH
PSV-A INVERSE R-32 WASHER MOTOR RELAY SW-13 TRAVEL ALARM SWITCH
PROPO.VALVE R-53 GLOW RELAY(ECU) CONFLUX/SINGLE SELECT
SW-15
E-1 FUSE AND RELAY BOX P2 UNLOAD (YY35V00013F1) SWITCH
PSV-B
E-2 ALTERNATOR PROPO.VALVE SOLENOID SW-16 ENG. ROOM LIGHT SWITCH
E-3 HOUR METER TRAVEL STRAIGHT VALVE ASSY PRESSURE SENSOR : SW-17 SKYLIGHT WIPER SWITCH
PSV-C SE-1
E-5 HORN (HIGH) PROPO.VALVE BUCKET DIGGING SW-19 WIPER INTERLOCK SWITCH
E-6 HORN (LOW) P1 UNLOAD PRESSURE SENSOR : SW-22 KPSS RELEASE SWITCH
(P) PROPORTIONAL
SOLENOID VALVE

PSV-D SE-2
E-7 TUNER AM/FM (KCMA) PROPO.VALVE BUCKET DUMP SW-26 CAB WORK LIGHT SWITCH
E-8 SPEAKER (LEFT) (KCMA) OPT. RELIEF ADJU- SE-3 PRESSURE SENSOR : BOOM UP SW-29 NIBBLER OPEN SWITCH
PSV-E

(SW) SWITCH
(E) ELECTRIC FITTINGS

E-9 SPEAKER (RIGHT) (KCMA) STMENT PROPO. VALVE PRESSURE SENSOR : SW-30 NIBBLER CLOSE SWITCH
SE-4
E-10 RECEIVER DRYER P1 PUMP BOOM DOWN SW-32 STROKE-END PROXIMILITY SWITCH
PSV-P1
E-11 AIR-CON COMPRESSOR PROPO VALVE (YY10V00013F1) SE-5 PRESSURE SENSOR : SWING SW-37 TRAVEL INDEPENDENT SWITCH
E-12 BATTERY P2 PUMP PUMP ACCESORY SE-7 PRESSURE SENSOR : ARM IN SW-55 BOOM WORK LIGHT SWITCH
PSV-P2
E-13 TRAVEL ALARM PROPO VALVE SE-8 PRESSURE SENSOR : ARM OUT SW-56 FUEL SUPPLY AUTO STOP SWITCH
E-14 CIGARETTE LIGHTER SE-9 PRESSURE SENSOR : TRAVEL RH SW-62 EXTRA (B) SWITCH
E-15 FUSIBLE LINK SE-10 PRESSURE SENSOR : TRAVEL LH SW-63 EXTRA (A) SWITCH

(SE) SENSOR
E-16 ONE WAY CALL AMP SE-11 (PRESSURE SENSOR : P2 OPT.) SW-68 PDC RELEASE SW.
E-17 ONE WAY CALL SPEAKER SE-13 E/G SPEED SENSOR SW-69 PDC RELEASE SW.(GLIP)
E-22 DC-DC CONVERTER SE-15 FUEL SENSOR
E-23 12V SOCKET SE-16 ACCEL POTENTIOMETER
E-24 GPS ANTENNA SE-17 BOOM POTENTIO
E-25 PDC ANTENNA SE-19 ARM POTENTIO
E-40 TUNER AM&FM (12V) (EU) SE-20 (PRESSURE SENSOR : P1 OPT.)
E-41 SPEAKER LEFT (12V) (EU) SE-22 PRESSURE SENSOR : PUMP P1
E-42 SPEAKER RIGHT (12V) (EU) SE-23 PRESSURE SENSOR : PUMP P2
SE-25 PRESSURE SENSOR : BOOM ROD
PRESSURE SENSOR : BOOM HEAD
SE-26
(FOR OVER LOAD ALARM)
SE-28 EXTRA PRESS
SE-29 OPT. SELECTOR DETECT SENSOR

NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only.

23-9
23. ELECTRIC SYSTEM

23.3 HARNESS
23.3.1 HARNESS LIST

DIVISION DRAWING No. HARNESS

REMARKS
POSITION ITEM NAME CODE No. NAME

3.2 INSTRUMENT PANEL ASSY

3.3 CONTROLLER INSTALL
3.4 OPERATORS CONTROL (SWITCH INSTALL)
3.5 UPPER ELEC ASSY
3.6 UPPER HARNESS ASSY 1-1 HARNESS UPPER
1-2 CABLE BATTERY TO BATTERY
UPPER FRAME

1-3 CABLE BATTERY TO GROUND

1-4 CABLE BATTERY TO RELAY
1-5 CABLE STARTER
1-6 HARNESS SUB HARNESS (ECU)
1-7 CABLE FLOOR GROUND

2-1 HARNESS OVER LOAD ALARM
3.7 UPPER HARNESS ASSY 1-1 HARNESS FLOOR
(FLOOR PLATE) 1-3 CABLE FLOOR GROUND
1-4 HARNESS CAB SUB
2-1 HARNESS TUNER 12V
3.8 ENGINE HARNESS ASSY 1 HARNESS ENGINE SUB
3.9 CAB INSTAL 1-1-49 HARNESS ROOM LAMP
3.10 WASHER TANK ASSY
CAB
3.11 CAB HARNESS 1 HARNESS CAB
5 HARNESS KEY SWITCH GROUND
BOOM 3.12 BOOM HARNESS ASSY 1 HARNESS BOOM LIGHT
3.13 BOOM LIGHT INSTALL
LIGHT

3.14 UPPER LIGHT INSTALL UPPER LIGHT

3.15 LAMP INSTALL (ENGINE ROOM) 2 HARNESS

The parts number may be changed due to the improvement of machine, so use the number for reference only.

23-10
 23. ELECTRIC SYSTEM

23.3.2 INSTRUMENT PANEL ASSY

INSTRUMENT PANEL ASSY (02)

ITEM PART NAME Q'TY REMARKS

1 INSTRUMENT PANEL ASSY - (05)

1-10 GAUGE CLUSTER 1 CROSS TAPPING SCREW

T=5.2N.m (3.86 lbf.ft)
2 SWITCH INSTALL - (01) Install to A/C unit

2-1 SWITCH 1 WORK LIGHT

T=TIGHTNING TORQUE VIEW I

Install to cab
T=5.0N.m (3.69 lbf.ft) FORWARD
SEMS-BOLT
Install to support of
electric device
T=5.0N.m (3.69 lbf.ft)
SEMS-BOLT
Install to cab TAPPING SCREW
T=5.0N.m (3.69 lbf.ft) T=5.2N.m (3.86 lbf.ft) 2-1
SEMS-BOLT
SEMS-BOLT 4 PLACES
Install to cab

SEMS-BOLT
T=2.8N.m Install to cab
(2.07 lbf.ft) T=8.5N.m (6.27 lbf.ft)
1-10 SEMS-BOLT
SEMS-BOLT
T=8.5N.m (6.27 lbf.ft)
Install to cab
Install to cab T=12N.m (8.85 lbf.ft)
T=5.0N.m (3.69 lbf.ft) SEMS-BOLT
SEMS-BOLT

TAPPING SCREW
T=5.2N.m (3.86 lbf.ft)

SEMS-BOLT
T=5.0N.m (3.69 lbf.ft)

CROSS TAPPING SCREW

SEMS-BOLT T=5.2N.m (3.86 lbf.ft)
T=5.0N.m (3.69 lbf.ft)

SEMS-BOLT
T=4.1N.m (3.02 lbf.ft)
SEMS-BOLT
SEMS-BOLT T=5.0N.m (3.69 lbf.ft)
T=4.1N.m (3.02 lbf.ft) Install to cab

SEMS-BOLT
T=5.0N.m (3.69 lbf.ft)

SEMS-BOLT
T=23N.m (17 lbf.ft) FORWARD
Install to cab
FORWARD

23-11
23. ELECTRIC SYSTEM

23.3.3 CONTROLLER INSTALL

CONTROLLER INSTALL (01) 4-1 4-2 Put in center of top cover

ITEM PART NAME Q'TY REMARKS

1 CONTROLLER INSTALL - (02)
1-3 SWITCH 1
1-12 SWITCH 1 KPSS RELEASE UPPER HEXAGON NUT
Install horn in this direction
1-14 RESISTOR 1 TOOTHED LOCK WASHER
2 CONTROLLER INSTALL - (01)
2-1 CONTROLLER 1 ECU HORN WASHER

2-2 CONTROLLER 1 COOLANT LEVEL

3 CONTROLLER - (01) LOWER HEXAGON NUT
3-1 CONTROLLER 1 MECHATRO
3-2 SOFTWARE 1 1-3
4 RELAY BOX ASSY - (01)
4-1 RELAY BOX ASSY 1 SECTION A-A
4-2 LABEL 1
5 CONVERTER - (01)
5-1 DC-DC CONVERTER 1
T=TIGHTNING TORQUE MACHINE FRONT
TYPE 8 RATING MARKING SIDE T= 1.7N.m (1.25 lbf.ft)
Assemble with nut of accessory
SEMS-BOLT
4 PLACES 1-3
T= 1.4N.m

T= 5.0N.m (3.69 lbf.ft) SEMS-BOLT

4 PLACES1-12 4-1 T= 5.0N.m (3.69 lbf.ft)
SEMS-BOLT RELAY BOX ASSY
T= 5.0N.m (3.69 lbf.ft)
1-14 3 PLACES
SEMS-BOLT
SEMS-BOLT
T= 5.0N.m (3.69 lbf.ft)
SEMS-BOLT
T= 3.2N.m (2.36 lbf.ft)
SEMS-BOLT
T= 5.0N.m (3.69 lbf.ft)

MECHATRO
CONTROLLER

SEMS-BOLT
5 PLACES 2-1
T= 23N.m (17 lbf.ft)

SEMS-BOLT
T= 9.7N.m (7.15 lbf.ft)

5-1

FORWARD

23-12
 23. ELECTRIC SYSTEM

23.3.4 OPERATOR'S CONTROL (SWITCH INSTALL)

OPERATORS CONTROLS (01)

ITEM PART NAME Q'TY REMARKS

2 CONTROL BOX ASSY - (03)
HORN
2-7 LIMIT SWITCH 1
3 GRIP ASSY - (02)

3-2 GRIP ASSY 1 L/H HORN

LEFT RIGHT

T=TIGHTENING TORQUE
3-2 DETAIL OF GRIP

CONTROL BOX 2-7

LEVER T=41.2 N.m (30.3 lbf.ft)

CHECK HOLE FOR LIMIT SWITCH
NUT
2 PLACES
BOLT
T= 5.0N.m (3.7 lbf.ft)
ADJUST THE CLEARANCE SO AS TO PROVIDE
2 PLACES 4.5 0.5mm (0.177 0.020in) WHEN THE LIMIT
SWITCH IS POSITIONED AT THE STROKE END.
SPRING WASHER
2 PLACES

PLATE

BOLT

SECTION AA
SEMS BOLT
PROCEDURE FOR ADJUSTING THE LIMIT SWITCH
T=23N.m (17 lbf.ft) APPLY GREASE ON SLIDING AREA.

23-13
23. ELECTRIC SYSTEM

23.3.5 UPPER ELECTRIC ASSY

UPPER ELECTRIC ASSY (01) P-3 GROUND

P-17 GROUND
HORN HIGH ; E-5
ITEM PART NAME Q'TY REMARKS HORN LOW ; E-6
GND
1 BATTERY RELAY 1 SEMS-BOLT
CONNECT AS SHOWN T=10.7 N.m CONNECT AS SHOWN
2 HORN 1 HIGH SO AS TO AVOID SHORT (7.89 lbf.ft) SO AS TO AVOID SHORT
CIRCUIT ON POWER CIRCUIT ON POWER
3 HORN 1 LOW SOURCE LINE. SOURCE LINE.
TIGHTEN FROM THE FOWARD
T=TIGHTNING TORQUE

P-3 P-17

BLACK
E-6 : BLACK
HORN LOW

E-5 : GREEN/ GREEN/

HORN HIGH ORANGE ORANGE
SET THE GND
TERMINAL BETWEEN SET THE GND
THE HONE STAY AND TERMINAL BETWEEN
THE SEMS-BOLT THE HONE STAY AND
2 3 THE SEMS-BOLT
HIGH LOW
SECTION AA VEW

GLOW RELAY
SEMS-BOLT
T=2.9 N.m
(2.14 lbf.ft)

CLIP

SEMS-BOLT
T=11.7 N.m
(8.63 lbf.ft) MAX

VEW (BATTERY RELAY, GLOW RELAY)

23-14
 23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (1/8)

UPPER HARNESS ASSY (01) TO ENG. REVOLUTION

FIX WHITE TAPING CLIP SENSER
ITEM PART NAME Q'TY REMARKS TO PUNP
POSITION CLIP ENG. SWING FLASHER RIGHT
1 UPPER HARNESS ASSY - (01) GND CABLE
1-1 HARNESS 1 UPP
1-1-3 FUSE 1 NOTES:
(1) TIGHTENING TORQUE OF
1-1-4 BOX,FUSE 1 BATTERY TERMINALS ARE 3.4N.m. (2.5lbf.ft)
(2) TIGHTENING TORQUE OF
1-2 CABLE 1 BATTERY-BATTERY GROUNDING CABLES ARE 10.7N.m. (7.89lbf.ft)
(3) UNLESS OTHERWISE SPECIFIED
1-3 CABLE 1 BATTERY-GND TIGHTENING TORQUE IS SHOWN BELOW.
M6 : 9.6N.m (7.08lbf.ft) SEMS-BOLT
1-4 CABLE 1 BATTERY-RELAY M8 : 23.5N.m (17.3lbf.ft) GND
M10 : 46.1N.m (34lbf.ft) SECTION AA TIGHTEN AFTER
1-5 CABLE 1 STARTER M12 : 79.4N.m (58.6lbf.ft) CHECKING NO PAINT.
(4) UNLESS OTHERWISE SPECIFIED, THE
INSTALLING PROCEDURE IS SHOWN BELOW. ECU HARNESS
1-6 HARNESS 1 SUB HARNESS (ECU) CLIP 1-6
UPP HARNESS
1-7 CABLE 1 FLOOR GND CLIP
2 UPPER HARNESS ASSY - (02)

2-1 HARNESS 1 OVER LOAD ALARM HARNESS

CLIP
SW-56 :FUEL SUPPLY AUTO STOP SWITCH SEMS-BOLT
SE-13 : STARTER FIX WHITE TAPING POSITION
E-13 :TRAVEL ALARM
M-11 : ENG. REVOLUTION CABLE TO STARTER MOTOR ANND
SE-5 : FUEL SUPPLY SENSOR TO ATT HARNESS ALTERNATON
SE-15 :FUEL SENSOR TO GLOW
PRESS SENSOR PUMP
: SWING SE-23 :PRESS SENSOR: PUMP P2 CLIP
FIX WHITE TAPING POSITION
PSV-P2 :PUMP 2 PROPORTIONAL SOL. SECTION BB
E-6 :HORN LOW
BATTERY CABLE
1-2
E-5 :HORN HIGH
SEMS-BOLT
PSV-P1 :PUMP 1 PROPORTIONAL SOL. GND
L-2 : TIGHTEN AFTER
FRAME WORKING SE-22 :PRESS SENSOR:PUMP P1 CHECKING NO PAINT.
LIGHT RIGHT
CLIP L-4 :SWING FLASHER RIGHT 1-3
FIX WHITE TAPING GND CABLE
TO HARNESS OF ATTACHED ENG.
POSITION
CLIP
SEMS-BOLT
FIX WHITE TAPING
POSITION

1-1 5
UPP HARNESS STARTER CABLE
1-4
CLIP BATTERY RELAY CABLE
FIX WITH THE CLIP FOR
DRAIN HOSE
CLIP
UPP HARNESS SEMS-BOLT DERAIL OF BATTERY

TO AIR FILTER RESTRICTION SW.

RECEIVER DRIER
SWING FLASHER LEFT
STARTER UPP HARNESS
FIX WHITE TAPING POSITION
CABLE DRAIN HOSE STARTER CABLE
L-3 :SWING FLASHER LEFT
SW-8 :AIR FILTER RESTRICTION SW.

E-10 :RECEIVER DRIER

1-7
FLOOR GND CABLE SEMS-BOLT
GND TO BATTERY TO HIGH REACH
TIGHTEN AFTER ROTARY LIGHT
CHECKING NO PAINT. CLIP
SEMS-BOLT
VIEW Ψ

23-15
23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (2/8)

FIX AND PUT WHITE TAPING POSITION

OF UPP HARNESS AND ECU HARNESS
CONNECT WITH ENG. ACCESORIES HARNESS CLIP
TO GLOW CLIP

CLIP P-11 TO UNDER FLOOR FRAME GROUND

SEMS-BOLT MECHATRO CONTROLLER ; C-1
FIX WHITE TAPING POSITION
CLIP CLIP P-10,P-16 TO UNDER FLOOR FRAME GROUND
FIX A CONNECTOR SEMS-BOLT MECHATRO CONTROLLER ; C-1
BY A CLIP ON BRACKET FIX WHITE TAPING POSITION
KPSS RELEASE SWITCH ; SW-22
OPT. SELECTOR SWITCH SOLENOID ; SV-13
12 PIN TO FLOOR PLATE
UPPER P-4,P-15 TO UNDER FLOOR FRAME GROUND
16 PIN ECU HARNESS
BATTERY RELAY ; R-1
STARTER CABLE
UPP HARNESS GND FUSE & RELAY BOX ; E-1
UPP HARNESS SEMS-BOLT AIR FILTER CLOGGING SWITCH ; SW-8
CLIP ECU HARNESS GND DIODE ; D-4
SEMS-BOLT TIGHTEN AFTER
CONNECT TO CAB HARNESS
FIX WITH THE CLIP FOR DRAIN HOSE CHECKING NO PAINT
UPP HARNESS
FIX WHITE TAPING POSITION
P-2,P-9 TO UNDER FLOOR FRAME GROUND
LEVER LOCK SOLENOID ; SV-4
ECU HARNESS DECK WORK LIGHT ; L-2
CLIP TRAVEL 2 SPEED SOLENOID ; SV-3
FIX A UPP HARNESS TO ECU HARNESS FOWARD CLIP SEMS-BOLT
GND
DRAIN HOSE CLIP SWING PARKING SOLENOID ; SV-1
DETAIL aa FIX WHITE TAPING TIGHTEN AFTER CHECKING NO PAINT
WATER SEPALATER RESTRICTI ON SW. ; SW-36
POSITION P-1 ECU HARNESS GROUND
OPT. HAND CONTROL,
SW-56 : ENGINE CONTROLLER ; C-6 ENGINE CONTROLLER ; C-6
FUEL SUPPLY FOWARD CONNECT A HARNESS WITH IN CAP. VIEW XI
FIX WHITE TAPING POSITION SE-15 : FUEL SENSOR
CLIP AUTO STOP SW. FIX A CONNECTOR TO THE BRACKET
FIX A CONNECTOR HAS FIX WHITE TAPING POSITION
TAG OF "SW-56" ON BRACKET L-4 :SWIBG FLASHER RIGHT CLIP CLIP CLIP

TO ENG. REVOLUTION SENSOR

FIX WHITE TAPING POSITION

CLIP
SEMS-BOLT
CLIP
CLIP
TO PUMP
SEMS-BOLT
FIX WHITE TAPING POSITION
E-13 :
TRAVEL ALARM
CLIP
TO ENG.
FIX WHITE TAPING POSITION
REVOLUTION SENSOR

CLIP
FIX A HARNESS
TO GUARD

TO TRAVEL ALARM
AND FUEL SENSOR
CLIP

FIX A CONNECTOR HAS TAG OF

"ALARM" ON BRACKET

FOWARD

VIEW (DETAIL OF TRAVEL ALARM INSTAL)

VIEW IX

23-16
 23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (3/8)

FIX WHITE TAPING POSITION
SV-4 :
FIX WHITE TAPING POSITION OPERATING LEVER LOCK SOL.
FIX A HARNESS TO THE GUARD
E-5 :HORN HIGH
CLIP
M-11 : FUEL SUPPLY PUMP FIX WHITE TAPING POSITION SV-1 : CLIP
CLIP SWING PARKING BRAKE SOL.

SV-3 :
TWO-SPEED SELECT SOL.
WHEN THERE IS NO FUEL
PSV-B : SUPPLY PUMP IT BUNDLES
P2 UNLOAD AND FIXES HERE.
CLIP PROPORTIONAL SOL.
TO FUEL SUPPLY PUMP, PSV-C :
WATER SEPALATER TRAVEL PRIORITY
FIX TO THE CONNECTOR RESTRICTION SW. PROPORTIONAL SOL.
WITH CLIP REMAINING
LENGHT OF THE WATER E-6 :HORN LOW PSV-D :
SEPALATER RESTRICTI ON P1 UNLOAD
PROPORTIONAL SOL. FIX WHITE TAPING POSITION
SIDE HARNESS CLIP
CLIP PSV-A :
ARM TWO-SPEED INVERSE CLIP
PROPORTIONAL SOL. FIX A HARNESS TO THE GUARD

SW-36 :
WATER SEPALATER
RESTRICTI ON SW.
VIEW

FOWARD L-2 :
FRAME WORKING CLIP
FIX WHITE TAPING POSITION
LIGHT RIGHT
FIX A CONNECTOR TO DETAIL bb
THE BRACKET

CLIP
SMSE-BOLT
FIX WHITE TAPING POSITION FIX WHITE TAPING
CLIP POSITION VIEW
FIX A HARNESS PART OF
COULGATED FOR PROPORTIONAL
VIEW VIEW SOL. VALVE BY CLIP. CONNECT A CONNECTOR WITH
SE-1 : "RELIEF1" TAG.
PRESS SENSOR : PROPORTIONAL PSV-E :
SE-1 : BUCKET DIGGING. SOL. OPT. RELIEF ADJUSTMENT FIX A HARNESS TO A CONNECTOR
PROPORTIONAL SOL. 1 FOR PIP BY A CLIP
PRESS SENSOR : SE-7 :
SE-3 :
BUCKET DIGGING. CLIP CLIP
PRESS SENSOR : PRESS SENSOR : CLIP
BOOM RAISING SE-3 : ARM IN
PRESS SENSOR : FIX A CORRUGATERD TUBE NOT
BOOM RAISING CONTACT LOCK OF CONNECTOR.
SE-8 : SE-8 :
PRESS SENSOR : M-CONNECTOR
PRESS SENSOR :
ARM OUT ARM OUT
SE-4 : SE-4 : SENSOR
PRESS SENSOR : PRESS SENSOR :
BOOM LOWERING. FIX WHITE TAPING POSITION
BOOM LOWERING. TO HORN LOW INSTALL TO REMAIN HOLE
AND FUEL SUPPLY OF CONTROL VALVE
SE-2 : SE-2 : PUMP CLIP
PRESS SENSOR : PRESS SENSOR : CLIP CLIP
SEMS-BOLT
BUCKET DUMP BUCKET DUMP FIX A HARNESS PART OF
WHITE TAPING WITH CLIP
SE-5 :
FOWARD PRESS SENSOR : SWING
FIX A CORRUGATERD CLIP
TUBE NOT CONTACT FIX WHITE TAPING POSITION
LOCK OF CONNECTOR.
SE-7 :
PRESS SENSOR : M-CONNECTOR
ARM OUT
CLIP CLIP
FIX A HARNESS PART OF FIX A HARNESS PART OF
COULGATED FOR PRESS SENSOR OF CLIP
COULGATED FOR PRESS DETAIL dd
SENSOR OF CLIP
SENSOR
DETAIL cc : CASE OF MULCH DETAIL cc : CASE OF SENSOR BLOCK VIEW

23-17
23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (4/8)

FIX A HARNESS PART

OF COULGATED FOR
SOL. OF CLIP FIX A HARNESS TO THELUG
CLIP BY A CLIP
CLIP
FIX A HARNESS PART OF FIX A HARNESS TO THELUG BY A CLIP
PSV-P1 : FIX A HARNESS PART OF COULGATED COULGATED CLIP
PUMP P1 FOR SOL. OF CLIP FOR SOL. OF CLIP
PROPORTIONAL SOL. CLIP PSV-P1 : CLIP FIX A HARNESS PART FOR SOL. OF CLIP
PUMP P1 CLIP
PROPORTIONAL SOL.

PSV-P2 : PSV-P2 :
CLIP PUMP P2 PROPORTINAL SOL.
PUMP P2
CLIP PROPORTIONAL SOL.
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft) CLIP
SEMS-BOLT
CLIP TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
SEMS-BOLT
TIGHTENING TORQUE 25.5N.m (18.8lbf.ft)
FIX WHITE TAPING POSITION

VIEW
VIEW (DETAIL OF PUMP P1, P2 PROPORTICNAL SOL. INSTALL)
(DETAIL OF PUMP P1, P2 PROPORTICNAL SOL. INSTALL) (CASE OF PUMP AUTO EMERGENCY FUNCTION)

FIX WHITE TAPING POSITION FIX A HARNESS PART OF COULGATED

FOR PRESS SENSOR OF CLIP
SE-22 : CLIP
SE-23 : SE-22 : CLIP SE-23 :
PRESS SENSOR : PUMP P1 PRESS SENSOR : PUMP P1
PRESS SENSOR : PUMP P2 PRESS SENSOR : PUMP P2

M-11 :
FUEL SUPPLY PUMP
FIX A CONNECTOR TO
THE BRACKET

TO WATER SEPALATER
RESTRICTION SW.

CLIP

VIEW VIEW
VIEW
(DETAIL OF PRESS SENSOR : PUMP P1, P2 INSTALL)
(DETAIL OF PRESS SENSOR : PUMP P1, P2 INSTALL) (CASE OF PUMP AUTO EMERGENCY FUNCTION)

23-18
 23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (5/8)

USE NUT OF ATTACHED GLOW

TIGHTENING TORQUE
3.2 ~ 4.4N.m (2.4 ~ 3.2 lbf.ft) FIX WHITE TAPING POSITION
GLOW CLIP
FIX WHUTE TAPING POSITION
SEMS-BOLT
FIX A HARNESS BY A CLIP ON TIGHTENING TORQUE
4.9 ~ 6.9N.m
E-2 :
THE BRACKET
(3.6 ~ 5.1 lbf.ft) ALTERNATOR
CLIP
B TERMINAL
CLIP
FIX TO THE CONNECTOR WITH M-1 :
CLIP REMAINING LENGTHOF THE STARTER MOTOR
ENGREVOLUTION SENSOR SIDE

SE-13 :
ENG. REVOLUTION SENSOR
FIX A CONNECTOR TO THE BRACKET

WASHER
CLIP

SEMS-BOLT
STARTER CABLE
CLIP
TIGHTENING TORQUE
38.2N.m (28.2 lbf.ft)
FIX WHITE TAPING POSITION
ENG. GROUND CABLE
CLIP
FIX A UPP HARNESS
WITH A HARNESS OF UPP HARNESS
ATTACHED ENG.

FOWARD

VIEW E-11 : CLIP

AIR COMPRESSOR FIX HARNESS BY A CLIP TO THE CONNECTOR

TWO TERMINALS ARM IN TOUCH WITH

USE NUT OF ATTACHED EACH OTHER TO THEIR BACK AND
STARTER MOTOR INSTAL AS DRAWING.
TIGHTENING TORQUE M-1 :
15.7 ~ 19.6N.m (11.6 ~ 14.5 lbf.ft)
VIEW
STARTER MOTOR
B TERMINAL BRACKET
UPP HARNESS

STARTER CABLE STARTER CABLE FIX THE HARNESS AS THIS DRAWING

R TERMINAL, E-11 : CLIP
S TERMINAL UPP HARNESS AIR COMPRESSOR FIX THE HARNESS AS THIS DRAWING
CLIP

TO ALTERNATOR
CLIP
FIX WHITE TAPING POSITION
SEMS-BOLT

CLIP
FIX WHITE TAPING POSITION
CLIP
FIX WITH UPP HARNESS AND STARTER CABLE
SEMS-BOLT
FIX WITH THE I/C TUBE BRACKET
STARTER CABLE TIGHTENING TORQUE
39.2N.m (28.9 lbf.ft)
DETAIL OF AIR COMPRESSOR
UPP HARNESS
VIEW

DETAIL OF STARTER MOTOR

23-19
23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (6/8)

E-1 : SW-22 : E-1 :

FUSE & RELAY BOX FASTEN UPP HARNESS ON
KPSS RELEASE SW. FUSE & RELAY BOX
CAB SUB HARNESS BY CLIP
C-1 : CLIP
MECHATRO C-8 :
CONTROLLER FLOOR HARNESS ENG. CONTROLLER
FIX WHITE TAPING POSITION
CLIP
CAB SUB HARNESS
CONNECT TO KPSS RELEASE SW.
FIX WHITE
TAPING POSITION
"CNT-1" WITH TAG.
CONNECTOR OF CONNECT
TO FLOOR HARNESS
CLIP
FIX A ECU HARNESS BY A CLIP
FASTEN UPP HARNESS "CNT-2" WITH TAG.
C-8 : CONNECTOR OF CONNECT
ON FLOOR HARNESS
ENGINE CONTROLLER
BY CLIP. CLIP TO FLOOR HARNESS
CLIP
CLIP FIX WHITE TAPING POSITION
FASTEN UPP HARNESS ON
CAB SUB HARNESS BY CLIP
FLOOR HARNESS
"CNT-5" WITH TAG.
CONNECTOR OF CONNECT CLIP
TO FLOOR HARNESS

ECU HARNESS

FLOOR HARNESS UPPER HARNESS

SECTION CC
CLIP
FIX TO A FLOOR HARNESS
FIX WHITE TAPING POSITION

GROMMET ENG. CONTROLLER CONNECT CONNCTOR WITH "CN 4-1"CONNECT CONNCTOR WITH "CN 5"
PUT WHITE TAPING CHECK CONNECTOR TAG OF ITEM 1 : HARNESS
POSITION TOGETHER TAG OF ITEM 1 : HARNESS
UPP HARNESS
E-1 :
FUSE & RELAY BOX

ECU
HARNESS
FOWARD FOWARD

C-1 :
GROMMET R-19 : MECHATRO CONTROLLER
PUT WHITE TAPING POSITION TOGETHER FLASHER RELAY
E-14 : RESISTER

DETAIL OF FUSE & RELAY BOX CONNECTION.
CLIP
FIX UPPER HARNESS AND
FLOOR HARNESS TO STAND
CLIP CASE OF UNCONNECTION,
FASTEN UPP HARNESS ON BUNDLE AND FIX HARNESS
FLOOR HARNESS BY CLIP.
CONNECT CONNCTOR WITH "CN4-2"
TAG OF ITEM 1 : HARNESS
VIEW X VIII
CONNECT CONNCTOR WITH "CN1"
TAG OF ITEM 1 : HARNESS
C-1 :
MECHATRO CONTROLLER

1P CONNECTOR OF
CONNECT TO CAB HARNESS

CAB SUB HARNESS

16P CONNECTOR 17P CONNECTOR
31P CONNECTOR
28P CONNECTOR 24P CONNECTOR

VIEW X VII VIEW X IX

23-20
 23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (7/8)

L-10 : HIGH REACH ROTARY LIGHT SW-8 :
FIX THE CONNECTOR WITH CLIP AIR FILTER RESTRICTION SW.
"L-10" TAG TO THE BRACKET L-3 :AIR FILTER RESTRICTION SW.

E-10 :
RECEIVER DRIER

GROMMET FIX A HARNESS OF

WHITE TAPING POSITION
OF CLIP TO THE SWITCH.
CLIP
FIX WHITE TAPING POSITION
HOSE
FIX WHITE TAPING POSITION

CLIP CLIP
FIX WHITE TAPING
POSITION TO THE FAN GUARD

HARNESS
CLIP TO AIR FILTER
FIX WITH THE FAN GUARD
RESTRICTION SW.
AND CLIP CLIP
RECEIVER DRIER TO THE HOSE
TO AIR FILTER RESTRICTION SW.
CLIP

FIX WHITE TAPING POSITION

FOWARD

FOWARD
VIEW X X

SE-29 :
SE-28 : PRESS SENSOR :
PRESS SENSOR : SELECTOR DETECTION A CLIP DOES NOT HIT A RUBBER CAP.
EXTRA PRESS FIX A CORRUGATERD FIX A HARNESS OF WHITE TAPING POSITION
CONNECT A CONNECTOR M-CONNECTOR TUBE NOT CONTACT OF CLIP TO THE SWITCH.
FOWARD WITH "SELECTOR TAG."
CLIP CLIP SENSOR LOCK OF CONNECTOR. CLIP
FIX WITH THE CLIP
SEMS-BOLT CLIP
VIEW X INSTALL TO REMAIN HOLE
OF CONTROL VALVE. SV-13 : SW-8 :
PLATE OPT SELECTOR SOL. AIR FILTER
CONNECT A CONNECTOR
SEMS-BOLT WITH "SELECTOR TAG." FIX A HARNESS PART OF RESTRICTION SW.
WHITE TAPING WITH CLIP
CLIP CLIP
FIX A HARNESS TO
HOSE METAL FITTING
BY A CLIP. CLIP FIX A HARNESS
PART OF COULGATED
PSV-1 :
FOR PROPORTIONAL
OPT RELIEF ADJUSTMENT SOL. VALVE BY CLIP.
PROPORTIONAL SOL. 2
CONNECT A CONNECTOR
WITH "RELIEF2" TAG.

CLIP PROPORTIONAL
SEMS-BOLT
WHEN THERE IS NO OPT OF SE-29, SV-13, PSV-I CLIP
OR THERE IS REST HARNESS FOR SE-29, IT
BUNDLES AND FIXES HERE.
FIX WHITE TAPING POSITION
VIEW X X I
VIEW X II

23-21
23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (8/8)

CONNECT TO UPP HARNESS

CLIP
SEMS-BOLT UPP HARNESS
FIX WHITE TAPING POSITION
FOWARD

BATTERY RELAY CABLE

GROUND CABLE

STARTER CABLE

UPP HARNESS
SE-12 :
OVER LOAD ALARM SELECT SW.
CONNECT THE CONNECTOR
WITH TAG OF "OVER L"
VIEW VIII

R-3 :
FIX FUSE BOX WITH THE BRACKET
GLOW RELAY CONNECT THE TERMINAL WITH "A" OF HARNESS
PLATE
ADJUST THE LOCK OF THE FUSE SEMS-BOLT
BOX COVER TO THE UPPER SIDE
BATTERY RELAY CABLE
FIX A 1P CONNECTOR NUT
TO THE BRACKET
ROCK WASHER
FIX A 2P CONNECTOR
TO THE BRACKET
CONNECT THE TERMINAL WITH "B" OF HARNESS
CONNECT THIS TERMINAL
WITH BATTERY RELAY
CABLE
CLIP
R-1 : FIX WITH HARNESS FOR FUSE BOX AND BATTERY RELAY
BATTERY RELAY
FIX A CORRUGATED PART OF HARNESS
CONNECT THIS TERMINAL WITH FUSE BOX CABLE AND STARTER CABLE
FIX A CONNECTOR
TIGHTENING TORQUE 7.8N.m (5.8 lbf.ft) MAX
TO SENSOR WITH CLIP DETAIL OF CONNECT OVER LOAD ALARM
TO THE BRACKET
CLIP
CLIP SE-24 :
SEMS-BOLT PRESS SENSOR : BOOM HEAD
FIX WHITE TAPING POSITION CLIP CONNECT THE CONNECTOR WITH TAG OF "BOOM HEAD"

STARTER CABLE
SEMS-BOLT UPP HARNESS
FIX TO THE CONNECTOR
WITH CLIP REMAINING LENGTH INSERT HARNESS FOR SLIT OF INSULATION
OF THE BATTERY RELAY SECTION DD
SIDE HARNESS

CONNECT THE CONNECTOR

WITH TAG OF "SENSOR" OF
UPP HARNESS

2-1
FIX WHITE TAPING POSITION CLIP CLIP
VIEW DETAIL OF BOOM

23-22
 23. ELECTRIC SYSTEM

23.3.6.1-1 UPPER HARNESS (1/5)

23-23
23. ELECTRIC SYSTEM

23.3.6.1-1 UPPER HARNESS (2/5)

23-24
 23. ELECTRIC SYSTEM

23.3.6.1-1 UPPER HARNESS (3/5)

23-25
23. ELECTRIC SYSTEM

23.3.6.1-1 UPPER HARNESS (4/5)

23-26
 23. ELECTRIC SYSTEM

23.3.6.1-1 UPPER HARNESS (5/5) 23.3.6.1-2 BATTERY CABLE

110 (4.3")

CAP AV60B CAP

BTC-135L(RED) BTC-135R(RED)

TERMINAL TERMINAL
BC818( ) BC816( )

23.3.6.1-3 BATTERY GROUNDING CABLE

370 (14.6")

AV60B
TERMINAL
60-8
CAP TERMINAL TAPED IN TWO TURNS (JIS C 2805)
BTC-135L(BLACK) BC816

23.3.6.1-4 BATTERY RELAY CABLE

950 (37.4")
YAZAKI7034-1283
CAP
WHITE TAPING

AV60B
CORRUGATE TUBE
TO BE INSTALLED TERMINAL
CAP TERMINAL 60-8
TAPED IN TWO TURNS
BTC-135R(RED) BC818 (JIS C 2805)

23.3.6.1-5 STARTER MOTOR CABLE

(JIS D 5403)
BA710
(JIS C 2805) TERMINAL
2800 (9'2.2")
60-8
TERMINAL

AV60sq
CAP WHITE TAPING
YAZAKI7034-1283 CORRUGATE CORRUGATE TUBE
CAP TO BE INSTALLED IN TWO TURNS TO BE INSTALLED

23-27
23. ELECTRIC SYSTEM

23.3.6.1-6 ECU HARNESS

23.3.6.1-7 FLOOR GROUND CABLE

FLOOR PLATE UPPER FRAME GROUND CABLE

100 (3.94")
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010

23-28
 23. ELECTRIC SYSTEM

23.3.6.2-1 HARNESS FOR OVER LOAD ALARM (7/8)

23-29
23. ELECTRIC SYSTEM

23.3.7 UPPER HARNESS ASSY (FLOOR) (1/4)

UPPER HARNESS ASSY (01)

ITEM PART NAME Q'TY REMARKS

1 UPPER HARNESS ASSY - (01)

1-1 HARNESS 1 FLOOR

1-3 CABLE 1 FRAME GROUND
1-4 HARNESS 1 CAB SUB
2 UPPER HARNESS ASSY - (01) FLOOR HARNESS

2-1 HARNESS 1 TUNER 12V NOTE

1. ATTACHMENT OF WELDING CLIP WITHOUT
SW-1 : C-1 : DIRECTIONS IS MADE INTO THE FOLLOWING.
KEY SW. MECHATORO CONTROLLER E-1 :
FUSE & RELAY BOX CLIP
SE-16 :
ACCEL POTENTIO
TO TUNER HARNESS

C-8 :
ENG. CONTROLLER

CLIP FIX A CORRUGATERD TUBE NOT CONTACT LOCK OF CONNECTOR.

M-CONNECTOR

SENSOR
FIX A HARNESS PART OF WHITE TAPING WITH CLIP

VIEW

SW-13 :
SW-30 : TRAVEL ALARM SW.
CASE OF TRAVEL ALARM
NIBBLER CLOSE SW. (GREEN TAPING)
CONNECT WITH NAME
SW-10 : TUBE OF "ALARM"
HORN SW. LEFT (BLUE TAPING)
SW-34 :
REVOLUTION LEFT SW.(OPT)(RED TAPING) SW-37 :
INDEPENDENT TRAVEL SW.
FIX A HARNESS OF SW SIDE CONNECT WITH NAME TUBE OF "TRAVEL"
FOWARD

SW-11 : CLIP
SW-1 :
LEVER LOCK SW. FIX A HARNESS OF SW SIDE
KEY SW.
FIX A HARNESS WITH
CAB SIDE COVER ON CLIP
CLIP CLIP
FIX HARNESS BY A CLIP FIX HARNESS BY A CLIP ON HOLE
SE-16 : ON NOLE OF STAND BOAD. OF STAND BOAD.
ACCEL POTENTIO FASTEN FLOOR HARNESS FIX WHITE TAPING POSITION
AND LEVER SW. HARNESS
CLIP
IT BUNDLES AND
CAB HARNESS FIX WHITE TAPING POSITION
FIX WITH TILTED LEVER. FIX THE HARNESS FOR THE PLATE
AS SHOWN IN FIGURE WITH CLIP.
THROUGH THE HARNESS AT SEAT
FIX WHITE TAPING CLIP SIDE OF BRACKET.
POSITION
SW-33 : CLIP
REVOLUTION RIGHT SW.
CLIP (OPT)(BLUE TAPING)
FIX A HARNESS WITH CLIP SW-5 :
CAB SIDE COVER ON CLIP FIX WHITE TAPING POSITION
FIX HARNESS BY A CLIP HORN SW. RIGHT
CLIP ON HOLE OF SEAT STAND (OPT)(BLUE TAPING) E-7 : TUNER
CLIP
FIX WHITE TAPING POSITION
FASTEN WHITE TAPING POSITION OF SW-29 :
FIX HARNESS BY A CLIP ON HOLE
HARNESS WITH CLIP SIDE BY PILOT NIBBLER OPEN SW. OF SEAT STAND
HOUSE (GREEN TAPING)
FIX WHITE TAPING POSITION
VIEW VIEW VIEW

23-30
 23. ELECTRIC SYSTEM

23.3.7 UPPER HARNESS ASSY (FLOOR) (2/4)

C-1 :
MECHATORO CONTROLLER

E-1 :
FUSE & RELAY BOX

CAB SUB HARNESS CLIP

CONNECT TO ROTATION PARKING CANCEL SW.AND

CONNECTOR WITH NAME TUBE OF "PARKING"

CLIP

C-8 :
ENG.CONTROLLER
REFERENCE DRAWING OF ASSEMBLING
TO RIGHT
INST-PANEL E-1 :
FUSE & RELAY BOX
C-1 :
TO IT CONTROLLER HARNESS MECHATORO
CONTROLLER

TO LEFT
INST-PANEL
FIX WHITE TAPING POSITION
CLIP
TO FUSE & RELAY BOX

GROMMET
CONNECT THE "CNT-1" TAG
OF CONNECTOR WITH ECU
HARNESS

FIX TO THE UPPER

PART OF PLATE WITH CONNECT THE "CNT-2" TAG
CLIP. OF CONNECTOR WITH UPP
FOWARD HARNESS

DETAIL OF FUSE & RELAY BOX CONNECTION CONNECT THE "CNT-5" TAG
CONNECT CONNECTOR WITH "CN2-2" OF CONNECTOR WITH UPP
CONNECT CONNECTOR WITH "CN2-1" TAG OF ITEM 1:HARNESS HARNESS
TAG OF ITEM 1:HARNESS
TO LEFT INST-PANEL
ROTATION PARKING
CANCEL SW.
TO RIGHT
INST-PANEL.
CONNECT CONNECTOR
WITH "CN12" TAG OF ITEM
1:HARNESS
1-4
CAB SUB HARNESS
34PCONNECTOR 22PCONNECTOR 28PCONNECTOR 22PCONNECTOR 1-1
FLOOR HARNESS
CONNECT CONNECTOR WITH "CN2-3"
CONNECT CONNECTOR WITH "CN3-1" TAG OF ITEM 1:HARNESS
VIEW TAG OF ITEM 4:HARNESS
CONNECT CONNECTOR WITH "CN3-2"
TAG OF ITEM 4:HARNESS TO UNDER FLOOR

VIEW SECTION AA (STAND RIGHT SIDE A INSIDE)

23-31
23. ELECTRIC SYSTEM

23.3.7 UPPER HARNESS ASSY (FLOOR) (3/4)

E-1 :
FUSE & RELAY BOX
E-22 :
DC-DC CONVERTER
1-1
FOWARD

1-4 CONNECT TO DC-DC

CONVERTER.

TO LEFT INST-PANEL
ROTATION PARKING
CANCEL SW. CONNECT THE "CNT-4" TAG OF ITEM 1: HARNESS
WITH THE "CNT-4" TAG OF CAB HARNESS

CONNECT TO CAB HARNESS

FIX WHITE TAPING POSITION

CLIP

P-31 CONNECT TO FRAME GROUND

TUNER ; E-7
REVOLUTION RIGHT SW. ; SW-33
HORN SW. (RH) ; SW-5
NIBBLER OPEN SW. ; SW-29
REVOLUTION LEFT SW. ; SW-34
HORN SW. (LH) ; SW-10
WASHER MOTOR ; M-4
NIBBLER OPEN SW. ; SW-30
CONNECT TO ECU HARNESS
ENG. CONTOROLLER HARNESS SHIELD

FIX A CORRUGATED TUBE NOT CONTACT

LOCK OF CONNECTOR
M-CONNECTOR
SE-20 :
PRESS SENSOR : P1 OPT SENSOR
FIX HARNESS PART OF
CLIP WHITE TAPING WITH CLIP
CLIP
M-4 : FIX WHITE TAPING POSITION
TIGHTENING TORQUE
10.7N.m (7.9lbf.ft) WASHER MOTOR
TIGHTEN AFTER
CHECKING CAB SUB HARNESS
NO PAINT HERE
LOCK WASHER
P-31 WASHER
FLOOR HARNESS
NUT
FIX WHITE TAPING
CONNECT WITH POSITION
EARTH CABLE OF CLIP
UPPER FRAME

1-3
SE-10 :
PRESS SENSOR :
TRAVEL LEFT
SE-9 :
PRESS SENSOR :
TRAVEL RIGHT

SE-11 :
PRESS SENSOR :
P2 OPT
FIX WHITE TAPING
POSITION.
CLIP

CLIP CLIP TO THE FRONT SIDE OF FLOOR PLATE

1
TO FRONT
VIEW FROM THE BACK SIDE OF FLOOR PLATE
SECTION BB (PART OF FIX A HARNESS ON SEAT STAND)

23-32
 23. ELECTRIC SYSTEM

23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) (4/4)

2-1

CLIP

CLIP

CLIP

VIEW V
VIEW IV

23-33
23. ELECTRIC SYSTEM

23.3.7.1 FLOOR HARNESS (1/3)

23-34
 23. ELECTRIC SYSTEM

23.3.7.1 FLOOR HARNESS (2/3)

23-35
23. ELECTRIC SYSTEM

23.3.7.1 FLOOR HARNESS (3/3)

15. TO BE MAKE OF PART OF A HOW TO DRAWING.

TO MECHATRO CONTROLLER

TO FUSE & RELAY BOX

23-36
 23. ELECTRIC SYSTEM

23.3.7.1-3 FLOOR GROUNDING CABLE 23.3.7.2-1 TUNER HARNESS

100 (3.94")

1PAF
YAZAKI 7123-3010

23.3.7.1-4 CAB SUB HARNESS: YB13E01054P1

FUSE & WHITE TAPING WHITE TAPING

RELAY BOX
TO CAB
HARNESS

23-37
23. ELECTRIC SYSTEM

23.3.8 ENGINE HARNESS ASSY 23.3.8.4 ENGINE SUB CABLE

ENGINE HARNESS ASSY (01)

(12.2")
ITEM PART NAME Q'TY REMARKS TERMINAL TERMINAL
4 CABLE 1 ENGINE SUB

T=TIGHTENING TORQUE

AV60B
Corrugate tube to be installed

SEMS-BOLT
T=38.2 N.m
(28.2 lbf.ft)

BRACKET

SEMS-BOLT FORWARD
T=51.9 N.m
(38.3 lbf.ft)

23-38
 23. ELECTRIC SYSTEM

23.3.9 CAB INSTALL 23.9.1-1 CAB ASSY

CAB INSTALL (01) T=TIGHTENING TORQUE

CONNECTS WITH A LIMIT SWITCH OF WIPER
ITEM PART NAME Q'TY REMARKS
1 CAB ASSY 㧙 (01)

1-1 CAB ASSY 㧙 (06)

1-1-26 SWITCH 1 WIPER INTER LOCK

1-1-49 HARNESS 1 ROOM LAMP
1-1-50 ANTENA 1
1-1-52 ROOM LIGHT 1
1-1-55 WIPER ASSY 1 R/U MOTOR

1-1-50

1-1-49

1
CONNECTS IT
WITH THE MAIN
BODY HARNESS
1-1-55

SEMS-BOLT
6 PLACES WIPER MOTOR INSTOL
SECTION BB
T=8

CONNECT WITH A SWITCH

1-1-49

THE CONNECT POINT

DISTANCE IS ADJUSTED
2~3mm WITH THE FRONT
WINDOW LOCKED

1-1-26
1-1-52
CONNECTS IT
WITH HARNESS

FRONT WINDOW

DETAIL bb DETAIL cc

23-39
23. ELECTRIC SYSTEM

23.9.1-49 HARNESS 23.3.10 WASHER TANK ASSY

WASHER TANK ASSY (01)

ITEM PART NAME Q'TY REMARKS

WRAP THE TAPE TO THE 1 WASHER TANK 1
CONNECTOR BASE
TO INST-HARNESS 1-2 MOTOR 1

STRAIGHT WRAP THE TAPE TO THE

FEMALE CONNECTOR BASE

T=TIGHTENING TORQUE
WIPER INTERLOCK SWITCH

FORWARD T=46.5 N.m

(34.3 lbf.ft)
ROOM LAMP
SEMS-BOLT

CONNECTORS SELECTION TABLE

CONNECTOR PART No.
NAME MANUFUC.
(PIN NUM.) HOUSHING TERMINAL

PLATE
1
SUPPORT
PUT THE TUBE THROUGH A
HOLE OF THE TANK
TUBE
CLIP

HOSE LAYOUT UNDER FLOOR PLATE

GROMMET

CONNECTOR
WINDSHIELD WASHER

FORWARD
1-2

HOSE LAYOUT UPPER FLOOR PLATE WASHER TANK

23-40
 23. ELECTRIC SYSTEM

23.3.11 CAB HARNESS ASSY

CAB HARNESS ASSY (04)

ITEM PART NAME Q'TY REMARKS

1 HARNESS 1 CAB
5 HARNESS 1 KEY S/W GROUND
C-1 : E-1 :
MECHATRO CONTROLLER FUSE & RELAY BOX

CAB SUB HARNESS

SEMS BOLT
TIGHTENING TORQUE 4.4N.m (3.2 lbf.ft)
TIGHTEN AFTER CHECKING E-9 :
NO PAINT. SPEAKER RIGHT
THIGHTEN WITH THREE EYELET TERMINALS.
FIX WHITE TAPING
P-1,P-2 CAB HARNESS GROUND POSITION
CLIP
GAUGE CLUSTER CONNECT TO
CAB WORK LIGHT SW. UPPER HARNESS
AIR-CON UNIT CONNECT WITH CAB WORK LIGHT
CLIP
UPPER HARNESS (GND)
BOOM DECK WORK LIGHT SW. E-23 :
CAB WORK LIGHT FRONT 12V SOCKET CONNECT WITH ROOM LIGHT
WIPER INTERLOCK SW. E-14 : CAB HARNESS
HOUR METER CIGARETTE
WIPER MOTOR LIGHTER CONNECT WITH WIPER INTERLOCK SW.
FIX WHITE
CIGARETTE LIGHTER TAPING
12V POWER SOURCE SOCKET CLIP TO THE CUTTING HOLE
SKY ROOF WIPER (OPT) POSITION
SW-15 : ON THE DUCT
CONFLUX / SINGLE CHANGE SW. CLIP CLIP
CONFLUX / SINGLE FLOOR HARNESS
CAB WORK LIGHT
ROTARY LIGHT SELECT SW.
FIX WHITE TAPING
SW-55 : CONNECT TO
POSITION
BOOM , DECK WORKING CLIP CAB SUB HARNESS
5 LIGHT SW.
SW-1 :
KEY SW. E-8 : CONNECT "CNT-4" TAG TO
P-1 SPEAKER LEFT FLOOR HARNESS
1 P-2

C-2 : FLOOR HARNESS

GAUGE CLUSTER
CLIP
TO AIR
CLIP
CONDITIONER UNIT UPPER HARNESS

CLIP
DETAIL A
E-3 :
HOUR METER
SW-15 :
CONFLUX / SINGLE SELECT SW. SW-41 : SW-17 :
SW-55 : GREEN CONNECT WITH HIGH REACH CRANE SW. ROOF WIPER SW.
CONNECT WITH BOOM , DECK WORKING LIGHT SW. NAME TUBE OF "CONFLUX" BLACK CONNECT WITH NATURAL COLOR CONNECT WITH
M-3 : CAB WORK LIGHT BLUE CONNECT WITH NAME TUBE OF NAME TUBE OF NAME TUBE OF "WIPER"
WIPER MOTOR CLIP CAB SUB FRONT. "BOOM, DECK" "CRANE" TAGGED
FIX WHITE TAPING SW-26 :
CLIP TIE UP FLOOR HARNESS WITH TO AIR HARNESS TO ROOF WIPER
POSITION CAB WORK LIGHT SW.
CAB HARNESS USING CLIP CONDITIONER UNIT (OPT)
FIX WHITE TAPING NATURAL COLOR CONNECT WITH
E-14 :
POSITION NAME TUBE OF "CAB LIGHT"
CIGARETTE LIGHTER
CLIP E-14 :
FIX TO THE BRACKET CIGARETTE LIGHTER

WR B
(+) (-)

DETAIL B
DETAIL OF HOUR METER VIEW I

23-41
23. ELECTRIC SYSTEM

23.3.11.1 CAB HARNESS (1/2)

E-8 : SPEAKER LEFT

TO ROOF WIPER
(OPT)

DOUBLE
SPLICE
WHITE TAPING

DOUBLE
TAPING AFTER SPLICE
BUNDLED TAPING

TO CAB WORKING LIGHT

TO CAB WORKING LIGHT FRONT

DOUBLE DOUBLE E-9 :

SPLICE SPLICE SPEAKER RIGHT

WHITE TAPING

E-23 :
12V SOCKET SHIELD UN-CONNECTED
TAPING TAPING
C-2 :
GAUGE CLUSTER
L-5 : ROOM LIGHT

TAPING WHITE TAPING

M-3 : WIPER METER

SW-19 :
WIPER INTERLOCK SW. DOUBLE
SPLICE

E-3 :
DOUBLE SW-17 :
TO CAB GND. SPLICE HOUR METER
SW-41 : ROOF WIPER SW-15 :
HIGH REACH SW. CONFLUX / SINGLE
TO ROTALY LIGHT
CRANE SW. SELECT SW.
C-4 : E-14 : SW-26 :
AIR CONDITIONER SW-55 :
TO HARNESS (FLOOR) CIGARETTE LIGHTER CAB WORK LIGHT
UNIT BOOM, DECK
WHITE TAPING SW.
TO HARNESS (UPP) WORKING LIGHT SW.
DOUBLE
SPLICE

WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED

TAPING
TO CAB SUB HARNESS

23-42
 23. ELECTRIC SYSTEM

23.3.11.1 CAB HARNESS (2/2) 23.3.11.5 KEY SWITCH GROUND HARNESS

23-43
23. ELECTRIC SYSTEM

23.3.12 BOOM HARNESS ASSY 23.3.13 BOOM LIGHT INSTALL

BOOM HARNESS ASSY (01) INSTALLING BOOM LIGHT (04)

ITEM NAME Q'TY REMARKS ITEM NAME Q'TY REMARKS

1 HARNESS 1 BOOM 1 LIGHT 2

CLIP

TO CENTOR OF BUCKET
INSTALL WORKING LIGHT TO FACE THE CENTER OF BUCKET
WHEN ARM IS COMPLETELY STROKED AT THE END OF
PUSHING SIDE AND BUCKET IS STROKED AT 90 TO ARM.
1

VIEW I

23.3.12-1 BOOM HARNESS

TIGHTENING TORQUE : 18.6N.m

(13.7 lbf.ft)

SECTION AA

23-44
 23. ELECTRIC SYSTEM

23.3.14 UPPER LIGHT INSTALL

UPPER LIGHT INSTALL (01)

ITEM PART NAME Q'TY REMARKS

1 LIGHT 1

T=TIGHTENING TORQUE

NUT (SUPPLIED WITH LIGHT)

T=18.6 N.m (13.7 lbf.ft)

VIEW
(HOW TO INSTALL LIGHT AT RIGHT SIDE DECK)

23-45
23. ELECTRIC SYSTEM

23.3.15 ENGINE ROOM LIGHT INSTALL 23.3.15-2 BOOM LIGHT HARNESS

ENGINE ROOM LAMP INSTALL (01)

ITEM PART NAME Q'TY REMARKS

2 HARNESS 1
5 LIGHT ASSY 1

ENG. ROOM LIGHT

SEMS-BOLT
TIGHTENING TORQUE :
9.6N.m (7.08 lbf.ft) 2

5 CLIP Fasten white taping

Connect "L-11" tag with connector
UPP HARNESS of upper harness, fix it to the bracket.

SECTION AA

Tighten with ring terminal

DETAIL aa
DETAIL OF CONNECT ITEM 2 HARNESS

23-46
 24. COMPONENTS SYSTEM
TABLE OF CONTENTS

24.1 HYDRAULIC COMPONENTS .........................................................................................24-2

24.1.1 HYDRAULIC PUMP • REGULATOR ......................................................................24-2
24.1.2 CONTROL VALVE..................................................................................................24-16
24.1.3 PILOT VALVE (ATT)...............................................................................................24-58
24.1.4 PILOT VALVE (TRAVEL) .......................................................................................24-62
24.1.5 SWING MOTOR UNIT............................................................................................24-64
24.1.6 TRAVEL MOTOR ...................................................................................................24-76
24
24.1.7 SWIVEL JOINT.......................................................................................................24-88
24.1.8 CYLINDER..............................................................................................................24-90
24.2 ELECTRIC EQUIPMENT.................................................................................................24-96
24.2.1 ELECTRIC EQUIPMENT LIST ...............................................................................24-96
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS...................................................24-99

24-1
24. COMPONENTS SYSTEM

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP • REGULATOR

24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port

PSV1 MAX. FLOW RATE

ADJUSTING SCREW
2X4-M10
Dr1 Depth 16
A3
A2
a5

a4
A1
PSV2 B3
B1
EYE BOLT (M10) VIEW

4 4
a4 PSV1 PSV2 a5
a5
a6
2 2 PSV2 PSV1
MIN. FLOW RATE
ADJUSTING SCREW

Dr1 Dr1 B3 Dr1

B3

B1 3
B1
A3
a1 a2 Dr1 a3
B3
a3 Dr3

A1 A2 PH2
1 Dr3 Dr1

4-M12 Depth 18

Hydraulic ports
No. Parts Q'TY Code Ports name Size
1 Main pump assy 1 A1,2 Delivery port SAE 6000psi 3/4"
2 Regulator assy 2 B1 Suction port SAE 2500psi 2 1/2"
3 Gear pump assy(for pilot) 1 Dr1 Drain port PF1/2-19
4 Solenoid proportional reducing valve 2 PSV1,2 Servo assist port PF1/4-13
PH1,2 Pressure sensor port PF3/8-17
a1,a2 Gauge port PF1/4-15
a3 Gauge port PF1/4-14
a4,a5 Gauge port PF1/4-13
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15

Fig. 24-1 Hydraulic pump • regulator

24-2
 24. COMPONENTS SYSTEM

(2) Hydraulic circuit diagram

(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KR76-0E13-V) (KR76-0E13PV)
(KDRDE5K) (KDRDE5K)
Solenoid proportional Solenoid proportional
reducing valve (PSV-1) reducing valve (PSV-2)
a4 a5

Regulator
Regulator

Dr1

Gear pump for pilot

Main pump a3

B1 B3 Dr3 A3

PTO.
Gear Case
Fig. 24-2 Hydraulic circuit diagram of pump
(3) Specifications

Item Main pump Gear pump

Pump assy -
Parts No.
Single Pump
Pump model K7V63DTP179R-0E13-V ZX10L7RZ2-07G
Max.displacement capacity cm3 65.2 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2000
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure -
Max. flow L/min (gal/min) 130 (34) X 2 at 7.8MPa (1130 psi) 20 (5.3)
Max. input horse power kW (PS) 64.9 (88.3) 3.1 (4.2)
Max. input torque N.m (lbf.ft) 310 (229) 14.7 (10.8)
Part No.
Model KR76-0E13-V, KR76-0E13PV
Regulator Control function Electric flow control, positive flow control
With solenoid proportional reducing valve
Others
(KDRDE5K-31/30C50-123)
Weight kg (lb) 84 (185)

24-3
24. COMPONENTS SYSTEM

24.1.1.2 HYDRAULIC PUMP

24.1.1.2.1 CONSTRUCTION
(1) Main pump
Apply adhesive (Three Bond No.1305N)
533 789 733 732 532 214 548 531 702 792 901 954 724 717 723 402 151 981 983
535 534
806 808 152
953
211
490 255
256 04
261
Apply (sealub L101)
to the oil seal surface
circumferential
111 774
A A

127
710
406
123 Tightening torque
824 Flange socket
(4-M8X1.25)
17N.m (12.5 lbf.m)
251
212 271 153 468 156 466 157 313 124 711 116 312 886 314 401 467 141 272 113
727 723 Valve plate for clockwise rotation 732 05
Tightening torque Valve plate for c.clockwise rotation

Tightening torque
Item number Thread size
N.m (lbf.ft)
401, 402 M16 240 (177) 414
406 M6 12 (8.9)
326
533 M30 220 (162)
414 M10 57 (42) The grinding side is
O-ring seal side.
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 1/2 110 (81)
490 NPTF1/16 8.8 (6.5)
531,532 M20X1.5 240 (177)
806 M12 60 (44) SECTION A-A (without PTO) SECTION A-A (with PTO)
808 M16 130 (96)
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 272 Pump casing (R) 710 O-ring 1B G80 1
113 Drive shaft (R) 1 312 Valve block 711 O-ring 1B G95 1
116 Gear #1 1 313 Valve plate (R) 717 O-ring 1B G125 2
123 Roller bearing 2 314 Valve plate L 723 O-ring 1B P11 6
124 Needle bearing 2 326 Cover 724 O-ring 1B P8 12
127 Bearing spacer 2 401 Socket bolt M16X150 727 O-ring 1B P18 4
141 Cylinder block 2 402 Socket bolt M16X190 732 O-ring 1B P14 4
151 Piston 18 406 Socket bolt M6X16 733 O-ring 1B P28 2
152 Shoe 18 414 Socket bolt M10X20 774 Oil seal 1
153 Retainer plate 2 466 VP plug PF1/4 789 Back up ring; P14 2
156 Spherical bushing 2 467 VP plug PF3/8 792 Back up ring; G30 2
157 Cylinder spring 12 468 VP plug PF1/2 806 Nut M12 2
211 Shoe plate 2 490 Plug NPTF1/16 808 Nut M16 2
212 Swash plate 2 531 Tilting pin M20X1.5 824 Stop ring 2
214 Tilting bushing 2 532 Servo piston M20X1.5 886 Spring pin 4
251 Swash plate support 2 533 Plug M30 901 Eye bolt ; M10 2
255 Rotation lock pin 2 534 Stopper L 953 Socket screw ; M12X23 2
256 Set spring 2 535 Stopper S 954 Set screw ; M16 2
261 Seal cover (F) 1 548 Feed back pin 04 Gear pump 1
271 Pump casing F 1 702 O-ring 1B G30 05 PTO unit 1
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3

24-4
 24. COMPONENTS SYSTEM

(2) Gear pump (For pilot)

887
Front gear side Gear case side

SECTION X-X
(2 places)
710 700 354 351 Suction port : G3/4 887 433
Tightening torque : 74N.m
(54.5 lbf.ft)
Z
X

B3
X

434
X
A3
Delivery port : G1/2
311 Tightening torque :
312 X 53N.m (39 lbf.ft)

732 Dr3
a3 850
Dr3 Z
308 308 355

435 361 353 310 310 434 466

725
SECTION Z-Z
Drain port : G3/8
Tightening torque :
Tightening torque 34N.m (25 lbf.ft)

Tightening torque
Item number Thread size
N.m (lbf.ft)
312 M14X1.5 29 (21)
433, 434
M8 17 (13)
435
466 PF 1/4 16 (11)

No. Parts Q’ty No. Parts Q’ty

307 Poppet 1 433 Flange socket; M8×40 2
308 Seat 1 434 Flange socket; M8×55 2
309 Ring 1 435 Flange socket; M8×20 4
310 Spring 1 466 VP plug ; PF1/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14×1.5 1 710 O-ring 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1

24-5
24. COMPONENTS SYSTEM

(3) PTO gear case

125
711 468
118 825 710 728

117
126
326 262
115
128
826

414
435
886

885

No. Parts Q’ty No. Parts Q’ty

115 Idle shaft 1 435 Flange socket ; M10×20 4
117 2nd gear 1 468 VP plug ; PF3/4 1
118 3rd gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew ; M10×20 4 886 Pin 2

24-6
 24. COMPONENTS SYSTEM

24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the REGULATOR
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
auxiliary pump (OPT) arranged on another shaft. 116
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the 111
swash plate group that changes the delivery rate;
the valve block group that selects between oil
suction and delivery ; and the PTO group that
transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft (111) (113),
cylinder block (141), piston (151), shoe (152), plate AUXILIARY PUMP
(153), spherical bushing (156), bearing spacer (OPT)
(127) and cylinder spring (157). Fig. 24-4 Construction of hydraulic pump
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
block (141) is also pressed against valve plate
(314) by the action of cylinder spring (157).

313
124

312

111

116
124
314
141
157
156
151
. 153
152
211

Fig. 24-5 Rotary group

24-7
24. COMPONENTS SYSTEM

(1) Swash plate group 532

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
531
lock pin (255), set spring (256), tilting bushing 214 211
(214), tilting pin (531), and servo piston (532). The 212
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. 251
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is provided on
both sides of the servo piston. This moves the
servo piston to the right and left. The result is that
the swash plate swings on the swash plate support
via the spherical part of the tilting pin and changes
Fig. 24-6 Swash plate group
the tilting angle (a).
(2) Valve block group
The valve block group consists of valve block (312),
valve plates (313 or 314), and spring pin (886). The 313
312
valve plates having two crescent-shaped ports are
installed to valve block (312) to feed oil and recycle
it from cylinder block (141). The oil switched over by 116
the valve plate is connected with the external pipe 111
by way of the valve block. 314
141
886

Fig. 24-7 Valve block group

(3) PTO group 117
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd 126
gear are supported by bearings (125) and (126)
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with
respect to the cylinder while rotating with the 118
cylinder block. If we keep an eye on a single piston, 125
it makes a motion away from the valve plate (oil
suction process) in the first 180°and a motion
toward the valve plate (oil delivery process) in the
125
remaining 180°. If the swash plate is not inclined
(zero tilting angle), the piston does not stroke i.e.
Fig. 24-8 PTO group
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.

24-8
 24. COMPONENTS SYSTEM

24.1.1.3 REGULATOR

24.1.1.3.1 CONSTRUCTION
496 O-RING JIS B 2401 P20

325 079

624 627

631 A

643
B B
731
924
407

801
724

402

656

A 733

651 646

652 754 658 887 754

466

755
755 541 543

897 496 418 601

415 496 545

726 543
SECTION B-B

616 545 TIGHTENING TORQUE

Tightening torque
614 755 Item No. Thread size
N.m (lbf.m)
402,407 M6 12 (8.9)
875 541 415 M8 29 (21)
418 M5 6.9 (5.1)
724 708 466 PF 1/4 16 (12)
496 NPTF1/16 8.8 (6.5)
611 614 M14 1.5 27 (20)
801 M10 29 (21)
SECTION A-A
Fig. 24-9

24-9
24. COMPONENTS SYSTEM

No. Parts Q'ty No. Parts Q'ty

325 Valve casing 1 651 Sleeve 1
402 Socket bolt ; M6 X 16 4 652 Spool 1
407 Socket bolt ; M6 X 30 4 656 Block cover 1
415 Socket bolt ; M8 X 40 4 658 Plug with throttle 1
418 Socket bolt ; M5 X 12 2 708 O-ring : 1B G55 1
466 VP plug ; PF1/4 1 724 O-ring : 1B P8 5
496 Plug ; NPTF1/16 9 726 O-ring : 1B P12 1
541 Seat 2 731 O-ring : 1B G25 1
543 Stopper 1 2 733 O-ring : 1B P18 1
545 Ball 2 754 O-ring : 1B P10 2
601 Casing 1 755 O-ring : 1B P11 3
611 Feed back lever 1 801 Nut ; M10 1
614 Fulcrum plug 1 875 Pin 1
616 Prevention plug 1 887 Pin 1
624 Spring seat 1 897 Pin 1
627 Adjusting stem (Q) 1 924 Socket screw ; M10 X 20 1
631 Sleeve (For PF) 1 041 Sub-check valve 2
643 Pilot piston 1 079 Solenoid proportional reducing valve 1
646 Pilot spring 1
The codes in a rectangle represent adjust screws.
Do not tamper with the adjust screws as much as possible.

24-10
 24. COMPONENTS SYSTEM

24.1.1.3.2 OPERATION
(1) Control function
Control function …… Electric flow control.
•Positive flow control.

(2) Summary
The regulator KR76-0E13-V for the in-line type axial piston pump K7V series is composed of the control
mechanism as mentioned below:
1) Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to
attain optimum power according to the operating condition. Also, since the pump delivers only the necessary
oil flow, the machine does not consume excessive power.

(3) Explanation of operation

1) Flow rate electrical control
The pump delivery rate is controlled according to

Delivery flow rate Q

the command current value corresponding to the
movement of control devices. This relation is
shown in right figure.
2) Flow increasing action
As the command current I rises, the secondary
pressure of solenoid proportional reducing valve
(079) increases. This causes spool (652) to
Command current I
move via pilot piston (643) and stops where the
Fig. 24-10
hydraulic pressure pushing the spool rightwards
balances with the action of pilot spring (646).

If the spool (652) moves, port CL opens to the tank port. This causes the pressure of the large diameter part
of servo piston (532) to go away. This causes the servo piston (532) to the left by delivery pressure P1 of the
small diameter part, resulting in an increase in the tilting angle.
Feedback lever(611) is linked with the servo piston and sleeve(651). As the servo piston moves to the left, the
feedback lever rotates on point A which causes the sleeve to the right. As the servo piston moves to the right,
the feedback lever rotates on point A to move the sleeve to the 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.
3) Flow decrease function
As the command current I decreases, the secondary pressure of the solenoid proportional valve decreases.
This causes the spool to move to the left.
When the spool(652) has moved, delivery pressure P1 reaches port CL via spool and is admitted to the large
diameter chamber of the servo piston. Delivery pressure P1 is admitted to the small diameter part of the servo
piston at all times. The servo piston moves rightward by areal difference to decrease tilting angle. As the servo
piston moves to the right, the feedback lever rotates on point A to move the sleeve to the left. The sleeve
keeps moving till the opening of the spool sleeve closes and settles down when the spool sleeve closes
completely.

24-11
24. COMPONENTS SYSTEM

079

651 652
627
643 DELIVERY
801
PRESSURE
P1

924

808 646

954 611

953
P1
DELIVERY
PRESSURE
806

532

LARGE TILTING ANGLE SMALL

HYDRAULIC CIRCUIT
(KDRDE5K) PSV

CL PORT

Fig. 24-11 Regulator operation

24-12
 24. COMPONENTS SYSTEM

24.1.1.3.3 ADJUSTING THE REGULATOR

The regulator may be adjusted in terms of maximum
flow, minimum flow, horsepower (at emergency mode
control) control characteristics, flow control
characteristics using the adjust screw.
(1) Adjusting the maximum flow (See Fig. 24-3)
Adjust the maximum flow by loosening nut (808)
and by tightening set screw (954) (or loosening it).

Delivery flow rate Q

Tightening set screw (954) decreases the delivery
rate, as indicated in Fig. 24-12.
Only the maximum flow varies, but other control
characteristics remain unchanged.

Adjust screw no. 954

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change Input current I (Pilot pressure Pi)

Min. increase in delivery flow L/min 3.4 Fig. 24-12 Adjusting the max. delivery flow

(2) Adjusting the minimum flow (See Fig. 24-3)

Adjust the minimum flow by loosening nut (808) and
by tightening socket screw (953) (or loosening it).
Delivery flow rate Q
Tightening socket screw increases the delivery
rate, as indicated in Fig. 24-13.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care
should be used of the fact that overtightening may
increase a required power at the maximum delivery
pressure (at relieving action).
Input current I (Pilot pressure Pi)
Adjust screw no. 953
Fig. 24-13 Adjusting the min. delivery flow
No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min 2.9

(3) Adjusting the flow control characteristics (See Fig.

24-9)
Adjust them by loosening nut (801) and socket bolt
Delivery flow rate Q

(924) (or loosening it). Socket bolt causes the

control chart to move to the right as shown in Fig.
24-14.

Adjust screw no. 924

No. of turns for tightening 1/4
Increase Pilot pressure MPa 0.16
Input current I (Pilot pressure Pi)
Decrease in delivery flow L/min 10.1
Fig. 24-14 Adjusting the flow control
characteristics

24-13
24. COMPONENTS SYSTEM

24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble
and inspect it referring to "Chapter UPPER
STRUCTURE"
(1) When the engine is overloaded,
Load every unit of pump, and check on pumps on
the right and left sides for possible damages. When
pumps on both sides are failed, check on them for
the following failures 1), 2). When pump on the one
side is failed, start checking from para. 3).
1) Check that the power shift command current I is
normal.
2) The power shift pressure is high.
• Check the dither of amp.
• Replace solenoid proportional reducing
valve.
3) Stick of spool (652) and sleeve (651)
• Disassemble and clean it.
4) Stick of pilot piston (643)
• Disassemble and clean it.
(2) The max. flow rate is not delivered.
1) Check that secondary pressure of solenoid
proportional reducing valve is normal.
2) Stick of pilot piston (643)
• Disassemble and clean it.
3) Stick of spool (652) and sleeve (651)
• Disassemble and clean it.
Note : When the damage of part is severe, replace the
part with new one.

24-14
 24. COMPONENTS SYSTEM

24.1.1.4 CONTROL CURVE OF PUMP

250
[1] 49kW H mode at operating attachment
[2] 64kW H mode at traveling or optional working Input revolution ; 2000 min-1, 1800 min-1
[3] 44kW S mode at operating attachment Input horse power ; 64 kW
Input torque ; 303 N.m
200 Reference value in ( )
Two pumps are loaded at the same time
Delivery flow rate Q [ L/min ]

150
Q 2000min-1
(H mode)
1800min-1
(S mode)
100

[3] [2]
[1]

50
Min.Flow(at 2000min-1)

0 5 10 15 20 25 30 35 40
Delivery pressure Pd [MPa]

24-15
24. COMPONENTS SYSTEM

24.1.2 CONTROL VALVE

24.1.2.1 SPECIFICATIONS

24.1.2.1.1 OUTSIDE VIEW

PTb PCa

PBL

MU2

P2
P6 P5

P1

PCb PAL

T1
CT1 T2 CT2
PTb CMR1
P1 unload PCb PAL
CMR2 PL CP2
Travel PCb PAL Travel left PBL
straight
AL BL
CP1
Br Ar Travel PAr PB1 DR PCa
PBr PAr PB1 Boom CCb
right P2
Ab conflux unload
PAb Bb (ROD) LCb (HEAD) Bs
XAb PBs As LCs
PBb PBs Swing
Boom PBb PAs
CRb XAb
Pss
Pss CRa
Ac (HEAD) LCc Bucket
Bc PBc PAa1 Arm 1 PBa1
(ROD) LCa
PAc PBc PAa1 Aa
(ROD) LCo
MU1 PAa2
PBa2 Arm 2 PAa2 PAo PAo Option PBo
LCAT2 LCAP2 Ao Ba
(HEAD)
PBp1 PBp2 Bo

PAo PAa2
PAa2

PBa2

Arm 2 Option
PBo
PAc PBa1
Bucket Arm 1
(P3) (P4) PAb
PAa
Boom Swing

PBr PCa
Travel right P2 unload
T3
PTb PBL
Travel Travel left
straight
PBa2 PBo

A VIEW A
Fig. 24-15 Outside view

24-16
 24. COMPONENTS SYSTEM

24.1.2.1.2 PORTS

Port size Tightening torque Ports Description

PF3/4 150~180 N•m (111~133 lbf•ft) (MU1), (MU2) Pluged
T3
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
PF1/2 98~120 N•m (72~89 lbf•ft) (P3), (P5) Pluged
(P4), (P6) Pluged
PF3/8 69~78 N•m (51~58 lbf•ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (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
PF1/4 34~39 N•m (25~29 lbf•ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
(PL)
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
XAb Emergency manual valve port
M10 49~65N•m (36~48 lbf•ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)

24-17
24. COMPONENTS SYSTEM

Port size Tightening torque Ports Description

M12 83~110N•m (61~81 lbf•ft) T1 Tank port 1
T2 Tank port 2

24.1.2.1.3 SPECIFICATIONS

Item Specifications
Model KMX13YD/B44006
Maximum flow rate [L/min (gal/min)] 130 (34)×2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 30×2L/min (8×2gal/min)]
Overload relief valve set pressure [MPa (psi)] 37.8 (5480) [at 30L/min (8gal/min)]

24-18
 24. COMPONENTS SYSTEM

24.1.2.2 CONSTRUCTION AND OPERATION

24.1.2.2.1 CONSTRUCTION
(1) Control valve
K

155 163 101

(P5)
P2

T1
T2 CT2
K
PAL PBL

PB1 PCa

PBs PAs

Pss

PAa1 PBa1

PAo PBc

PAp2

(P4)
166 161 161155 163164
SECTION A-A
154 567 155 163
(MU2) (P6) 102
P1
973 973

CT1

PTb POb

973 973
PBr PAr

PAb PBb

973 973
PAc PBc

973 973
PBa2 PAa2

PBp1
973

(P3)
161 164 163 155 161 161
SECTION B-B
Fig. 24-16 Section (1/6)

24-19
24. COMPONENTS SYSTEM

273x10
6

H H
P1 unload PCb PAL
Travel left
(Travel straight) 273x10
C C
PAr PB1 Boom conflux
Travel right (P2 unload)
D D
XAb
XAb 977
PBb PBs 978x2
Boom Swing
E Pss
E
PBc PAa1
Bucket Arm 1
F F
PAa2 PAo
Arm 2 MU1 Option

G PBp1 PBp2
G

H H

B A
(P3)

PAa2 PAo PAo

PBp1

PBp2

275x4

213
274x4

(P4)

(P3)

212

PBa2 PBo

273x10
273x10
Fig. 24-17 Section (2/6)

24-20
 24. COMPONENTS SYSTEM

202 P1 unload 201

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

201 Travel right Boom conflux 201

333 PAr PB1 333
331 331
339 336
327 322
AbR
325 321
602
331 331
261 261
166 305
164 DR 511
162 521
Ar CCb
306
551
511 561
521
CP1
551
551 561
561
166 Br
310
164
166
161
166 T3

264 261
331
PBr
205 325
SECTION D-D 328
336
331
PCa 333
P2 unload 202

Fig. 24-18 Section (3/6)

24-21
24. COMPONENTS SYSTEM

203
333 Swing
331
PBs
339 Boom 204
320 PBb 333
Pss
319 331
379X3 336
211 322
331
L 216 321
L 266
261 M 331
M 266 XAb 261
166
160
303
301
561 CRb 161
Ab As
(HEAD)

556 511
524 524
LCb LCs
514
551 556
561 561
521 Bb Bs
511 (ROD)
161

264
264
602
PAb
205 PAs 206
BbR
160 266
SECTION E-E
201
201 333
333 Bucket Arm 1
PBc PAa1
331
331 336
339 322
320 321
BcR
319 AaR 602
602 331
331 261
261

161
304

Bc Aa(HEAD)
(ROD)
511 511
521 521
LCc LCa 551
561
551
561 161
Ac 561
(HEAD) CRa 556
Ba(ROD)
524
514
156
PLc2 167
264 160x2
L 302
602 L
PAc PBa1 264
205 211
AcR
205
SECTION F-F

Fig. 24-19 Section (4/6)

24-22
 24. COMPONENTS SYSTEM

201
333
331 Arm 2 Option 201
333
339 PAa2 PAo
331
326 337
325
330
331
329
261 604
154 AoR 331
567 261
MU1
161 311
308
162
515
521 Ao
551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
511 Ba(ROD)

162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 PaR

605 605
PBp1 PBp2

Bo

BoR
166 604
153

SECTION H-H

Fig. 24-20 Section (5/6)

24-23
24. COMPONENTS SYSTEM

T2

P1 T1
511
521
CT1
551
561
511
C P2
(MU2)
521
CT2

E 551
561

162 SECTION J-J SECTION M-M

278x5
160
266
207
267 267

528
527
T1
518
517
SECTION L-L

SECTION K-K

Fig. 24-21 Section (6/6)

24-24
 24. COMPONENTS SYSTEM

Tightening torque N•m (lbf•ft) No. Parts Q’ty Tightening torque N•m (lbf•ft) No. Parts Q’ty
101 Casing A 1 308 Arm 2 spool assy 1
102 Casing B 1 309 P1 unload spool 1
25~29 (18~21) 153 Plug 1 310 P2 unload spool 1
220~250 (162~184) 154 Plug PF3/4 2 311 Option spool 1
110~130 (81~96) 155 Plug PF1/2 4 319 Spring 2
13~17 (9.6~13) 156 Plug PF1/8 1 320 Spring 2
20~24 (15~18) 157 Plug PF1/4 MEC 1 321 Spring 3
34~39 (25~29) 159 Plug PT1/4 1 322 Spring 3
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC 5 325 Spring 6
161 O-ring : 1B G30 13 326 Spring 1
162 O-ring : 1B G25 6 327 Spring 2
163 O-ring : 1B P18 4 328 Spring 3
164 O-ring : 1B P15 4 329 Spring 1
166 O-ring : 1B P10 7 330 Spring 1
167 O-ring : 1B P8 1 331 Spring seat 24
168 O-ring : 1B P11 1 16~18 (11.8~13.3) Loctite #262 333 Spacer bolt 12
201 Cover 6 336 Stopper 6
202 Cover 4 337 Stopper 1
203 Cover 1 339 Stopper 5
204 Sub cover 1 511 Poppet 11
205 Cover 7 512 Poppet 2
206 Cover 1 514 Poppet 2
207 Back pressure check valve cover 1 515 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 517 Poppet 1
212 Plate 1 518 Poppet 1
213 Plate 1 521 Spring 11
216 Boom lowering valve 1 522 Spring 2
261 O-ring 12 524 Spring 3
264 O-ring : 1B G35 8 527 Spring 1
266 O-ring : 1B P7 4 528 Spring 1
267 O-ring : 1B P32 2 130~150 (96~111) 551 Plug 12
25~34 (18~25) 273 Socket bolt 40 130~150 (96~111) 556 Plug 5
98~120 (72~89) 274 Socket bolt 4 561 O-ring : 1B P20 17
98~120 (72~89) 275 Socket bolt 4 567 O-ring : 1B P24 2
9.8~14 (7.2~10.3) 278 Socket bolt 5 69~78 (51~58) 601 Main relief valve 1
9.8~14 (7.2~10.3) 279 Socket bolt 3 69~78 (51~58) 602 Port relief valve 5
301 Boom spool assy 1 69~78 (51~58) 604 Relief valve plug assy 2
302 Arm 1 spool 1 98~120 (72~89) 605 Bypass cut valve 2
303 Swing spool 1 69~78 (51~58) 606 Port relief valve 1
304 Bucket spool 1 140~180 (103~133) 973 Socket bolt 9
305 Boom conflux spool 1 977 Name plate 1
306 Travel spool 2 978 Rivet 2
307 Travel straight spool 1

24-25
24. COMPONENTS SYSTEM

(2) Main relief valve (601)

123 124 125 561 562 611 621 163 661 612

512 521 541 121 122 103 651 671

Fig. 24-22 Main relief valve

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
69~78 (51~58) 103 Plug ; M27 1 541 Seat 1
121 C-ring 1 561 O-ring 1
122 Spacer 1 562 Back up ring 1
123 C-ring 1 611 Poppet 1
124 Filter stopper 1 612 Spring seat 1
125 Filter 1 621 Spring 1
163 O-ring 1 651 Adjust screw 1
512 Plunger 1 661 O-ring 1
521 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1

24-26
 24. COMPONENTS SYSTEM

(3) Over load relief valve (602,606)

Fig. 24-23 Over load relief valve

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•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

24-27
24. COMPONENTS SYSTEM

(4) Arm 2 spool (308)

317 340 361 371 351

350 371 361 340 317 308

Fig. 24-24 Arm 2 spool

Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
308 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 2 18~20 (13~15) Loctite #638 351 Plug 1
340 Spring 2 361 O-ring 2
371 Backup ring 2

(5) Boom spool (301)

301 317 340 361 371 350

Fig. 24-25 Boom spool

Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
301 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Backup ring 1

24-28
 24. COMPONENTS SYSTEM

(6) Lock valve selector (211)

101

164
171
201

321
PLc A B Dr
166 541 167 511 161
Fig. 24-26 Lock valve selector

Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
101 Casing 1 10~14 (7.4~10.3) 171 Socket bolt 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

24-29
24. COMPONENTS SYSTEM

(7) Bypass cut valve (605)

! ! " "

2 2E

6 ,H

   
Fig. 24-27 Bypass cut valve

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•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

24-30
 24. COMPONENTS SYSTEM

(8) Swing shuttle valve cover (204)

PBs

Pss
555

A
G1/4
SECTION B-B A

542 541
PBs G3/8

166

B B
Pss

554

202

PAs

SECTION A-A
Fig. 24-28 Swing shuttle valve cover

Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
541 Steel ball 1 7.9~9.8 (5.9~7.2) 555 Plug 1

24-31
24. COMPONENTS SYSTEM

24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

P1 T1 T2 P2

CMR1

(PL) CMR2
PTb PBL

Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL

CT1
T3 Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr
CCb
PBs
LCb LCs Pss

Boom PAb PAs Swing

As
Bs
PBa1
(ROD) Bb
CRb LCa

(HEAD) Ab PAa1
Arm 1

PBb
Aa (HEAD)
XAb

LCc
CRa
PLc2
Bucket PAc

Ba (ROD)

(ROD) Bc
(HEAD) Ac

LCo
PAo Option
PBc
LCAT2

LCAP2
PAa2
Arm 2 Ao
Bo

PBa2 PBo
(MU)
PBp1 PBp2

(P3) (P4)

Fig. 24-29 Hydraulic circuit diagram

24-32
 24. COMPONENTS SYSTEM

24.1.2.2.3 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (605) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (307), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (605) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (605) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (605) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

52
605 (D)
517
307

T1
T1

P2
P1

309
605
(D)
Connected to low
55 310 pressure circuit of
P2 side casing

Fig. 24-30 In neutral position

24-33
24. COMPONENTS SYSTEM

(2) Actuation in travel operation

1) 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 Ar 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

306
327 325

PBL
PAL

(D)

Fig. 24-31 In left reverse travel (at PBL is pressurized)

24-34
 24. COMPONENTS SYSTEM

2) In travel straight operation

When actuator other than travel operation and the travel operation are operated simultaneously in the said
item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel
straight spool (307) moves upward.
With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used
for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into
main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel
simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oil delivered by
hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling
the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch
on travel straight spool (307) closes and the pump line on the travel sides is independent from pump line on
actuator.

CMR2 P2 CMR2 P2

B B

CMR1
P1 CMR1
P1

A A

307 307

325 325
328 328

PTb PTb
P2 P1 P2 P1

PTb PTb
Dr Dr Dr Dr
B A
To each actuator B A
To travel right To each actuator
To travel right

Circuit (I) Circuit (II)

Fig. 24-32 Movement of travel straight spool

24-35
24. COMPONENTS SYSTEM

(3) Actuation in bucket operation

1) In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward
the force of springs (319)(320), and simultaneously the secondary pressure of solenoid proportional valve
[XI] acts on port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of
bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.

53

PBc PAc

320
319

304
(D)
Bc LCc Ac
511

(R) (H)

Fig. 24-33 In bucket digging operation

24-36
 24. COMPONENTS SYSTEM

2) In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (319)(320), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by
hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows
through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied
to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of
bucket spool (304) and casing and flows through low pressure circuit (D’), boost check valve (517) and
returns to the hydraulic tank through tank port T1.

53 (D)

PBc PAc

320
319

304

Bc 511 LCc Ac

(R) (H)

Fig. 24-34 In bucket dumping operation

24-37
24. COMPONENTS SYSTEM

(4) Boom
1) 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 PCa and switches unloading spool (309).
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 bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of
boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.

(R) (R)

(H) (H)

53
BH chamber
(D) Bb 511 LCb Ab CRb 514
301

319

320

PAb PBb

Fig. 24-35 In boom up operation (Boom spool)

24-38
 24. COMPONENTS SYSTEM

2) In boom up conflux operation

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

PB1

322

321

305

511

CCb

Conflux passage
To Ab port of P1 casing

56
Fig. 24-36 In boom up conflux operation (Boom conflux spool)

24-39
24. COMPONENTS SYSTEM

3) In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward
against the force of springs (319) (320) and the secondary pressure of solenoid proportional valve [X1] acts
on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is
switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is
connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab).
Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is
released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and
passes through between the perimeter of boom spool (301) and casing, and flows through low pressure
circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part
of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since
the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through
inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and
flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb.
(Boom recirculation function)

(R) (R)

(H) (H)

511 BH chamber
Bb 53 CRb 514
317 LCb Ab

301

319

320

PAb
PBb

(D)

Fig. 24-37 In boom down operation

24-40
 24. COMPONENTS SYSTEM

(5) Arm operation

1) In arm out operation
When arm out operation is performed, the pilot pressure enters ports PBa1 and arm 1 spool (302) moves
rightward against the force of springs (321) (322). Simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (325)
(326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unload
spool (309).
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 by-pass passage (52)
and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens
load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber
through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRa (514) and is supplied to arm cylinder rod side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm
1 spool (302) and casing and passes though low pressure circuit (D) and casing inside passage (HH) and
then flows into low pressure circuit (D) through between the perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D) returns to hydraulic tank through tank port T1 passing through boost
check valve (517).

(H) (R)

CRa
514
511 Ba 302
Aa LCa
321
AR
322 chamber
211
P1
56
PAa1 PBa1 (D')
(D) LCAT2
Arm 1 LCAP2
P1
(D)
HH RH RR PAa2 PBa2
(D) Dr Dr
Arm 2 52
PBa2
[XR] To arm 1 spool
PAa2 Aa (HEAD)
53
Ba (ROD)
53
(MU1)
To bypass cut valve
326
325
308
515 LCAP2 LCAT2 511

Fig. 24-38 In arm out operation

24-41
24. COMPONENTS SYSTEM

2) In arm in operation (At light load: arm recirculation function)

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

CRa
Ba 514
Aa 511
LCa
302
321
AR
322 chamber 211

P1
56
PAa1
PBa1
(D')
Arm 1 (D) LCAT2 LCAP2
P1
HH (a) RH RR (D)
PAa2 PBa2
Arm 2 52 Dr Dr
PAa2
PBa2
[XR] 53 To arm 1 spool
Aa (HEAD)
(MU1) (D) Ba (ROD)
326 325
To bypass cut valve

308 317 515 Circuit (l)

LCAP2 LCAT2 511 319

Fig. 24-39 In arm in operation (At light load: arm recirculation function)

24-42
 24. COMPONENTS SYSTEM

3) 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 CRa (514)
which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve
poppet CRa (514) and enters AR chamber. The return oil in AR chamber flows through between perimeter
of arm 1 spool (302) and casing, and flows through low pressure circuit (D) and boost check valve (517).
And finally, the oil returns to hydraulic oil tank through tank port T1. The return oil in AR chamber is led to
arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308)
is connected to low pressure passage (D) at circuit (II), the return oil passes through between the perimeter
of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and
returns to the hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and
flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is
higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH),
but flows through check valve (319) and passes through boost check valve (517) through low pressure (D)
and returns to the hydraulic tank through port T1.

(H) (R)

CRa 514
511 Ba
Aa LCa
321 302
AR
322 chamber 211
P1

56 (D')
PAa1 (D) LCAT2
PBa1 LCAP2
P1
Arm 1 PAa2 PBa2
Dr Dr
HH (a) RH RR (D)
Arm 2 52
PAa2 To arm 1 spool
PBa2 Aa (HEAD)
[XR] 53 Ba (ROD)
(MU 1) (D) To bypass cut valve
326 325
Circuit (ll)

308 317 515

LCAP2 LCAT2 511 319

Fig. 24-40 In arm in operation (In heavy load operation)

24-43
24. COMPONENTS SYSTEM

(6) Swing operation

On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves rightward
or 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).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle
valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts
on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check
valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped
passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing
spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve
(517), and then returns to the hydraulic tank through tank port T1.

204

PAs PBs

Pss
(D)

322
303 321

Bs 56 As
(D)
511

A B

Swing motor

Fig. 24-41 Swing operation

24-44
 24. COMPONENTS SYSTEM

(7) Spool actuation for operation in option

This spool is used to control the attachment in option like Nibbler (Crusher), etc.
Where 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.

Oil passage to
N&B valve

Ao 511 Bo
LCo
311
604

56

330 329

PAo PBo

(D)

Fig. 24-42 Spool actuation for operation in option

24-45
24. COMPONENTS SYSTEM

(8) Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and
arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure
caused by each cylinder.
1) 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 Fig. 24-51 and restricts the leaking to the minimum.

Lock valve selector

(a) (b) 541

Return oil from 511

boom cylinder head
CRb Sb PLc Dr
Ab 321
PLc Sa Sb Dr
RH CHAMBER
A A SECTION A-A
514

BH CHAMBER Sa

319

320

PBb

(D) Dr 301

Fig. 24-43 Lock valve operation (At boom spool neutral position)

24-46
 24. COMPONENTS SYSTEM

2) 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 Fig. 25-52. 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 Fig. 24-52 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), and it is pushed upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out opening)
which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open,
the operation has no effect on the operability of boom down operation.
In case of arm in operation, the same operation is performed because pilot pressure PAa1 of arm in acts on
lock valve selector port PLc2.

Lock valve selector

(a) (b) 541

Return oil from
boom cylinder head
511
Sb PLc Dr
CRb
Ab 321
RH CHAMBER PLc Sa Sb Dr

A A SECTION A-A
514

BH CHAMBER Sa

319

320

PBb

(D) Dr 301

Fig. 24-44 Lock valve selector operation (At boom down operation)

24-47
24. COMPONENTS SYSTEM

(9) By-pass cut valve

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

[X1]

PBp1

301
302
(C) (b)
Dr
201 101
(D) (a)

52

Fig. 24-45 By-pass cut valve (In normal operation)

24-48
 24. COMPONENTS SYSTEM

2) At the time when failure occurred

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

PBp1

301
302

(C) (b)
Dr
101
201
(a)
(D)

202
52

Fig. 24-46 By-pass cut valve (In condition of failure)

24-49
24. COMPONENTS SYSTEM

(10)Boost check valve, By-pass 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.

528
527
T1
518
517
T2

(D)
Fig. 24-47 Boost check valve operation

24-50
 24. COMPONENTS SYSTEM

2) By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check
valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure,
and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected
from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518)
is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns
to the hydraulic tank through tank port T2.

528
527
T1

518
517
T2

(D)
Fig. 24-48 By-pass check valve operation
(11)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 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 lock nut at first and loosen the needle valve to the end of contact.

Needle valve is provided the mechanism of stopper against falling out. But the mechanism might cause
break by undue force.

The oil of boom cylinder head side flows into drain passage 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 through orifice. Operation of actuator with remote control valve is possible by leading medium
pressure via orifice from XAb port to shuttle valve. 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

24-51
24. COMPONENTS SYSTEM

by lowering boom, holding pressure disappears, and remote valve control becomes impossible.
When 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 remote control valve is
possible.

Boom cylinder head side

Main control valve Ab Port

Drain passage

Needle valve

Lever lock
solenoid valve XAb Port Lock nut
Shuttle valve

Remoto control valve

Fig. 24-49 Emergency manual valve for lowering attachment operation

24-52
 24. COMPONENTS SYSTEM

24.1.2.3 CARTRIDGE TYPE SOLENOID PROPORTIONAL RELIEF VALVE FOR N&B

24.1.2.3.1 INSTALLATION OF CARTRIDGE TYPE SOLENOID PROPORTIONAL RELIEF VALVE

(1) Tools

TIGHTENING TORQUE
No. PARTS TOOLS
N•m (lbf•ft)
36mm
101 BODY 73.5±5 (54.2±3.7)
SPANNER and TORQUE WRENCH
PROPORTIONAL SOLENOID 32mm
801 15.7 (11.8)
(COIL FIXING NUT) SPANNER and TORQUE WRENCH

(2) Installation

Procedure Caution
1) When attaching cartridge to control valve, if the
cartridge can not be screwed in because connector of
solenoid valve interferes with the surrounding parts,
perform the procedure in the following items 2) ~ 4).
If no interference and so on is found, only procedure in
item 3) should be performed.
2) Hold the hexagonal section (Opposing flats: 36mm) of Do not remove nut, but only loosen.
body (101) and loosen coil fixing nut on the solenoid
(801) upper part for the coil section to be rotated freely.

