E70 PDF

INTRODUCTION
WORKSHOP MANUAL
ENGLISH
Print N. 604.13.252.00
31102 60413252
Edition: 02/2003
English - Printed in Italy
Printed by Studio ti
0-1
INTRODUCTION
TO THE READER
• This manual has been written for a skilled - For any question or comment, or in case you
technician, in order to give him the information notice a mistake in this manual content,
necessary to repair this machine. please contact:
- Read this manual carefully for correct FIAT KOBELCO CONSTRUCTION

information about repair procedures. MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCE MANUALS
• In addition to this Workshop Manual, refer also to

the following:
- Operation and maintenance instruction

manual
- Spare parts catalog
DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL
• The complete repair manual consists of two equipment, information on maintenance

volumes: standards, remove and install procedures,
disassembly and assembly procedures.
- E70SR EVOLUTION - Workshop Manual
"Excavator" • The complete Workshop Manual for the excavator
model E70SR EVOLUTION consists of the
• "Excavator" and "Engine" Workshop Manuals following volumes identified by print number as
contain the technical information necessary for shown herebelow:
machine/engine service and repair, service
31102 60413252
VOLUME MACHINE TYPE PRINT No.

Workshop Manual - "Excavator" E70SR EVOLUTION 604.13.252
0-3
INTRODUCTION
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on

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

controlled equipment (such as showels, loaders, dozers, scrapers
etc.) be certain the equipment is lowered to the ground before servicing,
adjusting and/or repairing.
If it is necessary to have the equipment partially or fully raised to gain
access to certain items, be sure the equipment is suitably supported
by means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.
COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

Product Support - Documentation Centre
Strada di Settimo, 323 - S. Mauro T.SE (TO) ITALY
31102 60413252
All rights reserved. Reproduction of text and illustrations in whole or in part,

is strictly prohibited.
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INDEX
INDEX
SPECIFICATIONS
Section 1 - Preliminary remarks

Section 2 - Specifications
Section 3 - Attachment dimensions
MAINTENANCE
Section 11 - Tools
Section 12 - Standard maintenance time schedule
Section 13 - Maintenance standards and test procedures
SYSTEM
Section 21 - Mechatro control system

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

Section 32 - Attachments
Section 33 - Upper swing body
Section 34 - Travel frame
TROUBLESHOOTING
Section 41 - Mechatro control

Section 42 - Hydraulic system
Section 43 - Electrical system
Section 44 - Engine
ENGINE
Section 51 - Engine
OPTIONAL
Section 63 - Mounting the breaker and nibbler & breaker

31102 60413252
0-5
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS machine. Hang a “Do Not Operate” tag in the

Operators Compartment.
WARNING 5. Do not work on any machine that is supported

The proper and safe lubrication and maintenance for only by lift, jacks or a hoist. Always use blocks or
this machine, recommended by Distributor, are jack stands, capable of supporting the machine,
outlined in the OPERATOR’S MANUAL for the before performing any disassembly.
machine.
Improper performance of lubrication or maintenance
procedures are dangerous and could result in injury WARNING
or death. Read and understand the MANUAL before Do not operate this machine unless you have read
performing any lubrication or maintenance. and understand the instructions in the OPERATOR’S
MANUAL. Improper machine operation is dangerous
and could result in injury or death.
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 6. Relieve all pressure in air, oil or water systems
work. A knowledge of the system and or components before any lines, fittings or related items are
disconnected or removed. Always make sure all
is important before the removal or disassembly of any
raised components are blocked correctly and be
component. alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
Because of the size of some of the machine
components, the serviceman or mechanic should 7. Lower the bucket, dozer, or other attachments to
check the weights noted in this manual. Use proper the ground before performing any work on the
machine. If this cannot be done, make sure the
lifting procedures when removing any components.
bucket, dozer, ripper or other attachment is
Weight of components table is shown in the section; blocked correctly to prevent it from dropping
SPECIFICATIONS. unexpectedly.
The following is a list of basic precautions that must 8. Use steps and grab handles when mounting or
always be observed. dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
1. Read and understand all Warning plates and using. Always face to the machine when using
decal on the machine before Operating, steps, ladders and walkways. When it is not
Maintaining or Repairing this machine. possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
2. Always wear protective glasses and protective perform safe repair operations.
shoes when working around machines. In
particular, wear protective glasses when using 9. To avoid back injury, use a hoist when lifting
hammers, punches or drifts on any part of the components which weigh 20 kg (45 lbs) or more.
machine or attachments. Use welders gloves, Make sure all chains, hooks, slings, etc., are in
hood/goggles, apron and the protective clothing good condition and are the correct capacity. Be
appropriate to the welding job being performed. sure hooks are positioned correctly. Lifting eyes
Do not wear loose fitting or torn clothing. Remove are not to be side loaded during a lifting operation.
all rings from fingers, loose jewelry, confine long
hair and loose clothing before working on this 10. To avoid burns, be alert for hot parts on machines
machinery. which have just been stopped and hot fluids in
lines, tubes and compartments.
3. Disconnect the battery and hang a “Do Not
Operate” tag in the Operators Compartment. 11. Be careful when removing cover plates. Gradually
back off the last two capscrews or nuts located at
31102 60413252
Remove ignition keys.

opposite ends of the cover or device and carefully
4. If possible, make all repairs with the machine pry cover loose to relieve any spring or other
parked on a level, hard surface. Block the machine pressure, before removing the last two capscrews
so it does not roll while working on or under the or nuts completely.
12. Be careful when removing filler caps, breathers
0-6
SAFETY PRECAUTIONS
and plugs on the machine. Hold a rag over the sure that all heat shields, clamps and guards are
cap or plug to prevent being sprayed or splashed installed correctly to avoid excessive heat,
by liquids under pressure. The danger is even vibration or rubbing against other parts during
greater if the machine has just been stopped operation. Shields that protect against oil spray
because fluids can be hot. onto hot exhaust components in event of a line,
tube or seal failure must be installed correctly.
13. Always use the proper tools that are in good
condition and that are suited for the job at hand. 21. Do not operate a machine if any rotating part is
Be sure you understand how to use them before damaged or contacts any other part during
performing any service work. operation. Any high speed rotating component
that has been damaged or altered should be
14. Reinstall all fasteners with the same part number. checked for balance before reusing.
Do not use a lesser quality fastener if
replacements are necessary. 22. Be careful when servicing or separating the
tracks (crawlers). Chips can fly when removing
15. Repairs which require welding should be or installing a track (crawlers) pin. Wear safety
performed only with the benefit of the appropriate glasses and long sleeve protective clothing.
reference information and by personnel Tracks (crawlers) can unroll very quickly when
adequately trained and knowledgeable in welding separated. Keep away from front and rear of
procedures. Determine type of metal being machine. The machine can move unexpectedly
welded and select correct welding procedure when both tracks (crawlers) are disengaged
and electrodes, rods or wire to provide a weld from the sprockets. Block the machine to prevent
metal strength equivalent at least to that of the it from moving.
parent metal. Make sure to disconnect battery
before any welding procedures are attempted.
16. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will
be damaged in operation of the machine by
contacting sharp corners, or by rubbing against
some object or hot surface. Do not connect
wiring to a line containing fluid.
17. Be sure all protective devices including guards

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

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

lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect
lines, tubes and hoses carefully. Do not check for
leaks with your hands. Very small (pinhole) leaks
31102 60413252
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
0-7
SAFETY PRECAUTIONS
NOTE
31102 60413252
0-8
SECTION 1 PRELIMINARY REMARKS
TABLE OF CONTENTS
1. General precautions for repairs .............................................................................. 1-1

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

31102 60413252
PRELIMINARY REMARKS
1. GENERAL PRECAUTIONS FOR REPAIRS
3) Stop the engine before starting inspection and

1.1 PREPARATION BEFORE maintenance to prevent the operator being caught
DISASSEMBLING in machine.
(1) Understanding operating procedure 4) Identify the location of a first-aid kit and a fire
Read OPERATION & MAINTENANCE MANUAL extinguisher, and also where to make contact in a
carefully to understand the operating procedure. state of emergency.
5) Choose a hard, level and safe place, and place
(2) Cleaning machines the attachment on the ground securely.
Remove soil, mud, and dust from the machine 6) Use a lifter such as a crane to remove heavy parts
before carrying it into the service shop to prevent (23 kg [50 lbs] or more) from the machine.
loss of work efficiency, damage of parts, and diffi- 7) Use proper tools, and replace or repair defective
culty in rust prevention and dust protection while tools.
reassembling. 8) Support the machine and attachment with supports
or blocks if the work is performed in the lifted
(3) Inspecting machines condition.
Identify the parts to be disassembled before start-
ing work, determine the disassembling procedure
by yourself considering the workshop situations 1.3 DISASSEMBLING AND
etc., and request procurement of necessary parts ASSEMBLING HYDRAULIC
in advance. EQUIPMENT
(1) Removing hydraulic equipment
(4) Recording 1) Before disconnecting pipes, release the hydraulic
Record the following items for communication and pressure of the system, or open the return side
prevention of recurring malfunction. cover and take out the filter.
1) Inspection date and place 2) Carefully drain oil of the removed pipes into a
2) Model name, applicable machine number, and containers without spilling on the floor.
hour meter read 3) Apply plugs or caps on the pipe ends to avoid oil
3) Trouble condition, place and cause, if any spillage and dust intrusion.
4) Visible oil leakage, water leakage and damage 4) Clean off the external surface of the equipment
5) Clogging of filters, oil level, oil quality, oil contami- before disassembling, and drain hydraulic and gear
nation and loosening of connections oil before placing it on the workbench.
6) Result of consideration if any problem exists based
on the operation rate per month calculated from (2) Disassembling hydraulic equipment
hour meter indication after the last inspection date. 1) Do not disassemble, reassemble or modify the
hydraulic equipment without the permission of the
(5) Arrangement and cleaning in service shop manufacturer, who is not responsible for the
1) Tools required for repair work. performance and function of the product after
2) Prepare space to place the disassembled parts. reassembling.
3) Prepare oil containers for spilling oil etc. 2) When disassembling and reassembling for un-
avoidable reason, refer the work to qualified
personnel who have the specific knowledge or
1. 2SAFETY IN DISASSEMBLING completed the parts service training.
AND ASSEMBLING 3) Provide matching marks to facilitate reassembling
31102 60413252
1) Wear appropriate clothes with long sleeves, safety work.

shoes, safety helmet and protective glasses. 4) Before starting the work, read the manual of dis-
2) Suspend warning tag "DO NOT OPERATE" from assembling procedure, if it is provided, and decide
the doorknob or the operating lever, and have a whether the work can be performed by yourself.
preliminary meeting before starting work. 5) Use the special jig and tools without fail if they are
1-1
PRELIMINARY REMARKS
specified.
6) If it is hard to remove a part according to the WARNING
procedure, do not try it by force but investigate the Operation of the hydraulic equipment without filling
hydraulic oil or lubricant or without performing air bleeding
cause.
will result in damage to the equipment.
7) Place the removed parts in order and attach tags
to facilitate the reassembling.
8) Note the location and quantity of parts commonly 3) Perform air bleeding of the hydraulic pump and
applied to multiple locations. slewing motor after loosening the upper drain plug,
starting the engine and keep it in low idle condi-
(3) Inspecting parts tion. Complete the air bleeding when seeping of
1) Ensure that the disassembled parts are free from hydraulic oil is recognized, and tightly plug.
seizure, interference and uneven contact. 4) Perform air bleeding of the travel motor and the
2) Measure and record wear condition of parts and hydraulic cylinders by running the engine for more
clearance. than 5 minutes at low speed without load.
3) If the problem is found in a part, repair or replace it
with a new one.
WARNING
(4) Reassembling hydraulic equipment Do not allow the hydraulic cylinder to bottom on the
1) Turn ON the ventilation fan or open windows to stroke end just after the maintenance.
maintain good ventilation prior to starting the
cleaning of parts.
2) Perform rough and finish cleaning before assem- 5) Perform air bleeding of pilot line by performing a
bling. series of digging, slewing and travel.
3) Remove washing oil by air and apply clean hydrau- 6) Check hydraulic oil level after placing the attach-
lic or gear oil for assembling. ment to the oil check position, and replenish oil if
4) Always replace the removed O-rings, backup rings necessary.
and oil seals with new ones by applying grease in
Checking hydraulic oil level
advance.
5) Remove dirt and moisture from and perform Level gauge Oil level lines
(Level located
degreasing on the surface where liquid gasket to between the two
lines shows
be applied. appropriate
amount of oil)
6) Remove rust preventive agent from the new parts
before use.
7) Fit bearings, bushings and oil seals using special
jigs.
1.4 ELECTRICAL EQUIPMENT
8) Assemble the parts utilizing matching marks.
9) Ensure all the parts are completely assembled after
the work. (1) Do not disassemble electrical equipment.
(5) Installing hydraulic equipment (2) Handle it carefully not to drop and give a shock.
1) Ensure hydraulic oil and lubricant are properly
supplied. (3) Turn the key OFF prior to connecting and discon-
2) Perform air bleeding when: necting work.
a. Hydraulic oil changed
b. Parts of suction side piping replaced (4) Disconnect the connector by holding it and press-
31102 60413252
c. Hydraulic pump installed ing the lock. Do not pull the wire to apply force to
d. Slewing motor installed the caulking portion.
e. Travel motor installed
f. Hydraulic cylinder installed (5) Connect the connector and ensure it is completely
locked.
1-2
PRELIMINARY REMARKS
(6) Turn the key OFF prior to touching the terminal of used depending on the working pressure even
starter or generator. the size of fitting and the total length of the hose
is same.
(7) Remove the ground (earth) terminal of battery • Tighten the fitting at the specified torque. En-
when handling tools around the battery or its relay. sure no kink, tension, interference nor oil leak-
age is recognized.
(8) Do not splash water on the electrical equipment
and connectors during machine washing. 1.6 WELDING REPAIR
(1) Refer repair welding to qualified personnel accord-
(9) Check for moisture adhesion inside the waterproof ing to the appropriate procedure.
connector after pulling it out, since it is hard to
remove moisture from the connector. If moisture (2) Disconnect the ground (earth) cable of the battery
adhesion is found, dry it completely before the before starting the repair. Failure to do so will cause
connection. damage to the electrical equipment.
(3) Move away the articles in advance that may cause

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

1.5 HYDRAULIC PARTS Exposure of eyes to hydraulic oil will cause inflam-
mation. Wear protective glasses before handling
1) O-ring to avoid an accident. If an eye is exposed to the
• O-rings have elasticity and are not damaged oil, take the following emergency measures:
before use. • When an eye exposed: Immediately wash away
• Use the appropriate O-rings. O-rings are made with city water sufficiently till stimulative feeling
of various kinds of materials having different vanishes.
hardness to apply to a variety of parts, such • When swallowed: Do not let vomit, and receive
as the part for moving or fixed portion, sub- medical treatment immediately.
jected to high pressure, and exposed to corro- • When skin exposed: Wash with water and soap
31102 60413252
sive fluid, even if the size is same. sufficiently.

• Fit the O-rings without distortion and bend.
• Always handle floating seals as a pair. (4) Others
2) Flexible hose (F hose) Use replacement parts and lubricants authorized
• Use the appropriate parts. Different parts are as the Distributor genuine parts.
1-3
PRELIMINARY REMARKS
2. INTERNATIONAL UNIT CONVERSION SYSTEM

(Based on MARKS’ STANDARD HANDBOOK FOR MECHANICAL ENGINEERS)
Introduction (4) Derived Units bearing Peculiar Designations
Although this manual uses the gravitational unit [ Table 3-4 ]
system, if you need SI unit, refer to the QUANTITY UNIT SYMBOL FORMULA
following international system of units. Frequency hertz Hz 1/s
Force newton N kg • m/s 2
are related to this manual : Pressure and Stress pascal Pa N/m2
1. Etymology of SI Units Energy, Work joule J N•m
and Quantity
French :Le Systme International d’ Units of heat
English :International System of Units Power watt W J/s
2. Construction of SI Unit System Quantity of coulomb C A•s
electricity
Base units Electric volt V W/A
Table 3-1
potential
Derived units
of base units difference,
Supplemen Voltage, and
SI units tary units Table 3-3
SI unit Table 3-2 Electromotive
system Derived units
force
Derived bearing peculiar Quantity of farad F C/V
units designations static electricity
Table 3-4 and Electric
capacitance
Prefixes of SI Electric ohm ‰ V/A
(n-th power of 10, where n is an integer) resistance
Table 3- 5 Celcius celcius degree °C (t+273.15)K
temperature or degree
Illuminance lux lx l m/m2
(1) Base Units [ Table 3-1 ] Given hereinafter is an excerpt of the units that
QUANTITY UNIT SYMBOL (5) Prefixes of SI [ Table 3-5 ]
Length metre m MULTIPLI-
PREFIX SYMBOL
Mass kilogram kg CATION FACTORS
Time second s giga G 10 9
Electric current ampere A mega M 10 6
Thermodynamic kilo k 10 3
temperature kelvin K
hecto h 10 2
Amount of substance mol mol deca da 10
Luminous intensity candela cd deci d 10-1
centi c 10-2
(2) Supplementary Units [ Table 3-2 ] milli m 10-3
QUANTITY UNIT SYMBOL micro µ 10-6
Plane angle radian rad nano n 10-9
Solid angle steradian sr pico p 10-12
(6) Unit Conversion [ Table 3-6 ]

(3) Derived Units [ Table 3-3 ] QUANTITY Gravitational SI CONVERSION FACTOR
Weight kgf
QUANTITY UNIT SYMBOL
Mass kg 1 kgf=1 kg
31102 60413252
Area square metre m2

Force kgf N 1 kgf=9.807 N
Volume cubic metre m3 Torque kgf · m N·m 1 kgf·m=9.807 N·m
Velocity metre per second m/s Pressure kgf/cm2 MPa 1 kgf/cm2=0.09807 MPa
Acceleration metre per second squared m/s2 Motive power PS kW 1 PS=0.7355 kW
Density kilogram per cubic metre kg/m3 Revolution rpm min-1 r/min 1
1 Units that are allowed to use
* F14747gb
*
1-4
SECTION 2 SPECIFICATIONS
TABLE OF CONTENTS
1. Name of components .............................................................................................. 2-1
2. Machine dimensions ................................................................................................ 2-2

2.1 2.07 m (6 ft-9 in) arm ....................................................................................................................... 2-2
2.2 1.65 m (5 ft-5 in) arm ....................................................................................................................... 2-2
3. Weight and components ......................................................................................... 2-3
4. Transportation dimension and weight ..................................................................... 2-4
5. Specifications and performance ............................................................................. 2-7

5.1 Speed and climbing capability .......................................................................................................... 2-7
5.2 Engine .............................................................................................................................................. 2-7
5.3 Hydraulic components ...................................................................................................................... 2-7
5.4 Weight .............................................................................................................................................. 2-7
6. Type of crawler........................................................................................................ 2-8
7. Type of bucket ......................................................................................................... 2-9
8. Combinations of attachment ................................................................................. 2-10
9. Engine specification ............................................................................................. 2-11

9.1 Specifications ................................................................................................................................. 2-11
9.2 Engine characteristic curve (isuzu 4JG1)....................................................................................... 2-12
31102 60413252
SPECIFICATIONS
1. NAME OF COMPONENTS
2
1
27 4
6
26
7
8
25 9
28
29
10
24
11
12
23
22
F15814
21
20 13
19
14
18 15
17 16
1. Arm 16. Travel motor

2. Arm cylinder 17. Track link
3. Boom 18. Lower roller
4. Swivel joint 19. Upper roller
5. Slewing motor 20. Air cleaner
6. Battery 21. Crawler adjuster
7. Fuel tank 22. Front idler
8. Back mirror 23. Shoe plate
9. Hydraulic tank 24. Bucket
31102 60413252
10. Rotary multi control valve (option) 25. Bucket link

11. Control valve 26. Idler link
12. Hydraulic pump 27. Bucket cylinder
13. Engine 28. Boom cylinder
14. Counter weight 29. Cab
15. Radiator
2-1
SPECIFICATIONS
2. MACHINE DIMENSIONS
2.1 2.07 m (6 ft-9 in) ARM
5,510 (18´1˝) Unit: mm (ft-in)

4,350 (14´3˝) R 1,160 (3´10˝) Reference:
Arm cylinder pin A position
Transport positioning pin (B position)
(Working position)
Working height: 2920 mm (9 ft-7 in)
B
2,600 (8´6˝)
1,440 (4´9˝)
2,860 (9´5˝)
5,790 (18´12˝)
F15815
2.2 1.65 m (5 ft-5 in) ARM
R1,160
5,500 (18´0˝)
4,340 (14´3˝) R 1,160 (3´10˝)
2,600 (8´6˝)
2,600 (8´6˝)
750
31102 60413252
(15.7˝)
400
1,440 (4´9˝) 450 (17.7˝)

2,860 (9´5˝) [600 (23.6˝)]
5,780 (18´12˝) 2,320 (7´7˝)
[2,470 (8´1˝)] F15816
2-2
SPECIFICATIONS
3. WEIGHT AND COMPONENTS
Unit: kg (lbs)
2.07 M (6 ft-9 in) Arm 1.65 M (5 ft-5 in) Arm

ITEM MODEL
+600 mm (23.6 in shoe) +450 mm (17.7 in shoe)
Machine complete 7,180 (15,830) 6,940 (15,300)
1. Upper frame assy (including the following): 3,250 (7,160)
1.1 Counterweight 820 (1,810)
Counterweight (add-on) 400 (880)
1.2 Cab 210 (460)
1.3 Engine 250 (550)
1.4 Hydraulic oil tank
* 64 (140)
1.5 Fuel tank
* 53 (120)
1.6 Slewing motor (including reduction unit)
* 67 (150)
1.7 Control valve 42(93)
1.8 Boom cylinder 92 (200)
1.9 Pin (2pcs. for mounting boom)
* 14 (31)
1.10 Pump Including 125 kg (276 lbs) 41 (90)
1.11 Radiator of grease, water, etc 44 (97)
2. Lower frame assy (including the following):
*
2,590 (5,710) 2,370 (5,230)
2.1 Slewing bearing 115 (250)
2.2 Travel motor (including reduction unit) 90 (200) X 2
2.3 Upper roller 4 (9) X 2
2.4 Lower roller 15 (33) X10
2.5 Front idler 44 (97) X 2
2.6 Track tension adjuster 28 (62) X 2
2.7 Sprocket 27 (59) X 2
2.8 Swivel joint 21 (46)
2.9 Track link with 450 mm (17.7 in) shoes assy 420 (926) X 2
Track link with 600 mm (23.6 in) shoes assy 530 (1,170) X 2
Track link with 600 mm (23.6 in) triangle shoes assy 470 (1,040) X 2
2.9.1 Track link assy 155 (340) X2
3. Attachment
{3.72 m (12 ft-2 in) Boom+2.07 m (6 ft-9 in) Arm+0.22 m3 (0.28 cu·yd) Bucket} 1,110 (2,450)
{3.72 m (12 ft-2 in) Boom+1.65 m (5 ft-5 in) Arm+0.28 m3 (0.37 uc·yd) Bucket} — 1,080 (2,380)
3.1 Bucket assy 190 (420) 200 (440)
3.2 Arm assy (including the following): 290 (640) 250 (550)
3.2.1Arm 180 (400) 130 (290)
3.2.2Bucket cylinder 44 (97)
3.2.3Idler link 6 (13) X 2
3.2.4Bucket link 8 (17) X 2
3.2.5Pin (2 pcs. for mounting bucket cylinder / 2 pcs. for mounting bucket) 17 (37)
3.3 Boom assy (including the following):
* 630 (1,390)
3.3.1Boom 390 (860)
3.3.2Arm cylinder 72 (160)
3.3.3Pin (Mounting arm · Mounting arm cylinder) 16 (35)
4. Lubricant and water (including the following): 130 (290)
4.1 Hydraulic oil 49 (108)
4.2 Engine oil
* 5 (11)
31102 60413252
4.3 Fuel 71 (157)

4.4 Water 5 (11)
F15817
NOTE:
Numerical values marked
* indicate the dry weight.
2-3
SPECIFICATIONS
4. TRANSPORTATION DIMENSION AND WEIGHT

OVERALL DIMENSIONS OF MACHINE ON A TRAILER
• OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER
Item Type 2.07 M (6 ft-9 in) Arm + 600 mm (23.6 in) shoes 1.65 M (5 ft-5 in) Arm + 450 mm (17.7 in) shoes
Width m (ft-in) 2,470 (8´1˝) 2,320 (7´7˝)
Weight kg (lb) 7,180 (15,830) 6,940 (15,300)
F15818
Specification:
• The parenthesis shows 2.07 m arm model.
• Regarding 2.07 m arm machine, put the arm
cylinder rod in a transport position (B) by referring
to the outside dimensions on page 2.
• OVERALL DIMENSIONS OF WITHOUT ARM AND CUCKET

Type A : Shoe width L : Length H : Height W : Width Weight
Combination mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in)
600 (23.6˝) 5,670 (18´7˝) 2,600 (8´6˝) 2,470 (8´1˝) 6,700 (14,770)
Without arm and bucket
450 (17.7˝) 5,670 (18´7˝) 2,600 (8´6˝) 2,320 (7´7˝) 6,490 (14,310)
F15820
• OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

Type A : Shoe width L : Length H : Height W : Width Weight
Combination mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in)
Without boom, arm and 600 (23.6˝) 2,860 (9´5˝) 2,600 (8´6˝) 2,470 (8´1˝) 6,070 (13,380)
bucket 450 (17.7˝) 2,860 (9´5˝) 2,600 (8´6˝) 2,320 (7´7˝) 5,860 (12,920)
F15822
31102 60413252
2-4
SPECIFICATIONS
• OVERALL DIMENSIONS OF BOOM

Item Type 3.72 m (12 ft-2 in) Boom
Length X Height X Width 3.86 X 1.43 X 0.36
m (ft-in)
LXHXW (12´8˝ X 4´8˝ X 1´2˝)
Weight kg (lb) 500 (1,100)
H
L
F15824
• OVERALL DIMENSIONS OF ARM + BUCKET

Type 1.65 m (5 ft-5 in) Arm + 2.07 m (6 ft-9 in) Arm +
Item 0.28 m3 (0.37 cu·yd) Bucket 0.22 m3 (0.29 cu·yd) Bucket
Length X Height X Width 3.14 X 0.70 X 0.75 3.61 X 0.71 X 0.65
m (ft-in)
LXHXW (10´4˝ X 2´4˝ X 2´6˝) (11´10˝ X 2´2.4˝ X 2´2˝)
Weight kg (lb) 450 (990) 480 (1,060)

H
L
F15825
• OVERALL DIMENSIONS OF ARM

Item Type 1.65 m (5 ft-5 in) Arm 2.07 m (6 ft-9 in) Arm
Length X Height X Width 2.17 X 0.53 X 0.36 2.64 X 0.53 X 0.36
m (ft-in)
LXHXW (7´1˝ X 1´9˝ X 1´2˝) (8´8˝ X 1´9˝ X 1´2˝)
Weight kg (lb) 250 (550) 290 (640)

31102 60413252
L
F15826
2-5
SPECIFICATIONS
• OVERALL DIMENSIONS OF BUCKET

Type Hoe bucket
Length X Height X Width 1.10 X 0.60 X 0.40 0.98 X 0.89 X 0.48 0.98 X 0.89 X 0.55 0.98X 0.89 X 0.65
LXHXW m (ft-in) (3´7˝ X 1´12˝ X 1´4˝) (3´3˝ X 2´11˝ X 1´7˝) (3´3˝ X 2´11˝ X 1´10˝) (3´3˝ X 2´11˝ X 2´2˝)
Weight kg (lbs) 150 (330) 150 (330) 170 (380) 190 (420)
3
Bucket capacity m (cu·yd) 0.11 (0.14) 0.14 (0.18) 0.18 (0.23) 0.22 (0.29)
Type Hoe bucket V-bucket Slope finishing bucket

Length X Height X Width 0.98 X 0.89 X 0.75 0.98 X 0.89 X 0.85 1.08 X 0.47 X 1.41 0.79 X 0.62 X 1.50
LXHXW m (ft-in) (3´3˝ X 2´11˝ X 2´6˝) (3´3˝ X 2´11˝ X 2´9˝) (3´6˝ X 1´6˝ X 4´7˝) (2´7˝ X 2´0˝ X 4´11˝)
Weight kg (lbs) 200 (440) 220 (490) 180 (340) 300 (660)
3
Bucket capacity m (cu·yd) 0.28 (0.37) STD 0.35 (0.45) 0.24 (0.31) 0.26 (0.34)
• Hoe bucket • V-bucket • Slope finishing bucket
H
H
L
L
L F15827
31102 60413252
2-6
SPECIFICATIONS
5. SPECIFICATIONS AND PERFORMANCE
5.1 SPEED AND CLIMBING CAPABILITY
Model & Shoe spec. E70SR EVOLUTION

Item Iron shoe Rubber shoe
Swing speed 12.5 {12.5}
Travel speed km/h 3.1 / 5.3 3.2 / 5.3
Gradeability % (degree) 70 (35)
5.2 ENGINE
Engine model ISUZU CC-4JG1
Type Water-cooled 4-cycle direct injection type engine
Number of cylinders-Bore X Stroke 4-95.4 mm X 107 mm (3.76 in X 4.21 in)
Total displacement 3,059 cc (187 cu·in)
Rated output / Rotation speed 55 PS / 2,100 rpm
Maximum torque / Rotation speed 19.1 kgf·m (139 ft·lbs) / 1,800 rpm
Starter 24 V / 3.2 kW
Alternator 24 V / 30A
5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston+gear pump
Hydraulic motor (Swing) Axial piston motor
Hydraulic motor (Travel) 2-speed axial piston motor
Control valve 6-spool control valve
Cylinder
Double action cylinder
(Boom, arm, and Bucket)
Oil cooler Air-cooled type
5.4 WEIGHT
Fully equipped weight 6,940 (15,300) 7,180 (15,830)
Upper structure 3,250 (7,170)
Lower machinery
(With 600 mm (23.6 in) grouser shoe) 2,370 (5,230) —
(With 450 mm (17.7 in) grouser shoe) — 2,590 (5,710)
31102 60413252
Attachment
[ Boom+2.07 m (6 ft-9 in) Arm
1,080 (2,380) —
+0.22 m3 (0.29 cu·yd) bucket ]
[ Boom+1.65 m (5 ft-5 in) Arm
— 1,110 (2,450)
+0.28 m3 (0.37 cu·yd) bucket ]
F15828
2-7
SPECIFICATIONS
6. TYPE OF CRAWLER
Shoe width Overall width of crawler Ground pressure

Shape
mm (in) mm (in) kgf/cm2 (psi)
Iron crawler
450 (17.7) 2,320 (7´7˝) 0.32 (4.5)
600 (23.6) 2,470 (8´1˝) 0.24 (3.4)

39 links
Flat shoe
450 (17.7) 2,320 (7´7˝) 0.33 (4.6)
39 links
Triangle shoe
600 (23.6) 2,470 (8´1˝) 0.23 (3.3)
700 (27.6) 2,570 (8´5˝) 0.20 (2.9)

39 links
Rubber crawler
450 (17.7) 2,320 (7´7˝) 0.32 (4.5)
F15829
NOTE:
Use grouser shoes 600 mm (23.6 in) or 450 mm (17.7 in) on rough ground (areas covered with rocks and gravel).
If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly
(link, roller, etc.) damage.
31102 60413252
2-8
SPECIFICATIONS
7. TYPE OF BUCKET
Heaped Outer width mm (ft-in) Number Availability

Hoe bucket capacity Struck of W or W/O of face Weight
With side Without side
m3 (cu·yd) m (cu·yd) tooth side cutter shovel kg (lbs)
3
cutter cutter
0.09
0.11 (0.14) (0.12) — 3 No Yes 150
400 (1´4˝) (330)
0.12
0.14 (0.18) (0.16) — 3 Yes (welded) Yes 160
480 (1´6˝) (350)
0.14
0.18 (0.24) (0.18) 3 Yes Yes 170
550 (1´10˝) 480 (1´7˝) (380)
0.18
0.22 (0.29) (0.24) 4 Yes Yes 190
650 (2´2˝) 580 (1´11˝) (420)
STD 0.22 4 Yes Yes 200
0.28 (0.37) (0.29) 750 (2´6˝) 680 (2´3˝) (440)
0.26
0.35 (0.46) (0.34) 4 Yes Yes 220
850 (2´9˝) 780 (2´7˝) (640)
V-shape bucket
Capacity: 0.24 m3 (0.31 cu·yd)
7˝)
Weight: 180 kg (400 lbs)
0 (4´
Face shovel unavailable 1 ,41
1,2
70
(4´
2˝)
0
24 4˝)
( 9 ´
Slope finishing bucket

Capacity: 0.26 m3 (0.34 cu·yd)
Face shovel unavailable
˝)
4´11
74 0 0(
(2´ 0 1,5
5˝)
F15830
31102 60413252
2-9
SPECIFICATIONS
8. COMBINATIONS OF ATTACHMENT
BUCKET APPLICABLE ARM

Heaped capacity Struck 1.65 m (5 ft-5 in) 2.07 m (6 ft-9 in) 1.65 m (5 ft-5 in) Arm+
Type
m3 (cu·yd) m3 (cu·yd) Arm Arm Extension Arm
0.11 (0.14) 0.09 (0.12)
0.14 (0.18) 0.12 (0.16)
0.18 (0.24) 0.14 (0.18)

Hoe bucket
0.22 (0.29) 0.18 (0.24)
0.28 (0.37) 0.22 (0.29)
0.35 (0.46) 0.26 (0.34)
V-bucket 0.24 (0.31) 0.16 (0.21)

Slope finishing
0.26 (0.34) 0.14 (0.18)
bucket
Breaker — —
(Reinforced arm)
Nibbler — —
(Reinforced arm) (Reinforced arm)
F15831
NOTE:
Standard combination.
General operation: excavation or loading of sand, gravel, and clay.
Light operation: mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel).
Prohibited combination: there are problems from the view points of strength and stability.
• Use the attachments recommended by Manufacturer. Reinforcement of arm allows to use it as nibbler and
breaker.
The trouble due to the use in the condition “Use not allowed” described in the above table is not included in our
responsibility
• When bucket marked by has been attached or nibbler has been attached on long arm, the specified stability
may not be obtained. So add weight 400 kg (880 lbs) in add-on type as required.
CAUTION
31102 60413252
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2-10
SPECIFICATIONS
9. ENGINE SPECIFICATION
9.1 SPECIFICATIONS
MODEL E70SR EVOLUTION

Engine model ISUZU CC-4JG1
Type Diesel, 4-cycle water -cooled, in-line, Direct injection
Number of cylinder-Bore x Stroke 4-95.4mm (3.76 in) X 107 mm (4.21 in)
Total displacement 3,059 (187 cu·in)
Compression ratio 18.6
Rated out put 55 PS (40.4 kW) at 2,100 rpm
Maximum torque 19.1 kgf·m (138 lbf·ft) at 1,800 rpm
High idling 2,310 ± 25 rpm
Low idling 1,000 ± 25 rpm
Injection valve opening pressure 185 kgf/cm2 (2,632 psi)
Thermostat action Start 82°C (180°F) / Full open 95°C (203°F)
Firing order 1-3-4-2
Compression pressure 30 kgf/cm2 (427 psi) at 200 rpm
Lubrication oil pressure —
Fuel injection timing 10 ± 1° before top dead point
Valve clearance Open Close
Intake valve 0.4 mm (0.016˝) 24.5° before top 55.5° after bottom
Valve clearance in cold condition dead point dead point
Exhaust valve 0.4 mm (0.016˝) 54° before bottom 26° after top
in cold condition dead point dead point
Starter capacity 3.2kW X 24 V
Generator capacity (Alternator) 24 V X 30 A
Ø450 (17.7 in) suction type seven fans
Cooling fan drive method
V-belt drive, pulley ratio Crank / Fan=1.12
Full level 10.6 L (2.8 gal)
Engine oil quantity
Low level sensor actuation Oil filter, etc
Dry weight 250 kg (550 lbs)
Fuel consumption ratio 176 g / PS·h
Allowable inclination Front / Rear and Right / Left : 35°
Dimension (L X W X H) 760 mm X 610 mm X 710 mm (29.9 in X 24.0 in X 28.0 in)
Rotating direction Counterclockwise seeing from flywheel side
F15832
31102 60413252
2-11
SPECIFICATIONS
9.2 ENGINE CHARACTERISTIC CURVE (ISUZU 4JG1)

Condition to be measured: with fan and generator, without muffler and air cleaner.
N·m {kgf·m}
220 22
187.0±8.0 N·m / Approx.1800 min
-1
{19.1±0.8 kgf·m / Approx.1800 rpm} 200
Shaft torque
20
180 18
160 16
140 14
{PS} kW
60
40.5 ±1 .2 kW/2100 min-1
40 {55 ±1 .6 PS/2100 rpm }
50
40 30
30
20
20
2310 ±2 5 min-1
10
10
0 0
g/kW·h {g/PS·h}
260 190
Fuel consumption rate

{240.0 g/kWh or less/2100 min-1}
250
{176.5 g/PS·h or less/2100 rpm} 180
240
230 170
220 160
210
150
200
500 900 1300 1700 2100 2500
F15833
ENGINE SPEED rpm
Fuel consumption rate