COIL FIXING NUT

BODY (101)

3) Hold the hexagonal section (Opposing flats: 36mm) of Do not hold the parts other than body (101) for
body (101) and tighten it on the control valve. tightening.
Tightening torque: 73.5±5 N•m (54.2±3.7 lbt•ft)
4) Fit connector of solenoid valve to the proper position
and tighten coil fixing nut.
Tightening torque: 15.7 N•m (11.8 lbt•ft)

24-53
24. COMPONENTS SYSTEM

24.1.2.3.2 AIR BREATHING

(1) Tools

TIGHTENING TORQUE
No. PARTS TOOLS
N•m (lbf•ft)
PROPORTIONAL SOLENOID 17mm
801 23 (17)
(AIR BREATHING PLUG) SPANNER and TORQUE WRENCH

(2) Air breathing

Procedure Caution
1) Perform the operation in items 2) and 3) under the
condition where oil is flowing into control valve KMK
and consequently back pressure (R port pressure) is
produced.
2) Loosen air breathing plug of solenoid valve until the Be careful not to mistake it for pressure adjusting
hydraulic oil starts flowing out. screw fixing nut.
Air is flown out with hydraulic oil.   

  

 



 




3) After hydraulic oil left flowing out for a while, tighten air
breathing plug.
Tightening torque: 23 N•m (17 lbt•ft)

24-54
 24. COMPONENTS SYSTEM

24.1.2.3.3 OUTSIDE VIEW

M27x1.5
AIR BREEDER PLUG
WIDTH ACROSS FLATS 17 (1/2-20UNF-2B)
TIGHTENING TORQUE : 23N.m (17.6 lbf.ft)

MANUAL SCREW SEAL NUT

WIDTH ACROSS FLATS 12 (M6x1.0)
TIGHTENING TORQUE : 7.35 0.5N.m
(5.42 0.37 lbf.ft)
NUT
WIDTH ACROSS FLATS 32 (M22x1.5) WIDTH ACROSS FLATS 36 (M27x1.5)
TIGHTENING TORQUE : 15.7N.m TIGHTENING TORQUE : 73.5 5N.m
(11.6 lbf.ft) (54.2 3.7 lbf.ft)
USE THIS ACROSS FLATS FOR
WIDTH ACROSS FLATS 36 ATTACHING THIS VALVE TO THE CASING

TYPE OF CONNECTOR
EQUIVALENT TO AMP ECONOSEAL J SERIES
CONNECTORS MARK (+) CAP HOUSING

CAP HOUSING 174354-2

TERMINAL 173706-1

HYDRAULIC SYMBOL

SPECIFICATIONS
Working pressure range (Press. in port P) MPa (psi) 15~40 (2180~5800)
Max. working pressure (Press. in port T) MPa (psi) 1.0 (145)
Max. flow L/min (gal/min) 300 (79.3)
Rated current mA 700
Electrical specifications
Coil resistance 19.5 (at 20°C)

24-55
24. COMPONENTS SYSTEM

24.1.2.3.4 CONSTRUCTION

Across flats
for tightening 402
801 solenoid tube 701 403 202 401 204 304 305 102 303 301
assy

M22 X 1.5
1/2-20

M6 X 1.0

201 208 101 203 205 206 207 501 302 601
TIGHTENING TORQUE OF SOLENOID (801)
No. SIZE TIGHTENING TORQUE REMARKS
N.m (lbf.ft)
M16 X 1.0 44 (32.5) SOLENOID TUBE ASSY
M22 X 1.5 15.7 (11.6) COIL LOCK NUT
801
1/2-20 23 (17) AIR VENT PLUG
M6 X 1.0 7.35 0.5 (5.42 0.37) MANUAL SCREW SEAL NUT

Tightening torque Tightening torque

No. Name Q’ty No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
73.5±5 (54.2±3.7) 101 Body : M27×1.5 1 302 O-ring 1
102 O-ring 1 303 Back-up ring 1
110 (81.1) 201 Plug : M30×1.5 1 304 Spring 1
202 O-ring 1 305 Spring 1
203 O-ring 1 401 poppet 1
204 Back-up ring 1 402 Spring 1
205 Filter 1 403 Spring 1
206 Filter stopper 1 501 Sheet 1
207 C-ring 1 601 Sheet 1
208 Sheet 1 701 O-ring 1
301 Plunger 1 801 Solenoid 1

24-56
 24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-57
24. COMPONENTS SYSTEM

24.1.3 PILOT VALVE (ATT)

24.1.3.1 OUTLINE
(1) Outside view

5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)

The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A

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

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

24-58
 24. COMPONENTS SYSTEM

24.1.3.2 CONSTRUCTION

Apply Loctite #277

312

302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1

241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221

PORT 2,4 PORT 1,3

Fig. 24-50 Pilot valve (ATT)

Tightening Tightening
torque No. Name Q’ty torque No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.

24-59
24. COMPONENTS SYSTEM

24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-51)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216

509

221

201

PORT (2,4) PORT (1,3)

Fig. 24-51 Lever in neutral

(2) When the pilot lever is tilted (See Fig. 24-52 )
When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)] moves
downward to make the port P to connect with the
port 2, 4, with the result that the oil of the pilot pump 
flows to the port 2 ,4 to produce a pressure.




    
Fig. 24-52 When the lever is tilted
(3) Lever held (See Fig. 24-53)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4)
rises above a set value, ports (2,4) and the P port
close while ports (2,4) and the T port open. When
the pressure at ports (2,4) falls below a set value, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT

PORT (2,4) PORT (1,3)

Fig. 24-53 When the lever is held

24-60
 24. 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.

24-61
24. COMPONENTS SYSTEM

24.1.4 PILOT VALVE (TRAVEL)

24.1.4.1 OUTLINE
(1) Outside view

Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port

(2) Specifications

P T
Item Specifications
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)

1 5 2 3 6 4
Hydraulic symbol

(3) Performance characteristics

Secondary pressure
[MPa (psi)] Secondary pressure

2.35 + 0.15
(340 + 22)

0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram

24-62
 24. COMPONENTS SYSTEM

24.1.4.2 Construction and operation

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

5
3

8 10
3
11 12
4
10

9
9

7 6
2

control ports 1-3 P line control ports 2-4

T line

24-63
24. COMPONENTS SYSTEM

24.1.5 SWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view

PB L,IP DP Port
Pi1 Symbol Port name
size
THREAD FOR
EYE BOLT 2-M10 A,B Main port PF1/2
B DEPTH 18
DB Drain port PF3/8
GN C Make-up port PF3/4
PA PA,PB Pressure measuring port PF1/4
C PG Parking brake release port PF1/4
Pi1,Pi2 Bypass valve block pilot port PF1/4
L Gear oil level gauge PT3/4
PG
A IP Gear oil filling port PT3/4
DP Outlet port of gear oil PT1/2
AN Pi2 C Dr DP2 Outlet port of gear oil PF1/2
A,B
GN Inlet povt of grease PT1/4
AN Air vent port PT1/4

PG

IP
DP2
Pi1,Pi2

PG
DB

C
DP Safety relief valve

PA PB
AN Pi1

Pi2

GN

A B

Hydraulic diagram

24-64
 24. COMPONENTS SYSTEM

(2) Specifications

Swing motor unit

Hydraulic motor Type M2X63CHB-13A-36/285-60

Displacement cm3 (in3) / rev 60 (3.66)

Rated pressure MPa (psi) 28.0 (4060)
Braking torque N•m (lbf•ft) 314 (232)
Release pressure MPa (psi) 2.3 (334)
Relief set pressure MPa (psi) 28.0 (4060) at 110L/min (29 gal/min)
Weight kg (lbs) 29 (64)
Bypass valve
Type 2KAR6P72/240-302A
and swing
reactionless
Weight kg (lbs) 6 (13.2)
valve block
Type RG06D19J2
Reduction unit

Lubicate oil Gear oil SAE#90~#140 (API class GL-3~4 grade)

Lubicate oil volume L (gal) 1.65 (0.44)
Grease Extreme pressure lithum base #2 grease
Grease volume cm3 (in3) 500 (30.5)
Weight kg (lbs) 79 (174)
Total weight kg (lbs) 114 (251)

24-65
24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-66
 24. COMPONENTS SYSTEM

24.1.5.2 CONSTRUCTION
(1) Swing motor

992

451 452
303 131 444

b
A

351

355 SECTION A-A

051

401
488 469 (051-1)

468
106 487 444 433 981 390 438 452 980
391

Tightening forgue
303
472 Tightening Widfh
No. Size torque
451 N.m (lbf.ft) across flat
707
712 051 M33X1.5 177(131) 41
A 706
A 401 M16 240(177) 14
131
982
468 G1/4 36(27) 6
702
114 469 M22X1.5 108(80) 10
111
117 980 G3/8 1.7(1.3) 6
743 981 G3/4 4.4(3.2)
121 14
742 982 G1/4 0.9(0.66) 6
113
992 PT3/4 98(72) 14
123

116

117
301
432 471 443 106 101 491 304 437 124 122

24-67
24. COMPONENTS SYSTEM

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Drive shaft 1 444 Roller bearing 1
106 Spacer 3 451 Pin 2
111 Cylinder 1 452 Pin 1
113 Retainer (spherical bushing) 1 36 (27) 468 Plug : PF1/4 2
114 Cylinder spring 1 108 (80) 469 Plug : M22 2
116 Push rod 12 471 O-ring : 1B G80 1
117 Spacer 2 472 O-ring 1
121 Piston 9 487 O-ring : 1B P11 2
122 Shoe 9 488 O-ring : 1B P20 2
123 Set plate 1 491 Oil seal 1
124 Shoe plate 1 702 Brake piston 1
131 Valve plate 1 706 O-ring 1
301 Casing 1 707 O-ring 1
303 Casing 1 712 Brake spring 20
304 Front cover 1 742 Friction plate 3
351 Plunger 2 743 Separator plate 4
355 Spring 2 1.7 (1.2) 980 Plug : PF3/8 1
240 (177) 401 Socket bolt : M16×75 4 4.4 (3.3) 981 Plug : PF3/4 1
432 Snap ring 2 0.9 (0.6) 982 Plug : PF1/4 1
433 Ring 1 98 (72) 992 Plug : PT3/4 1
437 Snap ring 1 177 (131) 051 Relief valve : M33 2
438 Snap ring 1 051-1 O-ring : 1B G30 2
443 Roller bearing 1

24-68
 24. COMPONENTS SYSTEM

(2) Anti-reaction valve

(400-2) 151

(400-1)

400

A B
SECTION V-V
101

V V

A B
Pi2 Pi1
W W
AM BM

AM,BM 161 172 171

Tightening torque
Tightening Widfh
No. Size torque
N.m (lbf.ft) across flat

151 NPTF 1/16 9 (6.6) 4 Pi2 Pi1

171,172 M8 29 (21) 6
251 M27X1.5 162 (119) 27 251
252 M22X1.5 108 (80) 27
400 M22X1.5 69 (51) 24 301 262 252
324 261
SECTION W-W

Fig. 24-54

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 261 O-ring : 1B P24 1
9 (6.6) 151 Plug : NPTF1/16 8 262 O-ring : 1B P20 1
161 O-ring : 1B P22 2 301 Spool 1
29 (21) 171 Socket bolt : M8×60 3 324 Spring 1
29 (21) 172 Socket bolt : M8×90 3 69 (51) 400 Swing reactionless valve : M22 2
162 (119) 251 Plug 1 1 400-1 O-ring : 1B P20 2
108 (80) 252 Plug 2 1 400-2 Back-up ring 2

24-69
24. COMPONENTS SYSTEM

(3) Swing reduction unit

602 230 231 204 286 211 912 285 287 911 283 403 603 922
210
921
282
202
*
203

913
285

*
402
910

801

925

920
390

926

102

401

Apply Three Bond #1217 on . 915

201

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12×100 8
203 No.2 planetary gear 4 603 Socket bolt : M12×135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
230 No.2 spider 1 912 Retaining ring 1
231 No.1 spider 1 913 Retaining ring 1
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1

24-70
 24. COMPONENTS SYSTEM

24.1.5.3 OPERATION

24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR

If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as Cylinder block (111)

shown on the figure on the right, the hydraulic

pressure acts upon piston (121) and creates force F2
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) Drive shaft (101)

via 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
Valve
shaft by turns by pistons connected to inlet port of plate
high pressure oil. Shoe Shoe Piston
(131)

plate
If the oil supply and discharge directions are (122) (121)
(124)
reversed, the drive shaft rotates in the opposite
direction. Low pressure oil High pressure oil

Theoretical output torque T can be given by the

following equation.
P X q P ; Effective differential pressure MPa OUTLET INLET (a)

T=
2X q ; Displacement per revolution cc/rev

Fig. 24-55 Operation of hydraulic motor

24.1.5.3.2 VALVE CASING SECTION

(1) (1)Operation of anti-cavitation check plunger
Since the system using this type of motor is not
equipped with a valve having a counterbalance 351
function, the motor is rotated beyond the oil feed
rate in some cases.
The system has check plunger(351) and sucks in
deficient oil, in order to prevent cavitation from
occurring due to oil deficiency. M port
(Make-up port)

DIRECTIONAL VALVE

Fig. 24-56 Operation of anti-cavitation check

plunger

24-71
24. COMPONENTS SYSTEM

(2) Operation of relief valve Chamber h

Orifice m Spring (321) Piston I (302)
1) Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the tank
pressure at the beginning, as shown in Fig. 24-
57. P
The relief valve begins to operates when the
hydraulic pressure that is determined by the Pressure R Chamber g
product of the pressure-receiving area A1 of receiving Plunger(301) A3 A2 Orifice n A4
area A1
plunger(301) and the pressure P balances the Fig. 24-57 Functional explanation of relief valve (1)
hydraulic pressure that is determined by the
product of the pressure-receiving area A2 of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
plunger(301) and the pressure Pg of chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to
spring (321) increases by this movement of the P
piston.
As the result, the relief pressure P is raised and R
controlled in the pressure boost time t1 from P1 Plunger(301) Orifice n Chamber g
till Ps. Fig. 24-58 Functional explanation of relief valve (2)
This process is explained in the following in the
relationships between the movements of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
components shown in (2) to (4) of Fig. 24-
58~Fig. 24-60and the relief pressure :
a. Condition shown in Fig. 24-58.
P
If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the
R
restrictor m of plunger (301). Orifice n
The hydraulic pressure acting on plunger Plunger(301) Chamber g
(301) increases and when it balances the load Fig. 24-59 Functional explanation of relief valve (3)
Fsp of spring (321), the relief valve performs Orifice m Spring (321) Pin (303) Piston I (302)
relieving action by the pressure P1.
This relationship is expressed as :
P1×A1=FSP1+Pg1×A2
where FSP1 : P
primary set load value of spring (321)
b. Condition shown in Fig. 24-59. R
The pressure of chamber g acts upon the Plunger(301) Orifice n Chamber g
pressure-receiving area A3-A4 of piston 1
Fig. 24-60 Functional explanation of relief valve (4)
(302). When the hydraulic pressure rises
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to
the left while discharging the oil of chamber h
arranged between piston 1 and adjust plug
(401) into chamber g via orifice n provided in
piston 1 (302), chamber h serves as a
dumping chamber.
The load of the spring increases slowly till Fig. 24-61 Pressure boost characteristics
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.

24-72
 24. COMPONENTS SYSTEM

c. Condition shown in Fig. 24-60.

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
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. 24-61.
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.
24-57.
(3) Operation of anti-reaction valve

Fig. 24-62 Hydraulic circuit diagram for anti-

reaction valve.
1) Neutral condition :
Fig. 24-62 illustrates the relationship between
the neutral condition of the anti-reaction valve
and the hydraulic circuits. Now, let us consider a
L
braking condition in which brake pressure
generates on the AM port side.
k
322 313 321 311
Fig. 24-63 Neutral condition
2) When brake pressure occurs : m n
If pressure (P) generates at the AM port, it
passes through the passage L, the hole on the
shaft of seat (313) and the passage m of plunger P=PS
(311) and is led to the n chamber.
L
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
spring (321) and shifts it to the left. 322 313 321 311
Seat (313) compresses weak spring (322) as
Fig. 24-64 When brake pressure occurs
pushed by plunger (311) and moves to the left.

24-73
24. COMPONENTS SYSTEM

3) At anti-reaction action p t
When inertia load stops moving (point Y Fig. 24-
66), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the P<PS
right return side by the action of spring (321). L
Seat (313) tries to move to the right by the action
of spring (322), but since chamber p provides k
damping action by orifice g, the return of the seat 322 313 g r 321 311
makes a time delay with regard to the return of
Fig. 24-65 At anti-reaction action
the plunger.
Consequently, seat t opens. This makes a P Y
passage connecting the AM port and BM ports or
PS
both ports of the hydraulic motor by way of
→t→r→k. The result is that the pressures at the
AM and BM ports become equal (Pb), falling into PB
X
the condition at point Z in Fig. 24-66. Z
This prevents the hydraulic motor from swing T

shock by the closing pressure of the AM port. Fig. 24-66 Pressure change diagram of
4) Operation of bypass valve anti-reaction operation

a. Neutral condition : A PORT B PORT

In the case where pilot pressure Pi1 is not
inputted, the spool (301) is pushed rightward
with the spring (324). A and B port are not
connected in this state.
b. Operation state :
If pilot pressure Pi1 is inputted and the
hydraulic pressure is became higher than the Pi2 Pi1
set load of spring (324), the spool (301) moves
leftward and A and B port are connected.
If pilot pressure is lowered, the spool will
return according to spring power again, and a 301
324
connecting circuit will be blocked.
Fig. 24-67 Operation of bypass valve

24.1.5.3.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101) and a
Oil pressure
spline. Separator plate (743) is fixed in its Spring force
circumferential direction by circular grooves provided in
casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against casing 712
(301) via separator plate (743) and brake piston (702) 702
by the action of brake spring (712), frictional force is Oil 743
created between friction plate (742) and casing (301) chamber 742
and between separator plate (743) and brake piston 301
(702). The frictional force bounds the drive shaft to
101 111
brake the motor.
Fig. 24-68 Operation of swing brake
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).

24-74
 24. COMPONENTS SYSTEM

24.1.5.3.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the rotating Ring gear (Fixed) Planetary shaft
speed which is transmitted by the hydraulic motor and
to convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
Spider
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear, Sun gear
planetary pinion, planetary shaft, spider and ring gear,
as shown in Fig. 24-69.

For the operation of the 1st stage planetary, the

hydraulic motor rotates #1 sun gear (211). Sun gear
Planetary pinion
(211) is engaged with planetary pinion (210) and
rotates, but since ring gear (202) is fixed, planetary Fig. 24-69 Planetary mechanism
pinion (210) revolves about sun gear (211) with the
Swing motor
planetary shaft and spider (231).
211
The role of spider is to hold the planetary pinion and 204
planetary shaft and transmits the power from the
planetary pinion to the spider through the planetary 231
shaft.
The #1 spider (231) is linked with #2 sun gear (204) by 202
230
the involute spline, and transmits the power to the 2nd
stage planetary mechanism.
For the operation of the 2nd stage planetary, the power
is transmitted to sun gear (204)→planetary pinion
(203)→spider (230) similarly to the 1st stage. The #2 102 A
chamber
spider (230) is linked with pinion shaft (201) by the 402
involute spline, and pinion shaft (201) is engaged with
the swing gear fixed on the undercarriage (lower frame) 801 B
chamber
and rotates.
201

401
Fig. 24-70 Function of reduction unit

24-75
24. COMPONENTS SYSTEM

24.1.6 TRAVEL MOTOR

24.1.6.1 SPECIFICATIONS

24.1.6.1.1 General view

18-M16 X P2.0 Mounting surface of sprocket

20-M16 X P2.0
Oil filling port
(PF1/2)
A PF3/4
Oil level
D PF1/2 check port
(PF1/2)
Y Z
X

B PF3/4
Oil drain port
(PF1/2)

Oil filling port

P PF1/4 (PF1/2)
Oil level check port
(PF1/2)

VIEW Y

DIRECTION INLET OUTLET

(VIEW X) PORT PORT
CLOCK WISE A B Oil drain port
C . CLOCK WISE B A (PF1/2)
VIEW Z
Fig. 24-71 Travel motor (with reduction unit and brake valve)

24.1.6.1.2 SPECIFICATIONS

Item
Type GM21VA-A-45/76-2
Revolution min-1 51.4/31.3
reduction unit Lubricant oil Gear oil SAE#90 GL4
Lubricant oil valume L (gal) 2.1 (0.55)
Max. displacement cc (cu•in)/rev 44.9/75.5 (2.74/4.61)
Max. speed min-1 2777/1688 (2nd/1st)
Hydraulic motor
System pressure MPa (psi) 34.32 (4976)
2 speed change- over
MPa (psi) 1.96~6.86 (284~995)
pressure
Brake torque N•m (lbf•ft) 206 (152)
Parking brake
Release pressure MPa (psi) 0.76 (110)
Weight kg (lbs) 145 (320)

24-76
 24. COMPONENTS SYSTEM

24.1.6.2 CONSTRUCTION
(1) Outline

HIGH LOW
SPEED SPEED 2-SPEED
CHANGE
PISTON
PARKING
BRAKE
REDUCTION 2-SPEED
UNIT CHANGE
PISTON

HYDRAULIC MOTOR
BRAKE VALVE
PARKING BRAKE
HIGH AND LOW SPEED SHOCKLESS
CHANGE MECHANISM RELIEF
LOAD CHECK VALVE KIT
VALVE
&
CONTROL VALVE ANTI
CAVITATION
VALVE
BREKE
VALVE
HYDRAULIC PUMP
HYDRAULIC CIRCUIT DIAGRAM

Fig. 24-72

24-77
24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-78
 24. COMPONENTS SYSTEM

(2) Hydraulic motor

116
115
135

324 112
336 139
328 109
325
326 341
331 377
354
327 301
330

380 383358
352 113
353 150
329
398 376

396 358 352 343 323

327
353
358 352
381 383
380 379
366 330
398 378 331
363 399 398 326
359 208 201 325
357 384 210
208 207 328
210
209 336
324
212

203
103
204 202
106
105
213 206
211 107
205
108
151
104

110
114
110
145 132
149

102

171
167

185
161
162

Fig. 24-73

24-79
24. COMPONENTS SYSTEM

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

102 Shaft 1 185 Spring 1 341 Parallel pin 1
103 Swash plate 1 201 Valve seat 1 343 Socket bolt 10
104 Cylinder block 1 202 Valve 1 352 Plug 3
105 Piston 1 203 Sleeve 1 353 Ball 2
106 Shoe 1 204 Collar 1 354 Plug 5
107 Retainer plate 1 205 Plug 1 357 Plug 1
108 Thrust ball 1 206 Spring 1 358 O-ring 3
109 Timing plate 1 207 O-ring 1 359 O-ring 1
110 Washer 2 208 Back-up ring 2 363 Spool 1
112 Piston 1 209 O-ring 1 366 Spring 1
113 Spring 10 210 Back-up ring 2 376 Orifice 1
114 Spring 1 211 O-ring 1 377 Filter 1
115 Friction plate 3 212 O-ring 1 378 Ball 1
116 Separator plate 4 213 Shim 1 379 Plug 1
132 Oil seal 1 301 Rear flange 1 380 Plug 2
135 O-ring 1 323 Spool 1 381 Piston 1
139 O-ring 1 324 Plug 2 383 O-ring 2
145 THS snap ring 1 325 Washer 2 384 Orifice 2
149 Bearing 1 326 Plug 2 396 Plug 2
150 Bearing 1 327 Valve 2 398 Plug 8
151 Needle roller 3 328 Spring 2 399 Name plate 1
161 Piston 1 329 Orifice 2
162 Shoe 1 330 Spring 2
167 Pivot 2 331 O-ring 2
171 Parallel pin 2 336 O-ring 2

24-80
 24. COMPONENTS SYSTEM

(3) Reduction unit

22 24

29
24

29
23

2
33
34 32 35

14
13
4
36
15
6

3 16
8
10

717

31 30

11
27
5
11

12
28
9
12
Fig. 24-74

No. Parts Q’ty No. Parts Q’ty

1 Hub 1 16 Parallel pin (1) 3
2 Spindle 1 17 Parallel pin (2) 3
3 Spider (1) 1 22 Lock washer 2
4 Sun gear (1) 1 23 Shim 1
5 Planetary gear (1) 3 24 Bearing 2
6 Pin (1) 3 27 Needle bearing 3
7 Spider (2) 1 28 Needle bearing 3
8 Sun gear (2) 1 29 Floating seal 2
9 Planetary gear (2) 3 30 Plug 3
10 Pin (2) 3 31 O-ring 3
11 Thrust washer (1) 6 32 O-ring 1
12 Thrust washer (2) 6 33 O-ring 2
13 Thrust plate 1 34 Parallel pin 2
14 Cover 1 35 Socket bolt 12
15 Coupling 1 36 Snap ring 1

24-81
24. COMPONENTS SYSTEM

24.1.6.3 OPERATING DESCRIPTION

24.1.6.3.1 REDUCTION GEAR

(1) Function
This reduction gear unit is composed of two stage
planetary gear mechanism. The reduction gear
reduces the high speed of hydraulic motor and
converts it low-speed, high-torque rotation.
(2) Operating Description
The rotation of hydraulic motor shaft is transmitted
to sun gear (4) of the first stage which is linked with
shaft (102) in spline.
At that time, the hub (1) is rotated by the rotation of
the planetary gears (5). The hub (1) rotation is
transmitted to carrier (3) which connected to
planetary gears (5), and that causes sun gear (6)
rotation of the second stage.
The rotation of sun gear (6) is transmitted to the hub
via three planetary gears (7) of the second stage.
The generated rotation of reduction gear is output
Fig. 24-75
rotation.

24-82
 24. COMPONENTS SYSTEM

24.1.6.3.2 HYDRAULIC DRIVES

(1) Function
1) Hydraulic Motor
This hydraulic motor is a swash plate type axial
piston motor, converting the hydraulic force from
the pump to rotary motion.
2) Brake Valve
a) Controls inertia when stopping the hydraulic
motor, in order to provide smooth stopping.
b) Prevents runaway rotation when the hydraulic
motor is rotated by external force.
This is done by preventing hydraulic
cavitation.
c) Prevents the generation of abnormally high
pressure when the hydraulic motor is stopped
suddenly.
3) Parking Brake
The parking brake prevents the hydraulic motor
from being rotated by external force while
stopped. A friction plate type mechanism is used,
constructed so as to form one unit with the
hydraulic motor.
4) High-Low 2-Speed Switching Mechanism
Switches the hydraulic motor between high
speed rotation with low torque, and low speed
rotation with high torque.
(2) Operating Principles and Description
1) Hydraulic Motor
Hydraulic fluid fed from the hydraulic pump
enters the GM motor through the rear flange
(101), passes through the brake valve and timing
plate (109) and enters the cylinder block (104).
This hydraulic fluid is fed only into one side of a
line connecting the upper and lower dead points
(Y1-Y2) of the piston stroke (105). The hydraulic
fluid pushes each of the pistons (105), creating
force F(=P×A). This force operates on the
Fig. 24-76
oblique surface of the swash plate (103). Force
F is separated into components F2 and F3
according to the angle of the oblique surface.
Of the two components, the radial component
force F3 generates torque (=F3×ri). The sum of
the torque T(= (F3×ri) of each of the pistons
(105) is the rotary force of the hydraulic motor.
This rotary force passes through the pistons
(105) and rotates the cylinder block (104) and
the shaft (102).

Fig. 24-77

24-83
24. COMPONENTS SYSTEM

2) Brake Valve
a) Operation (Brake released)
The pressure oil is led to through port (A),
opens valve (327), and led to port (C) on the
section side of hydraulic motor to rotate
hydraulic motor.
At the same time, the pressure oil enters
chamber (a) through orifice (329), and exerts
on the end of spool (323) to generate the
force. Then the force of spring (328) slides the
spool (323) placed on the neutral position
leftward.
The sliding of spool (323) forms the space
(passage) between spool (323) and rear
flange (301) with spool groove.
This passage is connected to port (D) and port
(B) of the return circuit of the hydraulic motor,
and the returns oil returns to tank side,
enabling hydraulic motor to rotate.
Fig. 24-78
Then, the sliding of spool (323) leads pressure
oil to port (E). The pressure oil led to port (E)
moves piston (112) of parking brake, and
releases parking braking force. (For details,
refer to item "Parking brake".)
If pressurized oil is supplied from port (B), the
movements of spool (323) and valve (327) are
reversed so that the hydraulic motor is rotated
reversely.
b) Self-traveling
While machine is being operated, as the travel
speed is increased due to steep slope, the oil
flow rate of the hydraulic motor is higher than
the supply flow rate of the hydraulic oil pump.
The rotation of the hydraulic motor in this case
is called a self-traveling. (Overrun) While self-
traveling, the pressure is lowered similar to the
stopping condition. Then brake valve is
moved similar to the stopping condition,
throttles passage in the return side of
hydraulic motor, and generate backing
pressure.
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution
having a balance with the supply flow rate of
pump.

Fig. 24-79

24-84
 24. COMPONENTS SYSTEM

c) Stop / Stall (Braking Operation)

If pressurized oil supply through the port (A) is
suspended while traveling, the hydraulic force
to push up the spool (323) is lost, and the
spool (323) which is slid to left side, tries to
return to the neutral position due to the spring
(328) force. At that time, through the oil in the
chamber (a) tries to flow out to the port (A)
side through the orifice (329), its flow is
restricted and some back pressure is
generated by the throttle effect in the orifice
(329) controlling the return speed of the spool
(323). At the same time, the hydraulic motor
tries to rotate with its inertia force even though
the pressurized oil is suspended, and the
return oil from the hydraulic motor tries to
return to the port (B) side from the port (D)
through the passages on spool groove and
rear flange (301).
When the spool (323) entirely return to neutral Fig. 24-80
position, the passage on the hydraulic motor
of the oil return side is completely closed by
the spool (323), and the hydraulic motor
ceases its rotation. While machine working,
the brake valve smoothly stops rotation of-the
hydraulic motor which tries to rotate with its
inertia force, by means of throttling the return
side passage of the hydraulic motor,
generating back pressure due to shape of the
spool groove and controlling the return speed
of the spool.
On the other hand, when braking is operated,
the hydraulic motor tries to rotate with its
inertia force and to intake oil with its pumping
function. However, because the intake side is
closed its passage with the spool (323), the oil
supply is suspended. This causes cavitation in
the hydraulic motor. To prevent the cavitation,
the valve (327) is operated by very slight
negative pressure to open the passages of
port (A) side and intake port (C) of the
hydraulic motor.
And when pressurized oil is supplied through
the port (B), each motion of the mentioned
parts above becomes symmetrical right and
left to stop the hydraulic motor.

24-85
24. COMPONENTS SYSTEM

3) High-Low 2-Speed Switching Mechanism

a) Low Speed
When the pilot pressure is not supplied   
through the port (P), the valve (363) is pushed  

up to the upper position due to the spring 
(366) force and pressurized oil through the
port (A) or (B), the pressurized oil is cut off at
port (C), and oil in the chamber (W) is 

released into the drain (motor case) through Fig. 24-81

the valve (363).
Accordingly, the tilt angle of the swash plate
(103) becomes the maximum 1 resulting the
maximum stroke volume and low speed
rotation of the hydraulic motor.
b) High Speed
When the pilot pressure is supplied through
the port (D), it defeats the spring (366) force     

and pressurized oil through the port (A) or (B)
to push down the valve (363) to lower position, 
the pressurized oil at the port (C) is led to the
chamber (P) through the valve (363), and the
piston (161) pushes the swash plate (103) up 

to the plane X and maintain it at its position.

Fig. 24-82
At that time, the tilt angle of the swash plate
becomes the minimum 2 resulting the
minimum stroke volume and high speed
rotation of the hydraulic motor.
c) Automatic shifting to low speed during high
speed operation
If the load is increased while high speed   
operation, the oil pressure at the port (A) or (B)
 

is also increased. And when the oil pressure 
reaches to specified pressure, it excesses the
pilot pressure, and the valve (363) is pushed
up to upper position, and oil in the chamber 

(W) is released into the drain (motor case)

Fig. 24-83
through the valve (363).
At that time, the swash plate (103) gets touch
with the plane Y of spindle, and the tilt angle of
swash plate (103) becomes the maximum 1
and is maintained at its position resulting low
speed rotation.

24-86
 24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-87
24. COMPONENTS SYSTEM

24.1.7 SWIVEL JOINT

24.1.7.1 GENERAL VIEW

VIEW Y

VIEW Z

Fig. 24-84 General view of swivel joint

24.1.7.2 SPECIFICATIONS

Item Specifications
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
H, I Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (55 lbs)

24-88
 24. COMPONENTS SYSTEM

24.1.7.3 CONSTRUCTION

2 places Apply Three Bond

#1805 to stem

2 places
VIEW Y

5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH

Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242

Fig. 24-85 Construction

No. Name Q’ty No. Name Q’ty

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Capscrew (M8×20) 2
3 Thrust plate 1 9 Capscrew (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 1
6 Seal 1

24.1.7.4 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.

24-89
24. COMPONENTS SYSTEM

24.1.8 CYLINDER

24.1.8.1 SPECIFICATIONS
(1) General view

B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu

Part No. and Manufacturing No.

Stamp position

Fig. 24-86 General view of cylinder

(2) Specifications
Unit : mm (ft-in)

Cylinder bore / Center distance of pins Dry weight

Use Stroke Cushion
Rod Dia. Full extend B / Full retract A kg (lbs)
ø100 / ø70 1,092 2,648 / 1,556 With cushion on
Boom 101 (223)
(3.94" / 2.76") (3-7) (8-8.3 / 5-1.3) rod side

ø115 / ø80 1,120 2,835 / 1,715 With cushion on

Arm 148 (326)
(4.53" / 3.15") (3-8.1) (9-3.6 / 5-7.5) both sides

ø95 / ø65 903 2,293 / 1,390 With cushion on

Bucket 98 (216)
(3.74" / 2.56") (2-11.6) (7-6.3 / 4-6.7) rod side

24-90
 24. COMPONENTS SYSTEM

24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder

T= Tightening torque ; N.m (lbf.ft)

(3.54"-0.012 )
(3.15"-0.012 )

2 4-M10 P1.5 TAP DP 17 MIN

0
26 4 25 2
0

90 -0.3
80 -0.3

0
0

T=206~216 (152~159)
Apply Loctite #242 T=14.7(10.8)
T=981 (724) T=1860 (1372) Apply Loctite #242

11 9,10 8 24 6 7 5 14 12,13 3 1 15 16 19 18 17 20,21 22 23 2 PT1/8

PT1/4

Fig. 24-87 Construction of boom cylinder

No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty

1 CYLINDER TUBE
2 PIN BUSHING
3 PISTON ROD
4 PIN BUSHING
5 ROD COVER
6 BUSHING
7 RETAINING RING
8 BUFFER SEAL
9 U-PACKING
1 10 BACKUP RING 1 19 DUST RING 1
1 11 DUST WIPER 1 20 O-RING 1
1 12 O-RING: 1B G95 1 21 BACKUP RING 2
1 13 BACKUP RING 1 22 PISTON NUT 1
1 14 O-RING: 1B G100 1 23 SETSCREW: M8×16 1
1 15 CUSHION RING 1 24 SOCKET BOLT: M14 10
1 16 PISTON 1 25 WIPER PIN 2
1 17 SLIPPER SEAL 1 26 WIPER PIN 2
1 18 WEAR RING 2

24-91
24. COMPONENTS SYSTEM

(2) Arm cylinder

T= Tightening torque:
32 2 N.m (lbf.ft)
32 4
(4.13"-0.012 )

)
0

(4.13"-0.012
105-0.3
0
0
105-0.3
0

2 4-M10 P1.5 TAP DP 17 MIN

T=343~363 (253~268)
Apply Loctite #242 T=14.7(10.8)
T=981 (724) T=1860 (1372) Apply Loctite #242

11 5 10,9 8 26 6 7 14 12,13 3 1 15 16 19 18 17 20,21 22 23 25 24

PT1/8

PT1/4

27,28,29,30,31

Fig. 24-88 Construction of arm cylinder

No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty

1 CYLINDER TUBE 1 12 O-RING : 1B G110 1 23 SET SCREW : M8 1
2 PIN BUSHING 2 13 BACK-UP RING 1 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING : 1B G115 1 25 STOP RING 1
4 PIN BUSHING 2 15 CUSHION RING 1 26 SOCKET BOLT : M16 10
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 2 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING 1 31 PLUG : PT3/8 1
10 BACK-UP RING 1 21 BACK-UP RING 2 32 WIPER RING 4
11 DUST WIPER 1 22 PISTON NUT 1

24-92
 24. COMPONENTS SYSTEM

(3) Bucket cylinder

T= Tightening torque ; N.m (lbf.ft)

PT1/8
PT1/8

2 4-M10 P1.5 TAPDP 17 MIN

T=206~216 (152~159) T=14.7(10.8)

Apply Loctite #242 T=981 (724) T=1860 (1372) Apply Loctite #242

)
26 4 11 9,10 8 24 6 7 5 14 12,13 3 1 15 16 19 18 17 20,21 22 23 25 2

(3.34"-0.012
85 0 (3.34"-0.012 )

0
0

-0.3
-0.3

85 0
Fig. 24-89 Construction of bucket cylinder

No. PARTS Q’ty No. PARTS Q’ty No. PARTS Q’ty

1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING 1
3 PISTON ROD 1 12 O-RING: 1B G90 1 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 1 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING: 1B G95 1 23 SETSCREW: M8×16 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M14 8
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2

24-93
24. COMPONENTS SYSTEM

Hydraulic cylinder construction (See Fig. 24-87, Fig. 24-88, Fig. 24-89)
By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (3) that takes out the
motion of pistons reciprocating in the cylinder tube assy, and rod cover (5) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a piston mount (clevis) that connects piston rod assy (3) with other parts.
In addition to these main components, slipper seal (17) and ware ring (18) are located between, cylinder tube assy
(1) and piston rod assy (3) ; buffer seal (8), rod packing (9) and dust seal (11) are located between piston rod assy
(3) and rod cover (5) ; and an O-ring and a back-up ring are placed between cylinder tube assy (1) and rod cover (5).

24.1.8.2.2 OPERATION
If pressurized oil is fed alternatively to the oil inlet and
CUSHION RING (15) CHAMBER "A" PATH "B"
outlet provided in the cylinder, force acts on the piston TANK
which in turn causes the piston rod (3) to extend and PISTON (16)
retract. ROD (3)
ROD SIDE
HEAD
(1) Operation of cylinder with cushion
SIDE
1) Cushion on rod side
The cushion mechanism is provided to prevent (5)
CUSHION STROKE ROD COVER
the generation of shock when the moving speed
of piston (16) is not reduced and strikes rod Fig. 24-90 Cushion mechanism on the rod side
cover (5).
An oil in chamber "A" returns to the tank by RESTRICTED PATH "C"
TANK
passing through paths "B" and "C" at a fixed flow CLEARANCE "D"
rate in a intermediate stroke state (Fig. 24-90) of
pressing bottom side. Next, in a state of just
before stroke end (Fig. 24-91), cushion ring (15)
plunges into path "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-91 Cushioning action on the rod side

 
   

Fig. 24-92 Rod side cushion

24-94
 24. COMPONENTS SYSTEM

2) Cushion on head side

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

SPRING

SPRING SEAT

PLUG

O-RING
DETAIL E

Fig. 24-93 Cushioning action on the head side

24-95
24. COMPONENTS SYSTEM

24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST

Group Code Name

C-1 Mechatro controller
(C) Controller

C-2 Gauge cluster

C-4 Air-con controler (including panel)
C-8 Engine controller

D-4 Diode
D-5 Diode
D-6 Diode
D-9 Diode
D - 10 Diode
D - 11 Diode
D - 12 Diode
D - 13 Diode
D - 14 Diode
D - 15 Diode
D - 16 Diode
D - 17 Diode
E-1 Fuse and Relay box
E-2 Alternator
E-3 Hour meter
E-5 Horn high
E-6 Horn low
E - 10 Receiver dryer
(E) Electric fittings

E - 11 Air-con compressor
E - 12 Battery
E - 13 Travel alarm
E - 14 Cigaratte lighter
E - 15 Fusible link
E - 22 DC-DC converter
E - 23 12V socket
E - 40 Tuner
E - 41 Speaker left
E - 42 Speaker right

24-96
 24. COMPONENTS SYSTEM

Group Code Name

L-1 Boom work light (LH)
L-2 Frame work light (RH)
L-3 Swing flasher (LH)
(L) Light

L-4 Swing flasher (RH)

L-5 Room light
L-6 Boom work light (RH)
L-7 Cab work light
L-8 Cab work light
L-9 Boom cyl. work light
(M) Motor

M-1 Starter motor

M-3 Wiper motor
M-4 Washer motor
PSV - A Arm 2 speed inverse propo. valve
(P) Proportional
solenoid valve

PSV - B P2 unload propo. valve

PSV - C Travel straight propo. valve Solenoid valve assy
PSV - D P1 unload propo. valve
PSV - P1 P1 pump propo. valve Pump
PSV - P2 P2 pump propo. valve
R-1 Battery relay
R-2 Starter relay
R-3 Glow relay
R-4 Safety relay
R-5 Horn relay
R-6 Working light relay
R-8 Travel alarm relay
R-9 Cab working light relay
R - 11 Cab working light relay 2
(R) Reray

R - 17 Extra dis-press relay

R - 19 Flasher relay
R - 23 Auto idle stop relay 1
R - 24 Auto idle stop relay 2
R - 25 Engine emergency stop relay
R - 26 Lever lock relay
R - 28 Alternator relay
R - 29 Wiper motor relay
R - 30 Wiper motor revering relay
R - 31 Prevent spark relay
R - 32 Washer motor relay

24-97
24. COMPONENTS SYSTEM

Group Code Name

SE - 1 Pressure sensor : Bucket digging
SE - 2 Pressure sensor : Bucket dump
SE - 3 Pressure sensor : Boom up
SE - 4 Pressure sensor : Boom down
SE - 5 Pressure sensor : Swing
SE - 7 Pressure sensor : Arm in
SE - 8 Pressure sensor : Arm out
(SE) Sensor

SE - 9 Pressure sensor : Travel RH

SE - 10 Pressure sensor : Travel LH
SE - 11 Pressure sensor : P2 OPT.
SE - 13 E/G speed sensor
SE - 15 Fuel sensor
SE - 16 Accel potentiometer
SE - 20 Pressure sensor : P1 OPT.
SE - 22 Pressure sensor : Pump P1
SE - 23 Pressure sensor : Pump P2
SE - 29 Opt. selector detect sensor
SV - 1 Swing parking brake SOL.
(SV) Solenoid

SV - 2 —
SV - 3 Two speed select SOL Solenoid valve assy
SV - 4 Safety lock lever SOL
SW - 1 Key switch
SW - 4 Swing parking brake release switch
SW - 5 Horn switch (RH)
SW - 7 E/G oil pressure switch
SW - 8 Air filter clogging switch
SW - 10 Horn switch (LH)
SW - 11 Safety lock lever switch
SW - 12 Over load alarm select switch
(SW) Switch

SW - 13 Travel alarm switch

SW - 15 Conflux/single select switch
SW - 16 Engine room light switch
SW - 17 Skylight wiper switch
SW - 19 Wiper interlock switch
SW - 22 KPSS release switch
SW - 26 Cab work light switch
SW - 36 Water separator switch
SW - 37 Independent travel switch
SW - 55 Boom work light switch
SW - 56 Fuel supply auto stop switch

24-98
 24. COMPONENTS SYSTEM

24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YY05 - 12001 ~
YH05 - 07001 ~

C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YY05 - 12001 ~
YH05 - 07001 ~
C-4
Controller   

   
Air-con Controller       
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YY05 - 12001 ~
YH05 - 07001 ~

24-99
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-8
Controller
Weight 700g (711.5g)[1550 lbs]
32G87-01020
ECU Type : EDC16UC40
Engine controller BOSCH part No. : 0 281 B03 233
YY05 - 12001 ~ (978772-0627)
MHI part No. : 32F98-10115
YH05 - 07001 ~

(7.99")

(6.56")

E-1
Fuse capacity and circuit
Fuse & Relay box

Fuse & Relay

YY05 - 12001 ~
YH05 - 07001 ~

Front side of machine

24-100
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E-2
Alternator
Generator

E-3
Hour meter Movement Quarts
Operating voltage 10~80VC GM terminal : 2962447
GM connector : 2962448

E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V STAMP
Warning sound
Operating voltage range DC20~30V
Sound level 113+5dB(A)/2m
420+20Hz high sound
Basic frequency 350+20Hz low sound
Insulation resistance More than 3M /DC500V

o 8.5

24-101
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
Desiccant moisture 17% or over than the
weight of desiccant
adsorption capability (Include initial absorption 2%)
Refrigerant HFC-134a
Inner volume/Desiccant 578cm3/300g Inlet (From condenser)

E - 11
Air-con compressor  
 !"#$"###

 
 %&'
Air-con
 
 '### (
 
)*  +

$,!'
 -.$&#/,!0
 


E - 12
173 (6.81")

Type 115E41R
Battery
Voltage 12V
Capacity 5HR 88Ah
Power
Weight 28kg (62 lbs)
407 (16.02")
Negative Positive
terminal terminal
234 (9.21") MAX.
209 (8.22")
Taper 1/9

Taper 1/9

(0.67")
(0.67")

17
17

17.9 19.5
(0.705") (0.768")
392 (15.4")

24-102
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V Power AV 0.5 Red / Green

Travel alarm AMP Econoseal J series Mark II water-proof

Housing : 174354-2 Harness seal : 172888-2
Terminal : 171661-1 Retainer : 1-174355-1
VIEW A

Vinyl tube

E - 14
Cigarette lighter   !

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

  '  (
     )&% 
  * + (,$&

01 +

E - 15
Type Slow blow fuse
Fusible link
Allowable current 80A

Fuse

E - 41, 42
Model SX-M1024K
Speaker
Rated input 8W
Impedance 4
Radio

24-103
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L - 1, 6
Light (Halogen)  
 
 
Boom work light (LH, RH)
YN11 - 45001 ~
YQ11 - 06001 ~  
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~    
YY05 - 12001 ~
YH05 - 07001 ~
L - 2,7,8,9
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
Effective area of lens 71cm2
Frame work light
Cab working light front
Boom cyl. work light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YF05 - 02001 ~
YU05 - 02001 ~
YY05 - 12001 ~
YH05 - 07001 ~
L - 3, 4
Light Bulb 24V,6W
VINYL TUBE
(BLACK)

Swing flasher
(Right, left)
YF05 - 02001 ~
YU05 - 02001 ~
YY05 - 12001 ~ DRAIN HOLE
YAZAKI Part No.
YH05 - 07001 ~ 7322-2228

AV0.5B AV0.5B

24-104
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens

Room light

Bulb

SECTION A-A Door

Switch

M-1
Motor

Starter motor

M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
Rated voltage 24V
Wiper motor Swing angle Applox. 80
Controller

Wiper motor 24V

Wiper sw
OFF-Stop
Stop signal ON-Start

Reverse signal
Electric diagram

M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 1.2L (0.32 gal) / min or more
Capacity 1.5L (0.4 gal)
Window washer
Time rated Max. continuous 60 sec.
Injection nozzle 1 X 2 pcs.

PUMP

24-105
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A

Exciting current 0.4A or less / 24V

Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
Closed circuit voltage 16V or less VIEW I
Terminal B
Open circuit voltage 7V or less HOUSING AMP
GND terminal
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
TERMINAL AMP
171661-1
WIRE PROOF PLUG AMP
172888-2

VIEW Z Terminal L
Flowing direction of
main current F HOUSING YAZAKI
o 9 X 30L
Terminal A Terminal B Terminal B 7123-4210-30
Heart shrinkage tube
AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60

Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)

Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)

R-3
Relay

Glow relay

Specifications
Rated voltage DC24V
Exciting current 2.3A (AT 24V 20 )
Rated time 75 sec
Closing circuit volt. 16V MIN. Electric diagram
Opening circuit volt. 4V MAX.
Max. Permissible
200A
current
Weight 0.26kg (0.57lb)
Tightening torque M6NUT 2.45~3.43N.m (1.81~2.53lbf.ft)
for terminal M4BOLT 1.13~2.35N.m (0.83~1.73lbf.ft)

24-106
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R - 5,6,8,9,11,17,
23,24,25,26,28 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
Rated voltage DC 24V
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Travel alarm relay
Cab working light relay
Extra dis-press relay
Flasher relay Pin assignment
Auto idle stop relay 1, 2
Engine emergency stop relay
Lever lock relay
Alternator relay
Boom cyl. working light relay

Terminal arrangement

R -29, 30 ,31 ,32

Maker Tyco Electronics
Relay
Maker's p/No. V23134-A0053-C643
Type Relay
Wiper motor relay
Wiper motor reversing relay Rated voltage DC 24V
Prevent spark relay Contact 1C
Washer motor relay
* Accessory of relay box

Pin assignment

30 85 86 87 87a 30
87a
85 86

87

24-107
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 1 ~ 5, 7 ~ 11,20,29
Pressure range 0~3MPa (435 psi)
Pressure sensor
Allowable max. pressure 7.0MPa (1010 psi) O-ring
(Low pressure) (P11 1B)
Rated voltage 5+0.5V DC
HEX24 Vout
50M or more /DC50V megger
Bucket dig and dump, Insulation resistance
(Between Body terminal)
Boom up and down,
Swing, (Arrangement)
Connection
Arm in and out,
Travel RH and LH and other
Vcc GND
Opt. selector detect PF1/4
Tightening torque 29.4~34.3 N.m
(21.7~25.3 lbf.ft)

SE - 15
Float operation
Fuel sending unit
Float Resistance
+0.1
FULL 10 -0.6
Fuel level
3/4 (19)
1/2 32+5
1/4 (49.5)
EMPTY 85 +10
0

Machine side controller

Float

Electric diagram VIEW A

SE - 16
Total resistance value
Potentio meter
Effective electric angle
Number of notches
Accel dial
Source voltage
Notch part

Potentio
3MA JM II + AMP
Bracket HOUSING : 174359-2
TERMINAL : 171661-1

Dial

24-108
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 22, 23 Electric diagram (Arrangement)
Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
P3/8 Source (+)
YC10 - 03501 ~ Tightening torque Output (+) Econo seal J series
: 73.5 N.m O ring P14
YF05 - 02001 ~ JIS B2401
Common (+) (Mark II (+)
(54.2 lbf.ft) 3 pole
YU05 - 02001 ~
YY05 - 12001 ~
YH05 - 07001 ~
PSV - A, B, C, D
Proportional solenoid valve YN35V00049F1 YN35V00048F1 YN35V00050F1 YN35V00050F1
YN35V00051F1
Hydraulic solenoid valve
T=7N.m
Hydraulic symbol A5 to A8

T2
A1
A8 A7 A6 A5 A4 A3 A2 A1
P2
P1

PSV-A PSV-B PSV-C PSV-B SV-3 SV-1 SV-4

T2
HYDRAULIC SYMBOL P1
P2

A8 A7 A6 A5 A4 A3 A2 A1
Arm 2 speed
P1 unload

Travel straight

P2 unload

Travel 1,2 speed

Swing parling

Lever lock

PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
Rated voltage DC 24V

Sleeve O-ring Solenoid Seal nut

1B P20

24-109
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
Rated voltage DC 24V
valve (7 spool) assy pressure

Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A3 A2~A7 port PF1/4
AMP MARK II AMP MARK II
Connector specification HOUSING 174354-2
TERMINAL 173706-1

SW - 1 Auto return
Switch Connection
Terminal
Position
Starter switch
Auto return

VIEW A Terminal
arrangement

SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
T No. YAZAKI
Contact construction : Position Red (2) 7122-2237
7114-2020
Swing parking release
Normal

White (3) Blue (1)

SW - 5, 10
     *+ ,-   
Switch - 
   
  ).

   
 !" #$ $%
Horn & 
 & '
      (%" )

))   ) - /012-, 34+# 5! )6

))   ) - &$7-, 8!#+9!8!
7  5))   ) :  ( #6

24-110
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 8
Switch

Air cleaner Inlet

Clogging switch Connection port

Outlet

SW - 11
Switch   
  

 
Lock lever  


!  " 

!  " 

#$ 
SW - 12
Rated voltage DC 24V
Switch
Single pole single throw
Type (alternate)
Over load alarm select More than 1M /
Insulation resistance DC500V megger UP

Terminal connector
Connector
Position

SW - 13
Rated voltage DC 24V
Switch
Single pole single throw
Type (alternate)
Travel alarm More than 1M /
Insulation resistance DC500V megger UP

Terminal connector
Connector
Position

24-111
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 15
Rated voltage DC 24V
Switch
Single pole single throw
Type (alternate)
Conflux / single flow More than 1M /
Insulation resistance DC500V megger UP
switching
Terminal connector
Connector
Position

SW - 16
Maker's item TS-11
Switch
Single pole single throw
Type (Alternate)
Engine room light switch
M3
LA103
WIRE COLOR:BLACK
WIRE COLOR:RED

CA104 CB104
TERMINAL:YAZAKI TERMINAL:YAZAKI
:7113-1020-02 :7115-1050-02
CAP:YAZAKI CAP:YAZAKI
:7120-8012 :7120-1010

SW - 17
Rated voltage DC 24V
Switch
Single pole single throw
Type (alternate)
Roof window wiper More than 1M /
Insulation resistance DC500V megger UP
switch (OPT)
Terminal connector
Connector
Position

24-112
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 19
Switch
Rated voltage DC 12V
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
Operation force Initial motion 0.8+0.3
0 kg

Max. stroke
SW - 22
HOUSING : 6098-0258
Maker's part No. ET610N13
Switch TERMINAL : 8230-4282
Rated DC 30V

KPSS release More than 100M /

Insulation resistance 500V megger
After fixing the wires by soldering,
insulate them with insulation tape. VIEW I
(all terminals)
Bundle with vinyl tape
or tape.

SW - 26
Rated voltage DC 24V
Switch
Single pole single throw
Type (alternate)
Cab work light switch More than 1M /
Insulation resistance DC500V megger UP

Terminal connector
Connector
Position

24-113
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 36
Switch

Water separator

SW - 37
Rated voltage DC 24V
Switch
Single pole single throw
Type (alternate)
Independent travel More than 1M /
Insulation resistance DC500V megger UP

Terminal connector
Connector
Position

SW - 55
Switch   
  
  
   
 
 
Boom work light switch    !
   "## &%
$



$ 

%

24-114
 25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-2

25.1.1 AIR CYCLE.............................................................................................................25-2
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-3
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-4
25.2.1 COMPONENT ........................................................................................................25-4
25.2.2 CONSTRUCTION ...................................................................................................25-5
25.3 PIPING.............................................................................................................................25-8
25.3.1 AIR CONDITIONER................................................................................................25-8
25.3.2 AIR DRYER ASSY..................................................................................................25-11 25
25.4 FUNCTION ......................................................................................................................25-12
25.4.1 MECHANISM OF COOLING CIRCUIT...................................................................25-12
25.4.2 COOLING CIRCUIT................................................................................................25-14
25.4.3 COMPONENT PARTS ...........................................................................................25-15
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.6 CHARGING REFRIGERANT...........................................................................................25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-24
25.6.2 OPERATING PROCEDURE...................................................................................25-25
25.6.3 CHARGING PROCEDURE ....................................................................................25-26
25.7 ELECTRIC CIRCUIT........................................................................................................25-31
25.7.1 WIRING DIAGRAM AND CONNECTORS .............................................................25-31
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION ...25-33

25.8 TROUBLESHOOTING.....................................................................................................25-36
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-43
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-43
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-43
25.9.3 EXPLANATION OF MONITOR MODE ...................................................................25-45

25-1
25. AIR-CONDITIONER SYSTEM

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)

Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside /
outside air switching unit. And this unit changes hot air to cool air.

25.1.1 AIR CYCLE

• Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.

• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.

• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.

25-2
 25. AIR-CONDITIONER SYSTEM

25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE

AIR CONDITIONER CONTROL PANEL

COMPRESSOR

SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE

REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH

AIR-CON BLOWER REVOLUTION SIGNAL

AIR OUTLET SWITCHING SIGNAL CONTROLLER

INNER AIR SENSOR

EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL

OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR

AIR CONDITIONER UNIT FACE

FOOT MOTOR BLOWER

ACTUATOR CONTROLLER

25-3
25. AIR-CONDITIONER SYSTEM

25.2 COMPONENT AND CONSTRUCTION

25.2.1 COMPONENT

27

33 30
27-1

40

32

39

27-3 27-4

27-2
35

35-7 35-6

35-1
35-11

35-2 35-5

34 35-8

35-10
35-9

Fig. 25-1 Air-conditioner group

A/C ASSY (04)

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

27 Air-conditioner assy 1 33 Pulley 1 35–7 L hose 1
27–1 Air-conditioner unit 1 34 Condenser 1 35–8 L hose : Ø 15 1
27–2 Hose 2 35 Air dryer assy 1 35–9 S tube : Ø 16 1
27–3 Clamp 2 35–1 Receiver dryer 1 35–10 L tube : Ø 8.5 1
27–4 Filter 1 35–2 Bracket 1 35–11 D tube : Ø 12 1
30 Panel assy 1 35–5 S hose : Ø 24 1 39 Filter 1
32 Compressor 1 35–6 D hose 1 40 Solar radiation sensor 1

25-4
 25. AIR-CONDITIONER SYSTEM

25.2.2 CONSTRUCTION
(1) Air conditioner unit

"'

"& "%

"$ ""

!
" !
"
#
! 

"# 
"!
 ! )


!'

!%
!&

!$

"

!!

Fig. 25-2 Air conditioner unit (1/2)

25-5
25. AIR-CONDITIONER SYSTEM

" $
$   !

#
#
 !
$
 !

 
,
- "
%

) & 
 
%


 !
+ $
$

'
" !

!
"
&
# &! %'
#"
$!
'
%& + &" $


% -
&

!
,
*

'
 #

!
!
%%

Fig. 25-3 Air conditioner unit (2/2)

25-6
 25. AIR-CONDITIONER SYSTEM

Air conditioner (03)

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 Screw M5×16 23 21 Expansion valve 1 43 Foot joint lever 1
2 Main harness 1 22 O-ring 1 44 MA mode lever 1
3 MA air mix 3 23 O-ring 2 45 Foot lever 1
4 Blower controller 1 24 Screw M5×40 2 46 Face lever cam 1
5 Upper casing 1 25 Thermistor 1 47 Vent lever cam 1
6 Air mix door 1 26 Thermistor holder 1 48 Face rod 1
7 Air mix lever 1 27 Heater core 1 49 Vent rod 1
9 Air mix door sub 1 28 Pipe holder 1 50 Foot rod 1
10 Air mix lever sub 1 29 Thermistor 1 54 Capscrew 1
11 Blower 1 31 Screw M4×30 9 60 Evaporator packing 1
12 Lever MA air mix 1 32 Upper casing 1 61 Casing packing A 1
13 Intake door 1 33 Lower casing 1 62 Casing packing B 1
14 MA intake lever 1 36 Foot door 1 63 O-ring 1
15 Intake lever 1 37 Vent door 1 77 Packing 1
16 Intake rod 1 38 Face door 1 78 Tube 1
17 Air mix rod 1 39 KK box upper packing 1 79 Tube 1
18 Air mix rod sub 1 40 KK-box lower packing 1 82 Tube 1
19 Relay 2 41 Vent lever 1 83 Bracket 1
20 Evaporator 1 42 Face lever 1 84 Lower casing 1

(2) Receiver dryer

REFRIGERANT 2
INLET
REFRIGERANT
OUTLET

2-M6
1

No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1

Fig. 25-4 Receiver dryer

25-7
25. AIR-CONDITIONER SYSTEM

25.3 PIPING
25.3.1 AIR CONDITIONER

JAM NUT FOR

40 TENSION PULLEY
T=46.1 (33)
30

D
27

A
L
B

25

C
25 E
26
53
4
INITIAL BELT TENSION
When the belt is pushed by the
force of 23N, adjust the
deflection of L partto
l part tobe
be3mm.
3mm.
26
53
58 69 61
NOTE 62
66
1. Apply oil for refrigerant R134a to the
O-rings of all air-conditioner hose fittings.
33
16
2. Refrigerant volume : 800 50g
3. T : Tightening torque N.m(lbf.ft) 33

6
60 33
22 9
10

32
A B
Fig. 25-5 Air conditioner piping (1/2)

25-8
 25. AIR-CONDITIONER SYSTEM

53
12
8 26

8 65 13

25
63 2
1 1
2 5
54 X
5
53 51
52 50
55 5 64 53
8 67

24
53

X
15

39

C D

3
23
35
8 59
23

17

25

14
19
68
34

56
57
E
Fig. 25-6 Air conditioner piping (2/2)

25-9
25. AIR-CONDITIONER SYSTEM

Air conditioner (04)

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Hose : L = 2700 1 46.1 (33.0) 33 Pulley assy 1
2 Hose : L = 2800 1 34 Condenser 1
3 Bracket 1 35 Air dryer assy 1
4 V-belt 1 39 Filter 1
3.92~4.9 (2.9~3.6) 5 Clip 4 40 Solar radiation sensor 1
6 Sems bolt : M10×25 4 50 Connector 1
7 Sems bolt : M6×20 2 51 Connector 1
8 Sems bolt : M8×20 7 52 Clip 1
9 Capscrew : M8×100 4 46.1 (34.0) 53 Sems bolt : M10×20 5
10 Washer 4 54 Grommet 1
12 Tube for heater : L = 2400 1 55 Grommet 1
13 Tube for heater : L = 2400 1 4.4 (3.2) 56 Capscrew : M6×50 4
14 Tube for D hose : L = 2600 1 57 Washer 4
15 Tube for S hose : L = 2950 1 59 Bracket 1
16 Bracket 1 60 Pulley 1
17 Tube for L hose : L = 900 1 46.1 (34.0) 61 Capscrew : M10×25 1
19 Tube for L hose : L = 300 1 62 Washer 1
46.1 (34.0) 22 Sems bolt : M10×45 4 63 Support 1
23.5 (17.3) 23 Sems bolt : M8×25 6 64 Insulation 1
24 Clip 1 46.1 (34.0) 65 Sems bolt : M10×30 1
25 Clip 10 66 Nut 2
26 Clip 3 67 Bracket 1
27 Air conditioner assy 1 68 Bracket 1
30 Panel 1 70 Clip 1
32 Compressor assy 1

UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT

UNIT CONNECTION BOLT S TUBE
AIR CONDITIONER ASSY S D HOSE

COMPRESSOR ASSY

RECEIVER CONNECTION BOLT

S HOSE

L TUBE

L HOSE
L HOSE CONDENSER
RECEIVER DRYER RECEIVER DRYER MOUNTING BRACKET

25-10
 25. AIR-CONDITIONER SYSTEM

25.3.2 AIR DRYER ASSY

B
A
C

8 5
A
4 6 5
10 6
4 11
3

8
2

1 7

B C
Fig. 25-7

Air dryer assy (01)

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
20~25 3 Capscrew 2 9 S tube 1
(14.8~18.4)
8~12 (5.9~8.9) 4 Capscrew 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1

25-11
25. AIR-CONDITIONER SYSTEM

25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Specific volume of saturated
Many kinds of refrigerants that change in that 0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)

• It is easy to gasify (evaporate). (It evaporates

sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.

25-12
 25. AIR-CONDITIONER SYSTEM

(3) Characteristics of Refrigerant (Fig. 25-8) PRESSURE

In general, the fluid (general term of gas and liquid) MPa(psi)
R134a
has the following qualities: 4(580)

1) As a gas under certain pressure is cooled down,

3(435)
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
2(290)
condensation begins is unique to each
substance (fluid) at a given pressure. The 1(145) GAS
temperature determined by a given pressure is 0.5(75)
TEMPERATURE
called saturation temperature. [ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-8 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-8 illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in
the air-conditioner. At the temperature and the
pressure on the lower righthand side of the curve
in Fig. 25-8 the refrigerant take a gaseous state,
while at the temperature and the pressure on the
upper lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order to
cool the inside of the compartment down to 25°C
(77°F), the refrigerant must transform
(evaporate) from a liquid to a gaseous state at a
lower temperature. It can be seen from Fig. 25-8
that R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the circuits,
thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous
refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer
air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 MPa
(145psi), as seen from Fig. 25-8.

25-13
25. AIR-CONDITIONER SYSTEM

25.4.2 COOLING CIRCUIT

Fig. 25-9 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
heat off the surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the part at which EVAPORATOR EXPANSION
VALVE
vaporization of the refrigerant takes place is the BLOWER
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In INSIDE OF ENGINE
the meantime, liquid refrigerant (slightly wet vaporized S D ROOM
COMPRESSOR COOLING FAN
refrigerant) is fed into the evaporator, when "cooling"
effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-8 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-9 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.

25-14
 25. AIR-CONDITIONER SYSTEM

25.4.3 COMPONENT PARTS

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

25-15
25. AIR-CONDITIONER SYSTEM

Fig. 25-11 shows how the block type expansion

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

25-16
 25. AIR-CONDITIONER SYSTEM

(3) Compressor (See Fig. 25-13.)

D HOSE
The compressor performs the following three
functions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-13
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use
of an outer air of 35°C (95°F) and liquefy it. The
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only for
a short period, the refrigerant hardly exchanges
heat with outer air. That is to say, it takes a near
form of thermally insulated compression, so that
the refrigerant discharged by the compressor
turns into high-temperature high-pressure vapor
and is delivered to the condenser.
(4) Condenser ( See Fig. 25-14.)
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure
by the use of outer air and condenses the
refrigerant. The direction in which heat moves is
from the refrigerant to air, the opposite to the case
of the evaporator. Fins are equipped on the outer
air side to improve thermal transfer. If the
refrigerant is not cooled well by the condenser, the
air in the compartment can not be cooled
sufficiently by the evaporator. For that purpose, it is
necessary to secure ventilation required for the
cooling of the refrigerant.

Fig. 25-14 Condenser

25-17
25. AIR-CONDITIONER SYSTEM

(5) Receiver dryer ( See Fig. 25-15.) SIGHT GLASS

REFRIGERANT
1) Receiver Tank INLET
On the air-conditioner, the revolution of the REFRIGERANT
compressor varies greatly which causes the OUTLET
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it when
the cooling circuit needs much refrigerant. The
PRESSURE SWITCH
receiver tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil, DESICCANT
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion SUCTION
valve. It is desirable that the amount of water PIPE
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for FILTER
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3) Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the RECEIVER
TANK
only means of confirming the inside of the circuit
visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by Fig. 25-15
cutting off the power supply to the compressor
when high pressure increases abnormally high
[more than 3.14MPa (460psi) ].
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit falls
below 0.2MPa (28psi).

25-18
 25. AIR-CONDITIONER SYSTEM

25.5 DISASSEMBLY AND ASSEMBLY

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
Unit : N.m (lbf.ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils other PIPE FASTENING PART TIGHTENING TORQUE
than SP20 may not be used. Since SP20 tends to
D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
absorb moisture and may corrode paint and resin,
the following points must be noted: D hose and condenser 19.6~24.5 (14~18)

1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)

2) Use care so SP20 does not adhere to the

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

2) Screws and Bolts

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

25-19
25. AIR-CONDITIONER SYSTEM

25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

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

    

Fig. 25-16
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.

CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-17
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING

AIR MIX
ROD SUB
AIR MIX
ROD SUB

LOWER UNIT CASING

Fig. 25-18

25-20
 25. AIR-CONDITIONER SYSTEM

(5) Replacing blower controller UPPER UNIT CASING

1) Remove 2 plus screws and remove the blower
controller from the upper unit casing.
2) Install new blower controller by the reverse
procedure of removal.

* Do not disassemble the blower controller.

PLUS SCREW BLOWER CONTROLLER

Fig. 25-19
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.

(7) Replacing blower motor

1) Disconnect connector which is connected to the
blower motor and remove the blower motor from
the lower unit casing.

* Do not remove the fan from the blower motor.

LOWER UNIT CASING

2) Install it by the reverse procedure of removal.
Fig. 25-20
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off
EVAPORATOR
from the lower casing.
2) Remove evaporator sensor with sensor holder
from the removed evaporator. SENSOR HOLDER
3) Insert the sensor holder into the new evaporator 105mm
at the position shown in Fig. 25-21 and install the (4.1 inch)
evaporator sensor again.

11TH ROWS OF FIN

EVAPORATION SENSOR

Fig. 25-21

25-21
25. AIR-CONDITIONER SYSTEM

4) Remove 2 socket bolts M5×40 with Allen wrench

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

* When assembling again, fit O-ring paying

attention so as not to be caught with others. O-RING
(Socket bolt M5×40 (2 pcs.) Tightening torque :
6.9N•m (5.1lbf•ft)

* Do not apply undue force to pipe of evaporator

outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator. EXPANSION VALVE
Moreover, when tube assembly (27-6) (see Fig.
25-1) connected with expansion valve is
SOCKET BOLT M5X40(2 PCS.)
disconnected from expansion valve, similar
careful work is necessary.
Fig. 25-22

(9) Replacing motor actuator VENT ROD

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

Fig. 25-24

25-22
 25. AIR-CONDITIONER SYSTEM

3) Replacing inner and outer air switching actuator  

 

a) Disconnect connector connected to the

motor actuator. 
 
   
b) Remove intake rod from MA intake lever.  

c) Remove 3 plus screws and remove the

motor actuator with MA intake lever from the


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

  
   
  



Fig. 25-25

25-23
25. AIR-CONDITIONER SYSTEM

25.6 CHARGING REFRIGERANT

25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar
with how work is done for handling refrigerant.

• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)

(2) Storage and Transportation

1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is
filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises.
The can may blast as the result.
It is for this reason why the can temperature must be kept below 40°C (104°F).
2) For storage, choose a cold dark place not exposed to direct sunlight.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside
pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the
compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous
temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to
a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into
account.
5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6) Store cans beyond the reach of children.
(3) Charging
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low
pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent
that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a
direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge
manifold in any case.
(4) Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the air-
conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the air-
conditioner correctly and speedily. Pay full attention to the entry of water and dust.

• Be careful about overcharge of gas.

• Fasten pipes to the specified torque.

25-24
 25. AIR-CONDITIONER SYSTEM

25.6.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas charge
operation".
1) The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water
remains in the circuit, the small holes of the expansion valve are frozen during operation. This causes the
circuit to clog up or rust, resulting in a variety of malfunctions. Therefore, before filling refrigerant in the
circuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus
eliminated.
2) The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not
only depends upon the cooling performances of the air-conditioner, but also affects the service life of the
component parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes
the cooling performance to deteriorate. On the contrary, undercharge causes poor circulation of the
lubricating oil of the compressor and causes seizure of the moving parts of the compressor.
The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation
procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in
this manual.
(2) Operation Chart

Vacuum making operation Refrigerant filling operation

More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Lower than
-750mmHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1MPa (14 psi)

(3) Tools

No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side

Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter

25-25
25. AIR-CONDITIONER SYSTEM

25.6.3 CHARGING PROCEDURE

25.6.3.1 VACUUM MAKING OPERATION

(1) Connecting gauge manifold (See Fig. 25-26)
HIGH
1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE
pressure valve (LO) of the gauge manifold. GAUGE GAUGE MANIFOLD
(CLOSED)LOW HIGH PRESSURE
2) Connect the charging hoses (red and blue) with PRESSURE VALVE VALVE(CLOSED)
the service valves of the compressor. RED
BLUE
Red hose :
High pressure side (HI) of the gauge HIGH
PRESSURE YELLOW
manifold→high pressure side (DIS) of SIDE
compressor DIS
LOW
Blue hose : PRESSURE
Low pressure side (LO) of gauge manifold→low SIDE
SUC
pressure side (SUC) of compressor
COMPRESSOR VACUUM PUMP(STOP)

Fig. 25-26
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when  

connecting them. Put the hose in firmly till a clicking



sound is heard.



3) Connect the center valve of the gauge manifold 
with the charging hose of the vacuum pump.  

Fig. 25-27 Connecting gauge manifold

Some kinds of gauge manifolds are not equipped with

an open/close valve in the center.

25-26
 25. AIR-CONDITIONER SYSTEM

(2) Vacuum making (See Fig. 25-28)

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

2) Turn on the switch of the vacuum pump and

make vacuum for more than 30 minutes. GAUGE MANIFOLD
3) When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
DIS
4) Then turn off the vacuum pump.
(3) Air-tightness Check
Close the high pressure valve and the low pressure
valve of the gauge manifold, leave it as it is for more SUC
than five minutes and make sure that the gauge
indication does not return toward 0.
Fig. 25-28 Vacuum making operation

If the gauge indication goes toward 0, there is

somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.

25-27
25. AIR-CONDITIONER SYSTEM

25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See Fig. 25-29.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge AIR PURGE
manifold.) Then push the gas valve of the side CLOSE
service port on the low pressure side of the SCREW DRIVER OPEN SERVICE
gauge manifold, using a screw driver, in order to YELLOW CAN VALVE
let out the air in the charging hose by the
pressure of the refrigerant. (See Fig. 25-29.)
BLUE RED
(The operation ends when a hissing sound is
heard.)

Fig. 25-29 Gas charging operation

3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).] LOW PRESSURE HIGH PRESSURE VALVE
VALVE(CLOSE) (OPEN) (CLOSE)
After charging, close the high pressure valve of
RED FILL IN 1~1.5 CANS
the gauge manifold and the service and valve. BLUE OF REFRIGERANT
(See Fig. 25-30.)
DIS
YELLOW
SERVICE CAN
VALVE
(OPEN) (CLOSE)
• Do not run the compressor during this work,
CHARGE
(Otherwise the refrigerant flow in reverse
direction which causes the service can and the SUC

hoses to rupture. This is very dangerous.)

Fig. 25-30 Gas charging operation
(2) Checking for gas leak (High pressure side)
Check for gas leak in the cycle, using a gas leak
detector (electric type). Retighten and correct
leaking points.

• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)

25-28
 25. AIR-CONDITIONER SYSTEM

(3) Charging from low pressure side (See Fig. 25-31)

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

Fig. 25-31 Gas charging operation

(Low pressure side)
5) Open the low pressure valve of the gauge
SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver go away. (See Fig. 25-31)
[Total amount of gas to be charged :
800g±50g (1.76±0.11 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
RECEIVER DRYER

• Do not open the high pressure valve of the

gauge manifold in any circumstances. Fig. 25-32 Receiver dryer
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state.)

25-29
25. AIR-CONDITIONER SYSTEM

(4) Criterion for checking the amount of refrigerant

filled in

JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER

After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.

After A/C is turned on,

OVERCHARGE no air bubbles are seen.

After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.

• If the air-conditioner is run with poor refrigerant

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

(5) Removing Gauge Manifold

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

25-30
 25. AIR-CONDITIONER SYSTEM

25.7 ELECTRIC CIRCUIT

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

MAKER : YAZAKI CORP.

MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40 REAR HOLDER : 7157-6260-30
TERMINAL : 7116-2871 TERMINAL : 7114-2871

NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)

MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING

MAKER : YAZAKI CORP. MAKER : YAZAKI CORP. A/C MAIN POWER

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

FUSE 5A

MAKER : YAZAKI CORP. MAKER : YAZAKI CORP.

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

MAKER : YAZAKI CORP.

JAE IL-AG5-7S-S3C1 HOUSING No. : 7123-2228
TERMINAL : AG5-C1-5000 TERMINAL : 17111

COMPRESSOR

NIPPON AMP KK 174056-2 JAE IL-AG5-7S-S3C1

TERMINAL : 175062-1 TERMINAL : AG5-C1-5000

JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111

NOTE) 1. THe double chain lines indicate the wiring

on the excavator side. MACHINE SIDE WIRING (PARTS)
2. The connector colors indicate the cord colors seen
from the connecting part.
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE

Fig. 25-33 Electric diagram (1/2)

25-31
25. AIR-CONDITIONER SYSTEM

CCU (OPERATION PANEL + CONTROLLER)

EVA SENSOR

AIR INLET SENSOR

SUN SENSOR

MOTOR ACTUATER
(FOR AIR MIX)

MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)

BLOWER MOTOR

BLOWER AMP

MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY

AIR CONDITIONER SIDE

WIRING (PARTS) IN THE CAB

Fig. 25-34 Electric diagram (2/2)

25-32
 25. AIR-CONDITIONER SYSTEM

25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and
the signal input by each switch through control
panel with the function of the built-in micro
Fig. 25-35
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.

(2) Blower controller (TKS-B215A1)

The power transistor shifts the fan motor into
variable speed with base current from the control B
unit.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)

In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-36
* The installing position is provided on the left side
of air-con unit.

25-33
25. AIR-CONDITIONER SYSTEM

(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-37
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.

When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR

through the temperature control switch, the control LIMITER

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

either normal rotation or reverse rotation. Then as

the motor rotates, the contact point is moved, and HOT

when the contact point is detached or the output

signal of control unit turns OFF, the motor stops
rotating. Fig. 25-38

25-34
 25. AIR-CONDITIONER 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 INNER AIR SIDE

rotation direction of motor in either normal rotation OUTER AIR SIDE

or reverse rotation. Then as the motor rotates, the LIMITER

position detection switch also rotates and makes it

stop at the set position of the inner and outer air Fig. 25-39
damper.
(6) Evaporator sensor
This sensor is used to control the evaporator outlet
temperature with the compressor ON-OFF to
protect the evaporator from freezing, and this
evaporator sensor functions as a sensor of this
control.
• Evaporator sensor inspecting items
(Specification)
Terminal resistance : Fig. 25-40
at 0 degree C : 7.2 k
at 25 degree C : 2.2k
(7) Dual pressure switch
This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was
generated on the high pressure side.
Fig. 25-41
SPECIFICATION OF DUAL PRESSURE SWITCH

0.02MPa(2.9psi) 0.59MPa(86psi)

ON

OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)

(8) Solar radiation sensor

This solar radiation sensor, which is used to correct
the solar radiation to the auto air conditioner
detects the strength and solar orientation of
sunbeam after transforming them into current by
means of photo diode.
Inspection : Check for the continuity between
Fig. 25-42
terminals.

25-35
25. AIR-CONDITIONER SYSTEM

25.8 TROUBLESHOOTING

Air temperature does not fall. Note : M/A is motor

actuator
* is any of the
numbers 0 ~ 9.
If AUTO switch or A/C switch is pushed,
"HL.E" is indicated on the set temp. display of the panel.
NO YES

"HL. " is shown on the set temp.

* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on panel is flashing. Inspect and correct or replace parts.
NO YES

. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.

See section monitor mode.

Inspect and correct or replace parts.

A
NO YES

Blowout temp. falls if temp. is set . Evaporation sensor connector

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

Air mix damper is Cool air flowing

in COOLMAX. into inner air sensor Inspect and correct or replace parts.

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

NO YES

. Inspect, correct or replace M/A failed or controller

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

25-36
 25. AIR-CONDITIONER SYSTEM

Air temperature does not rise. Note : * is any of

the numbers 0 ~ 9.

HL.E is shown on the set temp. display of the panel.

NO YES

"HL. " is shown on the set temp.

* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
. Inner air sensor or harness is disconnected or shorted.
. Inner air sensor connector is disconnected or in poor contact. Inspect and correct or replace parts.
See section monitor mode.
NO YES
Inspect and correct or replace parts.

NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES

Air mix damper is Warm air is flowing into

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

NO YES
Inspect and replace.

. Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
. Clean lever link and apply grease.
Replace.

25-37
25. AIR-CONDITIONER SYSTEM

Blower motor does not run.

At air flow HI, battery voltage acts across

Note 1) both terminals (+) and (-) of blower motor.

NO YES

Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.

Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES

Controller is out of order. Remove blower amplifier and check for

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

Battery voltage acts across white /

red wire and body of blower motor relay. Eliminate cause Inspect and
and replace repair harness.
NO YES blower amplifier.

Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES

Replace relay. Inspect and correct harness

or replace controller.

Note 1) Measure with connector set.

Note 2) Always turn off air-conditioner, starter key switch and light switch before work.

25-38
 25. AIR-CONDITIONER SYSTEM

Blower motor speed does not change.

CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES

Replace blower . Inner air sensor or harness is disconnected or shorted.

amplifier controller. . Inner air sensor connector is disconnected or in poor contact.
See section monitor mode.

Inspect and correct or replace parts.

CASE (2)

Does not blower motor speed

change because the setting mode
is other face mode?
YES NO

Is door or front window open? See CASE (1).

YES NO

The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch.

25-39
25. AIR-CONDITIONER SYSTEM

Magnet clutch does not engage.

Snow mark ( ) lights

if A/C switch is pressed.
No Yes

Snow mark ( ) flickers and E is Voltage acts upon clutch.

shown on panel display.
No Yes

To A On page 25-37. Voltage is applied to Clutch faulty.

pressure switch harness.
No Yes

Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.

No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes

Replace harness. Replace controller.

Inner air and outer air do not change over.

Inner / outer air mode display on

operation panel is flickering.
No Yes

M/A lever includes foreign matter Connector of inner/outer air

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

M/A failed Remove foreign matter

and replace parts. Inspect or replace.

Replace

25-40
 25. AIR-CONDITIONER SYSTEM

Modes do not change.

Mode display (Mark of person)

on operating panel is flickering.
No Yes

M/A rod does not disengage. Mode M/A connector is

disconnected or in poor
No Yes
contact or M/A failed or main
harness is faulty.
Repair. Each damper lever does not disengage.
No Yes Inspect or replace.

Repair. When rod is removed and cam is operated

by hand, it is heavy. (more than 19.6N.)
No Yes

M/A or controller is out of order. . Cam or damper shaft includes

foreign matter or is broken
. Erroneous motion occurs due to
Replace. dirty grease.

. Remove foreign matter or replace parts.

. Clean cam and apply new grease.

25-41
25. AIR-CONDITIONER SYSTEM

Trouble with refrigeration cycle.

Both high and low pressures are lower.

Low pressure is higher.

NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES

Cooling does not work Oil comes out from

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

High pressure
is lower.

Air bubbles are seen in sight glass.

NO YES

High pressure gets Condenser is

lower slowly. fouled or clogged.

High pressure YES NO

circuit before
receiver is Air bubbles are hard to
clogged up. go out even if water
is poured on condenser.

Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.

25-42
 25. AIR-CONDITIONER SYSTEM

25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

The failure of motor actuator and each sensor can be identified on the display of panel.

25.9.1 POSITION OF INDICATION FOR FAILURE.

The error is indicated on 3 digits segment.

25.9.2 EXPLANATION OF INDICATION FOR FAILURE.

(1) Failure of Motor Actuator
1) HL.E is indicated on 3 digits segment.

Check harness or connector to motor actuator

for the air mix damper for disconnection.

2) MODE is flickering.

Check harness or connector to motor actuator

for the air outlet damper for disconnection.

3) R/F is flickering.

Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.

25-43
25. AIR-CONDITIONER SYSTEM

(2) Failures of sensors

1) HL.* is indicated on 3 digits segment.

Check the inner air sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

(* is any of the numbers 0 to 9.)

2) **E and mark are flickering.

(** is displayed leaving the present set temperature value.)

Check evaporator sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.

(3) Communication error of control amplifier and panel

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

  
  
    
 
  




 

    




25-44
 25. AIR-CONDITIONER SYSTEM

25.9.3 EXPLANATION OF MONITOR MODE

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

SEGMENT FOR ONLY MONITOR INDICATION

3 DIGITS SEGMENT

(2) Operation of monitor mode

SPEED UP AND DOWN

INNER OR OUTER
SWITCH FOR BLOWER
AIR INLET SELECT
SWITCH (R/F)

ON/OFF SW

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

SEGMENT ASSIGNMENT LIST

0 INNER AIR SENSOR

1 EVAPORATOR SENSOR

2 SOLAR RADIATION SENSOR

(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)

5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.

Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.

25-45
25. AIR-CONDITIONER SYSTEM

(3) Contents of monitor mode display

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

THIRD SEGMENT
SECOND SEGMENT
When the segment exclusively used for monitor indicates 0
(displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.

2) Example 2

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.

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.
-->The solar radiation sensor is in short-circuiting condition.

4) List of 3 segments

SECOND SEGMENT

INNER AIR SENSOR DISCONNECTION (0CH0 INDICATED)

EVAPORATOR SENSOR DISCONNECTION (0CH1 INDICATED)
SOLAR RADIATION SHORT-CIRCUITING (0CH2 INDICATED)
THIRD SEGMENT

EACH SENSOR IS NORMAL

SOLAR SENSOR 5V SIDE SHORT-CIRCUITING (C7H2 INDICATED)

INNER AIR SENSOR SHORT-CIRCUITING (F6H0 INDICATED)

EVAPORATOR SENSOR SHORT-CIRCUITING (F6H1 INDICATED)

25-46
 25. AIR-CONDITIONER SYSTEM

[MEMO]

25-47
25. AIR-CONDITIONER SYSTEM

25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ...........................31-2

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ..................................31-2
31.1.2 INDICATION OF TIGHTENING TORQUE .............................................................31-2

31

31-1
31. DISASSEMBLING AND ASSEMBLING

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

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

31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N•m(72 lbf•ft)
Tolerance is ±10% unless otherwise specified.
• Refer to "Chapter 11 TOOLS" for standard tightening torque.

31-2
 32. ATTACHMENT
TABLE OF CONTENTS

32.1 REMOVING AND INSTALLING.......................................................................................32-3

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

32

32-1
32. ATTACHMENT

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

32-2
 32. ATTACHMENT

32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY

(D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN
4. BOOM (A) BOOM FOOT PIN

(E) ARM CYLINDER ARM CYLINDER

ROD PIN

(F) BOOM TOP PIN

(G) BUCKET CYLINDER

HEAD PIN
3. ARM
BUCKET CYLINDER
(J) BUCKET DRIVE PIN
(I) IDLER LINK PIN
IDLER LINK BUCKET LINK (H) BOOM CYLINDER
(H) BUCKET CYLINDER ROD PIN (K) BUCKET ATTACHING PIN HEAD PIN
Fig. 32-1 Front attachment and position

32.1.2 BUCKET

32.1.2.1 REMOVING BUCKET

(1) Put the machine in position to remove bucket.

Fig. 32-2 Position to remove bucket

(2) Removing pin (2)
BOSS SECTION
Expand slit of ring (1) with screwdriver, and remove
it. Push out the pin (2) with flat-blade screwdriver . DRIVER
1 2

SECTION OF BOSS

Fig. 32-3 Removing pin (2)

32-3
32. ATTACHMENT

(3) Removing bucket attaching pin (K)

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

Fig. 32-4 Removing bucket attaching pin

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

Fig. 32-5 Removing bucket drive pin

32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in the
reverse procedure of removing.
J

• When aligning the pin holes, do not put your

finger in the pin holes, but align them visually.
• Check the seals for damaged and replace as
necessary.
• When inserting the pin, coat the shaft with
grease.

Fig. 32-6 Attaching bucket

32-4
 32. ATTACHMENT

32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm Apply rust preventive oil +1.0 +0.039"
251 -0.5 (9.88 -0.020" )
(1) Shift O-ring (3) toward the bucket boss, using a New bucket

spatula. (a→b) 12 : WASHER

B
3 : O-RING
11 : CAPSCREW b a
(2) When adjusting clearance (B), bring the non-
adjusting side of the bucket in contact with the arm.

(3) Measure clearance (B) and check that it is within

1.0mm (0.04in). 7 : BUSHING

8 : PLATE
(4) Adjust clearance (B) where it is more than 1.0mm
Install pin (10) until the top
(0.04in). 9 : SHIM 10 : PIN of pin is even surface
with bushing.

(5) An average of 5 shims (9) of 1mm (0.04in)

thickness are set in the plate (8) fixed by the three
capscrews (11). The clearance can be decreased
Fig. 32-7 Adjusting clearance between bucket and
by 1mm (0.04in) if one shim is removed.
arm
: 22mm,
Tightening torque : 181N•m (133 lbf•ft)

(6) After adjustment, tighten the capscrews evenly.

• The gap exceeding the specified dimension
causes early wear.

(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).

(8) Replace O-ring (3) on its original position.

• When shifting O-ring (3) by means of a spatula, use

care so as not to damage O-ring (3).
• Remove shims (9), push out bushing (7) rightwards
by means of three capscrews (11) and adjust
clearance (B) so it settles within the standard value
evenly all round.

32-5
32. ATTACHMENT

32.1.3 ARM

32.1.3.1 REMOVING ARM

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

Fig. 32-8 Position to remove arm

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

Plug both end of disconnected pipes.

Plug : Tools section 11.5.2-(4)
Tools section 11.5.2-(5)
OIL PAN
When the removal of bucket cylinder is not
required, skip to procedure (6). Fig. 32-9 Disconnecting piping of bucket cylinder

(3) Removing bucket cylinder rod pin (H) After adjustment of shim, the total gap
should be within 0.6~1.0mm (0.02~0.04in).
Loosen nut (9), remove capscrew M14×115 (8), SHIM
and push out pin (H).
9

: 22mm

8
G A
H D A
H SECTION D-D
Install plastic shims
to bucket link side.
D

PLASTIC SHIM STEEL SHIM

Fig. 32-10 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
Install plastic shims
Loosen nut (3), remove capscrew M16×130 (2), to bucket link side.
and push out pin (G). 3 2
SHIM
After adjustment of
shim, the total gap
should be within
: 24mm 0.6~1.0mm (0.02~0.04in).
SHIM Apply grease
to inner wall
of bushing

G
SECTION A-A
Fig. 32-11 Detail of bucket cylinder head pin (G)

32-6
 32. ATTACHMENT

(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight : 82 kg (181 lbs)

Fig. 32-12 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Apply grease to inner wall
Put a wooden block between the arm cylinder and of bushing
the boom. Install plastic shims 2
Loosen nut (3), remove capscrew M16×130 (4), to bucket link side.
SHIM
and push out arm cylinder rod pin (E). E

: 24mm

Retract arm cylinder rod, and return pin (E) to the 3

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

(7) Removing boom top pin (F)

Tightening torque 144N.m (106 lbf.ft)
Loosen capscrew M12×45 (2), and pull out boom Apply loctite #242 to bolt.
top pin (F). 2 1

: 19 mm SHIM
Install plastic
shims to arm
Insert pin (F) into the original hole. side.

SHIM Apply grease

to inner wall
After adjustment of of bushing
shim, the total gap
should be within
0.5mm (0.02in).
F
SECTION A-A
Fig. 32-14 Detail of boom top pin (F)

32-7
32. ATTACHMENT

(8) Slinging arm assy

Sling arm with nylon sling and remove it.

STD Arm weight : 367 kg (809 lbs)

Long Arm weight : 472 kg (1,041 lbs)

Fig. 32-15 Slinging arm assy

32.1.3.2 ATTACHING ARM

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

CLEARANCE

: 22, 24 mm

5) When installing the arm and the cylinder, inspect

the clearance in the thrust direction of the pins
and decide the thickness of shims by referring to
the Maintenance Standard.
6) Tightening torque

Tightening torque
Classfication Size
N.m lbf.ft
M12 115 84.8
Metric threads M14 144 106
M16 147 108
PF,PT threads 1/8" 16.7 12.3

32-8
 32. ATTACHMENT

32.1.4 BOOM

32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

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

32.1.4.2 REMOVING BOOM

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

BLOCK

Fig. 32-16 Position to remove boom

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

STAND

Fig. 32-17 Lifting up boom cylinder temporarily

(3) Press the boom cylinder rod pin (C)
Install plastic shim to cylinder side.
At the one side of pin (C), loosen nut (5), remove SHIM
capscrew (3) (M14×135), and remove collar (4). After adjustment of shim,
the total gap should be within
And push pin (C) to the end of boom boss. 0.6~2.0mm (0.02~0.08in).
SHIM

: 22 mm
4 3

(4) Preparing for disconnecting cylinder pipes

C
Retract the above mentioned cylinder rod, and 4
place one side of cylinder on stand. (See Fig. 32-
17) 5

SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)

32-9
32. ATTACHMENT

(5) Disconnecting the arm cylinder and bucket cylinder A1

A3
pipings
Release pressure from arm and bucket circuit and
bleed air in hydraulic tank, and then disconnect
A2
pipe at (A1), (A2), (A3), (A4) and 4 hoses.
HOSE (4 pieces)
A4
: 27, 36 mm

After disconnection of pipe, plug every pipe. 825 (32.5")

ARM (R)
) BU CKET (H)
ORS Plug : See Tools 11.5.2-(4). 795 (31. 3"

ARM (R)
BUCKET (H)

100 (2.76
70
(3.9 ") AR
ARM (H) 4")
BU M (H)
100 (5.12")

CK
130

BUCKET (R) ET )
BUCKET (R
(3.9 )BBUUC

Apply Loctite #242. (H) 825 (32.5")

ARM (H)
4"))A CKKEE

855 (33.7")
ARRM TT(
M(H(
H)) H))

SECTION CC VIEW I Fig. 32-19 Boom piping disconnection

H(

(6) Lifting up boom assy temporarily

Lift up boom with nylon sling so that boom foot pin
(A) is not loaded.

Weight of single boom : 1,256 kg (2,770 lbs)

BLOCK

Boom assy temporary lift up procedure

(7) Removing boom foot pin (A) After adjustment of shim,

the total gap should be SHIM
1) Loosen nut (3) or washer (4) and remove within 0.5mm (0.02in).
2
capscrew (2).

2) Draw out pin (A).

A 4
3
Apply molybdenum addition
grease to inner wall of bushing.

Install plastic shim to boom side.

SECTION A-A

Fig. 32-20 Details of boom foot pin (A) section

32-10
 32. ATTACHMENT

(8) Hoisting boom assy

Hoist and remove boom assy.

Weight of single boom : 1,256 kg (2,770 lbs)

D
D
BLOCK

Boom assy hoisting procedure

(9) Completion of removal of front attachments

When the removing and attaching of cylinder are
not required, the work is finished. 2

(10)Removing and installing arm cylinder F2

1) Lift up arm cylinder (2) with nylon sling so that
the head of cylinder is not loaded.
2) Disconnect hose (F1) and (F2) at position A. After adjustment of
After disconnection of hose, plug both ends of shim, the total gap
should be within F1
hose. 0.6~2.0mm (0.02~0.08in).
3 2 A
Install plastic shim to
Plug : TOOLS cylinder side. SHIM
11.5.2-(4) Plugs for ORS fitting SHIM
:27, 30, 32, 36 mm Apply grease
to inner wall
of bushing

3) Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew M16×130 (2) D
SECTION D-D
and pull out pin (D).
Fig. 32-21 Removing arm cylinder

: 24mm

4) Removing arm cylinder (2)

Weight of arm cylinder : 140 kg (309 lbs)

32-11
32. ATTACHMENT

(11)Removing and installing boom cylinder

1) Release pressure from boom circuit and bleed
air in hydraulic tank.
2) Sling boom cylinder (2) using nylon sling
temporally not to act the weight of cylinder upon
the cylinder head. 2
3) Disconnect each two hoses (C2) and (C3). And
plug their both ends. 2
B
Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting

: 27,32mm C3
C2
C3
Fig. 32-22 Removing and installing boom cylinder
4) Removing boom cylinder foot pin (B) After adjustment of shim,
(See Fig. 32-23,Fig. 32-24) the total gap should be within
0.6~2.0mm (0.02~0.08in).
Loosen nut (5), remove capscrews M10×20 (3) SHIM Apply grease
to inner wall
and pull out pin (B). of bushing

B B
: 17mm

5) Remove boom cylinder (2). 3

Weight of boom cylinder : 96 kg (212 lbs) Apply grease
to inner wall SHIM
6) Remove another boom cylinder the same way. of bushing
Install plastic shim
to cylinder side.
SECTION B-B

Fig. 32-23 Removing and installing boom cylinder

head pin (B)

32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the
boom assy.
Attach it in the reverse procedure of removing,
paying attention to the following points.
A
1) When aligning the pin holes, do not put your
finger in the pin holes, but align them visually.
2) Check that the dust seals is not damaged and
replace as necessary.
3) When inserting the pin, coat the shaft with
grease.
4) M16 capscrew tightening torque : 279 (3.11) N•m
B
(205 lbf•ft)
5) When installing boom and cylinder, check the
clearance of mounting section in thrust direction,
Fig. 32-24 Boom foot pin (A)
and decide the thickness of shim according to
the maintenance standard.
Install plastic shim first, and insert iron shim into
remaining gap.
Regarding the position of shim, refer to Fig. 32-
20.

32-12
 32. ATTACHMENT

32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER

32.2.1.1 PREPARATION BEFORE DISASSEMBLY

Before assembly, secure a dustfree workshop and necessary equipment and facilities.

32.2.1.1.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this
reason, the first condition is that the working area is long enough for the work. In terms of width, it is also
necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work
can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic
materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in
particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is
assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube
inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding
operation should not be performed in the neighborhood of the working area to keep it clean.

32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.

32-13
32. ATTACHMENT

32.2.1.1.3 NECESSARY TOOLS

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

• For the details of special tools and jigs, refer to the back pages of this manual.