Fuel consumption volume = X PS X Load factor ( )
0.835 X 1000
176 g / PS·h
31102 60413252
= X 55 PS X
0.835 X 1000
= 11.6 ·L/h : Standard load factor (0.60 ~ 0.70)

Fuel consumption in regular operation
(load factor: 0.60 ~ 0.70)
7.0 ~ 8.1 L/h
2-12
SECTION 3 ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
1. Boom ...................................................................................................................... 3-1

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

2.1 Arm dimensional drawing ................................................................................................................. 3-4
2.2 Arm maintenance standards ............................................................................................................ 3-5
3. Bucket..................................................................................................................... 3-7
3.1 Bucket dimensional drawing ............................................................................................................. 3-7
3.2 Bucket dimensional table ................................................................................................................. 3-9
3.3 Detail dimensional drawing of lug section ...................................................................................... 3-11
3.4 Detail dimensional drawing of boss section ................................................................................... 3-13
4. Dozer .................................................................................................................... 3-14

4.1 Dozer dimensional drawing ............................................................................................................ 3-14
4.2 Dozer maintenance standard ......................................................................................................... 3-15
31102 60413252
ATTACHMENT DIMENSIONS
1. BOOM
1.1 BOOM DIMENSIONAL DRAWING
VIEW Z
Fig. 1-1 Boom (3.7 m) dimensional drawing
Table 1-1 Unit: mm (ft·in)

CODE ITEM DIMENSION
A Boom length 3,715 (12´2˝)
B Boom foot width 360 (14.2˝)
C Boom end inner width 215 (8.46˝)
D Boom end outer width 315 (12.4˝)
E Height of boom cylinder rod pin 781 (30.7˝)
F Height of arm cylinder (head side) pin 1,085.5 (3´7˝)
G Distance between pins of boss R1,858.5 (6´1˝)
H Distance between of pins of bracket R1,706.5 (5´7˝)
I Arm cylinder (head side) inner width 100 (3.94˝)
J Inner width of bracket on the arm cylinder (rod side) mounting section 100 (3.94˝)
d1 Boom foot pin dia. Ø 60 (2.36˝)
31102 60413252
d2 Boom cylinder (rod side) pin dia. Ø 70 (2.76˝)

d3 Pin dia. of arm end Ø 60 (2.36˝)
d4 Arm cylinder (head side) pin dia. Ø 60 (2.36˝)
F15835
3-1
1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section
Fig. 1-2 Clearance of pin and bushing on boom section
Table 1-2 Unit: mm (in)

STANDARD DIMENSION CLEARANCE
POS. ITEM Pin dia. Bushing Standard Limit Service REMEDY
Pin dia. i.d. value for
tolerance tolerance value repair limit value
-0.06 +0.10
Ø60 (-0.0024) (+0.0039) 0.09~0.19
A Boom foot -0.09 +0.03 (0.0035~0.0075)
(2.3622)
(-0.0035) (+0.0012)
-0.06
(-0.0024) 0.11~0.37
-0.12 (0.0043~0.0146)
Boom cylinder Ø75 (-0.0047)
B -0.06
(Head side) (2.9528) (-0.0024) 0.11~0.34
-0.09 (0.0043~0.0134)
(-0.0035) Replace
-0.06 2.0 2.5 bushing
(-0.0024) +0.25 0.11~0.37 (0.08) (0.1)
Ø70
-0.12 (0.0043~0.0146) or pin
Boom cylinder (-0.0047) (+0.0098)
C -0.06 +0.05
(Rod side) (2.7559) (-0.0024) 0.11~0.34
-0.09 (+0.0020)
31102 60413252
(-0.0035) (0.0043~0.0134)
-0.06
(-0.0024) 0.11~0.37
-0.12 (0.0043~0.0146)
Arm cylinder Ø60 (-0.0047)
D -0.06
(Head side) (2.3622) (-0.0024) 0.11~0.34
-0.09 (0.0043~0.0134)
(-0.0035)
F15837
3-2
(2) Clearance in thrust direction on the boom and cylinder installation section
SECTION AA
SECTION BB SECTION CC SECTION DD

Fig. 1-3 Clearance in thrust direction on boom cylinder installation section

Clearance X adjusted by Length under
BASIC SIZE shim (total of both sides) pin neck
POS. ITEM REMEDY
Repair Service
Standard reference
Code Size limit No. Dimensions
value valve valve
Boom 360 (14.2) 0.6 (0.02) 1.0 1.5 481
A-A Boom foot
Upper frame
L1
365 (14.4) or less (0.04) (0.06)
1
(18.9)
*
Boom cylinder Head side 95 (3.74) 0.6~1.0 2.0 2.5 180
B-B L2 2
(Head side) Upper frame 100 (3.94) (0.02~0.04) (0.08) (0.10) (7.09) Adjusted
Boom cylinder Boom cylinder 95 (3.74) 0.6~2.0 3.0 4.0 221 by shim
C-C L3 3
31102 60413252
(Rod side) Boom 100 (3.94) (0.02~0.08) (0.12) (0.16) (8.70)

Arm cylinder Arm cylinder 95 (3.74) 0.6~1.0 2.0 2.5 215
D-D L4 4
(Head side) Boom 100 (3.94) (0.02~0.04) (0.08) (0.10) (8.46)
F15839
NOTE:
Provide
* indicates a full length ad it has no under neck.
3-3
2. ARM
2.1 ARM DIMENSIONAL DRAWING
1.65 m Standard arm
A POINT
B POINT
2.07 m Long arm
SECTION AA VIEW I SECTION BB

CODE ITEM DIMENSIONS CODE ITEM DIMENSIONS
1,650 2,070 210
C Arm length (5´5˝) (6´9˝) M Boss width (8.27˝)
R498 100
Distance between pins A point R483 (19.6˝)
N Bracket inner width (3.94˝)
D (19.0˝) R495 90
of boss and bracket B point (19.5˝) O Bracket inner width (3.54˝)
Ø65 436.5
D1 I.D of boss (2.56˝) P Link dimension (17.2˝)
Ø60 380±0.5
D2 I.D of boss (2.36˝) Q Link dimension (14.7˝±0.0197˝)
Ø75 15
D3 I.D of boss (2.95˝) R Height between pins of boss and center (0.591˝)
R1,504 Ø50
E' Distance between pins of boss and bracket (4´11˝) d1 Pin dia. (1.97˝)
R240 Ø50
F' Distance between of boss and boss (9.45˝) d2 Pin dia. (1.97˝)
405.5 Ø60
G Height between pins of boss and bracket (16.0˝) d3 Pin dia. (2.36˝)
308.5 Ø60
Height between pins A point d4 Pin dia.
31102 60413252
282.5 (12.1˝) (2.36˝)

H (11.1˝) 222.5 Ø50
of boss and bracket B point (8.76˝) d5 Pin dia. (1.97˝)
180
J Arm top end width (with bushing) (7.09˝)
162
K Boss width (6.38˝)
180
L Arm top end (7.09˝)
F15841
3-4
2.2 ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing
Fig. 2-2 Clearance of pin and bushing on arm section

STANDARD VALUE CLEARANCE
POS. ITEM Pin dia. Bushing Standard Limit Standard REMEDY
Pin dia. i.d. value for
tolerance tolerance value repair limit value
+0.12 +0.11
(+0.0047) (+0.0043)
A Arm point +0.05 +0.21
-0.06
(-0.0024) (+0.0020) (+0.0083)
-0.09 +0.11
Bucket link (-0.0035) (+0.043)
B +0.12 +0.21
(Bucket side) (+0.0047) (+0.0083)
+0.05
Idler link (+0.0020) +0.11
C (Arm connection) (+0.0043)
Bucket link +0.24
D (Idler link) Ø50 (0.0094)
(1.9685) -0.06 +0.25 +0.11
Bucket cylinder (-0.0024) (+0.0098) (+0.0043)
D' -0.12 +0.05 +0.37
(Rod side)
(-0.0047) (+0.0020) (+0.0146)
+0.06 Replace
(+0.0024) 2.0 2.5
+0.32 bushing
+0.20 (0.08) (0.1)
Bucket cylinder (+0.0079) (+0.0126) or pin
E +0.00
(Bottom side) -0.06 +0.06
(-0.0024) (+0.0000) (+0.0024)
-0.09 +0.29
(-0.0035) (+0.0114)
-0.06 +0.11
(-0.0024) (+0.0043)
-0.12 +0.25 +0.37
Arm cylinder (-0.0047) (+0.0098) (+0.0146)
G +0.05 +0.11
(Rod side) -0.06
Ø60 (-0.0024) (+0.0020) (+0.0043)
31102 60413252
(2.3622) -0.09 +0.34

(-0.0035) (+0.0134)
-0.06 +0.20 +0.14
Connecting part (-0.0024) (+0.0079) (+0.0055)
F -0.09 +0.08 +0.29
of arm and boom
(-0.0035) (+0.0032) (+0.0114)
F15843
3-5
(2) Clearance of arm and cylinder installing section in thrust direction
SECTION AA SECTION CC SECTION EE SECTION FF
SECTION BB SECTION DD SECTION GG
Fig. 2-3 Clearance in thrust direction

BASIC SIZE
shim (total of both sides) pin neck
POS. ITEM REMEDY
Standard Repair Service
Code Size reference limit No. Dimensions
value valve valve
Arm 180 (7.09) 0.1 (0.04) 2.0 2.5 335
A Arm point L1 1
Bucket 182 (7.17) or less (0.08) (0.10) (13.2)
Link side — 335
B Bucket link L2 2
Bucket — 0.6 (0.02) 1.0 1.5 (13.2)
Idler link Arm 180 (7.09) or less (0.04) (0.06) 263
C L3 3
(Arm connection) Link side — (10.4)
Bucket link BUcket link — 263
L4 4
(Idler link side) Idler link side — 0.6~1.0 2.0 2.5 (10.4) Adjusted
D by shim
Bucket link Rod side 85 (3.35) (0.02~0.04) (0.08) (0.10)
L4 — —
(Cylinder side) Link side —
Bucket cylinder Bottom side 85 (3.35) 0.6~2.0 3.0 4.0 185
L5
31102 60413252
E 5
(Arm side) Arm 90 (3.54) (0.02~0.08) (0.12) (0.16) (7.28)
Arm and boom Arm 210 (8.27) 0.6 (0.02) 1.0 1.5 328
F L6 6
connection Boom 215 (8.46) or less (0.04) (0.06) (12.9)
Arm cylinder Rod side 95 (3.74) 0.6~2.0 3.0 4.0 204
G L7 7
(Arm side) Arm 100 (3.94) (0.02~0.08) (0.12) (0.16) (8.03)
F15845
3-6
3. BUCKET
3.1 BUCKET DIMENSIONAL DRAWING

(1) Hoe bucket
(2) Slope finishing bucket
(3) V-shape bucket

31102 60413252
Fig. 3-1 Bucket dimensional drawing (1 / 2)
3-7
(4) Loader bucket
Fig. 3-2 Bucket dimensional drawing (2 / 2)
Table 3-1
CODE NAME
A Distance between pin and bracket
B Distance between bucket pin and tooth end
C Inner width of bucket top end
D Inner width of lug
E Inner width of bracket
F Outer width of side cutter
G Outer width of bucket bottom
H Tooth outer width
I Pitch between teeth
Io Pitch between teeth
J finishing plate depth
d1 Pin dia.
d2 Pin dia.
F15850
31102 60413252
3-8
3.2 BUCKET DIMENSIONAL TABLE
TYPE HOE BUCKET

0.28 m3 0.35 m3 0.22 m3 0.18 m3 0.14 m3 0.11 m3
Capacity (0.37 cu·yd) (0.46 cu·yd) (0.29 cu·yd) (0.24 cu·yd) (0.18 cu·yd) (0.14 cu·yd)
A 290 (11,4˝) 290 (11.4˝) 290 (11.4˝) 290 (11.4˝) 290 (11.4˝) 290 (11.4˝)
B R1,037 (3´5˝) R1,037 (3´5˝) R1,037 (3´5˝) R1,037 (3´5˝) R1,037 (3´5˝) R990 (39˝)
C 650 (25.6˝) 750 (29.5˝) 550 (21.7˝) 450 (17.7˝) 412 (16.2˝) 368 (14.5˝)
D 238 (9.37˝) 238 (9.37˝) 238 (9.37˝) 238 (9.37˝) 238 (9.37˝) 238 (9.37˝)
E 182 (7.17˝) 182 (7.17˝) 182 (7.17˝) 182 (7.17˝) 182 (7.17˝) 182 (7.17˝)
F 750 (29.5˝) 850 (33.5˝) 650 (25.6˝) 550 (21.7˝) 480 (18.9˝) 400 (15.7˝)
G 550 (21.7˝) 650 (25.6˝) 450 (17.7˝) 350 (13.8˝) 280 (11.0˝) 318 (12.5˝)
H 566 (22.3˝) 666 (26.2˝) 466 (18.3˝) 366 (14.4˝) 296 (11.7˝) 292 (11.5˝)
I 190 (7.48˝) 222 (8.74˝) 166 (6.54˝) 183 (7.20˝) 148 (5.83˝) 146 (5.75˝)
Io 188 (7.40˝) 222 (8.74˝) 150 (5.91˝) 183 (7.20˝) 148 (5.83) 146 (5.75˝)
d1 Ø65 (2.56˝) Ø65 (2.56˝) Ø65 (2.56˝) Ø65 (2.56˝) Ø65 (2.56˝) Ø65 (2.56˝)
d2 Ø50 (1.97˝) Ø50 (1.97˝) Ø50 (1.97˝) Ø50 (1.97˝) Ø50 (1.97˝) Ø50 (1.97˝)
F15851
31102 60413252
3-9

SLOPE FINISHING V-SHAPE
TYPE LOADER BUCKET
BUCKET BUCKET
0.26 m3 0.24 m3 0.34 m3 0.41 m3
Capacity (0.34 cu·yd) (0.31 cu·yd) (0.44 cu·yd) (0.46 cu·yd)
A 290 (11.4˝) 290 (11.4˝) R330 (13.0˝) R330 (13.0˝)
B R731 (28.8˝) R1,016.9 (3´4˝) R1,016.9 (3´4˝)
C – 1,350 (53.1˝) 910 (35.8˝) 1,058 (41.7˝)
D 244 (9.60˝) 238 (9.37˝) 242 (9.53˝) 242 (9.53˝)
d1 Ø65 (2.56˝) Ø65 (2.56˝) Ø65 (2.56˝) Ø65 (2.56˝)
d2 Ø 50 (1.97˝) Ø 50 (1.97˝) Ø 50 (1.97˝) Ø 50 (1.97˝)
E 182 (7.17˝) 182 (7.17˝) 204 (8.03˝) 204 (8.03˝)
F – – – –
G 1,500 (4´11˝) 240 (9.45˝) 962 (37.9˝) 1,110 (3´8˝)
H – – 834 (32.3˝) 982 (38.7˝)
I – 90 (32.8˝) 278 (10.9˝) 328 (12.9˝)
Io – – 278 (10.9˝) 327 (12.9˝)
J 740 (29.1˝) – – –
F15852
31102 60413252
3-10
3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION

3.3.1 For hoe bucket
SECTION BB
BOSS
2418P26830
SECTION AA
DETAIL OF PLATE
PLATE
BOSS
2418P27140
I
SHIM (t = 1.0)
DETAIL I
Fig. 3-3 Dimension of lug section

Boss outer dia.
Boss outer dia.
Spring pin dia.
Pin hole dia.
Bush length
Screw hole
Boss width
Boss width
Screw dia.
thickness
Lug plate
Hole dia.
CAPACITY
TYPE OF
P.C.D
OF BUCKET
BUCKET
m3 (cu·yd)
A B C D E F G H J M N
0.28 (0.37)
0.35 (0.46)
31102 60413252
0.22 (0.29)
Hoe bucket Ø50 19 53 Ø65 Ø8 Ø110 M12 19 Ø110 28 91
0.18 (0.24)
0.14 (0.13)
0.11 (0.10)
F15856
3-11
3.3.2 For special bucket
DETAIL II
DETAIL II DETAIL I
DETAIL I
Fig. 3-4 Dimension of lug section

Hole dia./ Hole depth
Boss outer dia.

Boss outer dia.
Spring pin dia.
Pin hole dia.
Screw hole
Boss width
Boss width
Screw dia.
Bolt head
thickness
Lug plate
TYPE OF CAPACITY OF
Hole dia.
BUCKET BUCKET m3 (cu·yd)

P.C.D
A B C1/C2 D E F G H J M N
Slope 1500 width
Ø20/13
finishing (4´11˝) X Ø50 Ø16 Ø65 Ø8 Ø106 22 Ø110 31 91
(0.787˝/ M10
bucket 740 length (1.97˝) (0.630˝) /0.512˝) (2.56˝) (0.315˝) (4.17˝) (0.866˝) (4.33˝) (1.22˝) (3.58˝)
31102 60413252
(29˝)
V-shape Ø50 Ø20/15 Ø65
Ø19 Ø8 Ø110 19 Ø110 28 91
0.24 (0.31) (0.787˝ M10
bucket (1.97˝) (0.748˝) /0.591˝) (2.56˝) (0.315˝) (4.33˝) (0.748˝) (4.33˝) (1.10˝) (3.58˝)
Loder 0.41 (0.46) Ø50 19 Ø65 Ø102 19 Ø102 19
– – – –
bucket 0.34 (0.44) (1.97˝) (0.748˝) (2.56˝) (4.02˝) (0.748˝) (4.02˝) (0.748˝)
F15858
3-12
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION
SECTIION II
Fig. 3-5 Dimension of boss section

TYPE OF CAPACITY OF BUCKET
m3 (cu·yd) ØA ØB ØC ØD E F ØG H I
BUCKET
0.28 (0.25)
82.6 54 75.5±0.2 80.5 23 38 13 10 2.5
0.35 (0.30)
(3.25˝) (2.13˝) (2.972˝±0.0078˝) (3.17˝) (0.906˝) (1.50˝) (0.512˝) (0.394˝) (0.0984˝)
Hoe 0.22 (0.20)
bucket 0.18 (0.16)
82.6 54 75.5±0.2 80.5 19 34 13 10 2.5
0.14 (0.13)
(3.25˝) (2.13˝) (2.972˝±0.0078˝) (3.17˝) (0.748˝) (1.33˝) (0.512˝) (0.394˝) (0.0984˝)
0.11 (0.10)
1,500 width
Slope
(4´11˝) X 82.6 54 75.5±0.2 80.5 23 38 13 10 2.5
finishing
740 length (3.25˝) (2.13˝) (2.972˝±0.0078˝) (3.17˝) (0.906˝) (1.50˝) (0.512˝) (0.394˝) (0.0984˝)
bucket
31102 60413252
(29˝)
V-shape
0.24 (0.20)
bucket 82.6 54 75.5±0.2 80.5 19 34 13 10 2.5
Loader 0.41 (0.35) (3.25˝) (2.13˝) (2.972˝±0.0078˝) (3.17˝) (0.748˝) (1.33˝) (0.512˝) (0.394˝) (0.0984˝)
bucket 0.34 (0.30)
F15860
3-13
4. DOZER
4.1 DOZER DIMENSIONAL DRAWING
VIEW I
Fig. 4-1 Dozer dimensional drawing
DOZER
DIMENSION
Code Name
A Blade width 2,494 (8´2˝)
B Blade height 470 (18.5˝)
C Distance from dozer attaching pin center to cutting edge end R1,375 (4´6˝)
D Inner width of dozer attaching bracket 653 (25.7˝)
E Width of dozer attaching bracket 60 (2.36˝)
31102 60413252
Distance from dozer attaching pin center to attaching pin on

F R933 (36.7˝)
dozer cylinder head side
G Attaching bracket inner width on dozer cylinder head side 82 (3.23˝)
d1 Dozer attaching pin dia. Ø50 (1.97˝)
d2 Attaching pin dia. on dozer cylinder head side Ø70 (2.76˝)
F15862
3-14
4.2 DOZER MAINTENANCE STANDARD
M10 X 16
T=6.7 kgf·m (48 lbf·ft)
DETAIL I
M12 X 125 M12 X 125

T=11.7 kgf·m (85 lbf·ft) T=11.7 kgf·m (85 lbf·ft)
M12 X 100
T=11.7 kgf·m
VIEW B VIEW A SECTION CC (85 lbf·ft)
Fig. 4-2 Dozer maintenance standard
(1) Clearance of pin and bushing

STANDARD VALUE CLEARANCE
POS. ITEM Pin dia. Bushing Limit Standard REMEDY
Pin dia. i.d. Clearance value for
tolerance tolerance repair limit value
Dozer cylinder
A -0.06 +0.10 +0.11
(Rod side) Ø70 (-0.0024) (+0.0098) (+0.0043)
Dozer cylinder (2.7519) -0.12 +0.03 +0.37 1.2
B 2.0 Replace
(-0.0047) (+0.0020) (+0.0015)
(Head side) (0.05) bushing
-0.06 +0.19 +0.12 (0.08) or pin
or more
Ø50 (-0.0024) (+0.0075) (+0.0015)
C Dozer foot (1.9685) -0.09 +0.06 +0.28
(-0.0035) (0.0024) (+0.0110)
(2) Clearance in thrust direction on the dozer cylinder installation section

BASIC SIZE
shim (total of both sides) pin neck
POS. ITEM REMEDY
Standard Repair Service
Code Size reference limit Code Dimensions
value valve valve
Dozer cylinder Rod side 80 (3.15)
31102 60413252
A L1 1 181
(Rod side) Lower frame 82 (3.23)
2.0
Dozer cylinder Head side 80 (3.15) 1.0~2.0 Adjusted
B L2 (0.08) 3.0 2 181
(Head side) Dozer 82 (3.23) (0.04~0.08) by shim
or more
Dozer 60 (2.36)
C L3 3 132
Dozer foot Lower frame 63 (2.48)
F15864
3-15
NOTE
31102 60413252
3-16
SECTION 11 TOOLS
TABLE OF CONTENTS
1. Tightening torques for capscrews and nuts ........................................................... 11-1
2. Screw size to tool sizes ......................................................................................... 11-2
3. Tightening torques for nuts and leeves .................................................................. 11-3
4. Plug ....................................................................................................................... 11-4
5. Special spanners for tube ...................................................................................... 11-6
6. Special tools .......................................................................................................... 11-7
7. Application of screw locking compound and sealing compounds.......................... 11-8
8. Suction stopper .................................................................................................... 11-9

8.1 Components ................................................................................................................................... 11-9
8.2 Dimension ...................................................................................................................................... 11-9
9. Counterweight lifting jig ...................................................................................... 11-10
10. Boom foot pin pulling tools ............................................................................... 11-11
11. Tranion cylinder pin pulling tools ....................................................................... 11-12
12. Upper frame lifting jig ....................................................................................... 11-13
13. Engine mounting pedestal ................................................................................ 11-14

31102 60413252
14. Track spring set jig ............................................................................................ 11-14

TOOLS
1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS
Tables 1-1 and 1-2 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.
Table 1-1 Standard tightening torques for metric coarse screw threads Unit: kgf·m (lbf·ft)
Table 1-2 Standard tightening torques for metric fine screw threads Unit: kgf·m (lbf·ft)
31102 60413252
11-1
TOOLS
2. SCREW SIZE TO TOOL SIZES
1) Capscrew 2) Socket bolt
Table 2-1 Table 2-2 Table 2-3

Nominal B mm Nominal B mm Nominal B mm
screw size screw size screw size
(d) Tool size (d) Tool size
Unified
M6 10 (screw threads) Tool size M6 5
M8 13 1/4-20 UNC 11 M8 6
M10 17 5/16-18 UNC 13 M10 8
M12 19 3/8-16 UNC 14 M12 10
(M14) 22 7/16-14 UNC 16 M14 12
M16 24 1/2-13 UNC 19 M16 14
(M18) 27 5/8-11 UNC 24 (M18) 14
M20 30 3/4-10 UNC 29 M20 17
(M22) 32 7/8-9 UNC 33 M24 19
M24 36 1-8 UNC 38 M30 22
(M27) 41 1 1/8-7 UNC 43 M36 27
M30 46 1 1/4-7 UNC 48 M42 32
(M33) 50 1 1/2-6 UNC 57 M48 36
M36 55
M42 65
M45 70
M48 75
M56 85
(M60) 90
M64 95
(M68) 100
M72 105
M76 110
M80 115
31102 60413252
11-2
TOOLS
3. TIGHTENING TORQUES FOR NUTS AND LEEVES
Table 3 indicates standard tightening torques applicable to cases where no particular note is given.
Overtightening or understanding of nuts and sleeves in flareless joint may develop oil leaks through pipe
connections.
Always tighten nuts and sleeves to proper torques.
Table 3-1
Manufacturer’s name Working pressure Tube size Opposing Tightening torque
size (PF) kgf/cm2 (psi) OD X thickness mm (in) flats (HEX) kgf·m (lbf·ft)
10 x 1.5 (0.394 x 0.095) 19 5 ± 1 (36 ± 7)
15 x 2.0 (0.591 x 0.079) 27 12 ± 1.2 (87 ± 9)
Nippon A.M.C 300 (4270) 18 x 2.5 (0.709 x 0.098) 32 15 ± 1.5 (108 ± 11)
22 x 3.0 (0.866 x 0.118) 36 22 ± 2.2 (159 ± 16)
28 x 4.0 (1.10 x 0.157) 41 28 ± 2.8 (200 ± 20)
Ihara Koatu 300 (4270) 35 x 5.0 (1.38 x 0.197) 55 45 ± 4.5 (330 ± 33)
Table 3-2
Tube size SLEEVE
Ød
6
8
10
12
15
18
22
28
32
35
38
Tube size Opposing NUT

Ød flats (HEX)
B
6 14
8 17
10 19
12 22
15 27
18 32
31102 60413252
22 36
28 41
32 50
35 55
38 60
11-3
TOOLS
4. PLUG
(1) Plug for hydraulic pipe joint Table 4-1
1) Cap nut Applicable Opposing flat
Tube T screw
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
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
T screw
2) Plug (tube plug) Table 4-2

Applicable
Tube
O. D: A
6
8
10
12
15
18
Nut and sleeve 22
type joint body Nut
28
3) Nut Table 4-3

Applicable
Tube T screw Opposing flat
O. D: A
D srew 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
31102 60413252
Opposing flat 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
11-4
TOOLS
(2) Plug for hydraulic equipment Table 4-4

1) PF screw PF screw B mm Nominal O-ring
PF 1/4 19 1B P11
O ring PF 3/8 22 1B P14
PF 1/2 27 1B P18
PF 3/4 36 1B P24
PF 1 41 1B P29
PF screw
2) PT screw Table 4-5

PT screw B mm
PT 1/8 5
PT screw
PT 1/4 6
PT 3/8 8
PT 1/2 10
PT 3/4 14
PT 1 17
PT 1 1/4 22
PT 1 1/2 22
(3) Plug for (F) flare hose Table 4-6

PF screw B mm
PT screw
PF 1/4 14
PF 3/8 17
PF 1/2 22
PF 3/4 27
Opposing PF 1 36
flat B
Table 4-7
PF screw E mm F mm
PF 1/4 14 19
PF 3/8 17 22
31102 60413252
PF
screw PF 1/2 23 27
Opposing PF 3/4 27 36
Opposing
flat F flat E PF 1 36 41
PF 1 1/4 40 50
11-5
TOOLS
5. SPECIAL SPANNERS FOR TUBE
Table 5-1
APPLICABLE TUBE DIAMETER HEX mm DIMENSIONS OF A SPECIAL SPANNER

mm (in) mm (in)
15 27
(0.591)
18 32
(0.709)
22 36
(0.866)
28 41
(1.10)
28 46
(1.10)
32 50
(1.26)
35 55
(1.38)
31102 60413252
11-6
TOOLS
6. SPECIAL TOOLS
Table 6-1
No. TOOLS NAME SKETCH APPLICABLE
Allen wrench
Pump suction
1 nominal
B: 10
Commercial tool length (L1) - cut length = Required length

40 (1.57˝) - 10 (0.39˝) = 30 (1.18˝)
Allen wrench
2 nominal Pump install
B: 14
Commercial tool length (L1) - cut length = Required length

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

73 (2.87˝) - 13 (0.51˝) = 60 (2.36˝)
M10 X 22 Additional
Plug threading for For slinging
4 M10 eye bolt
PF 3/4 the swing
motor
PF 3/4 O-ring
For slinging
Eye bolt the swing &
[15] (0.59)
M10 X 18
18 (0.71)
5 Flare hose
[M8 X 15)
M10
[M8]
M8 Eye bolt
Plug
(nominal
31102 60413252
tube dia. 22) Reference nut

6 Flare hose
reference
eye bolt
M8 X 18
nut Additional threading
for M8 Eye bolt
F15878
11-7
TOOLS
7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUNDS
(1) For general
Table 7-1
MANUFACTURER
SERVICE FEATURES
Loctite Three-Bond
#242 1360K Low strenght
Screw locking
#262 1374 Middle strenght
compound
#271 1305 Hight strenght
Sealing compound #515 1215 Sealing
(2) For specific location
Table 7-2
No. USE MANUFACTURER NAME EQUIVALENT APPLICABLE
(Manufacture: Locktite)
# 1901 Anti-seizure Cylinder
# 1215 gray # 5699 Swing motor

Three-bond
# 1211 white # 5301J Swing motor
# 1303B # 211 Main pump

Sealing compound and adhesive
(Manufacture: Three-bond)
# 222 #1344N Main pump

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

31102 60413252
Sumitomo Locktite # 515

Chemical Co.,Lad. Syano Bond P0-1 Three-bond # 1215 For swing bearing: Seal
Showa-shell
petroleum Shell Albania EP2 New Molyknock Grease 2 Swing bearing grease bath
F15880
11-8
TOOLS
8. SUCTION STOPPER
8.1 COMPONENTS
No. NAME Q’ty

Suction stopper assy
Rod
1 Rod 1
2 Nut 1
3 Cover 1
4 O-ring 1
Nut
Cover
8.2 DIMENSION O-ring
Fig. 8-1 Components of suction stopper
ROD COVER
Fig. 8-2 Dimension of suction stopper

31102 60413252
11-9
TOOLS
9. COUNTERWEIGHT LIFTING JIG
Bracket for left side Bracket for right side
Material: mild steel
Fig. 9-1 Counterweight lifting bracket

31102 60413252
11-10
TOOLS
10. BOOM FOOT PIN PULLING TOOLS
Fig. 10-1 Slide hammer for boom foot pin
Tools accessorois assy
Table 10-1
No. TOOL NAME SKETCH APPLICABLE
Boom foot pin

Rod
pulling
Boom foot pin

2 Hammer
pulling
31102 60413252
F15888
11-11
TOOLS
11. TRANION CYLINDER PIN PULLING TOOLS
Arm cylinder Spanner
Fig. 11-1 Tranion cylinder pin pulling tools
Tools accessories assy
Table 11-1
No. TOOL NAME SKETCH APPLICABLE
Arm cylinder
1 Guide
for pin
Arm cylinder
2 Screw
for pin
Arm cylinder
31102 60413252
3 Nut: M24 Standard item

for pin
B = 36
F15893
11-12
TOOLS
12. UPPER FRAME LIFTING JIG
Q’ty: 2 set
Material: mild steel
Fig. 12-1 Upper frame lifting jig

31102 60413252
11-13
TOOLS
13. ENGINE MOUNTING PEDESTAL

547 (21.54˝)
(0.827˝) 21 505 (19.88˝) 21 (0.827˝)
(5.12˝)
130
(11.81˝)
300
(0.827˝)
240(9.45˝) 265 (10.43˝)

21
(11.02˝)
280
8
R15 2˝)
21 (11.02˝)
(6.2
280
(5.51˝)
140
200 (7.87˝)
(0.827˝)
250 240 (9.45˝) 265 (10.43˝)

(9.84˝) 325 (12.8˝)
(11.81˝)
300
(5.12˝)
505 (19.88˝) 130
(0.827˝) 21 21 (0.827˝)
547 (21.54˝)
F15895
Material: plywood or wooden plate

Fig. 13-1 Engine stand
14. TRACK SPRING SET JIG
Retainer nut
Retainer plate
Stand
Hydraulic jack
31102 60413252
Base
Fig. 14-1 Track spring set jig
11-14
SECTION 12 STANDARD MAINTENANCE TIME SCHEDULE
TABLE OF CONTENTS
1. Standard working time table for the maintenance of excavator ............................. 12-1
2. Standard working time table for the maintenance of engine ................................. 12-9
31102 60413252
STANDARD MAINTENANCE TIME SCHEDULE
1. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR
(1) Standard maintenance time schedule (2) Classification of work code

1) Units of working time: 6 minutes = 0.1 hour (3) Condition for standard service time of the engine
2) Calculating method of standard maintenance time: 1) Tools designated by E/G marker are used
Maintenance time = Working time X Number of 2) Genuine parts are changed
workers 3) Correct working procedures are observed.
(Working time = Maintenance time / Number of • The time required for works specified in this
workers) Chapter shows the total time for maintenance.
3) When more than one work are done,
a) Add each standard maintenance time No. GROUP REMARKS
b) A net time (readily starting) is given except 01 Attachment Indicates installing,
covers easily removed by hand. 02 Cab and guard removing, replacement
c) Assy works include the following works marked 03 Swing frame and overhaul.
with black dot • 04 Travel system
Indicates the installing,
4) O / H: Basically the installing and removing
Electric removing and
operation are included. 06
equipments replacement of single
5) Abbreviations in the table.
items.
A/C ; Air condition E/G ; Engine
Indicates overhaul of
ASSY ; Assembly F hose ; Flexible hose
the single engine.
ATT ; Attachment O/H ; Overhaul 09 E/G relation
(Materials prepared by
BRG ; Bearing SOL ; Solenoid
manufacturer)
C/V ; Control valve SW ; Switch
F15897
Cyl ; Cylinder V ; Valve
WORK TO Maintenance time

GROUP LOCATION UNIT REMARK
BE DONE E70SR EV.
00 Bucket relation 2.Reference for bucket
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.5
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include omission of pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.1
06 • Bucket (single) O/H 1 pc. Not include attaching and detaching. 2.0
07 • Tooth Replace 1 pc. 0.5
08 • Side cutter Replace 1 pc. 1.0
09 • Bushing Replace 1 pc. 0.5
01 Attachment
10 Arm relation 3.Reference for arm

11 Arm ASSY Detach/attach 1 pc. 1.0
12 • Bucket cylinder attaching and detaching position and piping Preparation 1 pc. 0.3
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include omission of pin. 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1
17 • Boom top pin Detach/attach 1 pc. 0.1
18 • Arm sling and movement Detach/attach 1 pc. 0.1
31102 60413252
30 Boom relation 4.Reference for boom

31 • Boom ASSY Detach/attach 1 pc. 1.0
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 1 pc. 0.1
34 • Boom cylinder rod pin Detach/attach 1 Include omission of pin. 0.1
F15898
12-1

BE DONE E70SR EV.
35 • Boom cylinder piping Detach/attach 1 pc. 0.1
36 • Arm & bucket piping Detach/attach 1 pc. 0.2
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include omission of pin 0.2
39 • Boom assy slinging Detach/attach 1 pc. 0.1
40 • Arm cylinder attaching and detaching Detach/attach 1 pc. 0.3
41 • Arm cylinder piping Detach/attach 1 pc. 0.1
01 Attachment
42 • Arm cylinder head pin Detach/attach 1 Include omission of pin 0.1

43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 1 pc. 0.3
51 • Boom cylinder piping Detach/attach 1 0.1
52 • Boom cylinder head pin Detach/attach 1 pc. 0.1
53 • Boom cylinder slinging Detach/attach 1 0.1
60 Bucket cylinder O/H 1 3.0
61 • Pin bushing Preparation 1 Include seal 1.0
70 • Arm cylinder O/H 1 3.0
71 • Pin bushing Preparation 1 set Include seal 1.0
80 • Boom cylinder O/H 1 3.0
81 • Pin bushing Preparation 1 Include seal 1.0
10 Cab relation 1.Reference for cable
11 Cab ASSY Detach/attach 1 pc. 1.5
12 • Front lower glass, floor mat Detach/attach 1 pc.each 0.1
13 • Cab mounting bolts, nuts (front) Detach/attach 4 places 0.2
14 • Grille on seat rear side Detach/attach 1 pc. 0.2
15 • Grille on seat under side Detach/attach 1 pc. 0.1
16 • Air-con duct Detach/attach 2 0.2
17 • Coupler for cluster gauge (electric) Detach/attach 1 0.1
18 • Cab mounting bolts, nuts (rear side) Detach/attach 5 places 0.2
19 • Cab slinging Detach/attach 3 places 0.4
20 Guard relation 6.Reference for guard
02 Cab and guard
21 Cover (1) Detach/attach 1 pc. 0.2

22 • Cover (1) slinging Detach/attach 1 pc. 0.1
23 Panel assy (2) Detach/attach 1 pc. 0.1
24 Cover assy (6) Detach/attach 1 pc. 0.1
25 Guard assy (40) Detach/attach 1 pc. 0.1
27 Bonnet assy (65) Detach/attach 1 pc. 0.2
28 • Bonnet assy slinging Detach/attach 1 pc. 0.1
30 Bracket (44) Detach/attach 1 pc. 0.1
32 Cover assy (60) Detach/attach 1 pc. 0.1
31102 60413252

36 • Guard assy (8) slinging Detach/attach 1 pc. 0.1
40 Cover relation 7. Reference for cover
F15899
12-2

GROUP LOCATION Unit REMARK
BE DONE E70SR EV.
02 Cab and guard

50 Counter weight relation 5. Reference for counter weight
51 Counter weight ASSY Detach/attach 1 pc. 0.4
52 • Counter weight lifting jig Detach/attach 1 set 0.1
53 • Counter weight temporary slinging Preparation 1 pc. 0.1
54 • Counter weight mounting bolt Detach/attach 1 pc. 0.1
55 • Counter weight slinging Detach/attach 1 pc. 0.1
00 Control relation
01 E/G control ASSY Detach/attach 1 pc. Include adjustment. 0.2
02 • Emergency stop knob (control) cable Replace 1 pc. 0.1
10 Intake relation Detach/attach 8. Reference for Air cleaner
11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 • Hose (2) Detach/attach 1 0.1
13 • Hose (1) Detach/attach 1 0.1
14 • Element Replace 1 0.1
20 Exhaust relation 9. Reference for muffler
21 Muffler ASSY Detach/attach 1 pc. 0.4
22 • U bolt Detach/attach 1 pc. 0.1
23 • Clamp ASSY Detach/attach 1 pc. 0.1
24 • Gasket Replace 1 pc. 0.1
30 Radiator relation 13. Reference for Radiator
31 Radiator ASSY Detach/attach 1 pc. 3.5
32 • Coolant (LLC) Replace 1 pc. 0.2
03 Swing frame
33 • • Concentration of coolant Measuring 1 pc. 0.2

34 • A/C condenser Detach/attach 1 pc. 0.2
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.2
37 • Sub tank Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.2
39 • Water hose (radiator E/G) Detach/attach 1 0.2
40 • Radiator mounting bolts removing Detach/attach 1 pc. 0.2
41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tank • suction stopper Attach/detach 1 pc. 0.2
43 • Hydraulic oil piping coupling Detach/attach 1 pc. 0.8
44 • Hydraulic oil piping Detach/attach 1 pc. 0.2
45 • Water hose (E/G radiator) Detach/attach 1 0.2
46 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
50 Fuel relation 10. Reference for fuel tank
51 Fuel tank ASSY Detach/attach 1 pc. 1.5
52 Replace 1 pc. 0.2
31102 60413252
• Fuel
53 • Hose (water separator side) Detach/attach 2 0.1
54 • Water separator Detach/attach 1 pc. 0.1
55 • Tube (tank side) Detach/attach 1 0.1
56 • Connecting bracket between tanks Detach/attach 1 0.1
F15900
12-3

BE DONE E70SR EV.
57 • Fuel tank installing bolts Detach/attach 1 pc. 0.2
58 • Tank slinging Detach/attach 1 pc. 0.2
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.3
Removing and installing battery 0.2
60 Hydraulic oil tank relation 11. Reference for hydraulic oil tank
61 Hydraulic oil tank ASSY Detach/attach 1 pc. After removing fuel tank ; 3.5
62 • Hydraulic oil tank attaching and detaching position Detach/attach 1 pc. 0.1
63 • Return oil pipe on tank upper cover Detach/attach 1 pc. 0.4
64 • Hose on upper cover Detach/attach 1 pc. 0.2
65 • Cover Detach/attach 1 pc. 0.2
66 • Hydraulic oil Replace 1 pc. 0.4
67 • Other necessary works Detach/attach 1 pc. Multi C/V attaching bracket movement 0.2
Multi pilot hose removing and attaching 0.4
68 • Pilot drain hose Detach/attach 1 pc. 0.2
69 • Pump suction hose Detach/attach 1 0.4
70 • Mounting bolt Detach/attach 1 pc. 0.2
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.2
72 • Return filter Replace 1 0.2
73 • Suction filter Cleaning 1 0.2
80 Pump relation After removing counter weight
81 Pump ASSY Detach/attach 1 pc. 2.3
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.3
03 Swing frame
83 • Strainer & stopper Detach/attach 1 pc. 0.3

84 • Piping Detach/attach 1 set 0.8
85 • Guard Detach/attach 2 pc. 0.4
86 • Pump slinging Detach/attach 1 pc. 0.4
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc.
89 Pump ASSY O/H 1 pc. 3.0
Other necessary works Detach/attach 1 set Counter weight 0.4
90 Swing motor unit relation After removing boom
91 Swing motor ASSY Detach/attach 1 pc. 1.8
92 Piping Detach/attach 1 set 0.6
93 Drain hose clamp Detach/attach 1 0.2
94 Mounting bolt Detach/attach 1 pc. 0.5
95 Unit slinging Detach/attach 1 pc. 0.3
96 Cleaning and sealant Cleaning 1 set 0.2
97 • Swing motor O/H 1 pc. 3.0
98 • Swing reduction gear O/H 1 pc. 3.5
100 Swivel joint relation 20. Reference for swivel joint
101 Swivel joint ASSY Detach/attach 1 After removing boom 1.5
102 • Piping (Top part only) Detach/attach 1 set 0.3
103 • Stop gap Detach/attach 1 0.1
104 • Cover Detach/attach 1 0.2
31102 60413252
105 • Joint & elbow Detach/attach 1 set 0.2

106 • Mounting bolt Detach/attach 1 set 0.2
107 • Swivel joint Detach/attach 1 0.2
108 • Cleaning Cleaning 1 set 0.1
F15901
12-4

BE DONE E70SR EV.
109 Swivel joint O/H 1 set Removing and installing guard 3.0
Other necessary works Detach/attach 1 set Front attach ASSY 1.5
Detach/attach 1 set Lower piping 0.5
110 Multi control valve 15. Reference for multi C/V
111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.0
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.2
Other necessary works Detach/attach 1 set Guard 0.3
120 Main control valve 16. Reference for control valve
121 Main control valve ASSY Detach/attach 1 pc. 1.5
122 • Attach tag to port name of pipe Preparation 1 pc. 0.5
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY O/H 1 set 5.0
Other necessary works Detach/attach 1 set Guard 0.3
Detach/attach 1 set Battery 0.2
Detach/attach 1 set Fuel tank ASSY 1.5
Detach/attach 1 set Multi C/V movement 0.5
130 Dozer control valve OPT
03 Swing frame
131 Control V ASSY Detach/attach 1 0.5

132 • Write hose name on Control V connecting hose Detach/attach 1 set 0.1
136 Control V ASSY O/H 1 set 1.0
140 Engine (E/G) mounting relation 14. Reference for engine
141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.5
142 • Harness connector & grounding & cable connection Detach/attach 1 pc. 0.2
143 • Fuel hose Detach/attach 1 pc. 0.1
144 • Others Detach/attach 1 set 0.4
145 • Mounting bolt Detach/attach 1 pc. 0.4
146 • Engine slinging Detach/attach 1 set 0.2
148 Engine O/H 1 set Reference for engine
Other necessary works Detach/attach 1 set Removing and installing guard 0.5
Detach/attach 1 set Removing and installing counter weight 0.4
Detach/attach 1 set Removing and installing pump 2.3
Detach/attach 1 set Removing and installing cleaner 0.4
Detach/attach 1 set Removing and installing muffler 0.4
Detach/attach 1 set Removing and installing radiator 3.5
150 Upper frame 21 Reference for upper frame
31102 60413252
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.0
153 • Upper frame slinging Detach/attach 1 pc. 0.3
F15902
12-5

BE DONE E70SR EV.
155 • Sealant Apply 1 pc. 0.2
03 Swing frame
Other necessary Detach/attach 1 set Cab 1.5

Detach/attach 1 set Guard 0.3
Detach/attach 1 set Counter weight 0.4
Detach/attach 1 set Boom 1.5
00 Travel relation 2. Reference for crawler

01 Track link ASSY Detach/attach One side Include adjustment of tension 1.0
02 • Track link attaching 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 3. Reference for upper roller
11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0
20 Lower roller relation 4. Reference for lower roller
21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.0
30 Front idler relation 5. Reference for front idler
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 Disassemble One side 0.2
34 Idler ASSY O/H One side 1.0
04 Travel system
35 Idler adjuster ASSY O/H One side Replace spring 2.0

36 • Grease cylinder O/H One side 0.5
40 Sprocket 6. Reference for sprocket
41 Sprocket Replace One side After removing track link 0.5
50 Travel motor relation 7.Reference for travel motor
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 bolt 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
58 Travel reduction gear O/H One side 3.0
60 Swivel joint relation
61 Pipe on swivel joint travel side Detach/attach 1 pc. 0.5
62 Swivel joint O/H 1 pc. Refer to Upper structure 100.
70 Swing bearing 8. Refer to 6 Swing bearing
removing and installing
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper flame 0.6
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.4
73 Swing bearing slinging Detach/attach 1 pc. 0.2
80 Dozer relation OPT
31102 60413252
81 Dozer ASSY Detach/attach 1 pc. 0.6

81 • Dozer cylinder piping Detach/attach 1 pc. 0.2
82 • Dozer cylinder slinging Detach/attach 1 0.2
83 Dozer slinging Detach/attach 1 pc. 0.2
84 Dozer Cylinder O/H 1 2.0
F15903
12-6

BE DONE E70SR EV.
Controller
C-1 Controller (KPSS) Replace 1 0.2
C-2 Gauge cluster Replace 1 0.2
C-4 Air conditioner Amplifier Replace 1 0.2
C-5 Power window controller (OPT) Replace 1 0.2
Diode
D-1 Diode Replace 1 0.2
Electric equipments
Include C1 controller
E-1 Fuse box Replace 1 removing and installing. 0.3
Include bonnet assy
E-2 Alternator Replace 1 removing and installing. 1.0
E-3 Hour meter Replace 1 0.2
E-5 Horn Replace 1 0.2
E-6 Cigar lighter Replace 1 0.2
E-7 Tuner AM & FM (OPT) Replace 1 0.2
E-7 Tuner AM Replace 1 0.2
E-8 Speaker left (OPT) Replace 1 0.2
E-9 Speaker right Replace 1 0.2
06 Electric equipments
E-10 Receiver dryer Replace 1 Include gas sealing 0.3

Include counter weight
E-11 Air compressor Replace 1 removing and installing. 0.5
E-12 Hot water heater (OPT) Replace 1
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Room light Replace 1 0.2
L-4 CAB work light (OPT) Replace 1 0.2
L-5 CAB work light (OPT) Replace 1 0.2
Motor
M-1 Starter Replace 1 removing and installing. 1.0
M-2 Governor Replace 1 removing and installing. 0.5
M-3 Wiper motor (Non rise up) Replace 1 0.2
M-4 Washer motor Replace 1 0.2
M-5 Cable assy (P/W motor OPT) Replace 1 0.5
M-6 Power window lock motor (OPT) Replace 1 0.2
M-7 Power window lock motor (OPT) Replace 1 0.2
M-8 Skylight wiper motor (OPT) Replace 1 0.2
Proportionate valve
Include proportional valve
PSV-B P2 by-pass cut proportionate valve Replace 1 removing and installing. 2.0
PSV-C Travel straight proportionate valve Replace 1 removing and installing. 2.0
PSV-D P1 by-pass cut proportionate valve Replace 1 removing and installing. 2.0
Relay
31102 60413252
R-1 Battery Replace 1 0.2

R-3 Glow relay Replace 1 0.2
Include guard (9) removing
R-4 Safety relay Replace 1 and installing. 0.4
Include C1 controller removing
R-5 Wiper motor relay Replace 1 and installing. 0.3
F15904
12-7

BE DONE E70SR EV.
R-6 Washer motor relay Replace 1 0.3
R-7 Horn relay Replace 1 0.3
R-8 Work light relay Replace 1 0.3
R-9 Wiper relay assy (OPT) Replace 1 0.3
Sensor
SE-1 Pressure sensor (low pressure; bucket digging) Replace 1 0.2
SE-2 Pressure sensor (low pressure; bucket dump) Replace 1 0.2
SE-3 Pressure sensor (low pressure; boom up) Replace 1 0.2
SE-4 Pressure sensor (low pressure; boom down) Replace 1 0.2
SE-5 Pressure sensor (low pressure; swing left) Replace 1 0.2
SE-6 Pressure sensor (low pressure; swing right) Replace 1 0.2
SE-7 Pressure sensor (low pressure; arm in) Replace 1 0.2
SE-8 Pressure sensor (low pressure; arm out) Replace 1 0.2
Include removing and installing
SE-9 Pressure sensor (low pressure; travel right) Replace 1 guard on cab lower side. 0.4
Include removing and installing
SE-10 Pressure sensor (low pressure; travel left) Replace 1 guard on cab lower side. 0.4
Include guard removing and
SE-13 Engine speed sensor Replace 1 installing. 0.5
SE-14 Engine water temperature sensor Replace 1 0.2
Include guard removing and
SE-15 Fuel sensor Replace 1 installing. 0.3
06 Electric equipments
SE-16 Accel potentio Replace 1 0.2

Solenoid
SV-1 Swing parking SOL Replace 1 removing and installing. 2.0
SV-2 Conflux single flow switching SOL (OPT) Replace 1 removing and installing. 2.0
SV-3 2-speed travel SOL Replace 1 removing and installing. 2.0
SV-4 Lever lock SOL Replace 1 removing and installing. 2.0
Switch
SW-1 Key switch Replace 1 0.2
SW-2 Switch Replace 1 0.2
SW-3 2-speed travel switch Replace 1 0.2
SW-4 Swing parking release switch Replace 1 0.2
SW-6 Engine water temperature switch Replace 1 0.2
SW-7 Engine oil pressure switch Replace 1 0.2
SW-8 Clogged air filter switch Replace 1 0.1
SW-10 Horn switch Replace 1 0.2
SW-11 Lever lock switch Replace 1 0.3
SW-12 Heater switch (OPT) Replace 1 0.2
SW-13 Air conditioner switch Replace 1 0.2
SW-14 Power window switch (OPT) Replace 1 0.2
SW-15 Skylight wiper switch (OPT) Replace 1 0.2
SW-16 Work light switch (OPT) Replace 1 0.2
SW-17 Conflux-single flow select switch Replace 1 0.2
Include removing installing
SW-18 OPT pedal pressure switch (1) Replace 1 guard on cab lower side. 0.4
Include removing installing
SW-19 OPT pedal pressure switch (2) Replace 1 guard on cab lower side. 0.4
SW-20 Horn switch (R) (OPT) Replace 1 0.2
31102 60413252
F16671
12-8
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE
Introduction 2. Special equipments not listed in this table may be

This standard working time table provides time used for operation.
required for maintenance (if the work is carefully carried If such operations are performed, fill out reasons
out) under the following condition: in the Claim Application Sheet in detail and submit
• Tools designated by us are used. it to us.
• Genuine parts are prepared.
• Correct working procedures are observed. NOTE:
• The engine is mounted correctly to the machine. Unit of maintenance time.
1. The working hours given in this table can not be The maintenance time is given in 6 minutes = 0.1 hour
applied because of special machine construction. in the decimal system.
Applicable models: A-4JB1 - E70SR EVOLUTION.
Work Mainte- Work Mainte-

LOCATION OF WORK to be nance LOCATION OF WORK to be nance
done time done time
Detach and
Engine body Cam shaft attach 11.6
Detach and • Incl. replacement of bearing and tappet
Flywheel assy attach 0.9
• Including replacing of ring gear, etc.
Engine cushion rubber (both sides) Replace 0.4 Intake exhaust system Replace 0.3
Drain plug Replace 0.1 Air intake hose Retighten 0.3
Detach and Detach and
Engine assy attach 21.6 Manifold fastening bolts attach 1.1
Detach and
• Incl. overhaul of engine and cylinder body Inlet manifold attach 0.7
Detach and
Sealing plug Replace 0.2 Exhaust manifold attach 0.8
Cylinder block drain cock assy Replace 0.1 Throttle valve assy
Detach and • Incl. overhaul of throttle valve
Piston & conn rod (2 cycle) attach 11.2 Replace 0.1
Detach and
Incl. Replacing parts (4 cycle) 13.9 Intake shutter spring attach 0.5
Crank shaft rear oil seal Replace 0.2 Intake shutter
Crank shaft pulley attach 0.8 • Incl. overhaul of intake shutter attach 0.2
Detach and
• Incl. replacement of front oil seal Inlet pipe assy attach 0.2
Oil pan Retighten 0.3 Exhaust pipe adapt assy
Detach and
Oil pan attach 0.9
Detach and
• Incl. overhaul of oil pump Lubricating system attach 0.5
Detach and Oil filter element cover
Crank casing & oil pan attach 2.3
Incl. overhaul of oil pump and replacement of other parts • Incl. replacement of relief valve Replace 0.2
Detach and
Oil pan level gauge guide tube Replace 0.1 Oil filter element (cartridge) attach 0.6
Oil filter assy
Detach and
Cylinder head • Incl. overhaul of oil filter attach 0.1
Detach and
Valve clearance Adjust 0.5 Oil filter oil pipe attach 0.3
Cylinder head cover attach 0.5 Oil cooler assy (incl. replacement of one hose) attach 0.5
• Incl. retightening cylinder head Oil cooler assy (2 hoses) Replace 0.1
Detach and Oil cooler water hose
Cylinder head assy attach 7.9 Replace 0.2
• Overhaul of cylinder head, replacement of valve guide, etc. Oil relief valve
Valve timing mechanism Fuel system Adjust 0.3

Locker arm & shaft assy attach 0.6 Injection time attach 2.8
• Incl. overhauling locker arm Injection pump assy
31102 60413252
Tappet Replace 5.4 • Incl. replacement of governor, feed pump, etc. Replace 0.3
Tappet chamber cover attach 0.4 Injection pump overflow valve attach 1.0
Valve rocker stand Replace 0.4 Fuel feed pump assy
Detach and • Incl. overhaul of pump and replacement of check valve
Timing gear casing cover attach 1.2
• Incl. replacement of gear
F16672
12-9
Work Mainte- Work Mainte-

LOCATION OF WORK to be nance LOCATION OF WORK to be nance
done time done time
Feed pump strainer attach 0.3 Water pump assy attach 1.2
• Incl. cleaning strainer • Incl. overhaul of pump
Injection pipe (2 pcs.) attach 0.1 Water pipe and hose attach 1.0
Injection pipe (4 pcs.) 0.3 • Incl. replacement of pipe and packings
Detach and
Injection pipe clip Replace 0.1 Thermostat attach 0.6
Nozzle leakoff pipe Replace 0.3 • Incl. performance test
Priming pump Replace 0.4
Injection pump 0.1 Electrical equipments of engine
Detach and
Fuel cut solenoid Replace 0.1 Starter assy attach 0.6
Detach and
Nozzle holder assy (1 pc.) attach 0.7 Generator pulley Replace 0.6
• Incl. replacement of nozzle (2 pcs.) attach 1.0 Generator assy attach 0.7
Detach and
• Incl. replacement of nozzle (4 pcs.) attach 1.5 Generator drive belt Replace 0.1
Fuel filter (cartridge) Replace 0.1 Voltage regulator Adjust 0.5
Detach and
Fuel filter element attach 0.2 Voltage regulator Replace 0.1
Detach and
Fuel filter assy attach 0.6 Glow plug (2 pcs.) Replace 0.3
Detach and
Fuel filter overflow valve attach 0.4 Glow plug (4 pcs.) Replace 0.4
Fuel pump (feed pump filter) Replace 0.4 Glow plug relay Replace 0.1
Fuel pipe (Filter injection) Replace 0.4
Fuel return pipe Replace 0.4 Switch unit relay
Fuel hose Replace 0.2 Ignition & starter switch Replace 0.2
Oil pressure unit Replace 0.1
Cooling water system Oil pressure switch Replace 0.1
Fan belt Adjust 0.1 Thermo unit Replace 0.2
Fan belt Replace 0.1 Control resistor Replace 0.2
Cooling fan attach 0.3 Auto stop motor assy attach 0.2
F16673
31102 60413252
12-10
SECTION 13 MAINTENANCE STANDARD
AND TEST PROCEDURE
TABLE OF CONTENTS
1. How to use the maintenance standard and prcautions ......................................... 13-1
2. Performance inspection standard table ................................................................. 13-2
3. Measurement of engine speed .............................................................................. 13-4

3.1 Measurement of engine speed ....................................................................................................... 13-4
4. Measurement of hydraulic pressure ..................................................................... 13-5

4.1 Preparing to measure hydraulic pressure ...................................................................................... 13-5
4.2 Place to install pressure gauge ...................................................................................................... 13-5
4.3 Pressure adjustment position ......................................................................................................... 13-6
4.4 Procedure for adjusting relief valve ................................................................................................ 13-8
5. Measuring travel performances ............................................................................ 13-9

5.1 Travel speed ................................................................................................................................... 13-9
5.2 Deviation of travel ........................................................................................................................... 13-9
5.3 Performances of parking brake .................................................................................................... 13-10
5.4 Drain rate of travel motor .............................................................................................................. 13-10
6. Measuring swing performances ......................................................................... 13-11

6.1 Swing speed ................................................................................................................................. 13-11
6.2 Performance of swing brake ......................................................................................................... 13-11
6.3 Performance of swing parking brake ............................................................................................ 13-12
6.4 Drain rate of swing motor ............................................................................................................. 13-12
7. Measuring attachment operating performances ................................................. 13-13

7.1 Operating time of cylinders .......................................................................................................... 13-13
7.2 Oil tighteness of cylinders ............................................................................................................ 13-13
8. Measuring performances of swing bearing ........................................................ 13-14

31102 60413252
9. Mechatro controller “a” adjustment ..................................................................... 13-15

9.1 Engine control input / out ............................................................................................................. 13-15
9.2 Engine control installation ............................................................................................................ 13-15
9.3 E/g control equipment .................................................................................................................. 13-16
9.4 Adjustment of mechatro contorl ................................................................................................... 13-17
MAINTENANCE STANDARD AND TEST PROCEDURE
1. HOW TO USE THE MAINTENANCE STANDARD AND PRCAUTIONS
(1) Application machine performances deteriorate with time as

1) When the machine is new; parts wear and some deteriorated performances
confirm that the performances are in accordance may be restored to new levels. Therefore,
with standard specifications as compared to the determine correction, adjustment or replacement,
performance standards. depending upon the operating hours, kind of work
2) At specific self inspection; (Rule by country) and circumstances in which the machine is placed,
use the date for the criterion, for the purpose of and condition the machine performances to its
correction, adjustment and replacement. most desirable levels.
3) When performances are deteriorated;
determine whether it is caused by a fault or end of (4) Other cautions to be exercised
service life after long hours of operation, to be 1) Parts liable to degrade;
used for safety and economical considerations. rubber products, such as, hydraulic hoses, O-
4) When main components are replaced; rings, and oil seals deteriorate with time; replace
for example, use date to restore performances of them at regular intervals or at overhauls.
pumps and others. 2) Parts requiring regular replacement;
out of critical hoses that are necessary to secure
(2) Terminology safety, we designate Very Important Parts (V.I.P)
1) Standard values; and recommend that they should be replaced
values to be used to condition or assemble a new regularly.
machine. Where special notes are not given, 3) Inspection and replacement of oils and greases;
these values represent standard specifications in performing maintenance, it is necessary for the
(machine with standard attachments and standard user to familiarize himself with how to handle the
shoes). machine safely, cautions to be exercised and
2) Repairable level; inspection/lubrication procedures. Refer to the
values at which readjustment is required. In order operator’s manuals as well.
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 judgement

1) Evaluation of measured date;
disagreement of measuring conditions, variations
of date peculiar to a new machine, and measuring
errors are to be evaluated. Determine generally at
31102 60413252
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;
13-1
2. PERFORMANCE INSPECTION STANDARD TABLE
Table 1 (1 / 2)
NOTE:
The mode is already S mode when power is thrown. Unless otherwise specified, measure it on H mode.
MEASURING POSITION STANDARD TOLERANCE ADJUSTING MEASURING

INSPECTION ITEM UNIT
Position Size Port VALUE Hi Lo POINT CONDITION
Standard measuring condition
Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 +1 -1 Class — sampling

Hydraulic oil temperature Tank surface 50 (122) +5 (41) -5 (23) — Atmospheric temp.
°C 50°C~-10°C
Water temperature Radiator surface 75 (167) +15 (59) -15 (5) — (122°F~14°F)
Lo idle 1020 +30 -30 LOW throttle
Engine speed
FULL throttle
Hi idle 2250 +30 -30 (HI idle)
Adjustment
Decel Injection pipe 1050 +30 -30 rpm not
S mode 2100 +30 -30 required
FC mode 1800 +30 -30

Pilot primary pressure circuit G·pump a4 35 (500) +2 (30) -1 (10) PR1 HI idle
valve pressure
ATT P1 a1
Boom up
Main relief
300 (4270) +5 (70) 0 MR1

Travel P2 a2
Dozer P3 a3 200 (2840) +5 (70) 0 MR3 Dozer up
H 335 (4760) +5 (70) 0 OR3 Boom up
Boom a1
R 335 (4760) +5 (70) 0 OR4 Boom down
H 335 (4760) +5 (70) 0 OR1 Bucket digging
Bucket a1
High pressure circuit
R 335 (4760) +5 (70) 0 OR2 Bucket dump

Port relief valve pressure
Main pump
Forward —
RH a1 — — — Simultaneous
Travel
Reverse PF1/4 — operation of travel

Forward — RH and LH
LH a2 — — — (Without port relief)
Reverse —
LH 250 (3560) +40 (570) +10 (140) OR5 Swing LH
Swing a2 kgf/cm2
RH 250 (3560) +40 (570) +10 (140) (psi) OR6 Swing RH
H 335 (4760) +5 (70) 0{+0} OR7 Arm in
Arm a2
R 335 (4760) +5 (70) 0{+0} OR8 Arm out
H 280 (3980) 0{+0} -7.8{-80} OR9 Dozer down
Dozer a5
R 280 (3980) 0{+0} -7.8{-80} OR10 Dozer up
P2 by-pass A B Performs proportional
Indicated
Secondary pilot pressure circuit
B calculation from actual

cut valve 2, 8
C-1 Mechatro controller
current readings on dis-

Proportional valve block
current play No.

Travel C 3, 0 10 (140) +1.5 (20) -0.5 (7) Values which are calcu-
value
Hard check SW
Straight valve lated by converting pres-

sure values in the left figure
P1 by-pass (mA) to current values are shown.
D 2, 6 400 E/G Hi, Lever on neutral
cut valve position.
31102 60413252
P2 by-pass B 2, 8
cut valve
E/G Hi
Travel C 3, 0 16 (230) +2 (30) -1.5 (20) 700 Lever on full
Straight valve
stroke
P1by-pass D 2, 6
cut valve
F16674
13-2
Table 1 (2 / 2)
INSPECTION ITEM STANDARD UNIT

VALUE
1-speed 32.5~29.3
H mode
Sprocket revolution 2-speed 58.8~53.2
rpm
(RH, LH) S mode 2-speed 54.8~49.6
FC mode 2-speed 47.0~42.4
Raise 2.4~3.0
Boom
Lower 3.3~3.9
In 2.4~3.0
Operating time Arm
Operating speed
Out 2.0~2.6
of cyinder sec
Digging 3.2~3.8
(At no load) Bucket
Dumpig 1.6~2.2
Lower 1.8~2.4
Dozer
Raise 1.1~1.7
RH
Swing speed 4.7~5.2 sec / 1rev
LH
Rubber 22.3~23.7
1-speed
Iron 23.0~24.4
Travel speed sec / 20m
Rubber 11.9~13.9
2-speed
Iron 12.6~14.6
Amount of travel
2-speed 0~240 mm / 20m
deviation
Parking brake drift 1 / 5 Gradient 0 mm / 5min
Performance of Neutral position after

— degree
Performance
Swing brake 180° full speed swing

Performance of
1 / 5 Gradient 0 mm
Swing parking brake
Tip of the bucket tooth 85
Boom cylinder 5
ATT amount of drift mm / 5min (At no load)
Arm cylinder 5
Dozer cylinder 5
Amount horizontal play at the bucket tooth 30~45 mm
F16675
The port relifef valve No. PR1-PR8 on the control section are coincided with to the following operation numbers
in advance.
(1) Bucket digging (8) (4)
(2) Bucket dumping
31102 60413252
(3) Boom raise (5) (6) (4) (2)

(4) Boom lower
(5) Swing left (7) (3)
(6) Swing right LH RH
F16676
(7) Arm in
CONTROL LEVER
(8) Arm out
13-3
3. MEASUREMENT OF ENGINE SPEED
3.1 MEASUREMENT OF ENGINE SPEED PICK UP

(1) Warming up of engine
Start engine to raise the coolant temperature of
engine to 40° to 80°C (104° to 176°F).
Engine water The E/G coolant tempera-
temperature gauge SPEED METER
ture gauge is used to
measure. The range in
white color shows the tem-
perature of approx. 40° to
100°C (104° to 212°F), so
confirm that the measured
value indicates the tempe-
rature within the range of white color. Fig.1 Measurement of E/G speed
SERVICE DIAGNOSTIC DISPLAY

(2) Measuring with diesel engine speed meter
1) Install diesel engine speed meter pickup on and of
injection pipes on which the pickup can be easily
installed (see Fig. 1).
2) Check E/G speed shown in Table 1 in idling
speed.
(3) Engine speed measured value through service
diagnosis
Insert precision driver (-) into convex place
indicated by arrow of hard check SW A , B in C-
1 controller., then direct the arrow to A = 0, B = 2,
and 3 digits in unit of 10 rpm are displayed on
service diagnostic display of controller,
Remove grommet, and you can
Example: 2100 rpm 210 in display find the following switch
HARD CHECK SW
INTERNAL ADJUSTMENT SW
HARD CHECK SW
Fig.2 E/G speed measuring hard check SW

31102 60413252
13-4
4. MEASUREMENT OF HYDRAULIC PRESSURE
4.1 PREPARING TO MEASURE HYDRAULIC a2 a1

PRESSURE A2 a2 a1 A1
(1) Hydraulic equipment
70 kgf/cm2 (1000 psi) pressure gauge ..... 1 unit A3
500 kgf/cm2 (7100 psi) pressure gauge ... 2 unit
(3 pcs in dozer specification)
Pressure measuring equipment and
instrument for analysis .............................. 1 set
(2) Measuring cleanliness of hydraulic oil A4
Dr2 B1
WARNING
After releasing air in the hydraulic oil tank, open the F16926
cover and sample oil in the hydraulic tank, and measure
with the instrument for analysis. If the measured value Fig. 3 Gauge port on main pump
is higher than the reference value, replace the return
filter or change the hydraulic oil.
4.2 PLACE TO INSTALL PRESSURE

GAUGE
(1) Main circuit
Replace plugs PF 1/4 of main pump gauge ports
PUMP
a1 , a2 with plugs for pressure measurement, and
attach pressure gauge 500 kgf/cm2 (7100 psi).
(2) Dozer circuit
Replace dozer pump gauge plug PF1/4 a3 with
plug for pressure measurement, and attach
pressure gauge 500 kgf/cm2 (7100 psi).
(3) Pilot circuit
Replace pilot gauge plug a4 with plug PF1/4 for
Fig. 4 Gauge plug on dozer pump
pressure measurement, and attach pressure
gauge 70 kgf/cm2 (1000 psi).
PUMP
PUMP
31102 60413252
Fig. 6 Plug for pilot pressure measurement in dozer

Fig. 5 Plug for STD pilot pressure measurement specification
13-5
4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
BUCKET DIGGING BOOM UP

ARM OUT
OR1-A3 OR3-A2
OR8-D3
PC3' Pb2'
MAIN
DR3 DR5 RELIEF VALVE
MR1
D3 A2
A3
D1 D2 A1
P1
PS
DR2
P2
C1 B1
C2 C3 B3 B2
F16684
ARM IN BUCKET DUMPING BOOM DOWN

OR7-C3 OR2-B3 OR4-B2
Fig. 7 View from rear side of machine Fig. 8 View from front side of machine
(2) Control valve for dozer

(dozer specification only)
DOZER DOWN
OR9-A1
B1 A1
P T
MAIN RELIEF VALVE

DOZER UP
MR3
OR10-B1
P T
31102 60413252
F16685
Fig. 9 Control valve for dozer
13-6
(3) Pilot relief valve

a2 a1
Pilot relief valve PR1 is built in main pump.
A2 a2 a1 A1
PR1
A3 PILOT RELIEF
A4
Dr2 B1
F16686
Fig. 10 Pilot relief valve position
(4) Swing port relief RELIEF VALVE PLUG 2-PT 1/4

OR5-B PORT for pressure
The swing motor is equipped with plugs for measurement
pressure measurement, but the measurement is
carried out using gauge ports a1 and a2 (see Fig.
10).
PF3/8 (PLUG)
AIR RELEASE PORT
PORT RELIEF VALVE

OR6-A
Fig. 11 Swing port relief position

31102 60413252
13-7
4.4 PROCEDURE FOR ADJUSTING RELIEF

VALVE
(1) Pilot relief valve
Loosen nut (661) and adjust it with adjust screw
(660).
: 24 mm
T=3.0 kgf·m
: 6 mm (22 lbf·ft)
Fig. 12 Pilot relief valve
(2) Main relief valve T=2 kgf·m

(14 lbf·ft)
(Travel section, ATT common section)
Loosen lock nut (7) and adjust it with adjust screw
(6).
: 19 mm
: 4 mm
Fig. 13 Main relief valve
(travel section , ATT common section)
(3) Port relief valve (Boom, bucket, arm sections) T=2 kgf·m
(14 lbf·ft)
Loosen lock nut (8) and adjust it with adjust screw
(7).
: 19 mm
: 4 mm
Fig. 14 Port relief valve

(boom, bucket, arm, sections)
T=4 kgf·m (29 lbf·ft)

(4) Swing port relief valve
When the adjusted pressure is 10 kgf/cm2 (142
psi) or less, loosen nut (71) and adjust it with cap
(90).
: 24, 27 mm
: 5 mm
When the pressure adjusted value is over 10 kgf/
cm2 (142 psi), replace the relief valve assy.
Fig. 15 Swing port relief valve
31102 60413252
13-8
5. MEASURING TRAVEL PERFORMANCES
5.1 TRAVEL SPEED

(1) Purposes
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump
and the travel motor of the travel drive system.
(2) Conditions
Operating oil temperature : 45~55°C (113~ 131°F)
Crawler on the right and left sides are tensioned Fig. 17-1 One side lifted position
evenly.
(3) Preparation REFLECTION
Install the reflection panel with a magnet to the PANEL
travel motor cover.
Swing the swing frame through 90° as shown in
Fig. 17-1 and make the crawler on one side take
off the ground, using the attachment.
(4) Measurement
Engine revolution: Hi idle
2-speed travel switch: 1st and 2nd speed Fig. 17-2 Adhering position of reflection panel
Measuring points: right and left
Method, example 1: Table 6 Sprocket revolution Unit: rpm
Measurement Standard Repairable
measure revolution with a stroboscope. item value level Service limit
method, example 2: H1 32.5~29.3 25.4~22.9 21.8~19.6
Measure the revolutions per minute visually. RH
H2 58.8~53.2 45.9~41.5 39.4~35.6
&
LH S2 54.8~49.6 42.7~38.7 36.7~33.2
FC2 47.0~42.4 36.7~33.1 31.5~28.4
F16692
5.2 DEVIATION OF TRAVEL
(1) Purpose
Measure the amount of deviation at 20 m (66 ft)
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the
travel drive system.
(2) Condition
Hydraulic oil temperature : 45~55°C (113 ~ 131°F)
RH and LH crawler are tensioned evenly. Approx.1 ft
30~40cm
Plain, level and solid ground
Engine revolution: Hi idle Fig. 18 Travel position
(3) Preparation
1) Straight course more than 30 m (33 yard)
2) Travel position in which the bottom of the bucket
is lifted by about 30 cm (1 ft).
A
(4) Measurement
20 m (66 ft)
1) Measure the max. deviation distance of the circular
31102 60413252
arc in the 20 m (22 yard) length, excluding the

preliminary run of 3~5 m (10~16 ft).
Fig. 19 Measuring method
2) Operate the travel lever at the same time.
Table 7 Travel deviation Unit: mm/20m
Measurement Standard Repairable
item value level Service limit
A 240 (9´45˝) or less 480 (18´9˝) 720 (28.3˝)
F16694
13-9
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
(1 ft)
and on a 1/5 gradient slope. 30 cm
(2) Condition
1/5 GRADIENT
A slope with 1/5 (Approx. 12 deg) gradient and a Approx.12 deg
stopped condition in a no-load travel position.
Fig. 20 Parking brake operating position
(3) Preparation
Place an angle meter on the shoe plate and
confirm that it makes an angle more than 12°.
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.
(4) Measurement
ANGLE METER
Five minutes after the engine stops, measure the GUIDE FRAME
movement distance of the matching mark.
Fig. 21 Method of measurement
Table 8 Parking brake Unit: mm/5 min

Measuring Standard Repairable
position value level Service limit
C 0 1 (0.04 in) 2 (0.08 in)
5.4 DRAIN RATE OF TRAVEL MOTOR F16697
(1) Purpose
To measure the drain rate of the travel motor and FORWARD
to confirm the performances of the travel motor.
(2) Conditions PIPE
Hydraulic oil temperature: 45~55°C (113~131°F)