32.2.1.1.4 EXTERNAL CLEANING

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

32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and place the WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time, V BLOCK
connect a suitable hose to each port so that the
hydraulic oil may not gush out. PORT A

AIR

OIL PAN
Fig. 32-26 Preparation

32-14
 32. ATTACHMENT

32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)

32 2
32 4

2 4-M10 P1.5 TAP DP 17 MIN

11 5 10,9 8 26 6 7 14 12,13 3 1 15 16 19 18 17 20,21 22 23 25 24

PT1/8

PT1/4

27,28,29,30,31

Fig. 32-27 Construction of general cylinder

No. Parts name Q’ty No. Parts name Q’ty No. Parts name Q’ty
1 Cylinder tube 1 12 O-ring : 1B G110 1 23 Set screw : M8 1
2 Oiles bush 2 13 Back-up ring 1 24 Cushion plunger 1
3 Rod assy 1 14 O-ring : 1B G115 1 25 Stop ring 1
4 Oiles bush 2 15 Cushion ring 1 26 Socket bolt : M16 10
5 Rod cover 1 16 Piston 1 27 Check valve 1
6 DD-bushing 1 17 Slip seal 1 28 Spring 1
7 Retaining ring 1 18 Wear ring 2 29 Spring 1
8 Buffer seal 1 19 Dust ring 2 30 O-ring : 1B P14 1
9 U-packing 1 20 O-ring 1 31 Plug : PT3/8 1
10 Back-up ring 1 21 Back-up ring 2 32 Wiper ring 4
11 Dust seal 1 22 Piston nut 1

32-15
32. ATTACHMENT

32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in Fig. 32-27.
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.

32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Hold the clevis section of the tube in a vise.

Use mouth pieces so as not to damage the machined

surface of the cylinder tube. Do not make use of the
outside piping as a locking means.

(2) Pull out piston rod (3) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (26) of the rod
cover in sequence.

Fig. 32-28
Cover the extended piston rod (3) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 26

(4) Strike the corner of the rod cover flange by means

of a plastic mallet till rod cover (5) comes off.

Turn counterclockwise

5
Cover here with cloths
3
Fig. 32-29

32-16
 32. ATTACHMENT

• At this time, the weight of piston rod (3) is loaded KNOCK THIS EDGE
on rod cover (5). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.

5
3
Fig. 32-30 Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1

PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
tip of the piston rod (3) with a hoist and draw it out.
However, when piston rod (3) has been drawing out to
approximately two thirds of its length, lift it in its center OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out the piston rod
of piston rod (3) is lifted, do not use a wire rope which
assy
may score the surface, but use a strong cloth belt or a
rope.

(6) Place the removed piston rod on a horaizontal

wooden V-block.
PISTON ROD ASSY

• Cover a V-block with cloths.

WOODEN V-BLOCK
(PLACE CLOTHS)

Fig. 32-32 Method of placing the piston rod

(7) Remove wear ring (18) and dust ring (19) from 16
piston (16). Remove slide ring by
widening the slit toward
the arrow

19

18

Fig. 32-33 Remove wear ring (18) and dust ring (19)

32-17
32. ATTACHMENT

32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (3) by holding its clevis section in a 5 WOODEN BLOCK
vise. Fix the piston rod (3) securely as piston nut 3
(22) is tightened to a high torque. 16
22

• Note that the tightening torque differs with the type,

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

: 4 mm

22
23

Fig. 32-35 Removing setscrew (23)

(3) Loosen and remove piston nut (21).

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

(4) Loosen piston (16) with a pin wrench as shown in

Fig. 32-37, utilizing the two holes in the side face of
the piston. If the O-ring (20) comes off, the piston
may be turned easily by hand. When removing the   
last thread of the piston, hold the piston by hand to  
 
receive the weight  
 
Fig. 32-37 Removing piston (16)
If the piston is dropped with a bang, the O-ring seal face
on the piston interior may be damaged with the threads.

32-18
 32. ATTACHMENT

(5) After removing cushion ring (15), separate rod

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

32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1) Remove piston seal assy (17).


Cut the seal ring (17-1) by tapping it with a screwdriver 

  

or a chisel. Take care not to strike it too hard, otherwise
the groove may be damaged.

 
 

  


   

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

Fig. 32-40 Removing back-up ring (21) and

O-ring(20)

32-19
32. ATTACHMENT

32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (10) and back-up ring (11). SPATULA
Remove back-up ring (11) and O-ring (10) in that
order. Remove back-up ring (11) and O-ring (10) by 10
pulling and stretching them with an spatula like
earpick. 11

Fig. 32-41 Removing the outer circumferential seal

of rod cover (3)
(2) Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(8). Each seal is fixed in the groove on the bore and
removing in flawless is impossible.
8
Stab each seal with a gimlet and pull it out of the
3 7
groove.
6

Take care in this operation not to damage the grooves.

Fig. 32-42 Removing the inner circumferential seal

of rod cover (3)
(3) Remove wiper ring (9). When taking out wiper ring HAMMER SCREW- 3
(9), fix rod cover (3) in a vise. DRIVER

WOOD PIECE
WOOD PIECE
VISE

Fig. 32-43 Removing wiper ring (9)

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

Center the work on a lathe sufficiently so the bushing Fig. 32-44 Removing rod bushing (6)
may be shave on a lathe as thin as possible.

32-20
 32. ATTACHMENT

32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (32) of cylinder tube (1)  

and piston rod (3), and strike it by hammer lightly. 
(2) Push out pin bushing (4) press fitted in cylinder tube
(1) and piston rod (3) with press.

  
Fig. 32-45 Drawing out pin bushing (24)

32.2.1.3.6 REMOVING CHECK VALVE (ARM CYLINDER ONLY)

(1) Using allen wrench, remove check valve plug (31), 27
and remove the internal parts (27, 28 and 29)

: 8 mm
28

29

31
30

Configuration of check valve

Fig. 32-46 Removing of check valve

32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.

Never use benzene(gasoline, thinner, etc.) because it

may be damage the rubber, etc.

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

32.2.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
• Cylinder tube assy
• Piston assy
• Rod cover assy

32-21
32. ATTACHMENT

32.2.1.5.1 ASSEMBLING PIN BUSHING

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

• Before press fitting, apply grease on wiper ring and

boss hole. OIL HOLE LOCATION
• Before press fitting the pin bushing, align the Fig. 32-47 Press fitting of pin bushing (4)
position of oil hole.

32.2.1.5.2 ASSEMBLING OF PISTON ASSY

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

driver the corner is rounded.

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

  


Since it is hard to deform seal ring (17-1) in room
temperature, immerse and soften it in hydraulic oil 
heated about 150 to 180 C degrees. Therefore slip it in
piston seal groove quickly with fitting jig so as not to be
cooled. Fig. 32-48 Attaching seal ring (17-1)
To avoid burn, wear gloves when fitting the heated seal
ring (17-1), and fit it quickly. And the hydraulic oil must
be heated with electric heater. (Do not use fire. There is
a danger.)

(3) Shrink the seal ring (17-1) to the original size using
correcting jig.
 

(4) Fit back-up rings (17-3) to both sides of seal ring.    

Fig. 32-49 Correction of seal ring (17-1)


 

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

(5) Fit O-ring and back-up ring (2 places) to the bore 
 
side. Fig. 32-50 Direction of components

32-22
 32. ATTACHMENT

32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (6) in rod cover (5) with bushing PRESS HERE. (STRAIGHT DOWN)
press-fitting jig (A). Then, fit snap ring (7) in the METAL
groove. Apply hydraulic oil on internal surface of 6 (MAKE O.D.SMALLER
rod cover (5). THAN ROD BUSHING O. D.)
GROOVE FOR
FIXING CIRCLIP (18)

Press bushing till bushing

The snap ring (7) can not be fitted when the bushing (6) comes in contact with
5
is not press-fitted fully to the stop end. this face.

(2) Apply grease to dust seal (24) or the hole of rod PRESS HERE. (STRAIGHT DOWN)
cover (16), and fit dust seal (24) to the bottom of the
hole. At this moment, press the metal ring of dust PRESS METAL
PRESSING JIG RING.
seal (24) with a jig.
24
RUBBER
CLIP

METAL RING

Fig. 32-51 Pressing in rod bushing (6)

(3) Fit buffer seal (8), back-up ring (10) and rod INSERT U-RING INTO GROOVE FROM THIS SIDE.
packing (9) in their grooves in that order. Before
setting packings, coat them with hydraulic oil (or
vaseline if not available). If you forget the coating,
the packings may be scored. When attaching seals,
deform them in a heart shape as illustrated.

• Rod packing (9) is harder than other packing and it

would be difficult to deform them in a heart shape.
In such a case, put a U-ring in the groove obliquely Fig. 32-52 Inserting a seal into the inner
by hand as deep as possible and push in the last circumference of rod cover.
part with a push bar till it is set with a click.
PUSH BAR (WOOD OR PLASTIC)
• Buffer seal (8) should be fitted taking care of the 12
fitting direction. The reverse fitting may cause 13
deformation, damage, etc. of the piston due to high Tube side

pressure generated between the buffer ring and rod 5

packing (9).
• If rod packing (9) is set upside down, the lip may be
damaged. Check that it is positioned correctly.
• Attach back-up ring (13) on the open air side of O-
ring (12). (See Fig. 32-53).

8
9
10
11
Fig. 32-53 How to fit rod packing (9)

32-23
32. ATTACHMENT

32.2.1.5.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (5) to piston rod assy by the
INSERT GUIDE JIG (I) 5
following procedure.
(1) Fix piston rod assy on working bench. PUSH

(2) Install rod cover (5) on piston rod (3) with inserting
guide jig (I) as shown in Fig. 32-54 paying attention 3
for the lip section of rod packing not to be caught on
the stepped section.
Fig. 32-54 Inserting rod cover (5)

• For the rod the outer diameter of piston installing

section is small, insert spacer on the faucet section
of rod first, and attach inserting guide jig.
• Apply hydraulic oil on the inserting guide jig and
outer surface of piston rod lightly to make the
insertion smooth.

32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Inset in cushion ring and install the piston assy to
piston rod (3).
(2) Apply hydraulic oil or grease to the inside of the
piston assembly and to the piston mounting part of     
  
piston rod (3). Then install the piston assembly as
     
shown in Fig. 32-55, exercising care not to damage
O-ring (20) and the seal.
Always tighten the piston to a specified torque



  
  

         
     
Fig. 32-55 Tightening piston assy
(3) Piston nut (22) till it gets tight.
Always tighten the piston nut (22) to a specified
torque (Refer to 32.2.1.7.3.)

22 HOOK WRENCH

Always correct the threads of the tapped hole in piston 1.0~1.5m

(3'3"~4'11") TURN CLOCKWISE
nut (22) before fixing piston nut, using a tap.
Fig. 32-56 Tightening piston nut (22)

32-24
 32. ATTACHMENT

(4) Screw in and set setscrew (23). 23 ANTI-LOOSENING CAULKING

3

: 4mm
After tightening the setscrew to a specified torque
of 15 N•m (11 lbf•ft), caulk the two places of the
screw threads of the piston nut side to secure the
setscrew.
(5) Attach two wear rings (18) and dust rings (19). Take V BLOCK
off vinyl tape wound around the perimeter of piston 22
(16), apply high-quality grease (or vaseline) to wear
Fig. 32-57 Attaching setscrew (23)
ring (18) and dust ring (19) and attach the wear
rings in a manner that they may be coiled around 23 18 19
3
the groove. Set the wear rings about 90 degrees
apart with each other so that the 45 degree slits
may not point to the same direction.

22 V BLOCK

Fig. 32-58 Attaching wear ring (18)

32.2.1.5.6 OVERALL ASSEMBLY

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

: 14 mm, 12 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-60 Tightening socket bolts (26)
Take care so as not to damage the rod surface by
accidentally slip a wrench. Covering the rod surface
with cloth is recommended to prevent damage to it.

32-25
32. ATTACHMENT

32.2.1.6 INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load, operate the
piston rod 5 to 6 strokes by the directional valve and DIRECTIONAL VALVE
make sure that it operates without failure. PUMP

• Do not raise the hydraulic pressure above the H R

maximum pressure of 34.3MPa (4974 psi) for the
cylinder of the machine.
• Grease coated on the O-rings and the seals of the
HYDRAULIC CYLINDER
rod cover may come out. Wipe it off and retest the
Fig. 32-61 External leak test
cylinder in such a case.

(2) Leak test MEASURE THE

1) Apply a test pressure to the retracting and INTERNAL LEAK.
extending sides of the cylinder for three minutes
independently, and check that the rod section
and the welds have external leaks and
permanent deformation. For an internal leak test,
connect the cylinder with a test unit as shown in
FROM DIRECTIONAL VALVE
Fig. 32-62.
Fig. 32-62 Internal leak test
2) After completing the test, apply a plug to each 

port and store the cylinder. (Fig. 32-63)

• For storage, place the cylinder on wooden V-

blocks and bring the cylinder to the most    
retracted condition. Fig. 32-63 How to store the cylinder

32-26
 32. ATTACHMENT

32.2.1.7 MAINTENANCE STANDARDS

32.2.1.7.1 INSPECTION AFTER DISASSEMBLY

Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to
use are not present.
(1) Inspection Item
Part Name Inspecting Section
1. Neck of rod pin
2. Weld on rod hub
3. Stepped part to which
piston is attached
4. Threads
5. Bend
Piston rod 6. Plated surface
7. Rod
8. Bushing at mounting part
1. Weld on bottom
2. Weld on head
Cylindertube 3. Weld on hub
4. Tube interior
5. Bushing at mounting part
1. Bushing
Rod cover
Table32-2
Inspection Item Remedy
Presence of crack Replace.
Presence of crack Replace.
Presence of crack Replace.
Presence of seizure Recondition or replace
Measure degree of bend (See
Refer to (Table32-3)
Fig. 32-64)
Check that:
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on plating. 2) Replace or replate
3) Recondition, replate or
3) Scratches are not present.
replace.
Wear of O. D. Recondition, replate or replace.
Wear of I. D. Replace.
Presence of crack Replace.
Presence of crack Replace.
Presence of crack Replace.
Presence of damage Replace if oil leak is seen.
Wear on inner surface Replace.
1) Wear on inner surface 1) See para. 32.2.1.7.2
2) Replace if score is deeper than
2) Flaw on inner surface
coating.

(2) Repair method

Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores on
the piston rod, observe the following procedure:

1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone.
If the score or the indention is excessive, replace or replate the damaged part.

• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.

32-27
32. ATTACHMENT

32.2.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the
sliding surfaces of the cylinder tube and the rod that
have no such damage as may degrade the sealing
effect.
(1) Clearance between piston rod and rod bushing
Replace the bushing if the clearance between the
piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm /
1m (0.04"/3’3"). For measurement, support both
ends of the parallel section of the piston rod with V-
blocks, set a dial indicator in the center between the
two V-block turn the piston rod, and read the
difference between the maximum and minimum Fig. 32-64 Measuring Method
deflection on the dial indicator.
Table32-3 shows an example of measurement.

Table32-3 Example of Measurement

Distance between Deflection of the dial indicator
V-blocks in the middle of the rod. Remedy
m (ft-in) mm (in)

1 (3’3") 1 (0.04") Replace

Even if the bend is within the above limit, the cylinder

may not operate smoothly because of localized bend.
Beware of it during function test after assembly.
Replace the rod if the cylinder makes a squeaking
noise or dose not operate smoothly.

32.2.1.7.3 TIGHTENING TORQUE

B A C Unit : N.m (lbf.ft)

A B C
Cylinder Piston nut
or [Piston] Socket bolt Setscrew
Boom 2841 (2095) 267 (200) 56.9 (42)
Arm 2841 (2095) 367 (270) 56.9 (42)
Bucket 2841 (2095) 267 (200) 56.9 (42)

32.2.1.7.4 VOLUME OF OIL LEAK

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

Cylinder Volume of Internal Oil Leak

Boom 2.0cc (0.12 cu•in) or below / 10min
Arm 2.3cc (0.14 cu•in) or below / 10min
Bucket 1.9cc (0.11 cu•in) or below / 10min

32-28
 32. ATTACHMENT

32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Rod packing 1. Foreign matter is trapped in the 1. Remove foreign matter.
surface of piston rod. Oil bore of rod packing
ring is formed on piston 2. Lips on outer and inner diameter 2. Replace rod packing.
rod, and the ring grows up surfaces of rod packing are scored.
to oil drops, and they drip. 3. Other back-up ring are failed. 3. Replace rod packing
2. Buffer seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of seal.
OIL LEAKS FROM HERE 2. Score is present on the bore of seal. 2. Replace buffer seal.
3. Other seals are failed. 3. Replace buffer seal.
3. Dust seal 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of seal.
2. Score is present on the bore of seal. 2. Replace dust seal.
3. Other seals are failed. 3. Replace dust seal.
4. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.

OIL LEAKS FROM HERE

3. Oil leaks from welds. 1. Cylinder tube 1. Welds of cylinder are broken. 1. Replace cylinder tube.

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

32-29
32. ATTACHMENT

32.2.1.9 TOOLS AND JIGS LIST

The tool and jig list provides the materials and the dimensions of tools and jigs so that they may be utilized in
manufacturing in a service shop. Follow the directions given below in selecting, manufacturing and using the tools
and jigs.
(1) For the rod cover, piston nut and others that require
large tightening torques, use eye wrenches as
much as possible.
The tools and the jigs are so designed
dimensionally that they can withstand the
maximum tightening torques even if material
SS400 (JIS) is used. However, the hook of the tool
may be distorted if struck with a hammer. If such
occurs, apply reinforcement weld and finish it by
grinding. USE THIS PORTION.
(2) The pin section of pin wrenches and pin hook
Fig. 32-65
wrenches is loaded with large shearing force.
Therefore, take care when selecting pin material
and welding the pin to the body. It is recommended
to use the shank section of disused drills (Fig. 32-
65)

32.2.1.9.1 ALLEN WRENCH AND SPANNER WRENCH

Unit : mm (in)
For piston nut For check For 1/8 grease For 1/4 grease
CYLINDER For cover bolt
set screw valve plug nipple nipple
ARM 14 (0.55) 4 (0.16) 8 (0.32) 14 (0.55)
BOOM 12 (0.47) 4 (0.16) — 10 (0.39) 14 (0.55)
BUCKET 12 (0.47) 4 (0.16) — —

32.2.1.9.2 DUST SEAL PRESSING JIG

(FOR ROD COVER)
E
C1
C1
I
H J MATERIAL : SS400 (JIS)
F G

A
B
C
D

Fig. 32-66 Dust seal pressing jig

Table32-5
Unit : mm (in)
CYLINDER A B C D E F G H I J
84 89 92 106 5.5 25.5
ARM
(3.31) (3.50) (3.62) (4.17) (0.21) (1.00)
75 79 82 98 80 5 15 5
BOOM
(2.95) (3.11) (3.23) (3.86) (3.15) (0.20) 5 (0.59) (0.20) 25
75 74 77 93 (0.20) (0.98)
BUCKET
(2.76) (2.91) (3.03) (3.66)

32-30
 32. ATTACHMENT

32.2.1.9.3 EYE WRENCH (FOR PISTON NUT)

MATERIAL : SS400 (JIS), FINISH BY GRINDING AFTER GAS CUTTING
C

B A
D

E
Plate thickness :

Fig. 32-67 Eye wrench

Table32-6
Unit : mm (in)
CYLINDER A B C D E F G T Common use bolts
91 150 80 11 300 55 30 12~15
ARM
(3.58) (5.91) (3.15) (0.43) (11.8) (2.17) (1.18) (0.47~0.59)
81 140 75 11 300 55 30 12~15
BOOM —
(3.19) (5.51) (2.76) (0.43) (11.8) (2.17) (1.18) (0.47~0.59)
76 135 65 11 300 55 30 12~15
BUCKET
(3.00) (5.32) (2.56) (0.43) (11.8) (2.17) (1.18) (0.47~0.59)

32.2.1.9.4 WRENCH (FOR PISTON)

MATERIAL : SS400 (JIS), FINISH BY GRINDING AFTER GAS CUTTING


  

    

Fig. 32-68 Wrench

Table32-7
Unit : mm (in)
CYLINDER A B C D E F G T Common use bolts
60 120 90 12 300 55 30 12~15
ARM
(2.36) (4.72) (3.54) (0.47) (11.8) (2.17) (1.18) (0.47~0.59)
45 105 75 12 300 55 30 12~15 M8×20(2 pcs.)
BOOM
(1.77) (4.13) (2.95) (0.47) (11.8) (2.17) (1.18) (0.47~0.59) (0.79)
40 100 80 12 300 55 30 12~15
BUCKET
(1.58) (3.94) (3.15) (0.47) (11.8) (2.17) (1.18) (0.47~0.59)

32-31
32. ATTACHMENT

32.2.1.9.5 ROD COVER FIXING JIG

MATERIAL : SS400 (JIS)

G
R0.5 About
(0.02") E F
5~10
R0.5 (0.02")

R10
(0.39")

D
C

B
Fig. 32-69 Rod cover fixing jig
Table32-8
Unit : mm (in)
CYLINDER A B C D E F G

70.5 75 75 .3±0.1 80 32 28.5 155

ARM
(2.78) (2.95) (2.965±0.0039) (1.26) (1.12) (6.10)
(3.150 )

60.5 65 65.3±0.1 70 22 28.5 150

BOOM
(2.38) (2.56) (2.571±0.0039) (0.87) (1.12) (5.91)
(2.756 )

55.5 60 60.3±0.1 65 32 28.5 155

BUCKET
(2.19) (2.36) (2.374±0.0039) (1.26) (1.12) (6.10)
(2.559 )

32.2.1.9.6 PISTON (SLIPPER) SEAL FIXING JIG

C MATERIAL : SS400 (JIS)
D

About 12 F
R10
(0.39") G

A
B

Fig. 32-70 Piston (slipper) seal fixing jig

Table32-9
Unit : mm (in)
CYLINDER A B C D E F G
114.5±0.1 116±0.1 105 95 28.0 63 96
ARM
(4.508±0.0039) (4.567±0.0039) (4.13) (3.74) (1.10) (2.48) (3.78)
99.5±0.1 101±0.1 90 80 23.0 63 90
BOOM
(3.917±0.0039) (3.976±0.0039) (3.54) (3.15) (0.90) (2.48) (3.54)
94.5±0.1 96±0.1 85 75 23.0 63 90
BUCKET
(3.720±0.0039) (3.780±0.0039) (3.35) (2.95) (0.90) (2.48) (3.54)

32-32
 32. ATTACHMENT

32.2.1.9.7 PISTON SEAL HOLDING-DOWN JIG

C MATERIAL : SS400

R10
F (0.39")
E
HANDLE
D
G

A About 5~ 10
B

Fig. 32-71 Piston seal holding-down jig

Table32-10
Unit : mm (in)
CYLINDER A B C D E F G
125 133 117±0.1 46 75 10~15 100
ARM
(4.92) (5.24) (4.606±0.0039) (1.81) (2.95) (0.39~0.59) (3.94)
110 118 102±0.1 46 75 10~15 100
BOOM
(4.33) (4.65) (4.016±0.0039) (1.81) (2.95) (0.39~0.59) (3.94)
105 113 98±0.1 46 75 10~15 100
BUCKET
(4.13) (4.45) (3.858±0.0039) (1.81) (2.95) (0.39~0.59) (3.94)

32.2.1.9.8 PIN BUSHING PRESSING JIG

C1 (0.039") MATERIAL : SS400

Inner diameter : A1 A-20 (0.878")

A1

D
C
A
B

(Even if there is not the bore A1,

there is no problem.)
C1 E
(0.039")
F G H
I

Fig. 32-72 Pin bushing pressing jig

Table32-11
Unit : mm (in)
CYLINDER A B C D E F G H I

69.5 84.5±0.1 105 85 5.5±0.1 70 20 10 100

ARM
(3.327±0.0039) (4.13) (3.35) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.736 )

79.5 94.5±0.1 115 95 5.5±0.1 70 20 10 100

ROD SIDE
(3.720±0.0039) (4.53) (3.74) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(3.130 )
BOOM
69.5 84.5±0.1 105 85 5.5±0.1 70 20 10 100
HEAD SIDE
(3.327±0.0039) (4.13) (3.35) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.736 )

64.5 79.5±0.1 100 80 5.5±0.1 70 20 10 100

ROD SIDE
(3.130±0.0039) (3.94) (3.15) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.539 )
BUCKET
59.5 74.5±0.1 95 70 5.5±0.1 70 20 10 100
HEAD SIDE
(2.933±0.0039) (3.74) (2.76) (0.217±0.0039) (2.76) (0.79) (0.39) (3.94)
(2.343 )

32-33
32. ATTACHMENT

32.2.1.9.9 ROD BUSHING PRESSING JIG

MATERIAL : SS400 (JIS)

C1 (0.039")

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

B
A

(Even if there is not the bore A1,

there is no problem.)
C1
(0.039") C D
E

Fig. 32-73 Rod bushing pressing jig

Table32-12
Unit : mm (in)
CYLINDER A B C D E

80 84.8±0.1 30 90 120
ARM
(3.339±0.0039) (1.14) (3.54) (4.72)
(3.150 )

75 74.8±0.1 30 90 120
BOOM
(2.945±0.0039) (1.14) (3.54) (4.72)
(2.953 )

65 64.8±0.1 30 90 120
BUCKET
(2.551±0.0039) (1.14) (3.54) (4.72)
(2.559 )

32-34
 33. UPPER STRUCTURE
TABLE OF CONTENTS

33.1 REMOVING AND INSTALLING.......................................................................................33-3

33.1.1 OPERATOR SEAT .................................................................................................33-3
33.1.2 CAB ........................................................................................................................33-4
33.1.3 BATTERY ...............................................................................................................33-6
33.1.4 GUARD...................................................................................................................33-7
33.1.5 UNDER COVER .....................................................................................................33-14
33.1.6 FUEL TANK ............................................................................................................33-15
33.1.7 HYDRAULIC TANK ................................................................................................33-17
33.1.8 HYDRAULIC PUMP................................................................................................33-21
33.1.9 AIR CLEANER........................................................................................................33-26
33.1.10 MUFFLER...............................................................................................................33-28
33.1.11 COUNTERWEIGHT................................................................................................33-30
33.1.12 RADIATOR & OIL COOLER ...................................................................................33-32
33.1.13 ENGINE ..................................................................................................................33-39
33.1.14 CONSOLE COVER ................................................................................................33-42
33
33.1.15 CONTROL VALVE..................................................................................................33-44
33.1.16 PILOT VALVE (FOR ATT) ......................................................................................33-47
33.1.17 PILOT VALVE (FOR TRAVEL) ...............................................................................33-48
33.1.18 SWING MOTOR UNIT ............................................................................................33-50
33.1.19 SWIVEL JOINT.......................................................................................................33-52
33.1.20 UPPER FRAME......................................................................................................33-55
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-58
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................33-58
33.2.2 CONTROL VALVE..................................................................................................33-78
33.2.3 PILOT VALVE (ATT)...............................................................................................33-109
33.2.4 PILOT VALVE (FOR TRAVEL) ...............................................................................33-119
33.2.5 SWING MOTOR UNIT............................................................................................33-128
33.2.6 SWIVEL JOINT.......................................................................................................33-161

33-1
33. UPPER STRUCTURE

PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.

33-2
 33. UPPER STRUCTURE

33.1 REMOVING AND INSTALLING

33.1.1 OPERATOR SEAT

33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
seat (A1) to ease handling. A1-1

2) Move the whole control stand to its foremost A1

position.
3) Move the operator’s seat to its forward end.
4) Incline the reclining seat as forward as possible. B2

(2) Remove operator’s seat. (Include upper rail.) C1

1) With the above-mentioned condition, remove C2
C1
two cap screws (B2) M8×20 from the upper rail. C2
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8×20.

: 6 mm
2) Remove the operator’s seat. [about 28kg (62
lbs).] 1
7
Carry out the following operations as required.
13
3) Remove seat belt (C1). 10
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (7).

Fig. 33-1 Disassembling and Assembling seat

33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to A4
the tightening torque table.
A5
Allen
Tightening position wrench Tightening torque
HEX (mm) N·m (lbf·ft)
A6
Capscrew (B2) 6 23.5 (17.3) A1
Sems bolt (C2) 17 46.1 (34) A3 A2
Capscrew (A5) 13 23 (17)
Sems bolt (A6) 13 23 (17) A5

Reference : Movement on rail

Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height Fig. 33-2 Disassembling and Assembling armrest
[Up; 23mm (0.07in), down; 37mm (0.16in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]

33-3
33. UPPER STRUCTURE

33.1.2 CAB

33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6×16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×30 and 1 sems bolt (A39) M6×16. And right A3
A14
panels (A4) and (A4-2) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-8) of inside on right A40
A4-8
panel (A4-2). And free the harnesses connected A29
A4
to key switch. A4-8 A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-8
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-2
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-2). (See Chapter 23)
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×45 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2

A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-2), (A3) and (A5-2)

33-4
 33. UPPER STRUCTURE

FUSE & A3
RELAY BOX Front
ASSY

A1

Fig. 33-5 Move switch cover assy

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

2) 2 nuts (B4) M16 (Mark )

(8) Slinging cab
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling with A3
eye rings and a hook around the cab, as shown
in Fig. 33-7.
A1
2) Then lift up slowly avoiding interference with
surroundings.
Fig. 33-6 Removing and installing cab mounting
Wire with hook ;
bolts.
Length 1.5m (4ft 11in)×Dia. 8mm
(0.315in)×3pcs.
Weight of cab ; Approx. 250kg (550 lbs)

33.1.2.2 INSTALLATION
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX(mm)
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 80 (66)
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)

Fig. 33-7 Slinging cab

33-5
33. UPPER STRUCTURE

33.1.3 BATTERY

33.1.3.1 REMOVING
(1) Open panel assy (1).
1) Unlock with starter switch key.
2) Open panel assy (1).
3) Keep panel assy open with stay.
(2) Remove battery cable
1) Remove cable (A4) [between the earth and
battery (–)].
(Always remove (-) terminal first and install it at
last.)
2) Remove cable (A2) [between battery (+) and (-)] 1

3) Remove cable (A3) [between battery (+) and Fig. 33-8 Opening and closing of panel assy (1)
battery relay]
A2
: 13 mm
A3

Follow the battery removal order.

Start removing battery from grounding side, and finish
attaching to grounding side. If this order is missed,
short-circuits may occur. A4

(3) Remove battery (B1) Fig. 33-9 Removing and installing battery cable
1) Loosen nut (A6) M10 and remove cover (A1) and
spacer (A5).
2) Loosen 2 capscrews (A3) M12×200.

: 17 mm
3) Remove plate (A2).
4) Remove battery (B1).

33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing. A1 A6
Hold down plate (A2) against battery (B1), and
tighten capscrew (A3).

: 19 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft) A5

(2) Installing grounding cable A2

Install grounding cable (A4) last. Especially care A3
must be taken that the grounding face is free from B1
painting, rust, etc.

: 13 mm

Fig. 33-10 Removing battery

33-6
 33. UPPER STRUCTURE

33.1.4 GUARD

33.1.4.1 PREPARATION FOR REMOVAL

(1) Remove guard in the following procedure
Remove the guards in the order of (H1) → (H3) → (H2) → (5) → (Set of 3) → (Set of 1) → (20) → (22) → (21)
→ (A1) → (B1) → (33),(34) → (C4) → (C1) → (C3) → (D1) → (C2) → (A12) → (29) → (27) → (E1,E2) → (36)
→ (F1).
34 D1
A1 33
36
C3 H3

E2

H1
5

B1
C2
C4 H2
C1 E1
Fig. 33-11 Arrangement of guard assy

33.1.4.2 REMOVE GUARD

(1) Remove bonnet assy (H1) H1
1) Open bonnet (H1).
2) Remove snap pin (13) from head side of gas
cylinder (11) which is installed reverse side of
bonnet. And remove gas cylinder from bonnet
(H1). (See Fig. 33-15)
3) Remove 2 sems bolts (H5) M12X25.
4) Remove bonnet (H1).
H5
: 19 mm
Weight : 28kg (62 lbs)

Fig. 33-12 Removing bonnet assy (H1)

(2) Remove bonnet assy (H3)
H10
1) Remove 1 sems bolt (H9) M12X30.
2) Remove 2 sems bolts (H10) M12×25.
3) Remove bonnet assy (H3) together with duct H9 A6
assy (H3-2). H3

: 19 mm
Weight : 13kg (29 lbs)

H10

Fig. 33-13 Removing bonnet assy (H3)

33-7
33. UPPER STRUCTURE

(3) Remove bonnet assy (H2) H5

1) Remove 3 sems bolts (H5) M12×25. H2

2) Remove bonnet assy (H2).

H5
: 19 mm

Fig. 33-14 Removing bonnet assy (H2)

(4) Remove bracket (5)
1) Remove 2 capscrews (16) M12×30.
2) Remove bracket (5). 16 10

: 19 mm
13 5
14

13

11

13

Fig. 33-15 Removing bracket (5)

(5) Remove bracket assy (3)
3
1) Remove 3 sems bolts (17) M12×25.
2) Remove bracket assy (3). 7
1
: 19 mm
5
8

17
17
4

2
17 3 9

Fig. 33-16 Removing bracket assy (3)

33-8
 33. UPPER STRUCTURE

(6) Remove cover assy (1) (2) (4) (9), brackt assy (7)
and bracket (8). 17 17
2 1
1) Remove all tightened sems bolts (17) M12X25, X 7
and remove cover assy, guard assy and bracket 7-2
22
in order of following. X

17 17
: 19 mm
4 17 17
a. Remove cover assy (2).
17 17 17 21
b. Remove cover assy (1).
c. Remove guard assy (4). 8 17
17
20
d. Remove cover assy (9).
e. Remove bracket (7).
9
f. Remove bracket (8).
(7) Removing bracket (20), (22) and cover assy (21)
1) Loosen 2 sems bolts (17) M12X25 which fasten
brackets (20) (22). And remove bracket (20),
(22) and cover assy (21) as assembled parts.

: 19 mm

Fig. 33-17 Removing cover assy (1),(2),(4),(9),

bracket assy (7) and bracket (8).
(8) Removing cover assy (A1), (A3), (A4)
1) Loosen all fastened sems bolts (A2) M12X20,
and remove cover assy in the following order. A1
A2
: 19 mm
a. Remove cover assy (A1).
b. Remove covers (A3) and (A4) as assembled
parts.
A3 A2

A5

A2
A4
Fig. 33-18 Removing cover assy (A1),(A3),(A4)

33-9
33. UPPER STRUCTURE

(9) Remove panel assy (B1). B3

B3
1) Remove 6 sems bolts (B3) M12×25. B3
2) Remove panel assy (B1). B1
Weight : 13kg (29 lbs)

: 19 mm
(10)Remove guard assy (33) and (34).
33
1) Remove 3 capscrews (39) M12×25.
2) Remove 3 sems bolts (17) M12×25.
39 39
3) Remove guard assy (33).
4) Remove 2 capscrews (39) M12×25.
5) Remove guard assy (34).

: 19 mm 17 34

Fig. 33-19 Removing panel assy (B1) and guard

assy (33),(34)
(11)Remove cover assy (C4) and panel assy (C1) C15
C4
1) Remove 3 sems bolts (C15) M8×25.
2) Remove cover assy (C4). C8
C15
C1
3) Remove 2 sems bolts (C8) M12×30
C8
4) Remove a sems bolt (C14) M12×35.
5) Remove 2 sems bolts (C9) M12×40.
6) Remove panel assy (C1).

: 13 mm, 19 mm

C14

C9

Fig. 33-20 Removing cover assy (C4) and panel

assy (C1)
(12)Remove fuel tank side panel assy (C3) C3
C10
1) Remove 4 sems bolts (C9) M12×25.
C10
2) Remove 2 sems bolts (C10) M12×20.
3) Remove panel assy (C3).
Weight : 11.5kg (25 lbs)

: 19 mm

C9
Fig. 33-21 Removing panel assy (C3)

33-10
 33. UPPER STRUCTURE

(13)Remove stay (D1)

D1
1) Remove 4 capscrews (D3) M12×60, (D4)
M12×75, (D8) M10×65 and (D9) M16×80. D9
2) Remove stay (D1).
Weight : 12kg (26 lbs)

: 17 mm, 19 mm, 24 mm
D8

D4
D3

Fig. 33-22 Removing stay (D1)

(14)Remove panel assy (C2) and bracket (32) 31 17
1) Remove 2 nuts (C13) M12.
2) Remove panel assy (C2).
Weight : 16kg (35 lbs) 32
17
3) Remove 2 sems bolts (17) M12×25. 17
4) Remove bracket (32) together with bracket (31). 18 28 C13
17 18
Weight : 10kg (22 lbs) C2
29
: 19 mm 18

16
(15)Remove box (29) and bracket assy (27)
1) Remove 2 sems bolts (18) M12×35. 27
18
2) Remove box (29).
3) Remove a sems bolt (18) M12×35 and 3 Fig. 33-23 Removing panel assy (C2), box (29),
capscrews (16) M12×30. bracket assy (27)
4) Remove bracket assy (27) and bracket (28) as
assembled parts.
Weight : 17kg (37 lbs)

: 19 mm

33-11
33. UPPER STRUCTURE

(16)Remove cover assy (E1), (E2)

E1
1) Remove 2 sems bolts (E4) M12×25 for attaching L/H
cover assy (E1), (E2).
2) Remove cover assy (E1). 4
Weight : 18kg (40 lbs)
3) Remove cover assy (E2).
Weight : 18kg (40 lbs)
4
: 19 mm

E2
R/H

E2
4

E1
Fig. 33-24 Removing cover assy (E1), (E2)
(17)Remove cover assy (36) 17
1) Remove 3 sems bolts (17) M12×25.
36
2) Remove cover assy (36).

: 19 mm

17

Fig. 33-25 Removing cover assy (36)

33-12
 33. UPPER STRUCTURE

(18)Duct (F1) removal G12

1) Preparation
a. Remove counterweight. (See 33.1.11) G15
b. Remove hydraulic oil hose which connects to
top of radiator oil cooler. (See Fig. 33-55)
2) Push filter assemblies (G15) in the direction of
24
arrow, and remove them.
3) Remove air cleaner hose (2) (7) and air cleaner
assy (1). (See 33.1.9 AIR CLEANER)
4) Remove battery relay from battery cover. In this
time, disconnect battery relay which has
remained harness connection with the battery
relay.
(See Detail of battery relay of 23.3.6 Electric
System)
5) Remove clip at side of radiator cap and remove
hose (G12) of sub tank.
6) Remove a sems bolt (F9) M12×30, and remove
F12
a capscrew (9) M12×30.
7) Remove 6 capscrews (F12) M8×20. F1

8) Sling duct (F1) to hoist and remove the duct.

Weight : 40kg (88 lbs)

: 13 mm, 19 mm

F9

F11

F12

Fig. 33-26 Removing duct assy (F1)

33.1.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque

Unit : N.m (lbf.ft)

Size Capscrew Sems bolt
M8 35.3 (26) 23 (17)
M10 46.5 (34) 46.5 (34)
M12 121 (90) 80 (59)

33-13
33. UPPER STRUCTURE

33.1.5 UNDER COVER

33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,9)
1) Remove any relevant sems bolts (8) M12×30.
2) Remove covers.

: 19 mm

5
2 1
8
4

1 8 8
1
8
6 8
8

8
3
9
8 8
8

Fig. 33-27 Removing under cover assy

33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,9)

: 19 mm
Tightening torque : 80 N•m (59 lbf•ft)

33-14
 33. UPPER STRUCTURE

33.1.6 FUEL TANK

33.1.6.1 PREPARATION FOR REMOVAL

(1) Draining fuel. (See )
1) Unlock cap (B1) with a starter key and open it.
2) Loosen valve (A8) under the tank.
3) Draining fuel
Capacity of tank : 200L (53gal)
(2) Remove cover assy (36) and guard assy (34).
(See Fig. 33-19)
(3) Remove panel assy (C3). (See Fig. 33-21)
(4) Remove under cover (1),(2). (See Fig. 33-27)
(5) Remove the connector for fuel level sensor (A3).
(See Fig. 33-29)
B
(6) Remove fuel hose A

1) Loosen clip (20),(32) and draw out hoses (11)

and (12). 24
11
20 12
2) Put in plugs that match the hose bore. 24
33 17
16 32
DETAIL A
DETAIL B
Fig. 33-28 Removing fuel hose (11), (12) and
fuel filter assy

33.1.6.2 REMOVAL
(1) Remove 4 capscrews (A2) M16×35. B1
(2) Remove 2 capscrews (A7) M16×55.
A2

: 24 mm
B6
(3) Hook the wire to the lifting eye on the fuel tank assy
(B6) and remove the fuel tank.
Weight : 89kg (196 lbs)
(4) Remove shim (A14).

Record the shim locations. A3

A5

A8 A14

A7
Fig. 33-29 Removing fuel tank

33-15
33. UPPER STRUCTURE

33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A2) M16×35
Tank attaching bolt (A7) M16×55

: 24 mm, Apply Loctite #262

Tightening torque : 191 N•m (140 lbf•ft)

If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim
(A14) and tighten capscrew (A2) to install the tank.

(2) Tightening torque

Tightening torque Tightening torque

No. Name Q'ty N.m (lbf.ft) No. Name Q'ty N.m (lbf.ft)
A2 Capscrew 4 191 (140) A7 Capscrew 2 191 (140)
A5 Machine screw 5 1.96 (1.45) A8 Stop valve 1 34 (25)

When the stop valves (A8) was loosened, replace the seal tape with new one. On the occasion of this work, prevent
entry of dust.

33-16
 33. UPPER STRUCTURE

33.1.7 HYDRAULIC TANK

33.1.7.1 PREPARATION FOR REMOVAL

(1) Remove panel assy (B1), guard assy (33)(34) and
bonnet assy (3).
(See Fig. 33-19 Fig. 33-13.)
(2) Release internal pressure of tank 
Remove cap on air breather and push valve (head
of bolt) by your finger.   


 

Keep pressing until the hissing sound stops.
Fig. 33-30 Bleeding internal pressure of tank
(3) Remove cover (B6).
1) Remove 6 sems bolts (B8) M10×25. B8
B8

: 17 mm B7 B6
2) Remove cover (B6).
3) Remove suction strainer (B1).

(4) Remove cover (B7).

1) Remove 6 sems bolts (B8) M10×25.
B
: 17 mm
2) Remove cover (B7). C
3) Remove filter element (B5). B5
D B1

(5) Turn the handle of element assy (B), and

E
disassemble the removed filter element (B5).
Disassemble parts : (B), (C), (D), (E), (F) F
(6) Draining hydraulic oil
Place pump in tank and drain hydraulic oil.
Capacity of tank : 146 L (39gal)
Hyd.tank

Fig. 33-31 Remove cover (B6), (B7)

33.1.7.2 REMOVAL
(1) Draw out the suction hose (3)
Remove 2 clips (21) of the tank side and pull out
21
hose (3).
3 20
2 : Flat-blade screwdriver

Fig. 33-32 Removing the suction hose

33-17
33. UPPER STRUCTURE

(2) Disconnecting the main pipe return hose

Disconnect return hose (A2). Disconnect hose (A3)
returning to oil cooler.

: 41 mm
A2

C/V
(3) Disconnect pump drain hose (A5) of pump
T2
: 27 mm A3
O/C S/M
OUT DB
(4) Disconnect makeup hose (A4) of swing motor. A5
: 27 mm
PUMP
Dr1 A4
Fig. 33-33 Removing main piping return hose
(5) Disconnecting pilot return hose
1) Remove pilot hose (23).

: 22 mm

2) Remove pilot hose (21).

21
: 22 mm S/V
23 PT T2
T
A23
3) Remove pilot hose (A23).
C/V
: 22 mm Dr

Fig. 33-34 Removing pilot return hose

(6) Remove drain hose (2) of pilot pump PUMP Dr3
2
: 22 mm

Fig. 33-35 Removing pump drain hose

33-18
 33. UPPER STRUCTURE

(7) Remove hydraulic tank attaching bolt

Remove 4 capscrews (A1) M16×50.

: 24 mm
Hyd. tank

(8) Slinging hydraulic oil tank

Place a wire sling, using the lifting plate on top of
the tank.
Tank weight : Approx : 105kg (232 lbs)

(9) Remove shim (A3).

Record the shim locations.

A3

A1

Fig. 33-36 Removing hydraulic tank

33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M16×50.
(See Fig. 33-36.)

: 24 mm, Apply Loctite # 262

Tightening torque : 191 N•m (40 lbf•ft)

If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim (A3)
and tighten capscrew (A1) to install the tank.

33-19
33. UPPER STRUCTURE

(5) Connection of suction hose (3)(See Fig. 33-32) O-RING

1) Apply PERMATEX on pipe side of hose
connection and insert it.
2) Put the hose with clip (21).
Tightening torque : 5.39 N•m (4.0 lbf•ft)
(6) Assembling return element C
Assemble filter element by the use of element kit
(B5-400). (See Fig. 33-31,Fig. 33-37)
D

B1 SUCTION
1. Replace O-ring (C) and packing (F) with new ones
STRAINER
respectively. F

(7) Install return element (B5). (See Fig. 33-31)

ELEMENT KIT
(8) Installing suction strainer (B1)
(9) Tighten sems bolts (B8) M10×25 that attach tank
covers (B6), (B7).
M10 Tightening torque : 46.5 N•m (34 lbf•ft)
Fig. 33-37 Return element & suction strainer

Replace O-ring fitted on the back side of tank cover with

new one.

33-20
 33. UPPER STRUCTURE

33.1.8 HYDRAULIC PUMP

33.1.8.1 PREPARATION FOR REMOVAL

(1) Release pressure in hydraulic oil tank.
B8
(See 33.1.7HYDRAULIC TANK)
(2) Remove six capscrews (B8) M10×25.
B6
(3) Remove cover (B6)
Suction
: 17 mm stopper

(4) Take out suction strainer.

(5) Install suction stopper.
Suction
For suction stopper, see chapter 11. Tools. strainer
(6) Remove counterweight (See 33.1.11)

Hyd.tank

Fig. 33-38 Suction stopper installing

33.1.8.2 REMOVAL
(1) Loosen sems bolts (17) M10×35 and remove half 12
clamp (12). And disconnect 2 hoses (1), (2) from 17 17
the delivery side. C/V
1 12
: 17 mm C/V P1
P2
(2) Remove pilot pump suction hose (A4)
(See Fig. 33-40)

: 36 mm
(3) Remove suction hose (3) and drain hose (A5) 2 PUMP
1) Remove 4 capscrews (A15) M12×30. B1

: 10 mm
2) Remove elbow (A6) of suction hose (3) from A15
pump.
3) Remove drain hose (A5). A2
A6
: 36 mm 21
3
20

A5

TANK

Fig. 33-39 Removing and installing of suction and

delivery hose

33-21
33. UPPER STRUCTURE

(4) Removing other hoses A2

1) Disconnect hoses of the following ports. A1

Hose Tool
Port No. Remarks A3
(mm)
Dr3 A2 22 Drain
Dr3
PSV1 A3
*Psv1 A1 22 Pilot primary pressure P1 side
S/V
Psv1 A3 22 Pilot pump delivery P1

Remove the parts marked * only if necessary. B3

2) Attach tags to hoses to identify.

3) Put a plug in the hoses and the pump. B1

A4

Fig. 33-40 Removing other hoses

(5) Remove connector     ! "##$%
Remove 4 connectors of all pressure sensors and # "& !# " ! #$# "#'
proportional valves.
  (  


 


 

   

  
 
 
  

  
 

 
  
(    1
 )* ) 
+ ,',' -.'. /&'&0
Fig. 33-41 Removing connector

33-22
 33. UPPER STRUCTURE

(6) Remove main pump 3 0

1) Put a wire sling on the hydraulic pump and
tension the wire sling a little. Loosen 8
capscrews (4) M10×30.

: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of
the wire rope. 4
On that occasion, the assembly is drawn out with
the insert NA (2-3) remaining on the flywheel 3
side.
2-6
3) Remove element (2-1) from the tip of the spline 2-4
shaft.
4) Remove 4 capscrews (2-6) M16×45 that fasten
insert R (2-4) and remove insert R (2-4). 2-7

: 14 mm 2-2
5) Remove hub (2-2)
2-5
If you loosen 2 set screws (2-7) M16×18, hub
2-3 1
comes off from the spline shaft of the pump. 2-8 2-1
: 8 mm Fig. 33-42 Removing pump
6) Remove 4 capscrews (2-5) M16×55 that fasten
the insert NA (2-3) with the engine side flywheel,
as necessary. Then remove and spring pin (2-8)
from insert NA (2-3).

: 14 mm
7) Removing bracket (1)
Loosen 2 capscrews (3) M16×50, and remove
bracket (4) from pump (0).

33-23
33. UPPER STRUCTURE

33.1.8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install
bracket temporarily.

: 14 mm
Tightening torque : 191 N•m (141 lbf•ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 5mm
(0.12in) from the end face of the spline (See Fig.
33-43 Detail aa). Then install two set screws (2-7)
and fix them together.

: 8 mm
Tightening torque : 110 N•m (81 lbf•ft)
(3) Installing insert R (2-4)
Install insert R (2-4) into hub (2-2) by means of
capscrews (2-6).

: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)
(4) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (2-4).
(5) Installing insert NA (2-3)
Put spring pin (2-8) into insert NA (2-3) and install it
to the engine flywheel by means of capscrews (2-
5).

: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)

(See Fig. 33-42 about above mentioned (1) ~ (5).)

33-24
 33. UPPER STRUCTURE

(6) Installing the pump (See Fig. 33-42,Fig. 33-43)

Lift the pump with bracket (1). Place coupling (2) in
the groove of element (2-1) so as to receive insert
2-6
NA (2-3). 2
(7) Coat 8 capscrews (4) M10×30 with Loctite #262
and put them in place.
aa
: 17 mm
Tightening torque : 64.7N•m (48 lbf•ft) 2-7
T=110N.m (81 lbf.ft)
(8) Fasten hoses (1), (2) on the delivery side with half
clamp (12) and sems bolt (17) M10×35. 2-8 3
SPRING PIN
(4 places) T=191N.m (141 lbf.ft)
(See Fig. 33-39) 1
Apply Loctite #262
T=220N.m (162 lbf.ft)
Do not use Loctite
: 17 mm (The attached bolts are coated
with micro capsule coating) 4
Tightening torque : 57N•m (42 lbf•ft) T=64.7N.m (48 lbf.ft)
Apply Loctite #262
(9) Install suction hose (3) with 4 capscrews (A15)
M12×30. (SeeFig. 33-39) 4
5
: 10 mm (0.197")

Tightening torque : 66.7 N•m (49 lbf•ft)

(10)Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
50 (1.97")
(11)Installing the hose (See Fig. 33-40) DRAIN HOLE (Bottom)
DETAIL aa VIEW I

Port Tool Tightening torque

(mm) N m (lbf ft)
Fig. 33-43 Installing hydraulic pump
Cap nut Dr3 22 49 (36)
Cap nut Psv1 22 49 (36)
Cap nut B3 36 118 (87)

(12)Installing pressure sensor connector and

proportional valve connector.
(13)Remove suction stopper
(14)Install suction strainer

When the pump is replaced, replenish more than 1L

(0.26gal) of hydraulic oil from the drain port (Dr).

(15)Bleed air in pump

Dr
Bleed air by loosening the drain port (Dr).
(16)Check hydraulic oil level.
(17)Start engine and check it for oil leak and noise.
(18)Attach drain down pipe under engine muffler.
(19)Install counterweight.
(See 33.1.11)

Fig. 33-44 Bleed air port (Dr) in pump

33-25
33. UPPER STRUCTURE

33.1.9 AIR CLEANER

33.1.9.1 PREPARATION FOR REMOVAL

(1) Open bonnet assy (H1).
(See 33.1.4 GUARD)
(2) Open cover assy (E1).
(3) Remove 2 filters in front of radiator (G15).
(See Fig. 33-26)
(4) Unplug terminals on indicator (1-8) wiring.
(See Fig. 33-46)

Fig. 33-45 Preparation for removal

33.1.9.2 REMOVAL
(1) Pulling out hose (2).
1) Loosen clips (7), (8) on both sides of hose (2).
2) Pulling out hose (2)
: Flat-blade screw driver
dd
(2) Pulling out hose (4).
1) Loosen clip (8) on hose (4).
2) Pulling out hose (4).
: Flat-blade screw driver 3
(3) Remove air cleaner assy (1)
B
1) Loosen 4 sems bolts (12) M8×16
4
: 13 mm aa 1
2) Remove air cleaner assy (1) from bracket. 1 4

8
2
Alowance for
inserting hose 8

7 9
Fasten item 7 clip
in the drawing direction
TIGHTENING TORQUE : CLIP
RUBBER 5.9N.m (4.35 lbf.ft) Fasten item 6 clip
in the drawing direction
After connection of TIGHTENING TORQUE :
hose to tube, paste 5.9N.m (4.35 lbf.ft)
rubber to duct.
cc
Alowance for DETAIL aa INDICATOR
inserting hose
TIGHTENING TORQUE :
25 (0.98")
25
(0.98")

17.5N.m (12.9 lbf.ft) 4 places

Alowance for
inserting hose

30
(1.18")
(2)
Alowance for
inserting hose
CLIP
Fasten item 10 clip
CLIP in the drawing direction
Fasten item 8 clip in the drawing direction TIGHTENING TORQUE :
TIGHTENING TORQUE : 5.9N.m (4.35 lbf.ft) 5.9N.m (4.35 lbf.ft)
DETAIL cc DETAIL dd
VIEW B
Fig. 33-46 Removing air cleaner

33-26
 33. UPPER STRUCTURE

33.1.9.3 INSTALLATION
(1) Installing is the reverse order of removing with REPLACING PARTS
attention paid to the following items:
ELEMENT ASSY, OUTER (1-3)
1) Put in air hoses (2), (3) to the end as shown in (YY11P00008S003)
Fig. 33-46.
ELEMENT ASSY, INNER (1-2) O-RING (1-6)
2) Tightening torque :
(YY11P00008S002) (YY11P00008S006)

No. Name Tightening torque N.m (lbf.ft)

1-8 Indicator 3.9 (2.9)
6,7 Clip 5.9 (4.4)
9 Sems bolt 17.5 (12.9)

33-27
33. UPPER STRUCTURE

33.1.10 MUFFLER

33.1.10.1 PREPARATION FOR REMOVAL

(1) Remove bonnet assy (A3) with exhaust tube (20).
(See Fig. 33-13)
A3

Fig. 33-47 Preparation for removal

33.1.10.2 REMOVAL
(1) Remove hose (5).
12
1) Loosen clip (11) and remove hose (5). 13
(2) Remove U-bolt (4).
1) Remove 4 nuts (10) M8.

: 13 mm
2) Remove 2 U-bolts (4).
(3) Remove clamp assy (3)
1) Remove 2 capscrews (7) M10×35

: 17 mm 4
1
2) Separate clamp assy (3) from muffler (1).
(4) Removing other parts
1) Remove brackets (2) as necessary. 10
11
: 17 mm A 7
2) Remove exhaust tube (20) as necessary. 3
5 aa
: 17 mm A 6
8,9
Tightening torque: 68.6~98 N.m (51~72lbf.ft)
Tighten nut (11) till the no gap is here between
plates of clamp. 10
7 8 9
7,8,9 B
10mm (0.4 in) from
the tip of muffler slit

m
fro
in)
0 .8 lit
4~ s
3 B (0. ffler
0 mm f mu
1 o B
DETAIL aa 5~ e tip VIEW BB
th
C
A Procedure of fastening U-bolt

Fig. 33-48 Removing and installing the muffler

33-28
 33. UPPER STRUCTURE

33.1.10.3 INSTALLATION
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-48)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
(Decide C dimension after checking the piece-to-
piece variations in related parts.)
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (3)
1) Place the end of clamp (3) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-48)
2) Install the clamp assy (3) in the illustrated
direction.
(3) Tightening torque :

No. Name Tightening torque N.m (lbf.ft)

6 Sems bolt 64.7 (47.7) (Apply Loctite #262)
13 Sems bolt 39.2 (28.9)

(4) Replacing parts

Name Part No.

Muffler (1) YY12P00012P1

33-29
33. UPPER STRUCTURE

33.1.11 COUNTERWEIGHT

33.1.11.1 PREPARATION FOR REMOVAL

(1) Removing bonnet assy
Remove bonnet (B1) located at upper of engine.
(See Fig. 33-12)
(2) Remove dumper bracket (A17).
(See Fig. 33-15)
(3) Remove covers (A3), (A9).
(See Fig. 33-13, Fig. 33-14)
(4) Installing of lifting jig
Remove plugs (A5) from counterweight, and install
right and left jigs (Refer to Chapter 11. Tools) for
lifting to counterweight.
Fig. 33-49 Lifting up counterweight
: 75 mm

33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily A1
Hook wire rope to lifting jig, and lift it and stretch A5
wire rope to the degree where it is providing no
A3
slack temporarily. A1
Weight of counterweight ; C11
A5
Approx. 6,240kg (13,760 lb) C3
Wire more than ø16 (0.63 inch) ;
1.5m (5ft)×2 pcs. B1

(2) Removing counterweight

1) Remove 4 capscrews (A1) M36×300.
C1
: 55 mm C2
2) Remove shim (A3), (A4). (Select) A1 A1
A2 A2 ADDITIONAL
3) Remove counterweight (C1). COUNTERWEIGHT

(3) Removal of additional counterweight (Optional Fig. 33-50 Removing counterweight

weight)
1) Attach 2 eye bolts to additional counterweight in
the same way of standard counterweight and
hoist it temporally.
Additional counterweight ; 585 kg (1,290 lb)
2) Loosen 3 capscrews (C1) M20×135 and remove
counterweight (B1).

: 30 mm

33-30
 33. UPPER STRUCTURE

33.1.11.3 INSTALLATION
(1) Install counterweight in the reverse order of
removing. A1
(2) Slinging counterweight A5
Check that the 4 attaching bolts can be screwed in
by hand.
A4
(3) Apply Loctite #262 on capscrews (A1), and tighten
them with washers (A5).

: 41 mm
Tightening torque : 1270 N•m (937 lbf•ft)
(4) Remove lifting jigs, and attach plugs (A3).
A1
(5) Installation of additional counterweight (Optional A2
weight) Fig. 33-51 Fastening the counterweight attaching
1) Apply Loctite #262 to capscrews (C1) and capscrew
tighten them with washers (C2).

: 30mm
Tightening torque : 490 N•m (362 lbf•ft)
2) Loosen eye bolts and attach plugs (C3).

33-31
33. UPPER STRUCTURE

33.1.12 RADIATOR & OIL COOLER

33.1.12.1 PREPARATION FOR REMOVAL

(1) Bleed air from the hydraulic tank and install the
suction stopper.(See 33.1.7, and 33.1.8)
(2) Remove counterweight.
(See 33.1.11)
(3) Remove duct assy (F1). (See Fig. 33-26)
(4) Removing under cover installed on lower side of
radiator.
Remove under cover (1),(6),(9). (See Fig. 33-27)
(5) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose
for draining water.
[Water capacity of radiator : 6.6L (1.7gal)]

Do not loosen the joints of the hoses related to the air-

conditioner. Otherwise the refrigerant leaks.
RECEIVER 23
DRYER
(6) Move air-conditioner condenser and receiver tank
8
1) Loosen 6 sems bolts (23) M8×25. 23
: 13 mm 7
2) Move a set of air-conditioner condenser and
17
receiver dryer.
25
14
19
AIR-CON CONDENSER

Fig. 33-52 Moving condensers and receiver dryer

33-32
 33. UPPER STRUCTURE

33.1.12.2 REMOVAL
(1) Remove radiator stay (B1), (B4).
1) Remove 4 sems bolts (B2) M12×30.
A1
: 19 mm B2
2) Remove 2 stays (B1), (B4).
B4
(2) Remove water hose (2),(3)
1) Loosen the 2 hose bands (17) for water hose (2). B2

: Flat-blade screwdriver B2

2) Remove hose (2).

B1
3) Loosen 2 hose band (17) on water hose (3). B3
: Flat-blade screwdriver
4) Remove hose (3).
B3 B2

Fig. 33-53 Removing radiator assy

(3) Remove hoses (4)(5)(6) for inter-cooler 4
1) Remove a fixing U-bolt (19) from tube (7). 18
17 2 18
: 13 mm
17
2) Loosen sems bolt (21) M10×25. 20 17 B C 17
9 F
20 11 20
G 5
: 13 mm 17
E
3) Loosen tow hose bands (18) and remove hose 19
(4). 21
3 D
: Flat-blade screwdriver 8 7
17
4) Loosen hose bands (17),(18) and remove hose 17
(6). 6
18
: Flat-blade screwdriver
F
5) Loosen 2 hose bands (24) and remove hose (5). B

: Flat-blade screwdriver
G
(4) Remove guard (8), (9) (See Fig. 33-54)
1) Remove 4 sems bolts (20) M8×20. C

E
2) Remove guard (8), (9).
D

: 13 mm

Fig. 33-54 Removing hose for radiator/inter-cooler

33-33
33. UPPER STRUCTURE

(5) Disconnecting hydraulic oil tube (A8), (A9)

A21
1) Loosen 2 capscrews (A16) M12×55 for attaching
clamp (A17). A16
A17
2) Place an oil pan under the hose joint. Loosen 4
sems bolts (A21) M12×35, and remove hoses A9
(A8) and (A9).
(6) Remove radiator assy. (See Fig. 33-53)
A3
1) Remove 4 sems bolts (B3) M12×25.

: 19 mm
TANK
: 19 mm
2) When lifting the engine fan, shift the radiator so A21
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc. A8

4) Removing radiator C/V

T1
Place a wire sling in the lifting eyes of the radiator A17
A16
assy and remove the assy by crane.
Weight : 74kg (163 lbs) Fig. 33-55 Removing hydraulic oil tube (A8), (A9)

33-34
 33. UPPER STRUCTURE

33.1.12.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Adjust the engine fan so its rear end
sticks out 32 5mm (1.3 0.2 in) from
And removed clips of hose should be clamped at the radiator shroud.
original position. 32 5 (1.3" 0.2")

(2) Install radiator assy B4

Place a wire sling in the lifting eyes of the radiator
and move it to original position temporally. And
install hydraulic hose, radiator hose and hose of
inter-cooler. Regarding Inserting width of hose.
(See Fig. 33-57)
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A3) M12×35.

: 19 mm
Tightening torque : 121 N•m (89 lbf•ft)
(4) Installing radiator stays (A1), (A2)
Install radiator stays (A1), (A2) with 4 sems bolts B2 B3 B1 B2
TIGHTENING TIGHTENING TIGHTENING
(A3) M12×35. TORQUE
120.6N m.
TORQUE TORQUE
120.6N m (88.9 lbf ft) 120.6N.m (88.9 lbf.ft)
. .
Tighten circular hole side of stay (A1) to upper (88.9 lbf.ft) Apply Loctite # 262
or equivalent.
frame. 4 places

(5) Adjust the clearance between the fan and the The clearance between the fan and the radiator shroud should
be 20 5mm (0.79 0.2 in) along all circumferences.
radiator shroud all around the circumference, as
below :
Circumferential direction:
20±5mm (0.8in±0.2in)
32±5mm (1.3in±0.2in)

)
.6"
(6) Clean the plastering area of the insulation 23
0(
60

thoroughly before plastering it.

ia.
nd
Fa

(7) Making up hydraulic oil and LLC (Long Life

Coolant)
After completion of other installation, make up
hydraulic oil and water.
Coolant volume of engine body : 6 L (1.6gal)
Coolant capacity of radiator : 6.6 L (1.7gal) Fig. 33-56 Adjusting position of radiator
Hydraulic oil capacity of oil cooler : 2.1 L (0.55gal)

33-35
33. UPPER STRUCTURE

dd

cc

Fasten hose by clip

of guard.

Fasten hose by clip

bb of guard.

Fasten hose by
clip of guard
11 WATER SUB TANK ASSY HOSE
Fasten clip in the direction of drawing.
Tightening torque : 5.9N.m (4.35 lbf.ft)
17

4
27
(1.06") Fasten clip in the 18
50 direction of drawing.
(1.97") Tightening torque :
5.9N.m (4.35 lbf.ft)
Allowance for 21

(1.77")
(1.57")
inserting hose Tightening torque : 6 Allowance for

45
39.2N.m (30 lbf.ft) 7 17 inserting hose 40
Apply Loctite #262. Fasten clip in the direction of drawing. Allowance for
Tightening torque : inserting hose
VIEW III 5.9N.m (4.35 lbf.ft) 18
Fasten clip in the direction of drawing. Fasten clip in the
Tightening torque : 5.9N.m (4.35 lbf.ft) direction of drawing.
Tightening torque :
18 5.9N.m (4.35 lbf.ft)
3
6 2
(1.77")

Allowance for
(1.57")
45

inserting hose DETAIL bb 17

40

Fasten clip in the direction of drawing.

Fasten clip in the direction of drawing. Tightening torque :
Allowance for Tightening torque : 5.9N.m (4.35 lbf.ft)
inserting hose 17 Fasten clip in the direction of drawing. 5.9N.m (4.35 lbf.ft)
Tightening torque : 17
5.9N.m (4.35 lbf.ft)

VIEW IV

Fasten clip in the direction of drawing. 5 DETAIL cc

17 Tightening torque : 20 Tightening torque :
5.9N.m (4.35 lbf.ft) 19.6N.m (14.5 lbf.ft)
SECTION DD

Allowance for
inserting hose
D 35 (1.38")

Allowance for
inserting hose 3
(1.57")

(1.9
50
7")
40
40
(1.57")

Allowance for Allowance for

inserting hose inserting hose
D
2
4
6
VIEW V VIEW VI DETAIL dd

Fig. 33-57 Allowance of hose insertion

33-36
 33. UPPER STRUCTURE

33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE

(1) Preparation for disassembly and assembly
28 28 19
1) Remove one under cover (1), (9) at the bottom of
the radiator.
(See Fig. 33-27)
2) Wait till the engine coolant cools down so you do
not get burned. Then remove the cap of the
radiator, drain the coolant by opening the drain
valve located at the lower of engine and receive
it in a container. 1 19 17
* In case of removing inter cooler only, the above
2
mentioned work is not necessary.

(2) Disassembly
1) Loosen each 6 capscrews (19) at head and
bottom of shroud, remove upper plate (17) and
lower plate (18).
2) Loosen 2 sems bolts (28) M10×30 attaching
radiator core.
3) After confirming that the coolant has been
A
drained out completely, loosen and remove only
the radiator side of hose bands (17) at the top
and bottom of the radiator. (See Fig. 33-54)
4) Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Weight : 13kg (29 lbs)
Confirm the missing of rubber bushing (27)
under the radiator core.
5) Loosen 2 sems bolts (28) M10×30 attaching the
DRAIN VALVE
top of the inter-cooler core.
6) Loosen and remove only the inter-cooler side of
hose bands (18) at the top and bottom of the 27
inter-cooler. (See Fig. 33-54)
MOUNTING OF
7) Lift and remove inter-cooler using lifting eyes and RADIATOR CORE FOOT
hoist on the inter-cooler.
Weight : 4.8kg (11 lbs)
Confirm the missing of rubber bushing under the
inter-cooler.

19

18

VIEW A

Fig. 33-58 Removing radiator and inter-cooler

33-37
33. UPPER STRUCTURE

10) Disconnection of oil cooler tube

Disconnect tube (A8), (A9) from upper and lower
of cooler, and drain hydraulic oil. (See Fig. 33-
55)
11) Lift cooler temporally using cooler head flange
for slinging.
12) Loosen 4 bolts (19) M8×25 attaching oil cooler.
13) Lift the oil cooler.

There is no predetermined sequential order in

removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as
necessary.

(3) Installing
Installing is done in the reverse order of removing.

33-38
 33. UPPER STRUCTURE

33.1.13 ENGINE

33.1.13.1 PREPARATION FOR REMOVING

(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1) Remove E/G ground cable
2) Starter cable-Starter B terminal
3) Remove the connector that connects the upper harness with the engine and ECU harness.
4) Upper harness
CN-206-E/G sub harness
P1,P8-Alternator B terminal
CN-136-E/G speed sensor
CN-141, CN142-Pump proportional valve
CN-139, CN-140-P1,P2 pump pressure sensor
P5-Glow
P6-Starter motor B terminal

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)

OIL FILTER
ELEMENT

THERMOSTAT
STARTER

ALTERNATOR
Fig. 33-59 Outside view of engine

33-39
33. UPPER STRUCTURE

33.1.13.2 REMOVAL

9
A
10
9
7 10

4
7
2
6 4
5
3
4
9 9
10 10 4
8
7 8
7
4
4
1
9
5 2 11
A
4 6 4

8 8

Fig. 33-60 Dismantling and mounting engine

(1) Loosen engine mounting bolt of flame
1) Loosen a nut (11) M18 and 2 capscrews (10) M18×150.

: 27 mm
2) Loosen 3 other capscrews (10) M18×150 and remove them.

: 27 mm
3) Remove each 4 plates (7).
4) Remove upper rubber mounts (4) 4 each.
(2) Slinging engine body

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)

1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 400 kg (882 lbs)
Wire: ø6 (0.236")×1m (3ft 3in) - 2pcs.
(3) Position engine on the stand stably.

33-40
 33. UPPER STRUCTURE

33.1.13.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Tightening torque

Tightening torque
No. Name Remarks
N.m (lbf.ft)
Apply Loctite
5 Sems bolt 115 (84.8) #262
Apply Loctite
6 Sems bolt 115 (84.8) #262
Apply Loctite
10 Capscrew 226 (167) #271

33-41
33. UPPER STRUCTURE

33.1.14 CONSOLE COVER

33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
: Flat-blade screwdriver
2) Loosen 3 sems bolts (A5) M6×16.

: Plus screw driver
3) During lifting right upper console cover (A4-5) 
up; disconnect connector of tuner and antenna. 
 

Move boot (3) upwards and remove console
cover (A4-5).
• Removing of boot and lever is unnecessary. Fig. 33-61 Removing plate (4)
4) Loosen 3 sems bolts (15A) M6×16 and remove A5
lower console (3). A4-5
: Plus screw driver A5

(2) Removing left-hand console cover 15A

15B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 4X 15B 3 15A
61) 15B
: Flat-blade screwdriver
15C
2) Loosen 4 sems bolts (15B) M6×16.
: Plus screw driver
5X
3) Remove the left upper console cover (4X) in the
same way as right-hand console cover.
4) Loosen 2 sems bolts (15C) M6×16 while lifting
left under console cover (5X) up, and remove left
lower console cover.

Fig. 33-62 Removing console covers

33.1.14.2 INSTALLATION
Install it in reverse order of removing according to the
tightening torque table.
)$
Item Bolts Tightening torque N.m (lbf.ft)

15A~15C Sems bolt M6 5.0 (3.7)

A5 Sems bolt M6 5.0 (3.7)
A6 Sems bolt M8 23.5 (17.3)

Fig. 33-63 Removing left armrest

33-42
 33. UPPER STRUCTURE

This page is blank for editing convenience.

33-43
33. UPPER STRUCTURE

33.1.15 CONTROL VALVE

33.1.15.1 PREPARATION FOR REMOVING

(1) Remove cover assy (B1)
(See Fig. 33-19) 1

(2) Remove plate (C4), panel assy (C1).

(See Fig. 33-20)
(3) Remove panel assy (C13), bracket (31), box (29).
(See Fig. 33-21) 4 4
(4) Install the suction stopper to the hydraulic oil tank.
(5) Remove the hoses in Fig. 33-65 and Fig. 33-66.

Mark each hose with a port name before removing it. 2

Fig. 33-64 Removing the standard main control

valve

33.1.15.2 REMOVAL
(1) Remove 3 capscrews (4) M16×45, and remove
control valve (1) by hoist.

: 24 mm
Weight :Approx. 155kg (342 lbs)

33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 3 capscrews (4) M16×45.

: 24 mm
Tightening torque : 235 N•m (173 lbf•ft)
2)

Connector / Bolt Hose nut

Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
PF1/4 Pss,PLc2,PBp1,PBp2,(PL), ORS Joint 19 36 (27) 19 29 (21)
PB1,PTb,PCa,PCb
PF3/8 PAa1,PBa1,Pab,PBb,Pac, 22 74 (55) 22 49 (36)
PBc,PAL,PBL,Par,PBr,Pas,
PBs,PAa2,PBa2,Pao,Pbo,DR
PF3/4 (MU1), (MU2), Ab, Bb, Ao, Bo 36 162 (119) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc
M10 P1,P2 Sems bolt 14 57 (42)
M12 T1,T2 17 96 (70)

(2) Check for oil leak and operation.

33-44
 33. UPPER STRUCTURE

Functions Ports Ports on right front sides (on machine) Ports Functions

PBp1 P1 bypass cut

P2 bypass cut PBp2 PAa2 Arm 2 in
Option PAo Mu Make-up line
Bucket (R) relief valve
Arm (H) relief valve
PBC Bucket out
Arm 1 out PBa1
XAb Emergency manual valve drain
Swing (LH) PBs PBb Boom down
Boom (H) relief valve
Boom conflux PB1
PAr Travel right forward
Travel left forward PAL
Main relief valve
Tank return T2 Mounting surface PCb P1 unload
Ports on rear left sides (on machine)

Arm 2 out PBa2 LEFT RIGHT PBo Option

Bucket digging PAc Arm (R) relief valve

Bucket (H)relief valve PLc2 Arm in lock valve

Boom(R)relief valve PBa1 Arm out

Boom up PAb PAs Swing right

Travel right reverse PBr PCa P2 unload

Travel straight PTb PBL Travel left reverse

Mounting surface
Ports on bottom sides (on machine)
LEFT RIGHT

P2 pump P2

P1 pump P1

Fig. 33-65 Control valve ports (1/2)

33-45
33. UPPER STRUCTURE

Function Ports Ports on left side (on machine) Ports Function

FRONT REAR
Bucket dump BC SIDE SIDE

Boom up Ab AC Bucket digging

Bb Boom down

Emergency manual valve drain XAb BR Travel right reverse

Travel right forward AR

Mounting
surface

Ports on right side (on machine)

REAR FRONT
SIDE SIDE
Option Bo Ao Option

Aa Arm 1 out

Arm 1 in Ba Pss Swing low pressure sensor

Swing left Bs As Swing right

Travel left reverse BL Dr Drain

AL Travel left forward

Mounting
surface
T1 Tank return

Fig. 33-66 Control valve ports (2/2)

33-46
 33. UPPER STRUCTURE

33.1.16 PILOT VALVE (FOR ATT)

33.1.16.1 PREPARATION FOR REMOVING

The removing procedure for right and left is the same,
so the preparation for left side is described here.
(1) Put attachment on ground, stop engine and release
pressure in tank.
(2) Remove left console cover (4X), 5X) assy referring
to Section 33.1.14CONSOLE COVER.
3
(3) Disconnect harness connector for horn at 2-1
position.
5
(4) Attach a tag to the hose to make assembly work
easier. *

Fig. 33-67 Installing and removing boot and lever

part

33.1.16.2 REMOVAL
(1) Remove hoses from your side to far side in order. !
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-67)
 
: 22 mm

 
  
 
 
(3) Turn and loosen lever (2-1) tightened in pilot valve,        
and remove lever assy in a set. (See Fig. 33-67) *+, *!+
%& '
( ""'

(4) Remove 4 capscrews (A14) M6×25. (See Fig. 33- % '  ""'

68) % ' !

: 5 mm -%. /*/
(5) Remove pilot valve. *+, *!+
(6) Plug hose ends. " ## 
Plug PF1/4, PF3/8 )' '
( $
 
 
! 01 0 " ## 
Fig. 33-68 Pilot valve connector

33.1.16.3 INSTALLATION
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Swing (R)
Bucket (R)
(Blue)
(Red)
Swing (L)
(Gray)

Make sure the tightening torque for capscrews, Bucket (H) P

(Red)
because pilot valve is made of aluminum. Arm (H) (Blue) P
Boom (H) (Green)
LEFT SIDE RIGHT SIDE
Fig. 33-69 Pilot valve port position (from upper
side)

33-47
33. UPPER STRUCTURE

33.1.17 PILOT VALVE (FOR TRAVEL)

33.1.17.1 PREPARATION FOR REMOVING

(1) Release pressure in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (3) (See 33.1.5 UNDER
COVER)
A1
(3) Remove floor mat (B1). A8
A2 A7

A6
A7
A5

B1

A8

Fig. 33-70 Removing floor mat, pedal and and lever

33.1.17.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and A12
A9
SE-10 (A9) at the connector. A1
T : Tightening torque
: 24 mm N.m (lbf.ft)
SE-9
(2) Attach tag, and discount connectors and hoses 6
(A2), (A3), (A4), (A5) T=16.7 (12)
A9 5 T T=30 (22)
: 19 mm (P port) P
A2

: 19 mm, 22 mm (T port, 1~4 port)

3 A5
SE-10 PT
A2 PT T
(3) Plug hose ends C/V P
T=30 (22) 4
Plug PF1/4, PF3/8 PBr
A3
1
(4) Remove 4 sems bolts (A8) M8×20, and remove
2
C/V C/V
right and left pedals (A5), (A6). Opposing PAL
PAr
A5
PF3/8 flats 22 C/V
: 13 mm PF1/4 PAL
A3
(5) Remove 4 sems bolts (A7) M10×20 and remove
right and left lever (A1), (A2).
VALVE SIDE HOSE SIDE
: 17 mm
VALVE SIDE T PORT CONNECTOR
(6) Remove 4 sems bolts (A12) M10×30.
PF3/8
Opposing Opposing
: 17 mm flats 22 flats 19 Mark "F"
(7) Remove pilot valve lifting it upward. PF1/4 PF1/4 PF1/4
(8) Stop up holes with plugs PF1/4.
HOSE SIDE
PORT P PORT CONNECTOR
CONNECTOR (With filter)

Fig. 33-71 Installing and Removing pilot valve

33-48
 33. UPPER STRUCTURE

33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it.
Sems bolt (A12)

: 17 mm T = 37 N•m (27.3 lbf•ft)

Sems bolt (A7)

: 17 mm T = 46.1 N•m (34.0 lbf•ft)

Sems bolt (A8)

: 13 mm T = 23.5 N•m (17.3 lbf•ft)

Pressure sensor

: 24 mm T = 16.7 N•m (12.3 lbf•ft)

33-49
33. UPPER STRUCTURE

33.1.18 SWING MOTOR UNIT

33.1.18.1 PREPARATION FOR REMOVING

(1) Park machine on firm level ground and place C/V A6
attachment on ground. AS
C/V
(2) Remove bracket (5) for engine bonnet gas damper. 20 T3
(See Fig. 33-15) C/V
BS
(3) Remove top cover of swing motor and guard assy C
A4 A7
(1), (2), (4), (9), (7), (8). (See Fig. 33-17, Fig. 33-18) 21
B

(4) Operate the switch on gauge cluster and select the TANK
A
pressure release mode, and then release the inner S/J
pressure in circuit by operating control lever. (See DB
E
22.11 HYDRAULIC SYSTEM PRESSURE
DRAINING(RELEASING) CIRCUIT)
(5) Bleed air from the hydraulic oil tank and attach to PG
each hose a tag showing port name and other
information. 18
S/V
A2
Fig. 33-72 Removing swing unit piping

33.1.18.2 REMOVAL
(1) Remove hose. 1
1) Remove hose (A6) from the connector in the HYD. VALVE
makeup port C. VIEW A

: 36 mm 9
2) Remove hose (3), (4) from the elbow in the pilot C/V
pss
port pi1, pi2.
P/T
: 27 mm P
3) Remove hose (2) from the Hyd. valve in the pilot
port B.

: 19 mm
4) Remove hose (A4), (A7) from the elbow in the
drain port Dr.
4
: 27 mm
5) Remove hose (18) from the elbow of the PG port
2
(For swing parking brake)

: 19 mm
6) Remove 2 hoses (21), (22) from the connectors
of the A, B port.

: 32 mm
Put in plugs PF3/4, PF1/2, PF3/8 and PF1/4 into
3 C/V
the removed ports. pss
VIEW A

33-50
 33. UPPER STRUCTURE

(2) Removing the swing unit

2
1) Loosen clip (5).
2) Remove 9 capscrews (7) M20×55.
3
: 30 mm
3) Remove two plastic caps (2) M10 at the top of
the swing motor and install eye bolts.
7
: Flat-blade screwdriver
4) Put a wire sling in the eye bolts and remove the
swing motor unit.
Weight of swing motor unit ; 5 1
Approx. 113kg (249 lbs) (Include reduction assy)
5
Fig. 33-73 Removing swing unit

33.1.18.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.

33.1.18.4 INSTALLATION
Install the swing motor unit in the reverse order of
disassembly, confirming the orientation of the swing
motor unit.
(1) Tighten 9 capscrews (7) M20×55.

: 30 mm
Tightening torque : 539N•m (400 lbf•ft) Apply
Loctite #262
(2) Fill inside from motor drain port to casing with
hydraulic oil before piping for drain

Apply Loctite #262 LEVEL GAUGE

Tightening torque :
539N.m (400 lbf.ft)
TUBE
7 9 PLACES
Put sealing tape on the both
sides of thread portion of
filling tube.
Fix drain hose with the plug at Tightening torque :
the end of drain hose over the 1 108 N.m (80 lbf.ft)
hole of upp frame bottom plate.

Coat all the mounting surface of

the swing motor with Loctite #515
equivalent.
DETAIL OF SWING MOTOR
UNIT ASSY MOUNT
Fig. 33-74 Installing swing motor unit

33.1.18.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient.
Amount of oil : 1.65L (0.44gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leak and noise.

33-51
33. UPPER STRUCTURE

33.1.19 SWIVEL JOINT

33.1.19.1 PREPARATION FOR REMOVING

Remove boom piping hose

33.1.19.2 REMOVAL
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A15). (E port : PF1/2)

: 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft)

2) Remove tubes (A3), (A4). (C, D port : PF1)

: 36 mm, Tightening torque : 216 N•m (159 lbf•ft)

3) Remove tubes (A1), (A2). (A, B port : PF1)

: 36 mm, Tightening torque : 216 N•m (159 lbf•ft)

4) Remove 2 hoses (A16). (H,I port : PF1/4)

: 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft)

A B

C D
(TRAVEL MOTOR) (TRAVEL MOTOR)
B (LOWER) REVERSE A, B, C, D-PF1 A (LOWER) REVERSE
(LH) (RH)
A (UPPER) FORWARD E-PF1/2 B (UPPER) FORWARD
H, I-PF1/4

A4

A2

SWIVEL JOINT
D
B

A16
A1 A I

C E
H
E A15
A3

A15 A16

Fig. 33-75 Removing piping (lower side)

33-52
 33. UPPER STRUCTURE

(2) Disconnecting the hoses on the top part of swivel S/M

C/V C/V
joint DB Ar
Br
1) Remove drain hoses (A7). (E port : PF1/2) 23 A7
22

: 27 mm
Tightening torque : 78 N•m (58 lbf•ft) 2 2
C/V
2) Remove hoses (27), (23). BL 3 C/V
(C, D port : 1-14UNS) 27 AL
D E B 24
: 32 mm
Tightening torque : 137 N•m (101 lbf•ft) 1 1
3) Remove hoses (24), (22). A
C
(A, B port : 1-14UNS)

: 32 mm
Tightening torque : 137 N•m (101 lbf•ft)
4) Remove hose (19).
H
(Travel 2-speed change over port : PF1/4) 19 S/V
5 A3
: 19 mm
Tightening torque : 29 N•m (21 lbf•ft) Fig. 33-76 Disconnecting the hoses on the top part
of swivel joint
(3) Remove whirl-stop of swivel joint.
23 Tightening torque 22
1) Loosen the nut (23) M24. 157N.m (116 lbf.ft)
2) Remove a capscrew (22) M24×140.
in)
59
: 36 mm (0.
mm
15 At assembling,
this distance
should be 15mm (0.59in).

Fig. 33-77 Removing whirl-stop nut & the capscrew

(4) Remove joint for piping (See Fig. 33-75,Fig. 33-76) Tightening torque B28
6.8N.m (5 lbf.ft)
1) Remove 2 connectors (1). (F,G port)
Tightening torque B29
2) Remove elbow (5) (F port) for travel 2-speed 14.7N.m (11 lbf.ft)
change over. (PF1/4) To prevent from
entering water,
apply Loctite 572
: 19 mm or 577 around
(5) Remove seal (B25) this plate (B24).
B24
1) Remove 6 sems bolts (B29) M10×25.

: 17 mm Before mounting the seal

(B25), apply adhesive to B25
2) Remove clip (B28). the adhering surface of S/J
and the upper frame.
: Flat-blade screwdriver
3) Remove seal (B25). Fig. 33-78 Removing seal (B25)

33-53
33. UPPER STRUCTURE

(6) Remove sems bolts for installation

Attach eye bolt, lift it up temporarily, and remove 3
sems bolts (D2) M12×25.

: 19 mm EYE BOLT
(See 11.7 SPECIAL TOOLS No.9 Plug)

LOWER FRAME

D2
SEMS BOLT
M12 25
Loctite #262
T=108N.m D1
(80 lbf.ft) SWIVEL JOINT

Fig. 33-79 Removing sems bolts for installation

(7) Slinging the swivel joint
Weight : Approx. 63kg (139 lbs)

33.1.19.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Piping tightening torque

Tightening torque N.m (lbf.ft)

Size Tool.
PF HEX O-ring type Hydraulic hose
Connector
1/4 19 36 (27) 29 (22)
3/8 22 74 (54) 49 (36)
1/2 27 108 (80) 78 (58)
3/4 36 162 (120) 118 (87)
1 41 255 (180) 137 (100)
1-14UNS 32 - 137 (100)

(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.

33-54
 33. UPPER STRUCTURE

33.1.20 UPPER FRAME

33.1.20.1 PREPARATION FOR REMOVING

(1) Remove attachment
(See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight
(See 33.1.11 COUNTERWEIGHT) Note)
(5) Remove swivel joint This part is left blank
(See 33.1.19 SWIVEL JOINT) because we had not received related information
from "Engineering Division".

Fig. 33-80 Temporarily lift upper frame

33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily
Attach 2 upper-frame hoisting jigs to attaching
holes of counterweight. Attach 2 chain blocks to
  
holes of boom foot pin and use these four points 
and hoist upper-frame.
 
    

  
 
   

 
Fig. 33-81 Lifting up upper frame temporarily
(2) Marking match marks on swing bearing
 
Put match marks on upper frame and swing
bearing.

Fig. 33-82 Matching mark on swing bearing and

upper frame

33-55
33. UPPER STRUCTURE

(3) Removing upper frame attaching bolts

Remove 33 capscrews (B31) M16×85 and a
reamer bolt (B30) used to install swing bearing and
upper frame.

: 24 mm
(4) Slinging upper frame
Sling according to Fig. 33-80, and remove upper
frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)

Fig. 33-83 Removing upper frame attaching bolts

33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (B30)
and a washer (B6) temporarily.

Apply Loctite #262

equivalent (* mark 1 place).
T=256N.m (189 lbf.ft)
Confirm the reamer bolt positions referring to Fig. 33- B30,B31
85.
Fig. 33-84 Bearing mount

: 24 mm Apply Loctite #262 OUTER (S) ZONE POSITION

Tightening torque : 256 N•m (189 lbf•ft)
Apply Loctite #262 *
(5) Install swing bearing
Install 33 capscrews (B31) M16×85.

: 24 mm Apply Loctite #262

Tightening torque : 256 N•m (189 lbf•ft)
Install a reamer bolt (B30).

: 24 mm
Tightening torque : 256 N•m (189 lbf•ft)

Fig. 33-85 Reamer bolt position (*) Apply Loctite to

shaded area

33-56
 33. UPPER STRUCTURE

This page is blank for editing convenience.

33-57
33. UPPER STRUCTURE

33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP • REGULATOR

33.2.1.1 HYDRAULIC PUMP

33.2.1.1.1 Structural exploded view

(1) Main pump

534
531,548 792
702
272
532 251
732 808
490 X A 954
B
255
W Z 256
402
Y
732
789 901
535
733
533
806 981 490
824 983
953 127
727
123 468
04 C
124
113 726
466 314 D
717
401 E
141
157
156 886 312
153

151,152 D
E
211 F

214
212 B

116

711

A 406
F 326 05
271 261
724 774 414
Y 710
726
Z W
X

467

732 111

C
313 724
886

Fig. 33-86 Structural exploded view of main pump

33-58
 33. UPPER STRUCTURE

No. Name Q'ty No. Name Q'ty No. Name No.

111 Shaft(F) 1 272 Pump casing (R) 1 710 O-ring ; 1B G80 1
113 Shaft(R) 1 312 Valve block 1 711 O-ring ; 1B G95 1
116 1st gear 1 313 Valve plate (R) 1 717 O-ring ; 1B G125 2
123 Roller bearing 2 314 Valve plate (L) 1 723 O-ring ; 1B P11 6
124 Needle bearing 2 326 Cover 1 724 O-ring ; 1B P8 12
127 Bearing spacer 2 401 Socket bolt ; M16X150 2 727 O-ring ; 1B P18 4
141 Cylinder block 2 402 Socket bolt ; M16X190 2 732 O-ring ; 1B P14 4
151 Piston 18 406 Socket bolt ; M6X16 4 733 O-ring ; 1B P28 2
152 Shoe 18 414 Socket bolt ; M10X20 4 774 Oil seal 1
153 Retainer 2 466 VP plug ; PF1/4 2 789 Backup ring P14 2
156 Spherical bushing 2 467 VP plug ; PF3/8 2 792 Backup ring G30 2
157 Cylinder spring 18 468 VP plug ; PF1/2 4 806 Nut ; M12 2
211 Shoe plate 2 490 Plug ; NPTF1/16 9 808 Nut ; M16 2
212 Swash plate 2 531 Tilt pin ; M20X1.5 2 824 Stop ring 2
214 Tilting bushing 2 532 Servo piston ; M20X1.5 2 886 Spring pin 4
251 Swash plate support 2 533 Plug ; M30 2 901 Eye bolt ; M10 2
255 Lock pin 2 534 Stopper (L) 2 953 Socket screw ; M12X23 2
256 Set spring 2 535 Stopper (S) 2 954 Set screw ; M16 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing (F) 1 702 O-ring ; 1B G30 2 05 PTO gear case 1
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Tightening torque of bolt, plug, nut and servo piston
Tightening torque
No. Thread size
N.m (lbf.ft)
401,402 M16 240 (177)
406 M6 12 (8.9)
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 1/2 110 (81)
490 NPTF1/16 8.8 (6.5)
531,532 M20X1.5 240 (177)
533 M30 220 (162)
806 M12 60 (44)
808 M16 130 (95)

33-59
33. UPPER STRUCTURE

(2) Gear pump (For pilot)

887
Front gear side Gear case side

SECTION X-X
(2 places)
710 700 354 351 Suction port : G3/4 887 433
Tightening torque : 74N.m
(54.5 lbf.ft)
Z
X

B3
X

434
X
A3
Delivery port : G1/2
311 Tightening torque :
312 X 53N.m (39 lbf.ft)

732 Dr3
a3 850
Dr3 Z
308 308 355

435 361 353 310 310 434 466

725
SECTION Z-Z
Drain port : G3/8
Tightening torque :
Tightening torque 34N.m (25 lbf.ft)

Tightening torque
Item number Thread size
N.m (lbf.ft)
312 M14X1.5 29 (21)
433, 434
M8 17 (13)
435
466 PF 1/4 16 (11)

No. Parts Q’ty No. Parts Q’ty

307 Poppet 1 433 Flange socket; M8×40 2
308 Seat 1 434 Flange socket; M8×55 2
309 Ring 1 435 Flange socket; M8×20 4
310 Spring 1 466 VP plug ; PF1/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14×1.5 1 710 O-ring 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1

33-60
 33. UPPER STRUCTURE

33.2.1.1.2 Disassembly and assembly of main pump

(1) Tools
Tool Part
The right list shows the tools required for remove
and install. Name Size mm Size Item No.
4 M5 490
(2) Disassembling procedure 5 M6 406
Allen wrench
1) Selecting a place for disassembly. 6 M8 466, 953
• Choose a clean place. 8 M10 414, 467
10 M12 468
• Spread rubber sheet or cloth on work bench
to protect parts from damaging. 14 M16 401, 402
Eye wrench 19 M12 806
Socket wrench 24 M16 808
2) Cleaning Wrench ; Double
Remove dust and rust, etc. on pump surface with single 41 PF1
wash oil. Crescent wrench Medium size 1pc.

Driver Flat bladed 2pcs.

Hammer Plastic
Plier Snap ring
Steel bar 4X100
Torque wrench
3) Drain oil
REGULATOR
Drain out the oil in the pump casing by removing
drain port plug (468).

: 10 mm

• Drain out oil from the plug of the front pump

and the rear pump.

4) Removing regulator and PTO cover

Remove the socket bolts [414, 415 (See Fig. 33-
86, Fig. 33-104)]. Then remove the regulator and
the PTO cover (326).

: 6 mm, 8 mm

• Regarding the disassembly of the regulator,

refer to article of Regulator.

5) Removing gear pump  

Remove the socket bolt (435). Then remove the 
gear pump (04).

: 6 mm
6) Remove socket bolt (401),(402)
Loosen socket bolts (401),(402) that fasten
pump casing (271),(272) and valve block (312).

: 14 mm

Fig. 33-87 Remove socket bolt (401),(402)

33-61
33. UPPER STRUCTURE

7) Disassembling the pump casing and the valve

312 271
block
Place the pump level on a work bench with its
mounting surface of the regulator facing down.
Then separate pump casing (271) and valve
block (312).

• When facing the mounting surface of the

regulator down, place a rubber sheet on a
work bench so as not to score the mounting
surface.
Fig. 33-88 Disassembling the pump casing (271)
• When the pump casing has been separated and the valve block (312)
from the valve block, draw out the 1st gear
(116) at the same time.
8) Drawing out the cylinder assy %
Draw out cylinder block (141) out of pump casing
"##%
(271),(272) in parallel to shaft (111),(113). At the
same time draw out piston sub (151),(152), plate #!
(153), spherical bushing (156) and cylinder #$
spring (157).

• Use care so as not to score the sliding

surface of the cylinder block, spherical
bushing, shoe and the swash plate.

Fig. 33-89 Drawing out the cylinder assy

9) Remove seal cover (F) 406
Remove socket bolt (406) M8 and seal cover (F)
(261). 261
: 5 mm

• The seal cover (F) may be drawn out with

ease if it is taken out by flat bladed driver in
the notch of the seal cover (F).
• An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score the oil
seal.
Fig. 33-90 Removing seal cover (F)(261)

33-62
 33. UPPER STRUCTURE

10) Drawing out the shaft

Tap lightly the shaft end (111, 113) by means of a
plastic hammer and draw out the shaft from the
pump casings (271),(272).

Fig. 33-91 Drawing out the shaft (111), (113)

11) Remove shoe plate and swash plate
Draw out shoe plate (211) and swash plate (212) 271
from pump casings (271),(272). (272)

212
(211)

Fig. 33-92 Removing shoe (211) and swash plate

(212)
12) Insert wire into hole to keep pressing lock pin
(255) which locks swash plate support (251).
(See Fig. 33-93). And free the swash plate
support from locking, and rotate it in
counterclockwise. Then remove swash plate
support (251) from pump casing.

• When pressing with wire, do not mistake the

hole for lock release and small hole (oil
passage) on arc of swash plate support.
• Be careful of jumping out of lock pin and set
spring, during removal of swash plate Fig. 33-93 Removing swash plate support (251)
support.
13) Remove valve plate
Remove valve plate (313, 314) from valve block
(312).
312
• The valve plate may come off during the
operation under 7).
314
(313 :
Opposite Side)

Fig. 33-94 Removing valve plates (313), (314)

33-63
33. UPPER STRUCTURE

14) Remove other parts

If necessary, remove Q min-plug (533), stopper 534
(L) (534), stopper (S) (535), servo piston (532) 531
and tilting pin (531) from pump casing 272
532 808
(271),(272), and remove needle bearing (124)
from valve block (312).

• When removing the tilting pin, use care so as 533

535
not to score the head of the tilting pin, using 806
a jig.
• It is hard to separate the tilting pin from the
124
servo piston in some cases as Loctite is
coated on the mating part between them.
Use care so as not to score the servo piston
by applying undue force.
• Do not draw out needle bearings except
312
when their service life has ended.
• Do not loosen Q min-plug (533) of valve
block (312). A set flow rate changes.
Fig. 33-95 Removing other parts
(3) Installing procedure
1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly, but
notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and dry
them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O-
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.

33-64
 33. UPPER STRUCTURE

2) Installing swash plate support

Install set spring (256) and lock pin (255) in pump
casing (271). Then align swash plate support
(251) with spigot of pump casing, and rotate it in
clockwise. And fix swash plate support (251) with 251
lock pin.

• When the servo piston, the tilting pin, the

stopper (L), the stopper (S) and the Q min-
plug have been removed, install them to the
pump casing beforehand.
• When tightening servo piston and tilting pin,
use a jig so as not to damage the head of the
tilting pin and feedback pin.
Coat the screwed part with Loctite #262.

Fig. 33-96 Installing swash plate support (251)

3) Installing swash plate #
Install shoe plate (211) on swash plate (212). %#!
Then insert tilting bushing of swash plate into
tilting pin (531), and fix swash plate (212) and
shoe plate (211) to swash plate support (251)
properly.

• Confirm by the fingers of your both hands

that swash plate moves smoothly. 

• The shaft be installed easily if grease is

applied to the sliding parts of swash plate
and swash plate support.
• Do not damage the sliding surface of shoe
plate. Fig. 33-97 Installing swash plate (212)

33-65
33. UPPER STRUCTURE

4) Installing shaft
Install shaft (111),(113) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
pump casing (271),(272).
251

123
127,824

111

Fig. 33-98 Installing shaft (111)

5) Installing seal cover
Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406). %

: 5 mm $
Tightening torque : 12 N•m (8.9 lbf•ft)
"$
• Coat the oil seal in seal cover (F) with a thin
film of grease.
• Handle the oil seal with sufficient care so it is
not scored.