Engine revolution: Hi idle RIB
STOPPER
(3) Preparation
1) Place a stopper under the RH and LH travel
sprockets.
2) Stop the engine and vent air from the hydraulic oil ROTARY DIRECTION
tank. Fig. 22 Location of stopper applied to travel sprocket
3) Connect a hose with the drain port of the travel
motor and take drain in a container.
(4) Measurement; at travel lock
WARNING
Unless you observe the rotary force direction at travel
lock, rib “A” may be broken by stopper “B” in some
cases.
1) Start the engine and relieve pressure at the full

stroke of the travel lever.
2) Measure the drain rate for 30 seconds of relieving.
31102 60413252
Take three measurements in the forward motion Fig. 23 Method of measuring the drain rate of travel
on each side at one time and make the mean motor
value the measured value. Table 9 Drain rate of travel motor Unit: L/30sec
Drain rate 3.4 (0.9 gal) 6.8 (1.8 gal) 10 (2.6 gal)
F16698
13-10
6. MEASURING SWING PERFORMANCES
6.1 SWING SPEED

(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump and
the swing motor of the swing drive system.
1.5 m
(2) Conditions (5 ft)
Hard and level ground Fig. 24 Swing speed measuring position
Engine: Hi idle
(3) Preparation
The height of 1.5 m (5 ft) at which the bottom of the Table 10 Swing speed Unit: sec/rev
bucket matches the tip of the tooth on condition Measuring Standard Repairable
that the bucket is empty, the arm cylinder is most Standard swing 4.7~5.2 6.0~6.6 7.4~
retracted and the bucket is used for digging. F16701
(4) Measurement
Swing the machine by bringing the swing lever to
its full stroke. Measure the time required to make
two turns after one turn of preliminary run and
calculate the time required for one turn.
6.2 PERFORMANCE OF SWING BRAKE

1.5m
(1) Purpose (5 ft)
Confirm the braking torque performances by the
swing relief valve. Fig. 25 Swing brake performance measuring position
(2) Conditions
Hard and level ground
Engine: Hi idle Measuring the length of the arc over the
outer circumference of swing race
(3) Preparation Matching marks
1) A height of 1.5 m (5 ft) at which the bottom of the on swing race
bucket matches the tip of the tooth on condition
that the bucket is empty, the arm cylinder is most
retracted and the bucket is used for digging.
2) Put a mark (matching mark) on the outer
circumference of the swing bearing of the upper Matching marks on track frame
frame side and of the track frame side.
Erect two poles (flags) at the front and back of the Fig. 26 Measuring position of swing brake performances
extended line of the matching mark.
(4) Measurement
1) When operating in regular swing speed, by shifting Table 11 Swing brake performance Unit: degree
lever to neutral position at pole position the swing Standard value
Repairable
Service limit
level
operation stops. 55° 65° 70°
31102 60413252
2) Calculate the swing drift angle by the following F16704
equation, after the upper swing body stops, using

the amount of deflection (m) of the matching
marks on the swing race and the length (m) of the Amount of deflection of
Swing drift matching marks [m (ft·in)]
circumference of the swing race: angle (°) = X 360°
Circumferential lenght of
swing race [m (ft·in)]
13-11
6.3 PERFORMANCE OF SWING PARKING

BRAKE
(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of
the swing motor.
(2) Conditions
On a slope with 1/5 (Approx. 12 deg.) gradient
stop the machine at right angles with the slope at Fig. 27 Swing parking brake performance measuring
position
the height of 1.5 m (5 ft) at which the bottom of the
bucket matches the tip of the tooth on condition Measuring the length of the arc over the
that the bucket is empty, the arm cylinder is most outer circumference of swing race
Matching marks
retracted and the bucket is operated for digging. on swing race
(3) Preparation
Put the angle meter on the shoe plate and make
sure that the angle is more than 12°.
Put a matching mark over the outer circumference
of the swing bearing on the upper frame side and
Matching marks on track frame
on the track frame side.
(4) Measurement Fig. 28 Measuring position of swing brake performances
When five minutes has passed after the engine
stops, measure the length of the movement of the Table 12 Performance of swing
matching marks. Parking brake Unit: mm/5 min
C 0 1 (0.4 in) 2 (0.08 in)
6.4 DRAIN RATE OF SWING MOTOR F16706
(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)
Engine revolution: Hi idle
(3) Preparation
1) Stop the engine.
2) Vent air from inside the hydraulic oil tank.
3) Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take oil
in a container.
4) Put a plug to the tank side.
(4) Measurement; at swing lock
1) Start the engine and put the side faces against the
inside of the right or left shoe plate.
2) Relieve the swing motor at full stroke of the swing
motion.
31102 60413252
3) Receive in a container the amount of drain Fig. 29

accumulated in 30 seconds of relieving.
Table 13 Drain rate of swing motor Unit: L/30sec
Drain rate 5.0 (1.3 gal) 7.5 (2.0 gal) 10 (2.6 gal)
F16728
13-12
7. MEASURING ATTACHMENT OPERATING PERFORMANCES
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 (1 ft) 30 cm
attachment drive system. Fig. 30 Measuring position for bucket digging and dump
(2) Condition
Engine: Hi idle
Operating time excluding the cushion stroke
(3) Preparation
Hard and vevel ground with the bucket empty
(4) Measurement 1; Boom up and down Fig. 31 Measuring position for boom up and down motions
With the boom operating lever at full stroke,
measure the required operating time of the bucket
between the ground surface and its highest
position.
(1 ft) 30 cm
WARNING
When lowering the boom, allow the bucket onto a soft Fig. 32 Measuring position for arm in and out motions
ground or cushioning such as rubber tires; never put
the bucket against concrete or other solid material.
Measurement 2; arm in and out, bucket digging and
dump. Table 14 Cilinder operating time Unit: sec/rev
In a position in which the tooth of the bucket rises to a
level of about 30 cm (1 ft) above ground, measure the position value level Service limit
full stroke operating time required with the arm and 1 3.2~3.8 4.1~4.9 5.3~
bucket operating levers at full stroke. 2 1.6~2.0 2.2~2.8 2.9~
3 2.4~3.0 3.1~3.8 4.1~
4 3.3~3.9 4.2~5.0 5.5~
7.2 OIL TIGHTENESS OF CYLINDERS 7 2.4~3.0 3.1~3.8 4.1~
(1) Purpose 8 2.0~2.6 2.6~3.3 3.5~
Confirm that the cylinder oil tight by checking the Dozer down 1.8~2.4 2.3~3.1 3.2~
moving length of the cylinder rods. F16709
(2) Condition
Immediately after cylinders are replaced, bleed
CONDITIONS
off air from the cylinders, before checking for oil 1.5 m (5 ft)
tightness.
Fig. 33
The arm cylinder has moved 30 mm (1.2 in) from
the stroke end (off the cushioning range).
(3) Preparation Table 15 Oil tightness of cilynder Unit:mm/5 min
Keep the tip of the bucket at 1.5 m (5 ft) height, with Measuring Standard Repairable
Service limit
position value level
31102 60413252
the bucket empty and the arm cylinder is most A 5 8 10

retracted. [Provided the arm cylinder is extended B 5 8 10
by 30 mm (1.2 in).] C — — —
(4) Measurement D 85 140 170
Measure the items five minutes after the engine is Dozer 5 8 10
turned off. F16411
13-13
8. MEASURING PERFORMANCES OF SWING BEARING
(1) Purpose
Measure the gap between the lower frame and the
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
(2) Condition
The swing bearing mounting bolts are not
loosened.
The swing bearing is lubricated well, not making
abnormal sound during turning. Fig. 34 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.
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 of
the outer race on the swing body side and set the
Fig. 35 Measuring position I
reading at zero.
(4) Measurement 1 (Measuring position I and II)
1) Measure the travel of the outer race in the axial
direction in position I [The arm at 90°~110° and
the crawler front lifted about 30 cm (1 ft)] and in
position II, using a dial indicator.
Fig. 36 Measuring position II
Table 16 Axial play of

swing bearing Unit: mm
A 0.5~1.5 1.9~2.9
(0.02~0.06 in) (0.07~0.11 in) 3.0 (0.12 in)~
F16713
(5) Measurement 2 (Measuring position III)

1) With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the bucket
about 10 mm (0.4 in) and swing the tip of the
bucket to the right and the left by man power. (0.14 in)
10 mm
But in this case, the gap of the attachment is
included.
Fig. 37 Measuring position III
31102 60413252
Table 17 Right and left movement

of the tip of bucket Unit: mm
Bucket tiptoe 30~45 125 150
(1.2~1.8 in) (4.9 in) (5.9 in)
F16715
13-14
9. MECHATRO CONTROLLER “A” ADJUSTMENT

9.1 ENGINE CONTROL INPUT / OUT
SWITCH PANEL
AUTO ACCEL H.S.FC MODE SELECT SWITCH
RELEASE SWITCH MECHATRO CONTROLLER
BUZZER
SOP
GAUGE CLUSTER
GOVERNOR
ENGINE
MOTOR
ACCEL DIAL
STARTER SWITCH
Fig. 38 E/G SPEED SENSOR
9.2 ENGINE CONTROL INSTALLATION
CONTROL CABLE
FINE CAPSCREW M10 X 35

TIGHTENING TORQUE
6.6 kgf·m (48 lbf·ft)
Apply Loctite #242 or equivalent.
E/G 2 places
EMERGENCY STOP
FINE CAPSCREW M10 X 20
TIGHTENING TORQUE
6.6 kgf·m (48 lbf·ft)
SOCKET BOLT M6 X 25 SOCKET BOLT M10 X 35

TIGHTENING TORQUE TIGHTENING TORQUE
1.0 kgf·m (7.2 lbf·ft) 2.0 kgf·m (14 lbf·ft)
GOVERNOR LEVER
E/G STOP SET BOLT
ROD GOVERNOR MOTOR

FULL
STOP
LEVER
SECTION BB
31102 60413252
GOVERNOR MOTOR
VIEW I VIEW II
Details of lever installing sectiion (shows stop position)
Fig. 39
13-15
REDUCTION GEAR SECTION

9.3 E/G CONTROL EQUIPMENT
OIL SEAL
(1) Governor motor and C-1 controller MOTOR SECTION
OUTPUT SHAFT
1) By operating accel dial, the input voltage change
is sensed by 14-8 pins of C-1 controller.
2) The C-1 controller computes the input voltage,
and outputs command to governor motor (M-2), CAM
and incline governor lever of engine to the swing
angle corresponding to access dial set value. LIMIT
SWITCH
3) The limit switch in governor motor is set to a angle
from motor rotation OFF to ON position (Starting
point).
(2) Rotation sensor
1) Installing place
Opposing flat 19 SIGNAL
Engine flywheel housing Opposing flat 17 (YELLOW)
M16 X 1.5
2) Sensor attaching procedure
a. Apply Loctite #262 on pick-up thread section.
b. Tighten thread until it contacts flywheel ring
gear, and turn it back one and half turns. GND
(BLACK)
c. After turning it back one and half, check that
the tightening torque of nut is 2.5~3.5 kgf·m
(18 ~ 25 lbf·ft).
d. After installation, check that the engine speed
meter measured value corresponds to the
engine speed in service diagnostics while
operating engine.
• WORK MODE SW
e. Output voltage
at 850 rpm 4V (AC) or more
at 2250 rpm 20V (AC) or less
(3) Work mode selector switch
Press work mode selector switch, and the operation
signal is sent to C-1 controller, and the work mode
is switched.
(4) Buzzer stop switch
When the error is detected by self-diagnosis, the
C-1 controller sends alarm by sounding buzzer,
and CPU lamp on gauge cluster flickers. And
press buzzer stop switch to stop buzzer sounding.
Also, when engine coolant temperature has risen
or the engine oil pressure has lowered, buzzer
sounds. But in this case the buzzer sounding does
not stop. F16720
31102 60413252
13-16
9.4 ADJUSTMENT OF MECHATRO CONTROLLER DISPLAY
CONTORL
(1) When adjustment of mechatro control is required
"A" adjustment
Replacement of C-1 mechatro controller
GROMMET
Replacement of governor motor A
Disassemble governor rod
F16721
(2) Preparation
A
a. Warm up engine.
C-1 MECHATRO CONTROLLER
b. Turn starter switch OFF to stop engine, and turn A/C switch OFF.
c. Pull operator seat forward fully and incline seat-back forward.
d. Remove plastic cover on the rear side, then mechatro controller appears.
(Remove 5 attaching bolts form plastic cover with driver +).
NOTE:
Check to be sure that the engine emergency stop lever knob in fully pressed down. If mechatro controller in adjusted
in the condition where the knob is pulled out, the engine speed can not be set rightly.
(3) Adjustment
MODE DISPLAY ON
PROCEDURE GAUGE CLUSTER MOVEMENT OF GOVERNOR MOTOR
1 Remove grommet on upper surface of mechatro FULL
controller, and switch internal adjustment STOP
switch from RUN to TEST .
During
adjustment
LEVER
In normal
pisition GOVERNOR
MOTOR
SECTION AA
Internal adjustment jumper pin (JP) switch
H S FC A
2 Turn starter switch ON .
Stop at the position

Display lamp lights set by accel dial
on in order
3 Keep pressing buzzer stop switch for approx A
S
5 to 10 seconds and release. H S Automatically run
Check that the display on this gauge cluster to engine stop
is as the right. position (S)
4 After checking the right mode display, adjust S

the rod length so that the clearance A bet-
ween governor lever and engine stop set bolt Stop at S position
31102 60413252
in engine side is 0.1 mm (0.0039 in). adjust rod

H S
(5) length to 204 mm (8.03 in).
And, when the governor motor is replaced, [TOOLS]
confirm that the right display is indicated, then • Spanner 13 mm X 2
insert link rod. • Spanner 6 mm
• Thickness gauge
F16726
13-17
MODE DISPLAY ON
PROCEDURE GAUGE CLUSTER MOVEMENT OF GOVERNOR MOTOR
e. Press buzzer stop switch once, and wait until S A
the mode is switched to the right display.
S FC
Automatically run to the engine

available position A
A
f. After verification of the flowing mode, start
engine.
S FC
Then, any position of accel dial is allowable.
Stop at A position
g. Press buzzer stop switch once, and the mode Lo A

is switched to the following,and governor lever Hi
moves from A position to low idling position,
and reading the engine speed to high idling
automatically.
(Required time : approx. 3 minutes.) H FC
Note :
Governor lever is set to the position of approx.
1700rpm~1900rpm. According to the command Move from A position to Lo idling
of mechatro controller, the lever moves to the position, and self-travels from Lo
low idling position after engine starts, then starts position to high idling (H) position
reading out for self-travelling.
Hi
h. After completion of read out, wait until the
mode display on gauge cluster switches to
the following.
After the display switches, the engine speed H S FC
(Approx.
is returned automatically to the position set A
through accel dial. 5seconds) Hi
At this time, if CPU lamp goes off, the adjust-
ment is completed. If CPU lamp is flickering,
the adjustment is failed. So try again to adjust it.
F16727
(4) After completion of adjustment
a. Turn starter switch OFF to stop engine.
b. Switch internal adjustment JP switch from TEST to RUN position, and set hardware check “B” to 2.
NOTE:
When hardware check switch indicates "0-0", the mechatro controller displays error code.
c. Press the blank side of auto accel switch to release auto accel, and after starting engine the speed rises
to high idling position, then check the engine speed at the time of H,S and FC position indicated on the
display of mechatro controller.
d. By switching work mode through switch panel, the mode display on gauge cluster is also switched. Then,
check that the engine speed changes.
e. After setting accel dial to low idling position, press the symbol side of auto accel switch to actuate auto
31102 60413252
accel function.
f. Set accel dial to high idling, and check engine speed when running in auto accel position.
d. After verification of engine speed, set hardware check switch “B” on mechatro controller to "0", and attach
grommet.
h. Attach plastic cover as it was, and slide operator seat backward to move the seatback backward. Then,
check connector of speaker for disconnection.
13-18
(5) When adjustment of mechatro controller can not be performed.

1) After execution of procedure (g), H S FC is displayed, CPU lamp flickers, and adjustment can not be
executed (“E01” is indicated on controller display).
“A” (Display condition)
• While reading engine speed, the engine speed after stepping of governor motor is lower than that before
stepping in condition of engine speed 850rpm or high.
(Cause)
• The read-out of engine speed sensor is wrong.
(Corrective action)
• After measurement and adjustment of speed sensor voltage, carry out “A” adjustment.
High idling 3V or high (AC) (Voltage available for controller to read).
(When adjusting in factory, the voltage is set to 3V (AC) or high at high idling).
“B” (Display condition)
• When abnormal rotation (step-out) occurs on high idling side.
(Cause)
• Wrong connection of link rod of governor motor.
(Corrective action)
• After verification of connection of link rod, perform "A" adjustment. [Rod length: 204 mm (0.031 in)].
* When step-out occurs after adjustment, press buzzer stop switch once before stepping out as a
temporary repair, and it is switched to high idling temporarily.
2) The error code "E02" is indicated on the display of mechatro controller, but the adjustment cannot be executed.
(Display condition)
• Engine speed is 300 rpm or lower, or 3000 rpm or higher.
(Cause)
• The read-out of engine speed sensor is wrong.
(Corrective action)
• After measurement and adjustment of speed sensor voltage, carry out “A” adjustment.
High idling 3V or high (AC).
3) When buzzer stop switch is pressed once to proceed from procedure (f) to (g), it does not proceed to procedure
(g), but procedure (h) directly, and CPU lamp flickers and error code “E01” is indicated on the display on
mechatro controller.
(Display condition)
• Engine speed is 420 rpm or low.
(Cause)
• Buzzer stop switch is pressed once before starting engine.
• The read-out of engine speed sensor is wrong. (or disconnection).
(Corrective action)
• Adjust mechatro controller again as the procedure.
• After measurement and adjustment of speed sensor voltage, perform “A” adjustment.
High idling 4V or high (AC)
4) When buzzer stop switch is pressed once to proceed from procedure (d) to (e), but it does not proceed to
procedure (e).
(Display condition)
• Limit switch signal (grounding) is not input from governor motor to controller.
(Cause)
31102 60413252
• Failure of limit switch in governor motor.

• Disconnection of connector or harness on governor motor.
(Corrective action)
• Check that limit switch of governor motor goes ON and OFF.
• Check connector and harness from possible damage, and adjust it.
13-19
5) Others
Error code "E02" is indicated on the display of controller, and engine stops.
Engine oil pressure switch and harness are short-circuited.
(6) CPU lamp on gauge cluster flickers, or error code “E01” is indicated on display of controller.
When mechatro controller is replaced, and the adjustment of controller has failed, this display appears.
When the adjustment is completed normally, CPU lamp goes off, and error code "E01" also disappears.
To perform the adjustment of mechatro controller again, press starter switch once to turn the power OFF, and
turn starter switch on and perform the adjustment again.
31102 60413252
13-20
SECTION 21 MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
1. Mechatro control system ....................................................................................... 21-1
2. Boom raise conflux mechatro control system ........................................................ 21-3
3. Swing cut valve control mechatro control system .................................................. 21-4
4. Arm in / out conflux mechatro control system ....................................................... 21-5
5. Travel straight mechatro control system ................................................................ 21-6
6. Mechatro control ................................................................................................... 21-8

6.1 Troubleshooting .............................................................................................................................. 21-8
6.2 Service diagnostics ........................................................................................................................ 21-9
6.3 Component mechatro control ....................................................................................................... 21-11
31102 60413252
MECHATRO CONTROL SYSTEM
1. MECHATRO CONTROL SYSTEM
Electric Controller
Input / Output signal
Oil pressure Proportional secondary

pressure
Proportional pressure
C/V Up side
Boom cylinder raise conflux
LH RH LH RH 8 5 F F 3 1
Pilot valve
Pilot valve
P2 by-pass
for travel
P1 by-pass cut valve

for ATT
Travel straight valve

Arm cylinder in conflux
conflux valve cut valve

Arm cylinder out conflux
Travel right
Travel left
SE9
Bucket
Swing
Boom
Arm
SE10
Boom raise
Rotary
multi
C/V To control
Gauge cluster valve
SE1 7 6 R R 4 2
H/S/FC
display SE2 C/V Low side
SE3
SE4
Switch panel
SE5
SE6
H/S/FC
select SE7 Swing motor parking
SE8
Travel motor 2-speed select
P2 by-pass cut proportional valve

Travel straight proportional valve
Two speed travel SOL
Safety lock lever SOL

Accel dial
Swing P/B SOL

Controller
Engine
Governor motor
Pump PSV PSV PSV SV SV SV

31102 60413252
-B -C -D -1 -3 -4
Lever lock
: Low pressure sensor SW-11
: Accel dial
Proportional valve / Solenoid valve block F16728
21-1
OPERATIONS AND MECHATRO CONTROL EQUIPMENT FUNCTIONS
Mechatro control equipment Hydraulic

Hydraulic equipment pressure
Hydraulic Volt Solenoid valve
pressure (cut-off spool)
Mechatro control voltage Ampere (Current hydraulic pressure) voltage
equipment
Safety lock lever
Swing parking release

Travel 2-speed select
Governor motor
Low pressure sensor

Travel 2-speed
P2 by-pass cut
P1 by pass cut
Travel straight
Swing parking
Controller
Travel straight
Operation side
I O M
N U 2 3 4 B C D
T 2
Digging SE1
Bucket
Dump SE2
(Conflux) Raise SE3
Independent operation
Boom Lower SE4
Swing Left SE5

(Cut valve
control) Right SE6
(Conflux) In (Dig) SE7

Arm
(Conflux) Out (Extend) SE8
Oil pressure
Operation side output signal
Right SE9
Travel
Left SE10
SE1
Digging SE9,10
Bucket /
Travel SE2
Dump SE9,10
SE3
Combined operation
Raising SE9,10
Boom /
Travel SE4
Lowering SE9,10
SE5
Left SE9,10
Swing /
Travel SE6
Right SE9,10
SE7
In (Dig) SE9,10
Arm /
Travel SE8
Out (Extend) SE9,10
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Safety lock
SW-11 ON
lever
Electric
Travel 2-speed SW-3 ON

Swing parking
SW-4 ON
brake release
F16729
21-2
2. BOOM RAISE CONFLUX MECHATRO CONTROL SYSTEM
Pilot valve

for ATT
P2 by-pass

Travel right
cut valve
Travel left
Bucket
Swing
Boom
Arm
Boom raise operating
conflux valve
Pilot pressure
Boom raise
SE3
Low pressure sensor
Proportional voltage
Pilot signal process

Command PSV-B Proportional valve
proportional current P2by-pass cut secondary pressure
proportional
valve
Mechatro controller

secondary pressure
proportional valve
P2 by-pass cut
Pi
Operating pilot pressure

F16730
1) Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom
conflux spool, and inputs into low pressure sensor.
31102 60413252
2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes the
pilot signal and outputs the command corresponding to input voltage to P2 by-pass cut valve.
3) P2 by-pass cut valve outputs pilot proportional valve secondary pressure corresponding to the command
output by mechatro controller, and switches P2 by-pass cut valve of control valve.
4) Operation pilot pressure switches boom main spool and conflux valve. And the oil delivered by P1 and P2
pump is conflixed in P2 by-pass cut valve switched by mechatro control.
21-3
3. SWING CUT VALVE CONTROL MECHATRO CONTROL SYSTEM
Pilot valve

for ATT
P2 by-pass

Travel right
cut valve
Travel left
Bucket
Swing
Boom
Arm
conflux valve
Boom raise
SE5 or SE6
Low pressure sensor

Command PSV-B Proportional valve
proportional current P2by-pass cut secondary pressure
proportional
valve
Mechatro controller

secondary pressure
proportional valve
P2 by-pass cut
Pi

F16731
1) Start swing operation, and the swing pilot pressure switches swing spool, and is input into low pressure sensor.
31102 60413252
3) P2 by-pass cut valve outputs pilot proportional valve secondary pressure corresponding to the command
output by mechatro controller, and switches P2 by-pass cut valve of control valve.
4) By switching swing main spool with operation pilot pressure and switching P2 by-pass cut valve according to
mechatro control command, the swing operation control is performed more gently.
21-4
4. ARM IN / OUT CONFLUX MECHATRO CONTROL SYSTEM
Pilot valve

for ATT
P2 by-pass

Travel right
Travel left
cut valve
Bucket
Swing
Boom
Arm
conflux valve
Pilot pressure
Boom raise
SE7 or SE8
Low pressure sensor

Command PSV-D Proportional valve
proportional current secondary pressure
P1 by-pass
cut valve
Mechatro controller

secondary pressure
proportional valve
P1 by-pass cut
Pi

F16732
1) Start arm in and out operation simultaneously, and operation pilot pressure switches arm spool, and is input
into low pressure sensor.
31102 60413252
3) P1 by-pass cut valve outputs pilot secondary pressure corresponding to the command output by mechatro
controller, and switches P1 by-pass cut valve of control valve.
4) By switching arm main spool with operation spool pressure and switching P1 by-pass cut valve according to
mechatro control command, the oil delivered by P1 and P2 pumps is confluxed during arm operation.
21-5
5. TRAVEL STRAIGHT MECHATRO CONTROL SYSTEM
Pilot valve
for ATT

P2 by-pass

Travel right
Travel left
cut valve
Bucket
Swing
Boom
Arm
Pilot valve
for travel
Travel straight operating
(Left) (Right)
Pilot pressure
conflux valve
Boom raise
Pilot pressure
SE10 SE9 SE5

Low pressure sensor
Travel straight signal

Proportional

Command PSV-C proportional
voltage
proportionate valve secondary

Travel straight current proportional pressure
proportional valve for travel
valve command straight valve
Command PSV-B proportional

P2 by-pass cut current P2 by-pass cut pressure
Pilot signal process proportional proportional
valve command valve
Command PSV-D proportional

P1 by-pass cut current P1 by-pass cut pressure
proportional proportional
valve command valve
Mechatro controller
Pilot signal process Pilot signal process

secondary pressure
secondary pressure
proportionate valve
proportional valve
P1 by-pass cut
P2 by-pass cut
Pi Pi
Operating pilot pressure Operating pilot pressure

F16733
21-6
TRAVEL STRAIGHT SYSTEM

1) Start ATTs work operations (boom, arm, bucket, P1 by-pass cut valve command
swing) in travel operation (right and left), and the Outputs switching command corresponding to
pressure switches respective spools, and is input boom raise pilot pressure (ATT pilot pressure in
into respective low pressure sensors. high priority in operation) and the pressure selected
by travel left pilot pressure as high priority.
NOTE:
P2 by-pass cut vale command
Boom raise operation is explained here.
Outputs switching command corresponding to
2) If mechatro controller receives the input satisfying boom raise pilot pressure (ATT pilot pressure in
the following combination shown in Figure, the high priority in operation )and the pressure selected
con troller determines it as travel straight, and by travel right pilot pressure as high priority.
the travel straight signal turns on.
3) After the travel straight signal has turned on, the (Reference) Operating condition where travel straight
signal is input to respective proportional valve signal turns on
corresponding to the following commands.
Travel straight proportional command

Outputs switching command corresponding to
boom raise pilot pressure
(ATT pilot pressure in high priority in operation)
BOOM BUCKET ARM SWING

In travel right operation — —
In travel left operation — —
F16734
31102 60413252
21-7
6. MECHATRO CONTROL
6.1 TROUBLESHOOTING GAUGE CLUSTER

“CPU lamp on gauge cluster flickers”, and “buzzer
sounds intermittently”. In this case, error code is
displayed on LCD at the center of C-1 controller.
Determines the fault location and corrective action
referring to Error diagnostics shown in the following
page.
And in case “CPU lamp lights on”, and “buzzer sounds
continuously”, the display indicates the trouble on C-1
controller.
Error diagnostics
ERROR CPU LAMP
CODE ERROR DISGNOSTIC ITEMS CORRECTIVE ACTION
OFF: Normal
E01 EEPROM date error Readjust engine speed, Red lamp flickers:
System error
E02 Mechatro controller maladjustment or replace controller. Display error code on
C-1 controller.
E03 Boom raise pressure sensor error Red lamp lights on:
C-1 conroller error
E04 Boom lower pressure sensor error
E05 Arm in pressure sensor error
E06 Arm out pressure sensor error
E07 Bucket digging pressure sensor error Replace sensor or check C-1 MECHATRO CONTROLLER
E08 Bucket dump pressure sensor error harness between sensor and
E09 Swing right pressure sensor error controller for possible damage.
E10 Swing left pressure sensor error
E11 Travel right pressure sensor error
E12 Travel left pressure sensor error
E13 Accel dial error
E14 Travel speed 1,2 selector valve coil error Replace solenoid valve or check
harness between solenoid valve
E15 Swing parking selector coil error and controller for possible damage.
Replace battery relay or check
harness between battery relay
E16 Battery relay error
and controller for possible
damage.
E17 P1 by-pass cut valve coil error Replace by-pass cut valve or
check harness between by-pass
E18 P2 by-pass cut valve coil error cut valve and controller for
E19 Travel straight valve coil error possible damage.
E20 Governor motor current error Replace governor motor or check

harness between governor motor
E21 Governor motor start point error and controller for possible damage.
Replace engine oil pressure
switch or check harness between
E22 Engine reverse rotation
engine oil pressure switch and
controller for possible damage.
F14749
21-8
6.2 SERVICE DIAGNOSTICS

This service diagnostics is used to check equipment
and harness when CPU lamp flickers, and errors are
indicated on C-1 controller LCD section, and also to
determine normal / error according to the numeric
values in “Service Diagnostics” displayed by switching
hardware check switch (A) and (B). However, since
the hardware check SWs (A) and (B) are set to “0.0”
in factory, the numeric value in C-1 controller LCD
display indicated error code.
SERVICE DIAGNOSTICS DISPLAY ERROR CODE DISPLAY
Remove grommet,
and you can find the
following switches.
Hardware check SW A
Hardware check SW (the left shows the “0.0” setting
condition). Turn the arrow at the center of switch and
Internal adjustment jp SW set it to numeric value.
Insert precision driver (-) in to convex indicated by arrow
Hardware check SW B
and turn the arrow to set to numeric values.
31102 60413252
21-9
Hardware
check SW SERVICE DIAGNOSTICS CONTENTS OF DISPLAY EXAMPLE
A B
0 0 Normal (without service diagnostics) Error diagnostics (error code). —
0 1 Engine speed set value Display 3 digits per 10 rpm 2.2.5 per 2250 rpm. 2.2.5
0 2 Engine speed measure value Display 3 digits per 10 rpm 2.2.5 per 2250 rpm. 2.2.5
Display key SW input condition in column 10. 24V 1 0V 0
0 3 Key SW input / battery relay output
Display battery relay output condition in column 1. Deexcite 0 Excite 1
Display mode SW input condition in column 10. H.S.FC
0 4 Mode SW input / auto accel SW input
Display auto accel SW input condition column 1. ON 0 OFF 1
Display wiper SW in column 100 and washer SW in column 10. ON 1
0 5 Wiper SW washer SW / working light SW
Display working light SW condition in column 1. OFF 0
0 6 Accel dial voltage Accel dial input voltage (3 digits display). Eg. 2.34V 2.3.4
Governor motor position (%) calculated based on accel dial voltage.
0 7 Accel dial position 1.0.0
Example: for 4V or higher, the limit is 100%.
Display the present governor motor step number, Hi 1.0.0
0 8 Governor motor step number
integer 3 digits. Low 0.0.0
Hi 1.0.0
0 9 Governor motor position The present step number is displayed in %.
Low 0.0.0
1 0 Governor motor A phase current Motor coil A output current value 1.5.0
1.5A is required.
1 1 Governor motor B phase current Motor coil B output current value 1.5.0
Display governor motor limit SW input signal condition in
1 2 Governor motor limit SW Input 1 Release 0
column 1.
1 3 Boom raise pressure sensor
1 4 Boom lower pressure sensor
1 5 Arm out pressure sensor
1 6 Arm in pressure sensor
1 7 Bucket digging pressure sensor Value converted input from each pressure sensor to voltage
3.2.4
1 8 Bucket dump pressure sensor EG.: 3.24V
1 9 Swing right pressure sensor
2 0 Swing left pressure sensor
2 1 Travel right pressure sensor
2 2 Travel left pressure sensor
Travel SW condition in column 100, output command in ON 1 OFF 0
Travel 1,2 speed SW / selector valve output
2 3 column 10. Excite 1 Deexcite 0
command / feedback
Feedback condition in column 1. Hi 1 Lo 0
2 4 Swing parking selector valve output command / feedback Output command in column 10. Excite 1 Deexcite 0
2 5 Battery relay output command / feedback Display feedback condition in column 1. Hi input 1 Lo input 0
2 6 P1 by-pass cut valve command current (Prop. vale C)
2 7 P1 by-pass cut valve feedback current
2 8 P2 by-pass cut valve command current (Prop. valve A) Values each command current value (mA) is converted Eg: 600mA 6.0.0
2 9 P2 by-pass cut valve feedback current Values each feed back current (mA) is converted Eg.: 600mA 6.0.0
3 0 Travel straight prop. valve command current (prop. valve B)
3 1 Travel straight prop. valve feedback current
Wiper motor rise up LS in column 10.
3 2 Wiper motor rise-up LS / reverse LS ON 1 OFF 0
Display wiper motor rise-up LS condition in column 1.
Wiper motor arc protection relay / positive Display wiper motor arc protection relay, positive relay command
3 3 ON 1 OFF 0
relay / reverse relay command and reverse relay command in columns 100, 10, and 1 respectively.
Washer motor relay / working light relay / Washer motor relay command, working light relay command. CPU
3 4 ON 1 OFF 0
CPU lamp error command lamp error command conditions in columns 100, 10 and 1 respectively.
Wiper operation command / wiper window Display wiper operation command, power window operation input
3 5 ON 1 OFF 0
operation input command condition in columns 10 and 1 respectively.
3 6 Internal adjustment JP SW Display internal adjustment JP SW condition in column 1. TEST 1 RUN 0
F16735
21-10
6.3 COMPONENT MECHATRO CONTROL CN-11 CN-12

(1) C-1 Mechatronic controller Input Wire Input Wire
No. NAME REMARKS No. NAME REMARKS
Output color Output color
11-1 Battery relay (R-1) In WG 12-1 Boom raise pressure sensor (GND) (SE-3) In BR
11-2 Swing parking select solenoid valve (SV-1) Out V 12-2 Boom raise pressure sensor (SE-3) In LgY
11-3 Work mode select switch (SW-2) Out G 12-3 Boom raise pressure sensor (5V) (SE-3) In W
11-4 Washer switch (SW-2) Out BrW 12-4 Boom lower pressure sensor (5V) (SE-4) In OB
In adjusting operation 11-5 Buzzer stop switch (SW-2) Out LgR 12-5 Boom lower pressure sensor (SE-4) In LO
11-6 Work light switch (SW-2) Out LG 12-6 Boom lower pressure sensor (GND) (SE-4) In BrW
11-7 Wiper switch (SW-2) Out VG 12-7 Arm in pressure sensor (GND) (SE-7) In BrY
In normal operation
11-8 Buzzer (SW-2) In Br 12-8 Arm in pressure sensor (SE-7) In PG
11-9 Earth GND (SW-2) Out GW 12-9 Arm in pressure sensor (5V) (SE-7) In OL
SECTION AA
(Internal adjustment JP switch) 11-10 engine oil pressure switch (SW-7) In O 12-10 Arm out pressure sensor (5V) (SE-8) In OW
11-11 P2 by-pass cut proportionate valve (PSV-B) Out BO 12-11 Arm out pressure sensor (SE-8) In PL
11-12 Travel straight proportionate valve (PSV-C) Out GB 12-12 Arm out pressure sensor (GND) (SE-8) In Gr
11-13 P1 by-pass cut proportionate valve (PSV-D) Out BP 12-13 Bucket digging pressure sensor(GND) (SE-1) In BrR
11-14 Travel 1,2 speed select valve (SV-3) Out LgB 12-14 Bucket digging pressure sensor (SE-1) In LgR
11-15 Starter switch (SW-1) In GrL 12-15 Bucket digging pressure sensor (5V) (SE-1) In RB
11-16 Wiper motor rise up (stop) (M-10) In L 12-16 Opt. pedal pressure switch (SW-18, SW-19) In LO
11-17 Wiper motor (reverse) (M-10) In G CN-14

11-18 Wiper motor ark prevent relay (R-9) In LR Input Wire
No. NAME Output color REMARKS
11-19 Wiper motor rotation relay (R-9) Out GB
14-1 Governor motor A phase (M-2) Out G
11-20 Wiper motor reverse relay (R-9) Out Gr
14-2 Governor motor A phase (M-2) Out B
11-21 Washer motor relay (R-6) Out GrL
14-3 Governor motor A phase shield Out —
1-22 Work light relay (R-8) Out BrY
14-4 Travel left pressure sensor (GND) (SE-10) In BG
11-23 CPU error lamp In PG
14-5 Travel left pressure sensor (SE-10) In Sb
11-24 P2 by-pass cut proportionate valve (PSV-B) Out GrR
14-6 Travel left pressure sensor (5V) (SE-10) In YR
11-25 Travel straight valve (PSV-C) Out GrB
14-7 Accel dial (5V) (SE-16) In WR
11-26 P1 by-pass cut proportionate valve (PSV-D) Out PW
14-8 Accel dial (SE-16) In P
CN-13 14-9 Accel dial (GND) (SE-16) In BW
Input Wire
No. NAME Output color REMARKS 14-10 Travel 1, 2 speed switch (SW-3) In PL
13-1 Bucket extend pressure sensor (GND) (SE-2) In BL 14-11 Power supply 24V In RY
13-2 Bucket extend pressure sensor (SE-2) In LgW 14-12 Governor motor B phase (M-2) Out R
13-3 Bucket extend pressure sensor (5V) (SE-2) In RL 14-13 Governor motor B phase (M-2) Out W
13-4 Swing right pressure sensor (5V) (SE-6) In YB 14-14 Dctccts the starting point of the governor motor (M-2) Out V
13-5 Swing right pressure sensor (SE-6) In V 14-15 Power window operation signal (C-5) Out PB
13-6 Swing right pressure sensor (GND) (SE-6) In GrL 14-16 Wiper operation signal (C-5) Out YB
13-7 Swing left pressure sensor (GND) (SE-5) In Br 14-17 Work mode display (C-2) Out LO
13-8 Swing left pressure sensor (SE-5) In VG 14-18 Work mode display (C-2) Out L
31102 60413252
13-9 Swing left pressure sensor (5V) (SE-5) In YG 14-19 Engine speed sensor (SE-13) In B
13-10 Travel right pressure sensor (5V) (SE-9) In YL 14-20 Engine speed sensor (SE-13) In W
13-11 Travel right pressure sensor (SE-9) In VY 14-21 Shield earth In Gr
13-12 Travel right pressure sensor (GND) (SE-9) In BY 14-22 Power supply GND Out B
F16740
21-11
(2) Gauge cluster
Amp SCCS connector

(Nippon AMP 040)
Housing 174044-2
Terminal 173681-2
VIEW I
Connector
No. NAME Wire color No. NAME Wire color
1 Fuel sensor BrR 11 CPU trouble PG
2 Engine coolant temp. sensor YR 12 Swing parking release switch Lg
3 Alternator (charge) WR 13 Over load
4 Glow switch BrY 14 Spare 1
5 Engine oil pressure switch O 15 Spare 2
6 Engine coolant temp. switch GB 16 Mode display (Main controller) LO
7 Remaining fuel volume switch BrB 17 Mode display (Main controller) L
8 Air cleaner clogged switch BrL 18 Work light switch WB
9 Travel 1-2speed switch LgB 19 Power supply (+24V) W
10 Buzzer signal Br 20 GND B
Performances, lamp display and alarm

DISPLAY CONTENTS INPUT TERMINAL INPUT SIGNAL CONDITION BUZZER SOUNDS
No. Function No. Normal (OFF) Abnormal (ON) or not. Note 1
1 CN21-3 1 0
*
No
Battery charge faulty
2 Glow operation CN21-4 — 1 No
3 Engine oil pressure low CN21-5 — 0 Yes
4 Engine coolant temp. high temp. CN21-6 — 0 Yes
5 Fuel down CN21-7 800Ω or more 150Ω or less No
6 Air cleaner clogged CN21-8 — 0 No
7 Travel 2-speed operation CN21-9 — 1 No
8 Buzzer Note 2 CN21-10 — 0 Yes
9
*
CPU trouble CN21-11 0 — No
10 Swing parking CN21-12 — 34Ω No
11 Over load alarm CN21-13 — 0 Yes
12 Spare 1 CN21-14 — 0 No
13 Spare 2 CN21-15 — 0 No
14 Work light (Back light) CN21-19 — 1 No
F16742
31102 60413252
NOTE:
1:The buzzer sounds intermittently, 0.5 ± 0.2 sec: ON and 0.5 ± 0.2 sec: OFF when the battery charge is short, or
error Nos. 3, 4, 11 in the above Table occurred during normal operation.
2:The buzzer in error No.8 sounds only, and mechatro controls it.
21-12
(3) Switch assy
Wire
No. NAME color
1 Power supply+5V G
2 Address input Di1 LgR
3 Address input Di2 LG
4 Address input Di3 VG
CN22
5 Date output DO1 BrW
6 GND B
7 NC —
8 NC —
No. NAME Wire

color
View from rear side
1 Back light + WB
CN23
2 Back light - B
F16743
(4) Governor motor (M-2)
NAME PLATE
Connection diagram
Brown
(A) Red
(B)
MOTOR CONNECTOR
Orange
(A) Yellow
(A) LIMIT SWITCH CONNECTOR
Limit switch operation range
Limit switch connector wiring diagram Motor connector wiring diagram

31102 60413252
No. LEAD COLOR CONNECTION

LINE
No. LEAD COLOR CONNECTION
LINE
5 White COM 1 Brown A
_
6 Red NO 2 Orange A
7 Yellow NC 3 Red B
_
F16744
4 Yellow B
F16745
21-13
NOTE
21-14
SECTION 22 HYDRAULIC SYSTEM
TABLE OF CONTENTS
1. Summary .............................................................................................................. 22-1
2. Hydraulic circuits and component model .............................................................. 22-2

2.1 Standard specification .................................................................................................................... 22-3
2.2 Dozer specification (opt) ................................................................................................................ 22-4
2.3 Dozer and extra specification (opt) ................................................................................................. 22-5
2.4 Boom and arm safety specification (opt) ........................................................................................ 22-6
3. Hydraulic circuit operation .................................................................................... 22-7

3.2 Neutral circuit ................................................................................................................................. 22-8
3.3 Travel circuit .................................................................................................................................. 22-10
3.4 Bucket circuit ................................................................................................................................ 22-12
3.5 Boom circuit ................................................................................................................................. 22-14
3.6 Swing circuit ................................................................................................................................. 22-18
3.7 Arm circuit .................................................................................................................................... 22-20
3.8 Combined circuit (multiple circuit) ................................................................................................ 22-24
4. Pilot piping .......................................................................................................... 22-28
5. Main piping ......................................................................................................... 22-34
6. Additionl specifications ....................................................................................... 22-44

6.1 Boom / arm safety specification ................................................................................................... 22-45
6.2 Extra, N and B, dozer specification .............................................................................................. 22-47
31102 60413252
HYDRAULIC SYSTEM
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability,
safety, mass volume handling and low fuel consumption.
Table. 1-1
PERFOR-
DEVICE FUNCTION FEATURES
MANCE
• Travel straight. • Travel straight at composite operation.
• 2-speed travel changeover. • 2-speed changeover of travel speed.
• Auto parking brake. • Automatic braking when parking.
TRAVEL
• Motor overrun protection. • Secure people from danger caused by overrun-

ning of motor on the slope.
• Travel pilot operation. • Slow start and stop.
• Reverse rotation protective function. • Easy positioning to protect it from swinging

EASY OPERABILITY AND SAFETY
back when stops swinging.

SWING
• Swing priority circuit. • Easy operation of stable swing speed, arm

(simultaneous operation of arm digging and slanted leveeing, swing press digging.
swing motions). • Protect it from swing drift on the slope.
• Automatic swing parking brake.
• Hydraulic pilot control system. • Delicate operability.

ATTACHMENT
• Pilot lock system. • Cut out of pilot circuit by safety lock lever.
• Lock valve (boom / arm). • Protect boom and arm from natural drop when
parking.
• Closed pressure type hydraulic oil tank. •To prevent hydraulic oil from being contami-
nated and to promote self suction ability of
pump.
OTHERS
• Suction strainer. •Remove dust on suction side.

• Line filter: pilot circuit. •To prevent pilot operating circuit from malfunc-
tioning.
• Return circuit. • To prevent hydraulic oil from fouling.
• Cooling hydraulic oil by oil cooler. •To prevent hydraulic oil from being deteriorated.
MASS HANDLING CAPABILITY
• Total power shift control variable displacement • Use engine power effectively with 2 variable
displacement pumps (delivery side).
PUMP
pump.
COMPUTER ATTACHMENT
• Boom raise conflux circuit. • Speed up for boom raise operation.

• Arm conflux circuit. • Speed up for arm operation.
31102 60413252
CONSUMPTION
LOW FUEL
• Auto accel. • Reduce fuel consumption and noise by lowering

MICRO
engine speed when control lever is in neutral

position.
F16751
22-1
HYDRAULIC SYSTEM
2. HYDRAULIC CIRCUITS AND COMPONENT MODEL
STANDARD SPECIFICATION E70SR EVOLUTION
No. COMPONENT MODEL No.
1 PUMP ASSY (WITH GEAR PUMP) K3SP36B-101R-1001
2 CONTROL VALVE BCV75-A1-1
3 SWING MOTOR UNIT SG025E-096
4 TRAVEL MOTOR GM09VN
5 BOOM CYLINDER 110-70-916
6 ARM CYLINDER 95-65-813
7 BUCKET CYLINDER 80-55-735
8 SWIVEL JOINT
9 PILOT VALVE (ATT) PV48M1086
10 PILOT VALVE (TRAVEL) PVD6PC4017A
11 SOLENOID VALVE 6KWE5G-30/G24WR-608A
12 RETURN FILTER Y-418900
13 CHECK VALVE Y-2389
14 SUCTION STRAINER Y-497500
15 INLINE FILTER YTD9986
16 AIR BREATHER Y-382000
17 CONNECTOR
18 CONNECTOR
19 CHECK VALVE (SLOW RETURN)
CONTROL VALVE (OPT)

20
CONTROL VALVE (OPT)
21 HYDRAULIC VALVE ASSY

F16752
31102 60413252
22-2
HYDRAULIC SYSTEM
2.1 STANDARD SPECIFICATION

D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
A3 D1 P TRAVEL RIGHT TRAVEL LEFT P D2
M
250kgf/cm2 250kgf/cm2
A4 F GA C H E D B 8 (3550psi) (3550psi)
Dr1 B1 a3 36kgf/cm2 B SWING Mu A

(508psi)
16 TRAVEL RIGHT REVERSE

TRAVEL RIGHT FORWARD
RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
T1' TRAVEL LEFT REVERSE
13 T1 TRAVEL
PRIORITY
T2 300kgf/cm2
12 T2' (4260psi)
P0
DR1
14 2 TRAVEL
21 SE5
P
2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT 17 SE6
Pa1 Pd1 P
Pb1 Pc1 B A
A1 FORWARD FORWARD D1
B1 C1
REVERSE REVERSE Pd2' SWING LEFT
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2
21
Pb2 Pc2
11 Pb2'
DR5
335kgf/cm2
(4770psi)
LEFT D2
RIGHT C2 B A
A2 UP SE1
B C D DR2 BUCKET IN
B2 DOWN BUCKET DUMP P SE2
P2 TRAVEL P1 BYPASS CUT 335kgf/cm
2 Ps P
BY-PASS CUT PRIORITY & ARM CONFLUX (4770psi) ARM
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm2
(4770psi) OUT
DR3
D3
6 P SE3
B3 DUMP IN C3 RH P T LH
335kgf/cm2
SWING TRAVEL LEVER 335kgf/cm 2 (4770psi)
PARKING 1-2SPEED LOCK P1 (4770psi) ARM
BY PASS CUT BOOM P2
BRAKE CHANGEOVER CONFLUX BY-PASS CUT
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16754
22-3
HYDRAULIC SYSTEM
2.2 DOZER SPECIFICATION (OPT)
DOZER SPEC.
50 No. PART NAME MODEL No.
Pf P3 A1 A2 HYD.PUMP ASSY
50 K3SP368-101R-2001
GEAR PUMP
51 CONTROL VALVE ASSY KVS65-1
a1
a2
52 DOZER CYLINDER 120-70-150
F16755
A5 A3
NOTE:
M This hydraulic circuit is used to add to standard
B2
specification circuit.
A4 FG
Dr1 B1 a3 36kgf/cm2
(508psi)
P1 P2
52
T1 MAIN CONTROL VALVE
DOZER
T P
200kgf/cm2
(2840psi) 51
B1 DOZER UP
DOZER DOWN
2
280kgf/cm A1
(3990psi)
31102 60413252
22-4
HYDRAULIC SYSTEM
2.3 DOZER AND EXTRA SPECIFICATION (OPT)
50
Pf P3 A1 A2
a1
a2
A5 A3
M
B2
A4 FG
Dr1 B1 a3
2
36kgf/cm
(508psi)
P1 P2
52
T1 MAIN CONTROL VALVE
DOZER
T P
51
2
200kgf/cm
(2840psi)
A1 DOZER DOWN
DOZER UP
2
280kgf/cm B1
(3990psi)
Pa2 Pb2
A2
TO EXTRA HYD
220kgf/cm
2
B2
(3130psi)
53
DOZER AND EXTRA SPEC.

No. PART NAME MODEL No. T
T
HYD.PUMP ASSY P
P1
50 K3SP368-101R-2001
GEAR PUMP B A
51 CONTROL VALVE ASSY KVS65-2 C1 C2
LEVER P SE11
LOCK 52 DOZER CYLINDER 120-70-150
4 53 PILOT VALVE 16030-00000
F16756
NOTE:
This hydraulic circuit is used to add to standard
31102 60413252
specification circuit.
22-5
HYDRAULIC SYSTEM
2.4 BOOM AND ARM SAFETY SPECIFICATION (OPT)
A1 A2
BOOM AND ARM SAFETY SPEC.
No. PART NAME MODEL No.
50 HOLDING VALVE A-VB50-SECCAP90-EXC12-T-35
A3 NOTE:
This hydraulic circuit is used to add to standard
M specification circuit.
P1 P2
T1
BOOM
Pa2
Pb2
Pb2'
DR5 DR2
A2 UP ARM PS
B2 DOWN Pd3
Pc3 ARM IN
Pc3'
DR3
IN D3 C2 Pi1
OUT C3 335kgf/cm
2
(4770psi)
ARM
Pi1
V2 T
50
C2 Pi1
BOOM 335kgf/cm
2
(4770psi)
Pi1
V2 T
50
31102 60413252
BOOM DOWN
F16757
22-6
HYDRAULIC SYSTEM
3. HYDRAULIC CIRCUIT OPERATION
Blue : Feed, drain circuit, less than

3.5 kgf/cm2 (50 psi)
Green : Return, make-up circuit,
3.5~6 kgf/cm2 (50~85 psi)
Purple : Secondary pilot pressure,
6~36 kgf/cm2 (85~508 psi)
Red : Primary pilot pressure,
36~50 kgf/cm2 (508~710 psi)
Orange: Main pump drive pressure,
50~300 kgf/cm2 (710~4270 psi)
Blue tone : At valve selection.

Red valve : When proportional valve
(reducing) is operating
Red solenoid : In active and exciting
F16758
Displaying the flow circuit and standby circuit when

operating.
Regarding the electrical symbols in this manual, refer
to the electric circuit diagram.
31102 60413252
22-7
HYDRAULIC SYSTEM
3.2 NEUTRAL CIRCUIT

This section describes the following.
(1) SAFETY LOCK LEVER AND PILOT CIRCUIT

Purpose:
To protect attachment from unexpected operation for
safety, however, dozer is outside of adaptation.
Principle:
Cut pressure source of pilot valve for operation.
Operation:
After engine starts, push down the safety lock lever
(red), and the limit switch (SW-11) is turned on, the
pilot operation circuit is changed to standby condition.
(2) PUMP CONTROL

Type:
Total power shift control variable displacement pump
Operation:
1) Since the pump delivery flow rate is unloaded
when in neutral position, the pump delivery
pressure (P1, P2) is low, and the average pressure
(P1+P2) / 2 on compensating piston (621) stepping
section becomes small. Consequently the force of
spring (625, 626) becomes higher than the average
pressure, and the spool (652) is moved rightward.
And the passage to large bore of servo piston
(532) is connected with low pressure side and
moves leftward, then tilting angle becomes larger,
and pump delivery flow rate increases.
2) Lever (611) rotates at a fulcrum of pin, and moves
with this operation, the feedback sleeve (651)
rightward, then keep moving until the openings of
spool (652) and sleeve (651) are closed.
31102 60413252
22-8
HYDRAULIC SYSTEM
COMPENSATING
PISTON(621)
D2 D1
1 4 3 RED
SPOOL
(652) Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
SPRING 611
15
(625,626) D1 P TRAVEL RIGHT TRAVEL LEFT P D2
A3
(OPT)
SLEEVE M 20
(651) 2 2
250kgf/cm 250kgf/cm
SERVO PISTON
(532) A4 F GA C H E D B 8 (3550psi) (3550psi)
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
RIGHT LEFT 17 19 SE6
Pa1 Pd1 TRAVEL LEFT FORWARD P
Pc1 TRAVEL LEFT REVERSE
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
REVERSE REVERSE Pd2' SWING LEFT K M H
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
P2 TRAVEL P1 BYPASS CUT 2
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
SWING TRAVEL LEVER 335kgf/cm
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16759
Neutral circuit: safety lock lever ON
22-9
HYDRAULIC SYSTEM
3.3 TRAVEL CIRCUIT

(1) TRAVEL FORWARD PILOT SIMULTANEOUS (3) TRAVEL MAIN CIRCUIT

OPERATION CIRCUIT Operation:
Purpose: With travel pilot operation, the travel speed is switched,
Soft operability and the oil delivered through A1 port of main pump
Operation: passes through C/V P1-A1, flows into A port of travel
1) Start travel right and left at the same time with motor (4) through C port of swivel joint (8) allowing
control lever, and the pilot proportional secondary travel motor to perform the operation abovementioned.
pressure is delivered through P/V (10) 2, 4 ports, (Refer to “Travel Motor Function”)
at the same time select higher pressure and the
higher pressure is delivered through 5, 6 ports, (4) TRAVEL MOTOR FUNCTION
then acts on low pressure sensors (SE9) (SE10). Function:
2) Pilot proportional secondary pressure flows into 1) Secure people from danger caused by overrunning
Pd1, Pa1 ports of control valve, acts on travel of motor on downhill slope.
spool, and switches main circuit. 2) Hydraulic motor cavitation protective check valve
3) The signal output by low pressure sensor is input 3) Shockless relief valve and anticavitation valve
to mechatro controller, and executes signal when stopping it with the force of inertia.
processing. 4) High and low speed 2 stage switching mechanism
5) Travel parking brake
(2) TRAVEL 2 SPEED SOLENOID COMMAND
CIRCUIT
Purpose:
Change travel motor speed with switch.
Principle:
Electric signal because of switching excites travel 2
speed solenoid and pilot primary pressure varies
swash plate angle of variable motor.
Operation:
Press switches with rabbit and turtle marks on travel
lever grips, and the solenoid (SV-3) of proportional
valve block (11) is excited and is switched, and
solenoid command is output by port 3 and sends to P
port of travel motor (4), opens oil passage to 2 speed
piston, and switches it to 2 speed tilting angle with
self-pressure.
31102 60413252
22-10
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
JD
Dr1 B1 a3 36kgf/cm 2 B SWING Mu A
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16760
Travel circuit: travel 2nd speed operation
22-11
HYDRAULIC SYSTEM
3.4 BUCKET CIRCUIT

(1) BUCKET DIGGING PILOT CIRCUIT (4) BUCKET DIGGING MAIN CIRCUIT
Operation: Operation:
Start bucket digging operation, and pilot proportional With pilot operation, the pressure oil switches bucket
secondary pressure is output through port (1) of right spool, and is fed into bucket cylinder H side through
pilot V (9), and flows into C/V (2) Pa3 port, and switches C/V A3 port. And the return oil from cylinder R side
bucket spool. flows into tank circuit while being restricted by bucket
spool through C/V (2) B3 port.
(2) AUTO ACCEL OPERATION
Principle:
Start operating with signal output by low pressure
sensor.
Operation:
[ Lever in neutral position ]
When the signal is not input to low pressure sensor
for 4 seconds or more after turning accel dial to Max.
position, set engine speed to 1050 rpm.
[ Lever in operation position ]
When the pressure of 6 kgf/cm2 (86 psi) or more is
input to low pressure sensor in STD specification
(travel, bucket, boom, swing and arm), the proportional
voltage received from low pressure sensor is output
to C1 controller, and restores the E/G speed to the
speed set by accel dial with control lever operation.
(3) E/G OVERLOAD PROTECTION WITH PUMP

POWER CONTROL OPERATION
Principle:
Total power shift control with pump pressure (P1+P2)/
2
Operation:
1) With increase of pump delivery pressure P1 or P2,
(P1+P2)/2 pressure acts on compensating piston
(621) stepping section by the function of restriction.
2) With bucket operation, the delivery pressure is
raised and pushes spool (652) leftward, and moves
it to the position where the force of springs (625,
626) balances the hydraulic pressure.
3) With movement of spool (652) leftward, the oil
passage to large bore of servo piston (532) opens,
and delivery pressure is led into it and pushes the
piston rightward.
4) Then, the tilting angle becomes smaller and
31102 60413252
reduces the delivery flow rate from the pump used
to protect engine from overloading.
22-12
HYDRAULIC SYSTEM
COMPENSATING
PISTON(621)
D2 D1
1 4 3 RED
SPOOL
(652) Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
SPRING 611
15
(625,626) D1 P TRAVEL RIGHT TRAVEL LEFT P D2
A3
(OPT)
SLEEVE M 20
(651) 2 2
250kgf/cm 250kgf/cm
SERVO PISTON
(532) A4 F GA C H E D B 8 (3550psi) (3550psi)
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16761
Bucket circuit: bucket digging operation
22-13
HYDRAULIC SYSTEM
3.5 BOOM CIRCUIT

This section describes the boom raise conflux
operation.
(1) BOOM RAISE PILOT CIRCUIT 3) Then the oil passes through boom spool, opens
Operation: lock valve of boom lock valve,and is led into H side
1) Start boom raise operation, and pilot proportional of boom cylinder through C/V (2) A2 port.
secondary pressure from right pilot valve (9) is 4) The returm oil from boom cylinder R side flows into
output through port (3), and acts on low pressure tank circuit throgh boom spool from C/V (2) B2
sensor (SE3), and at the same time the pressure port.
is branched into 2 circuits and acts on Pa2 and
Pc4 port of C/V (2).
2) The voltage output by low pressure sensor is
processed by mechatro controller and outputs
command current to P2 by-pass cut valve (PSV-
B) and solenoid valve outputs porportional
secondary pressure and the pressure acts on C/
V (2) Pd4 port.
3) Then, the secondary pressure fed into C/V (2) Pa2
port switches boom conflux spool. And the solenoid
proportional secondary pressure fed into Pd4 port
switches P2 by-pass cut valve.
(2) BOOM RAISE 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
Purpose:
Boom raise speed up
Priciple:
Confluxing oil from 2 pumps
Operation:
1) The oil delivered through A1 port of P1 pump flows
into C/V (2) P1 port, and branches into by-pass
circuit and parallel circuit. However since the
boom spool is moved and by-pass circuit is closed,
the oil opens load check valve through parallel
circuit and flows into boom spool.
2) On the other hand, the oil delivered through A2
port of P2 pump passes through C/V (2) P2 port,
flows into travel straight section, and branches
into by-pass circuit and parallel circuit. However,
since P2 by-pass cut valve is switched and closed,
the oil passes through the outside of boom conflux
spool from parallel circuit, opens load check valve
from boom conflux circuit, confluxes with oil
delivered by P1 pump inside, and flows into boom
31102 60413252
spool.
22-14
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
2 2
250kgf/cm 250kgf/cm
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16762
Boom circuit: boom raise (up) operation, conflux function
22-15
HYDRAULIC SYSTEM
This section describes the boom lower operation.
(3) BOOM LOWER PILOT CIRCUIT [When boom lower secondary pressure is not actuated]
Operation: 1) Where the pilot pressure in boom lock valve relief
1) Start boom lower operation, and the pilot port Pb2’ is not actuated, the above needle valve
proportional secondary pressure is output through is pushed back by the force of spring, and the back
port (4) of pilot valve, and acts on low pressure pressure of lock valve becomes equal to the return
sensor (SE4), at the same time branches into two pressure.
circuits, then acts on C/V (2) Pb2 and Pb2’ port. 2) The area on back pressure side of lock valve is
2) The voltage output by low pressure sensor (SE4) larger, the lock valve is completely seated, and the
is input into mechatro controller. oil in boom cylinder H side is stopped from returning,
3) Then, the proportional secondary pressure fed protecting the boom from natural drop.
into C/V (2) Pb2 port switches boom spool. And
the proportional secondary pressure flown into C/
V (2) Pb2’ port releases boom lock valve.
(4) BOOM LOWER MAIN CIRCUIT

Operation:
1) The oil delivered through A1 port of P1 pump
passes through C/V (2) P1 port and flows into
travel straight section, and branches into by-pass
circuit and parallel circuit. However since the
boom spool is moved and by-pass circuit is closed,
the oil opens load check valve through parallel
circuit and flows into boom spool.
2) The oil passes through outside of boom spool,
and flows into boom cylinder R side through C/V
(2) B2 port.
3) On the other hand, the return oil boom cylinder H
side flows into C/V (2) A2 port, but since the boom
lock valve is open, it flows into boom spool.
4) Then the oil passes through orifices on boom
spool and returns into tank while restricting.
(5) NATURAL DROP PROTECTION WITH BOOM

LOCK VALVE
Operation:
[ When boom lower secondary pressure is actuated ]
1) The control secondary pressure flown into relief
port Pb2’ of boom lock valve pushes needle valve
on the rear side of the lock valve seat, and the
back pressure of lock valve flows into tank circuit
through port DR5 making the opening of valve
easier.
2) The return oil from boom cylinder R side opens
31102 60413252
lock valve, and flows into boom spool.
22-16
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
2 2
250kgf/cm 250kgf/cm
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16763
Boom circuit: boom lower (down) operation
22-17
HYDRAULIC SYSTEM
3.6 SWING CIRCUIT

This section describes the following operations.
(1) SWING LEFT PILOT CIRCUIT (3) SWING MAIN CIRCUIT

Operation: Operation:
1) Start swing left operation, and pilot proportional 1) The oil delivered through A2 port of P2 pump
secondary pressure through port (5) of left pilot passes through C/V (2) P2 port and flows into
valve (9) is output, and acts on low pressure travel straight section, and branches into by-pass
sensor (SE5), and at the same time the pressure circuit and parallel circuit. However since the
is branched into 2 circuits and acts on Pd2 and swing spool is moved and by-pass circuit is closed,
Pd2’ ports of C/V (2). the oil opens load check valve through parallel
2) The voltage output by low pressure sensor is circuit and flows into B port of swing motor through
processed by mechatro controller and outputs C/V (2) D2 port, and has swing motor rotated in
command current to P2 by-pass cut valve (PSV- counterclockwise.
B) and solenoid valve outputs proportional
secondary pressure and the pressure acts on C/
V (2) Pd4 port.
3) Then, the secondary pressure fed into C/V (2) Pd2
port switches swing spool. And the secondary
pressure fed into Pd2’ port flows into PS’ port
through check ball, then into PS port, and acts on
load check valve for arm operation. In addition, the
solenoid proportional secondary pressure switches
P2 by-pass cut valve.
(2) SWING AUTO PARKING BRAKE

Purpose:
Swing lock and parking in neutral position
Principle:
Release only when required to operate mechanical
brake.
Operation:
1) Swing parking release SW-4 excites swing parking
SOL (SV-1) by-turning switch on.
2) Only when operation secondary pressure during
swing and arm digging operation acts on any of
low pressure sensor (SE5, 6, 7), it release the
excitation to swing parking SOL.
3) After 5 seconds when the pressure of low pressure
sensor (SE5, 6) from swing operation has
exhausted, the swing parking SOL (SV-1) is
excited. And in case of arm in operation, at the
same time when the pressure of pressure sensor
(SE7) for arm in operation has been exhausted,
the swing parking SOL (SV-1) is excited.
31102 60413252
22-18
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
2 2
250kgf/cm 250kgf/cm
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16764
Swing circuit: swing operation (left)
22-19
HYDRAULIC SYSTEM
3.7 ARM CIRCUIT

(1) ARM CONTROL PILOT CIRCUIT 4) In addition, the return oil from arm cylinder R side
Operation: flows into arm lock valve through D3 port, but
1) Start arm in operation, and pilot proportional since the arm lock valve is open, it flows into arm
secondary pressure is output through port (7) of spool.
left pilot valve (9), and acts on low pressure sensor 5) Then, the oil passes through orifices on arm spool
(SE7), and at the same time the pressure branches and returns into tank while restricting.
into 2 circuits and acts on Pc3 and Pc3’ ports of C/
V (2).
2) The voltage output by low pressure sensor (SE7)
is input into mechatro controller and the controller
executes signal processing, and outputs command
current to P1 by-pass cut valve (PSV-D) and
solenoid valve outputs proportional secondary
pressure and the pressure acts on C/V (2) Pb4
port.
3) Then, the secondary pressure fed into C/V (2) Pc3
port switches arm conflux spool. And the solenoid
proportional secondary pressure fed into Pc3’ port
releases arm lock valve. In addition, solenoid
proportional secondary pressure switches P1 by-
pass cut valve.
(2) ARM IN 2 PUMPS CONFLUX MAIN CIRCUIT

Purpose:
Arm in speed up
Principle:
Confluxing oil from 2 pumps in C/V (2)
Operation:
1) The oil delivered by P2 pump flows into travel
straight section through C/V (2) P2 port, and
branches into by-pass circuit and parallel circuit.
However since the arm spool is moved and by-
pass circuit is closed, the oil opens load check
valve and flows into arm spool.
2) On the other hand, the oil delivered by P1 pump
passes through C/V (2) P1 port and flows into
travel straight section, and branches into by-pass
circuit and parallel circuit.
However, since P1 by-pass cut valve is switched
and low pressure circuit is closed, the oil opens
load check valve and confluxes with oil delivered
from load check valve on P2 parallel circuit, and
31102 60413252
flows into arm spool.
3) Then, the confluxed oil is fed into arm cylinder H
side through C/V (2) C3 port from arm spool.
22-20
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
JD
Dr1 B1 a3 36kgf/cm 2 B SWING Mu A
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
P2 TRAVEL P1 BYPASS CUT 335kgf/cm
2 Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16765
Arm circuit: arm in (digging) operation, conflux function
22-21
HYDRAULIC SYSTEM
(3) ARM OUT PILOT CIRCUIT 2) The area on back pressure side of lock valve is
Operation: larger, the lock valve is completely seated, and the
1) Start arm out operation, and the pilot proportional oil in arm cylinder R side is stopped from returning
secondary pressure is output through port (8) of to arm spool, protecting the arm from natural drop.
left pilot valve (9), and acts on low pressure sensor
(SE8), at the same time acts on C/V (2) Pd3 port.
2) The voltage output by low pressure sensor (SE8)
is processed by mechatro controller, and outputs
command current to P1 cut valve (PSV-D), and
the solenoid valve outputs secondary pressure
and acts on C/V Pb4 port.
3) Then, the proportional secondary pressure fed
into C/V (2) Pc3 port switches arm spool. And the
proportional secondary pressure flown into Pb4
port switches P1 by-pass cut valve.
(4) ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT

Purpose:
Arm out operation speed up
Operation:
1) The oil delivered by P1 and P2 pumps flows in the
same way until the oil reaches to arm spool.
2) Then, the oil passes through arm spool opens arm
lock valve with free flow and flows into arm cylinder
R side through C/V (2) D3 port.
3) And, the return oil from arm cylinder H side flows
into C3 port, passes through periphery on arm
spool, and returns into tank circuit.
(5) NATURAL DROP PROTECTION WITH ARM

LOCK VALVE
Operation:
[ When arm out operation pressure is actuated ]
1) The control secondary pressure flown into relief
port Pc3’ of arm lock valve pushes needle valve on
the rear side of lock valve seat, and the back
pressure of lock valve flows into tank circuit through
drain port DR3 making the opening of valve easier.
2) The return oil from arm cylinder R side opens lock
valve, and flows into arm spool.
[ When arm out operation pressure is not actuated]
1) Where the pilot pressure in arm lock valve relief
port Pc3’ is not actuated, the above needle valve
31102 60413252
is pushed back by the force of spring, and the
pressure of lock valve becomes equal to the return
pressure due to back pressure of lock valve.
22-22
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
2 2
250kgf/cm 250kgf/cm
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16766
Arm circuit: arm out (extend) operation, conflux function
22-23
HYDRAULIC SYSTEM
3.8 COMBINED CIRCUIT (MULTIPLE

CIRCUIT)
This section describes only the difference in combined
operation.
(1) BOOM RAISE/TRAVEL, PILOT CIRCUIT

Operation:
[ Points which are differed from the independent
operation ]
1) With signal processing of mechatro controller, the
controller outputs command current to travel
straight valve (PSV-C) and P2 by-pass cut valve
(PSV-B) and P1 by-pass cut valve (PSV-D), and
this solenoid valve outputs secondary pressure,
then acts on C/V (2) Pd4, Po and Pb4 ports.
2) Then, the proportional secondary pressure fed
into C/V (2) Pd4 port switches by-pass cut valve.
And the Pb4 port pressure switches P1 by-pass
cut valve.
(2) BOOM RAISE/TRAVEL, MAIN CIRCUIT

Purpose:
Travel straight operation is available even if the
attachment is operated during travel operation.
Principle:
The travel motion and attachment operations are
performed by respective pump.
Operation:
1) The oil delivered by P1 and P2 pumps flows into
travel straight section through C/V (2) P1, P2
ports. The travel straight spool is moved and the
oil delivered by P1 pump branches into P1 and P2
parallel circuits. In addition, the oil delivered by P2
pump branches into P1 and P2 by-pass circuits.
2) And, both travel operations are performed by by-
pass circuit, that is performed by the oil delivered
by P2 pump.
Since boom spool and other spool are operated
through parallel circuit, so oil delivered by P1
pump is available.
3) However, a part of flow is connected through
orifice of travel straight spool and the travel and
boom (ATT) speeds are regulated by connection
to this orifice.
31102 60413252
22-24
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
2 2
250kgf/cm 250kgf/cm
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16767
Combined (conflux) operation: boom raise (up) / travel simultaneous operation in travel straight function
22-25
HYDRAULIC SYSTEM
This section describes difference in combined

operation.
(3) SWING/ARM IN, PILOT CIRCUIT

Operation:
1) Start swing left and arm in operation
simultaneously, and with signal processing of
mechatro controller, the mechatro controller
outputs command to P2 by-pass cut valve (PSV-
B) and P1 by-pass cut valve (PSV-D), and this
solenoid valve outputs secondary pressure and
acts on C/V (2) Pd4 and Pb4 ports. (These
operations are the same as that of the combined
respective independent operation.)
2) Then, the higher pilot proportional secondary
pressure selected in swing control side flows into
C/V (2) PS port, acts on load check valve for arm
operation, and makes it less capable to the oil
flowing into arm spool.
(4) SWING/ARM IN, SWING PRIORITY MAIN

CIRCUIT
Purpose:
Stable swing speed
Principle:
Control the oil flow rate to arm cylinder, and give a
priority of the delivery of P2 pump to swing operation.
Operation:
1) The swing main circuit functions with the delivery
of P2 pump, but in P2 pump circuit the swing and
arm circuits are in parallel, therefore the oil flows
into swing and arm sides at the same time.
However, in swing operation, the selected higher
swing pilot proportional secondary pressure limits
the opening of load check valve on arm side,
allowing to stop confluxing with oil by P2 side.
Therefore, the oil delivered by P2 pump flows into
swing side prior to arm side.
This is called “Swing Priority Circuit”.
2) Arm in circuit functions with only P1 pump circuit,
but only when the pressure rises higher than the
pressure specified for arm in load check valve the
oil delivered by P1 and P2 pumps are confluxed.
31102 60413252
22-26
HYDRAULIC SYSTEM
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
a2
15
(OPT)
M 20
2 2
250kgf/cm 250kgf/cm
JD
(508psi)