Fig. 33-99 Installing seal cover F (261)

6) Inserting piston cylinder sub
Assemble the piston cylinder sub [cylinder block
141(151,152,157)
(141), piston (151), shoe (152), plate (153),
spherical bushing (156) and cylinder spring 156
(157)].
Align the spherical bushing with the cylinder 153
spline and insert them into the pump casing.

Fig. 33-100 Inserting piston cylinder sub

7) Installing valve plate
Install valve plate (313), (314) to valve block
(312) by aligning pin.

312
• Do not mistake the suction and delivery sides
of the valve plate.
314
(313 :
Opposite Side)

Fig. 33-101 Installing valve plates (313), (314)

33-66
 33. UPPER STRUCTURE

8) Installing valve block 312 271

Install valve block (312) to pump casing 401
(271),(272) and fasten them together with socket
bolts (401).

: 14 mm
Tightening torque ; 240 N•m (177 lbf•ft)

• Work will be promoted if assembly is started

from the rear pump.
• Exercise care so as not to mistake the
Fig. 33-102 Installing valve block (312)
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 the 1st gear into the valve block
beforehand and connect it with the spline of
the shaft.
9) Installing gear pump REGULATOR
Install gear pump (04) and fasten them together
socket bolts (435).

: 6 mm,
Tightening torque ; 17 N•m (12.5 lbf•ft)
10) Installing regulator and PTO cover
Pinch feedback pin of tilting pin in feedback lever
of the regulator and PTO cover (326), install the
regulator and fasten socket bolt.
(See Fig. 33-104)
Socket bolt (415) …… For regulator Fig. 33-103 Installing regulator and PTO cover

: 6 mm,
Tightening torque ; 29 N•m (21 lbf•ft)
Socket bolt (414) …… PTO Cover (326)

: 8 mm,
Tightening torque ; 57 N•m (42 lbf•ft)

• Do not mistake the front regulator for the rear

regulator.

11) Installing drain port plug

The work is complete when drain port VP plugs
(468) have been set.

: 10 mm
Tightening torque ; 110 N•m (81 lbf•ft)

33-67
33. UPPER STRUCTURE

33.2.1.1.3 Maintenance standards

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the following standards of wear.
However, always replace such parts that show excessive damage on appearance.

Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.032 0.056
bore Replace piston or cylinder.
(0.0013 ) (0.0022 )
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.3
Replace piston shoe assy.
(0.004 ) (0.012 )
( )
Thickness of shoe 3.9 3.7
Replace piston shoe assy.
(t) (0.154 ) (0.146 )
Free height of cylinder spring 41.1 40.3
Replace cylinder spring.
(L) (1.618 ) (1.587 )
Combined height of retainer plate and
17.0 15.8
spherical bushing Replace spherical bushing or retainer plate.
(0.669 ) (0.622 )
(H-h)

  

 
  
   
  
  
   
        



 
  
   

    
  
     

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)

Valve plate (sliding section) Surface roughness requiring

3-Z
Swash plate (shoe plate face) correction
Cylinder (sliding section) Standard surface roughness
Less than 0.4Z (lapping)
Roughness of each surface (correction value)

33-68
 33. UPPER STRUCTURE

33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valve’s relief valve’s are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.

(2) Troubleshooting
1) Overloading to engine

Cause Remedy Remarks

1. Revolution and pressure are higher 1) Set pressure to specified value.
than set values.
2. Regulator torque is set higher than 2) Readjust regulator. 2) Refer to Regulator Manual.
normal.
3. Pump’s internal parts are seized or 3) Replace damaged parts. 3) Check filter and drain oil to see if
broken. abnormal wear particles are present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.

2) Pump’s oil flow rate is extremely low and delivery pressure is not available.

Cause Remedy Remarks

1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pump’s internal parts are seized or 2) Replace damaged parts. 2) Check filter and drain oil.
broken.
3. Attached pump is out of order 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Replace attached valve. 4) Refer to Manual for Attached Valve.
5. Regulator is piped incorrectly. 5) Pipe correctly.

33-69
33. UPPER STRUCTURE
3) Abnormal Sound and Vibration
Cause
1. Cavitation
2. Caulked part of shoe is broken.
3. Cylinder is cracked
4. Pump is installed improperly.
5. Regulator is hunting.
6. Relief valve in attached valve is
hunting.
Remedy Remarks
1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil is not 1-2) The attached pump is in trouble.
clouded. 1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2)Replace piston shoe and shoe
plate.
3) Replace cylinder.
4) Correct installation.
5) Repair regulator, 5) See Regulator Manual.
6) Repair attached valve.
33-70
 33. UPPER STRUCTURE

33.2.1.2 REGULATOR

33.2.1.2.1 Structural exploded view

402
656
733
496 627
041 601
543 724 646
545 624
541
415 801
755 924

418
496
079

652 875
726
614
496 651 616
041
466 496 658
755 755
754
724
407 887
643
731 754
631 897
611 708

325
Fig. 33-104 Regulator exploded view

No. Name Q'ty No. Name Q'ty No. Name Q'ty

325 Valve casing 1 616 Prevention plug 1 731 O-ring ; 1B G25 1
402 Socket bolt ; M6X16 4 624 Spring seat 1 733 O-ring ; 1B P18 1
407 Socket bolt ; M6X30 4 627 Adjusting stem (Q) 1 755 O-ring ; 1B P11 3
415 Socket bolt ; M8X40 4 631 Sleeve (For Pi) 1 754 O-ring ; 1B P10 2
418 Socket bolt ; M5X12 2 643 Pilot piston 1 801 Nut ; M10 1
466 VP plug ; PF1/4 1 646 Pilot spring 1 875 Pin 1
496 Plug ; NPTF1/16 9 651 Sleeve 1 887 Pin 1
541 Seat 2 652 Spool 1 897 Pin 1
543 Stopper 2 656 Cover 1 924 Socket screw ; M10X20 1
545 Ball 2 658 Plug 1 041 Check valve sub 2
601 Casing 1 708 O-ring ; 1B G55 1 079 Solenoid proportional 1
611 Feed back lever 1 724 O-ring ; 1B P8 5 reducing valve
614 Fulcrum plug 1 726 O-ring ; 1B P12 1
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Tightening torque of bolt, plug and nut
Tightening torque
No. Thread size
N.m (lbf.ft)
415 M8 29 (21)
402,407 M6 12 (8.9)
418 M5 6.9 (5.1)
466 PF 1/4 16 (12)
496 NPTF1/16 8.8 (6.5)
614 M14X1.5 27 (20)
801 M10 29 (21)

33-71
33. UPPER STRUCTURE

33.2.1.2.2 Disassembly and assembly

(1) Tools
PARTS
The right list shows the tools required for remove TOOLS SIZE (mm)
and install. SIZE ITEM No.
4 M5 418, 496
(2) Disassembling procedure ALLEN WRENCH 5 M6 402,407
1) Selecting a place for disassembly. 6 M8 415,466
8 M10 801

• Choose a clean place. 12 M14 614

• Spread rubber sheet or cloth on work bench ADJUSTABLE

MIDDLE SIZE 1 pc.
WRENCH
to protect parts from damaging.
FLAT BLADE
SCREW DRIVER MIDDLE SIZE 1 pc.

2) Cleaning TORQUE WRENCH

Remove dust and rust, etc. on regulator surface STEEL BAR 4X100
with wash oil. SOCKET BOLT M4X50 ADJUSTING STEM

3) 3) Remove regulator (See Fig. 33-104)

Remove socket bolts (415) and separate the
regulator from the pump body.

: 6 mm

Take care so as not to lose O-rings and check valve sub

(541), (543), and (545).

4) Remove ROH-plug
Remove ROH-plug (466) for a port of valve
casing (601). And remove ROH-plug (466) for
psv port too.
(In case of KR76-0E13PV)

5) Remove valve casing (Fig. 33-104)

Remove socket bolts (407) and remove valve
casing (325) with solenoid proportional reducing
valve (079).

: 5 mm
Fig. 33-105 Removing ROH-plug (466)

Fig. 33-106 Removing valve casing (325)

33-72
 33. UPPER STRUCTURE

6) Remove cover (See Fig. 33-104)

Remove socket bolt (402) and cover (656).

: 5 mm

The cover is assembled with set screw (924) and hex

nut (801), but do not loosen them. If they are loosened,
the pressure settings change.

Fig. 33-107 Removing cover (656)

7) Remove Pi sleeve and pilot piston
(See Fig. 33-104)
Draw out sleeve (631) and pilot piston (643) from
the regulator body.

Fig. 33-108 Removing Pi sleeve (631) and pilot

piston (643)
8) Removing looseness prevention plug (616).
• Removing of looseness prevention plug may
cause damage of plug. (But in this case,
there is no functional problem.)

Fig. 33-109 Removing plug (616)

33-73
33. UPPER STRUCTURE

9) Remove fulcrum plug and feedback lever

(Fig. 33-104)
Remove fulcrum plug (614) and feedback lever
(611).

Fig. 33-110 Removing fulcrum plug and feedback

lever (611)
10) Drawing out the spool and the sleeve (See Fig.
33-104)
Draw out spool (652) and sleeve (651) from the
sleeve hole of the regulator casing.

Fig. 33-111 Removing spool (652) and sleeve (651)

11) Remove plunger, pilot spring and spring seat
(See Fig. 33-104)
Draw out plunger (627). Then take out pilot
spring (646) and spring (624).

The plunger comes off easily if an M4 bolt is used.

12) Drawing out the check valve (See Fig. 33-104)

The disassembly is complete when the check
valve [seat (541), ball (545), and stopper (543)]
have been drawn out. Fig. 33-112 Removing plunger (627),
pilot spring (646) and spring seat (624)

The check valves are placed on two places; the mating

surface of the pump casing and on the matching
surface of the valve casing.

Do not lose the parts because they are small.

33-74
 33. UPPER STRUCTURE

(3) Installing procedure

Assembly is a reverse order of disassembly, but
notice the following.
• Do not fail to correct parts damaged during
disassembly and get replacement parts ready
beforehand.
• Entry of foreign matter causes faulty functions;
clean parts thoroughly, dry them with jet air and
work in a clean place.
• Do not fail to coat the sliding parts with clean
hydraulic oil, before proceeding to assembly.
• In principle, replace seals such as O-rings with
new ones.
• Using torque wrench, the bolts and plugs should
be tightened to the specified torques that is
indicated in "Maintenance Standard".
1) Placing the check valve (See Fig. 33-104)
Install the check valve to casing (601) [Seat
(541), ball (545) and stopper (543)].

Assemble the check valve into the matching surface of

the pump casing and the matching surface of the valve
casing.

2) Fitting the sleeve and the spool (See Fig. 33-

104)
Place sleeve (651) and spool (652) into the
sleeve hole of casing (601).

• Make sure the spool and the sleeve slide smoothly

in the casing without catching.
• Make sure the direction of the spool is correct.

Fig. 33-113 Fitting sleeve (651) and spool (652).

3) Installing feedback lever (See Fig. 33-104)
Insert pin (897) of feedback lever (611) into the
pin hole of the sleeve and fix the feedback lever
with fulcrum plug (614).

Operate the feedback lever and make sure that it does

not have much looseness and that it operates without
catching.

Fig. 33-114 Installing feedback lever (611)

33-75
33. UPPER STRUCTURE

4) Installing plug
Place the prevention plug (616).

Fig. 33-115 Installing plug (616)

5) Installing spring seat, pilot spring and plunger
(See Fig. 33-104)
Place spring seat (624), pilot spring (646) and
plunger (627) into the hole in the sleeve.

6) Installing cover (See Fig. 33-104)

Attach cover (656) to casing (601) and fasten
them together with socket bolts (402).

The cover is fitted with adjusting screw (924) and hex

Fig. 33-116 Installing spring seat (624),
nut (801).
pilot spring (646) and plunger (627)

7) Assembling the Pi sleeve and the pilot piston

(See Fig. 33-104)
Assemble Pi sleeve (631) and pilot piston (643)
into casing (601).

Fig. 33-117 Assembling the sleeve (631) and the

pilot piston (643).

33-76
 33. UPPER STRUCTURE

8) Installing valve casing (See Fig. 33-104)

Attach valve casing (325) fitted with solenoid
proportional reducing valve (079) to casing (601)
and fasten them together with socket bolts (407).

Fig. 33-118 Installing valve casing (325)

9) Installing ROH-plug
Install ROH-plug (466) to A port of valve casing
(601). And install ROH-plug (466) to Psv port
too.
(In cased KR76-0E13PV)

This completes assembly.

Fig. 33-119 Installing ROH-plug (466)

33-77
33. UPPER STRUCTURE

33.2.2 CONTROL VALVE

33.2.2.1 SECTIONAL VIEW

K

155 163 101

(P5)
P2

T1
T2 CT2
K
PAL PBL

PB1 PCa

PBs PAs

Pss

PAa1 PBa1

PAo PBc

PAp2

(P4)
166 161 161155 163164
SECTION A-A
154 567 155 163
(MU2) (P6) 102
P1
973 973

CT1

PTb POb

973 973
PBr PAr

PAb PBb

973 973
PAc PBc

973 973
PBa2 PAa2

PBp1
973

(P3)
161 164 163 155 161 161
SECTION B-B
Fig. 33-120 Section (1/6)

33-78
 33. UPPER STRUCTURE

273x10
6

H H
P1 unload PCb PAL
Travel left
(Travel straight) 273x10
C C
PAr PB1 Boom conflux
Travel right (P2 unload)
D D
XAb
XAb 977
PBb PBs 978x2
Boom Swing
E Pss
E
PBc PAa1
Bucket Arm 1
F F
PAa2 PAo
Arm 2 MU1 Option

G PBp1 PBp2
G

H H

B A
(P3)

PAa2 PAo PAo

PBp1

PBp2

275x4

213
274x4

(P4)

(P3)

212

PBa2 PBo

273x10
273x10
Fig. 33-121 Section (2/6)

33-79
33. UPPER STRUCTURE

202 P1 unload 201

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

201 Travel right Boom conflux 201

333 PAr PB1 333
331 331
339 336
327 322
AbR
325 321
602
331 331
261 261
166 305
164 DR 511
162 521
Ar CCb
306
551
511 561
521
CP1
551
551 561
561
166 Br
310
164
166
161
166 T3

264 261
331
PBr
205 325
SECTION D-D 328
336
331
PCa 333
P2 unload 202

Fig. 33-122 Section (3/6)

33-80
 33. UPPER STRUCTURE

203
333 Swing
331
PBs
339 Boom 204
320 PBb 333
Pss
319 331
379X3 336
211 322
331
L 216 321
L 266
261 M 331
M 266 XAb 261
166
160
303
301
561 CRb 161
Ab As
(HEAD)

556 511
524 524
LCb LCs
514
551 556
561 561
521 Bb Bs
511 (ROD)
161

264
264
602
PAb
205 PAs 206
BbR
160 266
SECTION E-E
201
201 333
333 Bucket Arm 1
PBc PAa1
331
331 336
339 322
320 321
BcR
319 AaR 602
602 331
331 261
261

161
304

Bc Aa(HEAD)
(ROD)
511 511
521 521
LCc LCa 551
561
551
561 161
Ac 561
(HEAD) CRa 556
Ba(ROD)
524
514
156
PLc2 167
264 160x2
L 302
602 L
PAc PBa1 264
205 211
AcR
205
SECTION F-F

Fig. 33-123 Section (4/6)

33-81
33. UPPER STRUCTURE

201
333
331 Arm 2 Option 201
333
339 PAa2 PAo
331
326 337
325
330
331
329
261 604
154 AoR 331
567 261
MU1
161 311
308
162
515
521 Ao
551 511
LCAP2
561 521
LCo
561 551
LCAT2
561
551
Bo
521
511 Ba(ROD)

162
162
162
264
PBa2 PBo 606
264
205
SECTION G-G
205 PaR

605 605
PBp1 PBp2

Bo

BoR
166 604
153

SECTION H-H

Fig. 33-124 Section (5/6)

33-82
 33. UPPER STRUCTURE

T2

P1 T1
511
521
CT1
551
561
511
C P2
(MU2)
521
CT2

E 551
561

162 SECTION J-J SECTION M-M

278x5
160
266
207
267 267

528
527
T1
518
517
SECTION L-L

SECTION K-K

Fig. 33-125 Section (6/6)

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing A 1 162 O-ring : 1B G25 6
102 Casing B 1 163 O-ring : 1B P18 4
25~29 (18~21) 153 Plug 1 164 O-ring : 1B P15 4
220~250 (162~184) 154 Plug PF3/4 2 166 O-ring : 1B P10 7
110~130 (81~96) 155 Plug PF1/2 4 167 O-ring : 1B P8 1
13~17 (9.6~13) 156 Plug PF1/8 1 168 O-ring : 1B P11 1
20~24 (15~18) 157 Plug PF1/4 MEC 1 201 Cover 6
34~39 (25~29) 159 Plug PT1/4 1 202 Cover 4
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC 5 203 Cover 1
161 O-ring : 1B G30 13 204 Sub cover 1

33-83
33. UPPER STRUCTURE

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
205 Cover 7 327 Spring 2
206 Cover 1 328 Spring 3
207 Back pressure check valve cover 1 329 Spring 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 330 Spring 1
212 Plate 1 331 Spring seat 24
16~18 (11.8~13.3)
213 Plate 1 333 Spacer bolt 12
Loctite #262

216 Boom lowering valve 1 336 Stopper 6

261 O-ring 12 337 Stopper 1
264 O-ring : 1B G35 8 339 Stopper 5
266 O-ring : 1B P7 4 511 Poppet 11
267 O-ring : 1B P32 2 512 Poppet 2
25~34 (18~25) 273 Socket bolt 40 514 Poppet 2
98~120 (72~89) 274 Socket bolt 4 515 Poppet 1
98~120 (72~89) 275 Socket bolt 4 517 Poppet 1
9.8~14 (7.2~10.3) 278 Socket bolt 5 518 Poppet 1
9.8~14 (7.2~10.3) 279 Socket bolt 3 521 Spring 11
301 Boom spool assy 1 522 Spring 2
302 Arm 1 spool 1 524 Spring 3
303 Swing spool 1 527 Spring 1
304 Bucket spool 1 528 Spring 1
305 Boom conflux spool 1 130~150 (96~111) 551 Plug 12
306 Travel spool 2 130~150 (96~111) 556 Plug 5
307 Travel straight spool 1 561 O-ring : 1B P20 17
308 Arm 2 spool assy 1 567 O-ring : 1B P24 2
309 P1 unload spool 1 69~78 (51~58) 601 Main relief valve 1
310 P2 unload spool 1 69~78 (51~58) 602 Port relief valve 5
311 Option spool 1 69~78 (51~58) 604 Relief valve plug assy 2
319 Spring 2 98~120 (72~89) 605 Bypass cut valve 2
320 Spring 2 69~78 (51~58) 606 Port relief valve 1
321 Spring 5 140~180 (103~133) 973 Socket bolt 9
322 Spring 4 977 Name plate 1
325 Spring 6 978 Rivet 2
326 Spring 1

33-84
 33. UPPER STRUCTURE

33.2.2.2 PREPARATION FOR DISASSEMBLY

(1) General precautions
1) As all the hydraulic components are precisely machined, it is essential to carry out disassembly and
reassembly in an especially clean location.
2) When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or
sand.
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.
Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
4) When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed
spool, or the end cover. Handle the valve with care.
5) Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after
disassembly and reassembly require hydraulic testing apparatus.
For this reason, do not disassemble hydraulic units that you are capable of disassembling but cannot test or
adjust.
Prepare beforehand washing fluid, hydraulic oil, grease, etc. .
(2) Tools
Prepare the following tools before disassembling the control valve.

No. Tools Q’ty Remarks

a Vise 1
Box end 1 of each
b 19mm, 24mm, 27mm, 32mm
wrench size
1 of each
c Allen wrench 5mm, 6mm, 10mm, 12mm, 14mm, 22mm
size
d Spanner 1 32 mm
e Loctite #262 1
f Spatula 1
g Pincers 1
Adjustable
h 1
wrench

33.2.2.3 DISASSEMBLY
The figures in parentheses after part names in this
manual represent those item numbers in the structural
sectional drawing under Fig. 33-120 to Fig. 33-125.
(1) Place the control valve on a work bench so as to
locate back pressure check valve upwards.

Disassemble the valve in a clean place, and be careful

not to damage flange surfaces or plate mounting
surfaces.

Fig. 33-126 Preparation for disassembly

33-85
33. UPPER STRUCTURE

33.2.2.3.1 Disassembling P1 unload spool

(1) Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for P1
unload spool.

Fig. 33-127 Removing spring cover (202) for P1

unload spring cover
(2) Draw out, from casing B (102), as a assy of P1
unload spool (309), spring seat (331), springs
(325), (328), stopper (336) and bolt (333).

When drawing out the spool assy, use care so as not to

score casing B (102).

Fig. 33-128 Drawing out P1 unload spool assy (309)

(3) Fix the P1 unload spool assy with vise via a
protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs
(325), (328) and stopper (336) from P1 unload
spool (309).

Fig. 33-129 Disassembling P1 unload

spool assy (309)

33-86
 33. UPPER STRUCTURE

33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove the
spring cover (201) and the O-ring (261) for travel.

Fig. 33-130 Removing spring cover (201)

(2) Draw out the assy of travel spool (306), spring seat
(331), springs (325), (327), stopper (339) and bolt
(333) from casing A (101) or casing B (102).

When drawing out the spool assy, take care so as not

to score the casing A (101) or the casing B (102).

Fig. 33-131 Drawing out travel spool (306) assy

(3) Fix the travel spool assy with vise via a protective
plate (aluminum plate, etc.). Remove bolt (333) and
separate spring seat (331), springs (325), (327) and
stopper (339) from travel spool (306).

Fig. 33-132 Removing right travel spring cover

(201)

Fig. 33-133 Disassembling travel spool (306) assy

33-87
33. UPPER STRUCTURE

33.2.2.3.3 Disassembling the boom conflux spool

(1) Loosen socket bolts (273) and remove spring cover
(201) for boom conflux and O-ring (261).

(2) Draw out the assy of boom conflux spool (305),

spring seat (331), springs (321), (322), stopper
(339) and bolt (333) from casing A (101).

When drawing out the spool assy, use care so as not to

score casing A (101).
Fig. 33-134 Removing spring cover (202)

(3) Fix the boom conflux spool with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (339) from boom conflux spool
(305).

Fig. 33-135 Drawing out boom conflux spool (305)

assy

33.2.2.3.4 Disassembling the boom spool

(1) Loosen socket bolts (273) and remove spring cover
(203) for boom spool and O-ring (261), (266).

(2) Draw out the assy of boom spool (301), spring seat
(331), springs (319), (320), stopper (339) and bolt
(333) from casing B (102).

When drawing out the spool assy, take care so as not

to score casing B (102).
Fig. 33-136 Removing spring cover (203)

33-88
 33. UPPER STRUCTURE

(3) Fix the boom spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (319),
(320) and stopper (336) from boom spool (301). Do
not disassemble boom spool (301) further unless
there is special reason.

Fig. 33-137 Drawing out boom spool (301) assy

33.2.2.3.5 Disassembling the swing spool

(1) Loosen the socket bolts (273) and remove the
spring cover sub (204) and the O-ring (261), (266)
for swing. Do not disassemble spring cover sub
(204) further unless there is special reason.

(2) Draw out the assy of swing spool (303), spring seat
(331), springs (321), (322), stopper (336) and bolt
(333) from casing A (101).

Fig. 33-138 Removing spring cover sub (204)

When drawing out the spool assy, use care so as not to
score casing A (101).

(3) Fix the swing spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from swing spool (303).

Fig. 33-139 Drawing out swing spool (303) assy

33-89
33. UPPER STRUCTURE

33.2.2.3.6 Disassembling bucket spool

(1) Loosen socket bolts (273) and remove bucket
spring cover (201) and O-ring (261).

Fig. 33-140 Removing spring cover (201)

(2) Draw out the assy of bucket spool (304), spring
seat (331), springs (319), (320), stopper (339) and
bolt (333) from casing B (102).

When drawing out the spool assy, use care so as not to

score casing B (102).

Fig. 33-141 Drawing out bucket spool (304) assy

(3) Fix the bucket spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (319),
(320) and stopper (339) from bucket spool (304).

33-90
 33. UPPER STRUCTURE

33.2.2.3.7 Disassembling arm 1 spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 1 spool.

(2) Draw out the assembly which is consist of arm 1

spool (302), spring seat (331), spring (321, 322),
stopper (336) and bolt (333) from casing A (101).

When drawing out the spool assy, use care so as not to

score casing A (101).
Fig. 33-142 Removing arm 1 spring cover (201)

(3) Fix the arm 1 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 322)
and stopper (336) from arm 1 spool (302).

Fig. 33-143 Disassembling arm 1 spool (302) assy

33.2.2.3.8 Disassembling arm 2 spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 2 spool.

(2) Draw out the assembly which is consist of arm 2

spool (308), spring seat (331), spring (325, 326),
stopper (339) and bolt (333) from casing B (102).

When drawing out the spool assy, use care so as not to

Fig. 33-144 Removing arm 2 spring cover (201)
score casing B (102).

(3) Fix the arm 2 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (325, 326)
and stopper (339) from arm 2 spool (308). Do not
disassemble arm 2 spool (308) further unless there
is special reason.

Fig. 33-145 Disassembling arm 2 spool (308) assy

33-91
33. UPPER STRUCTURE

33.2.2.3.9 Disassembling option spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of option spool.

(2) Draw out the assembly which is consist of option

spool (311), spring seat (331), spring (329, 330),
stopper (337) and bolt (333) from casing A (101).

When drawing out the spool assy, use care so as not to

score casing A (101).
Fig. 33-146 Removing option spring cover (201)

(3) Fix the option spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (329, 330)
and stopper (337) from option spool (311).

Fig. 33-147 Drawing out option spool assy (311)

33.2.2.3.10 Disassembling travel straight spool

(1) Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for travel
straight.

(2) Draw out the assy of travel straight spool (307),

spring seat (331), springs (325), (328), stopper
(336) and bolt (333) from casing B (102).

When drawing out the spool assy, take care so as not

Fig. 33-148 Drawing out travel straight spool (307)
to score the casing B (102).
assy

(3) Fix the travel straight spool assy with vise via a
protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs
(325), (328) and stopper (336) from travel straight
spool (307).

33-92
 33. UPPER STRUCTURE

33.2.2.3.11 Disassembling P2 unload spool

(1) Loosen socket bolts (273), and remove spring
cover (202) of P2 unload spool and O-ring (261).

(2) Draw out the assembly which is consist of P2

unload spool (310), spring seat (331), spring (325),
(328), stopper (336) and bolt (333) from casing A
(101).

When drawing out the spool assy, use care so as not to

Fig. 33-149 Removing P2 unload spring cover (202)
score casing A (101).

(3) Fix the P2 unload spool assy with vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), spring
(325), (326) and stopper (336) from P2 unload
spool (310).

Fig. 33-150 Drawing out P2 unload spool assy (310)

33.2.2.3.12 Removing spool covers

(1) Travel, boom, bucket, arm 1, arm 2 and option
Loosen socket bolts (273) and remove spool cover
(205) and O-ring (264).

(2) Swing
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264), (266). Do not disassemble
spool cover (206) further unless there is special
reason.

Fig. 33-151 Removing spool cover (205),(206)

33-93
33. UPPER STRUCTURE

33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and overload
relief valve (602), (606) and relief hole plug (604)
from the casing.

• Distinguish overload relief valve between (602) and

(606) with a tag to prevent them from being
confused during reassembly, as they are the same
in appearance and shape but differ in pressure
setting.
Fig. 33-152 Removing main relief valve (601)
• Regarding the disassembly of the relief valves
themselves, do not disassemble it.

Fig. 33-153 Removing overload relief valve (602)

and (606)

Fig. 33-154 Removing plug assy (604) for relief

valve hole

33-94
 33. UPPER STRUCTURE

33.2.2.3.14 Removing by-pass cut valve

(1) Remove by-pass cut valve (605) from the casing.

Remove the by-pass cut valve, giving particular

attention to the poppet (605-201) and spring (605-202)
which may be remained on the inside of casing.

Fig. 33-155 Removing by-pass cut valve (605)

33.2.2.3.15 Removing lock valve selector valve sub

(1) Loosen socket bolt (211-171) and remove lock
valve selector valve sub (211) from the casing.
Further disassembly of the lock valve selector sub
is not allowed.
When the removal of lock valve selector sub on
boom spool side is required, remove the boom
lowering emergency manual valve (215)
simultaneously.
Further disassembly of the boom lowering
emergency manual valve (215) is not allowed.

Fig. 33-156 Removing lock valve selector sub (211)

33.2.2.3.16 Removing back pressure check valve

(1) Loosen socket bolt (278) and remove back
pressure check valve (207) from the casing.

Fig. 33-157 Removing back pressure check valve

cover (207)

33-95
33. UPPER STRUCTURE

(2) Remove springs (527), (528), boost check valve

poppet sub (517) and by-pass check valve poppet
(518) from the casing. The further disassembly of
boost check valve poppet sub (517) is not allowed.

Replace control valve so that the spool cover face

directs downward.

When replacing, take care so as not to score the spool

cover.
Fig. 33-158 Removing boost check valve sub (517)
and by-pass check valve poppet (518)

33.2.2.3.17 Removing plate

(1) Loosen socket bolts (274), (275) and remove plates
(212), (213).
(2) After removing plates, remove all O-rings (161),
(164) remained on the casing side.

Fig. 33-159 Removing plate (212),(213)

33-96
 33. UPPER STRUCTURE

33.2.2.3.18 Removing check valve

(1) Remove plugs of load check valve, conflux check
valve, etc. and then remove poppet (511) and
spring (521).
(2) Load check valve on the swing section
Remove plug (556) and then remove poppet (511)
and spring (524).

The plug and spring in use differ from the above (1). Do
not mix the parts when assembling parts again.

(3) Load check valve on arm 2 section Fig. 33-160 Removing plug (551),(556)
Remove plug (551) and then remove poppet (515)
and spring (521).

The poppet in use differs from the above (1). Do not mix
the parts when assembling parts again.

(4) Lock valve

Remove plug (556) and then remove poppet (514)
and spring (524).

Fig. 33-161 Removing poppet (511),(512),(514),(515)

The plug, poppet and spring in use differ from the

above (4). Do not mix the parts when assembling parts
again.

(5) Main relief valve

Remove plug (556) and then remove poppet (512)
and spring (522).

The plug, poppet and spring in use differ from the

above (5). Do not mix the parts when assembling parts
again.

The plugs in which the procedure for disassembly is not

included in the above procedure are usually used to
block auxiliary holes and holes caused by casting. Do
not disassemble further if unnecessary.

33.2.2.3.19 Disassembling casing

Further disassembly of the casing is not allowed.

33-97
33. UPPER STRUCTURE

33.2.2.3.20 Inspection after disassembly

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet
of paper or cloth for inspection.
(1) Control valve
1) Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2) Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3) If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.

Take care not leave lapping compound behind in the casing or block.

4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are
free from foreign matter.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.

(2) Relief valve

1) Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact
surface is even all over.
2) Manually confirm that the main poppet slides smoothly onto and off the seat.
3) Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from
defects such as scratches.
4) Confirm that each spring is free from breakage, deformation, and excessive wear.
5) Confirm that the orifices of the main poppet and its seat are not clogged.
6) Replace all O-rings with new ones. (Between casing and seal)

33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural
sectional drawing. (Fig. 33-120 to Fig. 33-125)
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after
installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards."

33-98
 33. UPPER STRUCTURE

33.2.2.4.1 Installing check valve

(1) Load check valve, conflux check valve, and so on
Attach poppet (511) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the specified
torque. (8 places)
(2) Load check valve of swing section
Attach poppet (511) and spring (524) in place, place O-ring (561) in plug (556) and tighten them to the specified
torque. (1 place)
(3) Load check valve of arm 2 section
Attach poppet (515) and spring (521) in place, place O-ring (561) in plug (551) and tighten them to the specified
torque. (1 place)
(4) Lock valve section
Attach poppet (514) and spring (524) in place, place O-ring (561) in plug (556) and tighten them to the specified
torque. (2 places)
(5) Main relief valve section
Attach poppet (512) and spring (522) in place, place O-ring (561) in plug (556) and tighten them to the specified
torque. (2 places)

Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar
in shape.

33.2.2.4.2 Assembling plate

(1) Place O-rings (161), (164) in casing.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.

Replace control valve so that this plate face directs downward.

33.2.2.4.3 Assembling back pressure check valve

(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).
(2) Attach O-rings (267) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278)
to the specified torque.

33.2.2.4.4 Assembling lock valve selector sub

(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the specified torque.

33.2.2.4.5 Assembling by-pass cut valve

(1) Attach by-pass cut valve (605) to casing and tighten it to the specified torque.

Take care to prevent drop of poppet (605-201) and spring (605-202) when attaching by-pass cut valve.

33-99
33. UPPER STRUCTURE

33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (606) and relief valve hole plug assembly (604) in
respective place to the specified torque.

Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief
valves (602), (606) are similar in shape.

33.2.2.4.7 Assembling P2 unload spool

(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform P2 unload spool (310) because of careless over clamping.

(2) Place P2 unload spool assembly in item (1) in casing A (101).

Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten
socket bolt (273) to the specified torque.

33.2.2.4.8 Assembling travel straight spool

(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform travel straight spool (307) because of careless over clamping.

(2) Place travel straight spool assembly in item (1) in casing B (102).

Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and
tighten socket bolt (273) to the specified torque.

33-100
 33. UPPER STRUCTURE

33.2.2.4.9 Assembling spool in option

(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (329), (330) and stopper (337) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform option spool (311) because of careless over clamping.

(2) Place spool assembly in option in item (1) in casing A (101).

Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten
socket bolt (273) to the specified torque.

33.2.2.4.10 Assembling arm 2 spool

(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (325), (326) and stopper (339) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform arm 2 spool (308) because of careless over clamping.

(2) Place arm 2 spool assembly in option in item (1) in casing B (102).

Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
socket bolt (273) to the specified torque.

33.2.2.4.11 Assembling arm 1 spool

(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit
spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform arm 1 spool (302) because of careless over clamping.

(2) Place arm 1 spool assembly in item (1) in casing A (101).

Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten
socket bolt (273) to the specified torque.

33-101
33. UPPER STRUCTURE

33.2.2.4.12 Assembling bucket spool

(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (319), (320) and stopper (339) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform bucket spool (304) because of careless over clamping.

(2) Place bucket spool assembly in item (1) in casing B (102).

Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of bucket spool assembly and tighten
socket bolt (273) to the specified torque.

33.2.2.4.13 Assembling swing spool

(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform swing spool (303) because of careless over clamping.

(2) Place swing spool assembly in item (1) in casing A (101).

Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and
tighten socket bolt (273) to the specified torque.

33-102
 33. UPPER STRUCTURE

33.2.2.4.14 Assembling boom spool

(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (319), (320) and stopper (339) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform boom spool (301) because of careless over clamping.

(2) Place boom spool assembly in item (1) in casing B (102).

Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and
tighten socket bolt (273) to the specified torque.

33.2.2.4.15 Assembling boom conflux spool

(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (321)(322) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform boom conflux spool (305) because of careless over clamping.

(2) Place boom conflux spool assembly in item (1) in casing A (101).

Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and
tighten socket bolt (273) to the specified torque.

33.2.2.4.16 Assembling travel spool (travel right and left)

(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (325), (327) and stopper (339) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform travel spool (306) because of careless over clamping.

(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).

Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
socket bolt (273) to the specified torque.

33-103
33. UPPER STRUCTURE

33.2.2.4.17 Assembling P1 unload spool

(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform P1 unload spool (309) because of careless over clamping.

(2) Place P1 unload spool assembly in item (1) in casing A (101).

Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten
socket bolt (273) to the specified torque.

33.2.2.4.18 Assembling spool cover, and so on

(1) Travel, boom, bucket, arm 1, arm 2, option
Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
(2) Swing
Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.

33-104
 33. UPPER STRUCTURE

33.2.2.5 MAINTENANCE STANDARDS

33.2.2.5.1 Inspection of components

Part name Inspection item Criterion and remedy

Casing 1) Look for scratches, rusting and corrosion. 1) If any of the following parts are damaged,
replace the casing.
• Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
• Area of sealing part that is in contact with
O-ring.
• Sealing and seating part of main or
overload relief valve.
• Area of seating part or sliding part of
poppet.
• Sealing part of plug.
• Defects of other parts that seem to
prevent normal function.
Spool 1) Look for scratches, galling, rusting and 1) If a detectable defect with your fingernail is
corrosion. found on the sliding part of the outer
circumference, replace the spool.
2) Insert the spool in the casing bore, and 2) If the spool damages the O-ring or does
move it while turning it. not move smoothly, repair or replace the
spool.
Poppet If spring is damaged, replace it.
1) Look for damage on the poppet and the 1) If the seat of poppet or spring are
spring. damaged, correct or replace it.
2) If the poppet moves lightly without
2) Insert the poppet in the casing, and move catching, it is normal.
it.
Spring and related parts 1) Look for rust, corrosion, deformation, and 1) If damaged heavily, replace.
breakage of the spring, spring seat,
stopper, spacer bolt and cover.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Port relief valve surface.
By-pass cut valve 2) Inspect the contact face of the valve seat. 2) If damaged, replace.
3) Inspect the O-ring, backup ring, and seal. 3) As a general rule, replace all parts with
new ones. (Between casing and seal)

33-105
33. UPPER STRUCTURE

33.2.2.6 TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main
pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure,
load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and
reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system
is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.

33.2.2.6.1 Control valve

Trouble Cause Remedy

1. Travel does not 1) Malfunctioning main relief valve. 1) Check travel relief valve pressure
occur. • Foreign matter between main poppet • Disassemble and clean. If damaged
Slow to start up and seat. heavily, replace the assy as a unit.
(or poor power).
• Same as above.
Slow response.
• Foreign matter between poppet and • Correct sticking part with oil stone.
seat.
• Replace spring.
• Sticking main poppet.
• Remove foreign matter.
• Broken or deformed spring.
• Readjust, and tighten lock nut to
• Clogged main poppet throttle. specified torque.
• Loosened adjusting screw.

2. Machine does not 1) Malfunctioning travel straight valve. 1) Check pilot pressure.
move straight during • Sticking spool. • Correct sticking part with oil stone.
simultaneous
• Replace spring.
operation of travel
• Broken or deformed spring. • Remove foreign matter.
and attachment.
• Clogged small hole in spool.
2) Malfunctioning main relief valve. 2) Remove main relief valve.

33-106
 33. UPPER STRUCTURE

Trouble Cause Remedy

3. Excessive natural 1) Excessive clearance between casing and 1) Replace spool.
falls of attachment spool.
under its own weight 2) Spool is not completely in neutral position. 2) Check secondary pilot pressure.
when spool is in • Foreign matter between casing and • Disassemble, clean and smooth
neutral. spool, or sticking spool. sticking part with oil stone.
• Broken or deformed spring. • Replace spring.
• Clogged pilot circuit. • Remove foreign matter.
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2)) • Clean and check damage on seat
• Foreign matter between valve seat and surface.
casing.
4) Lock valve function is faulty. 4) Replace
(Arm, boom)
• Foreign matter between poppet seat • Disassemble, clean.
and casing. • Correct stuck part with oil stone or
• Poppet is stuck. replace.
• Replace spring.
• Broken or deformed spring. • Replace lock valve selector assy.
• Selector spool is stuck.
4. When raising 1) Malfunctioning load check valve. 1)
attachment, at first it • Foreign matter between poppet and • Disassemble and clean. If heavily
drops. casing. damaged, replace control valve.
• Correct sticking part with oil stone.
• Replace spring.
• Sticking poppet.

• Broken or deformed spring.

5. Bucket, boom, arm or 1) Malfunctioning main spool. 1) Check secondary pilot pressure.
swing does not • Excessive clearance between casing • Replace spool.
operate. and spool. • Disassemble and clean.
Slow to start up (or
• Foreign matter between casing and • Correct stuck part with oil stone.
poor power).Slow
spool.
response. • Replace spring.
• Sticking spool.
• Remove foreign matter.

• Broken or deformed return spring.

• Clogged pilot circuit.
2) Malfunctioning main relief valve. Refer to 2) Check main relief valve pressure. Refer to
item 1. 1) above. item 1. 1) above.
(See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2))

33-107
33. UPPER STRUCTURE

Trouble Cause Remedy

6. Boom conflux does 1) Malfunctioning conflux valve. 1) Measure pilot pressure.
not operate. • Excessive clearance between casing • Replace spool.
and spool. • Disassemble and clean.
• Foreign matter between casing and • Correct stuck part with oil stone.
spool.
• Replace spring.
• Sticking spool.
• Remove foreign matter.

• Broken or deformed return spring.

• Clogged pilot circuit.

33.2.2.6.2 Relief valve

Trouble Cause Remedy

1.No pressure rise. Main or pilot poppet of relief valve is sticking Check for foreign matter on each poppet.
and valve is open, or there is foreign matter Confirm that each component slides
on valve seat. smoothly.
If failure is found, replace it in an assembly.
2. Unstable relief Main or pilot poppet of relief valve seat is If failure is found, replace it an assembly.
pressure. damaged.
3. Incorrect relief 1) Wear due to foreign matter. 1) Replace damaged assembly
pressure setting. 2) Loosened locknut or adjusting screw. 2) Adjust pressure.
4. Oil leak. Confirm that each component operates
smoothly. Replace damaged or worn
1) Damaged seat. component.
Damaged O-ring. 1) If failure is found, replace it an assembly.
2) Sticking component due to foreign matter. 2) Confirm that there are no scratches,
scores, or foreign matter present before
reassembling.
If failure is found, replace it an assembly.

33-108
 33. UPPER STRUCTURE

33.2.3 PILOT VALVE (ATT)

33.2.3.1 CROSS-SECTIONAL VIEW

312

302
Apply grease on
rotating and
501
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1

241-2 241-1

201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc

PORT PORT
2,4 1,3
Fig. 33-162 Pilot valve (For ATT)
Apply loctite #277 to areas marked

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (35) 301 Joint : M14 1
214 O-ring ; 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (51) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * might not be equipped depending on valve type.

33-109
33. UPPER STRUCTURE

33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).

Fig. 33-163 Removing boot (501)

(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
312
: 22mm, 32mm

302

Fig. 33-164 Removing adjusting nut (312)

(4) Remove circular plate (302)
302
: 32mm

Fig. 33-165 Removing circular plate (302)

Fig. 33-166 Circular plate is removed

33-110
 33. UPPER STRUCTURE

Fig. 33-167 Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig A to
remove.
Jig A : See page 33-118.

: 24mm
301

When the force of return springs (221) is strong, never

loosen joint (301). If loosened, it might result in jumping
out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with
two fingers. Fig. 33-168 Removing joint (301)

(6) Remove plate (151)

• When the force of return springs (221) are 151
strong, press plate to let it come up slowly.

Fig. 33-169 Removing plate (151)

• When the force of return springs (221) are weak,
plug is left in casing (101) due to sliding
resistance of O-ring (214).

Pull plug (211) out with a driver.

To prevent personal injury, plug (211) must be removed

slowly and evenly until the return spring (221) force is
completely released.
211

Fig. 33-170 Removing plug (211)

33-111
33. UPPER STRUCTURE

(7) Remove push rod (212), plug (211), pressure

reducing valve assy (spool), return springs (221)
212
from casing (101).

211

Record combination of port holes on casing and the 221

pulled out parts. The stroke differs according to
direction.

101

Fig. 33-171 Removing push rod, plug, pressure

reducing valve and spring
(8) Push springs (241-1), (241-2) in the range of 7mm
(0.276in) that the movement of spring seats (216- 216-1
216-2
1), (216-2) and shift the seats (216) in a side
direction, and remove spools (201-1), (201-2)
through the larger hole of seat.

Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
201-1
Never push down spring seat (216-2) in 9.4mm
201-2
(0.370in) or more. (For port 2,4)
Fig. 33-172 Removing spool (201)
(9) Remove spool (201-1), (201-2), spring seats (216-
1), (216-2), spring (241-1), (241-2) and washer 241-1 216-1
(217). 241-2 216-2

217

201-1
201-2

Fig. 33-173 Disassembling pressure reducing valve

(10)Remove spring (*246), spring seat (*218-1), (*218-
2) from push rod (212). *218-1 *246 214
*218-2

The parts marked * might not be equipped depending

on valve type.

212
211

Fig. 33-174 Disassembling push rod

33-112
 33. UPPER STRUCTURE

(11)Pull out push rod (212) from plug (211).

(12)Remove O-ring (214) from plug (211).

212

Fig. 33-175 Removing push rod (212)

(13)Remove inside seal (213) from plug (211) with
small driver.

213

Fig. 33-176 Removing seal (213)

33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.

33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2

217

Fig. 33-177 Assembling pressure reducing valve

33-113
33. UPPER STRUCTURE

(2) Push spring (241-1), (241-2) in the range of that the

movement of spring seats (216-1), (216-2) in a side 216-1
216-2
direction, and install spools (201-1) through the
larger hole of spring seat. (See Fig. 33-172)

Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4mm 201-1
201-2
(0.370in) or more. (For port 2,4)

Fig. 33-178 Installing spools (201-1), (201-2)

(3) Place spring (221) into ports 1,3 of casing (101),
and then install pressure reducing valve assy in it. PRESSURE REDUCING
VALVE ASSY
Place springs (221) into ports 2,4 and install it.

221

Install the removed respective assy into respective

holes. 101

Fig. 33-179 Installing pressure reducing valve assy

(4) Fit O-ring (214) and seal (213) into plug (211).
• Apply hydraulic oil on surface of push rod. 211

214 213
PLUG (211)
SEAL (213)

-RING (214)

PUSH ROD
(212) Apply hydraulic oil

For the assembling

direction of seal (213). Fig. 33-180 Installing O-ring (214) and seal (213)

(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.

The parts marked * might not be equipped depending

on valve type.
212 211 246 218-1

Fig. 33-181 Assembling push rod, spring (246) and

seat (218)

33-114
 33. UPPER STRUCTURE

(6) Fit plug (211) assy to casing (101).

1) When the force of spring (211) is weak, it stops
at the position where it is pushed in by the sliding
resistance of O-ring (214).

101 211

Fig. 33-182 Installing plug assy

2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the 301
same time, and tighten joint (301) temporarily.
• Install spool (201) straight and evenly into the
hole of casing (101).
• Take care so that plug (211) and plate (151) do
not jump out of casing (101).

151

Fig. 33-183 Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A securely.
Jig A : See page 33-118.
Tightening torque : 47.1 N•m (35±2.2 lbf•ft)

101
A

Fig. 33-184 Installing joint (301)

33-115
33. UPPER STRUCTURE

(8) Install circular plate (302) to joint (301)

• Screw it in until it comes in contact with 4 push rods 312

(212) equally.
• The exceeding of screw in may cause malfunction
of machine. 302

(9) Screw adjusting nut (312) in until it touches circular

plate (302), and tighten it applying spanner to stop
circular plate returning.
Fig. 33-185 Installing circular plate (302)
: 32mm

: 22mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 68.6 N•m (51 lbf•ft)
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE

(12)Spray rust preventives through each port and

attach plug respectively.

301
212

Fig. 33-186 Applying grease to joint section and

push rod

33-116
 33. UPPER STRUCTURE

33.2.3.5 MAINTENANCE STANDARDS

Check item Standard Remarks

When leakage quantity reaches to 1000cc/ min.
or more where handle is set in neutral position,
Conditions
or to 2000cc/min. or more in operation, replace
Leakage Primary pressure 2.94 MPa (426 psi)
spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced, replace
pilot valve assy with new one.
When the wear of sliding section is 10 more
This condition may be the same as the
Spool than the that of non sliding section, replace it
above.
with new one.
Push rod When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on
In case of the looseness due to the
Looseness of control circular plate (302) on control section and joint
loosening on tightening section, adjust
section section (301) due to wear is pro- duced, replace
it.
them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6 (
TROUBLESHOOTING), replace pilot valve
assy with new one.

• O-ring, etc. should be replaced with new one at every disassembling.

• If socket bolt (125) was loosened, seal washer (121) should be replaced.

33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.

Trouble Cause Remarks

1) Primary pressure is insufficient. 1) Secure primary pressure.
2) Secondary pressure springs (241) are
2) Replace with new ones.
broken or fatigued.
Secondary pressure
3) Clearance between spool (201) and
does not rise . 3) Replace spool (201).
cas-ing (101 ) is abnormally large.
4) Disassembly and reassembly or
4) Handle has a looseness.
replace handle section.
1) Sliding parts are caught. 1) Repair the unsmoothed section.
Secondary pressure is
2) Tank line pressure varies. 2) Bring pressure directly to oil tank.
unstable.
3) Air has mixed into pipeline. 3) Bleed air by operating it several times.
Secondary pressure is 1) Tank line pressure is high. 1) Bring pressure directly to oil tank.
high 2) Sliding parts are caught. 2) Correct.

33-117
33. UPPER STRUCTURE

33.2.3.7 JIG
(1) Jig for removing and installing joint (301)

(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2) BUSHING
Material ; S45C

SECTION AA

A A

Installing condition on joint

* (1) and (2) are tight fitted

Sectional drawing of jig

Material ; SCM415 (N)

Carburizing and Quenching
Q'ty ; 2
Detail of bushing

33-118
 33. UPPER STRUCTURE

33.2.4 PILOT VALVE (FOR TRAVEL)

33.2.4.1 CONSTRUCTION

T=Tightening torgue
N.m (lbf.ft) 12-o

12-o

7-h
12-o
12-y
5 12-y
12-x 12-x

13

6 8
f

d
Loctite 262 10
g
T=3
g
14
q 11
T=5 (3.7) r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3~5 (2.2~3.7)

Fig. 33-187 Exploded view of pilot valve

No. Parts Q’ty No. Parts Q’ty

5 Rubber boots 2 12-x Seal ø14×20×3 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8×28 4 14 Check valve kit (2)
6-g Set screw M5×8 4 14-q Plug M8 2
7 Retaining plate kit (1) 14-r Ball M6, 35 2
7-h Plate 1 15 Orifice (4)
7-i Capscrew M10×20 2 15-u Plug M6 4
7-j Shaft 2 15-t Orifice M6, ø0.6 4
7-k Set screw M4×10 2 17 Shuttle valve kit (2)
8 Flange kit 4 17-w’ Shuttle valve & orifice 2
10 Control spool 4 17-r Ball M6, 35 2
11 Return spring 4 17-z Orifice M5, ø0.8 2
12 Damper flange kit (4) 21 Plug 4
12-o Damper plunger ø14 4

33-119
33. UPPER STRUCTURE

33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement
 


The pilot control unit does not need to be removed from

the machine to perform this operation.

1) Remove both faulty boots.

(using a flat screw driver if necessary)
2) Replace both boots with a new one.
* Reassembly : 
   

• First fit the lower part of the rubber boot on
the retaining plate between the 2 switch
plates
• Then put the lower part in the external
groove of the retaining plate
• Finish by fitting the upper part of the rubber
boot on the switch plate.

Fig. 33-188
(2) Switch plate removal
1) Remove :

• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-189 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the   

locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)   
3) Fit a M3 screw on the switch plate axis in order
to remove it
(Using pliers if necessary). (See Fig. 33-189
No.2)  

* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-189 No.3)
4) Mark out the position of the switch plate before  
removing it.
Fig. 33-189
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.

33-120
 33. UPPER STRUCTURE

(3) Switch plate adjustment

If the switch plate is replaced, it is necessary to adjust

the regulation screws.
  

1) Unscrew the 2 locking screws using a 2,5mm    
socket wrench (See Fig. 33-190) 
* Reassembly :
• Apply a droplet of Loctite #262 on the
locking screw thread.
• Torque :3 N•m 2.2 (lbf•ft)
2) Set the switch plate horizontally.
3) Screw on simultaneously both regulation screws
using a flat screw driver (5,5×150) until feeling Fig. 33-190
some resistance.

Do not misadjust the two damping screws. (See Fig.

33-191)
Regulation Damping screws
screws to already adjusted
4) Tighten the locking screws to hold the regulation adjust and glued
screws in position.
5) Repeat the operation for the second switch plate
making sure both switch plates are parallel. (See
Fig. 33-190) SWITCH PLATE
The figure is shown
from the backside.
(4) Retaining plate removal
Fig. 33-191
1) Remove
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
2) Unscrew simultaneously both screws holding the
retaining plate using a 8mm socket wrench.
(See Fig. 33-192)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread.
• Torque :30 N•m (22 lbf•ft)

Fig. 33-192

33-121
33. UPPER STRUCTURE

3) Lift the retaining plate to remove it.

(See Fig. 33-193)
* Reassembly :
• Use the retaining plate to insert the 4 guides
into the body simultaneously and
perpendicularly.
(See Fig. 33-193 left side)
4) Reassemble parts in reverse order.
5) Drain the pilot control unit (See 33.2.4.3).

Fig. 33-193
(5) Damping plunger seals replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots. (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-194 No.1) Fig. 33-194
* Reassembly :
• Replace with a new wiper ring. 


  
Always place the damping plunger prior to the wiper


ring, and make sure the wiper ring is correctly

positionned.  


3) Remove the damping plunger (2).   

(Fig. 33-194 No.2)   

Fig. 33-195
4) Using a needle, remove the seal placed inside


 
the body (See Fig. 33-196 No.3, 4) 



* Reassembly :
• Replace with a new seal and grease it.

3 4 
Fig. 33-196

33-122
 33. UPPER STRUCTURE

• Squeeze the seal between your fingers to

obtain a 8-shape.
(See Fig. 33-197 No.5)
• Insert the seal within the groove with your
fingers (lip in bottom position).
(See Fig. 33-197 No.6, 7)
• Push the seal against the side using the 5 6
round head of a small socket wrench. (Fig.
33-197 No.8)

During the reassembly, make sure the seal is correctly

positionned, and pay attention not to damage nor twist
it. 7 8
5) Repeat the operation for the other 3 assemblies. Fig. 33-197

6) Extract the damping springs from the body (using

flat nose pliers).
7) Inspect the damping springs. If defects are
detected, replace the 4 springs.
8) Reassemble parts in reverse order.
(6) Guide/plunger and regulation unit replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
DAMPER
PLUNGER
2) Guide/plunger replacement :
BODY
• Insert the end of a thin screwdriver between
the guide and the body, carefully lift the guide
to remove it from the body.

Hold the guides with the other hand during the

extraction operation to limit the effect of the return
spring.

3) Remove the guide / plunger assembly.

4) Repeat the operation for the other 3 sub-
assemblies.
5) Visually check that the guides / plungers are in
good condition. If defects are present, replace
the 4 sub-assemblies.

Fig. 33-198

33-123
33. UPPER STRUCTURE

6) Guide/plunger and relulation unit replacement

• Extract the regulation units from the body
(using flat nose pliers).
• Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7) Return spring replacement :
• Extract the return springs from the body
(using flat nose pliers).

Fig. 33-199
• Inspect the return springs. If defects are
detected, replace the 4 springs.

8) Reassemble parts in reverse order.

Fig. 33-200
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))

Fig. 33-201

33-124
 33. UPPER STRUCTURE

2) Unscrew the screw using a 3mm socket wrench.

(See Fig. 33-201)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread
• Screw on until it sets just above the body.
(See Fig. 33-202)
3) Unscrew the throttle using a 3mm socket
wrench.
* Reassembly :
• Torque :4 N•m (3 lbf•ft)
4) Repeat the operation for the other 3 assemblies.
SCREW
5) Replace with new screws and new throttles.
6) Reassemble parts in reverse order.

THROTTLE

Fig. 33-202
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine

The pilot control unit does not need to be disassembled

to perform this operation.

2) Unscrew the shuttle valve using a 4mm socket

wrench. (See Fig. 33-203 and Fig. 33-204)
* Reassembly :
• Thoroughly clean the body to remove any
trace of loctite. Fig. 33-203

• Apply a droplet of Loctite #242 on the

shuttle valve thread.
• Torque :4 N•m (3 lbf•ft)

Wait for 8 hours before using the machine to let the

Loctite #242 dry completely.

Fig. 33-204

33-125
33. UPPER STRUCTURE

3) Turn the body upside down to remove the shuttle

valve and the ball. (See Fig. 33-206)
4) Unscrew the throttle using a 2,5mm socket
wrench.
* Reassembly:
• Hand tighten.
5) Repeat the operation for the other
subassemblies.
6) Inspect the shuttle valves, balls and throttles. If
defects are detected, replace all the assemblies.
7) Reassemble parts in reverse order.
Fig. 33-205

 

 

Fig. 33-206
(9) Check valve kit removal
1) Remove the pilot control unit from the machine

The pilot control unit does not need to be disassembled

to perform this operation.

2) Unscrew the check valve plug using a 4mm

socket wrench.
(See Fig. 33-207)
* Reassembly :
• Drain the pilot control unit
(See 33.2.4.3)
Fig. 33-207
• Torque :5 N•m (3.7lbf•ft)
3) Turn the body upside down to remove the ball.
4) Repeat the operation for the second check valve
kit.
5) Inspect the check valve plugs, O-rings and balls.
If defects are detected, replace all the
assemblies. (See Fig. 33-208)
6) Reassemble parts in reverse order.

  




Fig. 33-208

33-126
 33. UPPER STRUCTURE

33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

(1) When removing the retaining plate, the throttle kit or
the shuttle valve kit, it is necessary to drain the pilot
unit.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug using a 4mm
socket wrench. (See Fig. 33-209)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
• Torque : 5 N•m (3.7 lbf•ft)
(8) Repeat the operation for the other check valve plug.

Fig. 33-209

33-127
33. UPPER STRUCTURE

33.2.5 SWING MOTOR UNIT

33.2.5.1 CONSTRUCTION
(1) Swing motor

992

451 452
303 131 444

b
A

351

355 SECTION A-A

051

401
488 469 (051-1)

468
106 487 444 433 981 390 438 452 980
391

Tightening forgue
303
472 Tightening Widfh
No. Size torque
451 N.m (lbf.ft) across flat
707
712 051 M33X1.5 177(131) 41
A 706
A 401 M16 240(177) 14
131
982
468 G1/4 36(27) 6
702
114 469 M22X1.5 108(80) 10
111
117 980 G3/8 1.7(1.3) 6
743 981 G3/4 4.4(3.2)
121 14
742 982 G1/4 0.9(0.66) 6
113
992 PT3/4 98(72) 14
123

116

117
301
432 471 443 106 101 491 304 437 124 122

Fig. 33-210 Swing motor

33-128
 33. UPPER STRUCTURE

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Drive shaft 1 443 Roller bearing 1
106 Spacer 3 444 Roller bearing 1
111 Cylinder 1 451 Pin 2
113 Retainer (spherical bushing) 1 36 (27) 468 VP plug : PF1/4 2
114 Cylinder spring 1 108 (80) 469 RO plug : M22 2
116 Push rod 12 471 O-ring : 1B G80 1
117 Spacer 2 472 O-ring 1
121 Piston 9 487 O-ring : 1B P11 2
122 Shoe 9 488 O-ring : 1B P20 2
123 Plate 1 491 Oil seal 1
124 Shoe plate 1 702 Brake piston 1
131 Valve plate 1 706 O-ring 1
301 Casing 1 707 O-ring 1
303 Casing 1 712 Brake spring 20
304 Front cover 1 742 Friction plate 3
351 Plunger 2 743 Separator plate 4
355 Spring 2 1.7 (1.2) 980 Plug : PF3/8 1
240 (177) 401 Socket bolt : M16×75 4 4.4 (3.3) 981 Plug : PF3/4 1
432 Snap ring 2 0.9 (0.6) 982 Plug : PF1/4 1
433 Ring 1 98 (72) 992 Plug : PT3/4 1
437 Snap ring 1 177 (131) 051 Relief valve : M33 2
438 Snap ring 1 051-1 O-ring : 1B G30 2

33-129
33. UPPER STRUCTURE

(2) Swing reduction unit

602 230 231 204 286 211 912 285 287 911 283 403 603 922
210
921
282
202
*
203

913
285

*
402
910

801

925

920
390

926

102

401

Apply Three Bond #1217 on . 915

201

Fig. 33-211 Sectional view of swing reduction unit

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12×100 8
203 No.2 planetary gear 4 603 Socket bolt : M12×135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
230 No.2 spider 1 912 Retaining ring 1
231 No.1 spider 1 913 Retaining ring 1
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1

33-130
 33. UPPER STRUCTURE

33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

33.2.5.2.1 TOOLS AND JIGS

(1) Spanner wrench

OPPOSING
NAME SIZE APPLICABLE PARTS TOOL
FLATS mm
CAPSCREW M6 10 Selector valve for brake Spanner, Socket wrench
SOCKET BOLT M8 6 Swing shockless valve block Allen wrench
SOCKET BOLT M16 14 Valve casing Allen wrench
PLUG M22 10 RO plug Allen wrench
PLUG PF1/4 6 ROH plug Spanner, Socket wrench
ATTACHING SCREW M22 24 Swing shockless valve Spanner, Socket wrench
ATTACHING SCREW M33 41 Relief valve Spanner, Socket wrench

(2) Other tools and jigs

SPECIFICATION
REMARKS
TOOLS
For snap ring For ø35 (1.38") shaft
Pliers
For Locking ring For ø80 (3.15") hole
Screwdriver Flat-bladed type, medium size 2 pcs.
Steel bar 10×8×200 or so 1pc. (0.394"×0.315"×7.87" )
Hammer Plastic hammer Iron hammer 1 each
Torque adjusting range
Torque wrench
• For 0.09~24kgf•m (0.65~174 lbf•ft)
Slide hammer bearing puller
Brake piston drawing tool Fig. 33-212

2 X 7 (0.276")
(1.57")
40

M10 SCREW ON BOTH ENDS

(EFFECTIVE THREAD
LENGTH 20 (0.787") 40 (1.57")
100 (4")

250 (10")

BORE DIA. 11
(0.433")
10 (0.4")

2 X NUT M10

M10
123 (4.84")
200 (7.87")

Fig. 33-212 Brake piston drawing tool

33-131
33. UPPER STRUCTURE

33.2.5.2.2 DISASSEMBLY PROCEDURE

(1) Cleaning the swing motor
Place a wire sling around the motor, lift it up and
clean it. After cleaning, dry it with jet air.

Put plugs into all ports to prevent foreign matter from

entering the motor and clean the motor to be free from
dirt and dust.

(2) Draining out lube oil

Drain out the oil from the drain port of casing (301).
(3) Fixing the motor to the work bench.
Direct the shaft end of the drive shaft (101) down
and fix it on a bench convenient for disassembly.
On that occasion, leave a matching mark on the
mating part between casing (301) and valve cover
(303).
303

Choose a clean place. Place a rubber sheet or a cloth 301

on the work bench. Exercise care so as not to damage
parts.
Fig. 33-213 Fixing the motor to the work bench and
putting a matching mark
(4) Remove relief valve
Loosen relief valve (051) and separate it from valve 303
cover (303). 051

: 41 mm
(5) Remove swing shockless valve block
Loosen socket bolt (V171) and separate swing
shockless valve block (052) from valve casing
(303).

: 6 mm
(6) Removing the anti-cavitation check plunger Fig. 33-214 Removing relief valve
Separate RO plug (469) from valve casing (303)
V171 052 303
and draw out spring (355) and plunger (351).

: 10 mm

Exercise care so as not to score the plunger seat.

Fig. 33-215 Removing swing shockless valve block

33-132
 33. UPPER STRUCTURE

(7) Remove valve casing and valve plate

Loosen socket bolt (401) and separate valve casing
(303) from casing (301).
[If the socket bolt (401) are loosened, the valve 401
casing floats off casing (301) by the force of brake
spring (712)].
303
Then separate valve plate (131) from valve casing
(303). 301

: 14 mm

Fig. 33-216 Removing valve casing No.1

Work with care so the valve seat does not come off from
the valve casing.
(In some cases, the valve plate is adhered on the
cylinder side.)
When inserting a screwdriver or something between
the matching surfaces, use care so as not to score the
matching surfaces.

(8) Remove brake spring

303
Draw out brake spring (712) from brake piston
(702).

712

301

Fig. 33-217 Removing valve casing No.2

(9) Remove brake piston
Draw out brake piston (702) from casing (301),
using a jig (slide hammer).
702

Hold it upright, utilizing the bolt holes in the brake

301
piston.

Fig. 33-218 Removing brake piston

33-133
33. UPPER STRUCTURE

(10)Remove cylinder
301
Place the motor level and draw out the cylinder
(111) from the drive shaft (101). Then draw out
piston (121), retainer plate (123), spacer (117) and
shoe plate (124).

• Use care when drawing out the cylinder as push rod

(116) tends to come off. Exercise care so as not to
score the sliding surfaces of the cylinder, retainer
111
and shoe.
Fig. 33-219 Removing cylinder
• In case the shoe plate does not come off, remove it
after the work sequence (12).

(11)Remove separator plate

Draw out friction plate (742) and separator plate 437
(743) from casing (301).

304

301

Fig. 33-220 Removing snap ring

(12)Remove front cover
Take off snap ring (437) with pliers and separate
front cover (304) from casing (301).

304

• When drawing out the front cover, take care so as

not to score the sliding surface of the oil seal.
• You may remove the front cover with the drive shaft.
301

Fig. 33-221 Removing front cover

33-134
 33. UPPER STRUCTURE

(13)Remove drive shaft

Separate drive shaft (101) from casing (301) by
lightly tapping the end face of the valve casing side
(303) of drive shaft (101), using a plastic mallet.

Use care so as not to score the sliding surface of the oil

seal.

(14)Remove shoe plate 101 301

Draw out shoe plate (124) from the housing side of Fig. 33-222 Removing drive shaft
roller bearing (443) of casing (301) by lightly
tapping it with a steel rod.
(15)Remove inner race of roller bearing (443)

Remove snap ring (432) and spacer (106) from
 

drive shaft (101) and draw out the inner race of
roller bearing (443) by means of a press.
  


You may knock on the inner race of the roller bearing

with a steel bar, but knock on it evenly all around so the
bearing is not damaged.    
   
Do not use the removed bearing again.

Fig. 33-223 Removing inner race of roller bearing

(16)Remove oil seal
Draw out oil seal (491) from front cover (304),
utilizing the jig.
304
(491)

Do not reuse the removed oil seal.


 



Fig. 33-224 Removing oil seal

 

(17)Remove roller bearing

SLIDE HAMMER
Separate roller bearing (444) from valve casing
101
(303), using a slide hammer bearing puller.
444

303
Do not reuse the removed bearing.

Fig. 33-225 Removing roller bearing (444)

33-135
33. UPPER STRUCTURE

33.2.5.2.3 ASSEMBLY PROCEDURE

(1) Holding casing
301
Place the casing (301) facing its valve casing (303)
downward.

Fig. 33-226 Holding casing

(2) Installing inner race of roller bearing
Fit snap ring (432) and spacer (106) to drive shaft
(101), insert the inner race of roller bearing (443),
and shrinkage fit the inner race.
Put spacer (106) in and fix snap ring (432).
444

101

Beware of the orientation of the inner race of the roller 106

bearing.
   !
 
    

    
 Fig. 33-227 Installing roller bearing (443)
    

432



Fig. 33-228 Installing snap ring (432)

(3) Shrinkage fitting inner race of roller bearing (444)
Shrinkage-fit the inner race of roller bearing (444) to
drive shaft (101). Then fit snap ring (433). 444

(4) Installing outer race of roller bearing (443)

Place drive shaft (101) with roller bearing (443) on
its output shaft, and insert the drive shaft into casing
101
(301). Then lightly knock on the outer race of roller
bearing (443) via a steel bar, using a hammer.

Knock on the outer circumference of the outer race

Fig. 33-229 Shrinkage fitting inner race
evenly all round till it stops at the step of the casing.
of roller bearing (444)

33-136
 33. UPPER STRUCTURE

(5) Insert oil seal

Put oil seal (491) into front cover (304), using a jig.

• Be careful about the direction of the oil seal.

• Fix the oil seal till it stops at the step of the casing.

304 (491)

Fig. 33-230 Inserting oil seal

(6) Fit O-ring
Fit O-ring (471) to casing (301). 471

301

Fig. 33-231 Fitting O-ring

 
 




Fig. 33-232 Wind tape around the spline of the drive

shaft

33-137
33. UPPER STRUCTURE

(7) Installing front cover

Fit front cover (304) to casing (301) by lightly 304
tapping the cover with a plastic mallet

Coat the lip of the oil seal with a thin film of grease and
put it in with care so as not to score the lip of it. (Wind
tape on the spline of the drive shaft so the lip of it is not
scored by the spline.)
Tap the outer circumference evenly round to prevent it
from being scored.
Fig. 33-233 Installing front cover
(8) Fitting the snap ring
Fit snap ring (437) to casing (301), using pliers. 124
(9) Put shoe plate (124) into casing (301).

Put the larger chamfer side of the shoe plate into the
301
casing side.
Coat the matching surface with a thin film of grease to
prevent the shoe plate from falling off.

Fig. 33-234 Inserting shoe plate

(10)Insert push rod
Put push rod (116) in cylinder (111).

111
Use care so as not to score the sliding surface of the
cylinder.
(Put two push rods into one hole.)

116

Fig. 33-235 Inserting push rod

(11)Installing retainer
113
Then mount retainer (113) fitted with spacer (117)
on the cylinder.

117

Fig. 33-236 Installing retainer

33-138
 33. UPPER STRUCTURE

(12)Installing the piston sub assy to the plate

123
Set piston sub assy (121,122) to plate (123).

121,122

Fig. 33-237 Installing the piston sub assy to the

plate
(13)Assembling the piston sub assy into the cylinder
121,122,123
Assemble piston sub assy (121,122) with plate 111
(123) into cylinder (111) and insert it in place,
aligning it with the spline of drive shaft (101).

The drive shaft can be set easily if the phase of the

retainer (113) and the cylinder spline is matched.

101

Fig. 33-238 Assembling the piston sub assy into the

cylinder
(14)Installing separator plate and friction plate
743
Replace casing (301) so front cover (304) side
faces down. Then Assemble separator plate (743)
and friction plate (742) into casing (301), in that
order.
Fit four separate plates and three friction plates.

301

Assemble four notches in the gear teeth of friction plate

so the same phases are aligned up and down.
Fix notches in the four claws of separator plate in the
position in Fig. 33-239. Fig. 33-239 Installing separator plate

742

301

   

Fig. 33-240 Installing friction plate

33-139
33. UPPER STRUCTURE

(15)Fit O-ring
707 (706)
Fit O-rings (706)(707) to casing (301).

In that case, coat the O-rings with grease beforehand. 301

This will prevent the O-rings from breaking when
inserting brake piston.

Fig. 33-241 Fitting O-ring

(16)Installing brake piston
Fit brake piston (702) to casing (301). 702

301
Install the brake piston so four slits of it are positioned
as shown in the figure on the right. (Match the M8
screws to the figure on the right.)

   

Fig. 33-242 Installing brake piston


  

If brake piston is hard to enter because of the

resistance of the O-rings, screw in socket bolt M8 into
the brake piston and knock on it evenly by means of a
plastic mallet.

(17)Installing brake spring

702 712
Fit brake spring (712) to brake piston (702).

At that time, make sure that the spring is set snugly in

the spotface of the brake piston.

Fig. 33-243 Installing brake spring

33-140
 33. UPPER STRUCTURE

(18)Insert outer race of roller bearing

Insert the outer race of roller bearing (444) into
valve casing (303), knocking it lightly by means of a
steel bar.
444

303
Knock on the outer circumference of the outer race
evenly around and fix it so it stops at the step of the
valve casing.

Fig. 33-244 Inserting outer race of roller bearing

(19)Installing valve plate
Assemble valve plate (131) into valve casing (303) 
and then fit O-ring (472) in place.

Coat the contact surface of the valve plate with a thin

film of grease. (To prevent it from falling off.)

 


Fig. 33-245 Installing valve plate

(20)Installing valve casing
Attach valve casing (303) to casing (301) and
fasten it with socket bolt (401).

: 14 mm
Tightening torque : 240N•m (170 lbf•ft)

303

• Beware of the direction of the valve casing. 301

• Be careful so the valve plate does not come off.
• Use care so the brake spring does not fall down.
• Fasten the socket bolts evenly all around. Fig. 33-246 Installing valve casing

(21)Fitting plunger
Place plunger (351) and spring (355) into valve 401 351
casing. Fasten RO plug (469) with O-ring (488) into
valve casing.

: 10 mm
Tightening torque : 108N•m (80 lbf•ft)

Make sure that the plunger moves smoothly.

355(488,469)

Fig. 33-247 Fitting plunger

33-141
33. UPPER STRUCTURE

(22)Installing relief valve

Fit backup ring (162) and O-ring (161) to relief valve 303
051 (051-1)
(051) and fasten the relief valve against valve
casing (303).

: 41 mm
Tightening torque : 177N•m (130 lbf•ft)
(23)Installing plugs (464),(468)
Fit O-ring (487) to plug (468), attach it to valve
casing (303), fit O-ring (485) to plug (464) and
fasten it against casing (301). Fig. 33-248 Installing relief valve

: 19 mm
Tightening torque : 36N•m (27 lbf•ft)
(24)Installing swing shockless valve block
052(V161) 303
Fit O-ring (V161) to the swing shockless valve V171
block. Then fasten the valve block against valve
casing (303) with socket bolts (V171).

: 6 mm
Tightening torque : 29N•m (22 lbf•ft)

Fig. 33-249 Installing swing shockless valve block

33-142
 33. UPPER STRUCTURE

33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

33.2.5.3.1 TOOLS AND JIGS

(1) Tools

NAME REMARKS
Allen wrench Opposing flats 6,10mm
Socket wrench
Adjust wrench
Double ended wrench
Hammer
Plastic mallet
Screwdriver
Torque wrench
Liquid packing Three-Bond #1104B
Oil container for shrinkage fit work 80~100°C (176~212°F)

(2) Jigs

1) Oil seal fitting jig 2) Roller bearing (401) removing jig

3) Roller bearing (402) fitting jig

33-143
33. UPPER STRUCTURE

33.2.5.3.2 DISASSEMBLY PROCEDURE

(1) Remove swing motor unit and drain oil
Remove the swing motor unit from the machine,
loosen plug (902) at the oil outlet, discharge the
gear oil and place the unit on a work bench.

Receive gear oil in a clean container and inspect for the

presence of worn particles.

(2) Remove hydraulic motor

Loosen socket bolts (602) and remove the
hydraulic motor.

: 10 mm
(3) Remove No.1 sun gear (211)
211

Fig. 33-250 Removing No.1 sun gear

(4) Remove No.1 carrier assy
Remove the No.1 carrier assy with the No.1
planetary gear (210) and others.

210

Fig. 33-251 Removing No.1 carrier assy

33-144
 33. UPPER STRUCTURE

(5) Disassembly No.1 carrier assy

Put a matching mark on each of the planetary gears

and pins so combination and pairing do not change.

1) Remove snap ring (911). Then remove side plate 911

(287) at the top.
287
2) Remove No.1 planetary gear (210) and needle
bearing (403). Fig. 33-252 Removing snap ring

403 210

Fig. 33-253 Removing needle bearing

3) Remove side plate (285) under the planetary
gear. 285

Fig. 33-254 Removing side plate

4) After removing three No.1 planetary gears (210),
remove thrust washer (286) in the center.

286

• Do not remove No.1 pin (283) from No.1 carrier

(231) unless there is anything wrong.
• If the No.1 pin is removed, you need a special
caulking tool at reassembly.
2 (0.079")
However, make sure that the ø2(0.079") oil hole of
(OIL HOLE)
No.1 pin (283) is directed outwards with respect to
the center of No.1 carrier (231).
(Refer to Fig. 33-255 below.)

Fig. 33-255 Removing thrust washer

33-145
33. UPPER STRUCTURE

(6) Remove No.2 sun gear (204)

204

Fig. 33-256 Removing No.2 sun gear

(7) Remove No.2 carrier assy
No.2 CARRIER ASSY

Fig. 33-257 Removing No.2 carrier assy

(8) Disassembly No.2 carrier assy
282,910

Do not disassemble the No.2 carrier assy further unless 203,285

there is anything wrong. In this condition, inspect the
parts according to the inspection procedure specified
under 33.2.5.4.2 (1).
As mentioned above, it is recommended that the No.2
carrier assy be replaced as a pair, but in case part of it
must be replaced for an unavoidable reason, do it as
below:
Fig. 33-258 Removing No.2 pin
1) Push spring pin (910) in further and draw out
No.2 pin (282).

Do not reuse the removed No.2 pin.

2) Draw out No.2 planetary gear (203) and side

plate (285) sideways.

33-146
 33. UPPER STRUCTURE

(9) Remove ring gear (202) 202

The bottom of the two holes is provided with M12
screw threads to draw out the ring gear. Utilise
motor mounting socket bolts (602) to draw it out.

: 10 mm

Fig. 33-259 Removing ring gear

(10)Separate snap ring (913) from drive shaft (201).
(11)Remove drive shaft
913
Support the flanged part of the drive shaft so the
shaft end faces down and place the drive shaft on a
work bench. Draw out the shaft downwards, while 201
tapping the center of it with a plastic mallet.

• Do not disassemble it further unless there is

anything wrong.
At this stage, inspect the parts according to the
Fig. 33-260 Removing snap ring
inspection procedure specified under 33.2.5.4.2
(1).
As mentioned above, we recommend that the drive
shaft assy be replaced as a set. In case part of it
must be replaced for an unavoidable reason, do as
follows:
• If nothing faulty is discovered on inspection at this
stage, no further disassembly is needed.

33-147
33. UPPER STRUCTURE

(12)Remove roller bearing

As shown on Fig. 33-261 on the right, support the PRESS

drive shaft assy, and draw out bearing seal (915) JIG 2
and roller bearing (401), using a press.

• Roller bearing (402) is left in the casing. Since the

shaft falls down, use care so as not to damage it.
• The removed oil seal and the bearing seal can not
be used again.
915

401

Fig. 33-261 Removing roller bearing

(13)Remove oil seal (801) from casing (102).
102

801

Fig. 33-262 Removing oil seal

33-148
 33. UPPER STRUCTURE

33.2.5.3.3 ASSEMBLY PROCEDURE

(1) Assembly drive shaft assy
402
1) Insert bearing seal
801
Insert bearing seal (915) into drive shaft (201). 102
GREASE
401

915

201
Fig. 33-263 Assembling drive shaft
2) Press-fitting roller bearing
Coat the inside of roller bearing (401) with GREASE
sufficient grease and press it into the drive shaft,
using a press. Set the inner race firm into the
shaft by knocking on the steel bar, till the
hammer springs back. Then apply grease so it
reaps as shown in Fig. 33-264.

• Grease :EP type

201
(Shell Alvania grease EP2)
Fig. 33-264 Applying grease to roller bearing
• Roller bearing (401) has a bank in the middle. Push
grease in to both sides before assembling the
bearing into the shaft.

(2) Place casing (102) on a level bench.

(3) Installing drive shaft assy
Lift the drive shaft assy upright, using the screw in
the end of the shaft and put it into the casing.
Thread size : M10, Depth 20mm
201

102
Lightly tap the outer race of the bearing so it is
completely level. If the outer race is tilted, it does not
enter by light tapping in some cases. On such occasion,
pull it out once, place it level and do the job once again.
Fig. 33-265 Installing drive shaft assy
(4) Place the casing by supporting the flanged part so
the shaft end faces down.
(5) Installing oil seal
Insert oil seal (801) into casing (102).

• Use the jig 1) under 33.2.5.2.1 (2).

• Place the oil seal level and fix it so the lip is not
scored.

33-149
33. UPPER STRUCTURE

(6) Press-fitting roller bearing

Insert roller bearing (402) by using the jig that holds
JIG
down both the inner race and the outer race and
also using a press.
Always use the jig 33.2.5.2.1 (2) and set it properly.

402

Fig. 33-266 Press-fitting roller bearing

(7) Fit snap ring (913) 913
(8) Fitting the oil filling plug
Fill up the oil inlet with grease, wind seal tape
around plug (902) and set it to the casing.
Grease : EP type (Shell Alvania EP2)
Grease volume : about 500cc (31 cu•in)

: 6 mm
Tightening torque : 220N•m (160 lbf•ft)

Fig. 33-267 Fitting snap ring

(9) Assembly No.2 carrier assy
230 285 282 203
1) Place side plate (285) by matching it to the pin
holes.
2) Put No.2 planetary gear (203) in.
3) Check the hole location, peeping through it from
above. Match the No.2 pin (282) with the hole for
spring pin (910) and the hole in the No.2 carrier
910
and set the pin, while tapping it lightly.
(10)Apply liquid packing to the matching surface Fig. 33-268 Assembling No.2 carrier assy
between casing (102) and ring gear (202).

Three-Bond #1104B

33-150
 33. UPPER STRUCTURE

(11)Installing ring gear

Install ring gear (202) to casing (102), checking the
location of the matching marks and temporarily
fasten them together by means of four capscrews 202
or socket bolts M12×100. (Tightening torque :
78N•m (58 lbf•ft) or over). Always place plain 102
washers on the bolts so the matching surface of the
motor is not scored.

: 19mm or : 10mm

Fig. 33-269 Installing ring gear

(12)Installing No.2 carrier assy
Install the No.2 carrier assy into the ring gear.
No.2
(13)Installing No.2 sun gear CARRIER
Put in No.2 sun gear (204). ASSY

Fig. 33-270 Installing No.2 carrier assy

(14)Assembly No.1 carrier assy
204 286 211 285 287 283 403 210
1) Place No.1 carrier (231) on a level bench. 231
2) Make sure that all three ø2(0.079" ) oil holes of
No.1 pin (283) are directed outwards with
respect to the center of No.1 carrier (231), as
shown in the figure.

2 (0.079")
(OIL HOLE)
231 Fig. 33-271 Assembling No.1 carrier assy

3) Installing thrust washer

Put in thrust washer (286) in the center.

286

Fig. 33-272 Installing thrust washer

33-151
33. UPPER STRUCTURE

4) Installing side plate

Put in side plates (285).
286

The upper and lower side plates differ in thickness; take

care so as not to mistake one for another.

403
285

Fig. 33-273 Installing side plate and needle bearing

5) Installing needle bearing and No.1 planetary
gear
Fit needle bearing (403) and No.1 planetary gear
(210).

210

Fig. 33-274 Installing planetary gear

6) Installing side plate
Put side plate (287) in and fit snap ring (911).

'

&%
Fig. 33-275 Installing side plate and snap ring
(15)Installing No.1 carrier assy
No.1 CARRIER ASSY
Assemble the No.1 carrier assy. Make sure that
thrust washer (286) in the center sits in the convex
part of No.2 sun gear (204). 286

204

Fig. 33-276 Installing No.1 carrier assy

33-152
 33. UPPER STRUCTURE

(16)Installing No.1 sun gear

Assemble No.1 sun gear (211).
211
(17)Apply liquid packing
Remove the temporarily fastened bolts and coat the
mounting surface of the hydraulic motor of ring gear
202
(202) with liquid packing (Three-Bond #1104B).
(18)Installing hydraulic motor
Fit snap ring (912) to the drive shaft of the hydraulic
motor, lower it vertically, assemble the hydraulic
motor in place, while matching it with the spline
position and fasten it with socket bolt (602).

: 10 mm Fig. 33-277 Installing No.1 sun gear

Tightening torque : 98N•m (72 lbf•ft)
(19)Wind seal tape around oil drain plug (902) and fit it
to the casing.

: 6 mm
Tightening torque : 22N•m (16 lbf•ft)
(20)Filling oil
Fill in gear oil through the oil inlet.
Lubricating oil: SAE#90~#140, API class GL3~4
(Shell Spirax 90EP filled up at shipping)
Lubricant volume : 1.7L (0.45gal)

Temporarily fit the level bar to the pipe and check the
level.

33-153
33. UPPER STRUCTURE

33.2.5.4 MAINTENANCE STANDARDS

33.2.5.4.1 SWING MOTOR

(1) Replacement standards for parts
If part are worn out beyond the below standards, replace or recondition them. However if they show excessive
damage on their surface, replace them.

Recommended
Standard
Value for
Item Dimension Remedy
replacement
mm (in)
mm (in)
Clearance between piston and cylinder
bore (D-d)

0.016 0.046
Replace piston or cylinder.
d D (0.00063) (0.00181)

Gap between piston and caulked part of

shoe ( )

0 0.3
Replace piston and shoe assembly.
(0.012)

Thickness of shoe (t)

4.0 3.8
Replace piston and shoe assembly.
(0.157) (0.150)
t

Assembled height of shoe plate and

retainer (H-h)

5.5 5.0 Replace a spherical bushing and a

H (0.217) (0.197) retainer plate as a pair.
h

Thickness of friction plate

3.5 3.1
Replace.
t (0.138) (0.122)

33-154
 33. UPPER STRUCTURE

(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace the
part.

Standard for correcting sliding surfaces

STANDARD SURFACE SURFACE ROUGHNESS
NAME OF PART
ROUGHNESS REQUIRING CORRECTION
0.8-Z (Ra=0.2)
SHOE 3-Z (Ra=0.8)
(Lapping)
0.4-Z (Ra=0.1)
SHOE PLATE 3-Z (Ra=0.8)
(Lapping)
1.6-Z (Ra=0.4)
CYLINDER 12.5-Z (Ra=3.2)
(Lapping)
0.8-Z (Ra=0.2)
VALVE PLATE 6.3-Z (Ra=1.6)
(Lapping)

• Lap each sliding surface to a standard roughness level or finer.

• If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace
parts in pairs.

33-155
33. UPPER STRUCTURE

33.2.5.4.2 REDUCTION UNIT

(1) Parts inspection and replacement standards
1) If pitching is seen on the tooth surface of the sun gear, the planetary gear and the ring gear;
(Single pit is more than ø1mm(0.039in) and the area occupancy of all pits is more than 5%.)
2) Oil seal
Replace the oil seal if the lip face of it is scored and worn.
Always replace when the reduction gear is disassembled for inspection or some reason.
3) Drive shaft roller bearing (Front side)
Inspect as below without drawing it out from the drive shaft:
1. Inspect the race surface and the rollers as far as you can see and make sure that there is no pitching
and flaking.
2. Inspect the following as well:
a. The gear oil does not contain large worn particles.
b. Large worn particles are not deposited between the roller and the retainer.
c. The bearing turns smoothly by hand.
Replace it if there is any fault on the above inspection.
Do not reuse the bearings drawn out of the shaft.
4) Drive shaft roller bearing (Rear side)
Replace the bearing if the race surface and the rollers show pitching and flaking.
5) No.2 planetary gear
Check for the circumferential gap between the No.2 planetary gear and the No.2 pin without disassembling
the No.2 carrier assy. Replace the planetary gear if the gap is more than 0.5.
6) Thrust plate and thrust washers
Replace the gear if the sliding surface in contact with the No.2 sun gear is extremely scored.
7) If pitching and flaking are seen on the rolling surfaces of the needle cage and the No.1 pin that support the
No.1 planetary gear; Replace such faulty parts.

33-156
 33. UPPER STRUCTURE

(2) Table of parts to be replaced together

marks represent such parts that must be replaced together.

marks represent such parts that should preferably be replaced together.

Replace the inner race and the outer race of the roller bearing together.

$   ! 

        
     

  

  

 
 
 

# !
 !

 !
 

" 
"# 
 

 
  
  
  
   
$  !%

  !

   

"# 
 " 
   
  !
   
 # !

33-157
33. UPPER STRUCTURE

33.2.5.5 TROUBLESHOOTING

33.2.5.5.1 SWING MOTOR

(1) Hydraulic motor does not rotate.

TROUBLE CAUSE REMEDY

Pressure does not rise. 1. Relief valve in circuit is not set correctly. 1. Set to correct value.
2. Malfunction of relief valve. 2.
2-1 Correct the stuck areas or replace the
2-1 Sticking plunger.
plunger.
2-2 Orifice on plunger is clogged. 2-2 Disassemble and clean.
3. Plunger seat is faulty. 3. Check the seat surface and replace the
plunger if scored.
4. Swing shockless valve seat is faulty. 4. Replace the swing shockless valve
cartridge or block.
Pressure rises. 1. Overload 1. Eliminate overload.
2. Moving parts are seized. 2. Inspect and repair piston, shoe and
cylinder valve plate.
3. Brake release pressure is not working on 3. Check circuit and correct it.
the motor
4. Brake piston is stuck. 4. Disassemble and check.
5. Friction plate is seized. 5. Disassemble, check and repair.
Replace one that is seized.

(2) Rotating direction is opposite.

TROUBLE CAUSE REMEDY

Rotating direction is 1. Motor's assembling direction is reversed. 1. Assemble correctly.
opposite.
2. Piping inlets and outlets are reversed. 2. Pipe correctly.

(3) Revolution does not rise to set value.

TROUBLE CAUSE REMEDY

Revolution does not rise 1. Oil inflow is deficient. 1. Check pump's delivery rate and circuits to
to set value motor.
2. Oil leaks are excessive due to high 2. Lower oil temperature.
temperature.
3. Sliding surfaces are worn or broken. 3. Replace.

(4) Brake torque is insufficient.

TROUBLE CAUSE REMEDY

Brake torque is 1. Friction plate is worn.
insufficient.
2. Brake piston is stuck.
3. Brake release pressure is not released.
4. Spline of friction plate is broken.
1. Disassemble and check. Replace if wear
is beyond standard value.
2. Disassemble and check.
3. Check and correct circuit.
4. Disassemble and check.
Replace broken part.

33-158
 33. UPPER STRUCTURE

(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor. If it is less than 200cc/min(12cu•in/min), you should think that the
motor is not faulty.

TROUBLE CAUSE REMEDY

The swing motor drifts 1. Relief valve malfunctions. 1.
much when it is actuated Same as (1). Same as (1).
by external torques. (e.g. 2. Plunger seat is faulty. 2. Replace.
Machine is on a slope.) 3. Seat of the swing shockless valve is no 3. Replace the swing shockless valve
good. cartridge or block.

(6) Oil leaks

1) Oil leak from oil seal

TROUBLE CAUSE REMEDY

Oil leaks from oil seal 1. Lip of seal contains dirt and damaged. 1. Replace oil seal.
2. Shaft is damaged or worn. 2. Shift the lip and shaft positions or replace
oil seal.
3. Casing inner pressure has risen 3. Repair drain piping if clogged up.
abnormally high, with the result that lip of
oil seal has turned up.
4. Shaft is rusted. 4. Disassemble and correct.

2) Oil leak from matching surface

TROUBLE CAUSE REMEDY

Oil leak from matching 1. O-ring is missing. 1. Set O-ring correctly and assemble it.
surface 2. O-ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or broken. 4. Tighten to specified torque or replace.

33-159
33. UPPER STRUCTURE

33.2.5.6 REDUCTION UNIT

Trouble Cause Remedy

1) Reduction unit does not turn.

Hydraulic motor inlet pressure has risen. Overloaded Reduce the motor of load.

Reduction unit is broken. Replace reduction unit.

Parking brake of the hydraulic Inspect the release

motor is not released. pressure and the brake.

Check the release

Hydraulic motor inlet pressure has not risen. command pressure.

Rotating sound is heard from

Motor shaft is broken. Replace hydraulic motor.
hydraulic motor.

Reduction unit is broken. Replace reduction unit.

Rotating sound is not heard from

Pump and valve are out of order. Check for fault and correct.
hydraulic motor.

2) Oil leakage

Oil leaks through matching surface. Liquid packing is not applied. Disassemble and apply
liquid packing.

Bolts are not fastened tight. Disassemble, apply liquid

The matching surface is moving packing and reassemble
because of loosening. as specified.

The matching surface is scored. Replace faulty parts.

Oil leaks from shaft. Oil seal is scored. Disassemble reduction

unit and replace oil seal.

3) Temperature is high.

Temperature of reduction unit casing is high. The gear oil is not filled up or Check oil level and fill oil
the oil level is low. up to a specified level.

The amount of grease is small. Fill up grease.

Gear and bearing are damaged. Replace reduction unit.

33-160
 33. UPPER STRUCTURE

33.2.6 SWIVEL JOINT

33.2.6.1 CONSTRUCTION VIEW

2 places Apply Three Bond

#1805 to stem

2 places
VIEW Y

5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH

Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242

Fig. 33-278 Construction of swivel joint

No. Part name Q’ty No. Part name Q’ty

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Socket bolt (M8×20) 2
3 Thrust plate 1 9 Socket bolt (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring (P80) 2
6 Seal assy 1

33-161
33. UPPER STRUCTURE

33.2.6.2 DISASSEMBLY AND ASSEMBLY

33.2.6.2.1 Tools

No. Tool Name Used for Remarks

Hammer 1. Steel hammer
a
2. Wooden or plastic mallet
b Rubber mat Disassembly 750 mm (30in) square or more
Wrench Assembly 1. Allen wrench
c 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Pin Grind the tip of "a nail" to shape
as a screwdriver.
e Disassembly

Spatula Make from a hack-saw blade

Disassembly Approx. 120mm (4.72in)

f
Assembly

Remove the edge completely

Vinyl tape and make corner round smooth.

Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil

33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.

33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.
• Keep all ports plugged up while cleaning.

33-162
 33. UPPER STRUCTURE

33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure 
correspond to those of a construction drawing in Fig. 
33-278. 

(1) Removing cover
1) Mark cover (4) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt
 
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2)  


in a vise.

: 6 mm Fig. 33-279 Removing cover (4)

3) Remove cover (4) from body (1) and draw out O-
ring (7) from cover (4).
%

"

Fig. 33-280 Removing O-ring (7)

(2) Removing thrust plate 

Loosen socket bolt (8) fastening thrust plate (3), in   
the same manner as the removing of the above-  


mentioned cover.

: 6 mm



When removing thrust plate (3) by fixing body (1),

support stem (2) so it may not fall down.



Fig. 33-281 Removing thrust plate (3)

(3) Removing stem       % &'
Place body (1) on a V-block. Put a wooden block !
against stem (2) via the body so about half of the " #$
stem is covered by the wooden block and knock it
out using a mallet.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand.
Stem weight : 10.5 kg (23 lbs)

 
  
Fig. 33-282 Drawing out stem (2)

33-163
33. UPPER STRUCTURE

(4) Removing sealing parts SPATULA (f)

1) Remove rings (13) of seal assemblies (6) and (5)
with spatula (f).
13

Pay attention to the body (1) not to be damaged by the

top edge of spatula (f).

Fig. 33-283 Removing O-ring (13)

2) Pierce slipper ring of seal assemblies (6) and (5)
with pin (e) and remove them from the seal SLIPPER RING
groove. Fig. 33-284 shows only one pin, but use
two pins to remove it securely.
BACKUP RING
DETAIL (6)

O-RING
GROOVE

SEAL (6) PIN (e) SEAL GROOVE

ASSY

OIL GROOVE
SEAL (5) SEAL GROOVE

Fig. 33-284 Removing out seal assy (5)(6)

33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on
seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (13) thinly and insert
it in O-ring groove.
Check the twist of O-ring

33-164
 33. UPPER STRUCTURE

2) Slipper ring is assembled, after first inserting the

backup ring, by slightly-distorting the shape as
shown in Fig. 33-285. Also after inserting all of
the seals, be certain that these are installed in
the seal groove by use of the spatula.
3) Assemble seal (5) by the same procedure above
mentioned.

Fig. 33-285 Inserting slipper ring (6)

Remove grease, hydraulic oil and vaseline from the
groove of seal.
And insert seal (5).
Seals (5) have no back-up ring.

(2) Assembling stem

Press in by applying your weight by your hands.
Lightly coat the outer circumference of stem (2) and
the inner surface of body (1) with grease or vaseline
and slowly insert stem (2) into body (1).
2 STEM

• If stem (2) is pressed in too fast, the seal may be

O-RING 13
damaged. Do it slowly.
• The clearance between body (1) and stem (2) is 1 BODY
SEAL ASSY 6
about 0.1mm (0.004in). Push stem straight along
the shaft center. SEAL 5

WORK BENCH

Fig. 33-286 Inserting stem (2)

(3) Assembling thrust plate
& !
1) While holding stem (2) and body (1), match the
hole of thrust plate (3) and the stem (2) hole.
2) Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite #242 and
tighten to stem (2).

: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)

Fig. 33-287 Tightening socket bolt (8)

33-165
33. UPPER STRUCTURE

(4) Assembling cover

1
After installing O-ring (7) to cover (4) and aligning MATCHING MARK
the matching marks of the cover (4) and body (1),
coat socket bolt (9) with Loctite #242 and tighten it 9
which will then complete assembly.
4
: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)

ALLEN WRENCH

PIPE

Fig. 33-288 Tightening socket bolt (9)

33-166
 33. UPPER STRUCTURE

33.2.6.3 MAINTENANCE STANDARDS

33.2.6.3.1 Inspection procedure and remedy

Interval Check Item Checking Procedure Remedy

Seal for oil leakage Replace O-ring or dust seal , if any oil
2,000hr Check oil leakage outside
outside leakage can be found.
4,000hr All sealing parts Replace all sealing parts such as slipper
In principle, seal with back-up ring and O-ring.
disassemble All sliding parts
and check re- Check abnormal wear, scoringor
Repair or replace referring to their
gardless of corrosion caused by foreignmatters or
limit of service.
oil leakage or seizure.
not.
When All parts Repair or replace referring to their limit of
Check them for seizure, foreignmatters,
disassembled service.
abnormal wear, anddefect of seals.
for repair O-rings and dust seal should be replaced.

33.2.6.3.2 Service limit of the parts

Parts Maintenance Standards Remedy

Sliding surface with
Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface between 1) Worn abnormally or damaged more than 0.1mm
Replace
body and stem other than (0.004in) in depth due to seizure or contamination.
Body, Stem sealing sections 2) Damaged less than 0.1mm (0.004in) in depth. Smooth with oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
plate 3) Damage due to seizure or contamination repairable
Smooth
within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
Cover
plate 3) Damage due to seizure or contamination
Smooth
repairable within wear limit 0.5mm (0.02in).

33-167
33. UPPER STRUCTURE

Parts Maintenance Standards Remedy

1) Protruded excessively from seal groove.

  

Replace
(With back-up ring)

 

2) Slipper ring 1.5mm (0.06in) narrower than seal groove,
or narrower than back-up ring.

Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)

BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)

   
Replace

(With back-up ring)

33-168
 33. UPPER STRUCTURE

33.2.6.3.3 Inspection after assembly

After completion of assembly, inspection for oil leakage, 
pressure resistance, etc., using a device as shown in
Fig. 33-289.
(1) High pressure port (A,B,C,D and F port) 
Install a directional valve and pressure gauge to the   
 
stem side port and body side port respectively, and
while watching the pressure gauge (for high 
pressure) installed on the body side and also by
regulating high pressure relief valve (7), gradually   
  
increase the pressure and when the pressure has 
reached 1.5 times the maximum working pressure,
close stop valve (3) and lock in the hydraulic oil in 
the swivel. Keep stop valve (6) on the low pressure
relief valve side closed at this time.
Check that it is free from looseness, deformation, 
breakage, etc. under three minutes pressurizing.
And, the oil leakage must be checked for the first 1
minute, and if there be a pressure drop for any
reason, the pressure drop should be in 10% of the
trapped pressure.
This checking must be carried out for every circuit.
   
Fig. 33-289 Hydraulic circuit for inspection
equipment
(2) Low pressure port (E port)
  
Similar to the high pressure port, install a directional
valve and pressure gauge on each port of the stem '$ ( ) 
  
side and body side.  *(&

Open stop valve (6) on the side of low pressure   !
relief valve (5) and while watching the pressure   " 
gauge (for low pressure) connected to the body
 # "  #   +
side and also by regulating low pressure relief valve 
  ,&-. /
0
(5), gradually increase the pressure and check for
outside leakage with a color check at a pressure of  " 

0.49MPa (71psi).  # "  #  

$$  /1  2 &0

  " 

33.2.6.3.4 Troubleshooting
Trouble
1. External leakage of hydraulic oil
2. Internal leakage of hydraulic oil
3. Swivel stem seized
4. Loose swivel stem and cover
 % &
Cause Remedy
Defective O-ring & seal Replace all seals.
1) Defective slipper seal 1) Replace all seals.
2) Sliding face worn excessively 2) Replace assy.
1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body are too loose
and causing oil leakage.
2) Inappropriate swivel stopper bracket 2) Reinstall
Secure 2~3mm (0.08~0.12in) allowance for
bolt stopper.
Socket bolt tightened insufficiently. Retighten.
33-169
33. UPPER STRUCTURE

[MEMO]

33-170
 34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING.......................................................................................34-3

34.1.1 TRAVEL SYSTEM .................................................................................................34-3
34.1.2 CRAWLER..............................................................................................................34-3
34.1.3 UPPER ROLLER ....................................................................................................34-7
34.1.4 LOWER ROLLER ...................................................................................................34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-20
34.1.6 SPROCKET ............................................................................................................34-29
34.1.7 TRAVEL MOTOR ..................................................................................................34-32
34.1.8 SWING BEARING ..................................................................................................34-34
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT .......................................34-38
34.2.1 CONSTRUCTION OF TRAVEL MOTOR ...............................................................34-38
34.2.2 TOOLS AND JIGS ..................................................................................................34-43
34.2.3 PREPARATION FOR DISASSEMBLY ...................................................................34-47
34.2.4 ASSEMBLY ............................................................................................................34-63
34.2.5 MAINTENANCE STANDARD.................................................................................34-79

34

34-1
34. TRAVEL SYSTEM

PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.

34-2
 34. TRAVEL SYSTEM

34.1 REMOVING AND INSTALLING

34.1.1 TRAVEL SYSTEM

8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD LOWER FRAME
GREASE NIPPLE OF THE 3. UPPER ROLLER
TRACK SPRING ADJUSTER 4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage

34.1.2 CRAWLER

34.1.2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Find the master pin and place it in its removing/
fixing position in Fig. 34-3.
2) Loosen the grease nipple and slacken crawler.

: 19 mm

• When loosening the grease nipple of the adjuster,

Fig. 34-2 Crawler removing position
do not loosen it more than one turn.
• Where grease does not come out well, move the
machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring
danger of injury. So be careful not to over loosen
the grease nipple.

3) Pushing out master pin

Apply jig on master pin and strike it out with a
mallet.
(Refer to Fig. 34-7 Press fitting of master pin)



   
When using a big hammer, wear protective goggles
Fig. 34-3 Removing/fixing position of master pin
and a long-sleeved uniform so you do not injure
yourself by flying objects.

34-3
34. TRAVEL SYSTEM

(3) Removing crawler

REMOVING
Put attachment on ground so that weight is not MASTER PIN
loaded to the lower frame, and remove track link
assy rotating sprocket.

Crawler end section may fall on the ground just before

extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
Fig. 34-4 Removing crawler

34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they 
converge, facing the front idler, as shown in the
  
figure on the right.

(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
Fig. 34-5 Installing direction of crawler
2) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm above the ground level by
holding it by hand so the machine body weight is
not exerted on the shoe. Retract the sprocket to
help push the back winding of the crawler.

(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine Fig. 34-6 Winding crawler
adjustment turning sprocket.

• When using a big hammer, exercise care so you

are not injured by flying objects the same way as
when pushing out the master pin.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in.

(4) Press fitting of master pin  



Apply press fitting jig on master pin, and strike it   

with a mallet to press fit. Fig. 34-7 Press fitting of master pin

34-4
 34. TRAVEL SYSTEM

(5) Adjusting crawler tension (See Fig. 34-8)

After installing, adjust tension of crawler.

: 19 mm

 


   
  
  

  

Fig. 34-8 Adjusting crawler tension

34.1.2.3 CONSTRUCTION

FLAT SHOE
2
1-6
1-1
1-7
1-4
1-3
1-7 TRAIANGLE SHOE
2 GROUSER SHOE 6
1-8 2

1-1
7
1-8 1-5 6
1-2 1-2 6

Fig. 34-9 Track link assy and shoe plate

E135BSR E135BSRLC

No. NAME Q'TY No. NAME Q'TY

1 . LINK ASSY 1 1 1 1 1. LINK ASSY 1 1 1 1
1-1 .. TRACK LINK R 44 44 44 44 1-1.. TRACK LINK R 46 46 46 46
1-2 .. TRACK LINK L 44 44 44 44 1-2.. TRACK LINK L 46 46 46 46
1-3 .. BUSHING 43 43 43 43 1-3.. BUSHING 45 45 45 45
1-4 .. PIN 43 43 43 43 1-4.. PIN 45 45 45 45
1-5 .. MASTER BUSHING 1 1 1 1 1-5.. MASTER BUSHING 1 1 1 1
1-6 .. MASTER PIN 1 1 1 1 1-6.. MASTER PIN 1 1 1 1
1-7 .. SEAL 86 86 86 86 1-7.. SEAL 90 90 90 90
1-8 .. COLLAR 2 2 2 2 1-8.. COLLAR 2 2 2 2
2 . SHOE 500mm 44 - - - 2. SHOE 500mm 46 - - -
. SHOE 600mm - 44 - - . SHOE 600mm - 46 - -
. SHOE 700mm - - 44 - . SHOE 700mm - - 46 -
. SHOE 800mm - - - 44 . SHOE 800mm - - - 46
6 . BOLT 176 176 176 176 6 . BOLT 184 184 184 184
7 . NUT 176 176 176 176 7 . NUT 184 184 184 184

34-5
34. TRAVEL SYSTEM

34.1.2.4 MAINTENANCE STANDARD

F E
D D G
B

Fig. 34-10

Unit : mm (in)
REPAIRAB SERVICE
No. ITEM STANDARD VALUE REMEDY
LE LEVEL LIMIT
A Link pitch 171.45 ± 0.1 (6.750 ± 0.0039) 175 (6.89)
179 (7.05) Replace the link
B O.D. of bushing ø 53.9 ± 0.1 (2.122 ± 0.0039) ø 50 (1.97) ø 49 (1.93) assy if the service
C Height of link 95.2 ± 0.3 (3.748 ± 0.012) 89 (3.50) 87 (3.43) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.17
D Interference
and link ø 53.797 (+0.007) Interference
Shaft 0.05
(2.118) + 0.02 0
(0.0020) Replace
(+0.0010)
+ 0.01
Interference
Interference between track pin ø 33.338 (+0.0004) Interference
E Shaft 0.05
and link (1.313) - 0.03 0
(0.0020)
(-0.0010)
+ 0.19
Interference
Interference between master ø 33.338 (+0.007) Interference
F Shaft 0.05 Replace Link
pin and link (1.313) + 0.07 0
(0.0020)
(+0.003)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 392±29 N•m (289±21.4 lbf•ft) Reassembly

34.1.2.5 TOOLS AND JIGS

(1) Tightening tools

Unit : mm (in)
NAME OPPOSING FLATS

24 (0.945)
Socket

(2) Jig

NAME SHAPE

Master pin fixing jig for iron

crawler

34-6
 34. TRAVEL SYSTEM

34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY

(LC) (01)

(STD) (01)

ITEM NAME Q'ty REMARKS

1 ROLLER ASSY 2 4
CAPSCREW (SEMS
2 2 4 M20×P2.5×110
SCREW)
3 NUT 2 4
4 WASHER 4 8

34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
3 4 3 4
(2) Removing upper roller (1)
1) Remove nuts on support tightening section, and 1
also remove capscrew (2) M20×110. 1

: 30 mm 2
2

(STD SPEC.) (LC SPEC.)

Fig. 34-11 Removing upper roller

34.1.3.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING

(2) Installing upper roller (1)

1) To install the upper roller, turn up socket bolts (2)
toward the center of machine.

2) Insert it until collar comes in contact with support.

3) Fit it directing the countersinking mark of shaft

CENTER OF MACHINE

end upward.

4) Apply Loctite #262 on capscrew M20×110, and

tighten it to the specified torque.

: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
2 1 3,4

Fig. 34-12 Installing upper roller

34-7
34. TRAVEL SYSTEM

34.1.3.4 CONSTRUCTION

ROLLER ASSY PART NO.

11 T=21.6 24.5 N.m (16 18.1lbf.ft)
No. NAME Q'TY No. NAME Q'TY
9 T=65.7 N.m (48 lbf.ft) 7 3 2
1 ROLLER 1 7 FLOATING SEAL 1
2 SHAFT 1 8 O RING : 1A G55 1
3 COLLAR 1 9 SOCKET BOLT 2
4 PLATE 1 10 SNAP RING 1
5 COVER 1 11 PLUG PT1/8 1
6 BUSHING 1

10 8 5 4 6 1

Fig. 34-13 Construction of upper roller

34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly 10
9
1) Draining out oil
4 11
Remove plug (11) and drain out oil. 8
5
: 6mm
1

2) Removing snap ring (10)

Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (10), using
snap ring pliers.
f
3) Removing cover (5)
Take off cover (5) upwards, utilizing the screwed
hole for the plug.

4) Removing O-ring (8)

Separate O-ring (8) from cover (5). Fig. 34-14 Construction of upper roller

5) Removing plate (4)

Loosen 2 socket bolts (9) and draw out plate (4)
from roller (1).
h
: 10mm

2
6) Removing shaft (2)
Put the extrusion jig (h) against the end face of
7
shaft (2) and push shaft (2) with collar (3) for
floating seal (7), using a press or hammer. 3

Fig. 34-15 Extruding shaft

34-8
 34. TRAVEL SYSTEM

7) Removing floating seal (7).

Take out floating seal (7) from roller (1). 7

Fig. 34-16 Taking out floating seal

8) Removing floating seal (7). 2
Remove from collar (3), floating seal (7) that is
located on the side from which shaft (2) was
g
disassembled. 7
6

1
Collar (3) is press fitted into shaft (2). Therefore do not
3
disassemble it. f

Fig. 34-17 Removing floating seal and extruding

bushing
9) Removing bushing (6)
Push with press (e)
Since the bushing is thin, machine it on a lathe or
scrape it off, take care so as not to damage the
bore of roller (1). i
If the bushing is not worn much, mount upper
roller (1) on jig (f), insert jig (g) into the end face
6
of bushing (6) and push it out with a press.

1
(2) Assembly
Assembly of the upper roller is done in the reverse
order of disassembly.
1) Place upper roller (1) on the top end face of jig
f
(f), with its floating seal setting side facing down.

2) Confirm that the outer surface of bushing (6) is Fig. 34-18 Pushing in bushing
not scuffed and coat the outer surface of the
inserting side of the bushing, with molybdenum
2
disulfide grease.
7

3) Put jig (i) into bushing (6) and press it in, using
7
the bore of the bushing and the bore of the roller
1
as guides.

If you fail in this operation by pressing the bushing

unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing Fig. 34-19 Fixing floating seal
as it may develop malfunctioning after assembly.

34-9
34. TRAVEL SYSTEM

4) Installing floating seals (7)

Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
2
another to the inside of upper roller (1).
3
7
• Prior to placing floating seal (7) in, apply
engine oil lightly to seal surface.

1
5) Inserting shaft (2)
Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).

6) Installing plate (4) Fig. 34-20 Inserting shaft

Mount upper roller (1) on the stand jig (f) and 10
9
attach plate (4) to the end face of the shaft with
11
bolt (9). 4
8
: 8mm, 5
Tightening torque : 65.7N•m (48 lbf•ft)
1

7) Installing O-ring (8)

Fit O-ring (8) to the groove of cover (5).
• Apply grease to O-ring.

8) Installing cover (5) f

Attach cover (5) to upper roller (1). Use a press
in this operation as a press fit is used.

9) Installing snap ring (10)

Fix snap ring (10) into upper roller (1), using
snap ring pliers.
Fig. 34-21 Installing cover

10) Filling oil

Fill in 20cc (1.22cu•in) of engine oil API grade
CD #30 through the plug hole in cover (5). 5

11) Installing plug (11) 1

Wind seal tape around plug (11) and screw it into
the plug hole of cover (5).

: 6mm,
Tightening torque :
21.6~24.5N•m (16~18.1 lbf•ft)
f

• After assembling the upper roller, confirm that

oil is not leaking from it and that it rotates
smoothly by hand.

Fig. 34-22 Filling oil

34-10
 34. TRAVEL SYSTEM

34.1.3.6 MAINTENANCE STANDARD

2(0.079")

D
A

E
F
B C

Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. ø 99 (3.9) ø 94 (3.7) ø 90.5 (3.56)
B Width 140 (5.51) — —
C Installing length 60 (2.36) — — Replace

D Shaft dia. ø 40 (1.576 ) — —

Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 38 (1.496) Shaft
- 0.050 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.0020)
+ 0.025
Interference between Interference Clearance
F ø 42 (1.654) Hole (+0.00098)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 65.7 N•m (48 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 20cc (1.22cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly

34-11
34. TRAVEL SYSTEM

34.1.3.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

30
Socket

Allen wrench 6,8

(2) Jigs

Unit : mm (in)
No. NAME SHAPE
100 (3.94)
+ +
85 1(3.35 0.04 )

f Stand jig
160 (6.30)

1C (0.04) 1C (0.04)
)

)
(1.50 -0.001

(1.50 -0.001
40-0.025
53 (2.09)

38-0.025
0

0
0

For extruding
0

g
bushing
(1.58) 40 60 (2.39) 30 (1.18)
130 (5.12)

36 (1.42)
For extruding
h
(1.18)

shaft
38 -0.025

42 -0.025
(1.50-0.001)

(1.65-0.001)
57 (2.24)

0
0

Bushing fixing
i
jig
(0.08) 2 50 (1.97)

100 (3.94)

34-12
 34. TRAVEL SYSTEM

34.1.4 LOWER ROLLER

34.1.4.1 LOWER ROLLER ASSY

ROLLER STD
ASSY LC(HD)
ITEM NAME Q'TY REMARKS
1 LOW ROLLER 14 12
2 CAPSCREW 56 48 M16X75 (P=2.0)

2
Apply Loctite #262 1
T=279N.m (206 lbf.ft)
Fig. 34-23 Lower roller assy and track guide

34.1.4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame. SAFETY BLOCK
(WOOD BLOCK)
(2) Remove lower roller
Remove capscrews (2) and remove lower roller (1). Fig. 34-24 Preparation for removal

: 24 mm,
Weight of lower roller : Approx. 25kg (55 lbs)

Fig. 34-25 Installing lower roller

34.1.4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all 4 capscrews temporarily. Then tighten
them to a specified torque.

: 24 mm,
Tightening torque : 279N•m (206 lbf•ft)
(2) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.

: 19 mm,
Tightening torque : 59N•m (43 lbf•ft)

34-13
34. TRAVEL SYSTEM

34.1.4.4 CONSTRUCTION

3 15 764
LOWER ROLLER 8

No. NAME Q'TY REMARKS

1 ROLLER 1
2 SHAFT 1
3 BUSHING 2
4 PIN 2 2
5 FLOATING SEAL 2
6 O-RING 2 1A G45 Fig. 34-26 Construction of lower roller
7 COLLAR 2
8 PLUG 2 PT1/4

34.1.4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Drain oil L
Remove plug (8) and drain out oil.

: 6mm 7

2) Removing pin (4) 4

Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar (L) on
upper end face of pin (4), and push pin (4) out
striking with mallet.
K

3) Removing collar (7), O-ring (6)

Put lower roller on jig (M) for repair stand so that
the shaft (2) is perpendicularly located, apply
Fig. 34-27 Pushing out collar fixing pin (4)
push-out jig (P) on shaft end on upper side, and
push shaft (2) until the O-ring (6) separate from
collar (7) with press or mallet, and take out collar
(7) and O-ring (6). JIG P
6
7
4) Removing shaft (2)
In addition, push out and remove shaft (2) 1
together with the lower collar (7) and O-ring (6).
2

JIG M
The shaft (2) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.

Fig. 34-28 Removing shaft (2), collar (7), O-ring (6)

34-14
 34. TRAVEL SYSTEM

5) Removing collar (7), O-ring (6)

Remove O-ring (6) from shaft (2) that was drawn 5
out in the previous paragraph.

6) Removing floating seal (5)

Remove floating seal (5) from collar (7). 7

7) Removing floating seal (5)

Remove floating seal (5) from roller (1).
Fig. 34-29 Removing floating seal (5)

Fig. 34-30 Removing floating seal (5)

8) Removing bushing (3)
Since thickness of bushing (3) is thin [thickness
is 2.0mm (0.079in)], remove it through lathe or N
strip it with care not damage inner hole of roller.
When the wear of bushing is not large, place
1
upper roller (1) on jig (M) for repair stand and
apply the end of push-out jig on the end face of
bushing (3) end, and push it out striking it with 3
mallet.

JIG M

Hammer the inside surface of roller lightly so as not to

damage the surface. Put the extrusion jig (N) uniformly Fig. 34-31 Extruding bushing (3)
over the circumference of bushing (3) and extrude it
perpendicularly little by little.

34-15
34. TRAVEL SYSTEM

(2) Installing 6 2
1) Attach O-ring (6) to one side
Install O-ring (6) to groove on shaft.

• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-32 Attach O-ring (6) to one side
reassembling.

2) Press fitting bushing (3)

Align inner hole of roller (1) and bushing (3) and JIG Q
press fit it vertically in capacity of press fit load,
5ton (11000 lbs), in the condition that bushing 3
push-in jig (Q) is inserted into bushing (3).

• Apply molybdenum disulfide grease on press-

fit section of bushing, and press fit it in
ordinary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted. Fig. 34-33 Press fitting bushing (3)

3) Press fitting collar (7) PRESS

Fit O-ring (6) to the one side of shaft (2) mating
pin hole of collar (7) on which floating seal (5) is PIN HOLE
fit with pin hole of shaft (2) in advance. Use the 5
7
press of capacity 17 ton (37500 lbs) or more.
PIN HOLE
2 6
• Care should be taken not to damage O-ring
(6) while press-fitting collar (7) to shaft (2).

4) Inserting pin (4) Fig. 34-34 Press fitting collar (7)

Press-fit pin (4) to pin hole on aligning pin holes
of shaft (2) and collar (7).

5 4

6 7

Fig. 34-35 Inserting pin (4)

34-16
 34. TRAVEL SYSTEM

5) Attach floating seal (5) to roller side

Fit floating seal (5) to inner holes on both ends of
roller (1).
1
5
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
2
6) Inserting roller (1)
7
Insert roller (1) from the side where collar (7), 6
O-ring (6) is not press-fitted to the shaft (2).
Fig. 34-36 Inserting roller (1)
7) Installing O-ring (6)
PRESS
Install O-ring (6) to groove on shaft.

PIN HOLE
• Grease O-ring.
7
• Replace O-ring with new one without fail at
reassembling. PIN HOLE
6
8) Press fitting collar (7)
Press-fit collar (7) to shaft (2).

2
• Press-fit collar (7) on aligning pin (4) hole.

9) Inserting pin (4)

Press-fit pin (4) in to the pin hole mating pin hole
of collar (7) with pin hole on the end side of shaft
(2).

Fig. 34-37 Installing O-ring (6), collar (7)

10) Filling oil
Remove plug (8) and fill in 150cc (9.2cu•in) of
engine oil API grade CD #30.
11) Check it for leakage 8
Before tightening plug (8), check it for leakage in TIGHTENING
TORQUE
the condition of air pressure 0.2 MPa (29 psi). 21.6~24.5N.m
12) Installing plug (8) (16~18.1 lbf.ft)
Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (7) end 7
face.

: 6 mm,
Tightening torque : 21.6~24.5 N•m Fig. 34-38 Installing filling oil plug (8)
(16~18.1 lbf•ft)

After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.

34-17
34. TRAVEL SYSTEM

34.1.4.6 MAINTENANCE STANDARD

C C H
-0.5
+
ce 2.5
Clearan 0.020)
(0.09 8

D
B

E
A

Fig. 34-39 Lower roller (Track roller)

Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange ø 170 (6.70) — — Reinforcement weld,
B Tread dia. ø 140 (5.51) ø 132 (5.20) ø 126 (4.96) repair or replace
C Flange width 19 (0.748) 14 (0.551) 11 (0.433)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 50 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft Replace bushing
(1.96850) - 0.090 0.7 (0.276) 1.0 (0.394)
(-0.00354)
+ 0.030
Interference between ø 57 Interference Clearance
E Hole (+0.00118)
roller and bushing (2.24409) 0 0.01 (0.0004)
0
F Oil Engine oil API grade CD #30, 150cc (9.2 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly

34-18
 34. TRAVEL SYSTEM

34.1.4.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

24
Socket

Allen wrench 6

(2) Jig

Unit : mm (in)
No. NAME SHAPE

K V-block

100(3.94)
pin (4)
(0.551)

L
14

extrusion rod
16 (0.630)

200(7.87)
Bushing
N
extrusion rod

290(11.4)
140(5.51)

M Stand jig
(4.33)
110

270(10.6)
Shaft
P
(1.93)

extrusion jig
49
(0.98)
25

70(2.76)
70(2.76)

Bushing
45(1.77)

Q
fixing jig

+0.1
50 0
(1.97 +0.004
0 )

34-19
34. TRAVEL SYSTEM

34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY

FRONT IDLER ASSY APPLY LOCTITE #262 OR EQUIVALENT

T=115N.m (84.8 lbf.ft) 1-2
No. NAME Q'TY REMARKS 1,1-1
1-4
1 FRONT IDLER ASSY 2
1-1 IDLER ASSY 1
1-2 IDLER ADJUSTER ASSY 1
1-3 GREASE NIPPLE 1
1-4 CAPSCREW 2 M12X35
1-3
T=58.8 9.6N.m
(43.4 7.08 lbf.ft)

Fig. 34-40 Front idler assy

34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)

(2) Removing idler assy

Sling idler assy, and push it forward with bar.
Weight of front idler assy : 127kg (280 lbs) BAR

Keep away from the front side of front idler.

(3) Installing
Installing is done in the reverse order of removing.

(4) Where idling assy (1-1) has to be separated

Loosen capscrew (1-4), and separate idling assy
(1-1) from idler adjuster assy (1-2).
Fig. 34-41 Removing and installation the front idler
: 19 mm 1-1
Weight of idler assy : 69kg (152 lbs)
Weight of idler adjuster assy : 58kg (128 lbs)

• The separated idling assy (1) should be placed

on square timbers.
1-2

1-4 1-3

Fig. 34-42 Separating idling assy (1-1) from idler

adjuster

34-20
 34. TRAVEL SYSTEM

34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION

IDLER ASSY 1
No. NAME Q'TY REMARKS 8
1 4
1 IDLER 6
2 SHAFT 1 5
3 BUSHING 2
4 COLLAR 2
5 PIN 2
7
6 FLOATING SEAL 2 2
7 O-RING 2 3
8 PLUG 2 PT1/8

Fig. 34-43 Idler assy

34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing 5
R
1) Drain oil
Remove plug (8) on the side of collar (4) to drain.

: 5 mm

2) Removing pin (5)

Apply pin push bar (jig R) to the top of pin, and
push out striking bar (jig R) lightly by hammer. Fig. 34-44 Removing pin (5)

PUSH WITH PRESS

3) Removing collar (4)
Put idler (1) on stand (U), apply push-out jig (S) 2
S
on shaft (2), push out shaft (2) with collar (4), 4
then remove collar (4). 1

U
4

Fig. 34-45 Removing collar (4)

4) Removing collar (4) from shaft (2) PUSH WITH PRESS
If removal of collar (4) on the opposite side is
S
required, turn over front idler and proceed with
the procedure described in Par. 3). 2
4

Fig. 34-46 Removing collar (4)

34-21
34. TRAVEL SYSTEM

5) Removing bushing (3) 3

1 T
With idler (1) mounted on the stand, tap bushing
(3) lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing
(3) evenly all round, till it comes out.

6) Removing floating seals (6)

Take out floating seals (6) from idler (1), collar
(4). If you intend to re-use floating seals (6), U
confirm that there is no scoring and rusting on
the contact surface and store the floating seals
Fig. 34-47 Removing bushing (3)
in pairs by placing card board between the
sealing faces.

7) Removing O-ring (7)

Separate O-ring (7) from shaft (2).
(2) Assembly PUSH WITH
3 PRESS V
1) Pressing in bushing (3)
1
Align inner hole of idler (1) and bushing (3) and
press fit it vertically with press so that jig (V) for
bushing press-fitting is inserted into bushing (3).

2) Installing O-ring (7)

Fit O-ring (7) to O-ring groove on shaft (2).
Fig. 34-48 Pressing in bushing (3)
• Apply grease to O-ring

3) Installing collar (4) PRESSING

Press fit the O-ring (7) installed side of shaft (2)
into collar (4), and drive pin (5). 2

4) Installing floating seal (6)

4
Fit the half of floating seal (6) on each side of
5
collar (4) and idler (1).

5) Inserting idler (1)

Fig. 34-49 Installing collar (4), shaft (2)
Insert floating seal (6) fitted side of idler (1) into
shaft (2). 2
6

6) Installing floating seal (6)

Fit floating seal (6) on the other side of idler (1). 1

Fig. 34-50 Inserting idler (1) and installing floating

seal (6)

34-22
 34. TRAVEL SYSTEM

7) Installing collar (4)

Fit the half of floating seal (6) on the other collar 8 4
(4), press fit it in shaft (2), and drive pin (5) in with 5
hummer.
8) Filling oil•Inspection 1
Fill in 200cc (12.2cu•in) of engine oil API grade
CD #30 through the plug hole of collar (4), wind
seal tape and tighten plug (8).

: 5 mm
Fig. 34-51 Installing collar (4) and filling oil
• After installing the idler assy to the idler
adjuster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.

34.1.5.3.3 MAINTENANCE STANDARD

132 1.5(5.20 0.059)

C

F
D
E
B
A

Fig. 34-52 Front idler

Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection ø 496 (19.5) — —
B Tread dia. ø 456 (18.0) ø 450 (17.7) ø 448 (17.6) Replace
C Flange width 68 ± 1 (2.677±0.04) 63 (2.48) 60 (2.36)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 60 (-0.00118) Clearance Clearance
Shaft Replace
(2.36220) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
- 0.03 Clearance
Interference between idler and ø 64 Interference
E Hole (-0.00118) 0.01
bushing (2.51969) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 200cc (12.2cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble

34-23
34. TRAVEL SYSTEM

34.1.5.3.4 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

24
Socket

Allen wrench 5

(2) Jigs

Unit : mm (in)
No. NAME SHAPE
(0.591)

(1.18)
15

30
R Pin striking jig
(0.591)
105(4.13) 15

300(11.8)

S Shaft push out jig

(2.32)
59
(0.630)
16

300(11.8)

T Bushing drawing rod

Approx.150
(5.91)
Approx.600
(23.6)
U Stand
Approx.
400
(15.7)
2
(0.787)

70(2.76)
20
75(2.95)

Bushing press fitting

V
55(2.17)

jig

60 -0.030
-0.060

(2.36 -0.001
-0.002 )

103(4.06)
W Collar press fitting jig
(1.18)
30

34-24
 34. TRAVEL SYSTEM

34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION

IDLER ADJUSTER ASSY 2 4 3 5 1 8 7 6 9

No. NAME Q'TY REMARKS

1 GREASE CYLINDER 1
2 BRACKET 1
3 NUT 1
4 SPRING PIN 1 ‫ޓ‬6X63
5 SPRING 1
10 Apply grease to bleed air.
6 PISTON 1
7 O-RING 1
Fig. 34-53 Idler adjuster assy
8 U-PACKING 1
9 PIN 2
10 COVER 1

34.1.5.4.2 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
M30
HOLDING-DOWN NUT
1) Spring set special jig
Before disassembling and assembling the idler RETAINER PLATE
adjuster assy, prepare spring setting jig (V).
Capacity of hydraulic jack : more than 20 tons
(44000 lbs)
V
: 46 mm
HYDRAULIC JACK

Large power is needed to set the spring. Prepare a

BASE
special jig before disassembly and assembly.
Fig. 34-54 Spring set special jig (V)
2) Preparation for working
Place a hydraulic jack between the jig base and
2
the stand.
Loosen the holding-down nuts of the jig and draw
out the retainer plate upward.

: 46 mm
3) Draw out grease cylinder (See Fig. 34-53)
Draw out piston (6) from grease cylinder (1) of 5
the idler adjuster assy.
4) U-packing (8), O-ring (7) (See Fig. 34-53)
U-packing (8) and O-ring (7) from grease
cylinder (1).
V
5) Slinging work idler adjuster
Set the idler adjuster assy on the stand of the jig, Fig. 34-55 Slinging work idler adjuster
with its bracket side facing up.

34-25
34. TRAVEL SYSTEM

6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten holding- 3
down nuts alternately, and secure idler adjuster
assy.

: 46 mm HOLDING-DOWN NUT

RETAINER PLATE
4
Fig. 34-56 Fixing idler adjuster assy
7) Compression of spring (5) #
Remove spring pin (4), press spring (5) lifting it
with jack so that nut (3) can be turned freely, and
remove nut (3).
: Bar ø7.5×120

: 85 mm

Fig. 34-57 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to retract slowly till the
spring is extended to its free length. Remove the
retainer plate and take off bracket (2), cover (10). RETAINER PLATE
The free length of the spring : 427 mm (16.8 in)

2
10

Fig. 34-58 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M45×P3 on 9 
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), grease cylinder (1), in that
#
order.

Fig. 34-59 Removing spring (5), grease cylinder (1)

34-26
 34. TRAVEL SYSTEM

(2) Assembly
Assembly is done in the reverse order of W
disassembly. 1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into spring
5
(5) and attach lifting eye nut (W) to screw
M45×P3 at the tip of the grease cylinder. Lift the
grease cylinder by crane and erect it in the
center of the jig stand upright.

Fig. 34-60 Attach spring (5) and grease cylinder (1)

2) Fixing idler adjuster assy
to the jig
Install bracket (2), cover (10) on top of spring (5).
Center the rod of grease cylinder (1) and the
holes in bracket (2). Attach the retainer plate and
four holding-down nuts. Fasten the nuts evenly
all round and fix the idler adjuster assy to the jig
body.
(See Fig. 34-64)

: 46 mm
3) Compressing spring (5) and tightening nut (3)
HOLDING-
Extend the hydraulic jack, compress spring (5) to DOWN NUT
a set length and screw in nut (3) to the screwed
RETAINER
part at the tip of grease cylinder (1).
PLATE
Set length of the spring : 354.8mm (14.0in)

2
4) Installing spring pin (4)
4
Tighten nut (3) till the holes for locking spring 3
pins (4) are aligned. Then fit spring pin (4).
11
: 70 mm 1

Fig. 34-61 Compression of spring (5), and attaching

nut (3) and spring pin (4)
5) Removing idler adjuster assy
Remove idler adjuster assy from jig.

Fig. 34-62 Removing idler adjuster assy

34-27
34. TRAVEL SYSTEM

6) Installing U-packing (8), O-ring (7)

1 8 7 6
Fit U-packing (8) and O-ring (7) to grease
cylinder (1).
• Grease U-packing (8) and O-ring (7).

7) Filling grease cylinder (1) with grease.

Fill up grease in cylinder (1), remove the grease
nipple from piston (6) to discharge the inside air,
and press in the piston by hand. GREASE NIPPLE
• Direct grease nipple hole downward to make Fig. 34-63 Grease cylinder (1)
air discharge easier.

8) Installing grease nipple

Tighten grease nipple to piston (6).

: 19 mm,
Tightening torque : 59 N•m (43 lbf•ft)

34.1.5.4.3 MAINTENANCE STANDARD

No. ITEM STANDARD VALUE

A Installed length of spring 354.8mm (14.0 in)
B Free length of spring Approx. 427mm 16.8 in)
C Stroke 39.4mm (1.55in)
D Set length 686mm (27.0in)
E Outside view of piston Nor scoring and rusting
Tightening torque of
F 59N•m (43 lbf•ft)
grease nipple

X E

aa F
C Apply grease to bleed air
A,B
D
X
INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.
U-PACKING
8 O-RING 35
7 BRACKET

DETAIL aa
SECTION XX

Fig. 34-64

34-28
 34. TRAVEL SYSTEM

34.1.6 SPROCKET

34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize.

Fig. 34-65 Preparation for removal

(2) Removing sprocket
Loosen 18 capscrews (3) M16×45, for the
attaching of the sprocket by means of a socket and
remove the sprocket (1).

Weight of sprocket : 39kg (86 lbs)

: 24 mm

Fig. 34-66 Removing sprocket

34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.

(2) Installing sprocket temporarily

Coat the sprocket attaching capscrews with Loctite
#262 and fasten the sprocket temporarily.

(3) Installing sprocket completely

Remove the wooden blocks under the truck frame,
bring the machine down on the ground and tighten
the sprocket.

: 24 mm
Tightening torque : 279 N•m (206 lbf•ft)

Fig. 34-67 Installing sprocket completely

34-29
34. TRAVEL SYSTEM

34.1.6.3 MAINTENANCE STANDARD (YY51D01008P1)

86.69mm NUMBER OF
PITCH 21
(3.4130in) TEETH
SPECIFICATION
ø53.797mm 581.67
ROLLER DIA. PITCH DIA.
(2.1180in) (22.9in)

Unit : mm (in)

171.45 (6.750) B
86.69
)
(3.4130 8.25(0.3248)
(0.0984)
R

2.5

R
(1 R26

R 236
)
(1
36

26 )
. 0
.02

C
(22.9 81.67

INDUCTION HARDENING
D5
)

ON TWO DOTTED LINE

P.C.

Fig. 34-68 Sprocket

Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
ø 594±2 Reinforcement weld,
A O.D. of sprocket ø 586 (23.1) ø 584 (23.0)
(23.4±0.79) repair or replace.
B Width of sprocket teeth 61 (2.40 ) 54 (2.13) 52 (2.05) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 524.7 (20.66) ø 516 (20.3) ø 514 (20.2)
repair or replace.

34.1.6.4 TOOLS AND JIGS

(1) Tools

Unit : mm
NAME OPPOSING FLATS

24
Socket

34-30
 34. TRAVEL SYSTEM

(2) Sprocket tooth profile gauge : W

Unit : mm (in)

)
(22.9 .67
1
R D 8
5
P.C.
8.25 (0.3248)

(0.0984)
2.5
26 )
R 236
171.45 (6.750)

.0
(1

)
2 36
.0
(1 R26

R
INDUCTION HARDENING
ON TWO DOTTED LINE
)
(3.4130
86.69

Fig. 34-69 Tooth profile gauge (Full scale)

34-31
34. TRAVEL SYSTEM

34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR

INSTALL ASSY
No. NAME Q'TY REMARKS
1 CAPSCREW 40 M16X45
2 TRAVEL MOTOR ASSY 2
1
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N.m(206 lbf.ft)

Fig. 34-70 Installing travel motor

34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (4) M12×25 and also remove
covers (1).
4
: 19 mm
1
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Release pressure from travel circuit, and bleed air Fig. 34-71 Removing and installing cover (1)
in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all pipes
and joint section to protect them from entry of dust.

: 19mm, 27mm, 36mm

Refer to "Hydraulic pipe plug" 5.1
(See Chapter 11. TOOLS)
"Plug for flare hose" 5.2 (3) (See Chapter 11.
TOOLS)

Fig. 34-72 Removing and installing hydraulic pipe

34-32
 34. TRAVEL SYSTEM

(5) Removing sprocket

Removing eighteen (one side) capscrews (3A)
M16×45.

: 24 mm

3A

Fig. 34-73 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3) REMOVE PIPES (DISCONNECT)
Apply match marks on travel motor and crawler
frame, and remove twenty (one side) capscrews (3)
M16×45.

: 24 mm
3

Fig. 34-74 Removing and installing travel motor

attaching bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.

Weight of motor : About. 103kg (227 lbs)

Fig. 34-75 Slinging travel motor

34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the TOOLS TIGHTEING
NAME SIZE HEX NO.
TORQUE REMARKS
reverse order of removal. N.m(lbf.ft)

1) Cleaning SEMS BOLT M12 19 6 83.4 (61) APPLY

Check that contact surface of travel motor and LOCTITE
crawler frame is free from burr and stain. CAPSCREW M16 24 3 279 (206) #262

2) Tightening torque FLARELESS 10X1.5 19 - 49(36)

NUT FOR -
Tighten capscrew and hydraulic pipes to the PIPES, 15X2.0 27 118(87)
torque specified in "Tightening Torque". SLEEVE 22X3.0 36 - 275(200)
HOSE PF1/4 19 - 29.4(21.7)
3) Fill inside from motor drain port to casing with
CAP PF1/2 27 - 78.5(57.9)
hydraulic oil before piping for drain. When
PF1/4 19 - 36.3(27)
starting operation, operate motor in low idling
CONNECTOR PF1/2 27 - 108(80)
and at low speed for several minutes, and check -
PF3/4 36 162(119)
it for possible oil leakage and noise.

34-33
34. TRAVEL SYSTEM

34.1.8 SWING BEARING

34.1.8.1 SWING BEARING ASSY

SWING BEARING ASSY

No. NAME Q'TY REMARKS INNER S ZONE
POSITION OF
1 SWING BEARING 1
SWING BEARING
2 CAPSCREW 36 M16XP2.0X45

LOCTITE #262
OR EQUIVALENT
2
TO BE APPLYD
T=279N m . SECTION AA
(206 lbf.ft)

Fig. 34-76 Swing bearing assy

34.1.8.2 REMOVING
(1) Matchmarks  

Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame.  






(2) Remove 36 capscrews (2) M16×45 for installation
inner race.  

: 24 mm

(3) Removing grease

Remove grease in grease bath.
Fig. 34-77 Matchmarks

(4) Removing swing bearing   

Attach eyebolt on swing bearing and sling it. 
 
Weight of swing bearing : 150kg (331 lbs)

 

Fig. 34-78 Removing and installing swing bearing

34-34
 34. TRAVEL SYSTEM

34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust INNER S ZONE
POSITION OF
and dirt. SWING BEARING
(2) Installing
Install swing bearing on lower frame meeting the
matchmarks and positioning the S mark on inner
race as shown in Fig. 34-79.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.

: 30 mm
(4) Regular tightening of inner race
Tighten the capscrews (2) at 180 degrees intervals
alternately to a specified torque. Fig. 34-79 Location of S mark on swing bearing

: 24 mm,
Tightening torque : 279 N•m (206 lbf•ft)
(5) Filling grease
Fill grease bath with 8.2kg (18 lbs) of Nihon grease 1
(NIHON GREASE CO.LTD EP-2K) or equivalent. LOCTITE #262 OR 2
EQUIVALENT
TO BE APPLIED
T=279N.m (206 lbf.ft) SECTION AA

Fig. 34-80 Removing and installing capscrew (2)

34.1.8.4 CONSTRUCTION

6
SWING BEARING
1 1-2
No. NAME Q'TY No. NAME Q'TY
9
1 OUTER RACE 1 4 RETAINER 105
1-3
1-2 PLUG 1 5 SEAL 1 3,4
1-3 TAPER PIN 1 6 SEAL 1
5
2 INNER RACE 1 9 GREASE NIPPLE(PT1/8) 1 2
3 BALL 105
Fig. 34-81 Sectional view of swing bearing

34.1.8.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Remove seal (5) fitted in the groove in the outer EYE BOLT
6 2
circumference under inner race (2) and seal (5) 1-3
fitted in the groove in the inner circumference on
1
top of outer race (1) and place them level on a
SQUARE WOODEN
square wooden block or something. BLOCK
2) Remove taper pin (1-3), using a hammer and an
extrusion rod. 1-2
3) Remove plug (1-2), utilizing an pull bolt inserted 5
in the screwed hole (M10) in the center of the
plug and using a puller. Fig. 34-82 Disassembling swing bearing

34-35
34. TRAVEL SYSTEM

4) While rotating outer race (1) little by little, take out 

ball (3) and retainer (4) through plug hole, in that
order.

"
!
Fig. 34-83 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (5)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with 
adhesive Cyano Bond PX-3000 and fit seal (5).   

Then direct the seal (5) side downward and
place it on wood blocks horizontally. 
2) Lower outer race (1) to the position where upper  

   
surface of inner race (2) and lower portion of seal
groove is mated, put adjusting washer under Fig. 34-84 Fitting balls (3)
outer race (1) so that outer raceway surface of
ball (3) aligns with inner raceway, and support it. EYE BOLT
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (1-2) hole on outer race
(1), alternately. HOOKED ROD

To insert ball (3) and retainer (4), use a push rod, etc., 4
to protect persons from injury from inserting fingers into SQUARE
plug hole. WOODEN BLOCK
Fig. 34-85 Fitting retainer (4)
4) Fit plug (1-2) to outer race (1) while checking it
for direction and position of taper pin hole.
5) Coat seal (5) with adhesive Cyano Bond PX-
3000, and apply Cyano Bond PO-X to joint of
seal and glue seal together.
6) After completion of assembly, caulk the edge of
taper pin (1-3) by punching.
7) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 140cc (8.54cu•in)

34.1.8.6 MAINTENANCE STANDARD

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING
PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.

34-36
 34. TRAVEL SYSTEM

This page is blank for editing convenience.

34-37
34. TRAVEL SYSTEM

34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT

34.2.1 CONSTRUCTION OF TRAVEL MOTOR

34.2.1.1 CROSS-SECTIONAL VIEW OF TRAVEL MOTOR ASSEMBLY

 

     
 

         

  
  

              
 

     

Fig. 34-86 Cross-sectional view of travel motor unit assembly (1/2)

34-38
 34. TRAVEL SYSTEM

     
      
   
 


 

 
 

 

 

 

  

  

 


 


 




                   

 





     

Fig. 34-87 Cross-sectional view of travel motor unit assembly (2/2)

34-39
34. TRAVEL SYSTEM

34.2.1.2 EXPLODED VIEW OF REDUCTION UNIT

24
22

29

24

29

23

33
32
34 35

14
13
4
36
15
6

16
3
8
10

7 17

30
31

11
27
5
11

12
28
9
12

Fig. 34-88

34-40
 34. TRAVEL SYSTEM

34.2.1.3 EXPLODED VIEW OF HYDRAULIC MOTOR

116
115
135

324 112
336 139
328 109
325
326 341
331 377
354
327 301
330

380 383358
352 113
353 150
329
398 376

396 358 352 343 323

327
353
358 352
381 383
380 379
366 330
398 378 331
363 399 398 326
359 208 201 325
357 384 210
208 207 328
210
209 336
324
212

203
103
204 202
106
105
213 206
211 107
205
108
151
104

110
114
110
145 132
149

102

171
167

185
161
162

Fig. 34-89

34-41
34. TRAVEL SYSTEM

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

1 HUB 1 105 •••PISTON 1 213 •SHIM 1
2 SPINDLE 1 106 •••SHOE 1
CARRIER 1 ASSY 1 104 •CYLINDER BLOCK 1 REAR FLANGE ASSY 1
3 •CARRIER 1 1 107 RETAINER PLATE 1 •REAR FLANGE KIT 1
5 •PLANETARY GEAR 1 3 108 THRUST BALL 1 ••SPOOL ASSY 1
6 •CARRIER PIN 1 3 109 TIMING PLATE 1 323 •••SPOOL 1
11 •THRUST WASHER 1 6 110 WASHER 2 326 •••PLUG 2
16 •PARALLEL PIN 1 3 112 PISTON 1 327 •••VALVE 2
27 •NEEDLE ROLLER BEARING 3 113 SPRING 10 330 •••SPRING 2
CARRIER 2 ASSY 1 114 SPRING 1 331 •••O-RING 2
7 •CARRIER 2 1 115 FRICTION PLATE 3 301 ••REAR FLANGE 1
9 •PLANETARY GEAR 2 3 116 MAITING PLATE 4 324 •PLUG 2
10 •CARRIER PIN 2 3 132 OIL SEAL 1 325 •WASHER 2
12 •THRUST WASHER 2 6 135 O-RING 1 328 •SPRING 2
17 •PARALLEL PIN2 3 139 O-RING 1 329 •ORIFICE 2
28 •NEEDLE ROLLER BEARING 3 145 SNAP RING 1 336 •O-RING 2
4 SUN GEAR 1 1 149 BALL BEARING 1 352 •PLUG 3
8 SUN GEAR 2 1 150 BALL BEARING 1 353 •BALL 2
13 THRUST PLATE 1 151 NEEDLE ROLLER 3 354 •HEXAGON SOCKET PLUG 5
14 COVER 1 PISTON ASSY 1 357 •PLUG 1
15 COUPLING 1 161 •PISTON 1 358 •O-RING 3
22 LOCK WASHER 2 162 •SHOE 1 359 •O-RING 1
23 SHIM 1 167 PIVOT 2 363 •SPOOL 1
24 ANGULAR BALL BEARING 2 171 PARALLEL PIN 2 366 •SPRING 1
FLOATING SEAL KIT 1 185 SPRING 1 376 •ORIFICE 1
29 •FLOATING SEAL 2 377 •FILTER 1
30 PLUG 3 RELIEF ASSY 2 378 •BALL 1
31 O-RING 3 201 •VALVE SEAT 1 379 •PLUG 1
32 O-RING 1 202 •VALVE 1 380 •PLUG 2
33 O-RING 2 203 •SLEEVE 1 381 •PISTON 1
34 PARALLEL PIN 2 204 •COLLAR 1 383 •O-RING 2
35 HEXAGON SOCKET BOLT 12 205 •PLUG 1 384 •ORIFICE 2
36 SNAP RING FOR HOLE 1 206 •SPRING 1 396 •HEXAGON SOCKET PLUG 2
207 •O-RING 1 398 •HEXAGON SOCKET PLUG 8
102 SHAFT 1 208 •BACK-UP RING 2 399 •NAME PLATE 1
103 SWASH PLATE 1 209 •O-RING 1 341 PARALLEL PIN 1
CYLINDER & PISTON KIT 1 210 •BACK-UP RING 2 343 HEXAGON SOCKET BOLT 10
•PISTON KIT 1 211 •O-RING 1
••PISTON ASSY 9 212 •O-RING 1

34-42
 34. TRAVEL SYSTEM

34.2.2 TOOLS AND JIGS

(1) Standard tools

NAME SIZE Q'TY

2.5 (For M5), 3 (For M6),
4 (For NPTF1/16), 5 (For PF1/8),
HEXAGON WRENCH 1 each
6 (For PF1/4), 8 (For M10, PF3/8),
10 (For M12, PF1/2)
SOCKET WRENCH
(Ratchet handle) Barrel type 1
(JIS B 4641)
Dial type : Approx. 50N
TORQUE WRENCH Dial type : Approx. 100N
1 each
(JIS B 4650) Dial type : Approx. 300N
Dial type : Approx. 560N
TORQUE WRENCH ADAPTER 1 each
HEXAGON SOCKET Opposite side : 24mm, 41mm 1 each
EXTENSION BAR
150mm 1
(JIS B 4637)
HAND HAMMER Various kinds 1 each
PLASTIC HAMMER Approx. L=400mm 1 each
FLAT-BLADE SCREWDRIVER Approx. 50mm
1
(JIS B 4609) Approx. 150mm
For shafts
SNAP RING PLIERS 1 each
For holes
CUTTING PLIER
200mm 1
(JIS B 4623)
Lifting load 2940N (662 lb) or more 1
Eyeboly (For M16) (2)
LIFTING TOOL Eyeboly (For M12) (3)
Eyeboly (For PF1/2) (2)
Wire with hook (1)
RECEPTACLES Volume : W450×D300×H120mm 2
LEATHER GLOVES 1 pair

(2) Bolts

No. NAME TYPE / DIMENSIONS Q'TY

HEXAGON SOCKET
1 CAPSCREW Approx. M12 (P1.5)×40mm 2
(JIS B 1176)

34-43
34. TRAVEL SYSTEM

(3) TIGHTENING TORQUE

APPLICATION BOLT•NUT OPPOSING TIGHTENING

ITEM FLATS Q'TY TORQUE
NAME SIZE (mm)
(No.) N•m (lbf•ft)
30,357 PLUG PF1/2 10 4 98.1 (72.4)
HEXAGON SOCKET
35 M10 (P1.5) 8 12 66.7 (49.2)
CAPSCREW
203 SLEEVE PF1/2 24 2 98.1 (72.4)
205 PLUG PF1/4 6 2 29.4 (21.7)
324 PLUG M36 (P1.5) 41 2 441 (325)
HEXAGON SOCKET M12
343 10 10 102 (75.2)
CAPSCREW (P1.75)
352 PLUG PF1/8 5 3 12.3 (9.07)
HEXAGON SOCKET
354 NPTF1/16 4 5 9.81 (7.24)
CAPSCREW
380 PLUG PF3/8 8 2 58.8 (43.4)
HEXAGON SOCKET
396 PT1/4 6 2 29.4 (21.7)
CAPSCREW
HEXAGON SOCKET
398 PT1/8 5 6 12.3 (9.07)
CAPSCREW

(4) Tools

NAME SIZE APPLICATION ITEM (No.)

Product disassembly /
GENERAL WORK BENCH
assembly
WASHING TANK For rough and finish washing Product / parts washing
24 : Press capacity
9800N (2205 lb) or more
104 : Press capacity
PRESS MACHINE 24, 104, 149
1960N (441 lb) or more
149 : Press capacity
1960N (441 lb) or more
Heating capacity : over 100°C (212°F)
HEATING TANK 149
Volume : 500×500×500 (19.7"×19.7"×19.7") or more
Pressure : 0.29~0.49MPa
COMPRESSED AIR For drying washed parts
(42~71 psi)

34-44
 34. TRAVEL SYSTEM

(5) Jigs

No. NAME No. NAME

Working bench for travel motor Inserting jig for lock washer

1 5

This is used to carry out the work for assembly and For inserting lock washer (22) into spindle (2).
disassembly of travel motor easy and safe.
Retainer metal (I) Press fit jig for main bearing

2 6

• For inserting spring (114), washer (110) and

snap ring(145) into cylinder block (104).
• For removing spring (114) from cylinder block For press fitting angular ball bearing (24) into hub
(104). (1).
Retainer metal (II) Steel rod (I)

3 7

For removing ball bearing (149) from or inserting it For removing angular ball bearing (24) from hub
onto shaft (102). (1).
Press fit jig for oil seal Long eye bolt

USE "A"
HUB M16
4 8
HUB M10
SPINDLE M16
"A" GM MOTOR M16
For press fitting oil seal (132) into the oil seal hole
the spindle (2). For lifting the GM motor, spindle (2) and hub (1).

34-45
34. TRAVEL SYSTEM

No. NAME No. NAME

Slice Floating seal (F/S) fitting tool (II)

9 11

For removing timing plate (109) from rear flange For installing floating seal (29) to hub (1) and
(301). spindle (2).
Floating seal (F/S) fitting tool (III)
Floating seal (F/S) fitting tool (I)

10 12

For installing floating seal (29) to hub (1).

For installing floating seal (29) to spindle (2).

34-46
 34. TRAVEL SYSTEM

34.2.3 PREPARATION FOR DISASSEMBLY

34.2.3.1 GENERAL PRECAUTIONS FOR DISASSEMBLY

• Internal parts are covered with hydraulic fluid and gear oil during disassembly and are slippery.
If a part slips out from your hand and falls, it could result in bodily injury or could damage the part.
Be very careful for handling.
• It combustibles such as white kerosene are used for washing parts, be careful for handling.
These combustibles are easily ignited, and could result in fire or injury.
Be careful for handling.

(1) Before disassembling, perform inspections and confirm clearly the indication of no abnormality, which may be
occurring, and work according to the disassembly procedure.
(2) All parts are manufactured precisely.
Be careful for handling.
Avoid rough contact or drop of parts.
(3) Do not bang or remove parts forcefully.
Such act could cause burs or damages on the parts, which leads to failure of assembling or inferior performance.
(4) If you leave parts disassembled parts or with partially disassembling, rust could develop on the parts due to
moisture or dirt.
If you have to interrupt the work before completion, take measures to protect against rust or dust.
(5) Place a counter mark on mating faces of parts when disassembling.
(6) Tidy removed parts when disassembling so as not to damage or lose the parts while working.
(7) As a rule, once any type of seal are disassembled, they should be replaced with new ones even if they show no
signs of damage.
You should ready new parts before disassembling.
New parts shall be provided prior to disassembling.
(8) The photographs and drawings contained in the manual are of representative models.
However, disassembly procedure is not affected even if the disassembled product are different from this manual.

34.2.3.2 CLASSIFICATION OF DISASSEMBLY

This travel motor assembly consists of hydraulic motor, reduction unit, brake valve, and parking brake as one
assembly.
The disassembly works consist of the following items basically.
Select the required parts to disassemble between hydraulic motor, reduction unit, brake valve, and parking brake.
Decide the order of parts to be disassembled, and perform a service work according to the respective maintenance
procedure.

Don't perform unnecessary disassembly.

34-47
34. TRAVEL SYSTEM

34.2.3.3 DISASSEMBLY PROCEDURE

(1) Cleaning travel motor. (15) Disassemble brake valve section on rear fiange.
(2) Place travel motor. (16) Disassemble the 2-speed selector valve.
(3) Drain lubricating oil. (17) Disassembling the piston.
(4) Remove cover. (18) Disassembling the check ball.
(5) Remove thrust plate. (19) Disassembling the parking brake.
(6) Remove 1st stage planetary gears. (20) Disassemble hydraulic motor.
(7) Remove coupling. (21) Take out spring from cylinder block .
(8) Remove 2nd stage planetary gears. (22) Pull out shaft (102).
(9) Remove lock washer. (23) Remove the ball bearing (149) inner race.
(10) Remove hub. (24) Remove the ball bearing (149).
(11) Remove floating seal. (25) Remove spindle.
(12) Remove angular ball bearing. (26) Rough cleaning of every part.
(13) Remove rear flange. (27) Finish clean.
(14) Remove parts installing rear flange.

34.2.3.4 WEIGHT OF COMPONENT

NAME Weight [kg (lbs)]

TRAVEL MOTOR ASSY Approx. 145 (320)
HUB Approx. 46 (101)
SPINDLE Approx. 27 (60)
CARRIER 1 ASSY Approx. 12 (26)
CARRIER 2 ASSY Approx. 24 (53)
REAR FLANGE ASSY Approx. 13 (29)

34-48
 34. TRAVEL SYSTEM

34.2.3.5 REMOVING
(1) Cleaning travel motor
1) Tighten the eye bolts into the tapped holes of the EYE BOLT
spindle (2).
Eye bolt ; M16 2

Fasten two eye bolts into the tapped holes for the
spindle so they are located diagonally opposite to one
another.

2) Place a wire sling in the eye bolts, lift the travel

motor by hoist, and carry in to the cleaning bath. Fig. 34-90 Attaching eye bolt
Travel motor assy weight :
Approx. 144kg (320 lbs)

3) Clean the travel motor with a car brush.

Since soil and sand are entered in the clearance

(where the floating seal is fixed) between hub (1) and

spindle (2), clean it with particular care.

Fig. 34-91 Cleaning travel motor

(2) Installing travel motor
1) Placing travel motor on working bench.

Align threaded holes of hub (1) and working bench, and

place travel motor in fixing hole of working bench
slowly. 

Fig. 34-92 Placing travel motor on working bench

2) Fix travel motor with two socket bolts on working
bench.

: 14 mm

Tighten 2 socket bolts securely. Failure to tighten

securely, when the travel motor is reversed, it falls and   
causes injury.

Fig. 34-93 Fixing travel motor on working bench

34-49
34. TRAVEL SYSTEM

(3) Draining lubricating oil.

If you want to disassemble only the rear flange, go to 35, 31

(6) 1).

1) Turn over the travel motor.

30

Loosen plug (30) slowly to avoid spurt of lubricating oil.

Fig. 34-94 Removing plug (30)
2) Loosen and remove two socket plugs (30) to
release inner pressure.

: 10 mm

When draining out the lubricating oil, place a container

under the work bench.

4) Draw out the lube oil by reversely turning the

travel motor slowly.
5) Remove O-rings (31) from removed plugs.

EYE BOLT (PT1/2)

Do not reuse removed O-ring (31).
14
(4) Removing cover.
1) Turn over the travel motor.
2) Remove ten socket bolts (35).

: 10 mm
3) Because sealant is applied between cover (14)
and hub (1), hit upward the corner of cover with
a hammer using soft metal to protect the cover. Fig. 34-95 Removing cover (14)

The cover (14) may jump and remove suddenly by

hitting. Be careful not to drop the cover to avoid injury.
13
4) Place a hook and a wire sling on the PT eye
bolts, lift it up and remove cover (14).
(5) Removing thrust plate
1) Removing thrust plate (13)

Fig. 34-96 Removing thrust plate (13)

34-50
 34. TRAVEL SYSTEM

(6) Removing 1st stage reduction gear

1) Remove sun gear 1 (4) by hand.

Be careful not to drop sun gear 1(4) it could be slippery

by lubricant.

2) Fasten 3 eyebolts to the tapped holes of carrier

1 (3). And attach wire slings and hook in the eye
bolts. Lift the carrier (1) assembly with hoist.

Fig. 34-97 Removing sun gear 1 (4)

When carrier (1) assembly is lifted with hoist, the edge

of planetary gear 1 (5) may damage the internal teeth
of hub (1).
3
Align center line of hub (1) with that of carrier 1
assembly, lift carrier 1 slowly and straightly.

Fig. 34-98 Removing carrier 1 (3) Assy

(7) Removing coupling
1) Remove coupling (15) from shaft (102) 15

(8) 2nd stage reduction gear removal

1) Fasten three eyebolts to the tapped holes of
carrier 2 (7).
Place a wire sling and hook in the eyebolts, lift
carrier 2 assembly by crane. Fig. 34-99 Removing coupling (15)

When carrier 2 assy is lifted by crane, the edge of 7

planetary gear 2 (9) could damage the internal teeth of
hub (1).
Lift up slowly, and carefully.

2) Remove sun gear 2 (8) by hand.

Be careful not to drop sun gear 2 (8).

Fig. 34-100 Removing carrier 2 assy (7)
If could be slippery by lubricant.

34-51
34. TRAVEL SYSTEM

(9) Removing lock washer

1) Fix hub (1) and workbench with using three holes
(ø14) of hub (1).

Fig. 34-101 Removing hub (1) and lock washer

2) Put a flathead screwdriver into the clearance
between two lock washers (22), and widen the
clearance.
Place the tip of the screwdriver to the one end of
the lock washers (22), tap it by hammer, and
remove two lock washers (22).

22

(10)Removing hub
Fig. 34-102 Removing lock washer (22)
1) Remove the hexagon socket bolts, which fixed
hub (1) and workbench. 1
2) Fasten two eyebolts on the tapped holes of
spindle (101).
Place a wire sling and hook in the eyebolts. Lift
hub (1) by crane.

Lift up hub (1) slowly and carefully.

If hub (1) is inclined against spindle (2), for the
interference, wire sling or eyebolts could be
destroyed and hit the worker. If hub (1) does not Fig. 34-103 Removing hub (1)
come out smoothly, do not pull forcefully. Instead,
use other tools such as press machine.

(11)Removing floating seal

1) Grasp inner side of floating seal (29) and lift it up
by hand.

Use work gloves to prevent from cutting hands at the

edge of floating seal (29). If lifting up by hand is difficult 29
by mudpack or such reason, use flat head screwdriver
as a lever. Fig. 34-104 Removing floating seal (29)

34-52
 34. TRAVEL SYSTEM

(12)Removing angular ball bearing

1) Put a steel rod on the inner race of angular
bearing (24), tap 3 or 4 points evenly to take care 24
not to damage the bearing.

• Do not remove the angular ball bearing (24), except

for replacing the bearing.
When the outer race of angular ball bearing (24)
separates from fitness hub (1), angular ball bearing
(24) falls from hub (1 ).
Fig. 34-105 Removing angular ball bearing (24)
• Please place a container under the workbench and
cover with the rubber mat on it so that angular ball
bearing (24) does not get damage. 324

(13)Removing rear flange

1) Turn over GM motor. (Rear flange (301) is on
top.)

This work is carrying out to remove easily the pugs

(324) at the following work.
Do not loosen the plugs (324) if the inside of rear flange
Fig. 34-106 Removing plugs (324)
assembly is not disassembled.

2) Temporarily loosen plugs (324) (2 plugs). 380

3) Temporarily loosen plugs (380) (2 plugs).

352,357

This work is carrying out to remove easily the pugs

(380) at the following work.
Do not loosen the plugs (380) if the inside of rear flange
assembly is not disassembled.

4) Temporarily loosen plugs (352) (2 plugs).

Fig. 34-107 Removing plugs (380), (352), (357)

This work is carrying out to remove easily the pugs

(352) at the following work.
Do not loosen the plugs (352) if the inside of rear flange
assembly is not disassembled.

5) Temporarily loosen plugs (357).

This work is carrying out to remove easily the pug (357)

at the following work.
Do not loosen the plug (357) if the inside of rear flange
assembly is not disassembled.

34-53
34. TRAVEL SYSTEM

6) Temporarily loosen relief valve assy (203 others)

(2pcs).
7) Loosen the relief valve assemblies (203 others)
(2 pcs).

203

Fig. 34-108 Temporarily loosen

relief valve Assy (203)
8) Remove the relief valve assemblies (203 others)
(2 pcs).

Do not reuse O-ring (207), (209), (212) and backup ring

(208), (210) which have been removed.

203

Fig. 34-109 Removing the relief valve Assy (203)

9) Loosen and remove hexagon socket bolts (343)
(10 pcs) from rear flange (301).

: 8 mm

10) Remove rear flange (301) from spindle (2).

!"!
Fig. 34-110 Removing socket bolts (343)
Hold rear flange (301) with both hands, hold up rightly
and gently, and remove it. !
Timing plate (109) could fall off and get damaged
during this work.

11) Removing ten springs (113).

'!"
12) Removing parallel pins (341) from spindle (2). !
13) Removing O-ring (27), (30) from spindle (2).

Do not reuse O-ring (27), (30) which have been

removed. Fig. 34-111 Removing rear flange (301)

34-54
 34. TRAVEL SYSTEM

14) Pull out parallel pins (34) (2 pcs) from spindle

(2).

Fig. 34-112 Removing parallel pins (34)

15) Remove O-ring (32), (33) (2 pcs) from spindle
(2).

Do not reuse O-ring (32), (33) which have been

removed.

Fig. 34-113 Removing O-ring (32), (33)

(14)Removing the rear flange fittings
1) Place rear flange (301) on a work bench, with the
mating surface for spindle (2) facing up.
2) Remove timing plate (109) from rear flange
(301).

301(341)

If it is hard to remove the rear flange in some cases as

the mating surface of it is stuck with oil, insert a spatula
into the draft groove of the mating surface on the rear 150
flange side and hold the timing plate up. Then the rear
Fig. 34-114 Removing ball bearing (150)
flange comes off. If a sharp tool like screwdriver is put
into the mating surface, the mating surface is scored,
causing an oil leakage ; do not use sharp tools.

3) Remove parallel pins (341) from rear flange

(301).
4) Remove ball bearing (150) from rear flange
(301).

34-55
34. TRAVEL SYSTEM

(15)Removing the brake valve from the rear flange.

1) Remove two plugs (324) from rear flange (301).

: 36 mm
301
2) Remove O-ring (336) from plug (324).

Do not reuse removed O-ring (336).

324(336)

Fig. 34-115 Removing plug (324)

3) Remove two spring retainer (325) and two
springs (328) from rear flange (301).
4) Remove spool (323) from rear flange (301).
301

To remove spool (323), place your hand on one part of

328
the plug port of rear flange (301) and tilt it down. Then
spool (323) falls down. Hold the tip and remove it.

323 328 325

Fig. 34-116 Removing spool (323)
(16)Disassemble the 2-speed selector valve
1) Remove plug (357) from rear flange (301).

: 10 mm

357(359)

301

Fig. 34-117 Removing plug (357)

2) Remove spool (363) and spring (366) from rear
flange (301).
3) Remove O-ring (359) from plug (357).

Do not reuse removed O-ring (359).

301

363,366
Fig. 34-118 Removing spool (363) and spring (366)

34-56
 34. TRAVEL SYSTEM

(17)Removing piston 380(383)

1) Remove plugs (380) (2 pcs) from rear flange
(301).
2) Remove O-ring (383) from plug (380).

Do not reuse removed O-ring (383) 301

Fig. 34-119 Removing plug (380)

3) Remove piston (381) from rear flange (301).

381

Fig. 34-120 Removing piston (381)

(18)Disassembling ball check part
1) Remove plugs (352) (2 pcs) from rear flange
(301).
2) Remove O-ring (358) from plug (352).

Do not reuse O-ring (358) which have been removed.

352

Fig. 34-121 Removing plug (352)

3) Remove steel balls (353) from rear flange (301).

When it is hard to remove steel balls (353), remove

them using the magnet etc.

353

Fig. 34-122 Removing ball (353)

34-57
34. TRAVEL SYSTEM

(19)Disassembling parking brake

PROTECT COVER

The sudden blowing of compressed air may cause AIR HOSE

parts to fly out incurring the danger of injury. Cover
piston (112) for protection.

1) Blow jet air into the passage hole for the parking
brake of the spindle (2) and remove the piston
(112) from the spindle (2).
2 112

Fig. 34-123 Blowing jet air

2) Remove O-ring (135),(139) from piston (112).
112
(135,139)

Do not reuse removed O-ring (135), (139).

(20)Disassembling the hydraulic motor section

When placing the travel motor on its side, oil spills ;

place a container under the travel motor.
Fig. 34-124 Removing piston (112)
1) Lay down the travel motor through 90 degrees.
2) Drain out the oil of the travel motor. 104(103,106,115,116)
3) Hold cylinder block (104) by hand, turn it both
ways a few times alternately and separate shoe
(106) from swash plate (103).

If cylinder block (104) is drawn out in that condition,

shoe (106) stays with swash plate (103). Then parts
(pistons, shoes, etc.) attached to cylinder block (104)
come off from cylinder block (104) and fall into spindle
(2). Care should be used about it. Fig. 34-125 Removing cylinder block (104)

4) Hold the cylinder block (104) and remove the

shaft (102).

Also, friction plate (115) and separator plate (116) are

also removed with cylinder block (104).

34-58
 34. TRAVEL SYSTEM

5) Remove friction plate (115) and separator plate 106

(116), (117) attached on the removed cylinder 105
block (104). 107
6) Remove piston assy [piston (105) and shoe 110
(106)] and retainer plate (107) from cylinder 104
block (104).

108
• When removing the cylinder block, hold the retainer
plate (107) by both hands and remove it with the
piston assy.
• Cylinder block (104) and piston assy [piston (105)
and shoe (106)] are the minimum parts unit as
cylinder & piston kits. When they have to be
replaced, replace the cylinder & piston kit as a set. 116 115
(Refer to the parts manual.)
Fig. 34-126

7) Remove the piston assy (105),(106) from

retainer plate (107). [Nine pistons]
8) Remove thrust ball (108) from cylinder block
(104).
9) Draw out washer (111) from cylinder block (104).
10) Remove three needle rollers (151) from cylinder
block (104).

151
104
Fig. 34-127 Removing roller (151)

34-59
34. TRAVEL SYSTEM

(21)Remove spring from inside of cylinder block.

1) Place cylinder block (104) on the press bench. 104

145(110)
• Do not remove the spring except when spring is
replaced.
• When removing the spring, align the Jig (I) with the
washer in order to prevent the cylinder block from
being damaged by contact.
• Put a plastic sheet over the sliding surface of the
cylinder block so as not to damage it. Fig. 34-128 Removing snap ring (145)

2) Place the retainer metal jig (I) on washer (110)

and remove snap ring (145) from the snap ring
groove of cylinder block (104) by means of snap
114(110)
ring pliers, while holding down the jig (I).

104

If the press is loosened too suddenly, the spring jumps

out and injure yourself. Always loosen the press slowly.

3) Loosen the press slowly till the spring action is

released.
Fig. 34-129 Removing spring (114)
4) Remove the snap ring (145), washer (110),
spring (114), and washer (110) from inside the
cylinder block (104).
(22)Removing out shaft (102).
1) Removing swash plate (103) from spindle (2).

When removing it, check that pivot (167) is not adhered

on swash plate. 2(103,167)

2) Draw out shaft (102) from spindle (2). On that 149

occasion, the inner race of ball bearing (149)
comes off with the shaft.
102
3) Draw out two pivots (167), two parallel pins (171)
and the outer race of ball bearing (149) from Fig. 34-130 Removing shaft (102)
spindle (2).
4) Draw out the 2-speed switch piston assy [piston 162
(161) and shoe (162)] and spring (185) from
spindle (2). 161

185

Fig. 34-131 Removing 2-speed switching

piston assy

34-60
 34. TRAVEL SYSTEM

(23)Removing ball bearing (149)


Ball bearing (149) is removed only when replacing. 

1) Place holder (II) on the press bench and put shaft
(102) into the holder (II).
2) Remove ball bearing (149) from shaft (102) by
pressing on the shaft end with press.

Fig. 34-132 Removing ball bearing (149)

Do not reuse the removed ball bearing (149).

(24)Removing spindle fittings

1) Remove shim (23) from spindle (2).

23

Fig. 34-133 Removing shim (23)

2) Remove floating seal (29) from spindle (2).

Do not reuse floating seal (29) which have been

removed.

29

Fig. 34-134 Removing floating seal (29)

3) Remove oil seal (132) from spindle (2).

Do not reuse oil seal (132) which have been removed.



 


Fig. 34-135 Removing oil seal (132)

34-61
34. TRAVEL SYSTEM

(25)Rough washing of parts.

2
1) Distinguish the four parts ; hub (1), spindle (2), 3,7
cover (8), and rear flange (101) from other parts 301
(hereafter called built-in parts).
2) Put the hub, spindle, cover and rear flange in a
cleaning bath and clean them.

• Soil and sand are adhered to the outer surface of

parts in some cases ; clean them and remove soil
1(14)
and sand from the parts.
• Wash oil is combustible. Be careful not to cause fire Fig. 34-136 Rough washing of parts
and get burns.
• Before cleaning stained parts, immerse them in
wash oil until dust and stain become soft and are
floated to protect them from damaging when
cleaning.

3) Put the built-in parts in a rough cleaning

container containing wash oil and clean the
parts.

(26)Finish cleaning
1) Put parts in a finish cleaning container containing
wash oil and clean them well, turning them 3,7
slowly.
2) Blow parts with dry air to remove cleaning oil.

• Blow compressed air in the inner surface of hub (1),

spindle (2) and hold flange (3) to dry in the dust free
and dry conditions. After drying, apply hydraulic oil
to every part.
Fig. 34-137 Finish cleaning
• Inner surface of rear flange (101), hydraulic motor
components, and RV gear assy are to be dried
naturally in the dust free and dry conditions. After
drying every part, apply hydraulic oil to every part.
• Use care not to damage the surface of twenty four
pins (17) or lose them while handling.

Fig. 34-138 Finish cleaning

34-62
 34. TRAVEL SYSTEM

34.2.4 ASSEMBLY

34.2.4.1 GENERAL PRECAUTIONS FOR ASSEMBLY

(1) Assembly it by reversing the procedure of disassembly.
(2) Assemble it in clean air condition.
(3) Don’t use cloth gloves during assembly.
(4) Replace or repair the damaged parts during disassembly according to the instructions in the "Maintenance
standard".
Replace O-ring, oil seal, etc. with new one.
(5) Clean every part sufficiently, and blow them with compressed air don’t use waste cloth.
(6) Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor valve.
(7) Tighten bolt and plug to the specified torque using torque wrench.
(8) Replace reamer bolt with new ones. If it is unavoidably reused, remove completely the adhesive agent on
reamer bolt, repair flaws on bolt seat surface with oilstone, and degrease it.
(9) Prior to assembling, apply grease to lip portions of O-ring, oil seal, and floating seal to protect it from being
damaged, and to moving section and sliding section.
(10)After assembly, plug every port to protect the entry of dust, etc.

34.2.4.2 PREPARATORY ARRANGEMENT FOR ASSEMBLY

(1) After replacing parts with new ones, adjust the pre-load of bearing and thickness of snap ring without fail.
1) When the following parts are replaced, the pre-load adjustment of bearing is required.

HUB (1)
SPINDLE (2)
Bearing (24)

Where replacing the above parts, the previously adjusted parts should be used. If unadjusted parts are used, the
travel motor moves abnormally, causing early breakage.

34-63
34. TRAVEL SYSTEM

34.2.4.3 ASSEMBLING PROCEDURE

(1) Assembling hub

1) Place hub (1) on the press bench.
2) Place angular ball bearing (24) on hub (1), and 
press in by using the main plate and a press 

machine.   
3) Turn over hub (1).
4) Insert angular ball bearing (24) into hub (1) in the
same way 2).  
 

 
Make sure that the installing direction of angular ball Fig. 34-139 Inserting ball bearing (24)
bearing (24) is correct.

5) Apply grease on the O-ring of floating seal (29),

and fit the O-ring into the floating seal groove on F/S INSTALLATION
TOOL (II)
hub (1).

F/S INSTALLATION
TOOL (III)
• When applying grease to the O-ring, remove the O-
ring from floating seal (29), and then, apply grease
thinly to entire surface.
FLOATING SEAL
• Use floating seal installation tool (I) and (II).
Make sure to keep the parallel tolerance 1mm
HUB
(0.039") to end surface of the groove.
If not, it could cause seizure on floating seals (29)
or oil leak.

Fig. 34-140 Installing floating seal (29)

(2) Assembling spindle F/S INSTALLATION TOOL(II)
1) Apply grease on the O-ring of floating seal (29),
and fit the O-ring into the floating seal groove on
spindle (2).

F/S INSTALLATION
TOOL(III)

When applying grease to the O-ring, remove the O-ring

from floating seal (29), and then, apply grease thinly to
entire surface.
Use floating seal installation tool (II) and (III).
FLOATING SEAL
Make sure to keep the parallel tolerance 1mm (0.039")
SPINDLE
to end surface of the groove.
Fig. 34-141 Installing floating seal (29)
If not, it could cause seizure on floating seals (29) or oil
leak.

2) Install eyebolts to spindle (2) so they are

symmetrically positioned.

34-64
 34. TRAVEL SYSTEM

3) Fix spindle (2) on workbench with two hexagon

socket bolts, which should locate symmetrically.

Tighten the hexagon bolts securely.

Failure to do so could result in injury if GM motor is
inverted and falls.
2

Fig. 34-142 Installing spindle (2)

(3) Clearance adjustment procedure for angular ball
bearing C

If any of hub (1), angular ball bearing (24) or spindle (2)

is replaced, clearance adjustment should be
conducted.
If not, angular ball bearings (24) could break in short
period.

1) Insert lock washers (22) for measuring the

dimensions, and measure the distance C. Fig. 34-143 Measurement dimension C
2) Measure the distance D.

D
Rotate hub assembly for stabilizing the distance D.

3) Select one of the classified shim (23) which

makes the distance "C - D" from -0.17 to
-0.13mm (-0.0051"~0.0067").
Shim (23) thickness shall be refer to the following
table.
ITEM T (mm) ITEM T (mm)
A 0.9 (0.035") G 1.5 (0.059") Fig. 34-144 Measurement dimension D
B 1.0 (0.040") H 1.6 (0.063")
C 1.1 (0.043") I 1.7 (0.067")
D 1.2 (0.047") J 1.8 (0.071")
E 1.3 (0.051") K 1.9 (0.075")
F 1.4 (0.055") L 2.0 (0.079")

4) Attach shim (23) to spindle (2).

23

Fig. 34-145 Installing shim (23)

34-65
34. TRAVEL SYSTEM

(4) Assembling hub

1) Insert hub (1) into angular ball bearing (24)
assembled in spindle (2) with keeping both
center axes parallely.

Fig. 34-146 Assembling hub

2) Fix hub (1) to the workbench with three long
hexagon socket bolts.
3) Put steel rod on the inner race of angular ball
bearing (24) located on reduction gear, and tap
softly by hammer to stabilize angular ball bearing
(24).

Fig. 34-147 Fix hub (1) to the workbench

4) Place lock washers (22) to the groove of spindle
(2).

5) Fit lock washers (22) into the groove of spindle

(2) by using installation tool 22

Fig. 34-148 Fitting lock washer (22)

Insert lock washers (22) fully into the groove so as not
to interfere with carrier 2 (7).

6) Remove the long hexagon socket bolts, which fix

hub (1) and the workbench.
7) Rotate hub (1) two or three times.

Contacting state between both sliding surface of

floating seal (29) will be improved by rotating spindle 22
(2), and prevent initial oil leak.
Fig. 34-149 Fitting lock washer (22)
8) Turn over spindle (2).

34-66
 34. TRAVEL SYSTEM

(5) Assembling spindle fittings

1) Drive oil seal (132) into spindle (2) by using the
holder (III) to prevent it from being inclined.
 

  
Apply lithium grease around the lip portion of oil seal
 
(132) when mounting.
Be careful in the inclusion direction of oil seal (132).

2) Install two parallel pins (171) into the pin holes of

spindle (2).
3) Apply lithium grease to hemispherical surface of Fig. 34-150 Installing oil seal (132)
two pivots (167), and fit it into parallel pins (171)
of spindle (2).
4) Apply lithium grease to spring (185), and install
spring (185) into the piston kit (piston (161) and
shoe (162)).
5) Apply hydraulic fluid to the sliding surface of the
piston kit, install it into the piston hole of spindle
(2).
162
6) Install two parallel pins (34) into the pin holes of
spindle (2).
161
Fig. 34-151 Installing piston (161) and shoe (162)
(6) Assembling shaft 

Wear thick leather groves in handling the heated ball 

bearing (149).


 
1) Put ball bearing (149) in a heating tank to heat it 
 
at 90 to 110°C [194 to 230°F] for ten minutes and
then insert it onto shaft (102).

Fig. 34-152 Installing ball bearing (149)

2) Turn the workbench 90 degrees.

3) Insert shaft (102) to spindle (2).

Take care not to scratch or cut the lip portion of oil seal
(132) in place with the splined foremost end of shaft
(102). 102

Fig. 34-153 Installing shaft (102)

34-67
34. TRAVEL SYSTEM

(7) Install oil seal (132)

1) Turn over travel motor.
2) Coat the lip of the oil seal with lithium grease and
fix oil seal (132) into the oil seal hole in spindle 132
149
(2), using retainer metal and a hammer. (OUTER RACE)
3) Assemble the outer race (with roller) of bearing
2
(149) into spindle (2).

Fig. 34-154 Pressing oil seal (132)

4) Insert swash plate (103) into spindle (2).

Apply lithium grease on swash plate (103) where

mating surface of spindle (2). 103
Make sure that the locating pivots (167) of spindle (2)
enter pivots' holes of swash plate (103).

(8) Assembling cylinder block interior

Fig. 34-155 Installing swash plate (103)

• The sharp edge of snap ring (145) is turned and put

into the entrance side of cylinder block (104). 110
• Washer (110) which touches snap ring (145) turns
and puts its sharp edge side into snap ring side.
114
1) Insert washer (110), spring (114), washer (110)
and snap ring (145) in that order into cylinder
block (104).
104
2) Place cylinder block (104) on the press bench.

Fig. 34-156 Inserting spring (114)

When mounting snap ring (145), if the tip of the pliers
slips out of the hole of snap ring (145), snap ring (145)
could jump out.

109

Press force of spring (114) is 1128N (254 lb) or more.

Protect by covering cylinder block (104) with a vinyl
sheet so the contact surface with timing plate (109) of 145
cylinder block (104) does not become damaged.
104
3) Place holder (I) on washer (110), and while
Fig. 34-157 Installing snap ring (145)
clamping with the press, fit snap ring (145) in the
snap ring groove of cylinder block (104) with the
snap ring pliers.

34-68
 34. TRAVEL SYSTEM

(9) Assembling hydraulic motor

1) Put three rollers (151) into the holes of cylinder
block (104) and place washers (111) and thrust
balls (108) on them.

2) Fit nine piston assy to retainer plate (107).

151
After fixing it, immerse the whole unit in hydraulic oil. 104

3) Fit retainer plate (107) and 9 piston assy to Fig. 34-158 Installing rollers (151)
cylinder block (104).

Match retainer plate (107) with the spherical part of

thrust ball (108) and install them.
105,106 107
4) Assemble cylinder block (104) fitted with swash
108
plate (103), thrust ball (108), washer (111), 111
retainer plate (107), piston assy (105), (106) and 104(151)
roller (151), to shaft (102) that is placed level. (to
make a hydraulic motor assy)
Fig. 34-159 Assembling piston assy and
retainer plate (107)
5) Installing cylinder block (104) into shaft (102).

Install cylinder bock (104) into the spline of shaft (102)

by aligning the spine hole with the spline of shaft (102).

104

Fig. 34-160 Installing cylinder block (104)

6) After installing cylinder block (104), turn it by
hand and make sure that it fits properly.
If not, inspect it.

Cylinder block (104) is not flattered after installing it.

If cylinder block (104) is flattered, thrust ball (108) is
separated and GM motor does not rotate normally.

104 102

Fig. 34-161 Check for play of cylinder block (104)

34-69
34. TRAVEL SYSTEM

(10)Installing parking brake.

115

104

Immerse friction plate (115) in hydraulic oil before fitting

it.

1) Assemble separator plate (117) into the inner

groove of spindle (2) that houses cylinder block
(104).
2) Assemble three friction plates (115) and
separator plates (116), by turns, into the outer
groove of cylinder block (104) and into the inner Fig. 34-162 Fitting friction plate and
groove of spindle (2). On that occasion, fix the separator plate
friction plates first and then the separator plates.
3) Fit O-rings (135),(139) to the O-ring grooves of
piston (112). In that case, coat O-rings (135),
(139) with a thin film of grease.
4) Fitting piston (112) into spindle (2).

112
• If it is hard to fit the piston (112) into the spindle (2) (135,139)
due to the resistance of O-rings (135),(139), lightly
tap the end face of the piston (112), using a plastic 2
mallet.
Fig. 34-163 Fitting piston (112)
• Take care so as not to score the O-rings when
installing the piston (112).

(11)Attaching two-speed spool

1) Insert spring (366) and spool (363) into rear
flange (301).
2) Fit O-ring (359) to plug (357). 363
(366)

Apply grease to O-ring (359).

Fig. 34-164 Inserting spring (366) and spool (363)
3) Attach plug (357) to rear flange (301).
4) Temporarily tighten plug (357) into rear flange
(301) by hexagon wrench.

Fig. 34-165 Installing plug (357)

34-70
 34. TRAVEL SYSTEM

(12)Attaching ball check part

1) Fit two O-rings (358) to two plugs (352).

Apply grease to O-ring (358).

2) Insert steel ball (353) into rear flange (301).

353

Fig. 34-166 Installing steel ball (353)

3) Temporarily tighten plugs (352) into rear flange
(301) by hexagon wrench.

Fig. 34-167 Temporally fastening plug (352)

(13)Attaching piston
1) Fit two O-rings (383) to two plugs (380).

Apply grease to O-ring (383).

2) Insert piston (381) into rear flange (301).

381

Fig. 34-168 Installing piston (381)

3) Temporarily tighten plugs (380) into rear flange
(301) by hexagon wrench.

Fig. 34-169 Temporally fastening plug (380)

34-71
34. TRAVEL SYSTEM

(14)Assembling brake valve parts in rear flange

1) Insert spool (323) into rear flange (301).

Apply hydraulic fluid to spool (323) and insert spool

(323) into rear flange (301).
To insert spool (323), align the hole of rear flange (301)
with spool shaft center so as to prevent the inner
surface of rear flange (301) and the outer surface of
323
spool (323) from being damaged due to interference.
Otherwise internal leaks will occur after reassembly,
Fig. 34-170 Installing spool (323)
resulting in performance deterioration of GM motor.

2) Fit two O-rings (336) to two plugs (324).

Apply grease to O-ring (336).

3) Attach .washer (325) (2 pcs) and spring (328) (2

pcs) to plug (324) (2 pcs).
336
324
Fig. 34-171 Installing O-ring (336)
4) Attach plug (324) (2 pcs) to rear flange (301).

When attach plug (324) to rear flange (301), insert

carefully so as not to deform spring (328).

5) Temporarily tighten plug (324) (2 pcs) into rear

flange (301).

Fig. 34-172 Installing plug (324)

(15)Assembling rear flange mounted parts
1) Apply hydraulic fluid to ball bearing (150), and fit
ball bearing (150) into rear flange (301).
2) Insert two parallel pins (341) in the pin holes of
rear flange (301).
3) Apply grease to the mating face of timing plate
(109) in contact with rear flange (301) of timing
plate (109).
150

Fig. 34-173 Installing ball bearing (150)

34-72
 34. TRAVEL SYSTEM

4) Fit timing plate (109) on rear flange (301) using

parallel pins (341) as the guide.

Fitting of timing plate (109) is carried out until timing

plate (109) adheres to rear flange (301).
Adhesion prevents from dropping timing plate (109)
from rear flange (301) when mounting rear flange (301)
on spindle (2). 109

Fig. 34-174 Installing timing plate (109)

5) Mount ten springs (113) on the hole of rear flange 113
(301).

Apply grease to springs (113) in order to prevent from

dropping springs (113) from rear flange (301).

Fig. 34-175 Installing spring (113)

(16)Assembling rear flange
1) Fit O-rings (32), (33) (2pcs) in the O-ring grooves
of spindle (2).

Fit O-ring (32) without applying grease.

If reassembled with grease applied, the grease may
bleed from mating face of rear flange (301) and spindle
(2) when GM motor is running.

2) Put 1.0 litters of hydraulic fluid in spindle (2).

Fig. 34-176 Installing O-ring (32), (33)
3) Install rear flange (301) on spindle (2) so that two
parallel pins (34) on spindle (2) enter the pin
holes in rear flange (301).
4) Temporarily tighten hexagon socket bolts (343)
(10 pcs) into spindle (2) by hexagon wrench.

Fig. 34-177 Installing rear flange (301)

34-73
34. TRAVEL SYSTEM

(17)Tightening bolts
1) Tighten hexagon socket bolt (343) (10 pcs) with
the specified torque.
Tightening torque :
102±15.7 N•m (75±11 lbf•ft)

Fig. 34-178 Tightening hexagon socket bolt (343)

2) Tighten plugs (324) with the specified torque.
Tightening torque :
441±39.2 N•m (325±29 lbf•ft)

Fig. 34-179 Tightening plug (324)

3) Tighten plugs (380) with the specified torque.
Tightening torque :
58.8±9.81 N•m (43±7 lbf•ft)

Fig. 34-180 Tightening plug (380)

4) Tighten plugs (352) with the specified torque.
Tightening torque :
12.3±2.45 N•m (9±2 lbf•ft)

Fig. 34-181 Tightening plug (352)

34-74
 34. TRAVEL SYSTEM

5) Tighten plugs (357) with the specified torque.

Tightening torque :
98.1±19.6 N•m (72±14 lbf•ft)

Fig. 34-182 Tightening plug (357)

(18)Attaching relief valve assembly
1) Attach relief valve assembly (203 others) (2 pcs)
to rear flange (301).

Fig. 34-183 Installing relief valve assy

2) Tighten relief valve assembly (203 others) (2
pcs) with the specified torque.
Tightening torque :
98.1±19.6 N•m (72±14 lbf•ft)

(19)Assembling 2nd stage planetary gears

1) The workbench is rotated and the reduction-
gears side is turned upward. Fig. 34-184 Tightening relief valve assy
2) Attach san gear 2 (8) to carrier 2 (7).
3) Fasten three eyebolts to the tapped holes of
carrier 2 (7).
Place a wire sling and hook in the eyebolts, place
carrier 2 assembly slowly in hub (1).

When inserting carrier (2) assembly, take care so as not

to damage internal teeth of hub (1) by the egge of
planetary gears 2 (9).

Fig. 34-185 Installing carrier 2 assy

34-75
34. TRAVEL SYSTEM

  

Place carrier 2 (7) so that planetary gears 2 (9) should

be located as the left illustration.


  
  
Fig. 34-186
(20)Attaching coupling
1) Attach coupling (15) to shaft (102). 15

Fig. 34-187 Installing coupling (15)

(21)Assembling 1st stage planetary gears
1) Place carrier (1) assembly slowly in hub (1).

When inserting carrier (1) assembly, take care so as not

to damage internal teeth of hub (1) by the edge of
planetary gears 1 (5).

Fig. 34-188 Installing carrier 1 assy

2) Insert sun gear 1 (4) with aligning spline portion
to coupling (15) first, then gear portion second.

If the gear portion of sun gear 1 (4) does not engage

with planetary gears 1 (5), lift carrier (1) assembly until
the spline of sun gear 2 (8) is disengaged.
Insert sun gear 1 (4) first, then engage the spline of sun
gear 2 (8).

Fig. 34-189 Installing sun gear 1 (4)

34-76
 34. TRAVEL SYSTEM

3) Place thrust plate (13) on carrier 1 (3).

Fig. 34-190 Installing thrust plate (13)

(22)Assembling cover
1) Apply "Loctite #515" to the mating surface of hub
(1) for cover (14).

"Loctite #515" should be applied around the mating

surface without discontinuation.

Fig. 34-191 Apply Loctite #515

2) Fasten two eyebolts to the tapped holes (PF1/2)
of cover (14).
Place a wire sling and hook in the eyebolts, place
cover (14) on hub (1) with aligning the position of
bolt holes.

Fig. 34-192 Installing cover (14)

3) Apply "Loctite #242" to hexagon socket bolt (35)
(12 pcs).
Tighten hexagon socket bolts (35) (12 pcs) with
the specified torque.
Tightening torque :
66.7±3.92 N•m (49±3 lbf•ft)

Fig. 34-193 Installing hexagon socket bolt (35)

34-77
34. TRAVEL SYSTEM

(23)Filling lubrication oil

1) Fill gear oil (lubrication oil) into the filling port.

Supply 2.1 litters of gear oil.

Fig. 34-194 Filling lubrication oil

2) Attach plugs (30) to ports of cover (14), tighten
them with the specified torque.
Tightening torque : 98.1±19.6 N•m
98.1±19.6 N•m (72±14 lbf•ft)

(24)Removing reassembled GM motor from the

workbench
1) Turn the workbench upside down.
(The motor side of GM motor is turned up.)
2) Remove the bolts securing GM motor to the
workbench.
3) Fasten two eyebolts (Ml6) to spindle (2). Fig. 34-195 Removing reassemble travel motor
4) Place a wire sling and hook in the eyebolts,
remove GM motor from the workbench with the
crane.

34-78
 34. TRAVEL SYSTEM

34.2.5 MAINTENANCE STANDARD

34.2.5.1 PART MAINTENANCE STANDARD

(1) Replace all seals
Seal parts (O-ring, oil seal floating seal) should be replaced once disassembled even though no damage is
observed.
(2) Maintenance criteria for wearing parts
1) Replace any parts if they have severe damage on appearance.
2) Replace any parts if they have the following abnormalities.

REFERENCE ALLOWANCE
No. PARTS TROUBLE
VALUE VALUE
1 HUB • Severe damage on appearance.
• Pitting on ring gear teeth. — —
• Abnormal wear such as scoring.
2 SPINDLE • Severe damage on appearance.
— —
• Abnormal wear such as scoring.
3,7 CARRIER ASSY • Abnormal wear such as scoring.
— —
others
4 SUN GEAR 1 • Pitting on ring gear teeth.
8 SUN GEAR 2 • Flaking on the outer race for needle roller — —
5 PLANETARY GEAR 1 bearing.
9 PLANETARY GEAR 2
24 ANGULAR BALL • Dent, flaking or uneven wear on contact
— —
BEARING surface.
301 REAR FLANGE • Many scratch on sliding surfaces between
— —
spool (323) and piston (381).
102 SHAFT • Abnormal wear on contact surface between
oil seal (132). — —
• Abnormal wear on spline.
103 SWASH PLATE • Mark of sticking. — —
104 CYLINDER BLOCK • Abnormal wear on spline.
• Abnormal wear on bore surface.
— —
• Scratch or uneven wear on sliding surface
with timing plate (109).
105 PISTON ASSY • Abnormal clearance in the axial direction Clearance Clearance
106 PISTON between piston (105) and shoe (106). 0.05mm 0.15mm
SHOE • Abnormal wear on shoe (106). (0.002") (0.006")
107 RETAINER PLATE • Uneven wear on sliding surface with shoe
(106).
— —
• Scratch or uneven wear on sliding surface
with thrust ball (108).
108 THRUST BALL • Uneven wear on sliding surface with
— —
retainer plate (107).
109 TIMING PLATE • Sticking or uneven wear on sliding surface. — —
115 FRICTION PLATE • Uneven wear on both contact surface. Braking torque Braking torque
116 MAITING PLATE 206N•m 206N•m
• Specified torque cannot be obtained.
(152 lbf•ft) (152 lbf•ft)
• Mark of sticking. or over or over
105 PISTON • Scratch on sliding surface. — —

34-79
34. TRAVEL SYSTEM

REFERENCE ALLOWANCE
No. PARTS TROUBLE
VALUE VALUE
149 BALL BEARING • Dent, flaking or uneven wear on contact
— —
150 surface.
161 1st-2nd SPEED PISTON KIT • Uneven wear on both sliding surface.
162 PISTON • Abnormal wear on shoe (162). — —
SHOE
323 SPOOL • Abnormal and uneven wear on the outer
363 circumference. — —
• Severe scratch on the circumference.
381 PISTON • Severe scratch on the circumference. — —

34-80
 34. TRAVEL SYSTEM

34.2.5.2 PERFORMANCE CONFIRMATION TEST

After servicing GM motor, perform the following tests by the following procedure.
(1) Required measuring devices

1 Press gauge for 3.43MPa (500psi) 2 pcs.

2 Graduated cylinder for 5L (1.32gal) 1 pc.
3 Stopwatch 1 pc.

(2) Test procedure

1 GM motor mounting / Mount GM motor to body (frame section) and connect piping.
piping
The track shoe must not be attached here at this time.
(This is because for conducting the performance test (no-load operation) of GM motor.)

NOTE :
1. When connecting piping, connect so that the pressure gauge (main circuit)
can be mounted and drain volume of the hydraulic motor can be measured.
2. When mounting GM motor, do not strike with the hammer etc., but rather
mount gently using the bolt holes.

2 Break-in operation of Speed ranges Revolving speed of GM motor Pressure Rotation direction Running time
GM motor
Low speed 10min-1
No-load CW-CCW Min.1 min each
High speed 20min-1

3 GM motor performance
confirmation test

1 Pre-test preparatory operation

Hydraulic fluid temperature : 45~55 (113~131 )
Perform preparatory operation until
approximately the following temperature. Hub external temperature : 40~80 (104~176 )

2 Confirmation test
Passing GM motor drive pressure : Max. 1.57MPa (230psi) / at 10min-1
Measure the following items to criteria
decide with the motor passes or Hydraulic motor drain volume : Max. 1.2L/min (0.32gal/min)
fails the test. / at 10min-1

Good No good

Attach the track shoe Disassemble and adjust again

34-81
34. TRAVEL SYSTEM

34.2.5.3 TROUBLESHOOTING

Relief set pressure is low. Set it correctly.