RH T P T P LH
P1 P2
T1'
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
SE5 2 1 3 4 6 5 7 8
14 2 TRAVEL TRAVEL
P 9
BR
AR
SR
Pb1
BA
BK
AK
SL
B
B1 C1
19 PS'
SWING RIGHT
BL
BH
BD
BC
AD
AC
SC
S
BOOM SWING
Pa2 Pd2
Pc2
20
Pb2 (OPT)
11 Pb2' 335kgf/cm
(4770psi)
2
LEFT D2 19
DR5 RIGHT C2
A2 UP SE1
B C D DR2 BUCKET IN
335kgf/cm
Ps P
Pd3 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
18 7 P SE9 P SE10
10
BUCKET
31102 60413252
F16768
Conflux operation: swing / arm in (digging) operation, in swing priority function
22-27
HYDRAULIC SYSTEM
4. PILOT PIPING
No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS
(1) PUMP CONTROL (STD) 3 HOSE : L=1450 1 PRIMARY PRESSURE OF RIGHT P/V 25 CONNECTOR 1 1 PF 3/8
(2) PUMP CONTROL (DOZER) 4 HOSE : L=1400 1 DRAIN 26 CONNECTOR 1 1 PF 1/4 RESTRICTION Ø 0.8
1 INLINE FILTER 1 1 5 HOSE : L=3450 (RED) 1 SECONDARY PRESSURE 27 CONNECTOR 1 1 RESTRICTION Ø 0.6 WITH FILTER
FOR SWING RIGHT
2 CONNECTOR 1 1 PF 3/8 6 HOSE : L=3450 (BLUE) 1 SECONDARY PRESSURE 28 TEE 1 2 PF 3/8 - PF 1/4
FOR ARM IN
3 ELBOW 3 3 PF 3/8 7 HOSE : L=3800 (GREEN) 1 SECONDARY PRESSURE 29 HOSE : L=900 2 2 DRAIN
FOR ARM OUT
4 PLUG 1 1 PF 1/4 8 HOSE : L=3600 (GRAY) 1 SECONDARY PRESSURE 30 TEE 1 1 PF 3/8
FOR SWING LEFT
5 ELBOW 1 1 PF 3/8 9 HOSE : L=3200 (RED) 1 SECONDARY PRESSURE 31 HOSE : L=1500 — 1 DRAIN
FOR BUCKET DIGGING
6 TEE 1 1 PF 3/8 10 HOSE : L=2800 (BLUE) 1 SECONDARY PRESSURE 34 CONNECTOR 2 2 PF 1/4 WITH FILTER
FOR BUCKET DUMP
7 TEE 1 1 2 - PF 3/8 - PF 1/4 11 HOSE : L=3200 (GREEN) 1 SECONDARY PRESSURE
FOR BOOM UP
8 CAPSCREW 2 2 M10 X 20 12 HOSE : L=2800 (GRAY) 1 SECONDARY PRESSURE (7) TRAVEL REMOTE CONT
FOR BOOM DOWN
9 WASHER 2 2 M10 13 CLIP 2 1 HOSE : L=400 1 PRIMARY PRESSURE OF PILOT
10 HOSE : L=550 1 1 DELIVERY RELIEF 14 BOOTS 2 2 HOSE : L=450 1 DRAIN
11 HOSE : L=400 1 1 PILOT DELIVERY 15 PILOT VALVE 2 PA30V00002F3 3 HOSE : L=2300 2 1 : TRAVEL LEFT REVERSE 3 : TRAVEL RIGHT REVERSE
12 CONNECTOR — 1 PF1 - Ø 25.4 16 CAPSCREW 8 M6 X 25 4 HOSE : L=3000 1 4 : TRAVEL RIGHT FORWARD
13 HOSE — 1 SUCTION 17 WASHER 8 M6 5 ELBOW 4 PF 1/4
14 CLIP — 2 18 CLIP 1 7 CONNECTOR 1 PF 1/4 (WITH FILTER)
15 ELBOW — 1 PF 3/4 - Ø2 5.4 19 CAPSCREW 2 M10 X 20 8 CONNECTOR 1 PF 3/8 - PF 1/4
16 HOSE GUARD 2 2 20 WASHER 2 M10 9 PRESSURE SENSOR 2 LC52S00011P1
17 CONNECTOR 1 1 PF 1/4 21 CONNECTOR 8 PF 1/4 10 CAPSCREW 4 M8 X 25
18 ELBOW 1 1 PF 1/4 22 CONNECTOR 2 PF 3/8 - PF 1/4 11 WASHER 4 M8
19 TUBE 1 1 23 TUBE 1 12 PILOT VALVE 1 YN30V00070F1
20 HOSE : L=650 1 1 DRAIN 24 HOSE 1 DRAIN 13 HOSE : L=3200 1 2 : TRAVEL LEFT FORWARD
21 CONNECTOR 1 — PF 3/8 L=46 25 GROMMET 1
26 GROMMET 1 (8) BLOCK CONTROL
(3) SOL.VALVE CONTROL 27 CLIP 1 1 BLOCK 1
1 ELBOW 1 PF 3/8 28 CONNECTOR 2 PF 1/4 WITH FILTER 2 CONNECTOR 1 PF 3/8
2 ELBOW 6 PF1/4 29 HOSE 2 3 ELBOW 3 PF 3/8
3 CONNECTOR 1 PF 3/8 WITH FILTER 30 TUBE 1 4 ELBOW 3 PF 1/4
4 ELBOW 1 PF 1/4 5 CAPSCREW 2 M8 X 40
5 CAPSCREW 2 M10 X 70 (5) CONTROL VALVE CONT. BREAKER OPT. 6 WASHER 2 M8
6 WASHER 2 M10 (6) CONTROL VALVE CONT. 8 CONNECTOR 1 PF 1/4
7 HOSE : L=450 1 SAFETY LOCK LEVER COMMAND 1 ELBOW 13 16 PF 1/4 9 PLUG — PF 3/8
B : P2 CUT PROPORTIONAL SECONDARY PRESSURE 2 TEE 10 11 PF 1/4
8 HOSE : L=3300 2 C : TRAVEL VALVE PROPORTIONAL SECONDARY PRESSURE 10 ELBOW 1 PF 3/8
9 HOSE : L=1350 1 TRAVEL 2-SPEED SELECT COMMAND 3 CONNECTOR 17 21 PF 1/4 11 ELBOW 1 PF 3/8 - 1/4
SWING PARKING BRAKE 4 CONNECTOR 5 5 PF 1/4 L=38
10 HOSE : L=2000 1 RELEASE COMMAND 12 CONNECTOR 1 PF 1/4 L=23
11 HOSE : L=2500 1 P1 CUT PROPORTIONAL SECONDARY PRESSURE 6 CONNECTOR 1 1 PF 1/4 - PF 3/8 13 PLUG — PF 1/4
12 RUBBER 1 7 HOSE : L=1000 1 1 DRAIN 16 CONNECTOR 1 PF 3/8
13 HOSE : L=3200 1 SINGLE/ CONFFLUX FLOW SELECT COMMAND 8 HOSE : L=1200 1 1 DRAIN
14 HOSE : L=3200 1 DRAIN 9 HOSE : L=700 1 1 DRAIN
15 HOSE : L=2600 1 PRIMARY PRESSURE OF PILOT PUMP 10 HOSE : L=1600 1 1 DRAIN
PC3' : ARM LOCK VALVE RELEASE COMMAND
16 SOLENOID VALVE 1 11 HOSE : L=750 2 2 PS : SWING PRIORITY HIGH PRESSURE SELECTION COMMAND
BOOM CONFLUX VALVE
17 RUBBER 1 12 HOSE : L=1050 1 1 SWITCHING COMMAND
Pb2' : BOOM LOCK RELEASE COMMAND
18 RUBBER 1 13 HOSE : L=900 2 2 Pd2' : SWING PRIORITY COMMAND AT SWING LEFT
19 GROMMET 2 14 CONNECTOR 3 3 PF1/4 L=23
20 CLIP 9 15 CONNECTOR 1 1 PF 1/4 L=60
21 SOLENOID VALVE — 16 HYD.VALVE ASSY 1 1
22 ELBOW 2 PF 3/8 17 CLIP 2 2
23 RUBBER 1 18 ELBOW 1 1 PF 1/4
31102 60413252
24 TUBE 1 19 ELBOW 4 4 PF 1/4
25 GROMMET 1 20 ELBOW 1 1 PF 3/8
21 ELBOW 3 2 PF 1/4 - PF 3/8
(4) 1 REMOTE CONTROL LINES 22 HOSE : L=450 — 1 DRAIN
1 HOSE : L=2050 1 PRIMARY PRESSURE OF LEFT P/V 23 CHECK VALVE (SLOW RETURN) 1 1 YT21V00002P1
2 HOSE : L=1900 1 DRAIN 24 PRESSURE SENSOR 4 4 LC52S00011P1
F16769
22-28
HYDRAULIC SYSTEM
PILOT PIPING
(1) PUMP CONTROL (STD) (2) PUMP CONTROL (DOZER)
VIEW I VIEW I
31102 60413252
22-29
HYDRAULIC SYSTEM
(3) SOL. VALVE CONTROL
31102 60413252
22-30
HYDRAULIC SYSTEM
(4) REMOTE CONTROL LINE

31102 60413252
NOTE:
Do not over tighten the bolt for control valve because pilot valve is made of aluminum.
22-31
HYDRAULIC SYSTEM
(5) CONTROL VALVE CONTROL (STD)

(6) CONTROL VALVE CONTROL (WITH OPTION VALVE)
31102 60413252
22-32
HYDRAULIC SYSTEM
(7) TRAVEL REMOTE CONTROL (8) BLOCK CONTROL

31102 60413252
NOTE:
Ports in ( ) indicate lower side one on the control valve.
22-33
HYDRAULIC SYSTEM
5. MAIN PIPING
(1) PUMP DELIVERY (STD) 19 HOSE : L=2200 1 BOOM H 9 ELBOW — 1 PF 3/8 20 TUBE 1
1 CONNECTOR 2 PF 1/2 20 HOSE : L=2250 1 BOOM R 10 PLUG 2 — PF 3/8 21 TUBE 1
2 GROMMET 1 21 HOSE : L=2400 1 ARM H 22 HOSE 1
3 TUBE : Ø50.8 1 SUCTION 22 HOSE : L=2600 1 ARM R (8) LOWER HYD. LINES (STD) 23 HOSE 1
4 HOSE 1 SUCTION 23 HOSE : L=2450 1 BUCKET R 1 TUBE 1 Ø 18 24 CLAMP 2
5 HOSE : L=850 1 DELIVERY P1 24 HOSE : L=1250 1 TRAVEL LEFT FORWARD 2 TUBE 1 Ø 18 25 CASCREW 6 M8 X 40
6 HOSE : L=800 1 DELIVERY P2 25 HOSE : L=2500 1 BUCKET H 3 TUBE 1 Ø 18
7 O-RING 1 1A G55 26 WASHER — M12 4 TUBE 1 Ø 18 (13) BOOM HYD. LINES
9 CLIP 4 27 ROD BOLT — M12 L=160 5 TUBE 1 Ø 15 1 TUBE 1 Ø 22 X t3
10 CAPSCREW 2 M12 X 35 28 NUT — M12 6 TUBE 1 Ø 15 2 TUBE 1 Ø 22 X t3
11 LOCK WASHER 4 M12 7 TUBE 1 Ø 10 3 TUBE 1 Ø 22 X t3
12 CLIP 1 (4) RETURN HYD. LINES (STD) 8 TUBE 1 Ø 10 4 TUBE 1 Ø 22 X t3
13 ELBOW 2 PF 3/4 (5) 1 RETURN HYD. LINES (DOZER EXTRA) 9 TUBE 1 Ø 15 5 CLUMP 4
14 O-RING 2 1B P24 1 TUBE 1 1 10 TUBE 1 Ø 10 6 CLUMP 6
15 CAPSCREW 1 M12 X 25 2 TUBE — 1 11 CLUMP 2 7 CAPSCREW 8
16 CONNECTOR 1 Ø 12 - M12 3 TUBE 1 1 12 CLUMP 2 8 CAPSCREW 1
17 CONNECTOR 1 PF 1/4 4 HOSE : L=1700 1 1 DRAIN 13 SPACER 2 9 NUT 1
18 O-RING 1 1B P11 5 HOSE : L=450 1 1 DRAIN 14 SPACER 2 10 LOCK WASHER 11 M10
19 HOSE : L=540 1 FOR SURGE CUT 6 HOSE : L=1750 1 1 DRAIN 15 TEE 1 11 WASHER 11 M10
20 WASHER 1 M12 7 HOSE : L=1300 1 1 RETURN 16 TEE 1 12 CLAMP 2
21 PLUG 3 PF 1/4 8 HOSE : L=2300 1 1 RETURN 17 LOCK WASHER 4 M8 13 CAPSCREW 2 M10 X 50
22 CAPSCREW 2 M12 X 40 9 CONNECTOR 1 2 PF 1/2 18 WASHER 4 M8
23 SUPPORT 1 10 ELBOW 1 1 PF 1/2 19 CAPSCREW 4 M8 X 40
11 CONNECTOR 1 1 PF 3/4 L=60 (14) BOOM CYL. HYD. LINES
(2) PUMP DELEVERY (DOZER) 13 TEE 1 1 PF 3/8 (9) PROPEL HYD. LINES 1 TUBE 1
1 CONNECTOR 1 PF 1/2 L=32 14 TEE 1 1 PF 1/2 1 CONNECTOR 4 PF 1/2 2 TUBE 1
2 CONNECTOR 2 PF 1/2 15 TEE 4 1 PF 3/4 2 CONNECTOR 2 PF 1/4 3 CONNECTOR 1
3 ELBOW 2 PF 3/8 - PF 1/2 17 COUPLING 1 4 3 CONNECTOR 2 PF 3/8 4 ELBOW 1
4 TEE 1 2 - PF 1/2 - PF 1/4 18 COUPLING 4 1 4 O-RING 4 1B P18 5 O-RING 2 1B P18
5 PLUG 1 PF 1/4 19 U-BOLT 16 4 5 O-RING 2 1B P11 6 CLAMP 2
6 HOSE : L=500 1 DOZER R 20 NUT 8 16 M8 6 O-RING 2 1B P14 7 CAPSCREW 2 M10 X 50
7 HOSE : L=580 1 DOZER H 21 WASHER 2 8 M8 8 LOCK WASHER 2 M10
8 HOSE : L=1500 1 DOZER DELIVERY 22 WASHER 1 2 M10 (10) SWIVEL HYD. LINES (STD) 9 GREASE NIPPLE 1
9 TUBE 1 23 CAPSCREW 1 1 M10 X 60 (12) SWIVEL HYD. LINES (DOZER) 10 GREASE NIPPLE 1
10 TEE 1 PF 1/4 24 CLAMP 1 1 1 CONNECTOR 4 4 PF 1/2 11 PLUG 1
11 HOSE : L=300 1 DOZER POWER SHIFT 25 CHECK VALVE — 1 2 CONNECTOR 1 3 PF 3/8
12 CONNECTOR 1 PF 1/4 L=23 28 HOSE : L=1350 1 1 3 CONNECTOR 1 1 PF 1/4 (15) BUCKET CYL. HYD. LINES
13 CONNECTOR 1 PF 1/4 30 RUBBER 1 1 4 PLUG 2 — PF 3/8 1 TUBE 1
14 ELBOW 1 PF 1/2 31 BRACKET 1 1 5 O-RING 1 4 1B P18 2 TUBE 1
15 ELBOW 1 PF 1/4 32 CAPSCREW 1 1 M10 X 30 6 O-RING 3 3 1B P14 3 CONNECTOR 1
33 CLIP 1 1 7 O-RING 1 1 1B P11 4 ELBOW 1
34 CLIP 1 1 5 CLAMP 2
(3) UPPER HYD. LINES 36 TUBE : L=600 — 1 (11) LOWER HYD. LINES (DOZER) 6 CAPSCREW 2 M10 X 50
1 CONNECTOR 1 PF 1/2 L=32 37 TUBE : L=1100 1 1 1 TUBE 1 Ø 18 7 LOCK WASHER 2 M10
2 CONNECTOR 3 PF 1/2 38 TUBE : L=1400 1 1 2 TUBE 1 Ø 18 8 O-RING 2 1B P18
3 CONNECTOR 2 PF 1/2 39 ELBOW 1 1 PF 1/2 - PF 3/8 3 TUBE 1 Ø 18 9 GREASE NIPPLE 1
4 CONNECTOR 3 PF 1/2 41 CONNECTOR 1 1 PF 3/4 4 TUBE 1 Ø 18 10 GREASE NIPPLE 1
5 CONNECTOR 3 PF 1/2 42 TUBE 2 — 5 TUBE 1 Ø 15
6 ELBOW 3 PF 1/2 43 CAP 1 2 6 TUBE 1 Ø 15 (16) ARM HYD. LINES (1.65 m)
7 CLAMP 2 44 PLUG 1 7 TUBE 1 Ø 10 (17) ARM HYD. LINES (2.07 m)
8 CLAMP 1 8 TUBE 1 Ø 10 1 HOSE : L=1000 2 — BUCKET H & R
9 CLAMP 1 (6) SWIVEL HYD. LINES (STD) 9 TUBE 1 Ø 15 2 HOSE : L=1450 — 2 BUCKET H & R
10 BUSHING 6 (7) 1 SWIVEL HYD. LINES (DOZER) 10 TUBE 1 Ø 10
11 O-RING 6 1B P18 1 CONNECTOR 4 1 PF 1/4 11 CLAMP 2 (18) ARM CYL. HYD. LINES
31102 60413252
12 CAPSCREW 4 M18 X 40 2 O-RING 3 4 1B P18 12 CLAMP 2 1 TUBE 1
13 CLAMP 1 3 ELBOW 1 3 PF 1/2 13 SPACER 2 2 HOSE : L=650 2 ARM H & R
14 WASHER 4 M8 4 CONNECTOR 2 1 PF 1/2 14 SPACER 2 3 CONNECTOR 1
15 GROMMET 2 5 CONNECTOR 1 2 PF 1/2 L=41 15 TEE 1 4 CONNECTOR 1
SWING RIGHT,
16 HOSE : L=1150 3 TRAVEL RIGHT · LEFT FORWARD 6 CONNECTOR 1 1 PF 3/8 16 TEE 1 5 O-RING 3
17 HOSE : L=1200 1 TRAVEL RIGHT FORWARD 7 TUBE — 1 17 LOCK WASHER 6 M8 6 GREASE NIPPLE 1
18 HOSE : L=1300 1 SWING LEFT 8 ELBOW 1 PF 3/8 18 WASHER 4 M8
F16778
22-34
HYDRAULIC SYSTEM
MAIN PIPING
(1) PUMP DELEVERY (STD) (2) PUMP DELEVERY (DOZER)
31102 60413252
NOTE:
Ports in ( ) indicate lower side one on the valve.
22-35
HYDRAULIC SYSTEM
(3) UPPER HYDRAULIC LINES (1 / 2)
31102 60413252
22-36
HYDRAULIC SYSTEM
UPPER HYDRAULIC LINES (2 / 2)

31102 60413252
22-37
HYDRAULIC SYSTEM
(4) RETURN HYDRAULIC LINES (STD) (1 / 2)

(5) RETURN HYDRAULIC LINES (DOZER) (1 / 2)
31102 60413252
22-38
HYDRAULIC SYSTEM
RETURN HYDRAULIC LINES (STD) (2 / 2) (6) SWIVEL HYDRAULIC LINES (STD)

RETURN HYDRAULIC LINES (DOZER, EXTRA) (2 / 2) (7) SWIVEL HYDRAULIC LINES (DOZER)
31102 60413252
22-39
HYDRAULIC SYSTEM
(8) LOWER HYDRAULIC LINES

NOTE:
1.Tightening torques for nuts and sleeves
tube size - torques:
Ø 10x1.5 - 5.0 kgf·m (36.1 lbf·ft)
Ø 15x2.0 - 12.0 kgf·m (87.0 lbf·ft)
Ø 18x2.5 - 15.0 kgf·m (108 lbf·ft)
2.Tightening torques for PF-threads
threads size - torques:
PF 1/4 - 3.7 kgf·m (26.8 lbf·ft)
PF 3/8 - 7.5 kgf·m (54.2 lbf·ft)
PF 1/2 - 11.0 kgf·m (79.7 lbf·ft)
(9) PROPEL HYDRAULIC
(10) SWIVEL HYDRAULIC LINES
SECTION AA
31102 60413252
SECTION BB SECTION 2PLACES
22-40
HYDRAULIC SYSTEM
(11) LOWER HYDRAULIC LINES (DOZER)
(TRAVEL MOTOR) (TRAVEL MOTOR)

A (UPPER) REVERSE A (UPPER) REVERSE
B (LOWER) FORWARD B (LOWER) FORWARD
(LEFT SIDE) (RIGHT SIDE)
NOTE:
Ø 10x1.5 - 5.0 kgf·m (36.1 lbf·ft)
Ø 15x2.0 - 12.0 kgf·m (87.0 lbf·ft)
Ø 18x2.5 - 15.0 kgf·m (108 lbf·ft)
2.Tightening torques for PF-threads
PF 1/4 - 3.7 kgf·m (26.8 lbf·ft)
PF 3/8 - 7.5 kgf·m (54.2 lbf·ft)
PF 1/2 - 11.0 kgf·m (79.7 lbf·ft)
(12) SWIVEL HYDRAULIC LINES (DOZER)

31102 60413252
22-41
HYDRAULIC SYSTEM
(13) BOOM HYDRAULIC LINES (15) BUCKET CYLINDER HYDRAULIC LINES
(14) BOOM CYLINDER HYDRAULIC LINES

NOTE:
1.Tightening torques for M-threads
M10 - 3.21 kgf·m (23.2 lbf·ft)
Ø 22x3.0 - 22.0 kgf·m (159 lbf·ft)
3.Tightening torques for PF.PT-threads
PF 1/8 - 1.7 kgf·m (12.3 lbf·ft)
PF 1/4 - 3.7 kgf·m (26.8 lbf·ft)
PF 1/2 - 11.0 kgf·m (79.7 lbf·ft)
4.Apply Loctite #242 at the setting bolts of clamp.
31102 60413252
22-42
HYDRAULIC SYSTEM
(16) ARM HYDRAULIC LINES (1.65 m)

NOTE:
M10 - 3.21 kgf·m (23.2 lbf·ft)
Ø 22x3.0 - 22.0 kgf·m (159 lbf·ft)
PF 1/8 - 1.7 kgf·m (12.3 lbf·ft)
PF 1/4 - 3.7 kgf·m (26.8 lbf·ft)
PF 1/2 - 11.0 kgf·m (79.7 lbf·ft)
(17) ARM HYDRAULIC LINES (2.07 m)
(18) ARM CYLINDER HYDRAULIC LINES

31102 60413252
22-43
HYDRAULIC SYSTEM
6. ADDITIONL SPECIFICATIONS
6.1 BOOM / ARM SAFETY SPECIFICATION 18 LOCK WASHER 2 M8 4 HOSE : L=500 1 PF 1/4 18 CLAMP 7
(1) VALVE CONTROL LINES 19 LOCK WASHER 2 M10 5 NUT 2 M8 19 CLAMP 1
1 HOSE : L=3300 1 PF 3/8 6 PIN 2 20 CLAMP 3
2 HOSE : L=3100 1 PF 3/8 6.2 EXTRA, N & B , DOZER SPECIFICATION 7 WASHER 6 M8 21 CLAMP 10
3 TUBE 2 (1) UPPER HYD. LINES FOR EXTRA & DOZER 8 CAPSCREW 4 M10 X 20 22 CLAMP 10
4 TUBE 2 1 CONNECTOR 1 PF 1/4, L=23 9 LOCK WASHER 4 M10 23 CAPSCREW 8 M8 X 20
6 CLIP 2 2 CONNECTOR 1 PF 1/4 10 CAPSCREW 4 M10 X 25 24 CAPSCREW 2 M10 X 20
7 CLIP 1 3 CONNECTOR 1 PF 1/2 11 WASHER 8 M10 25 CAPSCREW 11 M10 X 35
8 CAPSCREW 1 M12 X 20 4 ELBOW 1 PF 1/4 12 CONNECTOR 2 PF 1/4, L=23 26 CAPSCREW 8 M10 X 45
9 WASHER 1 M12 5 ELBOW 4 PF 1/2 13 ELBOW 7 PF 1/4 27 CAPSCREW 1
10 HOSE : L=2500 1 PF 3/8 6 TEE 1 PF 1/4 14 ELBOW 2 PF 1/4 WITH FILTER 28 NUT 1 M10
11 HOSE : L=2400 1 PF 3/8 7 TEE 1 2 - PF 1/2 - PF 1/4 15 PILOT VALVE 2 29 LOCK WASHER 8 M8
12 BRACKET 1 8 PLUG 1 PF 1/4 17 CAPSCREW 4 M8 X 20 30 LOCK WASHER 22 M10
13 PLATE 1 9 HOSE : L=300 1 PF 1/4 18 LOCK ASSY 1 R/H 31 WASHER 1 M10
14 BUSHING 1 11 HOSE : L=1600 1 PF 1/2 19 PEDAL 2
15 CAPSCREW 3 M10 X 25 12 CAPSCREW 1 M12 X 70 20 RUBBER 2 (7) ARM HYD. LINES
16 WASHER 3 M10 13 BUSHING 2 22 PRESSURE SWITCH 2 PT 1/8 1 TUBE 2
17 CLIP 3 14 WASHER 2 23 CONNECTOR 1 PF 1/4 2 TUBE 1
18 TUBE 2 L=500 15 TUBE 2 L=400 24 HOSE : L=2150 1 PF 1/4 3 TUBE 1
16 TUBE 1 L=1200 26 HOSE : L=2300 1 PF 1/4 4 TUBE 1
(2) BOOM CYL. HYD. LINES 17 CLAMP 2 28 HOSE : L=420 1 PF 1/4 5 TUBE 1
1 TUBE 1 18 HOSE : L=1800 1 PF 1/2 34 LOCK ASSY 1 L/H 6 HOSE : L=1050 2
2 TUBE 1 19 TUBE 2 L=600 43 ELBOW 1 7 HOSE : L=900 2
3 TUBE 1 20 HOSE : L=1550 1 PF 1/2 44 CONNECTOR 1 PF 1/4, L=38 8 STOP VALVE 2 Ø 22 - PF 3/4
4 HOLDING VALVE 1 21 HOSE : L=500 1 PF 3/8 45 CONNECTOR 2 PF 1/4 - PT 1/8 9 CONNECTOR 2 3 - Ø 15
5 BAND 1 22 HOSE : L=580 1 PF 3/8 46 PLUG 2 PF 1/4 10 TEE 2 Ø 15
6 BAND 1 23 CONNECTOR 2 PF 1/2, L=32 47 HOSE : L=2800 1 PF 1/4 11 PULG 2 Ø 15
7 CONNECTOR 7 M30 X 1.5 - PF 1/2 24 ELBOW 2 PF 1/2 12 PLUG 2
8 CONNECTOR 1 25 CONNECTOR 2 PF 1/2, L=55 (5) BLOCK CONTROL LINES 13 NUT 2 1B P24
9 ELBOW 1 PF 1/4 - PF 3/8 26 CONNECTOR 2 PF 1/2 - PF 3/8 1 BLOCK 1 14 O-RING 2
10 ELBOW 1 M30 X 1.5 - PF1/2 27 HOSE GUARD 2 L=1000 2 CONNECTOR 1 PF 3/8 15 CLAMP 1
11 ELBOW 1 PF 1/4 - PF 3/8 28 NUT 1 M12 3 ELBOW 3 PF 3/8 16 CLAMP 2 M8 X 25
12 PLUG 1 PF 1/4 4 ELBOW 3 PF 1/4 17 CAPSCREW 8 M8 X 40
13 O-RING 4 1B P18 (2) UPPER HYD. LINES FOR N & B 5 CAPSCREW 2 M8 X 40 18 CAPSCREW 1 M10 X 45
14 GREASE NIPPLE 1 PT 1/8 1 CONNECTOR 1 Ø 18 - PF 1/2 6 WASHER 2 M8 19 CAPSCREW 2 M8
15 GREASE NIPPLE 1 PT 1/8 2 CONNECTOR 1 Ø 18 - PF 1/2 7 TEE 1 PF 3/8 20 LOCK WASHER 9 M10
16 CLAMP 2 3 O-RING 1 1B P18 8 CONNECTOR 2 PF 1/4 21 LOCK WASHER 2
17 CAPSCREW 2 M8 X 50 4 BUSHING 2 10 ELBOW 1 PF 3/8
18 CAPSCREW 2 M10 X 35 5 ROD BOLT 1 M12, L=240 11 ELBOW 2 PF 3/8 - PF 1/4
19 CAPSCREW 2 M10 X 50 6 WASHER 1 M12 12 CONNECTOR 1 PF 1/4, L=23
20 LOCK WASHER 2 M8 7 NUT 6 M12 14 ELBOW 1 PF 3/8
21 LOCK WASHER 4 M10 8 HOSE : L=2500 1 Ø 18 15 TEE 1 PF 1/4
9 CLAMP 2 16 CONNECTOR 1 PF 3/8
(3) ARM CYL. HYD. LINES 10 HOSE : L=2650 1 Ø 18
1 TUBE 1 Ø 22 X t3 (6) BOOM HYD. LINES
2 TUBE 1 Ø 22 X t3 (3) RETURN HYD. LINES 1 TUBE 1 Ø 22 X t3
3 TUBE 1 Ø 22 X t3 3 TUBE 1 Ø 31.8 2 TUBE 1 Ø 22 X t3
4 HOSE : L=650 2 9 CONNECTOR 2 PF 1/2 3 TUBE 1 Ø 22 X t3
5 HOLDING VALVE 1 12 ELBOW 1 PF 3/4 4 TUBE 1 Ø 22 X t3
6 BAND 1 16 HOSE GUARD 1 L=1000 5 TUBE 1 Ø 15 X t2
7 BAND 1 26 HOSE : L=3000 1 PF 3/4 6 TUBE 1 Ø 15 X t2
8 CONNECTOR 2 M30 X 1.5 - PF 1/2 27 BUSHING 1 7 SELECTOR VALVE 1
9 CONNECTOR 1 M30 X 1.5 - M30 X 1.5 29 CLIP 1 8 SUPPORT 1
10 CONNECTOR 1 PF 1/4 - PF 3/8 35 GROMMET 1 9 BRACKET 1
31102 60413252
11 CONNECTOR 1 PT 1/4 - PF 1/4 37 TUBE 1 L=1100 11 CONNECTOR 2 PF 1/2 - PF 3/8
12 CONNECTOR 1 2 - PF 1/4 40 BUSHING 1 12 CONNECTOR 2 PF 3/8 - M22 X 1.5
13 ELBOW 1 PF 1/4 - PF 3/8 45 HOSE : L=1450 1 PF 1/2 13 CONNECTOR 1 PF 3/4 - M30 X 1.5
14 O-RING 5 14 ELBOW 2 PF 3/4 - M30 X 1.5
15 GREASE NIPPLE 1 PT 1/8 (4) EXTRA REMOTE CONTROL LINES 15 O-RING 2 1B P14
16 CAPSCREW 2 M8 X 50 2 HOSE : L=2000 1 PF 1/4 16 O-RING 3 1B P24
17 CAPSCREW 2 M10 X 35 3 HOSE : L=400 2 PF 1/4 17 PLUG 2 PF 3/4
F16793
22-44
HYDRAULIC SYSTEM
6.1 BOOM / ARM SAFETY SPECIFICATION

(1) VALVE CONTROL LINES
31102 60413252
22-45
HYDRAULIC SYSTEM
(2) BOOM CYLINDER HYDRAULIC LINES (3) ARM CYLINDER HYDRAULIC LINES
NOTE:
M8 - 3.4 kgf·m (24.6 lbf·ft)
M10 - 3.21 kgf·m (23.2 lbf·ft)
Ø 22x3.0 - 22.0 kgf·m (159 lbf·ft)
31102 60413252
PF 1/8 - 1.7 kgf·m (12.3 lbf·ft)
PF 1/4 - 3.7 kgf·m (26.8 lbf·ft)
PF 3/8 - 7.5 kgf·m (54.2 lbf·ft)
PF 1/2 - 11.0 kgf·m (79.7 lbf·ft)
22-46
HYDRAULIC SYSTEM
6.2 EXTRA, N AND B, DOZER SPECIFICATION (2) UPPER HYDRAULIC LINES - FOR N AND B
(1) UPPER HYDRAULIC LINES - FOR EXTRA AND DOZER
NOTE:
Ports in ( ) indicate lower side one on the control valve.
31102 60413252
22-47
HYDRAULIC SYSTEM
(3) RETURN HYDRAULIC LINES (4) REMOTE CONTROL LINES
31102 60413252
NOTE:
Ports in ( ) indicate lower side one on the valve.
22-48
HYDRAULIC SYSTEM
(5) BLOCK CONTROL LINES

31102 60413252
22-49
HYDRAULIC SYSTEM
(6) BOOM HYDRAULIC LINES NOTE:

M8 - 3.4 kgf·m (24.6 lbf·ft)
M10 - 6.7 kgf·m (48.5 lbf·ft)
Ø 15x2.0 - 12.0 kgf·m (87 lbf·ft)
Ø 22x3.0 - 22.0 kgf·m (159 lbf·ft)
PF 3/8 - 7.5 kgf·m (54.2 lbf·ft)
PF 3/4 - 16.5 kgf·m (119 lbf·ft)
31102 60413252
22-50
HYDRAULIC SYSTEM
(7) ARM HYDRAULIC LINES

NOTE:
M8 - 3.4 kgf·m (24.6 lbf·ft)
M10 - 6.7 kgf·m (48.5 lbf·ft)
Ø 15x2.0 - 12.0 kgf·m (87 lbf·ft)
Ø 22x3.0 - 22.0 kgf·m (159 lbf·ft)
PF 3/8 - 7.5 kgf·m (54.2 lbf·ft)
PF 3/4 - 16.5 kgf·m (119 lbf·ft)
31102 60413252
22-51
HYDRAULIC SYSTEM
NOTE
31102 60413252
22-52
SECTION 23 ELECTRICAL SYSTEM
TABLE OF CONTENTS
1. Electric circuit ........................................................................................................ 23-1
2. Harness ................................................................................................................ 23-5

2.1 Harness and cable list .................................................................................................................... 23-5
2.2 Harness connection drawing .......................................................................................................... 23-6
2.3 Controller assy ............................................................................................................................... 23-7
2.4 Instrument panel assy .................................................................................................................. 23-11
2.5 Upper electric assy ...................................................................................................................... 23-12
2.6 Upper harness assy ..................................................................................................................... 23-14
2.7 Engine harness assy .................................................................................................................... 23-21
2.8 Floor plate harness ...................................................................................................................... 23-23
2.9 Cab harness assy ........................................................................................................................ 23-25
2.10 Battery ........................................................................................................................................ 23-30
2.11 Cab assy .................................................................................................................................... 23-31
2.12 Mounting cab .............................................................................................................................. 23-33
2.13 Mounting light ............................................................................................................................. 23-33
2.14 Mounting boom light ................................................................................................................... 23-33
2.15 Mounting cab work light ............................................................................................................. 23-34
2.16 Air conditioner ............................................................................................................................ 23-36
2.17 Mounting fuel pump .................................................................................................................... 23-37
31102 60413252
ELECTRICAL SYSTEM
1. ELECTRIC CIRCUIT
3 CIGARETTE LIGHTER
1 CONTROLLER
2 WASHER RELAY
930 WR (5V)
9 CONVERTER
14-7
MECHATRO
8 FUEL PUMP
SE-16:ACCEL POTENTIO 530 P 14-8
10 KEY SW.
970 BW (GND) 14-9 C-1:MECHATRO CONTROLLER
4 TUNER
5 HORN
WIPER
PRESS. SENSOR(LOW) 900 RB (5V) 851 GREEN A PHASE
12-15 14-1
SE-1:BUCKET DIGGING 500 LgR 12-14 852 BLACK
14-2
950 BrR(GND) 12-13 853 RED B PHASE M M-2:GOVERNOR MOTOR
14-12
WG
WV
WV
WY
RY
OL
YB
RL
1.25
1.25
E-1:FUSE BOX 901 RL (5V) 854 WHITE
13-3 14-13
501 LgW SHIELD
SE-2:BUCKET DUMP 13-2 14-3
10A
10A
10A
20A
560 V
20A
10A
B
10A
10A
951 BL (GND) 13-1 14-14
51 1.25W 52 5R 902 W (5V)
50 1.25L 12-3
53 5Y 502 LgY N L E
SE-3:BOOM RAISING 12-2
TIO A AS
10A
10A
20A
10A
20A
30A
20A
10A
20A
8 952 BR (GND) 12-1 S I RM L E
TERMINAL
P O NO R E
903 OB (5V) C-2: SW-4:
1.25B
12-4
WG
WORK LIGHT 16 1.25
CAB WORK LIGHT 17 1.25

GAUGE CLUSTER
RW
WIPER,WASHER 14 1.25
1.25
1.25
WR
WB
SWING PARKING BRAKE RELEASE SW.
WL
RB
503 LO
RL
W
SE-4:BOOM LOWERING 12-5
O
E
953 BrW(GND) 12-6 561 Lg
TRAVEL ALARM 11
GAUGE CLUSTER 13
SOLENOID 15
AIR CON.HEATER 18
AIR CON. 19
RESERVE 20
5 3 B
701 PB SV-1:
904 OL (5V) 12-9
2 SWING PARKING BRAKE SOL.
11-2 700 V 1
504 PG 12-8
SE-7:ARM IN
954 BrY(GND) 12-7 702 LgB
60A 60A 4 C-2:GAUGE CLUSTER
E-14: E-14: 905 OW (5V)
BATTERY BATTERY 12-10 702 LgB B
505 PL 11-14 SV-3:TWO-SPEED SELECT SOL.
B A 60B 60B 60B SE-8:ARM OUT 12-11
955 Gr (GND) 12-12
B 753 GB
B 906 YB (5V) 11-12 PSV-C:
13-4 754 GrB TRAVEL PRIORITY PROPOTIONAL SOL.
SW-1: L 506 V 11-25
SE-6:SWING RIGHT 13-5
STARTER KEY SW. 956 GrL(GND) 13-6
ION ATING 755 BP
POSIT
PREHE R-1:BATTERY RELAY 11-13
TERMINAL
D-3 PSV-D:
S 60 GrL 70 G 907 YG (5V) 13-9 756 PW P1 BY-PASS CUT PROPOTIONAL SOL.
O A O T 11-26
F C A
SE-5:SWING LEFT 507 VG 13-8
R D-1
F C N 60 GrL 957 Br (GND) 751 BO
60B
10 1.25WV
T R-3:GLOW RELAY 13-7 11-11
10 B PSV-B:
908 YL (5V) 13-10 752 GrR P2 BY-PASS CUT PROPOTIONAL SOL.
ACC 53 5Y 66 5W 11-24
61 0.5BrY C-2: GLOW 508 VY 13-11
M 3 GAUGE B SE-9:TRAVEL RIGHT
61 BrY 958 BY (GND) 13-12
G1 D-2 CLUSTER
G2 62 GrB D-5 909 YR (5V)
62 GrB 14-6
ST 63 WY M 509 Sb
60B B E M-1: SE-10:TRAVEL LEFT 14-5
M 959 BG (GND) 14-4
STARTER MOTOR
R-4:SAFETY RELAY S
65
63 WY 38 5BW
5L
S C 550 O
65 5L 5B SW-7:ENG.OIL PRESS.SW. 2 11-10
B B E ENG. OIL PRESS.
1.1kΩ R SW-30:
R 110 Br B
E-2:ALTERNATOR AUTO ACCEL RELEASE SW.
E B L SV-2: 94 G
DOUBLE·SINGLE 6
651 WR
3.6kΩ SELECT SOL.
64 GW
SW-18:OPT. PEDAL PRESS. SWICH 1

B D-4
94 G 556 LO 12-16
C-2:GAUGE CLUSTER 651 WR B
H·M
85 0.5WB ILLUMINATION E-3:HOUR METER SW-19:OPT.PEDAL PRESS.SWICH 2
R-8:WORK LIGHT RELAY 1 B
13 0.5W
13
SW-21:OPT.PEDAL PRESS.SWICH 3 SW-2:SWITCH ASSY
C-1:MECHATRO CONTROLLER 2 CHARGE 651 0.5WR B
G 5V MODE(H)
11-3 940
550 0.5O ENG. OIL PRESS. MODE(S)
SW-7:ENG. OIL PRESS. SW. 603 LgR DI1
OPTION 11-5
552 0.5GB ENG. WATER TEMP. 604 LG DI2 MODE(FC)
SW-6:ENG. WATER TEMP. SW. 11-6
COOLANT THERMO INDICATOR 605 VG DI3
537 0.5YR 11-7 BUZZER STOP
SE-14:COOLANT THERMO SENSOR DI4
B 551 0.5BrL AIR CLEANER 606 BrW DO1 LIGHT
SW-8:AIR FILTER RESTRICTION SW. 11-4
FUEL LEVEL 857 WG 607 GW GND WIPER
553 0.5BrB 11-1 11-9
FUEL METER WASHER
SE-15:FUEL SENSOR B 536 0.5BrR KEY ON 60 GrL 11-15
61 0.5BrY GLOW WB 85 B
SW-1:STARTER KEY SW. 3 B 559 PL 14-10 7
SW-3:TWO-SPEED SELECT SW.
702 0.5LgB TRAVEL TWO-SPEED R-8: BACK LIGHT
C-1:MECHATRO CONTROLLER 4 WORK LIGHT RELAY
0.5B 534 BL 14-19
SE-13:ENG. SPEED SENSOR 535 W 14-20
561 0.5Lg SWING PARKING SHIELD
SW-4:SWING PARKING BRAKE 5 14-21
RELEASE SW.
CPU ALLERGY 859 0.5G 11-23
B 555 OW 557 GrB OVERLOAD 860 0.5Br

31102 60413252
11-8
SW-24:OVERLOAD SW. SW-28:OVERLOAD INDICATE SW.
ONLY KCME 861 0.5LO 14-17

862 0.5L MODE
H S FC 14-18
1 1.25RY 14-11
1
TO 2/3
E 1.25B
CONTROLLER EARTH 8 14-22
Fig. 1 (1 / 4) F16800
23-1
ELECTRICAL SYSTEM
SW-15:ROOF WIPER SW.