No Check that motions other than

Pump fails.
pressure travel are okay and remedy if
out of order.

Directional valve is out of order. Check if spool is normal and

repair if necessary.
Motor does
not start. If spool or valve is seized, replace
Brake valve is out of order. spool. On other cases, repair.

Replace motor or check hydraulic

Hydraulic motor fails. oil. If faulty, replace hydraulic oil.

Pressure is okay.
Gear (in reduction unit) is broken. Replace motor.

Motor is overloaded. Eliminate load.

Orifice of parking brake passage is blocked. Remove the foreign materials from orifice.

Correct surface with grindstone,

Scratches on matching face
Through emery paper, etc.
matching faces
Bolts loosened Check after retightening

Plug is loosened Retighten

From casing
Casing cracked by stone, etc. Replace motor.
Oil leaks.
Sliding surface is worn. Replace motor.
From floating seal

Deterioration occurs to O-rings. Replace motor.

Bolts are loosened. Retighten

From hydraulic
motor O-ring is damaged. Replace O-ring.

Seal face is scored. Correct with grindstone, pa-per, etc.

Motor has poor volumetric efficiency. Replace motor.

Replace brake valve.

Machine slides down on a slope. Internal leakage from brake valve increased (Replace rear flange.)

Parking brake is not working.

Spring is broken. Replace spring.
Replace friction plate and
Friction plate is worn.
separator plate.
Orifice of passage is clogged. Clean oil passage and orifice.

34-82
 34. TRAVEL SYSTEM

Gear oil is short. Refill to a proper level.

Surface temperature of Replace parts of reduction unit

Pitching occurs to bearing and gear.
reduction unit casing is high. and gear oil.

Hydraulic oil intruded into gear casing. Replace oil seal and gear oil.

It occurs at low pressure.

Delivery rate differs on RH and LH motors. Repair pump.

Machine zigzage.

Drain rate differs on RH and LH motors. Replace rotary section of timing plate.

It occurs at high pressure.

Delivery rate differs on RH and LH motors. Repair pump and regulator.

Replace motor rotary section of

Drain rate differs on RH and LH motors. timing plate.

RH and LH brake valves moves Replace parts of brake valve.

differently. (Replace rear flange.)

Relief pressure of either the RH

Set pressure to a correct level.
or LH control valve is low.

The delivery rate of the pump is low.

The pump regulator does not work Repair the regulator.
correctly.
The pump has a large amount of Repair or replace the pump.
Speed does not go up.
external leakage.

The volumetric efficiency is bad.

Internal leakage. Replace rotary section of timing plate.

Set pressure of relief valve is low. Replace relief valve.

Abnormal sound is heard. Motor or reduction unit is broken. Replace motor or reduction unit.

Piping vibrates. Clamp piping.

34-83
34. TRAVEL SYSTEM

The speed does not Malfunction of high pressure selector Check it.
change from low to high. check valve. If necessary, repair or replace it.

Check that spool operates normally,

Malfunction of speed change valve. and if necessary, repair or replace it.

Pilot pressure is low. Set the pressure to the specified value.

Check it.
Malfunction of 2-speed change piston If necessary, repair or replace it.

Remove the foreign materials from

Orifice of 2-speed passage is clogged.
orifice.

The speed does not change Check that the spool operates normally.
Malfunction of selector valve
from high to low. If necessary, repair or replace it.

Check it.
Malfunction of 2-speed change piston If necessary, repair or replace it.

34-84
 46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS

46.1 JUDGMENT OF ACTUAL THING AT SITE .....................................................................46-2

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................................46-3
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ....................................................46-3
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-3

46

46-1
46. TROUBLE SHOOTING (BY ERROR CODES)

Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.

Fig. 46-1 Attending the field to verify actual thing.

46.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
(2) Verify background of trouble occurred
1) Model name and serial number
2) Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
Fig. 46-2 Verifying background of trouble occurred.
additional works.
(3) How to diagnose trouble
1) Verify defective part
2) Make the condition of trouble again
3) Where defective parts can not be verified,
surmise causes systematically.
4) Verify reasons for surmise
5) Report methods, procedure, and period for
repairing to user.
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
Fig. 46-3 Confirm the symptoms of the trouble.
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those Fig. 46-4 Diagnosing fail by means
surfaces. troubleshooting.

46-2
 46. TROUBLE SHOOTING (BY ERROR CODES)

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.

No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster code.
B When no failure is detected currently but error code When it is hard to recreate the failure situation, cancel
after self diagnosis is remained in trouble history the data in the history and reproduce the failed
situation or suppose the cause according to the
troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not • Carry out troubleshooting according to instructions
displayed or is not remained in the history in Chapter 47 "TROUBLESHOOTING BY
TROUBLE".
• Carry out troubleshooting according to instructions
in Chapter 48 "TROUBLE DIAGNOSIS MODE".

46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller :
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller
program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the solenoid, etc.
stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021

46.4 TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the
troubleshooting referring to applicable page in the contents of error codes.

Error Code Trouble Described

page
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed. 46-6
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. 46-6
A215 Written data of ROM adjustment data is incorrect. 46-7
A225 Writing of ROM adjustment data is incorrect. 46-7
A235 Written data of ROM hour meter data is incorrect. 46-8
A245 Writing of ROM hour meter data is incorrect. 46-8
A255 Writing of proportional valve adjustment data is incorrect. 46-9
B012 Incorrect output of boom up pressure sensor 46-9
B013 Disconnection of boom up pressure sensor 46-10
B014 Short-circuit of boom up pressure sensor 46-10
B022 Incorrect output of boom down pressure sensor 46-11
B023 Disconnection of boom down pressure sensor 46-11
B024 Short-circuit of boom down pressure sensor 46-12
B032 Incorrect output of arm out pressure sensor 46-12

46-3
46. TROUBLE SHOOTING (BY ERROR CODES)

Error Code Trouble Described

page
B033 Disconnection of arm out pressure sensor 46-13
B034 Short-circuit of arm out pressure sensor 46-13
B042 Incorrect output of arm in pressure sensor 46-14
B043 Disconnection of arm in pressure sensor 46-14
B044 Short-circuit of arm in pressure sensor 46-15
B052 Incorrect output of bucket digging pressure sensor 46-15
B053 Disconnection of bucket digging pressure sensor 46-16
B054 Short-circuit of bucket digging pressure sensor 46-16
B062 Incorrect output of bucket dump pressure sensor 46-17
B063 Disconnection of bucket dump pressure sensor 46-17
B064 Short-circuit of bucket dump pressure sensor 46-18
B072 Incorrect output of swing pressure sensor 46-18
B073 Disconnection of swing pressure sensor 46-19
B074 Short-circuit of swing pressure sensor 46-19
B092 Incorrect output of travel right pressure sensor 46-20
B093 Disconnection of travel right pressure sensor 46-20
B094 Short-circuit of travel right pressure sensor 46-21
B102 Incorrect output of travel left pressure sensor 46-21
B103 Disconnection of travel left pressure sensor 46-22
B104 Short-circuit of travel left pressure sensor 46-22
B113 Disconnection of pressure sensor of optional selector positioning 46-23
B114 Short-circuit of pressure sensor of optional selector positioning 46-23
B162 Incorrect output of P1 optional side pressure sensor 46-24
B163 Disconnection of P1 side optional pressure sensor 46-24
B164 Short-circuit of P1 side optional pressure sensor 46-25
B172 Incorrect output of P2 optional side pressure sensor 46-25
B173 Disconnection of P2 side optional pressure sensor 46-26
B174 Short-circuit of P2 side optional pressure sensor 46-26
C012 Incorrect output of P1 pump pressure sensor 46-27
C013 Disconnection of P1 pump pressure sensor 46-27
C014 Short-circuit of P1 pump pressure sensor 46-28
C022 Incorrect output of P2 pump pressure sensor 46-28
C023 Disconnection of P2 pump pressure sensor 46-29
C024 Short-circuit of P2 pump pressure sensor 46-29
C033 Disconnection of boom head pressure sensor 46-30
C034 Short-circuit of boom head pressure sensor 46-30
D012 Failure of output transistor ON at P1 unload proportional valve 46-31
D013 Disconnection of P1 unload proportional valve 46-31
D022 Failure of output transistor ON at P2 unload proportional valve 46-32
D023 Disconnection of P2 unload proportional valve 46-32
D032 Failure of output transistor ON at travel straight proportional valve 46-33
D033 Disconnection of travel straight proportional valve 46-33
D062 Failure of output transistor ON at arm in high speed proportional valve 46-34
D063 Disconnection of arm in high speed proportional valve 46-34
E012 Failure of output transistor ON at P1 pump proportional valve 46-35
E013 Disconnection of P1pump proportional valve 46-35
E022 Failure of output transistor ON at P2 pump proportional valve 46-36
E023 Disconnection of P2 pump proportional valve 46-36

46-4
 46. TROUBLE SHOOTING (BY ERROR CODES)

Error Code Trouble Described

page
E032 Failure of output transistor ON at OPT relief 1 proportional valve 46-37
E033 Disconnection of OPT relief 1 proportional valve 46-37
E042 Failure of output transistor ON at OPT relief 2 proportional valve 46-38
E043 Disconnection of OPT relief 2 proportional valve 46-38
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46-39
F023 Failure of output transistor ON and disconnection of swing parking SOL valve 46-39
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve 46-40
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve 46-40
F041 Failure of output transistor OFF and GND short of optional selector SOL valve 46-41
F043 Failure of output transistor ON and disconnection of optional selector SOL valve 46-41
G032 Overrun of speed sensor of direct input Mechatro-controller 46-42
G033 Disconnection of speed sensor of direct input Mechatro-controller 46-42
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-43
G043 Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-44
H013 Disconnection of acceleration potentio 46-45
H014 Power short-circuit of acceleration potentio 46-45
H091 Failure of GND short-circuit of fuel sensor 46-46
H093 Disconnection of fuel sensor 46-46
I111 Received error of CAN1 communication (passive error) 46-47
I113 Received error of CAN1 communication (time-out) 46-47
I313 Received error of cluster communication (time-out error) 46-48
K014 Adhesion of battery relay terminal 46-48
R014 Failure of arc prevention relay of wiper motor 46-49
R024 Failure of normal rotation relay of wiper motor 46-49
R034 Failure of reverse rotation relay of wiper motor 46-50
R044 Failure of washer motor relay 46-50
R134 Failure of swing flasher relay 46-51
R144 Failure of swing flasher relay 46-51
R154 Failure of travel alarm relay 46-52
R164 Failure of auto idling stop relay 2 46-52
R174 Failure of engine forcible stop relay 46-53
R184 Failure of lever lock relay 46-54

46-5
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-1
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3

Table46-2
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3

46-6
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-3
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
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

Table46-4
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
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

46-7
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-5
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
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

Table46-6
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
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

46-8
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-7
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
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

Table46-8
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-9
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-9
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-10
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-10
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-11
Error code B022
Trouble Boom down pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom 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
normal condition again.
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-12
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
SE-4 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-127F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-11
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-13
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-14
Error code B032
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom All operation speed slows down.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-12
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-15
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
SE-8 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-131F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-16
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-13
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-17
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F 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.

Table46-18
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
SE-7 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-130F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-14
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-19
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F 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.

Table46-20
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

46-15
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-21
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

Table46-22
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

46-16
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-23
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
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
normal condition again.
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
CN-125F
CN-101F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-24
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

46-17
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-25
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

Table46-26
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
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
normal condition again.
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-18
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-27
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B073 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-28
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B074 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-19
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-29
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
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
normal condition again.
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-30
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B093 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-20
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-31
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B094 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-32
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
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
normal condition again.
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-21
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-33
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B103 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-34
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B104 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-22
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-35
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and 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.

Table46-36
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and 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.

46-23
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-37
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-38
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work. All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

46-24
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-39
Error code B164
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work. All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

Table46-40
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-25
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-41
Error code B173
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work. All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

Table46-42
Error code B174
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work. All operation speed slows down.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current value in all operation is neutral.)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

46-26
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-43
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
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
normal condition again.
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-44
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the
P1 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C013 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-27
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-45
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the
P1 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-46
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
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
normal condition again.
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-28
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-47
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the
P2 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C023 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-48
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the
P2 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-29
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-49
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Overload alarm is not actuated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

Table46-50
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Overload alarm is not actuated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
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.

46-30
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-51
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
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.

Table46-52
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA 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
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

46-31
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-53
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

Table46-54
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA 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 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • 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.
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.

46-32
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-55
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
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.

Table46-56
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA 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 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
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.

46-33
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-57
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
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.

Table46-58
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA 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 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-6 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
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.

46-34
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-59
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom All operation speed slows down.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-60
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom All operation speed slows down.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-35
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-61
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom All operation speed slows down.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-62
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom All operation speed slows down.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-36
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-63
Error code E032
Trouble OPT relief 1 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Electromagnetic relief valve is disabled.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 E-3 OPT RELIEF 1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • OPT relief 1 proportional valve When E032 is cancelled and other error occurs by turning starter switch on
PSV-E after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between OPT relief 1 When E032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-148F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-64
Error code E033
Trouble OPT relief 1 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom Electromagnetic relief valve is disabled.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 E-3 OPT RELIEF 1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • OPT relief 1 proportional valve When E033 is cancelled and other error occurs by turning starter switch on
PSV-E after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between OPT relief 1 When E033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-148F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-37
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-65
Error code E042
Trouble OPT relief 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Electromagnetic relief valve is disabled.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 E-4 OPT RELIEF 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • OPT relief 2 proportional valve When E042 is cancelled and other error occurs by turning starter switch on
PSV-I after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between OPT relief 2 When E042 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-132F Check wiring for possible failure according to the wiring checking procedure
CN-106F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-66
Error code E043
Trouble OPT relief 2 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom Electromagnetic relief valve is disabled.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 E-4 OPT RELIEF 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • OPT relief 2 proportional valve When E043 is cancelled and other error occurs by turning starter switch on
PSV-I after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between OPT relief 2 When E043 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-132F Check wiring for possible failure according to the wiring checking procedure
CN-106F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-38
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-67
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
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.

Table46-68
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
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.

46-39
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-69
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
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.

Table46-70
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
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.

46-40
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-71
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
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.

Table46-72
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
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.

46-41
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-73
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

Table46-74
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
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
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

46-42
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-75
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.

46-43
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-76
G043
(When cranking is executed for five seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the engine failure diagnosis table of "Section 47.3
ENGINE RELATED TROUBLESHOOTING". Execute the following check when the error code
G043 is displayed after starting the engine.)
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.

46-44
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-77
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-78
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-45
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-79
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-80
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-46
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-81
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-82
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20°C.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-5 WATER TEMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.

46-47
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-83
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-600F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-84
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
4 • Mechatro controller Check that the error is corrected after replacement of controller.

46-48
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-85
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay, check relay
R-31 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor arc
prevention relay and controller
CN-109F, CN2-1
• Fuse & relay box
E-1
3 • Mechatro controller
When R014 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R014 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

Table46-86
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay, check relay
relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor
forward rotation relay and
controller
CN-109F, CN2-1
•Fuse & relay box
E-1
3 • Mechatro controller
When R024 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R024 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-49
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-87
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
condition power 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
Service Screen No. 25 CCW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor
forward rotation relay and
controller
CN-109F, CN2-1
•Fuse & relay box
E-1
3 • Mechatro controller
When R034 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R034 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

Table46-88
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 MOTOR RELAY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit for failure,
R-32 replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between washer motor
relay and controller
CN-112F, CN2-1
•Fuse & relay box
E-1
3 • Mechatro controller
When R044 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring checking
procedure and replace it if necessary.
When no failure found after checking on wiring and R044 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-50
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-89
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D13
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.

2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-90
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D14
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.

2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-51
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-91
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 23 D15
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit for failure,
R-8 replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between travel alarm
relay and controller
CN-109F, CN2-2
•Fuse & relay box
E-1
3 • Mechatro controller
When R154 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R154 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

Table46-92
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay unit for
R-24 failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between auto idle
stop relay 2 and controller
CN-109F, CN2-2
•Fuse & relay box
E-1
3 • Mechatro controller
When R164 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring checking
procedure and replace it if necessary.
When no failure found after checking on wiring and R164 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-52
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-93
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-3 ENG STOP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between engine
forcibly
stop relay and controller
CN-109F, CN2-2
• Fuse & relay box
E-1
3 • Mechatro controller
When R174 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R174 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-53
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-94
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-4 LOCK LEVER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between safety lock
lever relay and controller
CN-109F, CN2-2
• Fuse & relay box
E-1
3 • Mechatro controller
When R184 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R184 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-54
 47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS

47.1 HYDRAULIC SYSTEM ....................................................................................................47-2

47.2 ELECTRIC SYSTEMS .....................................................................................................47-26
47.2.1 WIRING CHECKING PROCEDURE ......................................................................47-26
47.2.2 TROUBLE...............................................................................................................47-29
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-32

47

47-1
47. TROUBLESHOOTING (BY TROUBLE)

47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.

(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(10)Slow bucket dumping
(11)Swing operation not functioned/slow
(12)Noise during swing operation
(13)Swing on a slope drifts when control lever is in neutral position
(14)Swing drifts when swing operation is stopped
(15)Slow travel speed/weak
(16)Travel deviation
(17)Travel 1st/2nd speed not changed
(18)Travel parking on a slope is not held
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20)Slow breaker (crusher) operation, weak power
(21)Option selector valve malfunction: not switched to breaker circuit
(22)Option selector valve malfunction: not switched to nibbler (crusher) circuit

47-2
 47. TROUBLESHOOTING (BY TROUBLE)

(1) All controls do not function/slow

No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.4 If the fuse is blown out, check on
(10A) the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by tester,
switch diagnosis Push down the lever and it turns on, push or check that the power voltage
up and it turns off. is lowered by pushing the lever
down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for possible
switching solenoid is switched connector. 24V by pushing the lever down, failure.
correctly 0V by pushing it up Check harness for possible
failure.
4 Safety lever lock relay Carry out service No.4 K-4 lock lever: Check action of relay by tester
diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor •Stop engine stop and key is on position. Check 5V power for controller
All pilot low pressure sensors are 0MPa to
0.1MPa.
6 Solenoid valve for Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve
safety lock lever solenoid A1 port 4MPa or more by push it down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot primary Check that it is 4MPa or more in high idling Check gear pump and the relief
pressure at gear valve for possible failure
pump
9 Multi control valve (in Change position Since all are blocked due to poor switching
case that travel is performance, check that the lever select
operable) pattern is set to the proper position.
10 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & relief proportional valve and controller
for possible failure.
11 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa in boom up full lever and high
directly at the ports A7 idling operation
and A5 of 7 sections
solenoid block
12 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis. E-2 P2 pump largely differed from the actually
pump proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever & proportional valve and controller
idling for possible failure.
Operation No.19 Travel left full lever &
idling
13 Secondary pressure of Measure the pump Check that pump proportional valve Replace proportional valve
pump proportional proportional valve secondary pressure is 2.7MPa or more in
valve secondary pressure right (left) travel full lever and high idling
directly in idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve

47-3
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

14 Main relief pressure Carry out service •See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures are Reset or replace
32MPa in boom up full lever, high idling
and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
17 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.

(2) Engine down/stalled

No. Sections Contents/normal value Corrective action, others

1 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
2 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly (Ports a3, a4) and high idling operation.
3 Pressure sensor of P1, Check pressure •See Service Diagnosis Data List Check pressure sensor and
P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
4 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage,
etc.
5 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.

(3) Move at lever neutral position

No. Sections Contents/normal value Corrective action, others

1 Pilot pressure sensor Carry out service Check that targeted pilot pressure of Check remote control valve
diagnosis sensor is 0MPa in high idling
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Main spool Check targeted spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage
4 Over load relief valve Check targeted spool Free from dust entered in port relief Replace
visually valve. Seat is free from abnormality

47-4
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Lock valve poppet Check targeted poppet Seat is free from abnormality Replace
(in case of boom and visually
arm)
6 Lock valve selector Exchange lock valve Check that the trouble is reversed Replace
(in case of boom and selector of boom/arm
arm) and boom/arm
7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace
boom sliding of spool in sleeve sliding Do not pull spool out of sleeve
(in case of boom) forcibly.
8 Holding valve relief Check targeted spool Filter free from abnormal Replace
valve for boom visually contamination
(in case of boom)
9 Cylinder Check targeted cylinder Make sure of no problem of seals by Replace cylinder or seals
visually disassembling and investigation

(4) Poor fine operability

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor Carry out service •See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
•All low pressure sensors are 0MPa to
0.1MPa
2 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
3 Secondary pressure of Measure the Check that P1/P2 unloads secondary Replace proportional valve
unload proportional proportional valve pressures is within the range of
valve secondary pressure 2.7MPa or more in control lever neutral
directly at the ports A7 and high idling operation
and A8 of 7 sections
solenoid block
4 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
5 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly. (Ports a3, a4) and high idling operation
6 Slow return check valve Visual check Check that slow return check valve Clean and replace
of pilot line installed on pilot line is free from dust
(in case of boom up or entered
arm out)

47-5
47. TROUBLESHOOTING (BY TROUBLE)

(5) Slow boom up, insufficient power

No. Sections Contents/normal value Corrective action, others

1 Boom up pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
boom up operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor.
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & proportional valve and controller
relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in boom up full lever and
directly at the ports A7 high idling operation
and A5 of 7 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.4 boom up full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 1.8 to 3.0MPa in boom up full lever and
directly (Ports a3, a4) high idling operation
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for boom Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.

47-6
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

13 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is low.
15 Conflux spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
16 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
17 Over load relief valve Visual check (Head Pressure is 32MPa or more in boom up When only relief pressure of
<Trouble> side) full lever and high idling. Free from boom up is low, replace valve
Relief pressure is low. dust entered in over load relief valve.
Seat is free from abnormality

(6) Slow boom down/insufficient power for lifting up body

No. Sections Contents/normal value Corrective action, others

1 Boom down pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control valve Measure remote control Check that pressure is 3.0MPa or more Check remote control valve
pressure of boom down in boom down full lever and high idling When equipped with multi
directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.5 boom down full lever & measured value, check
valve in operation proportional valve and controller
for possible failure.
4 Secondary pressure of Measure the Check that P1 unload secondary Replace proportional valve
P1 unload proportional proportional valve pressures are within the range of 0.8 to
valve secondary pressure 1.2MPa in boom down full lever and
directly at the ports A7 of high idling operation
7 sections solenoid
block.
5 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
pump proportional valve Operation No.5 boom down full lever measured value, check
& in operation proportional valve and controller
for possible failure.
6 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures are within the range of 2.0 to
valve secondary pressure 2.5MPa in boom down full lever and
directly (Ports a3, a4) high idling operation

47-7
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

7 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
8 Travel straight Measure directly the High idling pressure is 0.8MPa or less Replace proportional valve
proportional valve travel straight regardless neutral/operation
secondary pressure proportional valve
secondary pressure.
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
11 Holding valve (poppet) Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding Free from (Check on the casing side for
Boom down is slow. abnormal damage, etc on outside damage)
surface
12 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Machine can not be
lifted by supporting with
boom.
14 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
15 Over load relief valve Visual check Free from dust entered in port relief Replace
<Trouble> valve.
Machine can not be Seat is free from abnormality
lifted by supporting with
boom.

(7) Slow arm in, insufficient power

No. Sections Contents/normal value Corrective action, others

1 Arm in pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.6 arm in full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
pressure control pressure of arm in arm in full lever and high idling When equipped with multi
in operation control valve, check it while
changing lever pattern

47-8
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.6 Arm in full lever & proportional valve and controller
relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa in arm in full lever and high
directly at the ports A7 idling operation.
and A5 of 7 sections
solenoid block.
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.7 Arm in full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are 2.0MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, a4) operation. (Secondary pressure is
affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of arm in diagnosis Operation No. 1 Operation is nil largely differed from the actually
spool 2 proportional Operation No.6 Arm in full lever & measured value, check
valve relief proportional valve and controller
Operation No.7 Arm in full lever & in for possible failure.
operation
9 Secondary pressure of Measure directly the Check that secondary pressure of Replace proportional valve
arm in spool 2 proportional valve proportional valve secondary
proportional valve secondary pressure at pressures are within the range of
the ports A8 (arm 2 following
spool) of 7 sections Lever neutral: 0MPa
solenoid block. Motion in the air: 1.7 to 2.2MPa
Arm in relief: 2.5MPa or more
10 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
11 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 7 sections
solenoid block

47-9
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

12 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
13 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
14 Over load relief valve Visual check (Head Pressure is 32MPa or more in arm in When only relief pressure of arm
<Trouble> side) and relief. in is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality
15 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
17 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is high Free from abnormal damage, etc on damage)
or low. outside surface
Spring is free from breakage.
18 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Arm in power is poor.
19 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface

(8) Slow independent arm out (in the air)

No. Sections Contents/normal value Corrective action, others

1 Arm out pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of arm in arm out full lever and high idling When equipped with multi
out operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.8 Arm out full lever & proportional valve and controller
relief for possible failure.

47-10
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa in arm out full lever and high
directly at the ports A7 idling operation
and A5 of 7 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.9 Arm out full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 1.5 to 2.7MPa in arm out full lever and
directly (Ports a3, a4) high idling operation
(Secondary pressure is affected by oil
temperature and attachment weight)
8 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
9 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 7 sections
solenoid block
10 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
11 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
12 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve. Seat is free from
abnormality
13 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
14 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.

47-11
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

15 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation (spring sliding
<Trouble> side) Spring is free from breakage.
Both P1, P2 pressures
are low.
16 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface

(9) Bucket digging is slow

No. Sections Contents/normal value Corrective action, others

1 Bucket digging pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in bucket digging full lever and high When equipped with multi
bucket digging idling operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.12 Bucket digging full measured value, check
valve lever & relief proportional valve and controller
for possible failure.
5 Secondary pressure of Measure the Check that P1 unload secondary Replace proportional valve
P1 unload proportional proportional valve pressures are within the range of 0.5 to
valve secondary pressure 1.2MPa in bucket digging full lever and
directly at the ports A7 high idling operation
and A5 of 7 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
pump proportional valve Operation No.13 Bucket digging full measured value, check
lever & in operation proportional valve and controller
for possible failure.
7 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures is 2.7MPa or more in bucket
valve secondary pressure digging full lever and high idling
directly (Ports a3) operation.
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of travel diagnosis Operation No.12 Bucket digging full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
for possible failure.
9 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)

47-12
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

10 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
11 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.3 Boom up full lever and
relief
12 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
Spring is free from breakage.
14 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
Seat is free from abnormality.

(10)Bucket dump is slow

No. Sections Contents/normal value Corrective action, others

1 Bucket dump pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.14 Bucket dump full sensor
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in bucket dump full lever and high When equipped with multi
bucket dump idling operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.14 Bucket dump full measured value, check
valve lever & relief proportional valve and controller
for possible failure.
5 Secondary pressure of Measure the Check that P1 unload secondary Replace proportional valve
P1 unload proportional proportional valve pressures are within the range of
valve secondary pressure 0.5~1.2MPa in bucket dump full lever
directly at the ports A7 and high idling operation. Replace
and A5 of 7 sections proportional valve
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
pump proportional valve Operation No.15 Bucket dump full measured value, check
Carry out service lever & in operation proportional valve and controller
diagnosis. for possible failure.
7 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures is 2.7MPa or more in bucket
valve secondary pressure dump full lever and high idling
directly (Ports a3) operation.

47-13
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of travel diagnosis Operation No.14 Bucket dump full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
for possible failure.
9 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at dump full lever and high idling
the ports A6 (travel operation
straight) of 7 sections
solenoid block
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBP2 port.)
11 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
12 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 Boom up full lever and
Relief pressure is low. relief
13 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
14 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
Spring is free from breakage.
15 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
Seat is free from abnormality.

(11)Swing does not move/slow

No. Sections Contents/normal value Corrective action, others

1 Swing pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
swing operation control valve, check it while
changing lever pattern
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF
Swing parking brake Measurement of Lever neutral: 0MPa Replace solenoid valve
4
solenoid solenoid valve A2 port In operation: 4MPa or more
5 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle

47-14
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

6 Pump pressure sensor Carry out service •See Service Diagnosis Data List Check high pressure sensor
diagnosis for P2 pump Operation No.11 Swing full lever and
pressures in operation in operation
7 Actual measuring Carry out service •No.8 D-2 P2 unload valve (cut valve) In case where the reading is
current value of P2 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.11 Swing full lever & in measured value, check
valve operation proportional valve and controller
for possible failure.
8 Secondary pressure of Measure the Check that P2 unload secondary Replace proportional valve
P2 unload proportional proportional valve pressures are within the range of 0.5 to
valve secondary pressure 1.2MPa in swing full lever and high
directly at the ports A5 of idling operation
7 sections solenoid
block
9 Actual measuring Carry out service •No.9 E-2 P2 pump In case where the reading is
current value of P2 diagnosis largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.11 Swing full lever & in proportional valve and controller
operation for possible failure.
10 Secondary pressure of Measure the pump Check that P2 pump proportional valve Replace proportional valve
P2 pump proportional proportional valve pressure is 2.7MPa or more in swing
valve secondary pressure full lever and high idling operation
directly (Ports a3, a4)
11 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
(Check this trouble by Operation No.18 Travel right full lever actually measured value, check
only swing operation) & idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
12 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
(Check this trouble by the ports A6 (travel
only swing operation) straight) of 7 sections
solenoid block
13 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
14 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
15 Swing spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
16 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
Relief pressure is low. relief

47-15
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

17 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
18 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.

(12)Noise occurred at swing operation

No. Sections Contents/normal value Corrective action, others

1 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
4 By-pass check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from abnormal Replace
resistance against sliding
Spring is free from breakage.
7 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally worn Replace
and chipped.

(13)Swing drifts on a slope while swing control lever is in neutral position

No. Sections Contents/normal value Corrective action, others

1 Swing pressure sensor Carry out service •Engine stop & starter key ON Check and replace pressure
diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1MPa.
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake release
switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)

47-16

No. Sections
6 Parking brake
(14)Swing drifts at stopping
No. Sections
1 Shuttle valve
<Trouble>
Pilot pressure is low
2 Swing pressure sensor Carry out service
diagnosis
3 Swing relief valve
<Trouble>
Relief pressure is low.
4 Anti-reaction valve
5 Remote control valve
6 Swing motor
47. TROUBLESHOOTING (BY TROUBLE)
Contents/normal value Corrective action, others
Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage
Contents/normal value Corrective action, others
Visual check No contamination on spool cover Clean or replace
(short side) and orifice. No damage on
spool cover (long side) and shuttle.
•Engine stop & starter key ON Replace pressure sensor
All pilot low pressure sensors are
within range of 0 to 0.1MPa.
Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.10 Swing full lever and
relief
Visual check Free from dirt entering Clean or replace
Sliding part should be free from foreign
matter entering, abnormal damage and
wear.
Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
47-17
47. TROUBLESHOOTING (BY TROUBLE)

(15)Travel speed is slow/poor

No. Sections Contents/normal value Corrective action, others

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service •No.9 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
4 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 7 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
5 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
7 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure
8 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice

47-18
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

10 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
11 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
12 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
14 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.

(16)Travel deviation

No. Sections Contents/normal value Corrective action, others

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure.
4 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure

47-19
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 7 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
7 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
8 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2 Exchange delivery pipe Check the direction of deviation If the direction is changed,
of P1 for P2 inspect a pump. If the direction
is not changed, inspect a valve
and travel unit.
10 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
11 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
12 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
13 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
Replace as necessary

47-20
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
17 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage,
etc.
18 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.

(17)Travel 1/2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the
speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic
speed change.)

No. Sections Contents/normal value Corrective action, others

1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed Check pressure sensor
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON, MEAS on gauge cluster
ON
2 Travel 1/2 speed Measure A3 port Lever neutral: 0MPa Replace solenoid valve
switching solenoid pressure on solenoid In operation: 4MPa or more
valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in travel Visual check Free from abnormal wear on piston Replace
motor and seal (Check on the casing side for
damage)

(18)Machine does not stay on a slope in traveling

No. Sections Contents/normal value Corrective action, others

1 Pilot pressure sensor Carry out service •Engine stop & starter key switch is ON Check pressure sensor and
diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1MPa Check remote control valve
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage

47-21
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

3 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
Spring free from breakage, damage,
etc.
4 Orifice of passage for Visual check Free from entry of dust Remove dust or replace
parking brake in travel
motor

(19)Machine does not travel straight in simultaneous operation of traveling and attachment

No. Sections Contents/normal value Corrective action, others

1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be •Check voltage of low pressure
current value of travel diagnosis COMP 590mA and MEAS 560 to sensor other than travel sensor
straight proportional 620mA in both travel full lever and in •In case where the reading is
valve boom up full lever at high idling largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.
2 Secondary pressure of Measure directly the Check secondary pressure is within Replace proportional valve
travel straight proportional valve range of 1.8 to 2.2MPa in both travel
proportional valve secondary pressure full lever and in boom up full lever at
high idling
3 Travel straight spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.

(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor for Carry out service •See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full senso
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve0
control pressure of in optional attachment full lever and
travel right and left high idling operation
3 Actual measuring Carry out service •See Service Diagnosis Data List •In case where the reading is
current value of P1/P2 diagnosis Operation No.16 P2 side OPT full largely differed from the
unload proportional lever and relief actually measured value, check
valve proportional valve and
controller for possible failure.
4 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa
directly at the ports A7
and A5 of 7 sections
solenoid block
5 Actual measuring Carry out service •See Service Diagnosis Data List •Check voltage of low pressure
current value of travel diagnosis Operation No.16 P2 side OPT full sensor other than sensor for
straight proportional lever & relief optional attachment
valve •In case where the reading is
largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.

47-22
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

6 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in optional
proportional valve secondary pressure at attachment full lever and high idling
the ports A6 (travel operation
straight) of 7 sections
solenoid block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P1 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
8 Relief pressure Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is
24.5MPa.)
9 Remote control valve Check targeted remote Check sealing ability of shuttle valve Replace
control valve and entry of dust in orifice.
10 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
P1, P2 pressures are outside surface
high. Spring is free from breakage.
12 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve
Seat is free from abnormality.

(21)Selector valve for option malfunctions: Breaker circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
2 N&B selector solenoid Screw for emergency Check that the error indication is Replace solenoid valve
disappeared by turning emergency
screw
3 N&B selector solenoid Carry out service •No.11 F-4 Option selector is B mode Check solenoid valve
diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector pressure Carry out service •No.16 B-11 Check pressure sensor
sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa at A
mode

47-23
47. TROUBLESHOOTING (BY TROUBLE)

(22)Selector valve for option malfunctions: Nibbler circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
2 N&B selector solenoid Carry out service •No.11 F-4 Option selector is A mode Check solenoid valve
diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB

47-24
 47. TROUBLESHOOTING (BY TROUBLE)

Table47-1 Action of optional selector solenoid valve

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

47-25
47. TROUBLESHOOTING (BY TROUBLE)

47.2 ELECTRIC SYSTEMS

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

(When both ends measurement is difficult because

of long distance between connectors,)
Measure the resistance using tester. JUMPER
Pull out opposite connector first. WIRE

Where the resistance is zero (0), if the terminal on

one side is connected to frame body grounding with TESTER
jumper wire, it is in normal condition. FRAME BODY GROUNDING
The resistance is 1M or more when the terminal
on one side is not connected to frame body
grounding with jumper wire, it is in normal condition.

(2) Checking for presence or absence of short-circuit

with machine body
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M or more, it is in normal
condition. TESTER
FRAME BODY GROUNDING

(3) Checking for presence or absence of short-circuit

between wirings.
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M or more, it is in normal
condition. TESTER

47-26
 47. TROUBLESHOOTING (BY TROUBLE)

(4) Checking connector terminal for contact

Insert male terminal into female terminal unit, and INSERT
then check that the inserting force is equivalent to
other female terminals. MALE TERMINAL FEMALE TERMINAL
If looseness is there, replace the female terminal
with new one.
Clean the dirt terminal.

Do not insert the male terminal the thickness differs. It

may cause loose connection.

(5) Caution which should be paid in measuring voltage

When measuring the power supply to electric
equipment at connector position with the grounding
terminal contained inside of connector, measure
the voltage between grounding inside of connector
and power terminal.
When measuring the voltage between frame body
grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be
identified.
Since the voltage may vary between with connector
connected and with connector not connected.
Measure the voltage with each connector
connected whenever possible.
(6) Checking the general view of connector CRIMPED
PART
a. Check the terminal crimped condition.
Pull one electric cable with the about 3kg force,
RUBBER
and make sure that the cable does not come out PLUG
RECEPTACLE.
of the terminal. CONTACT

When came out, replace the terminal and crimp PLUG

SEALING
it again. (is housed in plug)

b. Check connector for imperfect insertion DOUBLE LOCK

PLATE FOR PLUG
Check that all top ends form a line on the same DOUBLE LOCK
PLATE FOR CAP
position as seen from the connector engaged
side. CAP

When moved along, push it in further through TAB.CONTACT

wire inserting hole. RUBBER PLUG

c. Check connector for intruding of water.

Pull out the connector and check that the inside
is free from intruding of water.
When water intruding is found, check rubber plug
for damage and also that the sealing is fitted
properly.

47-27
47. TROUBLESHOOTING (BY TROUBLE)

(7) When abnormality occurs at intervals

When the abnormality situation can not be
reoccurred during checking operation, try the
following operations.
a. Check that variable of display exists or not on the
service diagnosis screen while shaking the
harness or giving shock by operating the
machine.
b. Check that variables of resistance and voltage
exist or not using tester while shaking the
harness.
c. Turn starter switch on and apply electricity
continuously, and check it again after the
temperature of wiring and equipment was raised.
(8) Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose connection
due to corrosion.

There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding fixed
together with horn, body grounding placed on
attaching section of boom working light.
Block of grounding is located
under floor plate of cab.

47-28
 47. TROUBLESHOOTING (BY TROUBLE)

47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.

47-29
47. TROUBLESHOOTING (BY TROUBLE)

(1) Engine does not stop.

No. Sections Contents/normal value Corrective action, others

1 Starter key switch Check signal of starter No.4 K-3 Key switch Check continuity between
key switch ON by OFF at starter key switch OFF position terminals of starter switch using
carrying out service ON at starter key switch ON position tester
diagnosis.
2 Engine forcible stop When ON is displayed No.4 K-3 Key switch Check on engine forcible stop
relay with the starter switch OFF at starter key switch OFF position relay
OFF, then pull out R-25 ON at starter key switch ON position
engine forcible stop
relay and carry out the
service diagnosis.
3 Wiring Voltage between line 0V when starter switch is OFF Check harness
No.62 among starter Check diode D-9 between
switch, engine forcible starter switch and auto idling
stop relay, mechatro stop relay 1
controller and the body
grounding

(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No. Sections Contents/normal value Corrective action, others

1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro controller and
accel potentiometer operation. replace as necessary
(Use remote control because the auto
accel function is working.)
3 Wiring Transmission circuit line See "WIRING CHECKING Repair wiring
No.770 from mechatro PROCEDURE"
controller to gauge
cluster
4 Gauge cluster Gauge cluster Replace gauge cluster

(3) Auto accel does not actuate. (The engine speed does not automatically slow down).

No. Sections Contents/normal value Corrective action, others

1 Engine coolant Check engine coolant No.2 G-5 WATER TEMP Replace engine coolant sensor
temperature temperature by carrying Auto accel does not work in the
out service diagnosis. temperature -15°C or less.
Warm up and raise the coolant
temperature to – 15°C or more
2 Gauge cluster Indication of auto accel Mark "Display/not display" for auto Replace gauge cluster
accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is in the range of 0~0.1MPa at
control lever neutral position.

(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)

No. Sections Contents/normal value Corrective action, others

1 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.

47-30
 47. TROUBLESHOOTING (BY TROUBLE)

(5) Wiper does not function

Wiping range of
forward and
reverse movements

Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position

No. Sections Contents/normal value Corrective action, others

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

Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF

4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation relay Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON

R-30: Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.

47-31
47. TROUBLESHOOTING (BY TROUBLE)

47.3 ENGINE RELATED TROUBLESHOOTING

Checking
Filters Liquid Leak, clogging

Air leak between turbocharger and intake manifold

Factors

Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn

Poor or deteriorated battery

Shortage of fuel level

Improper fuel in use

Air cleaner clogged
Fuel filter clogged

Oil level of oil pan

Oil filter clogged

Muffler clogged
Engine oil leak
Coolant level
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-32
 47. TROUBLESHOOTING (BY TROUBLE)

Checking Electric equipment

Shovel side Shovel side Engine side

Loose mounting bolts, damage of mounting rubber

Factors

Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator

Loose connection of battery cable terminal

Failure of radiator pressure cap

Failure of hydraulic system

Startup circuit wiring
Starter switch key

Hydraulic switch
Starter motor
Battery relay

Safety relay
Glow relay
Glow plug
Alternator
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-33
47. TROUBLESHOOTING (BY TROUBLE)

Intake and Cooling

Fuel system exhaust system Lubrication system
system

Factors

Seizing and interference of turbocharger

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged

Leak and crush of hydraulic piping

Failure of thermostat (Not open)

Fuel leak into the head cover
Improper fuel injection time

Failure of regulator valve

Damage of water pump

Failure of supply pump

Failure of relief valve

Failure of oil pump
Failure of injector

Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-34
 47. TROUBLESHOOTING (BY TROUBLE)

Engine body
Factors

Wear and damage of rear oil seal and seal surface

Damage and seizing of piston and connecting rod
Damage of engine oil cooler core and O-ring

Damage of cylinder head and head gasket

Wear and failure of valve and valve guide

Wear of piston ring and liner, ring stick

Strainer clogged, damage of oil pipe

Failure of injection holder sleeve

Damage of flywheel gear

Hole due to cavitation

Damage of dumper
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-35
47. TROUBLESHOOTING (BY TROUBLE)

47-36
 48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS

48.1 TROUBLE DIAGNOSIS MODE .......................................................................................48-2

48

48-1
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

48.1 TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be
detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are automatically
actuated, the sensor detects the machine condition and the mechatro controller identifies the normal
condition or failed condition of the system.
(2) How to use and flow chart
The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing
buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.

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 the diagnosing items, see Table 48-1.

When required to stop in diagnosis
Turn engine on operation, press the buzzer stop switch
manually. BACK TO No.3 and the operation is forcedly 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 48-2.

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

48-2
 48. TROUBLESHOOTING (TROUBLE 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
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option

Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.

Table48-1 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
1 1 P1 UNLOAD
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1
2 2 P1 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P1
3 3 P1 UNLOAD
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
4 1 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2
5 2 P2 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P2
6 3 P2 UNLOAD
side flow rate is minimum?
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and
7 1 P1 PUMP
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and P1
8 2 P1 PUMP
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
9 3 P1 PUMP
and P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and
10 1 P2 PUMP
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and P2
11 2 P2 PUMP
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
12 3 P2 PUMP
and P2 side flow rate is maximum?

48-3
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Table48-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload
13 1 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload
14 2 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little
15 1 P1 ENGINE
when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little
16 2 P2 ENGINE
when P2 side flow rate is relieved?

When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2
PUMP" of No.10 are not given a diagnosis.

Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
SENSOR CHECK Disconnection of pressure sensor, Short
service diagnosis and replace it if
NG circuit, Abnormal output
necessary
Secondary pressure is excessive high against
the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command
Stuck at full-stroke side Check P1 unload spool and replace it
P1 UN-LOAD SPOOL NG
Stuck at neutral side if 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 and replace it if necessary
the command
Stuck at full-stroke side Check P2 unload spool and replace it
P2 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
Stuck at neutral side replace it if necessary
Secondary pressure is excessive high against
the command Check P1 pump proportional valve
P1 PUMP PSV NG
Secondary pressure is excessive low against and replace it if necessary
the 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
P2 PUMP PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command

48-4
 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
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
S-TRAVEL PSV NG
Secondary pressure is excessive low against valve and replace it if necessary
the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
Stuck at neutral side replace it if necessary
PUMP 1 PRESS. SENSOR Check P1 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
PUMP 2 PRESS. SENSOR Check P2 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary

48-5
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

48-6
 51. ENGINE
PREFACE

This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of MITSUBISHI HEAVY INDUSTRIES, Ltd.

51

51-1
51. ENGINE

51-2
 September 2007
SERVICE MANUAL

SERVICE MANUAL
for KOBELCO CONSTRUCTION MACHINERY CO., LTD.
for KOBELCO CONSTRUCTION MACHINERY CO.,LTD.

Pub. No.

September 2007
99616-21100

Printed in Japan Pub. No. 99616-21100 Pub. No. 99616-21100

 INTRODUCTION

This service manual describes the specifications, maintenance and service procedures
for Mitsubishi diesel engines.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct regular inspection and maintenance,
and also to take necessary measures which involves the disassembly, inspection, repair and
reassembly of the engine and engine parts.
Read this manual carefully and understand the work procedures fully before
disassembling, inspecting, repairing or reassembling the engine.
The contents of the manual are based on the engine models that are being produced at
the time of publication. Due to improvements made thereafter, the actual engine that you
work on may differ partially from the one described in this manual.

Pub.No.99616-21100
 INTRODUCTION

How to use this manual

This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to
specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly,
inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use).
A short summary describing the content of each Group is given in the General Contents page, and there is also a detailed table
of contents at the beginning of each Group.
Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance
Manual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and
function of the engine are described in the relevant training manuals.

Methods of presentation
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indi-
cation of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text.
They are also collectively indicated in Group 2, the General Contents group.
(4) Fasteners to be tightened in “wet” condition, or with engine oil applied, are identified by [Wet] placed after tightening
torque values. If no such indication is suffixed, the fastener should be tightened in “dry” condition, or without lubricating
with engine oil.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following marks headed.

'$1*(5

Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.

:$51,1*

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

&$87,21

Indicates an immediately hazardous situation which, if not avoided, may result in minor or moderate injury.

&$87,21

Indicates a potentially hazardous situation which, if not avoided, can result in property damage.



Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.

I
INTRODUCTION

Terms used in this manual

Nominal
means the rated (design) size or magnitude of a part to be measured.
Standard
means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of
tolerance. Therefore, the values shown are not in agreement with the design values.
Limit
means that, if this value is reached, the part must be repaired or replaced with a new part.

Abbreviations
• BTDC: Before Top Dead Center
• ATDC: After Top Dead Center
• BBDC: Before Bottom Dead Center
• ABDC: After Bottom Dead Center
• TIR: Total Indicated Runout
• API: American Petroleum Institute
• ASTM: American Society for Testing and Materials
• JIS: Japanese Industrial Standards
• LLC: Long Life Coolant
• MIL: Military Specifications and Standards (U.S.A)
• MSDS: Material Safety Data Sheet
• SAE: Society of Automotive Engineers (U.S.A)

Units of measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in
parentheses {}. For metric conversion, the following rates are used.
• Pressure: 1 MPa ＝ 10.197 kgf/cm²
• Torque: 1 N·m ＝ 0.10197 kgf·m
• Force: 1 N = 0.10197 kgf
• Horsepower: 1 kW = 1.341 HP = 1.3596 PS
• Meter of mercury: 1 kPa = 0.7 cmHg
• Meter of water: 1 kPa ＝ 10.197 cmH2O (cmAq)
• Rotational speed: 1min-1 ＝ 1 rpm

II

Safety Cautions
:$51,1*
Fire and explosion
Keep flames away
Store fuel and engine oil in a well
ventilated designated area.
Make sure that the caps of fuel and
engine oil containers are tightly
closed.
Do not use flames, do not smoke,
and do not work near a heater or other fire hazard
where fuel or oil is handled or when cleaning solvent is
being used for washing parts.
Wipe off spilled fuel, oil and LLC immediately and thor-
oughly. Spilled fuel, oil and LLC may ignite and cause
a fire.
Keep surrounding area tidy and clean
Do not leave combustible or explosive materials, such
as fuel, engine oil and LLC, near the engine. Such sub-
stances can cause fire or explosion.
Remove dust, dirt and other foreign materials accumu-
lated on the engine and surrounding parts thoroughly.
Such materials can cause fire or the engine to over-
heat. In particular, clean the top surface of the battery
thoroughly. Dust can cause a short-circuit.
Always operate the engine at a position at least 1 m
[3.28 ft.] away from buildings and other equipment to
prevent possible fire caused by engine heat.
INTRODUCTION
Care about fuel, oil and exhaust gas leakage
If any fuel, oil or exhaust gas leakage is found, immedi-
ately take corrective measures to stop it.
Such leakages, if left uncorrected, can cause fuel or
engine oil to reach hot engine surfaces or hot exhaust
gas to contact flammable materials, possibly leading to
personal injury and/or damage to equipment.
Use explosion-proof lighting apparatus
When inspecting fuel, engine oil, coolant, battery elec-
trolyte, etc., use a flameproof light. An ordinary light, if
accidentally broken, may ignite and cause an explo-
sion.
Prevent electrical wires from short-circuit-
ing
Avoid inspecting or servicing the electrical system with
the ground cable connected to the battery. Otherwise,
a fire could result from short-circuiting. Be sure to dis-
connect the battery cable from the negative (-) terminal
before beginning with the work procedure.
Short-circuits, possibly resulting in fire, may be caused
by a loose terminal or damaged cable/wire. Inspect the
terminals, cables and wires, and repair or replace the
faulty parts before beginning with the service proce-
dure.
Keep fire extinguishers and first-aid kit
handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the designated
place where it is easily accessible
by anyone at any time.
Establish response procedures to
follow in the event of fire or accident. Provide an emer-
gency evacuation route, contact points, and means of
communication in case of emergency.
III
INTRODUCTION
:$51,1*
Stay clear of all rotating and moving parts
Install protective covers on rotating parts
Make sure the protective covers for
engine rotating parts are properly
installed as intended. Repair loose
or damaged protective covers as
necessary.
Never remove the covers guarding
personnel from rotating parts, when the engine is oper-
ating.
When combining the engine with the engine-driven ma-
chine or radiator, always provide a cover on every ex-
posed moving part such as driving belt and coupling.
Never remove protective covers.
Ensure safety of neighboring people before
starting engine
Before starting the engine, ensure that there is nobody
in the neighborhood and that no tools are left on or near
the engine. Verbally notify people around the engine or
in the work area when starting the engine.
When the starter device is posted with a sign that pro-
hibits startup operation, do not operate the engine.
Stay clear of moving parts during engine
running
Do not approach rotating or sliding
parts of the engine when the engine
is in operation.
Keep objects likely to be caught by
rotating parts away from such parts.
If any part of the clothing or outfit-
ting is caught by a rotating part, se-
rious bodily injuries could result.
IV
Lockout and Tagout
Be sure to lockout and tagout before starting inspection
and maintenance.
Lockout and tagout are effective methods of cutting off
machines and equipment from energy sources.
To accomplish the lockout/tagout, remove the starter
switch key, set the battery switch to OFF and attach a
"Do Not Run" or similar caution tag to the starter switch.
The starter switch key must be kept by the person who
performs inspection and maintenance during the work.
In the case of pneumatic starting type, close the main
valve of the air tank and post a tag saying "Do Not
Open the Valve" or the like.
Keep engine stopped during servicing
Be sure to stop the engine before proceeding to inspec-
tion and service procedure. Never attempt to make ad-
justments on the engine parts while the engine is
running. Rotating parts such as belt can entangle your
body and cause serious injuries.
Always restore engine turning tools after
use
Do not forget to remove the tools which have been
used for turning the engine during inspection or servic-
ing, after the procedure is finished. Remember also
that the turning gear must be returned to the operating
condition before starting the engine.
Starting the engine with the turning tools inserted or
with the turning gear in engagement can lead to not
only engine damage but also personal injuries.
 INTRODUCTION

:$51,1* :$51,1*

Be careful of burns Protect ears from noises

Do not touch the engine during or immedi- Wear ear plugs
ately after operation Always wear ear plugs when enter-
Do not touch the engine during or ing the machine room (engine
immediately after operation to room). Combustion sound and me-
avoid risk of burns. chanical noise generated by the en-
To conduct maintenance and in- gine can cause hearing problems.
spection work, wait until the engine
has cooled sufficiently, checking
the temperature gauge.

Slowly and carefully open radiator cap

Never attempt to open the radiator cap while the engine
is running or immediately after the engine stops. Give a
sufficient cooling time to the engine coolant before
opening the cap.
When opening the radiator cap, slowly turn the cap to
release internal pressure. To prevent scalds with steam
gushing out, wear thick rubber gloves or cover the cap
with a cloth.
Close the radiator cap tightly without fail.
The coolant is very hot and under pressure during en-
gine running or just after the engine stops. If the radia-
tor cap is not closed tightly, steam and hot coolant may
gush out and can cause scalds.

Add coolant only after the coolant tempera-

ture dropped
Do not add coolant immediately after the engine stops.
Wait until the coolant temperature lowers sufficiently to
avoid a risk of burns.

V
INTRODUCTION
:$51,1*
Be careful of falling down
Lift engine correctly
To lift the engine, always use a cor-
rect wire rope capable of withstand-
ing the engine weight.
Attach the wire rope to the lifting
hangers provided on the engine us-
ing a correct sling.
During lifting process, keep the en-
gine in a well-balanced position by taking the center of
gravity of the engine into consideration.
During lifting process, keep the engine in a well-bal-
anced position by taking the center of gravity of the en-
gine into consideration.
If the wire rope contacts the engine directly, place a
cloth or other soft padding to avoid damage to the en-
gine and wire rope.
Do not climb onto the engine
Do not climb onto the engine, nor step on any engine
parts located on the lateral sides.
To work on parts located on the upper section of en-
gine, use a ladder, stool, etc., that is firmly secured.
Climbing on the engine may not only damage engine
parts but also cause parts to fall off and result in per-
sonal injuries.
VI
&$87,21
Be careful of handling fuel, engine
oil and LLC
Use only specified fuel, engine oil and long-
life coolant (LLC)
Use only the fuel, oil and LLC specified in this manual,
and handle them carefully.
Use of any other fuel, oil or LLC, or improper handling
may cause various engine problems and malfunctions.
Obtain the Material Safety Data Sheets (MSDS) issued
by the fuel, oil and LLC suppliers, and follow the direc-
tions in the MSDSs for proper handling.
Handle LLC (long life coolant) carefully
When handling LLC, always wear rubber gloves and
protective face mask. If LLC or cooling water containing
LLC comes into contact with your skin or eyes, or if it is
swallowed, you would suffer from inflammation, irrita-
tion or poisoning.
Should LLC be accidentally swallowed, induce vomit-
ing immediately and seek medical attention. Should
LLC enter your eyes, flush them immediately with plen-
ty of water and seek medical attention. If LLC splashes
onto your skin or clothing, wash it away immediately
with plenty of water.
Keep flames away from LLC. The LLC can catch
flames, causing a fire.
Coolant containing LLC is a hazardous material. Do not
dispose of it in unauthorized manner. Abide by the ap-
plicable law and regulations when discarding drained
coolant.
Proper disposal of waste oil and coolant
(LLC)
Do not discharge waste engine oil or coolant into sew-
erage, river, lake or other similar places. Such a way of
disposal is strictly prohibited by laws and regulations.
Dispose of waste oil, coolant and other environmentally
hazardous waste in accordance with the applicable law
and regulations, or consult a Mitsubishi dealer.

&$87,21
Service battery
Handle the battery correctly
• Never use flames or allow sparks
to generate near the battery. The
battery releases flammable
hydrogen gas and oxygen gas.
Any flames or sparks in the vicin-
ity could cause an explosion.
• Do not use the battery the fluid level of which is low-
ered below the lower limit line. Sustained use of the
battery could result in an explosion.
• Do not short the battery terminals with a tool or other
metal object.
• When disconnecting battery cables, always remove
the cable from the negative (-) terminal first. When
reconnecting the cables, attach the cable to the posi-
tive (+) terminal first.
• Charge the battery in a well-ventilated area, with all
filling hole plugs removed.
• Make sure the cable clamps are securely installed on
the battery terminals. A loose cable clamp can cause
sparks that may result in an explosion.
• Before servicing electrical components or conducting
electric welding, set the battery switch to the [Open/
OFF] position or disconnect the cable from the nega-
tive (-) battery terminal to cut off the electrical cur-
rent.
• Electrolyte (battery fluid) contains dilute sulfuric acid.
Careless handling of the battery can lead to the loss
of sight and/or skin burns. Also, keep the battery fluid
off the mouth.
• Wear protective goggles and rubber gloves when
working with the battery (when adding water, charg-
ing, etc.).
• If electrolyte is spilled onto the skin or clothing,
immediately wash it away with lots of water. Use
soap to thoroughly clean.
• The battery fluid can cause blindness if splashing
into eyes. If it gets into eyes, immediately flush it
away with plenty of clean fresh water, and seek
immediate medical attention.
• If the battery fluid is accidentally swallowed, gargle
with plenty of water, then drink lots of water, and
seek immediate medical attention.
INTRODUCTION
&$87,21
When abnormality occurs
Stop overheated engine after cooling run
Even if the engine comes to overheat, do not stop the
engine immediately. Abrupt stopping of an overheated
engine can cause the coolant temperature to rise, re-
sulting in seized engine parts. If the engine comes to
overheat, run the engine at low idling speed (cooling
operation), and stop the engine after the coolant tem-
perature lowers sufficiently.
Do not add coolant immediately after stopping the en-
gine. Adding coolant to a hot engine can cause the cyl-
inder heads to crack due to sudden change in
temperature. Add coolant little by little after the engine
cools down to room temperature.
Avoid immediate restart after abnormal stop
If the engine stops abnormally, do not restart the en-
gine immediately. If the engine stops with an alarm,
check and remedy the cause of the problem before re-
starting. Sustained use of the engine without any rem-
edy could result in serious engine problems.
Avoid continuous engine operation with too
low oil pressure
If an abnormal engine oil pressure drop is indicated,
stop the engine immediately, and inspect the lubrica-
tion system to locate the cause. Continuous engine op-
eration with low oil pressure may cause bearings and
other parts to seize.
Stop the engine immediately if the fan belt
breaks
If the fan belt breaks, stop the engine immediately. con-
tinuous engine operation with the broken fan belt could
cause the engine to overheat and thereby the coolant
to boil into steam, which may gush out from the reserve
tank or radiator, and cause personal injuries.
VII
INTRODUCTION

&$87,21

Other cautions
gine remarkably.
Modification of engine prohibited
Unauthorized modification of the engine will void the Cooling operation before stopping engine
manufacturer’s warranty. Always conduct the cooling operation (low speed
Modification of the engine may not only cause engine idling) for 5 to 6 minutes before stopping the engine.
damage but also produce personal injuries. Abruptly stopping the engine immediately after high-
load operation can cause partial overheating and short-
Pre-operational check and periodic inspec-
en the service life of the engine.
tion/maintenance
During cooling operation, check the engine for abnor-
Be sure to perform the pre-operational checks and pe-
malities.
riodic inspection/maintenance as described in this
manual. Protection of engine against water entry
Neglecting the pre-operational check or periodic in- Do not allow rainwater, etc. to enter the engine through
spection/maintenance can arouse various engine trou- the air inlet or exhaust openings.
bles such as damage to parts, eventually leading to Do not wash the engine while it is operating. Cleaning
serious accidents. fluid (water) can be sucked into the engine.
Starting the engine with water inside the combustion
Break-in operation
chambers can cause the water hammer action which
A new engine needs to be broken in for the first 50
may result in internal engine damage and serious acci-
hours of operation. During this period, do not subject
dents.
the engine to heavy loads.
Operating a new engine under high loads or severe Maintenance of air cleaner or pre-cleaner
conditions during the break-in period can shorten the The major cause of abnormal wear on engine parts is
service life of the engine. dust entering with intake air. Worn parts produce many
problems such as an increase of oil consumption, de-
Warming-up operation
crease of output, and starting difficulties. For effective
After starting the engine, run the engine at low idling
removal of dust from intake air, conduct maintenance
speeds for 5 to 10 minutes for warming-up. Start the
of the air cleaner according to the following instruc-
work after this operation is completed.
tions.
Warm-up operation circulates the lubricant through the
• Do not conduct maintenance of the air cleaner/pre-
engine. Therefore, individual engine parts are well lu-
cleaner while the engine is operating. Engine opera-
bricated before they are subjected to heavy loads. This
tion without the air cleaner/precleaner in place allows
is very important for longer service life, high-perfor-
foreign matters to enter the turbocharger, causing it
mance and economical operation.
to damage seriously.
Do not conduct warm-up operation for a longer time
• Remove the air cleaner/pre-cleaner slowly to prevent
than necessary. Prolonged warm-up operation causes
dust accumulated on the element from falling off.
carbon build-up in the cylinders that leads to incom-
After removing the air cleaner or pre-cleaner, imme-
plete combustion.
diately cover the opening (inlet port in case of air
Avoid engine operations in a overload con- cleaner; port in body in case of pre-cleaner) with
dition plastic sheet or similar means to prevent dust from
If the engine is considered to be in an overloaded con- entering the engine.
dition which is identified by too much black smoke, etc., • Air cleaners equipped with a dust indicator will issue
immediately reduce the load on the engine such that an alarm if the element gets clogged. Service the
the correct output and load conditions may be cleaner as soon as possible if an alarm is issued.
achieved.
Overloading the engine causes not only high fuel con-
sumption but also excessive carbon deposits inside the
engine. Excessive carbon deposits can cause various
engine problems and shorten the service life of the en-

VIII

Observe safety rules at work site
Observe the safety rules established at your workplace
when operating and maintaining the engine.
Do not operate the engine if you are feeling ill.
Operation of the engine with reduced awareness may
cause improper operation that could result in accidents.
In such a case, inform your supervisor of your condi-
tion.
When working in a team of two or more people, use
specified hand signals to communicate among work-
ers.
Work clothing and protective gear
Wear a hardhat, face shield, safety shoes, dust mask,
gloves and other protective gear as needed.
When handling compressed air, wear safety goggles,
hardhat, gloves and other necessary protective gear.
Works without wearing proper protective gear could re-
sult in serious injuries.
Use of tools optimum for each work
Always keep in mind to select most appropriate tools
for the work to be performed and use them correctly. If
tools are damaged, replace with new tools.
Avoidance of prolonged time of starter oper-
ation
Do not operate the starter for more than 10 seconds at
a time even if the engine does not start. Wait for at least
30 seconds before next engine cranking.
Continuous operation of the starter will drain the battery
power and cause the starter to seize.
Do not turn off battery switch during opera-
tion
If the battery switch is turned OFF when the engine is
running, not only various meters will stop working but
also the alternator may have its diode and transistor
deteriorated.
INTRODUCTION
Cautionary instructions for transporting en-
gine
When transporting the engine on a truck, consider the
engine weight, width and height to ensure safety. Abide
by road traffic law, road vehicles act, vehicle restriction
ordinance and other pertinent laws.
Avoid continuous engine operation in a low
load condition
Do not operate the engine continuously for more than
10 minutes at a load of less than 30%. Engine opera-
tion in a low load condition increases the emission of
unburned fuel. Therefore, a prolonged time of engine
operation in a low load condition increases the quantity
of unburned fuel adhering to engine parts, provoking
the possibility of engine malfunctioning and shortening
the service life of the engine.
Ventilation of engine room
Always keep the engine room well ventilated. Insuffi-
cient amount of intake air causes the operating temper-
ature to rise, resulting in poor output and lowered
performance.
It is highly recommended to calculate the required
amount of air supply to the engine and install an ade-
quate ventilation system before installing the engine.
Avoid contact with high-pressured fuel
Should fuel leak from a fuel injection pipe, do not touch
the spouting fuel directly.
Fuel in the fuel injection pipes is under high pressure. If
high-pressured fuel contacts you skin, it penetrates
through the skin and may result in gangrene.
IX
INTRODUCTION

&$87,21

About warning labels

Maintenance of warning labels
Make sure all warning/caution labels are legible.
Clean or replace the warning/caution labels when the description and/or illustration are not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other
chemicals to prevent the letters from getting blurred or the adhesion from being weakened.
Replace damaged or fractured labels with new ones.
If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning
label to the new part.

Warning labels

X
 GENERAL CONTENTS

Group Name Contents Group No.

External view
System flow diagrams
General Engine serial number location 1
Main specifications
Tips on disassembling and reassembling
Maintenance service data
Service data 2
List of tightening torque
Service tools Special tools 3
Determining overhaul timing
Determination of overhaul 4
Testing compression pressure
Disassembling and inspecting cylinder head and valve mechanism
Disassembling and inspecting flywheel
Disassembly of basic engine 5
Disassembling and inspecting gear case, timing gear and camshaft
Disassembling and inspection crankcase, crankshaft and piston
Inspecting and repairing cylinder head and valve mechanism
Inspecting and repairing flywheel
Inspection and repair of basic engine 6
Inspecting and repairing timing gear and camshaft
Inspecting and repairing piston, connecting rod, crankshaft and crankcase
Reassembling piston, connecting rod, crankshaft and crankcase
Reassembling timing gear and camshaft
Reassembly of basic engine 7
Reassembling flywheel
Reassembling cylinder head and valve mechanism
Removing fuel system
Fuel system 8
Installing fuel system
Removing and inspecting lubrication system
Lubrication system Disassembling, inspecting and reassembling lubrication system 9
Installing lubrication system
Removing cooling system
Cooling system Inspecting cooling system 10
Installing cooling system
Removing inlet and exhaust sysytem
Inlet and exhaust system Disassembling, inspecting and reassembling inlet and exhaust system 11
Installing inlet and exhaust system
Removing electrical system
Electrical system Disassembling, inspecting and reassembling electrical system 12
Installing electrical system
Adjusting engine
Adjustment and operation Break-in operation 13
Performance test (JIS standard)
Troubleshooting by diagnosis codes
Scan tester
Diagnosis code cross reference
Troubleshooting 14
Troubleshooting reference chart
Inspecting sensors
Inspecting wiring
 GENERAL
1. External view...................................1-2

2. System flow diagrams .....................1-3

2.1 Fuel system - flow diagram ...................... 1-3
2.2 Lubrication system - flow diagram ........... 1-3
2.3 Cooling system - flow diagram................. 1-4
2.4 Inlet and exhaust system - flow diagram.. 1-4
2.5 Electrical system - wiring diagram ........... 1-5

3. Engine serial number location.........1-6

4. Main specifications ..........................1-7

5. Tips on disassembling and

reassembling.................................1-10
5.1 Disassembling........................................ 1-10
5.2 Reassembling ........................................ 1-10

1-1
GENERAL

1. External view

Oil filler
Exhaust manifold
Front hanger Turbocharger
Thermostat

Fan Rear hanger

Front Rear

Alternator

Crankshaft pulley
Starter
Belt
Oil pan

Engine left view

Inlet manifold
Breather
Oil level gauge
Air heater

Oil filter Water pump

Rear Front

Common rail

Fuel pump

Flywheel housing Oil pump

Flywheel

Engine right view

1-2
 GENERAL

2. System flow diagrams

2.1 Fuel system - flow diagram

Injector

Common rail

Fuel pump

To fuel tank

From fuel tank

Fuel system - flow diagram

2.2 Lubrication system - flow diagram

Tappet Turbocharger Valve mechanism

Piston
Camshaft

Piston cooling nozzle

Oil filter

Main gallery
Oil cooler
Timing gear
Relief valve

Oil pump
Crankshaft
Oil strainer
Safety valve

Lubrication system - flow diagram

1-3
GENERAL

2.3 Cooling system - flow diagram

Outlet

Thermostat
Cylinder head
Bypass pipe

Inlet
Oil cooler Water pump
Water jacket

Cooling system - flow diagram

2.4 Inlet and exhaust system - flow diagram

Inlet
Exhaust Turbocharger

Muffler

Cylinder

Inlet and exhaust system - flow diagram

1-4
 GENERAL

2.5 Electrical system - wiring diagram

Injector power supply

Air heater relay
Inlet manifold pressure sensor

Water temperature sensor

Common rail

Common rail pressure sensor

Speed/timing sensor
(Camshaft side)
Speed/timing sensor
(Crankshaft side)
High pressure pump

High pressure pump

Engine oil pressure switch solenoid sensor (MPROP)

Connector

Electronic control unit

Electrical system - wiring diagram

1-5
GENERAL

3. Engine serial number location

The engine serial number is stamped on the side of the
crankcase.

Engine serial number

Stamp location of engine serial number

1-6
 GENERAL

4. Main specifications
Table 1-1 Main specifications (1 / 3)
Engine model D04FR-TAA
Type Water cooled, 4 cycle diesel engine, turbocharged
No. of cylinders - arrangement 4 cylinder in-line
Combustion system Direct injection
Valve mechanism Overhead
Cylinder bore × stroke 102 × 130 mm [4.02 × 5.12 in.]
Displacement 4.249 L [259 cu. in.]

Main Compression ratio 17.8

specification Fuel Diesel fuel
Firing order 1-3-4-2
Direction of rotation Counterclockwise when viewed from flywheel side
Length 911 mm [35.87 in.]
Dimensions
(varies depending on the Width 719 mm [28.3 in.]
specifications)
Height 940 mm [37.0 in.]
Dry weight Approx. 395 kg [870.8 lbs]
Cylinder sleeve type Dry
Compression ring 2
Number of piston ring
Oil ring 1 (with expander)
Open BTDC 15°
Inlet valve
Valve timing (when Close ABDC 45°
Engine engine is hot) Open BBDC 49°
main parts Exhaust valve
Close ATDC 15°

Internal EGR valve tim- Open ATDC 21°

Exhaust valve
ing Close BBDC 55°
Starting system Starter
Starting aid system Air heater
Type Common rail fuel injection system
Fuel
Model number CP1H
system
Manufacturer Bosch Corporation

1-7
GENERAL

Table 1-1 Main specifications (2 / 3)

Engine model D04FR-TAA
Lubricating method Forced circulation type (oil pump pressure feed type)
Classification API classification CF-4 or above class
Engine oil Total capacity
17.5 L [4.62 US gallons]
(including oil filter)
Type Gear type oil pump
Oil pump 40 L [10.57 US gallons]
Delivery capacity
Lubrication /1800 min-1
system Type Piston valve type
Relief valve 0.35 ± 0.05 MPa
Valve opening pressure
{3.5 ± 0.5 kgf/cm²} [50 ± 7 psi]
Oil cooler type Water-cooled, multi-plate type
Oil filter type Cartridge type paper element
1.1 MPa
Safety valve opening pressure
{11 kgf/cm²} [157 psi]
Cooling method Water-cooled, forced circulation
Coolant capacity (Engine water jacket) 6 L [1.6 US gallons] approx.
Type Centrifugal
Water pump 133 L [35 US gallons]
Discharge capacity
/1800 min-1
Cooling
Water pump pulley speed ratio Varies depending on the specifications
system
Fan belt type Ribbed belt
Fan Type ø600 mm [23.62 in.]
Type Wax type
Thermostat Valve opening tempera-
71 ± 2°C [160 ± 3.6°F]
ture
Inlet and Model number TD04HL
exhaust sys- Turbocharger
tem Qty 1

Control sys- ECU Model number EDC16UC40

tem (Electronic Control Unit) Manufacturer Bosch Corporation

1-8
 GENERAL

Table 1-1 Main specifications (3 / 3)

Engine model D04FR-TAA
Manufacturer Nikko Electric Industry
Type 0-24000-0188
Pinion meshing type Pinion shift
Output 24V - 5kW
Qty 1
Ring gear and pinion ratio 10/127
Voltage 23V
Starter No-load charac-
Current 85A or below
teristics
Speed 3300 min-1 or more
Voltage 9V
Load character-
Current 1400A or below
istics
Torque 88.26 N·m {9.0 kgf·m} [65 lbf·ft] or above
Minimam operating volt-
16V or below
Electrical age
system Minimam holding voltage 8V or below
Manufacturer Nikko Electric Industry
Model number 0-35000-4838
Output 24V - 50A
Rated speed 5000 min-1
Direction of rotation Clockwise when viewed from pulley side
Alternator
Drive system PK type, V ribbed, 12 ribs
Ground system One conductor (-) side
Regulated voltage 28.5V ± 1V
Temperature range
-30 to +100°C [-22 to +212°F]
tolarance
Type Electric heater
Air heater
Capacity 2.1kW
Heater relay Fuse capacity 127A

1-9
GENERAL

5. Tips on disassembling and reassem-

bling 5.2 Reassembling
This service manual specifies the recommended procedures (1) Wash all engine parts, except such parts as oil seals, O-
to be followed when servicing Mitsubishi engines. The rings and rubber sheets, in cleaning oil and dry them
manual also specifies the special tools that are required for with compressed air.
the work, and the basic safety precautions to follow when (2) Use correct tools and instruments.
working. (3) Use only high-quality lubricating oils and greases of
Note that this manual does not exhaustively cover potential appropriate types. Be sure to apply oil, grease or
hazards that could occur during maintenance, inspection and adhesive to the part wherever specified.
service work of engine. (4) Use a torque wrench to tighten parts correctly when
When working on an engine, follow the relevant directions their tightening torques are specified.
given in this manual and observe the following instructions: Refer to "List of Tightening Torque."
(5) Replace all gaskets and packings with new ones unless
5.1 Disassembling specified otherwise. Apply adhesive if necessary. Use
(1) Use correct tools and instruments. Serious injury or only the proper amount of adhesive.
damage to the engine will result from using the wrong
tools and instruments.
(2) Use an overhaul stand or work bench if necessary, and
follow the disassembling procedures described in this
manual.
(3) Keep the engine parts in order of removal to prevent
losing them.
(4) Pay attention to assembling marks. Put your marks on
the parts, if necessary, to ensure correct reassembling.
(5) Carefully check each part for defects during
disassembling or cleaning. Do not miss symptoms
which can not be detected after disassembling or
cleaning.
(6) When lifting or carrying heavy parts, exercise utmost
caution to ensure safety. Pay attention to balance of
heavy parts when handling. (Get help, and use jacks,
chain blocks and guide bolts as necessary.)

1-10
 SERVICE DATA
1. Maintenance service data ...............2-2
1.1 Engine general......................................... 2-2
1.2 Basic engine ............................................ 2-3
1.3 Lubrication system ................................... 2-7
1.4 Cooling system ........................................ 2-7
1.5 Inlet and exhaust system ......................... 2-7
1.6 Electrical system ...................................... 2-8

2. List of tightening torque...................2-9

2.1 Major bolts and nuts tightening torque..... 2-9
2.1.1 Basic engine...............................................2-9
2.1.2 Fuel system ..............................................2-10
2.1.3 Lubrication system ...................................2-10
2.1.4 Cooling system.........................................2-10
2.1.5 Inlet and exhaust system .........................2-11
2.1.6 Electrical system ......................................2-11
2.1.7 Sensors and ECM ....................................2-11
2.2 Standard bolt and nut tightening torque. 2-12
2.3 Standard eyebolt tightening torque ........ 2-13
2.4 Standard union nut tightening torque..... 2-13

2-1
SERVICE DATA

1. Maintenance service data

1.1 Engine general
Table 2-1 Maintenance service data table - Engine general Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
-1 -1
Maximum revolution speed 2240 min ± 10 min

Minimum revolution speed 1015 min-1 ± 20 min-1

When oil and water tem-
2.9 MPa 2.6 MPa
-1 peratures
Compression pressure (at 300 min ) {30 kgf/cm²} {27 kgf/cm²}
at 20 to 30°C
[427 psi] {[384 psi]
[68 to 86 °F]
0.2 to 0.4 MPa 0.15 MPa
Rated speed {2 to 4 kgf/cm²} {1.5 kgf/cm²}
[28.4 to 56.9 psi] [21.3 psi] Oil temperature
Lubricating
at 70 to 90 °C
oil pressure 0.1 MPa 0.05 MPa [158 to 194 °F]
Low idling {1 kgf/cm²} {0.5 kgf/cm²}
[14.2 psi] [7.1 psi]
Open BTDC 15°
Inlet
Close ABDC 45° ±3°
Valve timing
Open BBDC 49° (crank angle)
Exhaust
Close ATDC 15°

Internal EGR Open ATDC 21°

Exhaust
valve timing Close BBDC 55°

Valve clearance Inlet 0.25 [0.0098]

(when cold) Exhaust 0.40 [0.0157]
Deflection when the belt
forcefully pressed with a
7 to 9 thumb
Fan belt deflection
[0.276 to 0.354] New fan belt standard
value 4 to 6 [0.158 to
0.236]

2-2
 SERVICE DATA

1.2 Basic engine

Table 2-2 Maintenance service data table - Basic engine (1 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Reface minimum as possible.
Total grinding thickness of
Crankcase Flatness of top surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head bottom is 0.2 [0.008]
max.
ø 102 102.010 to 102.045 102.700 If limit (102.200 [4.0236]) is
Inside diameter
[4.02] [4.0161 to 4.0175] [4.0433] exceeded, use oversize
Cylinder sleeve, and hone to +0.010 to
Circularity 0.01 [0.0004] or less
sleeve +0.045 [0.0004 to 0.0018].
Use oversize piston and pis-
Cylindricality 0.015 [0.0006] or less
ton ring.
If the measured value
exceeds the standard and is
less than the limit, replace
Clearance between main bearing and 0.050 to 0.118 0.200
bearing.
crank journal [0.0020 to 0.0046] [0.0079]
Main If the limit is exceeded, grind
bearing the crank journal, and use
undersize bearing.
Replace thrust plate. The
Width of thrust journals 0.100 to 0.264 (0.300
limit value means a play in
(Thrust clearance) [0.0039 to 0.0104] [0.0118])
the direction of thrust.
ø 22 22.000 to 22.021 22.100 Repair limit:
Inside diameter
[0.87] [0.8661 to 0.8670] [0.8701] 102.200 [4.0236]
Tappet
hole Replace tappet if diameter of
Clearance between tappet and tappet 0.035 to 0.086 0.120
tappet hole is +0.10 [0.0039]
hole [0.0014 to 0.0034] [0.0047]
or less.
Front 0.04 to 0.09 0.15
Clearance between Middle [0.0016 to 0.0035] [0.0059]
Camshaft Replace bushing.
bushing and cam-
bushing 0.04 to 0.119 0.15 (Ream if necessary.)
shaft journal Rear
[0.0016 to 0.0047] [0.0059]
Reface minimum as possible.
Total grinding thickness of
Cylinder Distortion of bottom surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head head bottom is 0.2 [0.008]
max.
Compressed thickness of gasket 1.7 [0.07] ±0.05 [0.0020]
7.940 to 7.955 7.900
Inlet
Valve stem diame- ø8 [0.3126 to 0.3132] [0.3110]
ter [0.315] 7.920 to 7.940 7.850
Exhaust
[0.3118 to 0.3126] [0.3091]
Valve and
0.055 to 0.085 0.150
valve Inlet
Clearance between [0.0022 to 0.0033] [0.0059]
guide
guide and stem 0.070 to 0.105 0.200
Exhaust
[0.0028 to 0.0041] [0.0079]
17 17.2 to 17.4
Height to top of valve guide
[0.669] [0.6772 to 0.6850]

2-3
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Inlet
Valve seat angle 30°
Exhaust
0.4 0.3 to 0.5 1.1
Inlet Seat width
[0.016] [0.0118 to 0.0197] [0.0433]
Valve sinkage
0.5 0.4 to 0.6 1.1
Valve seat Exhaust
[0.020] [0.0157 to 0.0236] [0.0433]
and valve
Inlet Valve Valve
1.4 1.2 to 1.6 1.8 Valve sinkage margin
Seat width
Exhaust [0.055] [0.0472 to 0.0630] [0.071] seat angle

Refacing permissi-
Valve margin 2.13 [0.084] 2.13 [0.084] ble up to 1.2
[0.047]
Free length 56.40 [2.221] 55.00 [2.165]

θ = 2.0°or less ǰ
Δ = 2.0 [0.079] or Δ = 2.0 [0.079] ٌ
Perpendicularity
less over entire length Lf
Valve
springs Lf = 56.4 [2.221]

44.0 [1.732]/222.7 to
44.0 [1.732]/207 N
246.1 N
Set length/load {21.2 kgf}
{22.7 to 25.1 kgf}
[153.3 lbf]
[164.2 to 181.5 lbf]
ø 20 20.011 to 20.094
Rocker bushing inside diameter
[0.79] [0.7878 to 0.7911]
Rocker ø 20 19.966 to 19.984
Rocker shaft diameter
arm [0.79] [0.7861 to 0.7868]
Clearance between rocker bushing 0.027 to 0.128 0.150
and rocker shaft [0.0011 to 0.0050] [0.0059]
Pushrod Runout 0.4 [0.016] or less 0.4 [0.016] TIR

2-4
 SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (3 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.04 0.10
Runout TIR
[0.0016] or less [0.0039]
If the diameter is the limit or
more, replace bearing.
ø 90 89.95 to 89.97 89.85 If the diameter is less than
Crank journal diameter
[3.54] [3.5413 to 3.5421] [3.5374] the limit, grind the journal
and use undersize bearing.
Service limit: 89.10 [3.5079]
ø 65 64.945 to 64.965 64.800
Crankpin diameter
[2.56] [2.5569 to 2.5577] [2.5512]
Distance between centers of journal
65 [2.56] ± 0.05 [± 0.002]
and crankpin
Pin maximum defec-
Crank- Parallelism between journal and
tion: 0.01 [0.0004] or
shaft crankpin
less
Roundness of journals and crankpins 0.01 0.03
(diameter difference) [0.0004] or less [0.0012]
Cylindericity of journals and crank-
0.01 0.03
pins
[0.0004] or less [0.0012]
(diameter difference)
Fillet radius of journals R3 [0.12] ± 0.2 [± 0.008]
Fillet radius of pins R4 [0.16] ± 0.2 [± 0.008]
If end play is less than the
limit, replace thrust plates.
0.100 to 0.264 0.300
End play If end play exceeds the limit,
[0.0039 to 0.0104] [0.0118]
replace with oversize thrust
plates.
101.915 to 101.945 101.730
STD
[4.0124 to 4.0136] [4.0051]
Outside diameter 0.25 [0.0098]/ ø 102 102.165 to 102.195 101.980
(at piston skirt) OS [4.02] [4.0222 to 4.0234] [4.0150]
0.50 [0.0197]/ 102.415 to 102.445 102.230
OS [4.0321 to 4.0333] [4.0248]
Bearing clearance check.
Gasket compressed
Protrusion from crankcase 0.8 [0.031]
(installed) thickness: 1.7 ±
0.05 [0.067 ± 0.0020]
Pistons Clearance between piston pin hole 0.005 to 0.021 0.050
and piston pin [0.0002 to 0.0008] [0.0020]
Weight difference in one engine 5.0 g [0.2 oz.] or less
No.1
0.08 to 0.12 0.200
compression
[0.0031 to 0.0047] [0.0079]
ring
Clearance between
No.2
piston ring and 0.08 to 0.12 0.150
compression
ring groove [0.0031 to 0.0047] [0.0059]
ring
0.025 to 0.065 0.150
Oil ring
[0.0010 to 0.0026] [0.0059]
Compression 0.30 to 0.45
Piston rings [0.0118 to 0.0177] 1.50
End gap
ring 0.30 to 0.50 [0.0591]
Oil ring
[0.0118 to 0.0197]

2-5
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (4 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
ø 34 33.991 to 33.997
Outside diameter
[1.34] [1.3382 to 1.3385]
Clearance between pin and connect- 0.023 to 0.054 0.080
Piston pin
ing rod bushing [0.0009 to 0.0021] [0.0031]
ø 34 34.020 to 34.045
Inside diameter of bushing
[1.34] [1.3394 to 1.3404]
0.05/100 0.150
Bend and twist
[0.0020/3.94] or less [0.0059]
Clearance between crankpin and con- 0.035 to 0.100 0.200
Connect- necting rod bearing [0.0014 to 0.0039] [0.0079]
ing rod
0.15 to 0.35 0.50 Replace connecting rod bear-
End play
[0.0059 to 0.0138] [0.0197] ings.
Weight difference in one engine 10 g [0.4 oz.] or less
Flatness 0.15 [0.0059] or less 0.5 [0.0197]
Flywheel
Runout 0.15 [0.0059] or less 0.5 [0.0197]
TIR
0.10
Runout 0.04 [0.0016] or less Repair using a press, or
[0.0039]
replace.
Major axis Major axis - minor
+0.1 Major axis - minor
Inlet 46.911 -0.3 axis = 6.189
axis = 6.689 [0.2633] Major axis
[1.8469
+0.004
-0.012 ] [0.2437]
Cam lift Minor
Major axis Major axis - minor axis
+0.1 Major axis - minor
Camshaft Exhaust 46.256 -0.3 axis = 5.729
+0.004
axis = 6.229 [0.2452]
[1.8211 -0.012 ] [0.2256]

ø 54 53.94 to 53.96 53.90

Front, middle
[2.13] [2.1236 to 2.1244] [2.1220]
Journal diameter
ø 53 52.94 to 52.96 52.90
Rear
[2.09] [2.0842 to 2.0850] [2.0827]
0.10 to 0.25 0.30
End play Replace thrust plate.
[0.0039 to 0.0098] [0.0118]
Clearance between idler bushing and 0.009 to 0.050
0.100 [0.0039] Replace bushing.
shaft [0.0004 to 0.0020]
0.05 to 0.20 0.35
Idler Idler gear end play Replace thrust plate.
[0.0020 to 0.0079] [0.0138]
Interference between shaft and crank- 35 -0.016 to -0.035
case hole [1.38] [-0.0006 to -0.0138]
Between crankshaft gear 0.053 to 0.154 0.25
and idler gear [0.0021 to 0.0061] [0.0098]
Between camshaft gear 0.049 to 0.160 0.25
Timing and idler gear [0.0019 to 0.0063] [0.0098]
gear back- Replace gear.
lash Between injection pump idler gear 0.050 to 0.228 0.25
and idler gear [0.0020 to 0.0090] [0.0098]
Between injection pump idler gear 0.044 to 0.163 0.25
and injection pump gear [0.0017 to 0.0064] [0.0098]

2-6
 SERVICE DATA

1.3 Lubrication system

Table 2-3 Maintenance service data table - Lubrication system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Backlash between the oil pump idler gear and 0.051 to 0.197 0.35
the idler gear [0.0020 to 0.0078] [0.0138]
Replace gear.
Backlash between the oil pump idler gear and 0.049 to 0.166 0.35
the oil pump drive gear [0.0019 to 0.0065] [0.0138]
-0.01 to 0.054 0.150
End clearance of gears in case
[-0.0004 to 0.0021] [0.0059]
0.05 to 0.098 0.100
Radial clearance of gear in case
[0.0020 to 0.0039] [0.0039]
Oil pump Clearance between gear shaft and pump body,
0.04 to 0.07 0.15
and clearance between gear shaft and pump
[0.0016 to 0.0028] [0.0059]
cover.
ø 25 24.939 to 24.960
Spindle outside diameter
[0.98] [0.9818 to 0.9827]
ø 25 25.000 to 25.021
Oil pump idler gear bushing inside diameter
[0.98] [0.9843 to 0.9851]
0.10 to 0.27
Oil pump idler gear end play
[0.0039 to 0.0106]
0.35 ± 0.05 MPa
Relief valve Valve opening pressure {3.5 ± 0.5 kgf/cm²}
[49.8 ± 7.1 psi]
1.1 MPa
Safety valve Valve opening pressure {11 kgf/cm²}
[157 psi]

1.4 Cooling system

Table 2-4 Maintenance service data table - Cooling system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
71 ± 2°C
Valve opening temperature
[160 ± 3.6°F]
Thermostat
Temperature at which valve lift becomes 85°C
10mm [0.039 in.] or more [185°F]

1.5 Inlet and exhaust system

Table 2-5 Maintenance service data table - Inlet and exhaust system Unit: mm [in.]
Inspection point Nominal Standard Limit Remarks
Distortion of exhaust manifold 0.2 [0.008] or less

2-7
SERVICE DATA

1.6 Electrical system

Table 2-6 Maintenance service data table - Electrical system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.06
Armature shaft runout TIR
[0.0024]
0.10
Commutator runout
[0.0039]
0.7 to 0.9 0.2
Undercut depth
[0.028 to 0.035] [0.008]
Starter
17 to 18 10
Height
[0.67 to 0.71] [0.39]

Brush Less than

21.56 to 27.44 N
21.56 N
Spring tension {2.2 to 2.8 kgf}
{2.2 kgf}
[15.9 to 20.3 lbf]
[15.9 lbf]
25°C [77°F]
Alternator Adjusting voltage 27.5 to 29.5V
l=2

2-8
 SERVICE DATA

2. List of tightening torque

2.1 Major bolts and nuts tightening torque
2.1.1 Basic engine
Table 2-7 Major bolts and nuts tightening torque - Basic engine
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Cylinder head bolt 12 × 1.75 137 ± 5 14 ± 0.5 101 ± 3.6

Rocker cover bolt 8 × 1.25 20 ± 2 2.0 ± 0.2 14.5 ± 1.4
Rocker shaft bracket bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Rocker arm adjusting nut 8 × 1.25 20 ± 2 2.0 ± 0.2 14.5 ± 1.4
Main bearing cap bolt 14 × 2 137 ± 5 14 ± 0.5 101 ± 3.6
Connecting rod cap nut 12 × 1.25 103 ± 5 10.5 ± 0.5 76 ± 3.6
Flywheel bolt 12 × 1.25 83 ± 5 8.5 ± 0.5 62 ± 3.6
Camshaft thrust plate bolt 8 × 1.25 12 ± 2 1.2 ± 0.2 9 ± 1.4
8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Front plate bolt
10 × 1.5 35 ± 5 3.5 ± 0.5 25.3 ± 3.6
8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.5
Timing gear case bolt
10 × 1.5 35 ± 5 3.5 ± 0.5 25.3 ± 3.6
Crankshaft pulley nut 30 × 1.5 706 ± 59 72 ± 6 521 ± 43
Idler thrust plate bolt 10 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Piston cooling nozzle 12 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Oil pan bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Oil pan drain cock 24 × 1.5 49 ± 5 5 ± 0.5 36 ± 3.6
Oil pan drain plug 24 × 1.5 59 ± 5 6.0 ± 0.5 43.4 ± 3.6
Lifting bolt 12 × 1.75 102 ± 10 10.4 ± 1.0 75.2 ± 7.2

2-9
SERVICE DATA

2.1.2 Fuel system

Table 2-8 Major bolts and nuts tightening torque - Fuel system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Nozzle gland 8 × 1.25 30 ± 3.0 3.1 ± 0.3 22.4 ± 2.2

+2.5 +0.25 +1.8
Fuel pump fuel relief joint mouting eye bolt 12 × 1.25 25 0 2.5 0 18 0

Fuel pump gear nut 14 × 1.5 70 ± 5 7.1 ± 0.5 51.4 ± 3.6

Fuel injection pipe nut
14 × 1.5 25 ± 3 2.5 ± 0.3 18.1 ± 2.2
(Injector side, Rail side)
Fuel pump fuel supply high pressure pipe
14 × 1.5 25 ± 3 2.5 ± 0.3 18.1 ± 2.2
(Rail side)
Fuel pump fuel supply high pressure pipe
12 × 1.5 20 ± 2.0 2.0 ± 0.2 14.5 ± 1.4
(Pump side)
Fuel filter air bleed plug 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel filter fuel inlet eye bolt 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel filter fuel outlet eye bolt 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel pump mouting bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Fuel pump idler shaft wahsher mouting bolt 10 × 1.25 34 ± 5 3.5 ± 0.5 25.3 ± 3.6
Fuel pump idler shaft mouting bolt 12 × 1.25 112.2 ± 22 11.4 ± 2.2 82.5 ± 15.9

2.1.3 Lubrication system

Table 2-9 Major bolts and nuts tightening torque - Lubrication system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Relief valve 22 × 1.5 49 ± 4.9 5 ± 0.5 36.2 ± 3.6

Relief valve plug 18 × 1.5 44 ± 4.9 4.5 ± 0.5 32.5 ± 3.6
Safety valve 18 × 2.0 69 ± 4.9 7 ± 0.5 50.6 ± 3.6
Oil pump cover bolt 10 × 1.5 35 ± 3.5 3.6 ± 0.3 25.3 ± 2.4
Turbocharger oil feed eye bolt 10 × 1.25 17 ± 2 1.7 ± 0.2 12.3 ± 1.4

2.1.4 Cooling system

Table 2-10 Major bolts and nuts tightening torque - Cooling system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Fan and water pump pulley mouting bolt 10 × 1.5 49 ± 5 5.0 ± 0.5 36.2 ± 3.6
Water pump, oil pump mouting bolt(together
10 × 1.5 35 ± 3.5 3.6 ± 0.3 25.3 ± 2.4
with gear case)
Water pump mouting bolt(together with gear
8 × 1.25 19 ± 1.9 1.9 ± 0.2 13.7 ± 1.4
case)

2-10
 SERVICE DATA

2.1.5 Inlet and exhaust system

Table 2-11 Major bolts and nuts tightening torque - Inlet and exhaust system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Air heater terminal nut 6×1 9±1 0.9 ± 0.1 6.5 ± 0.7
Air heater terminal flange nut 6×1 9±1 0.9 ± 0.1 6.5 ± 0.7
Inlet manifold bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Exhaust manifold nut 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4

2.1.6 Electrical system

Table 2-12 Major bolts and nuts tightening torque - Electrical system
Threads TIghtening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Starter mouting bolt 10 × 1.25 35.3 ± 5.9 3.6 ± 0.6 255.4 ± 42.6
Starter B terminal 10 × 1.5 18 ± 2 1.8 ± 0.2 13.0 ± 1.4
Starter protection cover screw 5 × 0.8 2.25 ± 0.25 0.22 ± 0.02 1.6 ± 0.1
Starter through bolt 6×1 10.29 ± 2.45 1.0 ± 0.24 7.2 ± 1.7
Alternator E terminal 6×1 5.9 ± 1 0.6 ± 0.1 4.3 ± 0.7
Alternator B terminal 5 × 0.8 5.9 ± 1 0.6 ± 0.1 4.3 ± 0.7
Alternator pulley nut 20 × 1.5 97 ± 12.7 9.9 ± 1.3 71.6 ± 9.4
Alternator through bolt 6×1 5.9 ± 1 0.6 ± 0.1 4.3 ± 0.7
Alternator mounting bolt 14 × 1.5 97 ± 9.7 9.9 ± 1.0 71.6 ± 7.2

2.1.7 Sensors and ECM

Table 2-13 Major bolts and nuts tightening torque - Sensors and ECM
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Water temperature sensor 10 × 1.25 21 ± 2.1 2.0 ± 0.2 15.2 ± 1.5

Inlet manifold pressure sensor R1/4 25 ± 2 2.5 ± 0.2 18.1 ± 1.4
Engine oil pressure switch R1/8 10 ± 2 1.0 ± 0.2 7.2 ± 1.4
Speed/timing sensor mouting bolt
6 × 1.0 9±1 0.9 ± 0.1 6.5 ± 0.7
(camshaft, crankshaft)
ECU mouting bolt 6 × 1.0 8.0 ± 2 0.8 ± 0.1 5.8 ± 1.4
Pickup mouting hexagon bolt 6 × 1.0 29.4 ± 4.9 3.0 ± 0.5 212.8 ± 35.5

2-11
SERVICE DATA

2.2 Standard bolt and nut tightening torque

Table 2-14 Standard bolt and nut tightening torque
Threads Width Strength classification
Description Dia × Pitch across flats
(mm) (mm) [in.] 7T 10.9

7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M8 × 1.25 12 [0.47] 17 1.7 13 30 3.1 22
M10 × 1.25 14 [0.55] 33 3.4 24 60 6.1 44
M12 × 1.25 17 [0.67] 60 6.1 44 108 11.0 80
Metric automobile screw thread
M14 × 1.5 22 [0.87] 97 9.9 72 176 17.9 130
M16 × 1.5 24 [0.94] 145 14.8 107 262 26.7 193
M18 × 1.5 27 [1.06] 210 21.4 155 378 38.5 279
M20 × 1.5 30 [1.18] 291 29.7 215 524 53.4 386
M22 × 1.5 32 [1.26] 385 39.3 284 694 70.8 512
M24 × 1.5 36 [1.42] 487 49.7 359 878 89.5 648
M27 × 1.5 41 [1.61] 738 75.3 544 1328 135.5 979

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M10 × 1.5 14 [0.55] 32 3.3 24 58 5.9 43
M12 × 1.75 17 [0.67] 57 5.8 42 102 10.4 75
Metric course screw thread M14 × 2 22 [0.87] 93 9.5 69 167 17.0 123
M16 × 2 24 [0.94] 139 14.2 103 251 25.6 185
M18 × 2.5 27 [1.06] 194 19.8 143 350 35.7 258
M20 × 2.5 30 [1.18] 272 27.7 201 489 49.9 361
M22 × 2.5 32 [1.26] 363 37.0 268 653 66.6 482
M24 × 3 36 [1.42] 468 47.7 345 843 86.0 622
M27 × 3 41 [1.61] 686 70.0 506 1236 126.0 912

Note: (a) This table lists the tightening torque for standard bolts and nuts.
(b) The numerical values in the table are for fasteners with spring washers.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)

2-12
 SERVICE DATA

2.3 Standard eyebolt tightening torque

Table 2-15 Standard eyebolt tightening torque
Strength classification
Threads Width
Dia × Pitch across flats 4T
(mm) (mm) [in.]
N·m kgf·m lbf·ft
M8 × 1.25 12 [0.47] 8±1 0.8 ± 0.1 6 ± 0.7
M10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11 ± 1.5
M12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18 ± 2.2
M14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25 ± 3.0
M16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32 ± 3.7
M18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 55 ± 3.7
M20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72 ± 7.4
M24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108 ± 11.1
M27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 167 ± 14.8
(Dry)

2.4 Standard union nut tightening torque

Table 2-16 Standard union nut tightening torque
Width
Nominal Cap nut size
across flats N·m kgf·m lbf·ft
diameter M (mm)
(mm) [in.]
63 M14 × 1.5 19 [0.75] 39 4 29
80 M16 × 1.5 22 [0.87] 49 5 36
100 M20 × 1.5 27 [1.06] 78 8 58
120 M22 × 1.5 30 [1.18] 98 10 72
150 M27 × 1.5 32 [1.26] 157 16 116
180 M30 × 1.5 36 [1.42] 196 20 145
200 M30 × 1.5 36 [1.42] 196 20 145
220 M33 × 1.5 41 [1.61] 245 25 181
254 M36 × 1.5 41 [1.61] 294 30 217
(Maximum tolerance value: ±10%, dry condition)

2-13
 SERVICE TOOLS
1. Special tools ....................................3-2

3-1
SERVICE TOOLS

1. Special tools
Table 3-1 Special tool list (1 / 3)
Tool name Part number Illustration Use

Valve guide installer 32F91-00400 Valve guide installation

Valve guide remover 31391-10500 Valve guide removal

36791-00200
(Inlet)
Insert caulking tool Valve seat installation
36791-00300
(Exhaust)

Sleeve installer 34291-00200 Cylinder sleeve installation

Piston ring removal/

Piston ring pliers 30091-07100
installation

Piston guide 34291-00100 Piston installation

Injector remover 32G91-00100 Injector removal

3-2
 SERVICE TOOLS

Table 3-1 Special tool list (2 / 3)

Tool name Part number Illustration Use

Idler shaft puller MH061077 Idler shaft removal

Idler bushing removal/

Idler bushing puller 30091-07300
installation

Connecting rod bushing

Connecting rod bushing installer 32F91-03050
removal/installation

Oil and fuel filters removal/

Oil filter wrench 34591-00100
installation

Fuel injection pump

Universal extension 30091-01101
removal/installation

Socket 58309-73100 Engine turning

Engine compression pres-

Gauge adapter 32G91-00500
sure measurement

3-3
SERVICE TOOLS

Table 3-1 Special tool list (3 / 3)

Tool name Part number Illustration Use

Removal for
crankshaft gear,
Puller assembly 64309-12900
camshaft gear and
crankshaft pulley

Compression pressure mea-

Compression gauge 33391-02100
surement

Oil seal sleeve installation

Rear oil seal installer 34291-00020
on the crankshaft rear side

Camshaft bushing Camshaft bushing removal/

30691-00010
installer set installation

Camshaft bushing removal/

Valve spring pusher 30691-04500
Valve removal/installation
m
a
s
te
rt
e
c
h
Y
E
S

Scan tester 32G91-00600 Diagnosis codes display

H
E
L
P

N
O
R
C

F
V

1
1
S

E
E

N
N

T
4
D

E
R
4

2
E
X

F
IT

F
7

F
5

3
7

3
F

F
8

6
㧖

6
F

F
0
O

9
F
F

Ve
0

tr
O
N

on
#

ix

3-4
 DETERMINATION OF OVERHAUL
1. Determining overhaul timing ...........4-2

2. Testing compression pressure ........4-3

4-1
DETERMINATION OF OVERHAUL

1. Determining overhaul timing

In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in
engine oil consumption and blow-by gas are also considered to evaluate the engine condition. Besides, such symptoms as a
decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and increase in noise are
also considered for judging the overhaul timing, although those symptoms are often affected by other causes, and are not
always effective to judge the overhaul timing. Decreased compression pressure shows a variety of symptoms and engine
conditions, thus making it difficult to accurately determine when the engine needs an overhaul. The following shows typical
problems caused by reduced compression pressure.
(1) Decreased output power
(2) Increased fuel consumption
(3) Increased engine oil consumption
(4) Increased blow-by gas through the breather due to worn cylinder liners and piston rings (Visually check the blow-by
amount)
(5) Increased gas leakage due to poor seating of inlet and exhaust valves
(6) Difficulty in starting
(7) Increased noise from engine parts
(8) Abnormal exhaust color after warm-up operation
The engine can exhibit these conditions in various combinations. Some of these problems are directly caused by worn engine
parts, while others are not. Phenomena described in items (2) and (6) will result from improper fuel injection volume, fuel
injection timing, worn plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter. The
most valid reason to overhaul an engine is a decrease in compression pressure due to worn cylinder liners and pistons, as
described in item (4). In addition to this item, it is reasonable to take other problems into consideration for making the total
judgement.