POSITION
TERMINAL
O O M-8:ROOF WIPER MOTOR
F
N F
98 LB R-8:WORK LIGHT RELAY
99 LW B
14 RB M 16 1.25RW 16 85 1.25WB 85 B
C-1:MECHATRO CONTOLLER 16 L-1:BOOM WORKING LIGHT LEFT
14 RB 16 802 BrY 85 B
OPTION 10 L-2:WORKING LIGHT RIGHT
WORKING
FROM 1/3 14 RB LIGHT ON C-1:
MECHATRO 85 B
R-5: L-1:BOOM WORKING LIGHT RIGHT
CONTROLLER
WIPER MOTOR RELAY 80 LY KCME STD SPEC.
85 C-4:AIR CONDITIONER AMP.
11
14 1.25RB 81 BrB M
B 85
14 M-3:WIPER MOTOR 1 C-2:GAUGE CLUSTER
2 WY
2 85 SW-2:SWITCH ASSY
SW-23: 7
WIPER INTERLOCK SW.
11-19 800 GB 800 GB 180 OL R-10:CAB WORK LIGHT RELAY

R-9: 17 1.25WL 17 179 1.25L 179 B
9 WIPER RELAY ASSY R-6: 17 L-4:CAB WORKING LIGHT(FRONT)
WINDOW WASHER MOTOR RELAY 17 185 LY B 179 B
L-5:CAB WORKING LIGHT(FRONT)
14 RB 82 GO M
B SW-16:WORK LIGHT SW.(OPT) 179 B
14 M-4:WINDOW WASHER MOTOR L-9:CAB WORKING LIGHT(REAR)
2 WY
2
KCMA OPTION
11-21 801 GrL
11-22 802 BrY

10 R-8:WORK LIGHT RELAY
R-10:CAB WORK LIGHT RELAY
17 17 1.25WL 179 1.25L 179 B
17 L-4:CAB WORKING LIGHT(FRONT 1)
17 WL 185 LY B 179 B
L-5:CAB WORKING LIGHT(FRONT 2)
SW-16: 179 B
WORK LIGHT SW.(OPT) L-6:CAB WORKING LIGHT(FRONT 3)
17 1.25WL 191 1.25LR 191 B

L-8:CAB WORKING LIGHT(FRONT 4)
17 WL 191 B
L-9:CAB WORKING LIGHT(REAR)
KCMA ONLY
R-13:CAB WORK LIGHT RELAY
O 188 PG
11 E-13:
WY TRAVEL ALARM
2 KCME ONLY
R-11: B
717 BP TRAVEL ALARM RELAY
11-18
L-3:ROOM LIGHT
9 YB
9
R-20:TIMER SV-4:LEVER LOCK SOL.
15 WB 87 WL E D 86 OW B
15
SW-11:LEVER LOCK SW.
3 RL 1.25B
3 E-6:CIGARETTE LIGHTER
A B
TIMER
14-15
15 WB 100 LY 94 G SW-18:OPT. PEDAL PRESS.

15 6 SWITCH 1
SW-17:DOUBLE·SINGLE
SELECT SW. SV-2:DOUBLE·SINGLE SELECT SOL.
E-16:HYD.FLUID TEMP.ALARM LAMP SW-25:HYD.FLUID TEMP.SW.

R-7:HORN RELAY
13 W 563 O B
13
5 WG 5 83 WL B
5 E-5:HORN
5 84 WB B
KCMA OPTION
31102 60413252
SW-10:HORN SW.(LEFT) F16801
84 WB B
SW-20:HORN SW.(RIGHT)
OPT
Fig. 1 (2 / 4)
23-2
ELECTRICAL SYSTEM
E-17:CONVERTER
E-10: E-11:
4 OL 96 WG RECEIVER DRIER AIR COMMPRESSOR CLUTCH
4 IGN 12V E-15:SOCKET
DC-DC CONVERTER R-8: 85 WB C-4 92 BP 93 LW
9 YB 97 YV WORK LIGHT 11 ANT. E-7:TUNER AM&FM
9 24V MEM
B RELAY
B 2(+) E-9:SPEAKER RIGHT
GND 6(- )
18 1.25WG FM/AM
18 B
4 OL 1(+)
KCME ONLY 19 RL 4 3 E-8:SPEAKER LEFT
19 AIR 5(- )
CONDITIONER SW-13:AIR CONDITIONER SW. 9 YB (BACK UP) B
4 8 7
AMP.
24V 181 R 24V 6
ANT. E-7:TUNER AM&FM
TXD 182 G
RXD
RXD 183 W
1(+) 101 LW TXD
102 Br E-8:SPEAKER LEFT 184 B
7(-) COOLING GND
FM/AM UNIT KCMA OPTION
96 WG 4 103 LR
2(+) E-9:SPEAKER RIGHT
104 OB
97 YV (BACK UP) 11 8(-)
B
9
NOTE:
KCME ONLY R-21:BREAKER RELAY
1.Wires used to be:
M-9:FUEL PUMP SV-5:BREAKER SOL
10A
1) “AVS” or “AVS” for 0.75 mm2 and 1.25 mm2
8 1.25WV B R-24:CRUSHER OPEN RELAY SV-9:CRUSHER OPEN SOL.
8 M 2) “AVS” 2 mm2, 5 mm2
WR 223 YG B 3) “AV” for others.
20
262 LY B
2.Wires to be 0.75 mm2 unles otherwise specified.
SW-45:BREAKER SW. 3.Grounding for which wire color is not shown to be
SW-27: L-7: SW-48:CRUSHER OPEN SW. performed with component case.
ENGINE ROOM LIGHT SW. ENGINE ROOM LIGHT
9 YB R B 4.Number in square shows line No.
9 KCMA OPTION
HAND CONTROL FOR BREAKER
OR CRUSHER OPEN
SW-29: L-10: WIRE COLOR CODING TABLE

ROTARY LIGHT SW. ROTARY LIGH
17 WL 189 YR B Sign Color Sign Color Sign Color Sign Color
17
R-25: SV-10:
CRUSHER CLOSE RELAY CRUSHER CLOSE SOL.
WR 240 LW B B Black W White Br Brown V Violet
20
982 BG B
120 YG SW-49:CRUSHER CLOSE SW. G Green Y Yellow Lg Light Green

SV-6:CLOCKWISE SOL.
WR 121 O B
20 L
122 LO B Blue P Pink Gr Gray
SW-46:CLOCKWISE SW.
R-22:CLOCKWISE RELAY KCMA OPTION
HAND CONTROL R Red O Orange Sb Sky Blue
123 GR SV-7: FOR CRUSHER CLOSE
COUNTERCLOCKWISE SOL. F16802
124 GrL B
125 WG B
SW-47:COUNTERCLOCKWISE SW.
R-23:COUNTERCLOCKWISE RELAY
KCMA OPTION
31102 60413252
HAND CONTROL FOR ROTATION
Fig. 1 (3 / 4)
23-3
ELECTRICAL SYSTEM
Electric equipment list
GROUP CODE NAME GROUP CODE NAME GROUP CODE NAME
PROPORTIONAL
C-1 MECHATRO CONTROLLER M-1 STARTER MOTOR PSV-B P2 BY-PASS CUT PROPOTIONAL SOL.
CONTROLLER
C-1 MECHATRO CONTROLLER M-2 GOVERNOR MOTOR PSV-C TRAVEL PRIORITY PROPOTIONAL SOL.
VALVE
MOTOR
C-2 GAUGE CLUSTER M-3 WIPER MOTOR PSV-D P1 BY-PASS CUT PROPOTIONAL SOL.
C-2 GAUGE CLUSTER M-4 WASHER MOTOR
C-4 AIR CONDITIONER CONTROLLER M-8 ROOF WIPER MOTOR (OPT.)
M-9 FUEL PUMP SW-1 KEY SWITCH
R-1 BATTERY RELAY SW-2 SWITCH ASSY
D-1 DIODE R-3 GLOW RELAY SW-3 TWO-SPEED SELECT SWITCH
D-2 R-4 SAFETY RELAY SW-4 SWING PARKING RELEASE SWITCH
D-3 R-5 WIPER MOTOR RELAY SW-6 ENG. WATER TEMPERATURE SWITCH
DIODE
D-4 R-6 WASHER MOTOR RELAY SW-7 ENG. OIL PRESS SWITCH
D-5 R-7 HONE RELAY SW-8 AIR FILTER ALARM SWITCH
R-8 WORK LIGHT RELAY SW-10 HORN SWITCH (LEFT)
RELAY
R-10 CAB WORK LIGHT RELAY SW-10 HORN SWITCH (LEFT)
E-1 FUSE BOX R-11 TRAVEL ALARM RELAY SW-11 LEVER LOCK SWITCH
E-2 ALTERNATOR R-13 CAB WORK LIGHT RELAY 2 SW-13 AIR CONDITIONER SWITCH
E-3 HOUR METER R-20 TIMER SW-15 ROOF WIPER SWITCH (OPT.)
E-5 HORN R-21 BREAKER RELAY (OPT.) SW-16 WORK LIGHT SWITCH (OPT.)
SWITCH
E-6 CIGALETTE LIGHTER R-22 CLOCKWISE RELAY (OPT.) SW-17 DOUBLE·SINGLE SELECT SWITCH
E-7 TUNER AM & FM R-23 COUNTERCLOCKWISE RELAY (OPT.) SW-18 OPT. PEDAL PRESSURE SWITCH ASSY 1
ELECTRIC FITTINGS
E-7 TUNER AM & FM R-24 CRUSHER OPEN RELAY (OPT.) SW-19 OPT. PEDAL PRESSURE SWITCH ASSY 2
E-8 SPEAKER LEFT R-25 CRUSHER CLOSE RELAY (OPT.) SW-20 HORN SWITCH (RIGHT) (OPT.)
E-9 SPEAKER RIGHT SE-1 PRESSURE SENSOR (LOW) : BUCKET DIGGING SW-21 OPT. PEDAL PRESSURE SWITCH ASSY 3
E-10 RECEIVER DRIER SE-2 PRESSURE SENSOR (LOW) : BUCKET DUMP SW-23 WIPER INTERLOCK SWITCH
E-11 AIR COMMPRESSOR CLUTCH SE-3 PRESSURE SENSOR (LOW) : BOOM UP SW-24 OVER LOAD SWITCH
E-13 TRAVEL ALARM SE-4 PRESSURE SENSOR (LOW) : BOOM DOWN SW-25 HYD. FLUID TEMPERATURE SWITCH
E-14 BATTERY SE-5 PRESSURE SENSOR (LOW) : SWING LEFT SW-27 ENGINE ROOM LIGHT SWITCH
E-15 POWER SOCKET SE-6 PRESSURE SENSOR (LOW) : SWING RIGHT SW-28 OVERLDAD INDICATE SWITCH
SENSOR
E-16 HYD.FLUID TEMPERATURE ALARM LAMP SE-7 PRESSURE SENSOR (LOW) : ARM IN SW-29 ROTARY LIGHT SWITCH
E-17 CONVERTER SE-8 PRESSURE SENSOR (LOW) : ARM OUT SW-30 AUTO ACCEL RELEASE SWITCH
SE-9 PRESSURE SENSOR (LOW) : TRAVEL RIGHT SW-45 BREAKER SWITCH
SE-10 PRESSURE SENSOR (LOW) : TRAVEL LEFT SW-46 CLOCKWISE SWITCH
SE-13 E/G SPEED SENSOR SW-47 COUNTERCLOCKWISE SWITCH
L-1 BOOM WORKING LIGHT LEFT SE-14 E/G WATER TEMPERATURE SENSOR SW-48 CRUSHER OPEN SWITCH
L-1 BOOM WORKING LIGHT RIGHT SE-15 FUEL SENSOR SW-49 CRUSHER CLOSE SSWITCH
F16803
L-2 WORKING LIGHT RIGHT SE-16 ACCEL POTENTIO METER
L-3 ROOM LIGHT SV-1 SWING PARKING BRAKE SOL.
L-4 CAB WORKING LIGHT FRONT (OPT.) SV-2 DOUBLE·SINGLE SELECT SOL. (OPT.)
SOLENOID VALVE
LIGHT
L-5 CAB WORKING LIGHT FRONT (OPT.) SV-3 TWO-SPEED SELECT SOL.
L-6 CAB WORKING LIGHT (FRONT 3) SV-4 LEVER LOCK SOL.
L-7 ENGINE ROOM LIGHT SV-5 BREAKER SOL.
L-8 CAB WORKING LIGHT (FRONT 4) SV-6 CLOCKWISE SOL.
31102 60413252
L-9 CAB WORKING LIGHT (REAR) SV-7 COUNTERCLOCKWISE SOL.
L-10 ROTARY LIGHT SV-9 CRUSHER OPEN SOL.
SV-10 CRUSHER CLOSE SOL.
Fig. 1 (4 / 4)
23-4
ELECTRICAL SYSTEM
2. HARNESS
2.1 HARNESS AND CABLE LIST
INDEX No. DWG. No. HARNESS

KCME
Device Item Name No. Name
2.3 Controller assy 17-7-1 Harness

19-5-1 Harness
18-7-1 Harness
2.4 Instrument panel assy
2.5 Upper electric assy 10 Harness

Upper frame
2.6 Upper harness assy 1 Starter cable

2 Battery relay cable
3 Battery cable
4 Battery ground cable
5 Right guard harness
6 Main harness
8 Frame ground cable
2.7 E/G Harness 1 E/G Sub harness
2.8 Floor plate harness assy 1 Harness
3 Cable
2.9 Cab harness assy 1 or 9 Left instrument panel harness
2 Right instrument panel harness
3 Cab right front harness
2.10 Battery
2.11 Cab 2-37 Wiper harness

Cab
61 Curl code harness

64 Cab harness
65 Antenna
189 Room lamp harness
2.12 Mounting cab

2.13 Mounting deck light
2.14 Mounting boom work light 2 Boom light Harness
Light
2.15 Mounting cab work light 7 Tow light harness

9 Cab work light harness
12 Tow light harness
18 Fore light harness
31102 60413252
2.16 A/C Conditioner

Upper A/C
frame
2.17 Mounting fuel pump
F16808
23-5
ELECTRICAL SYSTEM
2.2 HARNESS CONNECTION DRAWING
MECHATRO CONTROLLER
GOVERNOR MOTOR (INNER LS)
HORN SW. (L.H)
SWING PARKING SOL.

TRAVEL 1·2-SPEED SOL.
LEVER LOCK SOL.
PEDAL PRESSURE SW. 1 (OPT.)
TRAVEL 1·2-SPEED SW.
HYD. FLUID TEMP. SW. (KCMA OPT)
SW. ASSY (BACK LIGHT)

HOUR METER
HORN
CIGAR LIGHTER
GAUGE CLUSTER
A/C AMPLIFIER (CONTROLLER)
STARTER MOTOR
WORK LIGHT SW. (OPT.)
ALTERNATOR
FUEL SENSOR
ENGINE WATER TEMP. SENSOR
WIPER MOTOR ON THE ROOF (OPT.)
ENGINE WATER TEMP. SW.
FUEL PUMP (OPT.)
ENGINE OIL TEMP. SW.
WIPER MOTOR
SAFETY RELAY
WASHER MOTOR
A/C CLUTCH
AIR FILTER CLOGGING SW.
GLOW PLUG
WIPER RELAY ASSY (OPT.)
HORN SW. (R.H) (OPT.)
WORK LIGHT (R.H)
BATTERY RELAY
GLOW RELAY POWER SOCKET
OVERLOAD INDICATE SW. (KCME) TUNER AM / FM
31102 60413252
TRAVEL ALARM (KCMA) CAB WORK LIGHT (KCMA OPT.)
ENGINE ROOM LIGHT SW. (KCME) CAB WORK LIGHT (KCME OPT.)
AUTO ACCEL RELEASE SW. ROTARY LIGHT (KCME OPT.)
TIMER ROOM LIGHT
HYD.FLUID TEMP. ALARM LAMP (KCMA OPT) DC/DC CONVERTER
F16809
23-6
ELECTRICAL SYSTEM
2.3 CONTROLLER ASSY
CONTROLLER ASSY
No. Name Q'ty
2 CONTROLLER —
7 SWITCH ASSY 1
8 RELAY 4
17 CAB HARNESS ASSY 1
17-7-1 INSTRUMENT PANEL HARNESS —
17-7-2 FUSE 1
18 CAB HARNESS ASSY —
18-7-1 INSTRUMENT PANEL HARNESS 1
18-7-2 FUSE 1
19 CAB HARNESS ASSY 1
19-5-1 INSTRUMENT PANEL HARNESS —
20 CONTROLLER —
21 CONTROLLER 1
F16811
31102 60413252
Fig. 2 Controller assy
23-7
ELECTRICAL SYSTEM
2.3-18-7-1 Instrument panel harness (1 / 3)
31102 60413252
Fig. 3 (1 / 3) Instrument panel harness
23-8
ELECTRICAL SYSTEM

31102 60413252
23-9
ELECTRICAL SYSTEM
31102 60413252
23-10
ELECTRICAL SYSTEM
2.4 INSTRUMENT PANEL ASSY
INSTRUMENT PANEL ASSY

No. Name Q'ty
1 R/H PANEL ASSY 1
1-2 ACCEL POTENTIO DIAL 1
1-3 KYE SWITCH 1
1-4 MODE SELECT SWITCH 1
11 SPEAKER 2
15 COVER ASSY 1
15-4 CIGALETTE LIGHTER 1
17 GAUGE CLUSTER 1
21 AUTO ACCEL RELEASE SWITCH 1
22 GAUGE CLUSTER –
26 DC-DC CONVERTER 1
38 SOCKET 1
40 OVERLOAD INDICATE SWITCH 1
41 ROTARY LIGHT SWITCH 1
43 TUNER –
44 ANTENNA 1
46 HOUR METER 1
F16753
31102 60413252
Fig. 4 Instrument panel harness
23-11
ELECTRICAL SYSTEM
2.5 UPPER ELECTRIC ASSY (1 / 2)
TO RIGHT GUARD 1FY-305 GLOW RELAY

UPPER ELECTRIC ASSY CLIP CONNECTOR TO THE BRACKET
RUBBER HARNESS 5Y (YELLOW)
No. Name Q'ty 1 GROW RELW
2FA-CNA
1 BATTERY RELAY 1 5W (WHITE)
2 PLACES 2 PLACES
2 HORN 1 SEMS-BOLT TIGHTENING
TIGHTENING TORQUE:
8 E/G ROOM LIGHT 1 TORQUE: 0.45 kgf·m (3.25 lbf·ft)
9 SWITCH 1 1.1 kgf·m (7.89 lbf·ft)
10 HARNESS 1
CABLE OF BATTERY~
11 ALARM ASSY — BATTERY RELAY
F16772
CLIP VIEW I
1
BATTERY
RELAY
CURRENT DIRECTION
A1 A B B1
TO MAIN HARNESS
FLW FLW
TO STARTER MOTOR 2.0 2.0
2
HORN
FRAME GROUND BRACKET GROUND

DATAIL OF BATTERY RELAY CIRCUIT DIAGRAM
TERMINAL A
TERMINAL B FLW 2.0
FIX THE RUBBER WITH THS HOLD
FLW 2.0
SEALING YAZAKI
7157-3580-60
REAR HOLDER YAZAKI
7157-6801-30
F TERMINAL YAZAKI
7116-3251
FIXING FHOUSING YAZAKI
RUBBER 7123-4220-30
STAMP PART NO. IV
2 L TERMINAL
TIGHTENING
TORQUE: GROUND
AVS1.25B TERMINAL B2 AVS1.25L
1.1 kgf·m (7.89 lbf·ft) AVS1.25G
HARNESS TO BE CONNECTED NOT
TO INTERFERE WITH FUEL TANK. FIX THE RUBBER AS DRAWING TERMINAL L SEAL AMP
WITH BATTERY RELAY
CN-152F 172888-2
CONNECT AS SHOWN SO AS TO AVOID TARMINAL AMP
SHORT CIRCUIT ON POWER SOURCE SIDE DATAIL OF FIXING THE RUBBER TERMINAL A1 LOCK 17166-1
31102 60413252
RETAINER AMP
HORN TO BE INSTALLED NOT TO 1-174360-1
INTERFERE WITH FRAME AND FUEL TANK. HOUSING AMP
174359-2
TERMINAL B2
TERMINAL B1 GROUND
VIEW II
CN-150M
VIEW III (DETAIL OF HORN)
Fig. 5 (1 / 2) Upper electric assy VIEW IV VIEW V
23-12
ELECTRICAL SYSTEM
2.5 UPPER ELECTRIC ASSY (2 / 2)
2.5-10 E/G room light harness

31102 60413252
Fig. 5 (2 / 2) Upper electric assy
23-13
ELECTRICAL SYSTEM
2.6 UPPER HARNESS ASSY (1 / 4)
UPPER HARNESS ASSY

No. Name Q'ty
1 STARTER CABLE 1
2 BATTERY RELAY CABLE 1
3 BATTERY CABLE 1
4 BATTERY GROUND CABLE 1
5 RIGHT GUARD HARNESS 1
6 MAIN HARNESS 1
8 FRAME GROUND CABLE 1
F16774
31102 60413252
Fig. 6 (1 / 4) Upper harness assy
23-14
ELECTRICAL SYSTEM

31102 60413252
23-15
ELECTRICAL SYSTEM
31102 60413252
23-16
ELECTRICAL SYSTEM

31102 60413252
23-17
ELECTRICAL SYSTEM
2.6-6 Main harness (1 / 2)
31102 60413252
Fig. 7 (1 / 2) Main harness
23-18
ELECTRICAL SYSTEM
2.6-6 Main harness (2 / 2)

31102 60413252
Fig. 7 (2 / 2) Main harness
23-19
ELECTRICAL SYSTEM
2.6-1 Starter cable 2.6-4 Battery ground cable
3420 (11´3˝) 400 (15.7)

TERMINAL TERMINAL
BB708 BB708
60 sq INSTALL 40
CORRUGATE TUBE (1.57˝)
INSTALL
CORRUGATE 150
WHITE TAPING CAP
CAP (5.91˝) YAZAKI
YAZAKI TO OLTERNATOR 7034-1283 AV60B TERMINAL
7034-1283 TERMINAL DOUBLE-WOUND
STARTER MOTOR SIDE TAPING
(1.97˝) TERMINAL
1PAF-58Y LA308
Fig. 11
AVX 5 sq (BLUE)
Fig. 8
2.6-5 Right guard harness
2.6-2 Battery relay cable
600 (23.6˝)
CONNECTORS SELECTION TABLE
TERMINAL TERMINAL
60-8 BC818
CAP AV60B CAP
YAZAKI BTC-135R (RED)
7034-1283
Fig. 9
Fig. 12
2.6-3 Battery cable
2.6-8 Frame ground cable

430 (16.9˝)
100 (3.94˝)
LA308 5B 5B
31102 60413252
1PAM
YAZAKI 7122-3010
AV60B
CAP RIGHT Fig. 13
CAP LEFT TERMINAL TERMINAL
LEFT RIGHT
Fig. 10
23-20
ELECTRICAL SYSTEM
2.7 ENGINE HARNESS ASSY
E/G HARNESS ASSY

No. Name Q'ty
1 E/G SUB HARNESS 1
F16775
DETAIL OF ENGINE SPEED

SENSOR CONNECTOR
NOTE:
1.Tightening torque
M 10 : 6.5 kgf·m (47 ft·lbs)
M 8 : 3.6 kgf·m (26 ft·lbs)
VIEW II
DETAIL C
VIEW I
31102 60413252
DETAIL OF ALTERNATOR
VIEW III
DETAIL A
(DETAIL OF MOUNTING ENGINE GROUND)
DETAIL B
Fig. 14 E/G Harness assy
23-21
ELECTRICAL SYSTEM
2.7-1 Engine sub harness
31102 60413252
Fig. 15 Engine sub harness
23-22
ELECTRICAL SYSTEM
2.8 FLOOR PLATE HARNESS
FLOOR PLATE HARNESS ASSY

No. Name Q'ty
1 UNDER FLOOR HARNESS 1
3 GROUND CABLE 1
F16804
31102 60413252
VIEW I
Fig. 16 Floor plate harness assy
23-23
ELECTRICAL SYSTEM
2.8-1 Under floor harness
31102 60413252
Fig. 17 Under floor harness
23-24
ELECTRICAL SYSTEM
2.9 CAB HARNESS ASSY (1 / 2)
CAB HARNESS ASSY

No. Name Q'ty
1 LEFT INSTRUMENT HARNESS —
2 RIGHT INSTRUMENT HARNESS —
3 CAB RIGHT FRONT HARNESS 1
4 CAB RIGHT FRONT HARNESS 1
9 RIGHT INSTRUMENT HARNESS 1
F16805
VIEW I
VIEW IV
31102 60413252
VIEW III
VIEW II
HOUR METER
VIEW VI
Fig. 18 (1 / 2) Cab harness assy
23-25
ELECTRICAL SYSTEM
2.9 CAB HARNESS ASSY (2 / 2)
VIEW V
Fig. 18 (2 / 2) Cab harness assy
31102 60413252
23-26
ELECTRICAL SYSTEM
2.9-3 Cab right front harness

31102 60413252
Fig. 19 Cab right front harness
23-27
ELECTRICAL SYSTEM
2.9-4 Left instrument panel harness
31102 60413252
Fig. 20 Left instrument panel harness
23-28
ELECTRICAL SYSTEM
2.9-9 Right instrument panel harness

31102 60413252
Fig. 21 Right instrument panel harness
23-29
ELECTRICAL SYSTEM
2.10 BATTERY 95D31R
Fig. 22 Battery
31102 60413252
23-30
ELECTRICAL SYSTEM
2.11 CAB ASSY

CLIP HARNESS 2-37 4PAM-HM
CAB ASSY
No. Name Q'ty
2 FRONT WINDOW ASSY 1
2-8 WIPER ASSY 1
2-37 WIPER HARNESS 1
CURL CODE
25 DOOR SWITCH 1
61 CURL CODE HARNESS 1
64 CAB HARNESS 1
65 ANTENNA 1 2-8
68 ROOM LAMP 1
189 ROOM LAMP HARNESS 1
195-3 INTER LOCK SWITCH 1
F16806
4PAF
GLASS MARK POSITION
(ROOF-PANEL)
61 CN-3M~4PAF-HM
25 2 CONNECT WITH CURL CODE HARNESS
CN-2F
195-3
64
SECTION CC
CONNECT WITH
ROOM LAMP
HARNESS
68
CONNECTOR WITH
CONNECT WITH INSTRUMENT PANEL
INSTRUMENT HARNESS 189
PANEL HARNESS 4PAM
2PAM 2PAF 4PAF
31102 60413252
CONNECT WITH 189

TUNER HARNESS
SECTION AA SECTION BB VIEW I
Fig. 23 Cab assy
23-31
ELECTRICAL SYSTEM
2.11-2-37 Harness 2.11-61 Curl code harness 2.11-64 Cab harness
Fig. 24 Fig. 25
F16807
Fig. 26
2.11-65 Antenna
Fig. 27
2.11-189 Room lamp harness
31102 60413252
Fig. 28
23-32
ELECTRICAL SYSTEM
2.12 MOUNTING CAB 2.13 MOUNTING LIGHT 2.14 MOUNTING BOOM LIGHT
MOUNTING CAB MOUNTING LIGHT MOUNTING BOOM LIGHT

No. Name Q'ty No. Name Q'ty No. Name Q'ty
4 WASHER TANK 1 1 LIGHT 1 1 LIGHT 2
F16812 F16814
2A BOOM LIGHT HARNESS —
2B BOOM LIGHT HARNESS 1
F16815
Both side only
TO MAIN HARNESS
(RIGHT SIDE)
Fig. 29 Mounting cab Fig. 32 Mounting boom light
2.12-4 Window washer tank and pump 2.14-2 Boom light harness
NUT (WORK LIGHT

ACCESSORY)
BRACKET TIGHTENING TORQUE:
1.9 kgf·m (13.7 lbf·ft)
RIGHT GUARD HARNESS MAIN

HARNESS
31102 60413252
PUMP
Fig. 30 Fig. 31 Mounting light Fig. 33
23-33
ELECTRICAL SYSTEM
2.15 MOUNTING CAB WORK LIGHT
MOUNTING WORK LIGHT

(FOUR LIGHT, HARNESS ONLY)
No. Name Q'ty
1 LIGHT —
6 SWITCH 1
7 TWO LIGHT HARNESS —
9 CAB WORK LIGHT HARNESS —
10 RELAY —
12 TWO LIGHT HARNESS —
18 FOUR LIGHT HARNESS 1
F16818
31102 60413252
Fig. 34 Mounting cab work light
23-34
ELECTRICAL SYSTEM
2.15-7 Two light harness 2.15-9 Cab work light harness
Fig. 36
Fig. 35
2.15-18 Four light harness 2.15-12 Cab work light harness

31102 60413252
Fig. 37
Fig. 38
23-35
ELECTRICAL SYSTEM
2.16 AIR CONDITIONER
AIR CONDITIONER (A/C)

No. Name Q'ty
1 A/C ASSY 1
1-1 A/C CONDITIONER 1
1-3 SENSOR 1
2 AIR DRYER ASSY 1
2-1 RECEIVER TANK 1
FIX IT TO THE
3 AIR COMPRESSOR 1 FRAME CLIP
4 PANEL 1
F16819
DETAIL OF PANEL
2.16-3 Air compressor
CP3.96MA
YAZAKI 7120-8019
310 (12.2˝)
AVX1.25 (BLACK)
AVX1.25 (GREEN)
31102 60413252
DETAIL OF RECEIVER TANK SETTING PORTION
Fig. 39 Air conditioner Fig. 40 Detail of compressor wiring
23-36
ELECTRICAL SYSTEM
2.17 MOUNTING FUEL PUMP 2.17-1 Fuel pump assy
MOUNTING FUEL PUMP FUEL PUMP ASSY

No. Name Q'ty No. Name Q'ty
1 FUEL PUMP ASSY 1 1 FUEL PUMP 1
F16820 F16831
STRAINER
HOSE
GROUND
STRAINER
31102 60413252
Fig. 41 Mounting fuel pump Fig. 42 Fuel pump assy
23-37
HYDRAULIC SYSTEM
NOTE
31102 60413252
23-38
SECTION 24 COMPONENTS SYSTEM
TABLE OF CONTENTS
Part I: Hydraulic components

1. Hydraulic pump - regulator ................................................................................... 24-1
1.1 Summary ........................................................................................................................................ 24-1
1.2 Construction ................................................................................................................................... 24-2
1.3 Function ......................................................................................................................................... 24-4
1.4 Adjusting the regulator ................................................................................................................... 24-7
2. Pilot valve (ATT) ................................................................................................... 24-9

2.1 Outline ............................................................................................................................................ 24-9
2.2 Construction, function and operation ........................................................................................... 24-10
2.3 Function ....................................................................................................................................... 24-11
3. Pilot valve (travel) ............................................................................................... 24-13

3.1 Outline .......................................................................................................................................... 24-13
3.2 Function ....................................................................................................................................... 24-15
4. Control valve ....................................................................................................... 24-18

4.1 Specifications ............................................................................................................................... 24-18
4.2 Construction ................................................................................................................................. 24-19
4.3 Hydraulic circuit ............................................................................................................................ 24-22
4.4 Functional explanation ................................................................................................................. 24-23
5. Swing motor unit ................................................................................................. 24-43

5.1 Specification ................................................................................................................................. 24-43
5.2 Explanation of construction .......................................................................................................... 24-44
5.3 Construction ................................................................................................................................. 24-45
5.4 Operation ..................................................................................................................................... 24-48
6. Travel motor ........................................................................................................ 24-51

6.1 Construction ................................................................................................................................. 24-51
31102 60413252
6.2 Hydraulic circuit ............................................................................................................................ 24-51

6.3 Specifications ............................................................................................................................... 24-52
6.4 Construction ................................................................................................................................. 24-53
6.5 Functional explanation ................................................................................................................. 24-56
INDEX
7. Swivel joint.......................................................................................................... 24-65

7.1 General view ................................................................................................................................ 24-65
7.2 Specifications ............................................................................................................................... 24-65
7.3 Construction ................................................................................................................................. 24-66
7.4 Operation ..................................................................................................................................... 24-66
8. Cylinder .............................................................................................................. 24-67

8.1 Specifications ............................................................................................................................... 24-67
8.2 Construction and operation .......................................................................................................... 24-68
Part II: Electric equipment

1. Electric equipment list ......................................................................................... 24-73
2. Specification of electric equipments .................................................................... 24-74
31102 60413252
COMPONENTS SYSTEM
Part I: HYDRAULIC COMPONENTS

1. HYDRAULIC PUMP - REGULATOR
1.1 SUMMARY
Spec. 1
(1) General view and hydraulic port
CODE PORT NAME SIZE

A1, A2 Delivery port PF 3/4
A3 Delivery port PF 3/8
A4 Relief port PF 3/8
A5 Delivery port PF 1/2 Spec. 2
a1, a2 Gauge port PF 1/4

a3 Air Bleed port PF1/4
B1 Suction port Ø48
B2 Suction port PF 1 Spec. 2 (side face)
Dr1, Dr2 Drain port PF 1/2
P3 Power shift port of the No.3 pump PF 1/4
Pf Power shift port of the pilot pressure PF 1/4
F16936 Spec. 1
Spec. 2
Spec. 2 (bottom face)

Fig. 1-1 Hydraulic pump - regulator
(2) Specifications
Table 1-1
SPECIFICATIONS SPEC. 1 SPEC. 2