4-2
 DETERMINATION OF OVERHAUL

2. Testing compression pressure

&$87,21
Compression gage
(a) Measure all cylinders for compression pressure. P/N:33391-02100
Do not measure only one cylinder and make
assumption about the other cylinders as it will lead
Gage adapter
to a wrong conclusion. P/N:32G91-00500
(b) Compression pressure varies depending on the
engine speed. When measuring the compression
pressure, be sure to measure the engine speed as
well.
(c) It is important to regularly check the compression
pressure so that you can tell the change with time.
Testing compression pressure
(1) Disconnect the harness connector from the injector
solenoid connector.
(2) Disconnect the harness connector from the MPROP
connector on the fuel pump.
(3) Select a cylinder, and remove the injector in the
cylinder. (Each cylinder is tested one at a time.)
(4) Install a gauge adapter in the same location that the
injector was mounted, and install a compression gauge
to the gauge adapter.
(5) Start the engine using starter. With the engine running
at specified speed, read the compression gauge.
(6) If the measured value is at the limit or below, overhaul
the engine.

Item Standard Limit

Engine speed 300 min-1 -
2.6 MPa
2.9 MPa
{27 kgf/cm²}
Compression pressure {30kgf/cm²}
[384 psi]
[427 psi]
or more

4-3
 DISASSEMBLY OF BASIC ENGINE
1. Disassembling and inspecting cylinder
head and valve mechanism ............5-2
1.1 Removing injector .................................... 5-3
1.2 Removing rocker shaft assembly............. 5-4
1.3 Disassembling rocker shaft assembly...... 5-4
1.4 Removing cylinder head bolt.................... 5-4
1.5 Removing cylinder head assembly .......... 5-5
1.6 Removing valve and valve spring ............ 5-5
1.7 Removing valve stem seal ....................... 5-5

2. Disassembling and inspecting

flywheel ...........................................5-6
2.1 Removing flywheel................................... 5-7
2.2 Removing flywheel housing ..................... 5-7

3. Disassembling and inspecting gear

case, timing gear and camshaft ......5-8
3.1 Removing crankshaft pulley..................... 5-8
3.2 Removing timing gear case ..................... 5-9
3.3 Measuring timing gear backlash .............. 5-9
3.4 Measuring idler gear end play.................. 5-9
3.5 Removing idler gear............................... 5-10
3.6 Removing camshaft ............................... 5-10
3.7 Separating camshaft gear...................... 5-10
3.8 Installing camshaft gear and thrust plate 5-11
3.9 Removing front plate.............................. 5-11

4. Disassembling and inspection

crankcase, crankshaft and piston..5-12
4.1 Removing connecting rod cap ............... 5-13
4.2 Removing carbon deposits from the upper part
of cylinder liner....................................... 5-13
4.3 Pulling out piston.................................... 5-13
4.4 Removing piston ring ............................. 5-14
4.5 Removing piston pin .............................. 5-14
4.6 Removing main bearing cap .................. 5-14
4.7 Removing crankshaft ............................. 5-15

5-1
DISASSEMBLY OF BASIC ENGINE

1. Disassembling and inspecting cylinder head and valve mechanism

12
8 6
Wear, damage Wear, clogging

11 Fatigue, damage
Wear
7 Wear, damage,
13 bend
17
10 18
9 Wear, 19 23 14
clogging 20

Fatigue, damage

3
Local wear
4
22

2
1

5 15 Replace

Crack, damage,
Replace water leak, oil leak,
carbon deposit,
scale deposit

16
21
Local wear, damage,
Local wear fatigue, carbon deposit

21

Disassembling and inspecting cylinder head and valve mechanism

Disassembling sequence

1 Leak off hose 9 Eye bolt, oil pipe 17 Valve cap

2 Nozzle ground 10 Snap ring, spacer 18 Valve cotter
3 Injector 11 Rocker arm 19 Valve retainer
4 Rocker cover 12 Rocker shaft spring 20 Valve spring
5 Rocker cover gasket 13 Rocker shaft 21 Valve, valve seat
6 Adjusting screw 14 Cylinder head bolt 22 Valve guide, stem seal
7 Bolt (short) 15 Cylinder head 23 Push rod
8 Bolt (long) 16 Cylinder head gasket

5-2
 DISASSEMBLY OF BASIC ENGINE

1.1 Removing injector

(1) Hold the injection connector by using a spanner, loosen
Leak off hose connector
the injection pipe nut and remove the injection pipe.
(2) With pushing the pin on top of the injector, remove the Injector Leak off hose
leak off hose. Pin
(3) Disconnect the harness connector of main harness and
Nozzle
injector connector.
gland
(4) Using the injector puller, remove the injector and the Injection pipe
nozzle ground at the same time. Injection connector
(5) Remove the gasket from the cylinder head injector
Gasket
insertion opening.
Removing injector

Injector

Push
Pin

Pushing pin on top of injector

Injector puller
P/N:32G91-00100

Injector

Pulling out injector

5-3
DISASSEMBLY OF BASIC ENGINE

1.2 Removing rocker shaft assembly

Adjusting screw
&$87,21
Always loosen shorter bolts first. Failing to do so may
cause the damage to the rocker shaft bracket.
(1) Loosen the rocker arm adjusting screws by rotating
about one turn.
(2) Loosen the shorter rocker bracket bolts first.
Rocker arm
(3) Then, loosen the longer rocker bracket bolts.
(4) Remove the rokcer bracket bolts, and remove the
Rocker bracket bolt
rocker shaft assembly from the cylinder head.
(5) Remove push rods. Removing rocker shaft assembly

1.3 Disassembling rocker shaft assembly

(1) Remove eye bolt, oil pipe, and snap ring.
(2) Disassemble the rocker shaft assembly into the rocker
arms, brakets, rocker shaft springs and rocker shaft.
Rocker shaft spring
Note: (a) Be sure to arrange the parts of rocker shaft
assembly in the order of disassembly. Rocker shaft
Reassemble the rocker shaft assembly in the Oil pipe Bracket
reverse order of disassembly by making sure of Rocker arm
the original combination of rocker arm and shaft
Snap ring
assembly so that the same clearance between the
rocker shaft and arms is restored when Eye bolt

reassembling. Disassembling rocker shaft assembly

(b) Do not remove the rocker bush when it is not
faulty, and its inside diameter is not exceed the
limit.

1.4 Removing cylinder head bolt

Loosen cylinder head bolts in the numerical order as shown
in the illustration.
3 7 11 15 16 12 8 4

1 9 17 10 2

5 13 14 6

Removing cylinder head bolt

5-4
 DISASSEMBLY OF BASIC ENGINE

1.5 Removing cylinder head assembly

&$87,21
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase surface
by tools such as a screwdriver.
(1) Remove the cylinder head bolt.
(2) Remove the cylinder head assembly by lifting it up.
Note: If the cylinder head assembly cannot be removed due
to crimping of the cylinder head gasket, tap the thick
area on the side of the cylinder head using a plastic
hammer to give a shock.
Removing cylinder head assembly
(3) Remove the gasket from the cylinder head.
Note: If there is a cylinder head problem, check the bolts for
tightness with a torque wrench before removing the
cylinder head bolts.

1.6 Removing valve and valve spring

Using a valve spring pusher, compress the valve spring Valve spring pusher
evenly and remove the valve cotters. P/N:30691-04500
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original
positions. Do not mix valve seats with other valve
guides.

Removing valve and valve spring

1.7 Removing valve stem seal

Grab the stem seal with pliers and remove.
Note: Be sure to replace the stem seal with the new one
when reassembling the valve and valve spring.
Stem seal

Removing valve stem seal

5-5
DISASSEMBLY OF BASIC ENGINE

2. Disassembling and inspecting flywheel

Replace

3
Replace 1

2
Wear, damage, aging

Wear, crack, damage

Disassembling and inspecting flywheel

Disassembling sequence

1 Flywheel 3 Oil seal 5 Speed/timing sensor (crankshaft

side), sensor bracket
2 Flywheel housing 4 Pick up

5-6
 DISASSEMBLY OF BASIC ENGINE

2.1 Removing flywheel

&$87,21
Guide bolt
(a) Be careful not to cut yourself with the ring gear
Crankshaft pulley
when pulling out the flywheel.
Be careful not to drop or hit the flywheel when
removing.
(b) The personnel who holds the pulley must pay due
attention to safety.
Also, personnel must stay in close contact with
each other during work. (Front) (Rear)
(1) One personnel must firmly hold the pulley with a
Removing flywheel
wrench to prevent the flywheel from turning.
(2) Remove one bolt from the flywheel.
(3) Screw a guide bolt into the threaded hole of the bolt that
has been removed.
(4) Remove remaining bolts from the flywheel.
(5) Hold the flywheel firmly with both hands, and by
moving it back and forth, pull it out straight.
Note: The ring gear is shrink fitted to the flywheel. Do not
remove the ring gear unless it is defective.

2.2 Removing flywheel housing

&$87,21
Be careful not to damage the oil seal.
(1) Remove bolts from the flywheel housing.
(2) Remove the flywheel housing.

Removing flywheel housing

5-7
DISASSEMBLY OF BASIC ENGINE

3. Disassembling and inspecting gear case, timing gear and camshaft

Damage, wear
Flaking, contact, damage, Oil hole clogging, wear
abnormality
Replace

10

7
6 Wear
9
Wear
4
Wear, damage,
5 8 11 aging

Crack, dowel hole defect,

oil hole clogging

Replace
Wear

2
1

Disassembling and inspecting gear case, timing gear and camshaft

Disassembling sequence

1 Crankshaft pulley 5 Idler gear 9 Tappet

2 Timing gear case 6 Thrust plate 10 Fuel pump gear,
Fuel pump idler gear
3 Oil seal 7 Camshaft
4 Thrust plate 8 Camshaft gear 11 Front plate

3.1 Removing crankshaft pulley

Prevent crankshaft
&$87,21 from rotating
The bar that stops the the crankshaft from turning may
Crankshaft pulley
come off. Pay due attention to safety.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Stick a bar across the guide bolts
to prevent the crankshaft from turning.
(2) Remove the crankshaft pulley.
(3) Take out the woodruff key of the crankshaft. Guide bolt (M12×1.25mm)
(Front) (Rear)

Removing crankshaft pulley

5-8
 DISASSEMBLY OF BASIC ENGINE

3.2 Removing timing gear case

&$87,21 Timing gear case

The front plate is bolted to the crankcase from inside
the gear case. Do not attempt to remove the front plate
together with the gear case by tapping.
(1) Remove bolts from the timing gear case.
(2) Remove the timing gear case.
Note: Bolts have different lengths. Pay attention to the
positions of bolts to ensure correct reassembling. Gasket

Removing timing gear case

3.3 Measuring timing gear backlash

Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the
dial gauge plunger applied to a tooth flank on the pitch
circle at a right angle to the tooth axis, or measure the
clearance between gears by inserting a feeler gauge between
the gears at the tooth-to-tooth contacting area. Replace the
faulty gear pair if the limit is exceeded.

Item Standard Limit

Backlash crankshaft gear and
idler gear
Backlash camshaft gear and
idler gear
0.053 to 0.154 mm 0.25 mm
[0.0021 to 0.0061 in.] [0.0098 in.]
Measuring timing gear backlash
0.049 to 0.160 mm 0.25 mm
[0.0019 to 0.0063 in.] [0.0098 in.]

Backlash Fuel injection pump 0.050 to 0.228 mm 0.25 mm

idler gear and idler gear [0.0020 to 0.0090 in.] [0.0098 in.]

Backlash fuel injection pump

0.044 to 0.163 mm 0.25 mm
idler gear and fuel injection
[0.0017 to 0.0064 in.] [0.0098 in.]
pump gear

Note: With the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump, install
the both gears to the front plate.

3.4 Measuring idler gear end play

Using a feeler gauge or dial gauge, measure the end play of
idler gear.
If the measured value exceeds the limit, replace the idler
gear with the new gear.

Item Standard Limit

0.05 to 0.20 mm 0.35 mm
End play
[0.0020 to 0.0079 in.] [0.0138 in.]
Idler gear

Measuring idler gear end play

5-9
DISASSEMBLY OF BASIC ENGINE

3.5 Removing idler gear

(1) Remove the thrust plate bolt.
(2) Remove the idler gear while turning the gear.
Idler gear

Thrust plate

Removing idler gear

3.6 Removing camshaft

&$87,21
Be careful not to damage the cams of camshaft and
the bushings. Camshaft gear

(1) Reverse the crankcase.

(2) Remove the thrust plate bolt.
(3) Remove the camshaft from the crankcase.
(4) Remove the tappet.

Removing camshaft

3.7 Separating camshaft gear

Using a puller, remove the camshaft gear and thrust plate Puller
from the camshaft. P/N: 64309-12900
Note: Do not remove the camshaft gear from the camshaft Camshaft gear
unless the camshaft gear or the thrust plate is
defective.

Separating camshaft gear

5-10
 DISASSEMBLY OF BASIC ENGINE

3.8 Installing camshaft gear and thrust plate

(1) Install the woodruff key and the thrust plate on the
crankshaft.
Note: Be sure to install the thrust plate before installing the
camshaft gear.
(2) Heat the camshaft gear with a gear heater to a
temperature of about 250°C [482°F].
Thrust plate
(3) Install the camshaft gear into the crankcase by tapping
with a plastic hammer. Camshaft gear

Installing camshaft gear and thrust plate

3.9 Removing front plate

(1) Remove the front plate bolts.
(2) Remove the front plate from the crankcase. Front plate
Note: If it is difficult to remove the front plate, lightly tap it
with a plastic hammer.

Removing front plate

5-11
DISASSEMBLY OF BASIC ENGINE

4. Disassembling and inspection crankcase, crankshaft and piston

Wear, scratch, rust

4
Wear, damage
5 Top surface distortion
6 Fatigue
9
Wear Scratch, crack, damage, Scale deposit,
wear, carbon deposit corrosion, flaking
8
7

Wear, crack,
oil hole clogging
19
Wear, oil hole
clogging

10
Damage

3 17
18
Wear, seizure,
flaking, damage
Scratch, crack, dent,
2 Clogging oil hole clogging, wear

1
16

Flaking,
14
local contact 15

Replace

12 13

Scratch, seizure,
flaking Damage
11

Crack

Disassembling and inspection crankcase, crankshaft and piston

Disassembling sequence

1 Nut 8 Piston pin 15 Main bearing (lower)

2 Connecting rod cap 9 Piston 16 Crankshaft
3 Connecting rod bearing 10 Connecting rod 17 Main bearing (upper)
4 No.1 compression ring 11 Main bearing cap bolt 18 Piston cooling nozzle
5 No.2 compression ring 12 Main bearing cap 19 Crankcase
6 Oil ring 13 Side seal
7 Snap ring 14 Thrust plate

5-12
 DISASSEMBLY OF BASIC ENGINE

4.1 Removing connecting rod cap

(1) Lay the engine by its side.
(2) Mark the cylinder number on the connecting rod and Connecting rod cap
connecting rod cap so that their combination is not
changed when reassembling.
(3) Remove the connecting rod caps.
Note: Mark the cylinder No. and upper/lower on connecting
rod bearings to ensure correct reassembling.

Removing connecting rod cap

4.2 Removing carbon deposits from the upper

part of cylinder liner

&$87,21
Be sure to remove carbon deposits from the upper part
of the cylinder liner before removing the piston, as they
could cause damage to the piston and piston ring.
Remove carbon deposits from the upper part of cylinder
liner using a cloth or oil paper.
Note: Be careful not to damage the inner surface of the
cylinder liner.

Removing carbon deposit from cylinder sleeve upper

area

4.3 Pulling out piston

(1) Turn the crankshaft to bring the piston to the top dead
center.
(2) Using a piece of wood such a hammer handle, push the
mating surface of the connecting rod cap, and pull the
piston and connecting rod upward from the cylinder.

Pulling out piston

5-13
DISASSEMBLY OF BASIC ENGINE

4.4 Removing piston ring

Remove the piston rings using piston ring pliers. Piston ring pliers
P/N:30091-07100

Removing piston ring

4.5 Removing piston pin

(1) Using snap ring pliers, remove the snap ring.
(2) Remove the piston pin, and separate the piston from the
connecting rod. Snap ring pliers
Note: Heat the piston with a piston heater or in hot water if
the piston pin is stubborn.

Removing piston pin

4.6 Removing main bearing cap

(1) Reverse the engine.
Sliding hammer
(2) Remove the main bearing cap bolt.
(3) Remove the main bearing cap together with the lower
main bearing.
Use a sliding hammer to remove main bearing caps on
the front and rear ends.
Main bearing
Note: (a) Be careful not to damage main bearings. cap bolt
(b) Mark each main bearing for its cylinder number.

Removing main bearing cap

5-14
 DISASSEMBLY OF BASIC ENGINE

4.7 Removing crankshaft

&$87,21
Be careful not to damage bearings when removing the
crankshaft.
(1) Slowly lift the crankshaft straight up.
(2) Arrange the bearings in the order of disassembly so that
their original positions are restored when reassembling.
Note: (a) When raising the crankshaft, do not allow wire
chain to come into contact with the crankshaft.
To avoid damage to the crankshaft when raising,
use a cloth belt or pad.
Removing crankshaft
(b) Mark the bearings for their cylinder numbers.

5-15
 INSPECTION AND REPAIR OF BASIC ENGINE
1. Inspecting and repairing cylinder head
and valve mechanism .....................6-2
1.1 Measuring clearance between rocker
bushing and rocker shaft.......................... 6-2
1.2 Replacing rocker bushing ........................ 6-2
1.3 Measuring valve stem outside diameter and
valve guide inside diameter ..................... 6-3
1.4 Replacing valve guide.............................. 6-3
1.5 Inspecting valve face ............................... 6-4
1.6 Refacing valve face.................................. 6-4
1.7 Refacing valve seat.................................. 6-5
1.8 Replacing valve seat................................ 6-6
1.9 Lapping valve and valve seat................... 6-7
1.10 Measuring perpendicularity and free length of
valve spring.............................................. 6-7
1.11 Measuring distortion of the bottom surface of
the cylinder head...................................... 6-8
1.12 Measuring push rod runout ...................... 6-8
2. Inspecting and repairing flywheel ....6-9
2.1 Measuring flatness of flywheel................. 6-9
2.2 Measuring flywheel face and
radial runouts ........................................... 6-9
2.3 Inspecting ring gear ................................. 6-9
2.4 Replacing ring gear.................................. 6-9
2.4.1 Removing ring gear ....................................6-9
2.4.2 Installing ring gear ......................................6-9
3. Inspecting and repairing timing gear and
camshaft........................................6-10
3.1 Measuring timing gear backlash ............ 6-10
3.2 Measuring cam lift.................................. 6-10
3.3 Measuring camshaft runout ................... 6-10
3.4 Measuring camshaft journal outside
diameter ................................................. 6-11
3.5 Measuring camshaft bushing inside
diameter ................................................. 6-11
3.6 Replacing camshaft bushing.................. 6-11
3.6.1 Removing camshaft bushing ....................6-11
3.6.2 Installing camshaft bushing ......................6-12
3.7 Measuring front idler bushing inside dia. and
front idler shaft outside diameter............ 6-12
3.8 Replacing idler bushing.......................... 6-13
3.9 Replacing idler shaft .............................. 6-13
3.10 Inspecting tappet.................................... 6-13
3.11 Measuring clearance between tappet and
tappet guide hole ................................... 6-14
4. Inspecting and repairing piston,
connecting rod, crankshaft and
crankcase ..................................... 6-15
4.1 Measuring crankcase top surface
distortion................................................. 6-15
4.2 Measuring cylinder inside diameter........ 6-16
4.3 Replacing cylinder sleeve ...................... 6-17
4.3.1 Removing cylinder sleeve........................ 6-17
4.3.2 Installing cylinder sleeve.......................... 6-17
4.4 Measuring piston outside diameter ........ 6-18
4.5 Measuring piston ring end gap............... 6-18
4.6 Measuring clearance between piston ring
groove and piston ring............................ 6-19
4.7 Measuring piston pin bore diameter and piston
pin outside diameter............................... 6-19
4.8 Measuring piston protrusion................... 6-20
4.9 Measuring clearance between connecting rod
bearing and crankpin.............................. 6-21
4.10 Measuring clearance between connecting rod
bushing and piston pin ........................... 6-21
4.11 Replacing connecting rod bushing ......... 6-22
4.12 Removing connecting rod bushing......... 6-22
4.13 Installing connecting rod bushing........... 6-22
4.14 Inspecting connecting rod bend and twist6-23
4.15 Inspecting connecting rod bearing ......... 6-23
4.16 Measuring connecting rod end play ....... 6-24
4.17 Weight difference of connecting rod assembly
in one engine.......................................... 6-24
4.18 Measuring crankshaft journal outside
diameter ................................................. 6-24
4.19 Measuring crankshaft crankpin outside
diameter ................................................. 6-25
4.20 Grinding crankshaft ................................ 6-25
4.21 Measuring crankshaft end play .............. 6-26
4.22 Measuring crankshaft runout.................. 6-26
4.23 Replacing crankshaft gear ..................... 6-27
4.23.1 Removing crankshaft gear....................... 6-27
4.23.2 Installing crankshaft gear......................... 6-27
4.24 Replacing front oil seal........................... 6-28
4.25 Replacing rear oil seal............................ 6-28
4.26 Inspecting main bearing surface ............ 6-29
4.27 Measuring clearance between main bearing
and crankshaft journal............................ 6-29
6-1
INSPECTION AND REPAIR OF BASIC ENGINE

1. Inspecting and repairing cylinder head and valve mechanism

1.1 Measuring clearance between rocker
bushing and rocker shaft
Measure the rocker bushing inside diameter and the rocker
shaft diameter. If the clearance exceeds the limit, replace
either rocker bushing or rocker shaft with a new one.
Measuring
Item Nominal Standard Limit directions

Rocker bushing ø 20 mm 20.011 to 20.094 mm

-
inside diameter [0.7874 in.] [0.7878 to 0.7911 in.]
Measuring
Rocker shaft ø 20 mm 19.966 to 19.984 mm points
-
diameter [0.7874 in.] [0.7861 to 0.7868 in.]

Clearance
between rocker 0.027 to 0.128 mm 0.150 mm Measuring rocker bushing and rocker shaft
-
bushing and [0.0011 to 0.0050 in.] [0.0059 in.]
shaft

1.2 Replacing rocker bushing

To replace rocker bushings, use a hydraulic jack.
Rocker bush installer
With the rocker bushing and the rocker arm oil holes mated,
and the bushing joint faced upward, press fit the rocker
bushing. Oil hole

Replacing rocker bushing

6-2
 INSPECTION AND REPAIR OF BASIC ENGINE

1.3 Measuring valve stem outside diameter and

valve guide inside diameter
Measure the diameter at the top and bottom ends at right Measuring
angles to the outer and inner surfaces, since valve stems and directions
valve guides are more likely to wear at both ends. If the
outside diameter is less than the limit, or the clearance
exceeds the limit, replace either the valve or the valve guide
with a new one. Measuring
points
Item Nominal Standard Limit

Valve ø 8 mm 7.940 to 7.955 mm 7.900mm

Inlet
stem [0.315 in.] [0.3126 to 0.3132 in.] [0.3110 in.]
Measuring valve stem outside diameter
outside ø 8 mm 7.920 to 7.940 mm 7.850 mm
diameter Exhaust
[0.315 in.] [0.3118 to 0.3126 in.] [0.3091 in.]
Measuring
Clearance 0.055 to 0.085 mm 0.150 mm directions
Inlet -
between [0.0022 to 0.0033 in.] [0.0059 in.] Internal micrometer
valve stem
and valve 0.070 to 0.105 mm 0.200 mm
Exhaust -
guide [0.0028 to 0.0041 in.] [0.0079 in.]

Valve guide mount- 17 mm 17.2 to 17.4 mm

-
ing dimension [0.67 in.] [0.6772 to 0.6850 in.]

Measuring
points

Measuring valve guide inside diameter

1.4 Replacing valve guide
Valve guide remover
&$87,21 P/N:31391-10500
Because valve guides must be inserted to the speci-
fied amount, be sure to use a valve guide installer.
(1) To remove valve guides, use a valve guide remover.

Removing valve guide

(2) To press-fit valve guides, use a valve guide installer.
(3) Check contacts between valves and valve seats after
17 mm [0.67 in.]

Press Valve guide installer

replacing valve guides. P/N:34491-00400

Press-fitting valve guide

6-3
 INSPECTION AND REPAIR OF BASIC ENGINE

1.5 Inspecting valve face

Apply a thin coat of Shinmyoutan or equivalent lead-free
coloring paste on the valve face, and strike the valve face
against the valve seat using a valve lapper to check for
contact condition. If the contact is not even, or any defects
Valve lapper
are found, or if the limit is exceeded, reface or replace the
valve.
Note: (a) Inspect the valve face after the valve guide is
repaired or replaced.
(b) Do not rotate the valve when pressing the valve Shinmyoutan
face coated with Shinmyoutan or equivalent lead-
free dye against the valve seat. Inspecting valve face
(c) Always lap the valve and valve seat after the
valve has been refaced or replaced.

Item Standard Limit

Valve seat angle 30° -

0.4 ± 0.1 mm
Inlet
Valve [0.0157 ± 0.0039 in.] 1.1 mm
Valve
sinkage 0.5 ± 0.1 mm [0.043 in.]
seat Exhaust
[0.0197 ± 0.0039 in.]
Good Bad
1.4 ± 0.2 mm 1.8 mm
Seat width
[0.0551 ± 0.0079 in.] [0.071 in.]

Refacing permissi-
2.13 mm Contact between valve seat and valve
Valve margin ble up to 1.2 mm
[0.0839 in.]
[0.047 in.]

Seat width

Valve margin
Valve seat
Valve sinkage
angle

Measuring positions of valve seat and valve

1.6 Refacing valve face
If the valve face is significantly worn out, reface the valve Valve refacer
face using a valve refacer.
Note: (a) Grind the valve face using the valve refacer at the
specified angle.
(b) Secure the valve margin width equal to or greater
than the limit. If the dimensions after refacing
does not meet the specified values, replace the Set the valve face
valve with a new one. angle at the specified
angle.

Refacing valve face

6-4
 INSPECTION AND REPAIR OF BASIC ENGINE

1.7 Refacing valve seat

(1) Use the valve seat cutter or valve seat grinder to reface
the valve seat. After refacing, sand the valve seat lightly
using 400 grit sandpaper, inserting it between the cutter
and valve seat.
(2) Lap the valve in the valve seat.
Note: (a) Valve seat refacing should be kept to an absolute
minimum.
(b) If the valve seat width exceeds the limit due to
wear or refacing, replace the valve seat with a
new one.
(c) If the valve sinkage exceeds the limit after Refacing valve seat
refacing, replace the valve seat with a new one.

6-5
INSPECTION AND REPAIR OF BASIC ENGINE

1.8 Replacing valve seat

(1) To remove the valve seat, weld a stud to the valve seat
as illustrated. Then, insert a rod into the valve guide
Weld
hole from the top of the cylinder head, and press out the
Shaft
valve seat with the rod.
Note: Be careful not to allow spatters to adhere to the Valve seat
machined surface of the cylinder head during
welding.
(2) Before inserting a new valve seat, measure the cylinder
head bore diameter and valve seat outside diameter to Stud

make sure the interference meets the specified value.

(3) Cool the valve seat for four minutes or more in liquid Removing valve seat
nitrogen (at approximately -170°C [-274°F]) before
fitting it into the cylinder head, while keeping the Inlet Exhaust Unit: mm [in.]
cylinder head at room temperature. Or heat the cylinder

4
head to 80 to 100°C [176 to 212°F] and cool the valve
seat sufficiently in ether or alcohol mixed with dry ice
before fitting it into the hot cylinder head.
(4) Fit the cold valve seat into the cylinder head using a
insert caulking tool.
9 ± 0.1 9.5 ± 0.1
[0.3543 ± 0.0039] [0.3740 ± 0.0039]

40° 45°
ø 48 +0.025
0 [ø 1.89 +0.0010
0 ] ø 39 +0.025
0 [ø 1.54 +0.0010
0 ]

Valve seat fitting bore

Insert caulking tool

(In)P/N:36791-00200
(Ex)P/N:36791-00300

Installing valve seat

6-6
 INSPECTION AND REPAIR OF BASIC ENGINE

1.9 Lapping valve and valve seat

Always lap the valve against the valve seat after refacing the
valve seat or after replacing the valve.
(1) Apply a thin coat of lapping compound evenly to the
valve face.
Note: (a) Do not allow the compound to adhere on the
valve stem.
(b) Compound spreads more evenly if it is mixed Compound
with a small amount of engine oil.
(c) Use medium-grain compound (120 to 150 mesh)
for initial lapping, then use fine-grain compound
(200 mesh or finer) for finishing. Coating valve with lapping
(2) Use a valve lapper for lapping. Strike the valve against
the valve seat while rotating the valve little by little.
(3) Wash off the compound using diesel fuel.
(4) Coat the contact surface of the valve with engine oil,
then lap the valve again.
(5) Check valve-to-seat contact.

Lapping valve and valve seat

1.10 Measuring perpendicularity and free length
of valve spring
Measure the perpendicularity and free length of the valve
spring. If the limit is exceeded, replace the valve spring with
Spring perpendicularity (gap)
a new one.

Item Standard Limit

56.40 mm 55.00 mm Free length
Free length
[2.2205 in.] [2.1653 in.]

θ = 2.0°or
less
ǰ Less than Entire length
Perpendicu- ٌ
Δ2.0 mm Δ = 2.0mm Measuring spring perpendicularity and free length
larity Lf
[0.079 in.] [0.079 in.]
Lf = 56.40 mm
[2.2205 in.]

44 mm
44 mm [1.73 in.]
[1.73 in.]
Set length/ /222.7 to 246.1 N
/207 N
set force {22.7 to 25.1 kgf}
{21.2 kgf}
[164.2 to 181.5 lbf]
[153 lbf]

6-7
INSPECTION AND REPAIR OF BASIC ENGINE

1.11 Measuring distortion of the bottom surface

of the cylinder head

&$87,21
Refacing of cylinder head should be kept to an abso-
lute minimum.
Excessive grinding of the cylinder head may result in
defects such as defective combustion and stamping
(contact between piston and valve).
With a straight edge placed on the bottom face of the
cylinder head, measure the bottom face distortion using a
feeler gauge. If the measurement exceeds the limit, grind the
Measuring distortion of cylinder head bottom surface
bottom face using a surface grinder.

Item Standard Limit

Bottom surface 0.05 mm 0.20 mm
distortion [0.0020 in.] or less [0.008 in.]

Note: Do not grind the surfaces more than 0.2 mm [0.008

in.] in total (cylinder head bottom surface plus
crankcase top surface).

1.12 Measuring push rod runout

Measure the runout of each push rod. Replace if the limit is
exceeded.

Item Standard Limit Remark

Pushrod
Push 0.4 mm
0.4 mm
rod [ 0.016 in.] TIR
[0.016 in.]
runout or less
1/2L 1/2L

Measuring push rod runout

6-8
 INSPECTION AND REPAIR OF BASIC ENGINE

2. Inspecting and repairing flywheel

2.1 Measuring flatness of flywheel
Place the flywheel on a surface plate and move a dial gauge
on the friction surface of the flywheel to measure the
flatness.
Grind the friction surface of the flywheel if the limit is
exceeded.

Item Standard Limit

0.15 mm 0.50 mm
Flywheel flatness
[0.0059 in.] or less [0.0197 in.]

Measuring flatness of flywheel

2.2 Measuring flywheel face and radial runouts
Measure the runouts of the flywheel in the installed
condition. If the measured value exceeds the standard,
check the bolt for looseness as well as the accumulation of
foreign matter on the mounting face.
Face runout
measuring point
Item Standard Limit
Radial runout
Flywheel face runout Within 0.15 mm 0.50 mm measuring point
and radial runout [0.0059 in.] [0.0197 in.]

Measuring flywheel face and radial runout

2.3 Inspecting ring gear

Inspect the ring gear for a missing tooth or worn teeth, and
if defects are found, replace the ring gear.

2.4 Replacing ring gear

2.4.1 Removing ring gear
(1) Heat the ring gear evenly using an acetylene torch or
other appropriate heat source.
(2) With a rod placed on the periphery of ring gear, tap the Flywheel
rod with a hammer evenly around the ring gear, and
remove the ring gear.

2.4.2 Installing ring gear

(1) Heat the ring gear evenly up to approx. 150°C [176°F] Ring gear
with an appropriate heater.
(2) Install the ring gear onto the flywheel with the no-gear- Removing ring gear
chamfering side faced to the flywheel.
Note: Do not heat the ring gear excessively.

6-9
INSPECTION AND REPAIR OF BASIC ENGINE

3. Inspecting and repairing timing gear and camshaft

3.1 Measuring timing gear backlash
Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the
dial gauge plunger applied to a tooth flank on the pitch
circle at a right angle to the tooth axis, or measure the
clearance between gears by inserting a feeler gauge between
the gears at the tooth-to-tooth contacting area. Replace the
faulty gear pair if the limit is exceeded.

Item Standard Limit

Backlash crankshaft gear and 0.053 to 0.154 mm 0.25 mm
idler gear [0.0021 to 0.0061 in.] [0.0098 in.]
Measuring timing gear backlash
Backlash camshaft gear and 0.049 to 0.160 mm 0.25 mm
idler gear [0.0019 to 0.0063 in.] [0.0098 in.]

Backlash Fuel injection pump 0.050 to 0.228 mm 0.25 mm

idler gear and idler gear [0.0020 to 0.0090 in.] [0.0098 in.]

Backlash fuel injection pump

0.044 to 0.163 mm 0.25 mm
idler gear and fuel injection
[0.0017 to 0.0064 in.] [0.0098 in.]
pump gear

Note: With the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump, install
the both gears to the front plate.

3.2 Measuring cam lift

Measure the minor and major axes of cam to determine cam Major axis
lobe lift. If the lift is less than the limit, replace the camshaft
Minor
with a new one.
Measuring Measuring
Item Nominal Standard Limit directions points
Major axis Major axis – Major axis –
+0.1 Minor axis Minor axis
Inlet 46.911 -0.3 mm
+0.004
= 6.689 mm = 6.189 mm
[1.8469 -0.012 in.] [0.2633 in.] [0.2437 in.]
Cam
lift Major axis – Major axis –
Major axis
+0.1 Minor axis Minor axis
Exhaust 46.256 -0.3 mm
+0.004
= 6.229 mm = 5.729 mm
[1.8211 -0.012 in.] [0.2452 in.] [0.2256 in.] Measuring cam lift

3.3 Measuring camshaft runout

Measure the camshaft runout using a dial gauge. If the limit
is exceeded, correct the camshaft using a press, or replace
the camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the
camshaft one turn and read the gauge indication.

Item Standard Limit Remark

0.04 mm 0.10 mm
Camshaft runout TIR
[0.016 in.] or less [0.0039 in.]

Measuring camshaft runout

6-10
 INSPECTION AND REPAIR OF BASIC ENGINE

3.4 Measuring camshaft journal outside diame-

ter Measuring
Measure the diameter of each camshaft journal in two points
direction at right angles to each other. If the limit is
exceeded, replace the camshaft with a new one.

Measuring
Item Standard Limit directions
Front, 53.94 to 53.96 mm 53.90 mm
Camshaft journal Middle [2.1236 to 2.1244 in.] [2.1220 in.]
outside diameter 52.94 to 52.96 mm 52.90 mm
Rear
[2.0842 to 2.0850 in.] [2.0827 in.]

Measuring camshaft journal outside diameter

3.5 Measuring camshaft bushing inside diame-

ter Measuring
With the camshaft bushings installed in the crankcase, directions
measure the inside diameters using a cylinder gauge. If the
limit is exceeded, replace the bushing with a new one.

Item Standard Limit

Clearance between Front, 0.04 to 0.09 mm

camshaft journal Middle [0.0016 to 0.0035 in.] 0.15 mm
and camshaft 0.04 to 0.119 mm [0.0059 in.]
bushing Rear
[0.0016 to 0.0047 in.]

Measuring camshaft bushing inside diameter

3.6 Replacing camshaft bushing

3.6.1 Removing camshaft bushing Adapter
(1) Install a camshaft bushing installer set to the camshaft Bushing

bushing.
(2) Remove the camshaft bushing by tapping the end of the
rod of camshaft bushing installer set.

Camshaft bushing
installer set Rod
P/N:30691-00010

Removing camshaft bushing

6-11
INSPECTION AND REPAIR OF BASIC ENGINE

3.6.2 Installing camshaft bushing

(1) Install the camshaft bushing to a camshaft bushing Piece Bushing
installer set. Adapter
(2) When driving in a bushing, tap the end of rod of
camshaft bushing installer set so that the oil hole in the
bushing aligns with the oil hole to the oil gallery.

Camshaft bushing Rod

installer set Oil hole
P/N:30691-00010

Installing camshaft bushing

3.7 Measuring front idler bushing inside dia.

and front idler shaft outside diameter
Measure the front idler bushing inside diameter and the
front idler shaft outside diameter. If the inside diameter of
front idler bushing exceeds the limit, replace the front idler
bushing with a new one. If the outside diameter of front
idler shaft is less than the limit, replace the front front idler
shaft with a new one.

Item Standard Limit

Clearance between 0.009 to 0.050 mm 0.100 mm
idler bushing and idler shaft [0.0004 to 0.0020 in.] [0.0039 in.]

6-12
 INSPECTION AND REPAIR OF BASIC ENGINE

3.8 Replacing idler bushing

(1) Use the idler bushing puller to replace idler bushing.
(2) To install the bushing, drive it from the boss side so that Idler bushing puller
it is flush with the gear boss face. P/N:30091-07300
(3) After installing the bushing, measure the bushing inside
diameter, and if the inside diameter exceeds the
standard, ream the bushing.

Removing Installing

Replacing idler bushing

Idler gear Idler gear bushing

1 mm
[0.039 in.]

Idler bushing press fitting dimension

3.9 Replacing idler shaft
To remove the idler shaft, use the idler shaft puller. Idler shaft puller
Note: When installing the idler shaft into the crankcase, P/N:MH061077
orient the idler shaft so that its oil hole faces the upper
crankcase.

Removing idler shaft

3.10 Inspecting tappet
Inspect the cam contact surface of the tappets. Fit new
tappets if the surface is excessively worn or damaged.

Good Bad Bad

Tappet surface in contact with camshaft

6-13
INSPECTION AND REPAIR OF BASIC ENGINE

3.11 Measuring clearance between tappet and

tappet guide hole Measuring Measuring
Measure clearance between the tappet and tappet hole. points directions
Replace the tappet with a new one if the limit is exceeded.

Item Standard Limit

Tappet hole 22.000 to 22.021 mm 22.10 mm
inside diameter [0.8661 to 0.8670 in.] [0.8701 in.]

Clearance between tappet 0.035 to 0.086 mm 0.12 mm

and tappet hole [0.0014 to 0.0034 in.] [0.0047 in.]

Measuring clearance between tappet and tappet guide

hole

6-14
 INSPECTION AND REPAIR OF BASIC ENGINE

4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase

4.1 Measuring crankcase top surface distor-
tion

&$87,21
Refacing of cylinder head should be kept to an abso-
lute minimum.
Excessive grinding of the cylinder head may result in
defects such as defective combustion and stamping
(contact between piston and valve).
Apply a straight edge to the top surface of the crankcase and
measure its distortion using a feeler gauge. If the distortion
exceeds the limit, grind the cylinder head using a surface
Measuring distortion of crankcase top surface
grinder.
Note: Do not overgrind the cylinder head, as the piston
protrusion deviates from the standard value.

Item Standard Limit

Distortion of crankcase 0.05 mm 0.20 mm
top surface [0.0020 in.] or less [0.008 in.]

Note: Do not grind the surfaces more than 0.2 mm

[0.008 in.] in total (cylinder head bottom surface plus
crankcase top surface).

6-15
INSPECTION AND REPAIR OF BASIC ENGINE

4.2 Measuring cylinder inside diameter

(1) Measure the inside diameter of the cylinder at three Measuring
directions
levels, i.e., upper (with much stepped wear), middle,

11 [0.43]
and lower levels, in both directions parallel to and

65 [2.56]
perpendicular to the crankshaft direction.

150 [5.91]
(2) If the measurement is between the repair limit and
replacement limit, re-bore the cylinder to +0.25 mm
[0.0098 in.] or +0.5 mm [0.0197 in.] oversize. Hone the
re-bored cylinder to the accuracy of the standard. Measuring
points
(3) Use an oversize piston and piston rings to fit the re-
Unit: mm [in.]
bored cylinder.
(4) If the cylinder is worn unevenly, select an oversize that Measuring cylinder sleeve inside diameter
ensures complete cylindericity when the cylinder is re-
bored to the maximum. All cylinders must be re-bored
to the same oversize if one cylinder is re-bored.
(5) If the cylinder has a slight wear and is reused after
replacing only the piston rings, remove the steps in
worn portion in the upper part of the cylinder using a
ridge reamer. Hone it as necessary.

Item Standard Limit

Repair limit:
Cylinder sleeve 102.010 to 102.045 mm 102.200 mm [4.0236 in.]
inside diameter [4.0161 to 4.0175 in.] Replacement limit:
102.700 mm [4.0433 in.] Refacing using a ridge reamer
0.01mm
Roundness -
[0.0004 in.] or less

0.015 mm
Cylindericity -
[0.0006 in.] or less

Note: The roughness of cylinder sleeve inner surface is

Ra 6.3 µm [0.248 µ in.]

6-16
 INSPECTION AND REPAIR OF BASIC ENGINE

4.3 Replacing cylinder sleeve

If the inside diameter of a cylinder sleeve exceeds the limit 0.5 mm [0.020 in.]
or a clinder is found defective, replace the cylinder sleeve
only, provided that the defective cylinder has no effects on
the other cylinders.
4.3.1 Removing cylinder sleeve
(1) Set up a boring machine on the crankcase by aligning it
with the center of the less-worn area of the sleeve at the
bottom.
(2) Bore the sleeve until its stock thickness becomes
approximately 0.5 mm [0.020 in.].
(3) Carefully break and remove the sleeve, taking care not Boring cylinder sleeve
to cause damage to the inside surface of crankcase.

Removing cylinder sleeve

4.3.2 Installing cylinder sleeve
(1) Use a cylinder sleeve installer to install a sleeve. Sleeve installer
(2) Put the sleeve into the crankcase, leaving a protrusion P/N:34291-00200
of 0.3 to 0.5 mm [0.012 to 0.020 in.] at the top. Then
make it flush with the crankcase top.
(3) Bore and hone the sleeve to the specified diameter.

Installing cylinder sleeve

6-17
INSPECTION AND REPAIR OF BASIC ENGINE

4.4 Measuring piston outside diameter

(1) Measure the piston outside diameter of the piston skirt
at right angles to the piston pin. If it is less than the
limit, replace the piston with a new piston. When
replacing piston, be sure to select a piston so that the Measuring point
piston weight difference in one engine is kept within
the permissible range.

Measuring piston outside diameter

(2) The piston weight is stamped on the top of piston head.

Weight stamp Number stamp

Item Standard Limit
(The prefix letter "F"
101.915 to 101.945 mm 101.730 mm and the last five
STD
[4.0124 to 4.0136 in.] [4.0051 in.] digits of part number)
Piston
outside 102.165 to 102.195 mm 101.980 mm F
0.25 OS
diameter [4.0222 to 4.0234 in.] [4.0150 in.]
(iskirt) Front mark
102.415 to 102.445 mm 102.230 mm
0.50 OS
[4.0321 to 4.0333 in.] [4.0248 in.]

Weight difference per

5g [0.2 oz.] or less -
piston

Piston weight stamp location

4.5 Measuring piston ring end gap

Place the piston ring in a gauge or a new sleeve to measure Gauge inside diameter:
the ring end gap. If the limit is exceeded, replace all the ø 101.5 +0.045
+0.010 mm

rings as a set. [ø 4 +0.0018

+0.0004 in.]

Note: Use a piston to push the piston ring squarely into the
gauge or the sleeve. Piston ring
Feeler gauge

Item Standard Limit

Compres- 0.30 to 0.45 mm
Piston sion ring [0.0118 to 0.0177 in.] 1.50 mm
ring
0.30 to 0.50 mm [0.0591 in.]
end gap Oil ring
[0.0118 to 0.0197 in.]
Measuring piston ring end gap

6-18
 INSPECTION AND REPAIR OF BASIC ENGINE

4.6 Measuring clearance between piston ring

groove and piston ring
Piston
&$87,21 Feeler gauge
Remove carbon deposits from pistons and check the
entire circumference of the piston.
(1) Remove deposits such as carbon from each ring groove. Straight edge
(2) Check each ring groove for wear or damage. If it is Piston ring

worn or damaged, replace the piston with a new one.

(3) Insert the piston ring into the piston ring groove. Apply
a straight edge and insert thickness gauges to measure
the clearance between ring and ring groove.
Measuring clearance between piston ring groove and
If the limit is exceeded, replace the piston ring with a piston ring
new one.
(4) When the piston ring has been replaced, measure the
clearance again, and if the limit is exceeded, then
replace the piston with a new one.

Item Standard Limit

No.1 com- 0.08 to 0.12 mm 0.200 mm
pression [0.0031 to 0.0047 in.] [0.0079 in.]
Clearance
between pis- No.2 com- 0.08 to 0.12 mm 0.150 mm
ton ring and pression [0.0031 to 0.0047 in.] [0.0059 in.]
ring groove
0.025 to 0.065 mm 0.150 mm
Oil
[0.0010 to 0.0026 in.] [0.0059 in.]

4.7 Measuring piston pin bore diameter and

piston pin outside diameter
Measure the piston pin bore diameter and piston pin outside
diameter. Replace if the limit is exceeded.

Item Nominal Standard Limit

Piston pin
outside
ø 34 mm 33.991 to 33.997 mm
- Measuring points Measuring directions
[1.34 in.] [1.3382 to 1.3385 in.]
diameter

Clearance
between piston 0.005 to 0.021 mm 0.050 mm
-
pin bore and [0.0002 to 0.0008 in.] [0.0020 in.]
piston pin
Measuring piston pin bore and piston pin

6-19
INSPECTION AND REPAIR OF BASIC ENGINE

4.8 Measuring piston protrusion

&$87,21
Piston protrusion must always meet the standard, as
the amount of protrusion not only influences on the
engine performance, but also it is important to prevent
valve interference.
Measure the protrusion of each piston following the
instructions below. If the measured value does not meet the
standard, inspect the clearances between various parts
involved.
(1) Bring the piston to the top dead center.
Measuring piston protrusion
(2) Apply the dial gauge plunger to the top surface of the
crankcase, and zero the dial gauge.
(3) Measure the protrusion at four points on the piston
head, and calculate the mean value.
Note: Subtract the mean value from the thickness of the
gasket compressed by tightening the cylinder head,
and the clearance between the piston top and cylinder
head will be determined.

Item Standard
0.8 mm
Piston protrusion
[0.031 in.]
Compressed thickness of 1.7 ± 0.05 mm
cylinder head gasket [0.067 ± 0.0020 in.]

6-20
 INSPECTION AND REPAIR OF BASIC ENGINE

4.9 Measuring clearance between connecting

rod bearing and crankpin Connecting rod cap
tightening torque
&$87,21 Measuring Measuring
103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
When grinding crank pins, be sure to grind all the pins directions points
[76 ± 3.6 lbf·ft]
to the same size.
Finish the fillet radius to the specified dimension.
(1) Reassemble the bearing into the big end of the
connecting rod.
(2) Tighten the connecting rod cap bolts to the specified
torque.
(3) Measure the inside diameter of the connecting rod
Measuring connecting rod bearing inside diameter
bearing.
(4) Measure the outside diameter of the crank pin.
(5) Calculate the clearance from the difference between the
inside diameter of the connecting rod bearing and
outside diameter of the crank pin.
(6) Replace the connecting rod bearing if the clearance Measuring Measuring
exceeds the limit. directions points
(7) Measure the clearance between the connecting rod
bearing and the crank pin again. Use the undersize
bearing if the limit is exceeded.
(8) If an undersize bearing is used, grind the crank pin to
the specified undersize. Measuring crank pin diameter

Item Nominal Standard Limit

Crankpin outside ø 65 mm 64.945 to 64.965 mm 64.800 mm
diameter [0.026 in.] [2.5569 to 2.5577 in.] [2.5512 in.]

Clearance between
crankpin and 0.035 to 0.100 mm 0.200 mm
-
connecting rod [0.014 to 0.0039 in.] [0.0079 in.]
bearing

4.10 Measuring clearance between connecting

rod bushing and piston pin
Measure the inside diameter of the connecting rod bushing
and the outside diameter of the piston pin. Replace if the
limit is exceeded.
Measuring
Item Nominal Standard Limit directions
Bushing inside ø 34 mm 34.020 to 34.045 mm
- Measuring
diameter [1.34 in.] [1.3394 to 1.3404 in.]
points
Clearance between
0.023 to 0.054 mm 0.080 mm
bushing and piston -
[0.0009 to 0.0021 in.] [0.0031 in.]
pin
Measuring connecting rod bushing inside diameter

6-21
INSPECTION AND REPAIR OF BASIC ENGINE

4.11 Replacing connecting rod bushing

Use a connecting rod bushing installer to replace the
Oil hole
connecting rod bushing.
(1) With the bushing joints oriented as shown in the
40°
illustration, align the oil hole of bushing with the oil
hole of connecting rod, and press-fit the connecting rod
bushing into the connecting rod.
30°
(2) After press-fitting, insert the piston pin, and make sure
Oil hole
the smooth movement of the connecting rod and piston
without looseness. 30°
Bushing joint

Replacing connecting rod bushing

4.12 Removing connecting rod bushing
(1) Apply engine oil to the inner surface of the connecting Connecting rod Mandrel
rod bushing. bushing installer
Collar A
P/N:32F91-03050
(2) Install the collar A to the connecting rod bushing. Connecting rod
(3) Install the collar A and B to the mandrel, and tighten bushing
the nut.
(4) Align the match mark (red line) on the collar A with the Connecting
rod
match mark on the base.
Collar B
(5) Using a press, apply pressure slowly on the head of the
Align match Nut
mandrel to force out the connecting rod bushing. mark.
Base

Removing connecting rod bushing

4.13 Installing connecting rod bushing

(1) With the oil hole of busing aligned with the match mark Connecting rod Connecting rod
on the collar A, install the new connecting rod bushing bushing installer bushing
P/N:32F91-03050
onto the collar A. Align match
(2) Install the collars A and B to the mandrel, and tighten mark.
the nut.
(3) Apply engine oil to the outer periphery of the
connecting rod bushing. Align the oil hole in the
connecting rod bushing with the match mark (red line)
on the collar, then press the bushing into the connecting Collar A
rod.
Installing connecting rod bushing (1)

Connecting rod Mandrel

bushing installer Collar B
P/N:32F91-03050
Connecting rod
bushing

Connecting
rod
Collar A
Align match Nut
mark.
Base

Installing connecting rod bushing (2)

6-22
 INSPECTION AND REPAIR OF BASIC ENGINE

4.14 Inspecting connecting rod bend and twist

(1) Measure the dimensions of C and L in the illustration to Connecting rod cap tightening torque:
103 ± 5 N·m {10.5 ± 0.5 kgf·m}
check bend and twist of the connecting rod. Straighten [76 ± 3.6 lbf·ft]
the connecting rod with a press to meet the standard. C 0.05 0.002
C [ ]
L 100 3.9
If the standard is exceeded after correction, replace the
L
connecting rod with a new one. L
C 0.05 0.002
Piston [ ] C
(2) In general, a connecting rod aligner is used to check pin L 100 3.9
bend and twist. Twist of
Note: Before checking bend, tighten the connecting rod cap connecting rod
to the specified torque. Bend of
connecting rod Unit: mm [in.]
(3) To inspect the connecting rod with the piston installed,
turn the piston upside down and place it on a surface Inspecting connecting rod bend and twist
plate. Insert a round bar having the same diameter as
the crankpin into the big-end bore, and measure the D
height of the bar using a dial gauge.
C
Item Standard Limit
Connecting rod 0.05/100 mm 0.15 mm C 0.05
bend and twist [0.0020/3.94 in.] or less [0.0059 in.] ҇ A B
D 100

Unit: mm [in.]

Measuring with a dial gauge

4.15 Inspecting connecting rod bearing
Inspect the connecting rod bearings. If any defect is found,
replace it with a new one.

Scratches
Flaking
Fusion

Inspecting connecting rod bearing

6-23
 INSPECTION AND REPAIR OF BASIC ENGINE

4.16 Measuring connecting rod end play

(1) Install the connecting rods onto the respective
crankpins and tighten the connecting rod cap bolts to Connecting rod cap
the specified torque. tightening torque:
(2) Measure the clearance to the crank arm (end play) at 103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
two positions (above and below the crankpin). [76 ± 3.6 lbf·ft]
(3) If the limit is exceeded, replace the connecting rod with
a new one.

Item Standard Limit

0.15 to 0.35 mm 0.50 mm
Connecting rod end play
[0.0059 to 0.0138 in.] [0.0197 in.]
Measuring connecting rod end play

4.17 Weight difference of connecting rod

assembly in one engine
When replacing a connecting rod, be sure to check the
weight rank of the connecting rod. In one engine, all the
connecting rods must be of the same weight rank.

Tolerance on
Item Mating mark
weight

#
for assembly
Weight difference of connecting rod 10 g [0.35 oz.]
assembly or less per engine Weight rank mark

Weight difference in connecting rod assembly

4.18 Measuring crankshaft journal outside diam-

eter
Measure the crankshaft journal diameter using a
micrometer. Check the crankshaft journal for roundness,
cylindricality and the clearance with the bearing. If the
measurement value is below the repair limit, grind the
Measuring Measuring
journal to fit the undersize bearing. If the measurement directions points
value is below the service limit, replace the crankshaft with
a new one.

Item Nominal Standard Limit

Repair limit = Measuring crankshaft journal outside diameter
ø 90 mm 89.95 to 89.97 mm 89.85 mm [3.5374 in.]
Diameter
[3.54 in.] [3.5413 to 3.5421 in.] Service limit =
89.10 mm [3.5079 in.]

0.01 mm 0.03 mm
Roundness -
[0.0004 in.] or less [0.0012 in.]

Cylinderic- 0.01 mm 0.03 mm

-
ity [0.0004 in.] or less [0.0012 in.]

Deviation of
0.01 mm [0.0004 in.]
Parallelism - -
or less over entire
pin length

6-24
 INSPECTION AND REPAIR OF BASIC ENGINE

4.19 Measuring crankshaft crankpin outside

diameter
Measure the crankpin outside diameter using a micrometer.
Check the crankpin for roundness, cylindricality, and the
clearance with the bearing. If the measurement value is
below the limit, grind the journal to fit the undersize Measuring Measuring
bearing. If the measurement value is below the service limit, directions points
replace the crankshaft with a new one.

Item Nominal Standard Limit

Service limit =
ø 65 mm 64.945 to 64.965 mm
Diameter 64.800 mm
[2.56 in.] [2.5569 to 2.5577 in.] Measuring crankshaft diameter
[2.5512 in.]

0.01 mm 0.03 mm
Roundness -
[0.0004 in.] or less [0.0012 in.]

Cylinderic- 0.01 mm 0.03 mm

-
ity [0.0004 in.] or less [0.0012 in.]

Deviation of
0.01 mm [0.0004 in.] or
Parallelism - -
less over entire pin
length

4.20 Grinding crankshaft

Grind the crankshaft journal (or pin) in the diameter that fit
the inside diameter of the next undersize main (or
connecting) bearing. By doing so, the fitness check with an
actual bearing can be omitted.
When grinding, be careful not to change the fillet radius and
width. If the surface hardness is considered to have been
reduced considerably, re-harden the crankshaft and check
for flaws by means of magnetic particle inspection.
Ensure that the surface finish accuracy of the crankpins and
journals is kept within the standard even after the correction
by grinding.

Item Undersize Finished size

0.25 mm 89.70 to 89.72 mm
[0.0098 in.] [3.5315 to 3.5323 in.]
Crank 0.50 mm 89.45 to 89.47 mm
journal [0.0197 in.] [3.5216 to 3.5224 in.]
0.75 mm 89.20 to 89.22 mm
[0.0295 in.] [3.5118 to 3.5126 in.]
0.25 mm 65.695 to 65.715 mm
[0.0098 in.] [2.5864 to 2.5872 in.]
0.50 mm 65.445 to 65.465 mm
Crankpin
[0.0197 in.] [2.5766 to 2.5774 in.]
0.75 mm 65.195 to 65.215 mm
[0.0295 in.] [2.5667 to 2.5675 in.]

6-25
INSPECTION AND REPAIR OF BASIC ENGINE

4.21 Measuring crankshaft end play

(1) Measure the crankshaft end play (clearance between the
33 +0.039
0 mm
crank arm at the thrust force receiving journal and the [1.3 +0.0015
0 in.]
bearing cap with thrust plate attached). If the limit is
exceeded, replace the thrust plate with a new one.
(2) If the limit is still exceeded after a new thrust plate has
been installed, use an oversize thrust plate.
Note: In general, the rear thrust bearing wears faster than
the front thrust bearing. Therefore, in most cases, the
correction is achieved by replacing the rear thrust
plate with a next oversize one.
Width of crankshaft thrust journal
Item Standard Limit
0.100 to 0.246 mm 0.300 mm
Crankshaft end play
[0.0039 to 0.0104 in.] [0.0118 in.]

Crankshaft thrust size after grinding

OS, used OS, used
Item on one on both Tolerance
side sides
+0.15 mm 33.15 mm 33.30 mm
[+0.0059 in.] OS [1.3051 in.] [1.3110 in.]

+0.30 mm 33.30 mm 33.45 mm 0 to 0.039 mm

[+0.0118 in.] OS [1.3110 in.] [1.3169 in.] [0 to 0.0015 in.]
Measuring crankshaft end play
+0.45 mm 33.45 mm 33.60 mm
[+0.0177 in.] OS [1.3169 in.] [1.3228 in.]

4.22 Measuring crankshaft runout

Support the crankshaft at the front and rear journals with V-
blocks, and measure the crankshaft runout at the center
journal using a dial gauge. If the runout deviates from the
standard only slightly, grind the crankshaft to repair. If the
runout exceeds the standard considerably, straighten the
crankshaft using a press.
If the limit is exceeded, replace the crankshaft.
If the crankshaft has been repaired by grinding or pressing,
inspect the crankshaft for cracks and other harmful damage
using a magnetic particle method.
Measuring crankshaft runout
Item Standard Limit Remark
Crankshaft 0.04 mm 0.10 mm
TIR
runout [0.0016 in.] or less [0.0039 in.] or less

6-26
 INSPECTION AND REPAIR OF BASIC ENGINE

4.23 Replacing crankshaft gear

4.23.1 Removing crankshaft gear
Using a gear puller, remove the gear from the crankshaft.
Note: Do not strike the gear with a hammer. Crankshaft gear

Puller
P/N:64309-12900

Removing crankshaft gear

4.23.2 Installing crankshaft gear

(1) Install the key on the crankshaft.
(2) Press-fit the gear fully in alignment with the key.
Key
Aligning position

Crankshaft gear

Installing crankshaft gear

6-27
INSPECTION AND REPAIR OF BASIC ENGINE

4.24 Replacing front oil seal

&$87,21
Be careful not to damage the crankshaft pulley with a
chisel when breaking the sleeve. Be careful not to dent Crankshaft
or scratch the outer surface of sleeve. pulley
When a oill leaks from the oil seal, replace both sleeve and
oil seal with new ones.
(1) Removing sleeve
Apply a chisel at right angles to the end surface of the
Sleeve
sleeve and strike it with a hammer at three locations to
loosen the sleeve and then remove the sleeve.
Removing front oil seal sleeve
Note: If the sleeve cannot be removed, apply the chisel to
the sleeve in the axial direction of the sleeve and tap it
lightly to make a cut and remove crankshaft-to-sleeve
interference.
(2) Installing sleeve Sleeve
Install the sleeve using a press so that the end of pulley
Crankshaft pulley
becomes flush.

Installing front oil seal sleeve

4.25 Replacing rear oil seal

&$87,21
Be careful not to damage the crankshaft when remov- Rear slinger
ing the rear oil seal. Be careful not to dent or scratch
the outer surface of sleeve.
When a oill leaks from the oil seal, replace the oil seal with
a new one.
(1) Removing rear oil seal
Remove the oil seal with a puller.
(2) Installing rear side oil seal
Apply an oil on the slinger inner surface of oil seal.
Removing rear oil seal sleeve
Install the oil seal with an oil seal installer.
Note: The oil seal is united with the slinger.
Rear oil seal installer
P/N:34291-00020
Oil seal

Installing rear oil seal sleeve

6-28
 INSPECTION AND REPAIR OF BASIC ENGINE

4.26 Inspecting main bearing surface

Check the inside surface of each main bearing shell for
abnormal contact, scratches, corrosion and peeling from Scratch on the inner
foreign material. Also check the outside surface of each and outer circumference,
corrosion, and detachment
bearing shell which comes into contact with the crankcase
or main bearing cap for abnormal seating.

Inspecting main bearing surface

4.27 Measuring clearance between main bear-

ing and crankshaft journal Measuring Measuring
directions points

&$87,21
(a) When grinding crank journals, be sure to grind all
the journals to the same size.
(b) Finish the fillet radius to the specified dimension.
(1) Reassemble main bearings.
(2) Tighten the main bearing caps to the specified torque.
Main bearing cap bolt
(3) Measure the inside diameter of the main bearings. tightening torque:
(4) Measure the outside diameter of the crank journal. 137 ± 5 N·m {14 ± 0.5 kgf·m} [101 ± 3.6 lbf·ft]
(5) Calculate the clearance between the inside diameter of Measuring inside diameter of lower hole of main
the main bearing and outside diameter of the crank bearing
journal.
(6) Replace the main bearing if the clearance exceeds the
limit.
(7) Measure the clearance between the main bearing cap
and the crank journal again. Use the undersize bearing
if the limit is exceeded. Measuring Measuring
(8) If an undersize bearing is used, grind the crank journal directions points
to the specified undersize.

Item Standard Limit

Clearance between main 0.050 to 0.118 mm 0.200 mm
bearing and crankshaft journal [0.0020 to 0.0046 in.] [0.0079 in.]
Measuring crank journal outside diameter

6-29
 REASSEMBLY OF BASIC ENGINE
1. Reassembling piston, connecting rod,
crankshaft and crankcase ...............7-2
1.1 Installing main bearing ............................. 7-2
1.2 Installing thrust plate ................................ 7-2
1.3 Installing crankshaft ................................. 7-2
1.4 Installing main bearing caps .................... 7-3
1.5 Inserting side seal .................................... 7-3
1.6 Installing main bearing cap bolt ............... 7-3
1.7 Measuring crankshaft end play ................ 7-4
1.8 Reassembling piston and connecting rod 7-4
1.9 Installing piston ring ................................. 7-5
1.10 Preparation for installing pistons.............. 7-5
1.11 Installing connecting rod bolt and connecting
rod bearing............................................... 7-6
1.12 Installing Pistons ...................................... 7-6
1.13 Installing connecting rod cap ................... 7-7

2. Reassembling timing gear and

camshaft..........................................7-8
2.1 Installing front plate.................................. 7-8
2.2 Installing tappet........................................ 7-8
2.3 Installing camshaft ................................... 7-8
2.4 Installing front idler gear........................... 7-9
2.5 Inspecting and adjusting timing gear after
installation ................................................ 7-9
2.5.1 Inspecting backlash and end play ..............7-9
2.6 Installing front oil seal ............................ 7-10
2.7 Installing timing gear case ..................... 7-10
2.8 Installing crankshaft pulley..................... 7-10

3. Reassembling flywheel .................7-11

3.1 Installing flywheel housing ..................... 7-11
3.2 Installing flywheel................................... 7-11

4. Reassembling cylinder head and valve

mechanism ....................................7-12
4.1 Cleaning cylinder head bottom surface.. 7-12
4.2 Installing valve stem seal ....................... 7-12
4.3 Installing valve and valve spring ............ 7-12
4.4 Installing cylinder head gasket............... 7-13
4.5 Installing cylinder head assembly .......... 7-13
4.6 Tightening cylinder head bolts ............... 7-13
4.7 Inserting push rod .................................. 7-14
4.8 Reassembling rocker shaft assembly .... 7-14
4.9 Installing rocker shaft assembly............. 7-14
4.10 Installing injector .................................... 7-15
4.11 Adjusting valve clearance ...................... 7-15
4.12 Installing rocker cover ............................ 7-15

7-1
REASSEMBLY OF BASIC ENGINE

1. Reassembling piston, connecting rod, crankshaft and crankcase

1.1 Installing main bearing
Main bearing upper
&$87,21
Do not apply oil to the bearing outer surface, as the oil
may cause the bearing seizure.
(1) Press the upper main bearing into position by aligning
its lug to the lug groove on the crankcase.
Note: The oil hole of the main bearing is aligned with the Align with lug groove.
oil hole of the crankcase by installing the upper main
bearing in alignment with the lug groove. Thrust plate
(2) Apply a small amount of engine oil to each bearing.
Installing main bearing upper

1.2 Installing thrust plate

Install the thrust plates to the crankcase outside face of
Thrust plate, upper
rearmost bearing and to the main bearing cap with their
grooves facing outward.

Thrust plate, lower

Thrust plate, lower

Installing thrust plate

1.3 Installing crankshaft

(1) Make sure that the main bearing upper shells that are
installed in the crankcase bores have their inner
periphery (the surface comes into contact with the
journal) lubricated with an even coat of fresh engine
oil.
(2) Wash the crankshaft thoroughly with cleaning oil and
dry it completely by blowing compressed air. Then,
apply an even coat of fresh engine oil to the crankshaft
journals.
Note: When cleaning the crankshaft, pay special attention to
the oil holes in the crank journals and crankpins, and Installing crankshaft
make sure that they are free from any foreign matter.
(3) Sling up the crankshaft horizontally, then move it above
the crankcase and lower it slowly into position.
Note: When lifting the crankshaft with a chain block, do not
attach a metal hook or similar fitting directly onto the
crankshaft. Such metal fittings can damage the
crankshaft easily. Always lift the crankshaft using
cloth belts or pads on the supporting points.

7-2
 REASSEMBLY OF BASIC ENGINE

1.4 Installing main bearing caps

&$87,21
The foremost and rearmost caps should be installed
so that they are flush with the crankcase surface.
Install the main bearing caps from the front side in the order
of the numbers marked on them.
(1) Apply engine oil to lower main bearings and install
them to the main bearing caps.
(2) Apply ThreeBond 1212 to the mating surface of the Apply ThreeBond 1212.
foremost and rearmost caps and the crankcase mating
faces before installing the main bearing caps.
Installing main bearing cap
Note: Do not apply ThreeBond 1212 to any other surface
other than the mating surfaces of the foremost and
rearmost caps and the crankcase mating faces.
(3) Install the main bearing caps and temporarily tighten
bolts.

1.5 Inserting side seal

(1) Apply a sealant to the outer periphery of new side seals.

Crankcase Bearing cap Side seal

Sealant THREEBOND 1212 or 1211

(2) With the round section of the side seals facing outward,
press them partway into the front and rear caps using
hands.
(3) When the side seals are installed partway into caps, use
a tool with flat surface such as flat-head screwdriver to
R section
install completely, taking care not to bend them.

Inserting side seal

1.6 Installing main bearing cap bolt

(1) Tighten the main bearing cap bolts alternately and Main bearing cap bolt tightening torque
progressively to the specified torque. 137 ± 5 N·m {14 ± 0.5 kgf·m}
[101 ± 3.6 lbf·ft]
(2) Make sure that the crankshaft rotates smoothly.

Installing main bearing cap bolt

7-3
REASSEMBLY OF BASIC ENGINE

1.7 Measuring crankshaft end play

Attach a dial gauge to the end of the crankshaft to measure
the end play.
If the end play deviates from the standard value, loosen the
main bearing cap bolts and retighten.
Make sure that the camshaft turns freely.

Item Standard Limit

0.100 to 0.246 mm 0.300 mm
Crankshaft end play
[0.0039 to 0.0104 in.] [0.0118 in.]

Measuring crankshaft end play

1.8 Reassembling piston and connecting rod

(1) Apply engine oil to the piston pin, and reassemble the
piston and the connecting rod by inserting the piston F

Front
pin, observing the orientation of piston and connecting Piston pin
rod shown in the illustration. Snap ring
Note: The pistons and piston pins are assembled to each
other in clearance fit. However, the piston pins are
more easily inserted into the pistons if the pistons are Apply engine oil
warmed up with a heater or in hot water.

Matching mark

Reassembling piston and connecting rod

(2) Using ring pliers, install the snap ring. Check the snap
ring for its tension, and make sure the ring fits snugly in
the groove.
Note: Install all the snap rings so that their end gap faces
toward the bottom of the piston.

7-4
 REASSEMBLY OF BASIC ENGINE

1.9 Installing piston ring

&$87,21 No.1 compression ring

Every piston ring has a top mark such as “R” near the Top mark
end gap. Install all piston rings with this mark facing
upward. No.2 compression ring
If the rings are installed upside down, it could cause
malfunctions such as excessive oil consumption or an
engine seizing.
(1) Install the piston rings to the piston with a ring Oil ring
expander.
(2) Install the oil ring with its end gap 180° away from the
Reassembling piston and piston ring
butt joint of the coil spring, as shown in the illustration.

Coil spring butted ends

180°

Oil ring abutment

Reassembling oil ring

1.10 Preparation for installing pistons

(1) Lay the engine along its side.
(2) Clean the cylinder sleeve inner surface and the crank
pin with a cloth, and apply engine oil.

Cleaning and lubricating cylinder sleeve inner surface

7-5
REASSEMBLY OF BASIC ENGINE

1.11 Installing connecting rod bolt and connect-

ing rod bearing
(1) Press fit the connecting rod bolts into the connecting Lug groove
rod.
Note: When press fitting the bolt, make sure that the bolt
fully contacts its seating position without any
interference with the shoulder of mounting surface.
(2) Install the upper connecting rod bearing with its lug
fitted in the lug groove of connecting rod.
(3) Install the lower connecting rod bearing with its lug
fitted in the lug groove of connecting rod cap.
(4) Apply engine oil to the inner surface of bearing. Installing connecting rod bolt and upper bearing

Lug groove

Installing lower connecting rod bearing

1.12 Installing Pistons

&$87,21 Camshaft side

Do not forcefully insert the piston, as it may cause
No.1
damage to the piston rings and crank pin. 180° compression
(1) Apply engine oil to the circumference of the piston and ring end gap
piston rings.
No.2
(2) Orient the ring end gaps diagonally opposite each other compression Oil ring end gap
avoiding the piston pin direction and its right angle ring end gap 60° 60°
direction.
Combustion chamber side
(3) Turn the crankshaft to bring the crank pin of the
cylinder to the top dead center.
Orientation of piston ring end gap
(4) Orient the front mark on the top of piston toward engine
front.
(5) Using a piston guide, insert the piston from the top face
of crankcase into the cylinder sleeve.

Piston guide
P/N:34291-00100

Installing piston

7-6
 REASSEMBLY OF BASIC ENGINE

1.13 Installing connecting rod cap

(1) When the big end of the connecting rod comes into
Camshaft
contact with the crank pin, turn the crankshaft 180°
Matching mark
while pressing the piston head.
(2) Install the connecting rod cap with its match mark
facing on the same side as the match mark on the Connecting rod cap
connecting rod. nut tightening torque:
(3) Tighten the connecting rod cap nuts evenly and 103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
progressively to the specified torque.
[76 ± 3.6 lbf·ft]
(4) Inspect end play of the connecting rod. If end play is Wood block
small, loosen and retighten the cap nuts.
Installing connecting rod cap

7-7
REASSEMBLY OF BASIC ENGINE

2. Reassembling timing gear and camshaft

2.1 Installing front plate
(1) Clean the mounting surface of the gasket. Front plate bolt tightening torgue:
M10 × 1.5 35 ± 5 N·m {3.5 ± 0.5 kgf·m} [25.3 ± 3.6 lbf·ft]
(2) Apply sealant to the gasket to prevent it from falling. M8 × 1.25 19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
(3) With aligning to the dowel pin, install the gasket and
the front plate. Front plate
(4) Secure the front plate with mounting bolts.

Installing front plate

2.2 Installing tappet
Coat the periphery of tappets with engine oil, insert them
into the tappet holes and place them gently on the
camshafts.

2.3 Installing camshaft

&$87,21
Be careful not to damage camshaft journals, cams and
camshaft holes during insertion. Camshaft gear

(1) Apply engine oil to the camshaft journals and cams.

(2) Slowly insert the camshaft assembly.
(3) Tighten the thrust plate bolt to the specified torque.
Camshaft thrust plate
(4) Make sure that the camshaft rotates lightly. Move the
bolt tightening torque
camshaft gear back and forth, and make sure there is 12 ± 2 N·m{1.2 ± 0.2 kgf·m}
end play. [9 ± 1.4 lbf·ft]

Installing camshaft

7-8
 REASSEMBLY OF BASIC ENGINE

2.4 Installing front idler gear

(1) Apply engine oil to the idler gear shaft.
Thrust plate bolt
(2) Install the idler gear with all match marks on it aligned tightening torque
with the marks on the other gears. 34 ± 5 N·m
Idler gear
(3) Install the thrust plate with its hole matching the pin of {3.5 ± 0.5 kgf·m}
[25 ± 3.6 lbf·ft]
the idler gear shaft.
(4) Tighten the thrust plate bolt to the specified torque.
(5) Move the idler gear back and forth, and make sure there
is end play.

Thrust plate

Installing idler gear

Injection pump
idler gear
Camshaft gear

 


 

㩩

Injection pump Idler gear

gear Crank gear

Timing gear train

2.5 Inspecting and adjusting timing gear after
installation
Be sure to inspect and adjust the timing gear when the
timing gear has been reassembled.

2.5.1 Inspecting backlash and end play

After installing the timing gears, be sure to inspect and
adjust the backlash and end play between gears.

Idler gear

Measuring idler gear end play

Measuring backlash of timing gear

7-9
REASSEMBLY OF BASIC ENGINE

2.6 Installing front oil seal

Using an installer, install new oil seal in the timing gear
case. Make sure the oil seal is flush with the gear case.

Installing front oil seal

2.7 Installing timing gear case
(1) Install the baffle plate to the front end of crankshaft. Timing gear case tightening torque:
M10 × 1.5 35 ± 5 N·m {3.5 ± 0.5 kgf·m} [25.3 ± 3.6 lbf·ft]
(2) Apply sealant to the gasket to prevent it from M8 × 1.25 19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
displacing, and install the gasket on the front plate.
(3) Apply engine oil to the oil seal lip.
(4) Orient the cutaway of the baffle plate so that the baffle
plate does not overlap the oil pump idler gear.
(5) Install the timing gear case, and secure it with the bolts.

Gasket
Timing gear case

Installing timing gear case

Oil pump idler gear

Baffle plate cutaway

Baffle plate cutaway position

2.8 Installing crankshaft pulley
Crankshaft pulley nut The bar that prevnets
&$87,21 tightening torque: crankshaft rotation
706 ± 59 N·m {72 ± 6 kgf·m}
The bar could come off. Be very careful.
[521 ± 43 lbf·ft]
(1) Screw two guide bolts into the threaded holes at the rear Crankshaft pulley
end of the crankshaft. Place a bar across the two guide
bolts so that the crankshaft does not turn.
(2) Install the woodruff key on the crankshaft.
(3) Install the crankshaft pulley and tighten the nuts to the
specified torque. Guide bolt (M12×1.25mm)
(Front) (Rear)

Installing crankshaft pulley

7-10
 REASSEMBLY OF BASIC ENGINE

3. Reassembling flywheel
3.1 Installing flywheel housing
(1) Clean the mounting surface of the gasket.
(2) Apply sealant to the gasket to prevent it from falling
off.
(3) Install the gasket.
(4) Install the flywheel housing, aligning its dwel pin holes
and dowel pins, and tighten the bolts.
Note: When the dowel pins are worn or when the flywheel
housing is replaced, replace the dowel pins with new
ones.

Installing flywheel housing

3.2 Installing flywheel

Flywheel bolt tightening
&$87,21 torque:
83 ± 5 N·m {8.5 ± 0.5 kgf·m}
The person who holds the pulley must be very careful
Crankshaft pulley [62 ± 3.6 lbf·ft]
to assure safety by communicating with the person Guide bolt
who is installing the flywheel.
(1) One person must firmly hold the pulley with a wrench
to prevent the crankshaft from turning.
(2) Screw the guide bolt into the rear end of the crankshaft.
(3) Align the bolt hole of flywheel with the guide bolt and
install the flywheel to the crankshaft.
Front
Rear
(4) Temporarily tighten bolts. Installing flywheel
(5) Remove the guide bolt and temporarily tighten the last
bolt.
(6) Tighten the flywheel bolts to the specified torque.

7-11
REASSEMBLY OF BASIC ENGINE

4. Reassembling cylinder head and valve mechanism

4.1 Cleaning cylinder head bottom surface
Taking care not to damage the cylinder head bottom surface,
remove residue of old gasket.
Note: First, roughly scrape off residue of old gasket using a
scraper. Then, grind off the remaining residue using
an engine-oil immersed oil stone.

Cleaning cylinder head bottom surface

4.2 Installing valve stem seal

&$87,21 Push the shoulder of valve stem seal.

Do not apply oil or liquid gasket to the inner side of ω ω
stem seal that comes in contact with the valve guide.
Valve stem seal
(1) Apply engine oil to the lip of new valve stem seal.
(2) Push the shoulder of the valve stem seal and fit the
valve stem steal into the valve guide. Valve guide
(3) Insert the valve stem seal into the valve guide using the
valve stem seal installer.

Installing valve stem seal

4.3 Installing valve and valve spring
(1) Install the valve spring and retainer on the valve guide. Valve spring pusher
Install the valve cotter using a valve spring pusher. P/N:30691-04500
(2) Tap the top of valve stem lightly several times with a
soft hammer to make sure that the valve spring and
valve cotter are properly installed and seated firmly.

Installing valve and valve spring

Valve cotter

Installing valve cotter

7-12
 REASSEMBLY OF BASIC ENGINE

4.4 Installing cylinder head gasket

(1) Make sure that there is no dirt or dents on the top
surfaces of the crankcase and pistons.
(2) Place new gasket on the crankcase by aligning it with
dowel pins on the crankcase.

4.5 Installing cylinder head assembly

Install the cylinder head on the crankcase by aligning it with
the dowel pins.
Note: Be careful not to displace the cylinder gasket when
installing.

Installing cylinder head assembly

4.6 Tightening cylinder head bolts

In the numerical order as shown in the illustration, tighten
cylinder head bolts progressively to the specified torque. Cylinder head bolt tightening torque:
137 ± 5 N·m {14 ± 0.5 kgf·m} [101 ± 3.6 lbf·ft]

15 11 7 3 2 6 10 14

17 9 1 8 16

13 5 4 12

Tightening order of cylinder head bolt

7-13
REASSEMBLY OF BASIC ENGINE

4.7 Inserting push rod

(1) Insert each push rod into its hole in the cylinder head.
(2) Make sure that the ball end of each push rod is placed
Pushrod
correctly on the tappet cup.

Tappet

Inserting push rod

4.8 Reassembling rocker shaft assembly

(1) Apply engine oil to the rocker shaft.
(2) When reassembling, install the rocker shaft assembly in
the same position as it was.
Rocker shaft spring
Note: If the rocker shaft assembly is not installed as it was,
the clearance becomes different, and it may result in a Rocker shaft
defect such as wear increase. Oil pipe Bracket
(3) After reassembling, make sure the rocker arm and oil Rocker arm
pipe move freely.
Snap ring
Eye bolt

Reassembling rocker shaft assembly

4.9 Installing rocker shaft assembly

(1) Install the valve caps to the valve heads.
(2) Tighten the long bolts of the rocker bracket to the
specified torque.
(3) Tighten the short bolts of the rocker bracket.

Rocker shaft bracket bolt tightening torque:

19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]

Installing rocker shaft assembly

7-14
 REASSEMBLY OF BASIC ENGINE

4.10 Installing injector

(1) Install the gasket to the injector.
Leak off hose connector
(2) Install the injector with the nozzle gland to the cylinder
head. Injector Leak off hose
(3) With the washer spherical side faced toward nozzle Pin
gland, install the washer, and secure it by tightening the
Nozzle
hexagon socket head bolt to the specified torque.
gland
(4) Apply engine oil to the O-ring of leak off hose Injection pipe
connector. Injection connector
(5) With pushing the pin on top of the injector, install the
Gasket
leak off hose connector.
(6) Install the injection pipe to the injector. Installing injector
Note: Make sure that the injector is reassembled into the
same cylinder as it was before.

Injector

Push
Pin

Pushing pin on top of injector

4.11 Adjusting valve clearance
Adjust the valve clearance.
For adjusting procedures, refer to "Adjustment and
Operation."

Adjusting valve clearance

4.12 Installing rocker cover
(1) Make sure that the gasket is firmly installed into the Rocker cover bolt tightening torque:
rocker cover. 20 ± 2 N·m {2.0 ± 0.2 kgf·m}
[14.5 ± 1.4 lbf·ft]
(2) Tighten the rocker cover mounting nuts to the specified
torque.

Installing rocker cover

7-15
 FUEL SYSTEM
1. Removing fuel system.....................8-2
1.1 Removing fuel system (Part 1)................. 8-2
1.2 Removing fuel system (Part 2)................. 8-3

2. Installing fuel system.......................8-4

2.1 Installing fuel system (Part 1)................... 8-4
2.2 Installing fuel system (Part 2)................... 8-5
2.3 Replacing fuel pump ................................ 8-6
2.3.1 Removing fuel pump ..................................8-6
2.3.2 Replacing fuel pump gear ..........................8-6
2.3.3 Replacing fuel pump idler gear ..................8-6
2.3.4 Installing fuel pump ....................................8-7

8-1
FUEL SYSTEM

1. Removing fuel system

&$87,21
(a) Keep open flame or heat away from fuel system before conducting the removal work. It could cause a fire.
(b) Wipe off any spilled fuel. Spilled fuel could cause a fire.
(c) Cover or plug any inlet and outlet openings to prevent dust from entering the fuel system.
(d) For fuel pump, common rail, and injector, have a specialized maintenance shop do the maintenance work.
1.1 Removing fuel system (Part 1)

Replace: Sealing washer

O-ring 8
B
Gasket
Leak off hose
6

10
2
3
4 1
5 11
16
A
18 14
17 D
15 7 9
B
C 13

12
19
D

A 20

Removing fuel system (Part 1)

Removing sequence

1 Pipe clamp 8 Pipe cramp 15 Common rail

2 No.1 injection pipe 9 Fuel pipe 16 Hexagon bolt
3 No.2 injection pipe 10 Bracket 17 Nozzle ground
4 No.3 injection pipe 11 Bolt 18 Injector
5 No.4 injection pipe 12 Hose cramp 19 Fuel pump nut
6 Leak off hose 13 Fuel hose 20 Fuel pump flange, fuel pump
7 Fuel hose 14 Fuel return pipe

8-2
 FUEL SYSTEM

1.2 Removing fuel system (Part 2)

1
2

6
5

Removing fuel system (Part 2)

Removing sequence

1 Fuel pump nut 4 Fuel pump 7 Fuel pump idler gear, bearing
2 Fuel pump gear 5 Bolt
3 Bolt 6 Washer

8-3
FUEL SYSTEM

2. Installing fuel system

2.1 Installing fuel system (Part 1)

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

70 ± 5 N·m
{7.1 ± 0.5 kgf·m}
[51.4 ± 3.6 lbf·ft]
112 ± 22 N·m
{11.4 ± 2.2 kgf·m}
[82.5 ± 15.9 lbf·ft]

34 ± 5 N·m
{3.5 ± 0.5 kgf·m}
[25.3 ± 3.6 lbf·ft]

Installing fuel system (Part 1)

8-4
 FUEL SYSTEM

2.2 Installing fuel system (Part 2)

Replace: Sealing washer 8

O-ring B
Gasket
Leak off hose

30 ± 3.0 N·m
{3.1 ± 0.3 kgf·m}
25 ± 3 N·m
[22.4 ± 3 lbf·ft]
{2.5 ± 0.3 kgf·m}
[18.1 ± 2.2 lbf·ft]
A
D

25 ± 3.0 N·m B 20 ± 2.0 N·m

{2.5 ± 0.3 kgf·m} C {2.0 ± 0.2 kgf·m}
[18.1 ± 3 lbf·ft] [14.5 ± 1.4 lbf·ft]
C

25+2.5
0 N·m

{2.5 +0.25
0 kgf·m}
[18.1 +1.8
0 lbf·ft]

Installing fuel system (Part 2)

8-5
FUEL SYSTEM

2.3 Replacing fuel pump

2.3.1 Removing fuel pump
(1) Remove the inspection cover for fuel pump idler gear Put a mating mark
and idler gear from the timing gear case. Fuel pump gear
mouting nut
(2) Put a mating mark on the fuel pump idler gear and idler
gear with white paint.
(3) Remove the inspection cover for fuel pump nut. Loosen
the fuel pump nut and tighten it by hand temporary.
Fuel pump
(4) Disconnect fuel pipe and oil pipe from the fuel pump. idler gear
Idler gear
Fuel pump gear
(5) Remove the harness connector.
(6) Remove the fuel pump together with the fuel pump
flange from timing gear case. Removing fuel pump
(7) Remove the fuel pump nut, and remove the fuel pump
gear from the fuel pump.
(8) Remove the fuel pump from the fuel pump flange.

2.3.2 Replacing fuel pump gear

(1) Remove the fuel pump nut, and remove the fuel pump
gear.
(2) Install the new fuel pump gear, aligning with the fuel
pump shaft key.
Fuel pump gear
(3) Install the fuel pump nut and tighten it by hand
temporary.

Fuel pump

Replacing fuel pump gear

2.3.3 Replacing fuel pump idler gear

(1) Remove the bolt and the washer from the fuel pump
idler gear.
(2) Remove the fuel pump idler gear from the shaft
together with the bearing and the snap ring.
(3) Remove the bearing and the snap ring from the fuel
pump idler gear.
(4) Install the bearing and the snap ring to the new fuel
pump idler gear.
(5) Install the fuel pump idler gear to the shaft together Fuel pump
Fuel pump idler gear
with the snap ring and the bearing, and install the
washer and the bolt. Replacing fuel pump idler gear

8-6
 FUEL SYSTEM

2.3.4 Installing fuel pump

(1) Install the fuel pump to the fuel pump flange.
(2) Install the fuel pump nut and tighten it by hand
temporary.
(3) Install the O-ring to the fuel pump flange.
(4) With the match marks on the fuel pump idler gear and
the idler gear aligned, install the fuel pump flange to the
timing gear case.
(5) Tighten the fuel pump nut to the specified torque.
(6) Connect the harness connector.
(7) Install the fuel pipe and the oil pipe, and tighten to the
specified torque. Installing fuel pump
(8) Install the fuel pump idler gear and idler gear inspection
cover and the fuel pump nut inspection cover to the
timing gear case.

8-7
 LUBRICATION SYSTEM
1. Removing and inspecting lubrication
system .............................................9-2
1.1 Removing and inspecting oil filter and
oil cooler................................................... 9-2
1.2 Removing and inspecting oil pan and
breather.................................................... 9-3

2. Disassembling, inspecting and

reassembling lubrication system .....9-4
2.1 Disassembling and inspecting oil pump... 9-4
2.1.1 Removing oil pump gear ............................9-4
2.1.2 Removing spindle and idler gear................9-5
2.2 Inspecting and adjusting oil pump............ 9-5
2.2.1 Measuring end clearance between gears and
case............................................................9-5
2.2.2 Measuring side clearance between gears and
case............................................................9-5
2.2.3 Measuring clearance between outside diameter
of gear shaft and inside diameters of pump body
and pump cover .........................................9-6
2.2.4 Measuring spindle outside diameter and idler
bushing inside diameter .............................9-6
2.3 Reassembling oil pump............................ 9-7
2.3.1 Reassembling oil pump gear and drive gear
assembly ....................................................9-7
2.4 Inspecting oil filter .................................... 9-8
2.5 Inspecting relief valve .............................. 9-8
2.6 Inspecting safety valve............................. 9-8

3. Installing lubrication system ............9-9

3.1 Installing oil filter and oil cooler ................ 9-9
3.2 Installing oil pan and breather................ 9-10

9-1
LUBRICATION SYSTEM

1. Removing and inspecting lubrication system

1.1 Removing and inspecting oil filter and oil cooler

Clogging, crack
Replace: Every 500 hrs

Replace

Clogging, crack
8 Replace: Every 500 hrs

Replace
1
10

6 3
Replace 5

Replace
4
2
9

Replace

Removing and inspecting oil filter and oil cooler

Removing sequence

1 Oil filter 5 Filter base 9 Oil cover

2 Drain hose 6 Rail bracket 10 Relief valve
3 Filter bracket 7 Oil cooler cover
4 Drain plug 8 Oil cooler element

9-2
 LUBRICATION SYSTEM

1.2 Removing and inspecting oil pan and breather

3
Replace
5 2

Replace Replace

Replace 8

Replace
6

Removing and inspecting oil pan and breather

Removing sequence

1 Breather hose 4 Breather 7 Oil pan

2 Breather pipe 5 Oil level gauge 8 Oil strainer
3 Vinyl tube 6 Drain cock 9 Safety valve

9-3
LUBRICATION SYSTEM

2. Disassembling, inspecting and reassembling lubrication system

2.1 Disassembling and inspecting oil pump

Gear defect, wear

Once removed, replace the gear
with a new one.

Gear defect, wear

3

Wear

2
Replace

4
Crack, damage
1 Gear defect, wear

Disassembling and inspecting oil pump

Removing sequence

1 Gear cover 3 Oil pump gear 5 Spindle

2 Driven gear 4 Drive gear 6 Idler gear assembly
Note: Inspect the oil pump prior to the removal of gears.

2.1.1 Removing oil pump gear

Oil pump gear
&$87,21
Puller
Once the oil pump gear is removed, the oil pump gear P/N:64309-12900
and the drive gear are no longer reusable. Replace
them with new ones.
Remove the oil pump gear with a puller.

Removing oil pump gear

9-4
 LUBRICATION SYSTEM

2.1.2 Removing spindle and idler gear

Remove the spindle and the idler gear as a unit. Remove the
spindle and the idler gear by tapping the edge of idler gear
with a wood rod inserted through the oil seal mounting hole
of timing gear case.
Note: When tapping the idler gear with a wood rod, turn the
gear.

Spindle Idler gear

Removing spindle and idler gear

2.2 Inspecting and adjusting oil pump
2.2.1 Measuring end clearance between gears
and case
Measure the end clearance between gear width and case
depth with a dial gauge placed as shown in the illustration.
If the limit is exceeded, replace the drive and driven gear
assemblies.

Item Standard Limit

End clearance between -0.01 to 0.054 mm 0.150 mm
gear width and case depth [-0.0004 to 0.0021 in.] [0.0059 in.]

Measuring clearance between gear and case

2.2.2 Measuring side clearance between gears
and case
Measure the side clearance between gear teeth and case bore
with feeler gauges. If the limit is exceeded, replace the drive
and driven gear assemblies.

Item Standard Limit

Side clearance between 0.05 to 0.098 mm 0.100 mm
gear teeth and case bore [0.0020 to 0.0039 in] [0.0039 in.]

Measuring clearance between gear teeth and case

9-5
LUBRICATION SYSTEM

2.2.3 Measuring clearance between outside

diameter of gear shaft and inside diameters Pump body Pump cover
of pump body and pump cover
Measuring
locations
&$87,21
When replacing drive and driven gears, replace the
gear assemblies.
(1) Check gear teeth for condition. If the teeth are
defective, replace the gear assemblies.
(2) Measure the inside diameters of pump body (cover) and
Measuring points
the diameter of gear shafts. If the clearance is more than
the limit, replace the gear assemblies, pump body, and
Measuring clearance between gear shaft outside
pump cover whichever is badly worn. diameter and pump body, pump cover inside diameter

Item Standard Limit

Clearance between gear shafts 0.04 to 0.07 mm 0.15 mm
and pump body (cover) [0.0016 to 0.0028 in.] [0.0059 in.]

2.2.4 Measuring spindle outside diameter and

idler bushing inside diameter
Measure the spindle outside diameter and the idler bushing
inside diameter. If excessive wear is found, replace the part
with a new one.

Item Nominal Standard

ø 25 mm 24.939 to 24.960 mm
Spindle outside diameter
[0.98 in.] [0.9818 to 0.9827 in.]
ø 25 mm 25.000 to 25.021 mm
Bushing inside diameter
[0.98 in.] [0.9843 to 0.9851 in.]

Measuring spindle outside diameter and idler gear

bushing inside diameter

9-6
 LUBRICATION SYSTEM

2.3 Reassembling oil pump

Heat to 180 to 220°C [356 to 428°F].

Oil pump gear should be flush with
the shaft. Backlash
Standard: 0.049 to 0.166 mm
[0.0019 to 0.0065 in.]
Limit: 0.35 mm [0.0138 in.]

35 ± 3.5 N·m
{3.6 ± 0.3 kgf·m}
[25.3 ± 2.4 lbf·ft]

Make sure the oil pump

Apply ThreeBond 1215 gear rotates smoothly
(ash color) to the mating
surface with the case and
cover.

Apply engine oil to every sliding section.

Reassembling oil pump

2.3.1 Reassembling oil pump gear and drive gear

assembly Flush

&$87,21
The oil pump gear and drive gear assembly is nonre-
usable parts. Replace the assembly with a new one.
(1) Heat the oil pump gear between 180 to 220°C [356 to
428°F]
(2) Support the shaft at end and force the gear onto the
shaft until its end face is flush with the end of shaft.
Shaft end surface

Reassembling oil pump gear and drive gear assembly

9-7
LUBRICATION SYSTEM

2.4 Inspecting oil filter

When replacing the oil filter, sample the oil (500 ml
[30.5 cu.in.]) and check for metal and other particles. If
metal or other particles are found, cut and unfold the
element, and inspect the color and shape of metal particles
trapped in the element to identify the cause.

Inspecting oil filter

2.5 Inspecting relief valve

(1) Check the relief valve and its seat for contact. Check
the spring for fatigue and damage. If faulty, replace the Tightening torque
relief valve with new one. 49 ± 4.9 N·m
{5 ± 0.5 kgf·m}
(2) Measure the relief valve opening pressure. If the [36.2 ± 3.6 lbf·ft]
pressure does not fall within the standard range, replace
the relief valve with new one. Tightening torque
44 ± 4.9 N·m
Item Standard {4.5 ± 0.5 kgf·m}
[32.5 ± 3.6 lbf·ft]
0.35 ± 0.05 MPa
Relief valve opening pressure
{3.5 ± 0.5 kgf/cm² } [49.8 ± 7.1 psi] Relief valve

Inspecting relief valve

2.6 Inspecting safety valve

(1) Make sure that the steel ball inside safety valve slides
smoothly. If faulty, replace the safety valve with new
one.
(2) Measure the safety valve opening pressure. If the
pressure does not fall within the standard range, replace
the safety valve with new one.
Tightening torque
Item Standard 69 ± 4.9 N·m
Safety valve opening pressure 1.1 MPa {11 kgf/cm² } [157 psi] {7 ± 0.5 kgf·m}
[50.6 ± 3.6 lbf·ft]

Inspecting safety valve

9-8
 LUBRICATION SYSTEM

3. Installing lubrication system

3.1 Installing oil filter and oil cooler

When installing, apply engine

oil to the gasket, and tighten
Replace the filter 3/4 to one turn after
the gasket contacts with the
mounting surface.

Replace Replace

Replace
49 ± 4.9 N·m
{5 ± 0.5 kgf·m}
[36.2 ± 3.6 lbf·ft}

Replace

Replace

Installing oil filter and oil cooler

To install the lubrication system, follow the removal procedure in reverse order, observing the followings:
(1) Use new gaskets and O-rings when reinstalling.
(2) Clean oil passage of each part thoroughly in wash oil,
and dry it completely using compressed air.
(3) Install the bracket first, then install the oil filter.

9-9
LUBRICATION SYSTEM

3.2 Installing oil pan and breather

Replace

Replace Replace

Replace

69 ± 4.9 N·m
{7 ± 0.5 kgf·m}
[50.6 ±3.6 lbf·ft}
Replace

Installing oil pan and breather

9-10
 COOLING SYSTEM
1. Removing cooling system .............10-2

2. Inspecting cooling system .............10-3

2.1 Checking water pump for smooth rotation10-3
2.2 Inspecting thermostat............................. 10-3

3. Installing cooling system ...............10-4

10-1
COOLING SYSTEM

1. Removing cooling system

Replace
5

Crack, water leakage, damage

Replace
4

2 3

Crack, wear

Removing cooling system

Removing sequence

1 Fan 3 Belt 5 Thermostat assembly

2 Spacer 4 Water pump assembly

10-2
 COOLING SYSTEM

2. Inspecting cooling system

2.1 Checking water pump for smooth rotation
Check to make sure that the impeller and shaft of water
pump rotate smoothly without noise and irregularities. If
faulty, replace the water pump assembly.

2.2 Inspecting thermostat

&$87,21
Be careful of burns or a fire when measuring tempera-
ture, as it involves a high-temperature and open flame.
To test the thermostat operation, immerse the thermostat in a
container filled with water. Heat the water, while measuring
the water temperature. Record the temperature at the
conditions shown in the table below. If the temperatures are
not within the standard range, replace the thermostat.
Note: (a) Stir the water in the container with a stick to
ensure uniform temperature distribution.
Inspecting thermostat
(b) Before installing the thermostat, be sure to check
the valve opening temperature stamped on the
thermostat valve side face.

Item Standard
Temperature at which valve starts 71 ± 2°C
opening [160 ± 3.6°F]
Temperature at which valve lift
85°C [185°F]
becomes 10 mm [0.39 in.] or more.

Note: When assembling, orient the thermostat with its air

breed hole faced upward.

10-3
COOLING SYSTEM

3. Installing cooling system

Replace

Crack, water leakage, damage

Replace

M10 × 1.5
35 ± 3.5 N·m {3.6 ± 0.3 kgf·m} [25.3 ± 2.2 lbf·ft]
M8 × 1.25
19 ± 1.9 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]

Crack, wear

Installing cooling system

10-4
 INLET AND EXHAUST SYSTEM
1. Removing inlet and exhaust
sysytem .........................................11-2
1.1 Removing inlet system........................... 11-2
1.2 Removing exhaust system..................... 11-3

2. Disassembling, inspecting and

reassembling inlet and exhaust
system ...........................................11-4
2.1 Measuring exhaust manifold distortion .. 11-4

3. Installing inlet and exhaust system11-5

3.1 Installing inlet system............................. 11-5
3.2 Installing exhaust system....................... 11-6

11-1
INLET AND EXHAUST SYSTEM

1. Removing inlet and exhaust sysytem

1.1 Removing inlet system

Air inlet
Cylinder head

Replace Replace
2

Replace

Removing inlet system

Removing sequence

1 Air inlet elbow 2 Air heater 3 Inlet manifold

11-2
 INLET AND EXHAUST SYSTEM

1.2 Removing exhaust system

Replace 1

Cylinder head

Replace

Removing exhaust system

Removing sequence

1 Turbocharger 2 Exhaust manifold

11-3
INLET AND EXHAUST SYSTEM

2. Disassembling, inspecting and reassembling inlet and exhaust system

2.1 Measuring exhaust manifold distortion
(1) Check the flange for crack.
(2) Check the flange suface for distortion. If the distortion
exceeds the standard, retouch the surface.

Item Standard
Less than 0.2 mm
Exhaust manifold distortion
[0.008 in.]

Measuring exhaust manifold distortion

11-4
 INLET AND EXHAUST SYSTEM

3. Installing inlet and exhaust system

3.1 Installing inlet system

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

Air inlet
Cylinder head

Replace Replace

Replace

Installing inlet system

11-5
INLET AND EXHAUST SYSTEM

3.2 Installing exhaust system

Replace

Cylinder head

Replace

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

Installing exhaust system

11-6
 ELECTRICAL SYSTEM
1. Removing electrical system ..........12-2
1.1 Removing starter.................................... 12-2
1.2 Inspecting before removing alternator ... 12-3
1.2.1 Inspecting alternator operation.................12-3
1.2.2 Handling precaution .................................12-3
1.3 Removing alternator............................... 12-4
2. Disassembling, inspecting and
reassembling electrical system .....12-5
2.1 Disassembling and inspecting starter .... 12-5
2.1.1 Removing pinion set.................................12-6
2.1.2 Removing magnet switch .........................12-7
2.1.3 Removing rear bracket .............................12-7
2.1.4 Removing brush holder and
brush assembly ........................................12-8
2.1.5 Removing yoke and armature ..................12-8
2.1.6 Removing planetary gear .........................12-9
2.1.7 Removing overrunning clutch.................12-10
2.1.8 Removing internal gear ..........................12-11
2.2 Inspecting and repairing starter ........... 12-12
2.2.1 Inspecting magnetic switch ....................12-12
2.2.2 Inspecting magnetic switch contactor ....12-12
2.2.3 Measuring armature shaft runout ...........12-12
2.2.4 Measuring commutator radial runout .....12-13
2.2.5 Measuring undercut depth .....................12-13
2.2.6 Inspecting insulation between commutator and
shaft (core) .............................................12-13
2.2.7 Inspecting field coil .................................12-14
2.2.8 Inspecting overrunning clutch ................12-14
2.2.9 Inspecting reduction gear .......................12-14
2.2.10 Inspecting bearings ................................12-14
2.2.11 Inspecting brushes for wear ...................12-15
2.2.12 Measuring brush spring load ..................12-15
2.2.13 Inspecting safety switch .........................12-15
2.3 Reassembling starter ........................... 12-16
2.3.1 Installing E-ring ......................................12-16
2.3.2 Installing shaft lever ...............................12-16
2.3.3 Installing ball ..........................................12-16
2.3.4 Installing cover .......................................12-17
2.3.5 Installing yoke ........................................12-17
2.3.6 Installing pinion ......................................12-18
2.4 Disassembling and inspecting alternator12-19
2.4.1 Removing cover .....................................12-20
2.4.2 Removing through bolts .........................12-20
2.4.3 Disassembling the alternator to front side and
rear side .................................................12-20
2.4.4 Removing fan and pulley........................12-21
2.4.5 Removing rotor.......................................12-21
2.4.6 Removing front bearing ..........................12-21
2.4.7 Removing field coil ................................ 12-22
2.4.8 Removing stator .................................... 12-22
2.4.9 Removing rear bracket locked-in parts.. 12-23
2.5 Inspecting alternator............................. 12-24
2.5.1 Inspecting rectifier ................................. 12-24
2.5.2 Inspecting condensor ............................ 12-24
2.5.3 Inspecting regulator ............................... 12-24
2.5.4 Inspecting field coil ................................ 12-25
2.5.5 Inspecting stator coil.............................. 12-25
2.5.6 Inspecting bearings ............................... 12-26
2.6 Reassembling alternator ...................... 12-27
2.6.1 Installing rectifier.................................... 12-27
2.6.2 Slodering field coil and regulator ........... 12-27
2.6.3 Slodering stator coil and rectifier ........... 12-27
2.6.4 Reassembling front bearing................... 12-27
2.6.5 Reassembling front bracket and rotor ... 12-28
2.6.6 Installing rear bracket ............................ 12-28
2.6.7 Installing through bolt ............................ 12-28
2.7 Inspecting after reassembling .............. 12-28
2.8 Performance test of alternator.............. 12-29
2.8.1 Measuring regulator adjusting voltage... 12-29
2.8.2 Measuring output current....................... 12-29
3. Installing electrical system .......... 12-30
3.1 Installing starter.................................... 12-30
3.2 Installing alternator............................... 12-31
3.3 Replacing ECU..................................... 12-32
3.3.1 Removing ECU...................................... 12-32
3.3.2 Installing ECU........................................ 12-32
3.3.3 Test operation after replacing ECU ....... 12-32
3.4 Installing sensors ................................. 12-33
12-1
ELECTRICAL SYSTEM

1. Removing electrical system

1.1 Removing starter

Removing starter
Removing sequence

1 Starter

12-2
 ELECTRICAL SYSTEM

1.2 Inspecting before removing alternator

1.2.1 Inspecting alternator operation
Locate the cause of faulty charging from malfunctions
described below. Do not remove the alternator for
inspection and repair unless inspection cannot be performed
with the alternator installed on the engine.

Adjusted value of voltage regulator is high.

Overcharge
Faulty battery.
Low adjusted value of voltage relay.
Faulty alternator output.
Over dis-
Electric power consumption is extremely high.
charge
Special load is used.
Faulty wiring.

1.2.2 Handling precaution

Improper handling could cause damage or failure to the
alternator.
(1) Connect battery cables correctly. B terminal is positive
(+), and E terminal is negative (-).
(2) Do not use any high voltage tester such as megger.
(3) Do not disconnect lead wire from B terminal of the
alternator while the engine is running.
(4) Battery voltage is constantly applied to B terminal of
the alternator. Do not ground at this terminal.
(5) Do not short circuit or ground at L terminal. (For a
built-in IC regulator type)
(6) When a steam cleaner is used, do not allow the steam
directly contact the alternator.

12-3
ELECTRICAL SYSTEM

1.3 Removing alternator

Removing alternator
Removing sequence

1 Alternator 2 Adjusting plate 3 Set bolt

12-4
 ELECTRICAL SYSTEM

2. Disassembling, inspecting and reassembling electrical system

2.1 Disassembling and inspecting starter

11
12
4
14
Open or short circuit

25
18
15
16
17 Damage, wear

13

23 Damage, wear
24
22
Damage, wear
3 21
19 Replace

20 Function of
overrunning clutch
2
6
1 Replace
5
Wear
Damage, wear
7

Replace Brush dust accumulation,

8
local wear, rust,
Replace
deterioration, insulation

Open or short circuit

9

Open or short circuit,

10 ground, damage, wear

Disassembling and inspecting starter

Disassembling sequence

1 Clip ring 10 Armature 19 E ring

2 Pinion stopper, pinion, spring 11 Cover 20 Over runnning clutch
3 Bolt 12 Packing 21 Internal gear
4 Magnet switch 13 Planetary gear 22 Plate
5 Screw 14 Ball 23 Gear shaft
6 Through bolt 15 Packing 24 Front bracket
7 Rear bracket 16 Plate 25 Safety relay
8 Brush holder 17 Spring
9 Yoke assembly 18 Shift lever

12-5
ELECTRICAL SYSTEM

2.1.1 Removing pinion set

(1) Install the jig to hold the pinion.

Removing pinion set (1)

(2) Place an appropriate tube on the pinion stopper.
Hit the tube with a hammer to push the pinion stopper
down.

Removing pinion set (2)

(3) Remove the clip ring using snap ring plier.
Note: Do not reuse the clip ring for reassembly.

Removing pinion set (3)

(4) Remove the pinion stopper, pinion, spring.

Note: Check the pinion for wear and damage.

Removing pinion set (4)

12-6
 ELECTRICAL SYSTEM

2.1.2 Removing magnet switch

(1) Disconnect the terminal M leads on the magnetic
switch.

Removing magnet switch (1)

(2) Remove the through bolts, and remove the magnetic
switch.

Removing magnet switch (2)

2.1.3 Removing rear bracket
(1) Remove the screws from the rear bracket.

Removing rear bracket (1)

(2) Remove the through bolts, and remove the rear bracket.

Removing rear bracket (2)

12-7
ELECTRICAL SYSTEM

2.1.4 Removing brush holder and brush assem-

bly
(1) Remove the brush holder.
(2) Lift the brush spring up, and remove the brush from the
brush holder.

Removing brush

2.1.5 Removing yoke and armature

(1) Remove the yoke, and the armature.

Removing yoke and armature (1)

(2) Remove the front side O-ring and the rear side O-ring.
Do not reuse the removed O-ring. Replace it with new
one.

O-ring O-ring

Removing yoke and armature (2)

12-8
 ELECTRICAL SYSTEM

2.1.6 Removing planetary gear

(1) Remove the cover.

Removing planetaly gear (1)

(2) Remove the packing.

Removing planetaly gear (2)

(3) Remove the planetary gears.

Removing planetaly gear (3)

(4) Remove the balls from the shaft.

Note: Be careful not to lose the ball.

Removing planetaly gear (4)

12-9
ELECTRICAL SYSTEM

2.1.7 Removing overrunning clutch

(1) Remove the packing, the plate and the spring.

Removing overrunning clutch (1)

(2) Remove the shift lever and overrunning clutch from the
front bracket cover.

Removing overrunning clutch (2)

(3) Insert the flat-blade screwdriver to the groove of the E-
ring, then remove the E-ring.

Removing overrunning clutch (3)

(4) Remove the overrunning clutch.

Removing overrunning clutch (4)

12-10
 ELECTRICAL SYSTEM

2.1.8 Removing internal gear

Remove the internal gear.

Removing internal gear

12-11
ELECTRICAL SYSTEM

2.2 Inspecting and repairing starter

2.2.1 Inspecting magnetic switch
Inspect the pressure coil and the holding coil for open
circuit using the tester.
Inspect the electrical continuity between the terminal M and
the case, if there is no electrical continuity between them,
the magnetic switch circuit is an open circuit.

Inspecting magnetic switch

2.2.2 Inspecting magnetic switch contactor

The service limit of the contactor is decided by the S.S
condition of the contact surface. Inspect the contactor by C
following method. B
A
Measure the load current of the starter. If the voltage drop Ammeter
between the terminal B and the terminal M is 0.3 V per 100 C2 C1
M V

Battery
A or more, replace the magnetic switch. F1
Note: (a) When measuring the voltage drop, use a digital Digital voltmeter
volt meter. Measuring by an analog volt meter Ar

results breakage. E
Starter
(b) Be extremely careful when connecting an
ammeter to the starter because of the high current Inspecting magnetic switch contactor
flowing into the starter.

2.2.3 Measuring armature shaft runout

Using a dial gauge, measure the shaft runout. If the runout
exceeds the standard, repair or replace the armature.
Armature shaft
Item Standard
0.06 mm
Armature shaft runout
[0.0024 in.]

Measuring armature shaft runout

12-12
 ELECTRICAL SYSTEM

2.2.4 Measuring commutator radial runout

(1) Inspect the commutator surface. If the surface is rough,
polish it using a 400 to 600 grit sandpaper.
(2) Measure the commutator radial runout with a dial
gauge. If the measured value exceeds the limit, replace
the armature with a new one.

Item Limit
Commutator radial
0.10 mm [0.0039 in.] Commutator
runout

Measuring commutator radial runout

2.2.5 Measuring undercut depth
Measure the depth of undercutting between the commutator
segments.
If the measured value is less than the limit, repair or replace Insufficient recutting
with a new part. Defective Good
(need recutting)

Item Standard Limit

0.7 to 0.9 mm
0.7 to 0.9 mm 0.2 mm [0.028 to 0.035 in.]
Undercutting depth
[0.028 to 0.035 in.] [0.008 in.]

Measuring undercut depth

2.2.6 Inspecting insulation between commutator
and shaft (core)
(1) Inspect the armature coil using a growler. Apply a iron Iron plate
Growler tester
plate to the armature core. Replace the armature if the
iron plate vibrates.

Inspecting armature coil for short circuit

(2) Check the insulation between the commutator and the
shaft with a tester. If faulty, replace the armature with a
new one.

Inspecting insulation between commutator and shaft

12-13
ELECTRICAL SYSTEM

2.2.7 Inspecting field coil

(1) Inspect the field coil for open circuit with a tester. It is
an open circuit if there is no conticuity between the
terminal M of field coil and the bush lead.
(2) Inspect the electrical conticuity between the field coil
and the yoke with a tester.

Inspecting field coil for open circuit

2.2.8 Inspecting overrunning clutch
(1) Rotate the pinion by hand and check that the pinion
rotates lightly to one direction.
(2) Inspect the tooth flank. If wear or damage is found,
replace it with new one.

Inspecting over running clutch

2.2.9 Inspecting reduction gear
Inspect the reduction gear for wear.

Inspecting reduction gear

2.2.10 Inspecting bearings
Rotate the outer race of bearing by hand. Check that the
outer race rotates smoothly. Bearing

Inspecting bearing

12-14
 ELECTRICAL SYSTEM

2.2.11 Inspecting brushes for wear

Measure the length of the brushes. If the measured value is Unit: mm [in.]
less than the limit, replace both the brush holder assembly
and the brush assembly with new ones.

[0.67 to 0.71]
[0.40]
17 to 18
10
Item Standard Limit
17 to 18 mm 10 mm
Brush length
[0.67 to 0.71 in.] [0.40 in.]

Wear limit

Inspecting brush for wear

2.2.12 Measuring brush spring load

Using a new brush, measure the spring load at which the
spring lifts from the brush. If the measured value is less than
the limit, replace the spring with a new one.

Item Standard Limit

Less than
21.56 to 27.44 N
Brush spring load 21.56 N
{2.2 to 2.8 kgf}
(when brush is installed) {2.2 kgf}
[15.9 to 20.3 lbf]
[15.9 lbf]

2.2.13 Inspecting safety switch

&$87,21 Safety relay

ground (E) terminal
When connecting the battery, be sure to connect the
battery in correct polarity. Terminal S

Connect the components as shown and check the operation

of starter and safety switch.
(1) Connect the terminal R to the battery negative terminal.
(2) Turn on the switch and check if the starter operates
Terminal R
(rotates).
(3) While operating the starter, disconnect the terminal R
from the battery negative terminal and connect the Inspecting operation of safety switch
terminal R to the battery positive terminal. Check if the
starter stops.
Note: On some specifications, starter stops operation when
the connection to the battery negative terminal is
disconnected.

12-15
ELECTRICAL SYSTEM

2.3 Reassembling starter

To reassemble the starter, follow the disassembly in reverse order and observe bellow.
2.3.1 Installing E-ring
Install the washer, the center bracket and overrunning clutch
assembly to the shaft, and install the E-ring.
Note: Install the E-ring using a plier.

Installing E-ring

2.3.2 Installing shaft lever

Being careful with the direction, install the shift lever.
Note: Apply grease (Nikko grease R) to the shift lever when
reassembling.

Installing shift lever

2.3.3 Installing ball

Be careful not to forget to install the ball to the shaft before
installing the planetary gears.

Installing ball

12-16
 ELECTRICAL SYSTEM

2.3.4 Installing cover

(1) Be careful with the installation position when installing
the cover.
Notch

Cover

Installing cover

2.3.5 Installing yoke

(1) Install the yoke to the front bracket with aligning the
mark.

Installing yoke (1)

(2) Install the yoke to the rear bracket with aligning the
mark.

Installing yoke (2)

12-17
ELECTRICAL SYSTEM

2.3.6 Installing pinion

(1) Install the spring and the pinion, and install the jig.
(plate)

Plate

Installing pinion (1)

(2) Install the pinion stopper. Insert the clip ring to the jig
(holder) and install the clip ring using the jig. (guide)

Holder

Guide

(3) Using the jig (presser), install the clip ring to the pinion Installing pinion (2)
stopper.

Installing pinion (3)

12-18
 ELECTRICAL SYSTEM

2.4 Disassembling and inspecting alternator

4 5
6
3
3
11 Crack, damage

Rotation
10

9
12
7
17
Coil open circuit, ground
3

14

8 13

Rotation
22 Short or open circuit

16 20

18 19

23
15
Crack, damage
21

2 1

Disassembling and inspecting alternator

Disassembling sequence

1 Screw 9 Retainer 17 Stator coil

2 Cover 10 Front bearing 18 Holder
3 Through bolt 11 Front bracket 19 Regulator
4 Nut, spring washer, plain washer 12 Collar 20 Terminal B
5 Pulley 13 Rear bearing 21 Condensor
6 Fan 14 Rotor 22 Rectifier
7 Collar 15 Screw 23 Rear bracket
8 Screw 16 Field coil

12-19
ELECTRICAL SYSTEM

2.4.1 Removing cover

Remove the screws, and remove the cover.

Removing alternator cover

2.4.2 Removing through bolts
Remove the through bolts which secures front side and rear
side.

Removing through bolt

2.4.3 Disassembling the alternator to front side
and rear side
(1) Disassemble the alternator to front side and rear side. Heat the
Disassemble the alternator with heating the rear bracket bearing case
bearing case. Disassembling the alternator without
heating the rear bracket bearing case cause the damage
of the alternator.
Note: Be sure to heat the rear bracket bearing case only. Do
not heat the other parts.

Disassembling alternator to front side and rear side (1)

(2) Remove the rotor from the front bracket using press.
Then, use the through bolt hole.
Note: Do not hit the alternator with plastic hammer.
Protect the parts
from damage

Disassembling alternator to front side and rear side (2)

12-20
 ELECTRICAL SYSTEM

2.4.4 Removing fan and pulley

Remove the nuts using an inpact wrench, then remove the
spring washer, the plain washer, the pulley, the fan and the
collar.
Note: Fixing the rotor with vice could result the
deformation. Do not use the vice.

Removing fan and pulley

2.4.5 Removing rotor
Remove the rotor from the front bracket.
Note: (a) Remove the rotor using the press.
(b) When working with the rotor, place the buffer
under the rotor to prevent the damage.

Removing rotor
2.4.6 Removing front bearing
(1) Remove the screws, and remove the retainer.

Removing retainer
(2) Remove the front bearing from the front bracket.
Note: Do not reuse the removed front bearing. Replace it
with new one.

Removing bearing

12-21
ELECTRICAL SYSTEM

2.4.7 Removing field coil

(1) Unsolder the field coil and regulator.
Note: Unsoldering must be finished by 5 seconds or less.

(2) Remove the screws, and remove the field coil. Removing field coil (1)

Removing field coil (2)

2.4.8 Removing stator
(1) Unsolder the stator coil and the rectifier.

Removing stator (1)

(2) Remove the stator from the rear bracket.

Removing stator (2)

12-22
 ELECTRICAL SYSTEM

2.4.9 Removing rear bracket locked-in parts

(1) Remove the screws from the rear bracket.
Rectifier
(2) Remove the screws from the regulator, and remove the Terminal B
regulator. Condensor
(3) Remove the screw from the terminal B, and remove the
terminal B.
(4) Remove the screw from the condensor, and remove the
Regulator
condensor.
(5) Remove the rectifier assembly.

Removing rear bracket locked-in parts

12-23
ELECTRICAL SYSTEM

2.5 Inspecting alternator

2.5.1 Inspecting rectifier
Check the rectifier for resistance of forward direction and
reverse direction.
If the resistance of forward direction is low, and the
resistance of reverse direction is high, it is normal.
If test result is not as above, it is faulty. Replace the rectifier
with new one.

Inspecting rectifier

2.5.2 Inspecting condensor

Charge the condensor with a tester. (RangeΩ × 1000)
Connect the tester lead in reverse direction. It is normal that
the pointer moves slightly and return.
If test result is not as above, it is faulty. Replace the
condensor with new one.

Inspecting condensor

2.5.3 Inspecting regulator

Measure the resistance between the regulator connector R
and L with a tester. (Range Ω × 1000)
If the diode of the regulator and the resistor of the regulator
are normal, the resistance of the forward direction is low
and the resistance of the reverse direction is high.
If test result is not as above, it is faulty. Replace the
regulator with new one.

Inspecting regulator

12-24
 ELECTRICAL SYSTEM

2.5.4 Inspecting field coil

(1) Inspect the insulation of the field coil.
Measure the electrical continuity between the terminal
and the core with a tester. (RangeΩ × 1000)
Replace the field coil with new one if electrical
continuity is indicated.

Inspecting field coil (1)

(2) Measure the resistance between the terminals of field
coil.
If measured resistance is Approx 6.62Ω (When 20°C
[68°F]), it is normal.
If test result is not as above, it is faulty. Replace the
field coil with new one.

Inspecting field coil (2)

2.5.5 Inspecting stator coil
(1) Inspect the insulation of the stator coil.
Measure the electrical continuity between the stator coil
and the core with a tester. (RangeΩ × 1000)
Replace the stator coil with new one if electrical
continuity is indicated.

Inspecting stator coil (1)

(2) It is normal that the electrical continuity is indicated
between the stator coil lead N and other three leads.
If test result is not as above, it is faulty. Replace the
stator coil with new one.

Inspecting stator coil (2)

12-25
ELECTRICAL SYSTEM

2.5.6 Inspecting bearings

Inspect the bearing for smooth rotation and abnormal noise.
If abnormality is found, replace the bearing with new one.

Inspecting bearing

12-26
 ELECTRICAL SYSTEM

2.6 Reassembling alternator

To reassemble the alternator, follow the disassembly in reverse order and observe bellow.
2.6.1 Installing rectifier
When reassembling the rectifier, apply rocktite to the
screws.

Installing rectifier
2.6.2 Slodering field coil and regulator
Soldering field coil and regulator must be finished as
quickly as possible.

Soldering field coil and regulator

2.6.3 Slodering stator coil and rectifier
Solder the stator coil and rectifier after caulking.
Soldering must be finished as quickly as possible.

Soldering stator coil and rectifier

2.6.4 Reassembling front bearing
Reassemble the front bearing with heating the front bearing
case.
Reassembling the front bearing without heating the front
bearing case cause the damage of front bearing.

Reassembling front bearing

12-27
ELECTRICAL SYSTEM

2.6.5 Reassembling front bracket and rotor

Use a press to reassemble the front bracket and the rotor.
Note: Be careful not to forget to install the collar when
Collar
reassembling.

Reassembling front bracket and rotar

2.6.6 Installing rear bracket
Reassemble the rear bracket with heating the bearing case.
Note: (a) Reassembling the rear bracket without heating
the bearing case cause the damage of the bearing.
(b) Be sure to heat the bearing case only. Do not heat
the other parts.

Installing rear bracket

2.6.7 Installing through bolt
Install the through bolt with fixing the front side and the rear
side using the alternator installation hole.

Installing through bolt

2.7 Inspecting after reassembling
After reassembling, rotate the pulley by hand to check the
smooth rotation.

Inspecting alternator after reassembling

12-28
 ELECTRICAL SYSTEM

2.8 Performance test of alternator

Measure the adjusting voltage and output current with wiring as schematic bellow.

Terminal R Terminal L SW1 SW2

CL (24V 3W)

+
V
-

Electric schematic of IC regulator built-in alternator performace test

2.8.1 Measuring regulator adjusting voltage 2.8.2 Measuring output current

(1) Close the SW1, and operate the alternator at 1500min-1
for 5 to 10 minutes until the ammeter indicates 6 A or
less.
(2) Make sure that ammeter indicates 2 to 6 A or less, then
operate the alternator at 3000 to 4000min-1.
If the indication of voltmeter is within the standard
value, the adjusting voltage of the alternator is normal.
(3) If the indication of ammeter is 6 A or more, charge the
battery for a while or replace the battery with fully
charged one.
If the indication of voltmeter is out of the standard
value, replace the regulator with new one.
Close the SW1 and SW2. Measure the maximaum output
current with a variable resistor operating the alternator at
5000min-1 and keeping the indication of voltmeter at 27 V.
It is normal that the measured output current is 50A or
more.
&$87,21
(a) Do not disconnect the battery when operating the
alternator.
(b) Do not connect the terminal L when the charge
lamp （24V, 3W）is not used. The terminal L and
circuit B must not be connected. It causes damege
of diode.

Item Standard
Adjusting voltage 27.5 to 29.5 V (at 25°C [77°F])

12-29
ELECTRICAL SYSTEM

3. Installing electrical system

3.1 Installing starter

35.3 ± 5.9 N·m

{3.6 ± 0.6 kgf·m}
[255.4 ± 42.6 lbf·ft]

Installing starter

12-30
 ELECTRICAL SYSTEM

3.2 Installing alternator

97 ± 9.7 N·m
{9.9 ± 1.0 kgf·m}
[71.6 ± 7.2 lbf·ft]

Installing alternator

12-31
ELECTRICAL SYSTEM

3.3 Replacing ECU

3.3.1 Removing ECU
(1) Make sure that the ignition switch is in the OFF
position.
(2) Uplift the lever of the connector, and pull out the
connector. Then, do not pull the harness. Pull out the
connector with holding the connector.
Note: (a) Do not forget to uplift the lever before pulling out
the connector. Do not pull the connector forcedly.
(b) Be careful for the removed connector not to
contact with other parts.
(3) Remove the ECU mouting bolts. Replacing ECU（1）
(4) Remove the ECU.

3.3.2 Installing ECU

(1) Make sure that the Q-Rank number attached on the new
ECU is same as the number attached on the previous
ECU.
Note: If the ECU which has different Q-Rank number is
installed, it causes the excess and deficiency of the
engine power.
(2) Install the ECU and tighten the ECU mouting bolts to
specified torque.
(3) Push the connector into the ECU securely, and push Replacing ECU（2）
down the lever to lock. After connecting, check the
connector for excessive play.

3.3.3 Test operation after replacing ECU

(1) Turn the ignition switch to ON position. If the diagnosis
code is not displayed on the monitor for 2 to 3 minutes,
start the engine and operate the engine in low idle.
(2) Inspect that the diagnosis code is displayed on the
monitor. Inspect the engine for noise, odor and
vibration.

12-32

3.4 Installing sensors
Speed/timing sensor
(crankshaft side)
9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.5 ± 0.7 lbf·ft]
Pick up
29.4 ± 4.9 N·m
{3.0 ± 0.5 kgf·m}
[212.8 ± 35.5 lbf·ft]
ELECTRICAL SYSTEM
Inlet manifold pressure sensor
25 ± 2 N·m
{2.5 ± 0.2 kgf·m}
[18.1 ± 1.4 lbf·ft]
Water temperature sensor
21 ± 2 N·m
{2.0 ± 0.2 kgf·m}
[15.2 ± 1.5 lbf·ft]
Oil pressure switch
1.0 ± 2 N·m
{1.0 ± 0.2 kgf·m}
[7.2 ± 1.4 lbf·ft]
Speed/timing sensor
(camshaft side)
9 ± 1 N·m
{0.9 ± 0.1 kgf·m}
[6.5 ± 0.7 lbf·ft]
Installing sensors
12-33
 ADJUSTMENT AND OPERATION
1. Adjusting engine............................13-2
1.1 Inspecting and adjusting valve clearance13-2
1.1.1 Inspecting valve clearance .......................13-2
1.1.2 Adjusting valve clearances.......................13-2
1.2 Inspecting belt and adjusting belt tension13-3
1.2.1 Checking the belt .....................................13-3
1.2.2 Adjusting the belt tension .........................13-3

2. Break-in operation.........................13-4
2.1 Starting up.............................................. 13-4
2.2 Inspecting engine condition after
starting up .............................................. 13-4
2.3 Break-in operation time.......................... 13-4
2.4 Inspection and adjustment after break-in
operation ................................................ 13-4

3. Performance test (JIS standard) ...13-5

3.1 Engine equipment condition................... 13-5
3.2 Test items and purposes........................ 13-5
3.2.1 Operation load test ...................................13-5
3.2.2 Continuous load test ................................13-5
3.2.3 Low idle test .............................................13-5
3.3 Other inspections ................................... 13-5
3.4 Engine output adjustment ...................... 13-5
3.4.1 Standard atmospheric conditions: ............13-5
3.4.2 Calculation of corrected power.................13-6

13-1
ADJUSTMENT AND OPERATION

1. Adjusting engine
1.1 Inspecting and adjusting valve clearance
Inspect and adjust the valve clearance.
The valve clearance should be inspected and adjusted when
the engine is cold.
Note: (a) The inlet values are on the left side and the
exhaust values are on the right side when the
cylinder head is viewed from the camshaft gear
side.
(b) The valve clearance standard values are indicated
on the caution plate on the No.1 cylinder rocker
cover.

Item Standard
0.25 mm
Inlet
[0.0099 in.]
Valve clearance
0.40 mm
Exhaust
[0.0157 in.]

1.1.1 Inspecting valve clearance

(1) Inspect the valve clearance for all cylinders in the firing
Model Firing order Turning angle
order by turning the crankshaft to the specified degrees
D04FR 1-3-4-2 180°
in the normal direction (clockwise when viewed from
engine front side) to bring each piston to the top dead
center on the compression stroke.
"0" graduation mark on
Note: To turn the crankshaft, fit a socket and ratchet handle
crankshaft pulley
on the crankshaft pulley nut.
(2) When the No. 1 piston is at the top dead center on the
0 40
compression stroke, the "0" graduation mark on the
periphery of the crankshaft pulley is aligned with the
pointer on the timing gear case, and neither the inlet Inspecting valve clearance
valve nor the exhaust valve is not lifted off its seat by
the push rod.
(3) Insert a thickness gauge between the rocker arm and
valve cap to inspect the clearance.

1.1.2 Adjusting valve clearances

(1) Insert the feeler gauge of the specified thickness
between the rocker arm and bridge cap, then adjust the
clearance by turning the screw in either direction so that
the gauge is gripped softly between the rocker arm and
bridge cap.
(2) After adjusting the clearance, tighten the lock nut
firmly, and inspect the clearance again.

Adjusting valve clearance

13-2
 ADJUSTMENT AND OPERATION

1.2 Inspecting belt and adjusting belt tension

&$87,21
(a) If defects such as cuts or surface separations are Adjusting bolt
found during inspection, replace the belt. Alternator
(b) Keep oil and grease away from the belt, since they
may cause the belt to slip and shorten the service
life.
(c) Excessive belt tension can cause rapid wear of the Belt
alternator bearing and shorten the service life of
the belt. Adjust the belt tension accurately by fol-
lowing the procedures below.
Adjusting belt tension
1.2.1 Checking the belt
(1) Inspect the belt visually for separation or damage. If
any abnormality is found, replace the belt with a new
one.
(2) Inspect belt tension (deflection).
When pressing the belt strongly at the center of its span,
the deflection for a new belt should be 5±1 mm
[0.20±0.04 in.] and the deflection for the belt that is
reused should be 8±1 mm [0.32±0.04 in.]
Force on the belt: Approximately 98±10 N {10±1 kgf}
[22±2.2 lbf]
If the deflection of belt is not within the standard, adjust
the belt tension.
1.2.2 Adjusting the belt tension
(1) Remove the belt cover.
(2) Loosen all retaining bolts of the alternator and adjusting
plate.
(3) Adjust V-belt tension properly with the adjusting bolt.
(4) Tighten all retaining bolts of the alternator and
adjusting plate.
(5) Install the belt cover.

13-3
ADJUSTMENT AND OPERATION

2. Break-in operation
After the engine is overhauled, couple the engine to the 2.3 Break-in operation time
dynamometer, and run the engine for break-in operation and The relationship between the load in break-in operation and
inspection. the operation time is as shown below.

2.1 Starting up Break-in operation time

(1) Before starting the engine, check the levels of coolant, Duration
Engine speed (min-1) Load
engine oil and fuel. (min)
Bleed air from the fuel and cooling systems. Low
(2) Stop the fuel supply, and crank the engine with the 1 rotation 800 to 1100 No-load 5
speed
starter for about 10 seconds to lubricate the engine.
(3) Move the control lever slightly in the fuel increase Medium
2 rotation 1200 to 1500 No-load 5
direction (but not to the "full injection" position), and
speed
then turn the starter switch key to the [START] position
High
to start the engine.
3 rotation 1600 to rated speed No-load 10
(4) After the engine is started, adjust the control lever to let speed
the engine operate at a minimum no-load speed (low
4 25 % 10
idle speed).
5 50 % 10
(5) Turn the starter switch key to the [OFF] position and Rated speed
make sure that the engine is stopped. 6 75 % 30
7 100 % 20
2.2 Inspecting engine condition after starting
Note: The table above is provided solely for reference
up
During the break-in operation, check the followings. purpose. Run the engine at appropriate speed and
If any abnormality is found, stop the engine, investigate the load for the break-in operation of your engine. Be
cause, and take appropriate measures. sure to perform break-in operation after overhaul or
installation.
(1) The oil pressure must be within the specified value.
(2) The coolant temperature must be within the specified
2.4 Inspection and adjustment after break-in
value.
operation
(3) The engine must be free from any leakages such as oil,
(1) Valve clearance adjustment
coolant and fuel. Pay special attention to oil leakage
(2) Ignition timing inspection
from the fitting face of turbocharger lube oil pipe.
(3) Exterior bolt and nut tightness check
(4) Check for an abnormal noise.
Note: Knocking noise will disappear as the coolant
temperature rises.
(5) Check for the color of smoke and odors.

13-4
 ADJUSTMENT AND OPERATION

3. Performance test (JIS standard)

The following describes the procedures specified in "Earth
moving machinery - Engines - Part 1: Test code of net
power (JIS D0006-1)" and "Earth moving machinery -
Engines - Part 2: Standard format of specifications and
testing methods of diesel engines (JIS D0006-2)."
Other test items may be required in some applications. All
test results should be evaluated comprehensively in order to
determine the engine performance.

3.1 Engine equipment condition

The engine must be equipped with standard auxiliary
devices such as cooling fan, air cleaner and alternator.

3.2 Test items and purposes

3.2.1 Operation load test
Conduct this test to evaluate the engine output, torque, fuel
consumption rate and governor performance under various
load conditions.
3.2.2 Continuous load test
Operate the engine continuously for 10 hours at 90% load
(continuous load application) of nominal net brake power
while the engine speed is maintained at revolutions
corresponding to the nominal brake power. In this test,
evaluate the fuel consumption rate and operating condition,
and confirm that the engine is capable of continuous
operation.
3.2.3 Low idle test
Conduct this test to confirm that the engine can operate
stably at the specified low idle speed.

3.3 Other inspections

Check for gas, coolant and oil leaks; abnormal odors; and
hunting. Make adjustment as needed.

3.4 Engine output adjustment

Diesel engine output is affected by atmospheric pressure,
temperature and humidity. Therefore, correction
calculations must be performed to obtain the value of engine
output under the standard atmospheric conditions.
3.4.1 Standard atmospheric conditions:
Base temperature: 298 K (25°C) [77°F]
Total pressure: 100 kPa (750 mmHg)
Dry pressure: 99 kPa [743 mmHg]

13-5
ADJUSTMENT AND OPERATION

3.4.2 Calculation of corrected power

Multiply the measured brake power or torque by the
calculated diesel engine correction factor to obtain a
corrected value.
If the applicable range of the correction formula is
exceeded, indicate the corrected values and record the test
conditions on the test record.

Colculation output = Correction factor

ǩc˜Measured brake power
࡮Atmospheric conditions during test
Temperature(T ):-
q
=q
% (?҇T ҇-
q
=q
% (?
Dry atmospheric pressure(Pd ):M2C
OO*I҇Pd ҇M2C
OO*I

ǩc=( f a ) f m ‫ޓ‬f a:Atmospheric factor‫ޓ‬fmEngine factor

࡮Range of correction equation use
‫ޓ‬6JGTCPIGQHEQTTGEVKQPHCEVQT
ǩcKUCUHQNNQYU
0.9҇ǩc҇1.1.
Calculation of engine factor
fm
Calculation of correction factor( f a ) f m0.036qc㧙1.14
࡮Natural aspiration engine and engine with qc%QTTGEVGFHWGNUWRRN[XQNWOG
mechanically driven air charger q
qc r
99 T 
f a 
㨯

z˜
(WGNHNQYTCVGg/s
Pd 298 q=

5VTQMGXQNWOGl˜
'PIKPGURGGFmin-1
࡮Turbocharged engine without air cooler z=120000
4E[ENGGPIKPG
or with air-to-air cooler r4CVKQDGVYGGPRTGUUWTGCVVWTDQEJCTIGTQT
99 
f a 
 T  CKTEQQNGTQWVNGVCPFCVOQURJGTKERTGUUWTG
㨯

Pd 298 ‫
ޓ‬r=1HQTPCVWTCNCURKTCVKQPGPIKPG
࡮Applicable range of engine factor
fm 
࡮Turbocharged engine with air-to-liquid
‫ޓ‬37.2҇qc҇65mg
lE[ENG
cooler
99  T  㨯qc҇37.2mg
lE[ENG㧦f m
EQPUVCPV
f a 
 㨯
 㨯65mg
lE[ENG҇qc㧦f m
EQPUVCPV
Pd 298

13-6
 TROUBLESHOOTING
1. Troubleshooting by diagnosis
codes.............................................14-2
1.1 Outline of control system ....................... 14-2
1.2 Diagnosis codes..................................... 14-2
1.3 Connecting scan tester and ECU........... 14-2
1.4 When ECU does not respond ................ 14-2

2. Scan tester ....................................14-3

2.1 Operation of scan tester......................... 14-3
2.1.1 Basic operation of scan tester ..................14-3
2.2 Check engine status .............................. 14-4
2.3 Check diagnosis codes .......................... 14-4
2.4 Check freeze data.................................. 14-4
2.5 Clear diagnosis codes............................ 14-4

3. Diagnosis code cross reference ....14-5

4. Troubleshooting reference chart ...14-7

4.1 Troubleshooting with diagnosis code..... 14-7
4.2 Related diagnosis code........................ 14-21

5. Inspecting sensors ......................14-25

5.1 Speed/timing sensor (crank, cam) ....... 14-25
5.2 Inlet manifold pressure sensor............. 14-25
5.3 Water temperature sensor ................... 14-25
5.4 Engine oil pressure switch ................... 14-26
5.5 Common rail pressure sensor.............. 14-26
5.6 Injector solenoid................................... 14-26
5.7 High pressure pump solenoid sensor
(MPROP) ............................................. 14-26

6. Inspecting wiring .........................14-27

6.1 Inspecting connector and harness ....... 14-27
6.1.1 Inspecting the intermittent fault ..............14-27
6.1.2 Inspecting connectors ............................14-27
6.1.3 Inspecting harness .................................14-27
6.1.4 Inspect open circuit and short circuit ......14-27
6.2 Pin location of the ECU connector and
extension harness connector ............... 14-28

14-1
 TROUBLESHOOTING
1. Troubleshooting by diagnosis codes
1.1 Outline of control system
This engine is controlled by electronic control unit (ECU).
The engine has the control parts and the sensors that
monitors the engine operation.
The ECU monitors the engine operation using the inputs
from various sensors, and controls the injectors and the fuel
injection pump.
This control system can provide appropriate engine control
for operating condition.
1.2 Diagnosis codes
When the ECU detects the abnormal engine operation
receiving signal input from the sensors, the ECU generates
an error code which is called a diagnosis code.
The diagnosis code includes the one which warns the
critical failure, and also the one which warns the light fault.
The diagnosis code can be seen on the monitor located on
the vehicle. It also can be seen by connecting the scan tester
（32G91-00600）to the ECU directly.
14-2
1.3 Connecting scan tester and ECU
To see the diagnosis code, connect the scan tester to the
ECU.
(1) Turn the ignition switch to OFF position.
(2) Connect the scan tester connector to the service
connector which is located on the vehicle.
(3) Turn the ignition switch to ON position.
1.4 When ECU does not respond
If the scan tester does not display with connecting to the
service connector, following conditions can be concerned.
• The harness and/or the connector between the service
connector and the ECU are faulty.
• The ECU is faulty.
At first, inspect the harness and connectors between the
service connector and the ECU. For the inspection, refer to
"Inspecting wiring"(14-28).
If the harness and the connectors are not faulty, replace the
ECU. For the replacement of ECU, refer to "Replacing
ECU"(12-32).
&$87,21
The engine may operates even if the ECU does not
respond with the scan tester. In this case, it is possible
that there are faults on the CAN circuit (communica-
tion circuit connecting the ECU and vehicle control
unit) inside the ECU. Do not operate the engine except
emergency situation, replace the ECU.
 TROUBLESHOOTING

2. Scan tester

mastertech

Startup screen OBD ΤFUNCTION MENU

YES NO ENTER

F1 F2 F3
HELP
1 2 3

F4 F5 F6
RCV
4 5 6
FUNCTION MENU OBD ΤTEST MENU
F7 F8 F9
SEND
7 8 9

F0 ON
EXIT 㧖 0 #
OFF

Vetronix

Scan tester

SELECT PROGRAM

Scan tester

2.1 Operation of scan tester (9) The menu screen of OBD Ⅱ FUNCTIONS is
Use scan tester to check the engine status and the diagnosis displayed.
codes. (10)Press EXIT key to return the previous screen.
2.1.1 Basic operation of scan tester (11)With pressing ON key, press EXIT key to turn off the
(1) Make sure that ignition key is OFF position. scan tester.
(2) Connect the scan tester to the service connector on the (12)Turn the ignition key to OFF position to turn off the
vehicle. ECU.
(3) Turn the ignition key to ON position to energize the
ECU.
(4) Press ON key located on the lower right section of scan
tester to energize the scan tester. When the scan tester is
energized, startup screen is displayed.
(5) Press ENTER key.
(6) FUNCTION MENU is dispalyed. Select SCAN TEST
and press ENTER key.
(7) SELECT PROGRAM is displayed. Select GLOBAL
OBD Ⅱ and press ENTER key.
(8) OBD Ⅱ TEST MENU is dispalyed. Select OBD Ⅱ
FUNCTIONS and press ENTER key.

14-3
TROUBLESHOOTING

2.2 Check engine status

(1) Select DATA LIST from the OBD Ⅱ FUNCTIONS
mastertech
menu and press ENTER key.
(2) The engine status is displayed. Check the engine status.

Vetronix

Engine status screen

2.3 Check diagnosis codes
(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is dispalyed. Select READ DTCs and
press ENTER key.
(3) The diagnosis codes are displayed. The diagnosis codes
are displayed in the order of generating. To display the
previous generated codes, press down key.
Vetronix

Diagnosis code screen

2.4 Check freeze data
(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is dispalyed. Select FREEZE DATA and
press ENTER key.
(3) The FREEZE DATA is displayed. The FREEZE DATA
is a backup data saving the engine status screen of when
the diagnosis code is generated.
Vetronix

Freeze data screen

2.5 Clear diagnosis codes
(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is dispalyed. Select CLEAR DIAG INFO
and press ENTER key.
(3) The confirmation screen is displayed. Press YES key,
and press ENTER key to delete the diagnosis codes.
However, the diagnosis codes cannot be deleted until
Vetronix

the recovery is completed.

Clear DIAG screen

14-4
 TROUBLESHOOTING

3. Diagnosis code cross reference

The P code shown in the chart below is displayed by connecting the scan tester to the service connector.
The vehicle side code is displayed on the vehicle monitor. Check the correspoding codes by following chart.
For the detail and treatment of diagnosis codes, refer to "Troubleshooting reference chart".

Table 14-1 Diagnosis code cross reference (2 / 4)

Table 14-1 Diagnosis code cross reference (1 / 4)
J1939 Vehicle
J1939 Vehicle P
P Item code side
Item code side code
code (DTC) code
(DTC) code
Shut off
Discrepancy between P0215 1110-12 1110-8
P0016 228-3 228-1 pass test
crank and cam signal
MPROP power stage
Backup control using P0230 2001-3 2001-1
P0021 635-3 635-1 short-circuit to battery
cam side signal
MPROP power stage
P0089 DBV valve opening 2041-3 2041-1 P0231 2002-4 2002-2
short-circuit to ground
P0089 DBV kick off 2042-4 2042-2 MPROP power stage open
P0252 2000-2 2000-4
P0090 DBV closed fixation 2043-2 2043-4 circuit

P0091 DBV pressure is too low 2045-4 2045-2 MPROP power stage over-
P0252 2000-12 2000-8
load
P0092 DBV pressure is too high 2044-3 2044-1
Inlet manifold pressure
P0235 102-12 102-8
P0117 Water temperature sensor 110-4 110-2 sensor
P0118 Water temperature sensor 110-3 110-1 Inlet manifold pressure
P0237 102-4 102-2
sensor
Accelerator signal
P0121 383-12 383-8
comparison Inlet manifold pressure
P0238 102-3 102-1
sensor
P0122 Accelerator sensor 1 29-4 29-2
P0261 Injector No.1 657-2 657-4
P0123 Accelerator sensor 1 29-3 29-1
P0262 Injector No.1 657-3 657-1
Rail pressure governor
P0191 2013-3 2013-1
deviation P0263 Injector No.1 657-12 657-8
Rail pressure governor P0264 Injector No.2 659-2 659-4
P0191 2014-3 2014-1
deviation
P0265 Injector No.2 659-3 659-1
Rail pressure governor
P0191 2015-3 2015-1 P0266 Injector No.2 659-12 659-8
deviation
P0192 Rail pressure SRC 2011-4 2011-2 P0267 Injector No.3 661-2 661-4

P0193 Rail pressure SRC 2011-3 2011-1 P0268 Injector No.3 661-3 661-1

Rail pressure sensor P0269 Injector No.3 661-12 661-8

P0192 2012-4 2012-2
offset monitoring P0270 Injector No.4 663-2 663-4
Rail pressure sensor P0271 Injector No.4 663-3 663-1
P0193 2012-3 2012-1
offset monitoring
P0272 Injector No.4 663-12 663-8
P0194 Rail pressure governor 2016-3 2016-1
Speed/timing sensor
P0194 Rail pressure governor 2017-3 2017-1 P0336 637-4 637-2
(crankshaft side)
P0201 Injector No.1 658-2 658-4 Speed/timing sensor
P0339 637-3 637-1
P0202 Injector No.2 660-2 660-4 (crankshaft side)

P0203 Injector No.3 662-2 662-4 Speed/timing sensor

P0341 636-4 636-2
(camshaft side)
P0204 Injector No.4 664-2 664-4
Speed/timing sensor
Shut off P0344 636-3 636-1
P0215 1110-4 1110-2 (camshaft side)
pass test
Air heater relay
Shut off P0540 677-12 677-8
P0215 power stage
1110-2 1110-4
pass test

14-5
TROUBLESHOOTING

Table 14-1 Diagnosis code cross reference (3 / 4) Table 14-1 Diagnosis code cross reference (4 / 4)
J1939 Vehicle J1939 Vehicle
P P
Item code side Item code side
code code
(DTC) code (DTC) code
Air heater relay P060B ADC monitoring 2008-12 2008-8
P0541 677-4 677-2
power stage
P060D CAN accelerator 91-2 91-4
Air heater relay
P0542 677-3 677-1 P060E APPREQ message time out 1674-2 1674-4
power stage
P061C Engine speed 2005-3 2005-1
Air heater relay
P0543 677-2 677-4
power stage Injector
P062D 651-12 651-8
drive bank 1
Power supply unit voltage
P0562 1543-4 1543-2
too low Injector
P062E 653-12 653-8
drive bank 2
Power supply unit voltage
P0563 1542-3 1542-1
too high P062F EEPROM 1235-4 1235-2
P0600 CAN transmitting time out 2028-2 2028-4 P062F EEPROM 1235-2 1235-4
P0600 CAN (A) pass off 1671-3 1671-1 P062F EEPROM 1235-12 1235-8
P0600 CAN (C) pass off 1673-3 1673-1 P0933 Oil pressure switch 19-12 19-8
P0606 SPI communication error 1231-3 1231-1 P0933 Oil pressure switch 100-12 100-8
P0606 Super vision 1484-12 1484-8 Injector
P2047 652-2 652-4
drive bank 1
P0607 Recovery occurred 1668-12 1668-8
Injector
P0607 Recovery occurred 1670-12 1670-8 P2048 651-4 651-2
drive bank 1
P0607 SPI watch dog error 2010-12 2010-8
Injector
P2049 651-3 651-1
P0611 Injector IC 655-3 655-1 drive bank 1
P0611 Injector IC 655-4 655-2 Injector
P2050 654-2 654-4
drive bank 2
P0611 Injector IC 655-2 655-4
Injector
P0611 Injector IC 655-12 655-8 P2051 653-4 653-2
drive bank 2
P0611 Injector IC 656-3 656-1
Injector
P2052 653-3 653-1
P0611 Injector IC 656-4 656-2 drive bank 2

P0611 Injector IC 656-2 656-4 Atomospheric pressure

P2228 108-4 108-2
sensor
P0611 Injector IC 656-12 656-8
Atomospheric pressure
Sensor supply voltage P2229 108-3 108-1
P0642 1079-4 1079-2 sensor
monitoring 1
Sensor supply voltage
P0643 1079-3 1079-1
monitoring 1
Sensor supply voltage
P0652 1080-4 1080-2
monitoring 2
Sensor supply voltage
P0653 1080-3 1080-1
monitoring 2
Sensor supply voltage
P0698 620-4 620-2
monitoring 3
Sensor supply voltage
P0699 620-3 620-1
monitoring 3
P060A TPU monitoring 2009-12 2009-8
P060B ADC monitoring 2008-3 2008-1
P060B ADC monitoring 2008-4 2008-2
P060B ADC monitoring 2008-2 2008-4

14-6
 TROUBLESHOOTING

4. Troubleshooting reference chart

4.1 Troubleshooting with diagnosis code
Note: The diagnosis codes which has * mark in the "Recovery" column recovers when the cause of fault has deleted and the
engine has restarted.

P0016 : Discrepancy between speed/timing sensor P0117 : Water temperature sensor

(crankshaft side/camshaft side) signal Vehicle side code : 110-2
Vehicle side code : 228-1 Faulty part Water temperature sensor
Speed/timing sensor The ECU detectes a faulty operation of
Faulty part
(crankshaft side/camshaft side) the water temperature sensor (open cir-
Detail
The ECU detects a discrepancy between cuit, short circuit). The input voltage
Detail speed/timing sensor (crankshaft side/ falls below the limiting value.
camshaft side) signal. Recovery *
Recovery * When engine is operated, the ECU con-
The ECU controls the engine using trols the engine as overheated
speed/timing sensor (crankshaft side) with fixing the temperature 120°C
Control signal. Control (warm mode). When starting the engine,
The ECU limits the maximum speed of the ECU controls the engine with fixing
the engine. the water temperature -20°C (cold
mode).
Speed limit The maximum speed is limited to 50%.
When the water temperature is 100°C or
Inspection Contact a Mitsubishi dealer. Speed limit above, the ECU controls the engine as
overheated.
P0021 : Backup control using camshaft side signal
Water temperature sensor, and wiring of
Vehicle side code : 635-1 Inspection
water temperature sensor.
Speed/timing sensor
Faulty part
(crankshaft side) P0118 : Water temperature sensor
The engine is operating without speed/ Vehicle side code : 110-1
timing sensor (crankshaft side) signal. Faulty part Water temperature sensor
Detail
The ECU controls the engine using cam-
shaft side signal. The input voltage exceeds the limiting
Detail
value.
Recovery *
Recovery *
The ECU limits the maximum speed of
Control When engine is operated, the ECU con-
the engine.
trols the engine as overheated
Speed limit The maximum speed is limited to 50%. with fixing the temperature 120°C
Speed/timing sensor (crankshaft side) Control (warm mode). When starting the engine,
Inspection and wiring of speed/timing sensor the ECU controls the engine with fixing
(crankshaft side). the water temperature -20°C (cold
mode).
When the water temperature is 100°C or
Speed limit above, the ECU controls the engine as
overheated.
Water temperature sensor, and wiring of
Inspection
water temperature sensor.

14-7
TROUBLESHOOTING

P0121 : Accelerator signal comparison P0191 : Rail pressure governor deviation

Vehicle side code : 383-8 Vehicle side code : 2013-1
Accelerator signal (CAN signal, analog Faulty part Common rail
Faulty part
signal)
The rail pressure control is abnormal.
Detail
The ECU compares the CAN signal and The target pressure is not achieved.
Detail analog signal, and detects a discrepacy
Recovery *
between them.
The ECU limits the maximum speed of
When a discrepancy is deleted, it recov- Control
Recovery the engine.
ers automatically.
Speed limit The maximum speed is limited to 75%.
Control The ECU warns to the operator.
Inspection Damage on the common rail.
Speed limit -
Inspection CAN signal and analog signal wiring.
Vehicle side code : 2014-1
P0122 : Accelerator sensor 1
Faulty part Common rail
Vehicle side code : 29-2
The rail pressure control is abnormal.
Faulty part Accelerator signal (analog signal)
Detail The target pressure is not achieved even
The ECU detects a faulty analog signal fully pressured by fuel pump.
Detail input from vehicle controller. The input
Recovery *
voltage falls below the limiting value.
Control Engine stop
When the input voltage recovers to the
Recovery specified value, it recovers automati- Speed limit -
cally.
Inspection Damage on the common rail.
When operating by CAN signal, the
ECU warns to the operator. When oper- P0192 : Rail pressure sensor offset monitoring
Control ating by analog signal, the ECU warns
Vehicle side code : 2012-2
to the operator and the engine operation
switches to the redundancy operation. Faulty part Rail pressure sensor
Speed limit - The input voltage falls below the limit-
Detail
ing value.
Inspection Accelerator signal (analog signal)
Recovery *
P0123 : Accelerator sensor 1 The ECU limits the maximum speed of
Vehicle side code : 29-1 Control
the engine.
Faulty part Accelerator signal (analog signal) Speed limit The engine speed is fixed to 8%.
The ECU detects a faulty analog signal Rail pressure sensor, and wiring of rail
Detail input from vehicle controller. The input Inspection
pressure sensor.
voltage exceeds the limiting value.
When the input voltage recovers to the
Recovery specified value, it recovers automati-
cally.
When operating by CAN signal, the
ECU warns to the operator. When oper-
Control ating by analog signal, the ECU warns
to the operator and the engine operation
switches to the redundancy operation.
Speed limit -
Inspection Accelerator signal (analog signal)

14-8
 TROUBLESHOOTING

P0193 : Rail pressure sensor offset monitoring P0202 : Injector No.2

Vehicle side code : 2012-1 Vehicle side code : 660-4
Faulty part Rail pressure sensor Faulty part Injector No.2
The input voltage exceeds the limiting The ECU detects an open circuit of the
Detail Detail
value. injector and/or injector harness.
Recovery * Recovery *
The ECU limits the maximum speed of The engine keeps operating if only one
Control
the engine. Control injector is faulty. The engine stops if
two or more injectors are faulty.
Speed limit The engine speed is fixed to 8%.
There is no specific control by the ECU,
Rail pressure sensor, and wiring of rail Speed limit
Inspection but the engine speed decreases.
pressure sensor.
Inspection Injector, and wiring of injector.
P0194 : Rail pressure governor
Vehicle side code : 2016-1 P0203 : Injector No.3
Vehicle side code : 662-4
Faulty part Common rail
Faulty part Injector No.3
The rail pressure falls below the limiting
Detail
value. The ECU detects an open circuit of the
Detail
injector and/or injector harness.
Recovery *
Recovery *
Control Engine stop
The engine keeps operating if only one
Speed limit -
Control injector is faulty. The engine stops if two
Inspection Damage on the common rail. or more injectors are faulty.
There is no specific control by the ECU,
P0201 : Injector No.1 Speed limit
but the engine speed decreases.
Vehicle side code : 658-4
Inspection Injector, and wiring of injector.
Faulty part Injector No.1
The ECU detects an open circuit of the P0204 : Injector No.4
Detail
injector and/or injector harness. Vehicle side code : 664-4
Recovery * Faulty part Injector No.4
The engine keeps operating if only one The ECU detects an open circuit of the
Detail
Control injector is faulty. The engine stops if two injector and/or injector harness.
or more injectors are faulty.
Recovery *
There is no specific control by the ECU,
Speed limit The engine keeps operating if only one
but the engine speed decreases.
Control injector is faulty. The engine stops if two
Inspection Injector, and wiring of injector. or more injectors are faulty.
There is no specific control by the ECU,
Speed limit
but the engine speed decreases.
Inspection Injector, and wiring of injector.

14-9
TROUBLESHOOTING

P0215 : Shut off pass test P0235 : Inlet manifold pressure sensor
Vehicle side code : 1110-2 Vehicle side code : 102-8
Faulty part ECU Inlet manifold pressure sensor power
Faulty part
supply line
The emergency injection stop circuit
Detail does not operate. The shut-off by watch The ECU detects an open circuit or short
Detail
dog is disabled. circuit of the sensor power supply (5V).
Recovery * Recovery *
Control The ECU warns to the operator. The ECU controls the engine using the
Control
backup data.(Approx. 1013 hpa)
Speed limit -
Speed limit The maximum speed is limited to 75%.
Inspection Contact a Mitsubishi dealer.
Inlet manifold pressure sensor power
Inspection
supply line wiring
Vehicle side code : 1110-4
P0237 : Inlet manifold pressure sensor
Faulty part ECU
Vehicle side code : 102-2
The emergency injection stop circuit
Faulty part Inlet manifold pressure sensor
Detail does not operate. The shut off by high
voltage monitoring is disabled. The ECU detects the faulty operation of
the inlet manifold pressure sensor (open
Recovery *
Detail circuit, short circuit, characteristic
Control The ECU warns to the operator. fault). The input voltage falls below the
limiting value.
Speed limit -
Recovery *
Inspection Contact a Mitsubishi dealer.
The ECU controls the engine using the
Control
backup data.
Vehicle side code : 1110-8 Speed limit The maximum speed is limited to 75%.
Faulty part ECU Inlet manifold pressure sensor, and wir-
Inspection
ing of inlet manifold pressure sensor.
The emergency injection stop circuit
Detail does not operate. The shut off by low
voltage monitoring is disabled. P0238 : Inlet manifold pressure sensor
Vehicle side code : 102-1
Recovery *
Faulty part Inlet manifold pressure sensor
Control The ECU warns to the operator.
The input voltage exceeds the limiting
Speed limit - Detail
value.
Inspection Contact a Mitsubishi dealer. Recovery *

P0231 : MPROP power stage short-circuit to ground The ECU controls the engine using the
Control
backup data.
Vehicle side code : 2002-2
Speed limit The maximum speed is limited to 75%.
Faulty part MPROP
Inlet manifold pressure sensor, and wir-
The ECU detects a short circuit on the Inspection
Detail ing of inlet manifold pressure sensor.
ground line of the MPROP harness.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection MPROP, and wiring of MPROP.

14-10
 TROUBLESHOOTING

P0261 : Injector No.1 P0265 : Injector No.2

Vehicle side code : 657-4 Vehicle side code : 659-1
Faulty part Injector No.1 Faulty part Injector No.2
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery.
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Speed limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Speed limit -
Inspection Injector, and wiring of injector. P0266 : Injector No.2
Vehicle side code : 659-8
P0262 : Injector No.1
Faulty part Injector No.2
Vehicle side code : 657-1
Unclassifiable error in the injector and/
Faulty part Injector No.1
Detail or the injector harness. The injector is
The injector is faulty. The low side is a disabled.
Detail
short circuit to the battery.
Recovery *
Recovery *
Control Engine stop
Control Engine stop
Speed limit -
Speed limit -
Inspection Injector, and wiring of injector.
Inspection Injector, and wiring of injector.
P0267 : Injector No.3
P0263 : Injector No.1 Vehicle side code : 661-4
Vehicle side code : 657-8
Faulty part Injector No.3
Faulty part Injector No.1
The ECU detects a short circuit of the
Unclassifiable error in the injector and/ injector and/or injector harness. There
Detail
Detail or the injector harness. The injector is are short circuits on the high side and
disabled. low side.
Recovery * Recovery *
Control Engine stop Control Engine stop
Speed limit - Speed limit -
Inspection Injector, and wiring of injector. Inspection Injector, and wiring of injector.

P0264 : Injector No.2 P0268 : Injector No.3

Vehicle side code : 659-4 Vehicle side code : 661-1
Faulty part Injector No.2 Faulty part Injector No.3
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery.
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Speed limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Speed limit -
Inspection Injector, and wiring of injector.

14-11
TROUBLESHOOTING

P0269 : Injector No.3 P0336 : Speed/timing sensor (crankshaft side)

Vehicle side code : 661-8 Vehicle side code : 637-2
Faulty part Injector No.3 Speed/timing sensor
Faulty part
(crankshaft side)
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is The ECU detects the fault of speed/tim-
disabled. ing sensor (crankshaft side)(open cir-
Detail cuit, short circuit, tooth brakage). The
Recovery *
number of crank pulse and/or crank
Control Engine stop pulse position are faulty.

Speed limit - Recovery *

Inspection Injector, and wiring of injector. The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
P0270 : Injector No.4 nal.
Vehicle side code : 663-4 The maximum speed is limited to 50%
Speed limit
only when starting the engine.
Faulty part Injector No.4
Speed/timing sensor (crankshaft side),
The ECU detects a short circuit of the
Inspection and wiring of speed/timing sensor
injector and/or injector harness. There
Detail (crankshaft side).
are short circuits on the high side and
low side.
P0339 : Speed/timing sensor (crankshaft side)
Recovery * Vehicle side code : 637-1
Control Engine stop Speed/timing sensor
Faulty part
Speed limit - (crankshaft side)

Inspection Injector, and wiring of injector. The speed/timing sensor (crankshaft

Detail side) is faulty. The ECU is not receiving
P0271 : Injector No.4 the crank pulse.
Vehicle side code : 663-1 Recovery *
Faulty part Injector No.4 The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
The injector is faulty. The low side is a
Detail nal.
short circuit to the battery.
The maximum speed is limited to 50%
Recovery * Speed limit
only when starting the engine.
Control Engine stop
Speed/timing sensor (crankshaft side),
Speed limit - Inspection and wiring of speed/timing sensor
(crankshaft side).
Inspection Injector, and wiring of injector.

P0272 : Injector No.4

Vehicle side code : 663-8
Faulty part Injector No.4
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is
disabled.
Recovery *
Control Engine stop
Speed limit -
Inspection Injector, and wiring of injector.

14-12
 TROUBLESHOOTING

P0341 : Speed/timing sensor (camshaft side) P0541 : Air heater relay power stage
Vehicle side code : 636-2 Vehicle side code : 677-2
Speed/timing sensor Faulty part Air heater relay
Faulty part
(camshaft side)
The air heater relay and/or connecting
Detail
The ECU detects the fault of speed/tim- harness are short circuits to the ground.
ing sensor (camshaft side) (open circuit,
Recovery *
Detail short circuit, tooth breakage). The num-
ber of cam pulse and/or cam pulse posi- The air heater is disabled. The ECU
Control
tion are faulty. warns to the operator.
Recovery * Speed limit -
The ECU controls the engine using Inspection Air heater relay, and wiring of air heater.
Control speed/timing sensor (crankshaft side)
signal. The ECU warns to the operator. P0542 : Air heater relay power stage
Speed limit - Vehicle side code : 677-1
Speed/timing sensor (camshaft side), Faulty part Air heater relay
Inspection and wiring of speed/timing sensor (cam-
The air heater relay is faulty. The air
shaft side).
Detail heater relay is a short circuit to the bat-
tery.
P0344 : Speed/timing sensor (camshaft side)
Vehicle side code : 636-1 Recovery *

Speed/timing sensor The air heater is disabled. The ECU

Faulty part Control
(camshaft side) warns to the operator.

The speed/timing sensor (camshaft side) Speed limit -

Detail is faulty. The ECU is not receiving the Inspection Air heater relay, and wiring of air heater.
cam pulse.
Recovery * P0543 : Air heater relay power stage
Vehicle side code : 677-4
The ECU controls the engine using
Control speed/timing sensor (crankshaft side) Faulty part Air heater relay
signal. The ECU warns to the operator.
The ECU detects an open circuit of air
Detail
Speed limit - heater relay and/or connecting harness.
Speed/timing sensor (camshaft side), Recovery *
Inspection and wiring of speed/timing sensor (cam-
The air heater is disabled. The ECU
shaft side). Control
warns to the operator.
P0540 : Air heater relay power stage Speed limit -
Vehicle side code : 677-8 Inspection Air heater relay, and wiring of air heater.
Faulty part Air heater relay
P0562 : Power supply unit voltage too low
The ECU detects an overload of air
Detail Vehicle side code : 1543-2
heater relay and/or connecting harness.
Faulty part ECU
Recovery *
The voltage of the power supply unit
The air heater is disabled. The ECU
Control Detail inside the ECU falls below the limiting
warns to the operator.
value.
Speed limit -
Recovery *
Inspection Air heater relay, and wiring of air heater.
Control Engine stop
Speed limit -
Inspection Replace the ECU.

14-13
TROUBLESHOOTING

P0563 : Power supply unit voltage too high P0600 : CAN (C) pass off
Vehicle side code : 1542-1 Vehicle side code : 1673-1
Faulty part ECU Faulty part CAN communication line
The voltage of the power supply unit The CAN communication is faulty. The
Detail
Detail inside the ECU exceeds the limiting ECU detects the CAN (C) pass off.
value.
Recovery *
Recovery *
The ECU uses the analog signal for
Control Engine stop Control backup control. The ECU warns to the
operator.
Speed limit -
Speed limit -
Inspection Replace the ECU.
Inspection CAN comunnication line, and ECU.
P0600 : CAN transmitting time out
Vehicle side code : 2028-4 P0606 : SPI communication error
Vehicle side code : 1231-1
Faulty part CAN communication line
Faulty part ECU
Detail The CAN message cannot be tranmitted.
There are serial communication errors
Recovery * Detail
between CPU and other IC.
The ECU uses the analog signal for
Control Recovery *
backup control.
Control Engine stop
Speed limit -
Speed limit -
Inspection CAN comunnication line, and ECU.
Inspection Replace the ECU.
P0600 : CAN (A) pass off
Vehicle side code : 1671-1 P0606 : Super vision
Vehicle side code : 1484-8
Faulty part CAN communication line
Faulty part ECU
The CAN communication is faulty. The
Detail ECU detects an open circuit or short cir- The ECU detects an abnormality by
Detail
cuit of CAN line. using self-diagnosis function.
Recovery * Recovery *
The ECU uses the analog signal for Control Engine stop
Control backup control. The ECU warns to the
Speed limit -
operator.
Inspection Replace the ECU.
Speed limit -
Inspection CAN comunnication line, and ECU. P0607 : Recovery occurred
Vehicle side code : 1668-8
Faulty part ECU
The recovery occurred by the fault of the
Detail
ECU.
Recovery *
Control The ECU warns to the operator.
Speed limit -
Inspection -

14-14
 TROUBLESHOOTING

Vehicle side code : 1670-8 Vehicle side code : 655-4

Faulty part ECU Faulty part ECU
The recovery occurred by the fault of the The injector control IC inside the ECU
Detail Detail
ECU. is faulty.
Recovery * Recovery *
Control The ECU warns to the operator. Control Engine stop
Speed limit - Speed limit -
Inspection - Inspection Replace the ECU.

P0607 : SPI watch dog error

Vehicle side code : 2010-8 Vehicle side code : 655-8
Faulty part ECU Faulty part ECU
The ECU detects an abnormality by The injector control IC inside the ECU
Detail
Detail using self-diagnosis function. Watch dog is faulty.
error.
Recovery *
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Recovery two seconds. The engine stops if an Speed limit -
error occurs four times or more in two
seconds. Inspection Replace the ECU.

Control Engine stop

Speed limit - Vehicle side code : 656-1

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
P0611 : Injector IC Detail
is faulty.
Vehicle side code : 655-1
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Speed limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Speed limit - Vehicle side code : 656-2

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
Detail
is faulty.
Vehicle side code : 655-2
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Speed limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Speed limit -
Inspection Replace the ECU.

14-15
TROUBLESHOOTING

P0652 : Sensor supply voltage monitoring 2

Vehicle side code : 656-4 Vehicle side code : 1080-2
Faulty part ECU Faulty part ECU
The injector control IC inside the ECU The 5V power supply to the inlet mani-
Detail
is faulty. fold pressure sensor is faulty. The sup-
Detail
ply voltage falls below the limiting
Recovery *
value.
Control Engine stop
Recovery *
Speed limit -
The ECU controls the engine using the
Control
Inspection Replace the ECU. backup data.
Speed limit The maximum speed is limited to 75%.

Vehicle side code : 656-8 Inspection Replace the ECU.

Faulty part ECU P0653 : Sensor supply voltage monitoring 2

The injector control IC inside the ECU Vehicle side code : 1080-1
Detail
is faulty.
Faulty part ECU
Recovery *
The 5V power supply to the inlet mani-
Control Engine stop Detail fold pressure sensor is faulty. The sup-
ply voltage exceeds the limiting value.
Speed limit -
Recovery *
Inspection Replace the ECU.
The ECU controls the engine using the
Control
P0642 : Sensor supply voltage monitoring 1 backup data.
Vehicle side code : 1079-2 Speed limit The maximum speed is limited to 75%.
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt- P0698 : Sensor supply voltage monitoring 3
age falls below the limiting value. Vehicle side code : 620-2

Recovery * Faulty part ECU

Control The ECU warns to the operator. The 5V power supply to the rail pressure
Detail sensor is faulty. The supply voltage falls
Speed limit - below the limiting value.
Inspection Replace the ECU. Recovery *

P0643 : Sensor supply voltage monitoring 1 Control The ECU warns to the operator.
Vehicle side code : 1079-1 Speed limit -
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt-
age exceeds the limiting value.
Recovery *
Control The ECU warns to the operator.
Speed limit -
Inspection Replace the ECU.

14-16
 TROUBLESHOOTING

P0699 : Sensor supply voltage monitoring 3

Vehicle side code : 620-1 Vehicle side code : 2008-2
Faulty part ECU Faulty part ECU
The 5V power supply to the rail pressure The AD converter inside the ECU is
Detail sensor is faulty. The supply voltage Detail faulty. The standard voltage falls below
exceeds the limiting value. the limiting value.
Recovery * Recovery occurs. It recovers automati-
cally if an error occurs three times in two
Control The ECU warns to the operator.
Recovery seconds. The engine stops if an error
Speed limit - occurs four times or more in two sec-
onds.
Inspection Replace the ECU.
Control Engine stop
P060A : TPU monitoring Speed limit -
Vehicle side code : 2009-8
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a fault of rotating pulse
Detail Vehicle side code : 2008-4
arithmetic circuit inside the ECU.
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an
Detail faulty. The ECU detects the conversion
error occurs four times or more in two
error by using a test pulse.
seconds.
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Speed limit - Recovery two seconds. The engine stops if an
error occurs four times or more in two
Inspection Replace the ECU. seconds.

P060B : ADC monitoring Control Engine stop

Vehicle side code : 2008-1 Speed limit -
Faulty part ECU Inspection Replace the ECU.
The AD converter inside the ECU is
Detail faulty. The standard voltage exceeds the
limiting value. Vehicle side code : 2008-8
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an Detail
faulty. The conversion time is abnormal.
error occurs four times or more in two
seconds. Recovery occurs. It recovers automati-
cally if an error occurs three times in
Control Engine stop
Recovery two seconds. The engine stops if an
Speed limit - error occurs four times or more in two
seconds.
Inspection Replace the ECU.
Control Engine stop
Speed limit -
Inspection Replace the ECU.

14-17
TROUBLESHOOTING

P060D : CAN accelerator P062D : Injector drive bank 1

Vehicle side code : 91-4 Vehicle side code : 651-8
Faulty part ECU communication circuit Faulty part ECU
The ECU detects a fault of accelerator The ECU detects the short circuit of the
Detail
Detail opening (APPREQ) receiving from injector drive circuit inside the ECU.
CAN.
Recovery *
Recovery *
Control Engine stop
The ECU uses the analog signal for
Speed limit -
Control backup control. The ECU warns to the
operator. Inspection Replace the ECU.
Speed limit -
P062E : Injector drive bank 2
Inspection CAN communication circuit Vehicle side code : 653-8

P060E : APPREQ message time out Faulty part ECU

Vehicle side code : 1674-4 The ECU detects the short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part ECU communication circuit
Recovery *
The ECU cannot receive the accelerator
Detail
opening (APPREQ) signal. Control Engine stop
Recovery * Speed limit -
The ECU uses the analog signal for Inspection Replace the ECU.
Control backup control. The ECU warns to the
operator. P062F : EEPROM
Speed limit - Vehicle side code : 1235-2

Inspection CAN communication circuit Faulty part ECU

The ECU detects a read-write error of
P061C : Engine speed Detail the data memory bank inside the ECU.
Vehicle side code : 2005-1 The ECU cannot read the data.
Faulty part ECU Recovery *
The ECU is faulty. The engine speed Control The ECU warns to the operator.
Detail
data is faulty.
Speed limit -
Recovery occurs. It recovers automati-
cally if an error occurs three times in Inspection Replace the ECU.
Recovery two seconds. The engine stops if an
error occurs four times or more in two
seconds. Vehicle side code : 1235-4
Control The ECU warns to the operator. Faulty part ECU
Speed limit - The ECU detects a read-write error of
the data memory bank inside the ECU.
Inspection Replace the ECU. Detail
The ECU cannot write to the data mem-
ory.
Recovery *
Control The ECU warns to the operator.
Speed limit -
Inspection Replace the ECU.

14-18
 TROUBLESHOOTING

P2047 : Injector drive bank 1

Vehicle side code : 1235-8 Vehicle side code : 652-4
Faulty part ECU Faulty part ECU
The ECU detects a read-write error of The ECU detects an open circuit of the
Detail
Detail the data memory bank inside the ECU. injector drive circuit inside the ECU.
The ECU is using the substitute data.
Recovery *
Recovery *
Control Engine stop
Control The ECU warns to the operator.
Speed limit -
Speed limit -
Inspection Replace the ECU.
Inspection Replace the ECU.
P2048 : Injector drive bank 1
P0933 : Oil pressure switch Vehicle side code : 651-2
Vehicle side code : 19-8
Faulty part ECU
Faulty part Oil pressure switch
The ECU detects a short circuit of the
Detail
The oil pressure switch remains OFF injector drive circuit inside the ECU.
Detail position even the engine speed reaches
Recovery *
500min-1.
Control Engine stop
Recovery *
Speed limit -
Control The ECU keeps the engine low idling.
Inspection Replace the ECU.
Speed limit -
Oil pressure switch, and wiring of oil P2049 : Injector drive bank 1
Inspection
pressure switch. Vehicle side code : 651-1
Faulty part ECU
Vehicle side code : 100-8 The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part Oil pressure switch
Recovery *
The oil pressure switch remains OFF
position for 30 second after engine start- Control Engine stop
Detail
ing. The oil pressure switch remains
Speed limit -
OFF position during engine operation.
Inspection Replace the ECU.
Recovery *
Control Engine stop P2050 : Injector drive bank 2
Speed limit - Vehicle side code : 654-4

Oil pressure switch, and wiring of oil Faulty part ECU

Inspection
pressure switch. The ECU detects an open circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Speed limit -
Inspection Replace the ECU.

14-19
TROUBLESHOOTING

P2051 : Injector drive bank 2 P2229 : Atomospheric pressure sensor

Vehicle side code : 653-2 Vehicle side code : 108-1
Faulty part ECU Faulty part ECU
The ECU detects a short circuit of the The ECU detects a faulty operation of
Detail
injector drive circuit inside the ECU. the atomospheric pressure sensor (open
Detail circuit, short circuit, characteristic
Recovery *
fault). The input voltage exceeds the
Control Engine stop limiting value.

Speed limit - Recovery *

Inspection Replace the ECU. The ECU controls the engine by using
Control
backup data.
P2052 : Injector drive bank 2 Speed limit The maximum speed is limited to 75%.
Vehicle side code : 653-1
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Speed limit -
Inspection Replace the ECU.

P2228 : Atomospheric pressure sensor

Vehicle side code : 108-2
Faulty part ECU
The ECU detects a faulty operation of
the atomospheric pressure sensor (open
Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
limiting value.
Recovery *
The ECU controls the engine by using
Control
backup data.
Speed limit The maximum speed is limited to 75%.
Inspection Replace the ECU.

14-20
 TROUBLESHOOTING

4.2 Related diagnosis code

There are diagnosis codes which are caused by other diagnosis codes, for example, the diagnosis code generated by the fault of
the common rail causes the diagnosis code related to the DBV (pressure limiting valve). These codes can be recovered by
eliminating the fault of the causal diagnosis code.
Causal diagnosis code in the following chart must be checked when Related diagnosis code is generated.
Related diagnosis code can be recovered by eliminating the fault of Causal diagnosis code.
Also Related diagnosis code B can be generated by Related diagnosis code A. In this case, Causal diagnosis code and Related
diagnosis code A must be checked.

Table 14-2 Related diagnosis code (1 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
There is an open cir-
cuit on the MPROP.
P0089 The MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-4 The DBV will be
MPROP open circuit opened.
P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
There is an overload
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-8 The DBV will be
MPROP overload opened.
P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
There is a short circuit
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
P0230 - - -
2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2001-1 The DBV will be
MPROP power stage opened.
short circuit to battery
P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
The pressure in the
P0089 common rail keeps The ECU clears
Vehicle side code : exceeding the limiting P0089(2042-2) when
- -
P0089 2041-1 value, the engine P0089(2041-1) is gen-
Vehicle side code : DBV opening operation switches to erated.
2042-2 the limp home mode.
DBV kick off P0090
Pressure shock is The ECU clears P0089
Vehicle side code :
requested to open the - - when P0090 is gener-
2043-4
DBV ated.
DBV closed fixation

14-21
TROUBLESHOOTING

Table 14-2 Related diagnosis code (2 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
The pressure in the
P0089 common rail keeps
Vehicle side code : exceeding the limiting
P0191 - - -
2041-1 value, the engine
Vehicle side code : DBV opening operation switches to
2015-1 the limp home mode.
Rail pressure gover-
nor deviation P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
The pressure in the
P0089 common rail keeps
If DBV does not open,
Vehicle side code : exceeding the limiting
- - the ECU generates
P0194 2041-1 value, the engine
P0090, not 0089.
Vehicle side code : DBV opening operation switches to
2017-1 the limp home mode.
Rail pressure governor P0089 P0090
Pressure shock is The ECU clears P0089
Vehicle side code : Vehicle side code : The DBV does not
requested to open the when P0090 is gener-
2042-2 2043-4 open.
DBV ated.
DBV kick off DBV closed fixation
An error is detected
by SRC. The ECU
cannot control the
P0192 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-2 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
An error is detected
by SRC. The ECU
cannot control the
P0193 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-1 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
After the ECU deter-
P0091 mined that DBV has
Vehicle side code : been opened, the
P0091 is not gener-
2045-2 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
P0089 high value during backup
Vehicle side code : operation.
2041-1 After the ECU deter-
DBV opening P0092 mined that DBV has
Vehicle side code : been opened, the
P0092 is not gener-
2044-1 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
high value during backup
operation.

14-22
 TROUBLESHOOTING

P0089 : DBV valve opening P0092 : DBV pressure is too high.

Vehicle side code : 2041-1 Vehicle side code : 2044-1
Faulty part DBV Faulty part DBV
Detail The DBV is opening. The DBV pressure is abnormal. (too
Detail
high)
Recovery *
Recovery *
The ECU limits the maximum speed of
Control
the engine. Control Engine stop
Speed limit The engine speed is fixed to 8%. Speed limit -
Inspection Contact a Mitsubishi dealer. Inspection Contact a Mitsubishi dealer.

P0089 : DBV kick off P0191 : Rail pressure governor deviation

Vehicle side code : 2042-2 Vehicle side code : 2015-1
Faulty part DBV Faulty part Common rail
Pressure shock requested The rail pressure control is abnormal.
Detail Detail
to apply limp home mode. The pressure exceeds the target value.
Recovery * Recovery *
The ECU limits the maximum speed of The ECU limits the maximum speed of
Control Control
the engine. the engine.
Speed limit The engine speed is fixed to 8%. Speed limit The engine speed is fixed to 8%.
Inspection Contact a Mitsubishi dealer. Inspection Damage on the common rail.

P0090 : DBV closed fixation P0192 : Rail pressure sensor SRC (Signal Range
Vehicle side code : 2043-4 Check)
Faulty part DBV Vehicle side code : 2011-2

The DBV does not open. Closed fixa- Faulty part Rail pressure sensor
Detail
tion. The ECU detects an open or short circuit
Recovery * of rail pressure sensor and/or sensor har-
Detail
ness. The input voltage falls below the
Control Engine stop limiting value.
Speed limit - Recovery *
Inspection Contact a Mitsubishi dealer. The ECU limits the maximum speed of
Control
the engine.
P0091 : DBV pressure is too low
Speed limit The engine speed is fixed to 8%.
Vehicle side code : 2045-2
Rail pressure sensor, and wiring of rail
Faulty part DBV Inspection
pressure sensor.
The DBV pressure is abnormal. (too
Detail
low)
Recovery *
Control Engine stop
Speed limit -
Inspection Contact a Mitsubishi dealer.

14-23
TROUBLESHOOTING

P0193 : Rail pressure sensor SRC (Signal Range P0252 : MPROP power stage overload
Check) Vehicle side code : 2000-8
Vehicle side code : 2011-1 Faulty part MPROP
Faulty part Rail pressure sensor The ECU detects an overload of
Detail
The input voltage exceeds the limiting MPROP and/or MPROP harness.
Detail
value. Recovery *
Recovery * The ECU limits the maximum speed of
Control
The ECU limits the maximum speed of the engine.
Control
the engine. Speed limit The engine speed is fixed to 8%.
Speed limit The engine speed is fixed to 8%. Inspection MPROP, and wiring of MPROP.
Rail pressure sensor, and wiring of rail
Inspection
pressure sensor.

P0194 : Rail pressure governor

Vehicle side code : 2017-1
Faulty part Common rail
The rail pressure exceeds the limiting
Detail
value.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection Damage on the common rail.

P0230 : MPROP power stage short-circuit to battery

Vehicle side code : 2001-1
Faulty part MPROP
The ECU detects a short circuit on the
Detail
battery line of the MPROP harness.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection MPROP, and wiring of MPROP.

P0252 : MPROP power stage open circuit

Vehicle side code : 2000-4
Faulty part MPROP
The ECU detects an open circuit of the
Detail
MPROP and/or MPROP harness.
Recovery *
The ECU limits the maximum speed of
Control
the engine.
Speed limit The engine speed is fixed to 8%.
Inspection MPROP, and wiring of MPROP.

14-24
 TROUBLESHOOTING

5. Inspecting sensors
5.1 Speed/timing sensor (crank, cam)
Measure the resistance between terminal A - B.
Standard value : 860±86Ω
If measured value is out of standard, replace the sensor with
a new one.
C B A

Speed/timing sensor
(crank, cam)
5.2 Inlet manifold pressure sensor
With applying pressure using an air compressor, measure
the voltage between terminal B - C.
Standard value
C A
• at 0 MPa {0 kgf/cm²} : 0.5V
• at 0.34 MPa {3.5 kgf/cm²} : 4.5V
If measured value is out of standard, replace the sensor with
a new one. B

Air compressor

Inspecting inlet manifold pressure sensor (1)

0.5
Air pressure MPa

0.4
0.3
0.2
0.1
0

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

Output voltage Vdc

Inspecting inlet manifold pressure sensor (2)

5.3 Water temperature sensor
Put the water temperature sensor to the container filled with
water, measure the output resistance between terminal 1 - 2.
Standard value
• 20°C : 2.38 ～ 2.63kΩ
• 80°C : 0.30 ～ 0.34kΩ
If the sensor is an open circuit, its resistance is infinity. If
measured value is out of standard, replace the sensor with a
new one. 1 2

Inspecting water temperature sensor

14-25
TROUBLESHOOTING

5.4 Engine oil pressure switch

Apply 50±10 kPa {0.5±0.1 kgf/cm²} [7.11±1.42 psi]
pressure to the sensor using an air compressor.
Check that the micro switch is in OFF position. Air compressor
If the switch is not operate, replace the engine oil pressure 50 ± 10 kPa
switch with a new one. {0.5 ± 0.1 kgf/cm²}
[7.11 ± 1.42 psi]
On-Off differences
30 kPa
{0.3 kgf/cm²}
[4.27 psi]

Inspecting oil pressure switch

5.5 Common rail pressure sensor
Apply 5V between terminal A - C, and measure the voltage
at terminal B.
Standard value : Approx. 0.5V
If measured value is out of standard, replace the common
A B C
rail with a new one.

Inspecting common rail pressure sensor

5.6 Injector solenoid
Measure the resistance between terminal 1 - 2.
Standard（at 20 to 70°C [68 to 158 °F]）: 0.215 to 0.295 Ω
If measured value is out of standard, replace the injector
with a new one.

2 1

Inspecting injector solenoid

5.7 High pressure pump solenoid sensor
(MPROP)
Measure the resistance between terminal 1 - 2.
Standard （at 20°C [68 °F]）: 2.6 to 3.15 Ω
If measured value is out of standard, replace the fuel pump
with a new one.

2 1

Inspecting high pressure pump solenoid sensor

(MPROP)

14-26
 TROUBLESHOOTING

6. Inspecting wiring
6.1 Inspecting connector and harness
When the ECU generates the diagnosis code for the sensors,
the ECU and the relays, check the wiring that connects these
parts.
The looseness of the harness connection and/or poor
connection of connector may cause the electrical faults. In
these cases, reconnecting the connector and/or the repairing
the harness deletes the fault. Inspect the wiring connecting
to the sensor which causes diagnosis code.

6.1.1 Inspecting the intermittent fault

Wiggle the harness and connector in order to reproduce the Inspecting intermittent fault
intermittent fault.
If the diagnosis code is generated, reset the ECU and repeat
the above procedure. If the intermittent fault exists, replace
the connector and harness.
Inspecting locking device

6.1.2 Inspecting connectors

(1) Disconnect the connector and inspect the connector for
moisture and wear.
(2) Inspect that the terminals are correctly located in the
connector. Inspect that the terminals are not lost.
Inspect that the terminals does not rattle.
(3) Inspect that the locking wedge works correctly. Inspecting connector

6.1.3 Inspecting harness

(1) Inspect harness visually for wear, nicks and cuts.
Especially the part which is exposed to the engine must
be inspected. Nick
(2) Inspect the harness for pinch point caused by cramp.

6.1.4 Inspect open circuit and short circuit

(1) Remove the connector from either end of the harness. Pinch point
Measure the resistance between both ends of the
harness using tester. If measured value is between 0.1～
0.3 Ω, it is normal. If measured value is not in this Inspecting harness
range, it is an open circuit.
(2) Remove the connector from either end of the harness.
Measure the resistance between all terminals in the
connector. If measured value is 100kΩ or more, it is
normal. If measured value is 100kΩ or less, it is a short
circuit.

Inspecting open circuit and short circuit

14-27
TROUBLESHOOTING

6.2 Pin location of the ECU connector and extension harness connector
The wirings of the sensors, the injectors and the fuel pump are connected to the ECU through the extension harness connector.
Inspect the pin of the ECU connector and extension harness connector when inspecting the wiring of the sensors, the injectors
and the fuel pump.

ECU terminal A ECU terminal B

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 2
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
3 4
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
5 6
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

1‫ޓ‬Injector 3, + 1‫ޓ‬ECU power supply, +㧔1㧕

2‫ޓ‬Injector 2, + 2‫ޓ‬ECU ground, -㧔1㧕
7‫ޓ‬Speed/timing sensor (crankshaft side), shield 3‫ޓ‬ECU power supply, +㧔2㧕
8‫ޓ‬Rail pressure sensor, ground 4‫ޓ‬ECU ground, -㧔2㧕
10‫ޓ‬Speed/timing sensor (camshaft side) 5‫ޓ‬ECU power supply, +㧔3㧕
12‫ޓ‬Speed/timing sensor (crankshaft side) 6‫ޓ‬ECU ground, -㧔3㧕
14‫ޓ‬Inlet manifold pressure sensor, power supply 9‫ޓ‬Accelerator㧔1㧕
15‫ޓ‬Heater relay 12‫ޓ‬PTO accelerator, ground
16‫ޓ‬Injector 1, 23‫ޓ‬PTO accelerator, power supply
17‫ޓ‬Injector 4, 25‫ޓ‬K-LINE
19‫ޓ‬MPROP, + 28‫ޓ‬Ignition switch
20‫ޓ‬Speed/timing sensor (camshaft side), shield 36‫ޓ‬PTO accelerator
23‫ޓ‬Inlet manifold pressure sensor, ground 41‫ޓ‬Signal, ground
24‫ޓ‬Heater relay, power supply 54‫ޓ‬Oil pressure switch
26‫ޓ‬Rail pressure sensor, power supply 61‫ޓ‬CAN-L1
27‫ޓ‬Speed/timing sensor (crankshaft side) 62‫ޓ‬CAN-H1
31‫ޓ‬Injector 2, - 72‫ޓ‬Main relay
33‫ޓ‬Injector 4, - 73‫ޓ‬24V power supply
40‫ޓ‬Inlet manifold pressure sensor
41‫ޓ‬Water temperature sensor, ground
43‫ޓ‬Rail pressure sensor
46‫ޓ‬Injector 3, -
47‫ޓ‬Injector 1, -
49‫ޓ‬MPROP, - Point of view
50‫ޓ‬Speed/timing sensor (camshaft side)
58‫ޓ‬Water temperature sensor

Pin location of ECU connector

14-28
 TROUBLESHOOTING

Extension harness connector, 16 terminals Extension harness connector, 12 teminals

4 3 2 1
4 3 2 1
8 7 6 5
8 7 6 5
12 11 10 9
12 11 10 9
16 15 14 13

1‫ޓ‬Speed/timing sensor (camshaft side), power supply 1‫ޓ‬Injector 1, +

2‫ޓ‬Speed/timing sensor (camshaft side) 2‫ޓ‬Injector 1, -
3‫ޓ‬Speed/timing sensor (camshaft side), shield‫ޓ‬ 3‫ޓ‬Injector 4, +
5‫ޓ‬Speed/timing sensor (crankshaft side), power supply 4‫ޓ‬Injector 4, -
6‫ޓ‬Speed/timing sensor (crankshaft side) 5‫ޓ‬Injector 3, +
7‫ޓ‬Speed/timing sensor (crankshaft side), shield 6‫ޓ‬Injector 3, -
8‫ޓ‬MPROP, - 7‫ޓ‬Injector 2, +
9‫ޓ‬Rail pressure sensor, power supply 8‫ޓ‬Injector 2, -
10‫ޓ‬Rail pressure sensor 9‫ޓ‬Water temperature sensor
11‫ޓ‬Rail pressure sensor, ground 10‫ޓ‬Water temperature sensor, ground
12‫ޓ‬MPROP, + 11‫ޓ‬Oil pressure switch
13‫ޓ‬Inlet manifold pressure sensor, power supply 12‫ޓ‬Oil pressure switch
14‫ޓ‬Inlet manifoldpressure sensor‫ޓ‬
16‫ޓ‬Inlet manifoldpressure sensor, ground

Point of view for 16 teminals Connector location Point of view for 12 terminals

Pin location of extension harness connector

14-29