Model K3SP36B-101R-1001 K3SP36B-101R-2001
Displacement capacity
cm3/rev 31.4 X 2
Main Max. pressure
pump kgf/cm2 (psi) 300 (4270)
Max. flow
L/min (gal/min) 66 (18) X 2
Pilot hydraulic pressure Dozer pressure Pilot hydraulic
Purpose of use source (A3) source (A5) pressure source (A3)
Attached Displacement capacitycm3/rev 9.5 23.1 9.5
gear pump Max. pressure
kgf/cm2 (psi) 35 (500) 200 (2840) 35 (500)
Max. flow 20 (5.3)
L/min (gal/min) 20 (5.3) 48.5 (13)
Revolution rpm
31102 60413252
Rate: 2100 (Clockwise as seen from the shaft), high idle : 2310
Weight kg (lbs) 41 (90) 44 (88)
Oil quantity L (gal) 1.0 (0.26)
Total power control Total power control
Control characteristics of regulator Power shift control of air- Power shift control of air-conditioner
conditioner Power shift control of the No.3 pump
F16937
24-1
COMPONENTS SYSTEM
1.2 CONSTRUCTION
GEAR PUMP
SECTION VV
Apply adhesive (Three bond No.1303B)
SECTION WW SECTION XX
SECTION YY
Coat the circumference of the

oil seal with adhesive (Loctite No. 222)
31102 60413252
SECTION ZZ
Fig.1-2 Hydraulic pump · regulator
24-2
COMPONENTS SYSTEM
Table 1-2
No. PARTS Q'TY No. PARTS Q'TY

111 SHAFT 1 621 COMPENSATING PISTON 1
114 COUPLING 1 624 SPRING SEAT 1
115 COLLAR 1 625 SPRING 1
123 ROLLER BEARING 1 626 SPRING 1
124 NEEDLE BEARING 1 627 PLUNGER 1
127 SPACER 1 628 ADJUST SCREW (C) 1
141 CYLINDER BLOCK 1 630 LOCK NUT: M30 1
151 PISTON 10 641 SPRING COVER 1
152 SHOE 10 651 SLEEVE 1
153 PLATE 1 652 SPOOL 1
156 SPHERICAL BUSHING 1 653 PIN 1
157 SPRING 10 654 PIN 1
212 SWASH PLATE 1 655 PIN (Pf PISTON) 1
214 BUSHING 1 656 PIN 1
215 PIVOT BALL 1 660 ADJUST SCREW (R) 1
216 PIVOT BALL 1 661 LOCK NUT: M14 X 1.5 1
271 CASING 1 662 SPRING SEAT 1
273 COVER 1 663 SPRING 1
312 VALVE COVER 1 664 POPPET 1
313 VALVE PLATE 1 665 SEAT (R) 1
401 SOCKET BOLT: M16 X 40 4 700 O-RING: 1B G35 1
402 FLANGE SOCKET BOLT: M8 X 16 2 701 O-RING: 1B G55 1
403 SOCKET BOLT: M16 X 70 1 702 O-RING: 1B G135 1
404 SOCKET BOLT: M6 X 20 9 705 O-RING: 1B P16 2
467 DRAIN PLUG: PF 1/2 1 706 O-RING: 1B P11 8
468 PLUG: PF1/4 2 707 O-RING: 1B P18 1
490 PLUG: NPTF1/16, Meck coated 14 708 O-RING 1
492 PLUG: PT1/8, Meck coated 1 709 O-RING: 1B P26 1
493 PLUG: PT3/8 1 710 O-RING 1
751 GASKET 1
508 ORIFICE SCREW: NPTF1/16 4 774 OIL SEAL 1
531 TILTING PIN: M16 X 1.5 1 787 BACKUP RING 1
532 SERVO PISTON: M16 X 1.5 1 789 BACKUP RING 2
534 SET SCREW: M27 X 1.5 1 801 LOCK NUT: M8 1
535 STOPPER 1 803 LOCK NUT: M27 X 1.5 1
541 SEAT 2 824 SNAP RING 1
543 STOPPER 2 825 SNAP RING 1
545 BALL 2 885 SPRING PIN 2
548 FEED BACK PIN 1 901 EYE BOLT: M8 1
611 FEED BACK LEVER 1 924 SET SCREW: M8 X 25 1
F16944
31102 60413252
24-3
COMPONENTS SYSTEM
1.3 FUNCTION
(1) This pump is of split flow double-pump type capable
of obtaining two independent delivery lines by
branching off the oil delivered from single cylinder
block (141) to two delivery ports by the action of
the valve plate (313). Further, the pump has a
common suction construction that integrates the
suction of the gear pump at the rear end and the
suction of the main pump. The pump contains a
relief valve for the gear pump for pilot pressure.
The pump consists mainly of:
the rotary group that makes rotary-movements,
the swash plate group that changes the delivery
rate, and the regulator group that controls the
tilting angle.
(2) Rotary group (See Fig.1-3)
The rotary group consists of shaft (111), cylinder Fig. 1-3 Rotary group
block (141), piston (151), shoe (152), plate (153),
spherical bushing (156), and spring (157). The
(3) Swash plate group (See Fig.1-4)
shaft is supported by bearings (123, 124) at its
The swash plate group consists of swash plate
both ends. The shoe makes a spherical joint
(212), pivot balls (215, 216), tilting bushing (214),
caulked to the piston and relieves thrust load
tilting pin (531), and servo piston (532). The
occurring by load pressure. Since the shoe slides
swash plate (212) is supported by pivot balls (215,
lightly on swash plate (212), it has a pocket that
216) on two spherical faces formed on the opposite
achieves hydraulic balance. The subgroup
side of the shoe sliding surface. The regulator
consisting of the piston and the shoe is pressed
controls the supply and delivery of hydraulic oil to
against swash plate (212) by spring (157) via the
and from the large diameter chamber of the servo
plate that slides smoothly on swash plate (212).
piston. The result is that the servo piston is moved
Likewise, the cylinder block is pressed against
to the right and left. The swash plate swings pivot
valve plate (313) by a spring.
balls (215, 216) via the spherical part of tilting pin
Now, if the shaft is driven by the engine, the
(531) and changes the tilting angle ( ) or the
cylinder block (141) is driven (rotates) via a spline
delivery rate of the pump.
joint. If the swash plate is tilted, the pistons arranged
in the cylinder block make reciprocating motion
relative to the cylinder while rotating with the
cylinder block. Now let us take a lock at a single
piston: while the cylinder block makes one turn,
the piston moves away from valve plate (313) (the
process of sucking oil) in 180°and moves close to
valve plate (313) (the process of deliverying oil) in
the remaining 180°. The valve plate is provided
with one suction port and two delivery ports that
are arranged in valve cover (312). The oil sucked
into the cylinder block via the suction port is
branched off to two delivery ports of the valve
31102 60413252
plate and is connected to the external piping past

valve cover (312).
Fig. 1-4 Swash plate group
24-4
COMPONENTS SYSTEM
(4) Regulator group

1) Summary (See Fig.1-5 and 1-6)
DELIVERY RATE Q
The regulator group consists of feedback lever
(611), compensating piston (621), springs (625,
626), pilot sleeve (651), and pilot spool (652).
Thus it makes up a hydraulic servo mechanism
consisting of servo piston (532) and a positional
feedback.
DELIVERY PRESSURE (P1+P2)/2
The delivery pressures P1, P2 of the pump are F16947
combined in the regulator and changes the delivery Fig. 1-5 Power shift control chart
rate of the pump according to the level of the
pressure as shown in Fig.1-5. For this reason, the
input torque is kept nearly constant which realizes
a total horsepower control, in order to prevent the
engine from being overloaded. This pump system
is equipped with one or two gear pumps at its rear
SPRING CHECK VALVES
end. The load pressures P3 Pf of the pump (625),(626) (541),(543),(545)
HORSEPOWER PORT
enables power shift control that shifts the
horsepower set as illustrated in the figure on the No.3 PUMP SHIFTED
PILOT REDUCED
HORSEPOWER PORT
right. ORIFICE
SPOOL (652) (508)
2) Function of added total horsepower control
COMPENSATING
(See Fig.1-6) PISTON (621)
If pump delivery pressure P1 or delivery pressure
PIN (P3 PISTON)
P2 rises, the mean pressure (P1+P2)/2 acts upon (655) GAUGE
PORT
the stepped section of compensating piston (621) SLEEVE (651)
by the action of four orifices (508). In this case, FIXED PIN (653)
spool (652) is pushed to the right and moves till the FEEDBACK
LEVER (611)
action of spring (625) and spring (626) balances
the hydraulic force. As the spool moves to the SERVO PISTON (532)
TILTING PIN (531)
right, the oil path to the larger diameter part of FEEDBACK PIN (548)
servo piston (532) consisting of the sleeve and the SWASH PLATE (212) DRAIN PORT SUCTION PORT
spool opens. This admits the delivery pressure to

Fig. 1-6 Functional explanation of regulator
push the spool to the left. The delivery pressure
enters the check valve [seat (541), stopper (543),
and ball (545)] from which the higher of the
pressures P1, P2 is put out selectively to the
smaller diameter side of the servo piston so that
the delivery pressure is admitted at all times. In the
meantime, swash plate (212) and servo piston
(532) are linked together by tilting pin (531). This If the pump delivery pressures P1, P2 decrease,
decreases the tilting angle which in turn decreases the spool is pushed back by the action of springs
the delivery rate of the pump, in order to prevent (625, 626). This connects the oil path for the larger
the engine from being overloaded. The action of diameter of the servo piston to the tank. This
the servo piston is transmitted to feedback lever moves the servo piston to the right by the oil
(611) via the feedback pin (548). The feedback pressure from the smaller diameter side. The
31102 60413252
lever turns on pin (653) that is fixed to casing (271) result is that the tilting angle ( ) increases which
and moves sleeve (651) to the right. The sleeve in turn increases the delivery rate of the pump.
moves till the opening of the path to the larger Then the feedback lever turns on the pin which
diameter part of the servo piston closes and stops moves the sleeve to the left till it closes the
just when the opening is closed. opening of the spool-sleeve.
24-5
COMPONENTS SYSTEM
3) Horsepower shift control function

The function is capable of power shift control that
changes a set horsepower of the pump with the
DELIVERY RATE Q
load pressure P3 of the gear pump installed to the
rear end of the pump as a command pressure, as
shown by doted lines in Fig.1-7.
The power shift pressure P3 is admitted to the left
end of pin (655). The spool moves to the right as
load pressure P3 of the No.3 pump rises. This DELIVERY PRESSURE (P1+P2)/2
F16949
decreases the tilting angle of the pump as
mentioned above which in turn decreases the Fig. 1-7 Power shift control
horsepower set. Inversely, the horsepower set
rises as pressure P3 falls.
Likewise, power shift control is possible if the
pump horsepower is changed with load pressure
Pf of the gear pump installed to the rear end of the
pump as a command pressure. Power shift
pressure Pf acts upon the mount (smaller diameter)
of the compensating piston. As the load pressure
of the pilot pressure pump rises, the tilting angle
( ) of the pump decreases which in turn reduces
the horsepower set as mentioned above. Inversely,
the horsepower set rises as the pressure Pf falls.
31102 60413252
24-6
COMPONENTS SYSTEM
1.4 ADJUSTING THE REGULATOR (628)

(630) (HORSEPOWER
The maximum flow and the horsepower control CHARACTER
ADJUST SCREW C)
characteristics may be adjusted by the adjust screws
(801)
of the regulator. However, since they are set to optimum (924) (INPUT
(801) HORSEPOWER
at shipment, use care so as not to tamper with these
(924) ADJUST SCREW)
adjust screw in normal condition.
(803) (534) (MAX.FLOW

ADJUST SCREW)
Fig. 1-8 Regulator adjust screws
(1) Adjusting the max. flow (See Fig.1-8, 1-9)

Loosen lock nut (803) and tighten (or loosen) set
DELIVERY RATE Q
screw (534) to adjust the flow. If the set screw
(534) is tightened 1/4 turn, the theoretical flow
decreases by approx. 0.7 cm3/rev. Only the max.
flow changes by it, leaving other control
characteristics unchanged.
DELIVERY PRESSURE (P1+P2)/2
Fig. 1-9 Max. flow adjustment
(2) Adjusting the horsepower control characteristics

(See Fig1-8, 1-10)
DELIVERY RATE Q
Adjust the spring by loosening lock nut (630) and

tightening (or loosening) adjust screw (C) (628). If
the adjust screw (C) is tightened 1/4 turn, the
compensating control start pressure rises by
approx. 12.4 kgf/cm2 (180 psi), as shown in Fig.1-
10 on the right. If adjust screw (C) is rotated by N DELIVERY PRESSURE (P1+P2)/2
turns, a set spring pressure changes also ; return
the set screw (924) by N X 1.2 turns. Fig. 1-10 Adjusting the horsepower control characteristics
(3) Adjusting the input horsepower

(See Fig.1-8 and 1-11.)
DELIVERY RATE Q
Adjust the spring pressure by loosening lock nut

(801) and tightening (or loosening) set screw
(924). The flow increases as in the figure on the
right if the adjust screw is tightened. (The input
31102 60413252
horsepower increases also.) If the set screw is

tightened by 1/4 turn, the theoretical flow increases DELIVERY PRESSURE (P1+P2)/2
F16951
by approx. 2.5cm3/rev.
Fig. 1-11 Adjusting the input horsepower
24-7
COMPONENTS SYSTEM
(not including the consumed torque of the gear pump)

Control chart of pump Models E75SR EVOLUTION
20K 280P
66±1L 17.4±0.3G
Standard specification (Spec.1)
H mode A/C power cut pressure Pf=0K (0 psi)
70 115±5K 1640±71P
(18) S mode 64.6L 17.0G
60
Pf
(16) FC mode
=
0K
(O
(94) 13
Delivery flow rate L/min (gal/min)
P)
50
(13) (87) 12
Input torque Tin kgf·m

(80) 11
40 (72) 10
(11)
(65) 9
193K 2740K
25.1L 6.6G (58) 8
30
(8) (51) 7
(43) 6
20 (36) 5
300K
(5)
(29) 4 12.5L
2740K
(22) 3 3.3G
10
(3) (14) 2
(7) 1
0
50 (710) 100 (1420) 150 (2130) 200 (2840) 250 (3550) 300 (4270)
Pd1+Pd2
Delivery pressure kgf/cm2 (psi)
2
20K 280P 50±15K 710±210P Control chart of pump

Models E75SR EVOLUTION
H mode 66±1L 17.4±0.3G 65.6L 17.1G
A/C power cut pressure Dozer pump pressure
70 115±5K 1640±71P
(18) a Pf = 0K P3 = 20K
64.6L 17.0G
S mode b Pf = 35K P3 = 20K
30K 95K
66.9L 64.9L c Pf = 0K P3 = 200K
Pf
Pf
Pf
Pf
60
(5 5K
(O K
(5 5K
(O K
=3
=0
=3
=0
430P 1350P d Pf = 35K P3 = 200K

00 P
00 P
(16)
P) P3 40P
P) P3 0P)
17.7G 17.1G
P) 3
P) 3
FC mode
(2 0K
(94) 13
(2 00K
=2
=2
(2 200
(2 20K
Delivery flow rate L/min (gal/min)
80
=
=
84
50
8 K
P)
0)
(87) 12
Input torque Tin kgf·m
(13)
)
(80) 11
40 (72) 10
(11) 173K 1820P
25.4L 6.9G (65) 9
128K 193K 1820P
26.1L 25.1L 6.9G (58) 8
30 1820P 300K (51) 7
(8) 6.9G 12.5L
1540P 108K 4270P (43) 6
7.0G 26.4L 3.3G
20 (36) 5
(5) 4270P
(29) 4 2.7G
(22) 3 300K
10 10.2L
31102 60413252
(3) (14) 2 300K

3970P 279K (7) 1 5.4L
4270P
1.5G 5.7L
0 1.4G
50 (710) 100 (1420) 150 (2130) 200 (2840) 250 (3550) 300 (4270)
F16952
Pd1+Pd2
Delivery pressure kgf/cm2 (psi)
2
24-8
COMPONENTS SYSTEM
2. PILOT VALVE (ATT)
2.1 OUTLINE
(1) General view
ANGLE ANGLE
(PORT 2, 4) (PORT 1, 3)
The adjust nut

(opposing flats : 22)
Fix adjust nut
(opposing flats : 22)
when the lever is 6-PF1/4
installed by means of T=29.4 ± 2.0N·m
spanner or the like. {3.0 ± 0.2 kgf·m}
Then tighten the
mating lock nut to VIEW A
4.2 ± 0.3 kgf·m T=Tightening torque : kgf·m (lbf·ft)
(30 ± 2.2 lbf·ft).
Max. primary pressure 6.9 MPa (70 kgf/cm2)

Rated flow 15 L/min
F16958 Weight 1.6 kg
F16957
A
Fig. 2-1
PORT1, 3
Secondary pressure kgf/cm2 (psi)
50.0 0.500
Operation torque kgf·m (lbf·ft)
Single operation torque

Secondary pressure (MPa)
Operation torque (N·m)
40.8 0.408
35
31.5+60
30.6 Secondary pressure
0.306
0.235
0.222
20.4 0.204
19 ± 1 0.179
0.104
10.2 0.102
5.5 +0.5
-0.75
0 0
Push rod stroke (mm)
Operation angle (deg)
PORT2, 4
50.0 0.500
Secondary pressure kgf/cm2 (psi)
Single operation torque

40.8 Secondary pressure 0.408

35
31.5
30.6 0.306
0.250
0.236
20.4 0.204
19 0.192
0.108
31102 60413252
10.2 0.102
5.5
0 0
Push rod stroke (mm)

Fig. 2-2 F16956
24-9
COMPONENTS SYSTEM
2.2 CONSTRUCTION, FUNCTION AND OPERATION
Rotating
sliding part,
apply grease.
Beware of the 312
assembly
direction 301
302 501
212 Apply grease to top
213 151
Pilot valve right
211
218-2 246 PORT Operation
214 No.
218-1 1 Bucket in
216-2 216-1 2 Boom lower
3 Bucket dump
241-2 241-1 4 Boom raise
221-2 221-1 Secondary
pressure
217 adjusting shim Pilot valve left
201-2 201-1
PORT Operation
131 101 No.
126 122 1 Swing left
111 2 Arm out
121 Not to be reused 3 Swing right
PORT 2, 4 PORT 1, 3 125 4 Arm digging
F16953 F16954
Fig. 2-3 Pilot valve
NO. PARTS Q'TY NO. PARTS Q'TY NO. PARTS Q'TY

101 CASING 1 211 PLUG 4 221-2 SPRING 2
111 PORT PLATE 1 212 PUSH ROD 4 241-1 SPRING 2
121 SEAL WASHER 2 213 SEAL 4 241-2 SPRING 2
122 O RING 1 214 O RING: 1B P20 4 246 SPRING 4
125 SOCKET BOLT 2 216-1 SPRING SEAT 1 2 301 JOINT: M14 1
126 SPRING PIN Ø5 X 10 1 216-2 SPRING SEAT 1 2 302 CIRCULAR PLATE 1
131 BUSHING 1 217 WASHER 2 (SHIM) 4 312 ADJUST NUT: M14 1
151 PLATE 1 218-1 SPRING SEAT 2 2 501 BOOTS 1
201-1 SPOOL 2 218-2 SPRING SEAT 2 2
201-2 SPOOL 2 221-1 SPRING 2
F16955
31102 60413252
24-10
COMPONENTS SYSTEM
2.3 FUNCTION
1) Lever in neutral (See Fig. 2-4)
The action of spring (241-2) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon spool
(201-2). Therefore, spool (201-2) (for return) is
pushed up by spring (221-2) [spring seat 1 (216-
2)]. The output ports (2, 4) connect with the T port.
The result is that the output pressure is equal to
the tank pressure.
PORT 2, 4 PORT 1, 3
Fig. 2-4 Lever in neutral
2) When the pilot lever is tilted (See Fig. 2-5)

When the lever is tilted and the push rod (212-2)
strokes, the spool (201-2) spring seat (216-2)
moves down-ward to make the port P to connect
with the port 2, 4, with the result that the oil of the
pilot pump flows to the port 2, 4 to produce a
pressure.
PORT 2, 4 PORT 1, 3
Fig. 2-5 When the lever is tilted
3) Lever held (See Fig. 2-6)
When the pressure at ports (2, 4) rises to a level
equivalent to the action of spring (241-2) that is set
by tilting the handle, the hydraulic pressure
balances the spring action. When the pressure of
ports (2,4) rises above a set value, ports (2, 4) and
the P port close while ports (2, 4) and the T port
open. When the pressure at ports (2,4) falls below
a set value, ports (2, 4)and the P port open while
ports (2, 4) and the T port close. Thus the secondary
pressure is kept constant.
31102 60413252
PORT 2, 4 PORT 1, 3
Fig. 2-6 When the lever held
24-11
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. Threafter, 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.
31102 60413252
24-12
COMPONENTS SYSTEM
3. PILOT VALVE (TRAVEL)
3.1 OUTLINE
(1) General view
4-M8 X P1.25
T=1.7 kgf·m
(21.3 lbf·ft)
Back side
2-PF1/4
T=3.0 kgf·m
2-PF1/4 (21.7 lbf·ft)
T=3.0 kgf·m
(21.7 lbf·ft)
4-PF1/4
T=3.0 kgf·m
(21.7 lbf·ft)
Hydraulic diagram
Fig.3-1
(2) Specifications
Type PVD6PC4017A
Max.primary pressure 70 kgf/cm2 (1000 psi)
Rated flow 10 L/min (2.64 gal/min)
Weight 3.9 kg (8.6 lbs)
F16966
(3) Performance characteristics

40.8 1.224
Operation torque
Secondary pressure kgf/cm2
30.6 0.918
0.916
24.0 0.600
20.4 0.612
0.570
0.524
10.2 0.306
Secondary pressure
5.5
• Torque required (Damper)
31102 60413252
0 0 1.93 ± 0.29 kgf·m (13.9 ± 2.07 lbf·ft)

Push rod stroke (mm) Push rod speed 0.0275 m/s
Actual required torque is the valve
operation torque shown in left diagram
adding to damper operation torque.
F16967
Fig.3-2
24-13
COMPONENTS SYSTEM
SECTION CC
Fig. 3-2 Assembly view of pilot valve (travel)
Tightening Tightening
torque No. PARTS Q'TY torque No. PARTS Q'TY
kgf·m (lbf·ft) kgf·m (lbf·ft)
101 CASING 1 6.9 {0.7} 252 PLUG 6
102 CASING (Damper) 1 11.8{1.2} 253 RO PLUG 2
191 SEAT 1 2 261 O-RING 3
192 SEAT 2 2 263 O-RING 2
193 BUSHING 2 2 8.8 {9.0} 271 CAPSCREW 4
194 BALL 2 301 SPOOL 4
201 COVER 2 311 SPRING SEAT 4
202 PLUG 4 313 WASHER 4
203 GREASE CUP 4 324 SPRING 4
210 SEAL 4 335 SPRING 4
211 O-RING 4 336 SPRING 4
212 O-RING 4 413 CAM SHAFT 2
213 O-RING 2 414 BUSHING 4
31102 60413252
214 PUSH ROD 4 420 CAM 2

217 SHIM 4 471 BALL 4
218 SPRING SEAT 4 6.9 {0.7} 472 LOCK NUT 2
224 PISTON 4 501 BOOTS 2
225 BALL 12
29.4 {3.0} 251 RO PLUG 3
F16965
24-14
COMPONENTS SYSTEM
3.2 FUNCTION
(1) Reducing valve
1) Neutral (Fig. 3-4)
Spool (301) is pushed up by spring (335) (for
return) via spring seat (311) and washer (215) and
is located in the neutral position as shown in the
cross-sectional view. Therefore, since the output
port connects only with port T by the spool select
function, the pressures at output ports 1, 2 are
equal to that of port T.
311
335
301
F16964
PORT 2 (4) PORT 1 (3)
Fig. 3-4
2) The control of the remote control valve is tilted NEUTRAL

from its neutral (Fig. 3-5) At the full stroke
If cam (420) is rotated clockwise in the cross-
sectional view, push rod (214) on port 1 is pushed 420
down. This moves the spool down via washer 1,
spring seat (for secondary pressure setting), spring 214
(324), washer 2 (217), and washer 3 (313) and
connects port P with port 1. The oil supplied by the
pilot pump runs to port 1 and generates pressure.
If the control lever (or pedal) is inclined and when
the pressure at port 1 rises to a level equivalent to
the action of the spring that sets the secondary 311
pressure, the hydraulic pressure acting on the
324
spool balances the spring action, thereby keeping
the output pressure at port 1 constant. 217
The spool at port 2 is held neutral ; the oil returning 313
from the control valve is discharged via port T.
On some specifications, the push rod comes in
direct contact with the top of the spool in the
neighborhood of the maximum angle of the control.
F16963
This pushes in the spool forcibly which connects
31102 60413252
PORT 2 (4) PORT 1 (3)

port P with the output port and makes the pressures
at both ports equal.
Fig. 3-5
24-15
COMPONENTS SYSTEM
(2) Damping mechanism of the control

1) Neutral
The push rod is pushed up by springs (336) via piston (224) (damping) and is located as shown in the cross-
sectional view.
2) The control is inclined from its neutral position :
[Refer to the functional explanation (1) of damping]
If the cam is turned clockwise in the cross-sectional view, the push rod on the port 1 side is pushed down which
brings the piston down.
On that occasion, the oil in the damping piston chamber is discharged through the orifice. The pressure then
generated creates a damping force.
In the meantime, the push rod on the port 2 side moves up by the damping spring via the piston.
On that occasion, the oil in the tank chamber is sucked into the damping piston chamber through the ball
checks (3 places) that consists of bushing (223) and ball (225). The oil outside of the piston chamber gets out
of the path to port T, from the top end of the casing.
CAM
PUSH ROD
ORIFICE
PISTON
PISTON CHAMBER
If the lever is stroked in

the arrow direction from
its neutral, the oil in the
right-hand (left-hand)
piston chamber is
discharged from the
orifice. Damping force
occurs by the pressure
then generated.
BALL
F16962
PORT 2 (4) PORT 1 (3)

31102 60413252
Fig. 3-6 Functional explanation of damping
24-16
COMPONENTS SYSTEM
3) The control lever (or pedal) is inclined from its maximum angle to its opposite side :
[Refer to the functional explanation (2) of damping.]
On the cross-sectional drawing, if the cam is tilted in its full clockwise direction and then turned counterclockwise,
the push rod on the port 2 side is pushed down. This moves the piston down.
On that occasion, the oil in the damping piston chamber is discharged from the orifice of the piston. The
pressure then generated creates a damping force.
In the meantime, the push rod on the port 1 side moves spring (335) (for return) and damping spring (336)
upwards.
The oil in the tank chamber is sucked into the damping piston chamber through the ball checks (3 places)
consisting of a bushing and a ball. The oil outside of the piston chamber gets out from the top end of the casing
to the path that leads to the tank port.
That is to say, the mechanism is so constructed that damping force acts on any tilting operations i.e. from
neutral to full tilting or from full tilting to neutral.
NEUTRAL
At the full stroke
CAM
PUSH ROD The oil outside of the piston

flows out of the path to the
T port, from the top end of
the casing
( at operation)
PISTON
Oil
When the lever is neutral DAMPING
to reverse direction, the SPRING
push rod is pushed up by
the damping spring.
( operation) The oil in the piston
chamber is discharged
The oil in the T line through the orifice.
is sucked into the The oil then created
damper generates a damping
chamber through the ball force.
check (3 places).
( at operation) ( at operation)
When the lever is operated RETURN

in the reverse direction SPRING
(from to state), the
left-hand piston serves as a
damper piston this time.
Damping force is
generated on both
at all times.
F16961
PORT 2 (4) PORT 1 (3)

31102 60413252
Fig. 3-7 The control lever is inclined from its maximum angle to its opposite side
24-17
COMPONENTS SYSTEM
4. CONTROL VALVE
(2) Specifications Table 4-1
4.1 SPECIFICATIONS Item Spec. Tightening

Port torque Port
(1) General view and hydraulic ports Model BCV75-A1 kgf·m name Description
size
6-PF1/2 (lbf·ft)
3-M12 Main relief valve set pressure 300 kgf/cm2 (4270 psi)
ACTUATOR PORT DEPTH OF TAPPED HOLE 8~9
(A1~A3, B1~B3) PF3/4 T1 Tank port
(attach, travel) at 28 L/min (7.4 gal/min) (58~65)
ORV-A2 Over load relief valve P1 Pump A1 port
ORV-B2
335 kgf/cm2}(4760 psi)
set pressure P2 Pump A2 port
at 20 L/min (5.3 gal/min) A1 Travel right port (forward)
(OR-A2, A3, B2, B3, C3, D3)
B1 Travel right port (reverse)
Pilot pressure (MAX) 40 kgf/cm2(569 psi)
C1 Travel left port (reverse)
PF1/4 (Pb2)
LOCK VALVE D1 Travel left port (forward)
RELEASE
6~7
PF1/2 A2 Boom up port
(43~51)
B2 Boom down port
ORV-A3 C2 Swing port (right)
ORV-B3 D2 Swing port (left)
PF1/4(DR5) 2-M12
DRAIN PORT ROD SIDE DEPTH OF TAPPED HOLE A3 Bucket digging port
HEAD SIDE B3 Bucket dump port
VIEW A
C3 Arm in port
3-M12 D3 Arm out port
DEPTH OF TAPPED 6-PF1/2
ACTUATOR PORT 2-PF1/2 (P1,P2) 4~5
HOLE 19 FP TANK PUMP PORT
(C1~C3, D1~D3) PF3/8 (DR2) PF3/8 DR4 Drain port
M12, DEPTH 19 TANK PORT (29~36)
PS Load check valve for swing priority
TRAVEL STRAIGHT pilot port
PF1/4 (Pd2´) PS' Higher pilot pressure select port for swing
ORV-D3 TRAVEL (L) TRAVEL (R) P0 Travel straight spool select pilot port
Pa1 Travel right pilot port (forward)
ORV-C3 SWING BOOM Pb1 Travel right pilot port (reverse)
Pc1 Travel left pilot port (reverse)
BUCKET Pd1 Travel left pilot port (forward)
ARM
PF1/4 (Pc3´) Pa2 Boom up pilot port
LOCK VALVE BYPASS
RELEASE BYPASS CUT Pb2 Boom down pilot port
CUT VALVE 1 Pb2' Boom lock valve release pilot port
HEAD SIDE PF1/4 (DR3) VALVE 2
Pc2 Swing right pilot port
10-PF1/4 ROD SIDE DRAIN
PF1/4 (DR2) PORT 9-PF1/4 Pd2 Swing left pilot port
PILOT PORT PF1/4 (PS) DRAIN PORT PILOT PORT 2.5~3
PS,DR1,Pb1~Pb4 PF3/8 (DR4) PF1/4 (18~22) Pd2' Higher pilot pressure select port for swing left
Pc1~Pc4 DRAIN PORT PO,Pd1~,Pd4 Pa3 Bucket digging pilot port
Pa1~Pa3,DR6
Pb3 Bucket dump pilot port
Pc3 Arm in pilot port
Pc3' Arm lock valve release pilot port
Pd3 Arm out pilot port
Pb4 P1 bypass cut pilot port
Pc4 Boom conflux spool pilot port
Pd4 P2 bypass cut pilot port
DR1 Drain port
31102 60413252
DR2 Drain port
DR3 Drain port
DR5 Drain port
2-M12 DR6 Drain port
DEPTH OF TAPPED HOLE 15
F16971
Fig. 4-1 General view and hydraulic ports
24-18
ELECTRICAL SYSTEM
4.2 CONSTRUCTION
In case that pilot section
is disassembled, replace
spool end with new ones. Tighten it using care Tightening torque:
so the backup ring is 0.4~0.5 kgf·m (2.9~3.6 lbf·ft)
not caught. Lock it with Loctite #242.
TRAVEL STRAIGHT
TRAVEL (L)
SWING
ARM
ARM CONFLUX P2 BYPASS

CUT VALVE
Beware of the washer

on each pilot cover Rainbow color plating applied
This plug differs from SECTION AA Travel straight and the supply of hydraulic oil
41 and 50. (black) Tightening torque:
0.4~0.5 kgf·m (2.9~3.6 lbf·ft)
Rainbow color plating applied Lock it with Loctite #242.
TRAVEL (R)
BOOM
BUCKET
P1 BYPASS CUT VALVE

31102 60413252
Rainbow color plating applied Tightening torque:

0.4~0.5 kgf·m (2.9~3.6 lbf·ft)
Lock it with Loctite #242.
SECTION BB Travel L, R
This plug differs from

Fig. 4-2 Construction of contral valve 41 and 50. (black)
24-19
ELECTRICAL SYSTEM
Rainbow color plating applied Tightening torque: Tightening torque:

0.4~0.5 kgf·m (2.9~3.6 lbf·ft) 0.4~0.5 kgf·m (2.9~3.6 lbf·ft)
Lock it with Loctite #242. Lock it with Loctite #242.
Tightening torque :
0.4~0.5 kgf·m
(2.9~3.6 lbf·ft)
Lock it with
Loctite #242.
Rainbow color plating applied

Rainbow color plating applied Tightening torque: This plug differs from Tightening torque:
SECTION CC Swing and boom 2.0 kgf·m (14 lbf·ft) 41 and 73. 0.4~0.5 kgf·m (2.9~3.6 lbf·ft)
Lock it with (No surface treatment) Lock it with Loctite #242.
Loctite #242.
Rainbow color plating applied SECTION EE Bypass cut valve and boom conflux valve, P1 bypass cut valve
Tightening torque: Tightening torque:

2.5~3.0 kgf·m (18~22 ft·lbs) 0.4~0.5 kgf·m (2.9~3.6 ft·lbs)
Lock it with Locktite #242, Lock it with Locktite #242,
Take care of assembling

direction of piston.
(Orifice on spring side)
Tightening torque:
0.4~0.5 kgf·m (2.9~3.6 lbf·ft)
31102 60413252
Lock it witah Loctite #242.
Tightening torque: Tightening torque:
Lock it with Loctite #242. Lock it with Loctite #242.
Rainbow color plating applied
Detail of lock valve (boom)
SECTION DD Arm and bucket
Fig. 4-3 Construction of control valve (1 / 2)
24-20
ELECTRICAL SYSTEM
1 BODY 1 39 SPOOL END 1
2 O-RING 1 40 CHECK VALVE 1
3 O-RING: 1B P22 4 4.0~5.0 (29~36) 41 PLUG: PF3/8 7
4 O-RING: 1B P16 3 42 CHECK VALVE SPRING 1
5 END COVER 1 6.0~7.0 (49~51) 43 PLUG 1
6.8~7.0 (49~51) 6 SOCKET BOLT: M12 X 30 4 44 O-RING 1
7 TRAVEL STRAIGHT SPOOL 1 45 TAPER SOCKET PLUG 2
8 TRAVEL SPOOL 2 46 STEEL BALL 1
Tightening Tightening Take care of 9 SWING SPOOL 1 1.0~1.1 (7.2~8.0) 47 SOCKET BOLT: M6 X 40 32
torque: torque: assembling
2.5~3.0 kgf·m 0.4~0.5 kgf·m direction of 10 BOOM SPOOL 1 1.0~1.1 (7.2~8.0) 48 SOCKET BOLT: M6 X 90 6
(18~22 lbf·ft) (2.9~3.6 lbf·ft) piston. 11 ARM SPOOL 1 49 WASHER 1
Lock it with Lock it with (Orifice on
Loctite #270. Loctite #270. spring side) 12 BUCKET SPOOL 1 4.0~5.0 (29~36) 50 PLUG : PF3/8 1
13 BOOM CONFLUX SPOOL 1 51 RETAINING RING 2
14 P2 BYPASS CUT VALVE 1 52 O-RING 18
15 P1 BYPASS CUT VALVE 1 53 O-RING: 1B P6 2
Detail of swing priority 16 PILOT COVER D 2 54 O-RING: 1B P8 1
17 PILOT COVER E 1 55 O-RING: 1B P10 1
18 PILOT COVER C 8 56 O-RING: 1B P11 2
4.0~5.0 (29~36) 19 PILOT COVER B1 7 57 O-RING: 1B P14 11
20 PLUG: M18 X 1.5 15 58 O-RING: 1B P15 16
21 LOAD CHECK VALVE 9 59 O-RING: 1B P18 3
22 LOAD CHECK VALVE SPRING 10 6.0~7.0 (49~51) 60 MAIN RELIEF VALVE ASSY 1
23 SPRING HOLDER A 10 4.0~5.0 (29~36) 61 OVER LOAD RELIEF VALVE 6
24 SPRING HOLDER B 8 6.0~7.0 (49~51) 62 PLUG: PF3/4 1
25 SPOOL END 8 63 O RING: 1B P24 1
26 SPRING 10 1.0~1.2 (7.2~8.7) 64 TAPER SOCKET PLUG: NPTF 1/16 3
27 SPOOL END 2 65 STOPPER PIN 1
28 LOCK VALVE 2 66 PILOT COVER F 1
29 NEEDLE VALVE (POPPET) 2 67 PISTON D 1
Tightening torque: Tightening torque: 30 LOCK VALVE RESTRICTOR 2 68 PILOT TIE 1
Lock it with Loctite #242. Lock it with Loctite #242. 31 LOCK VALVE SPRING B 2 3.0~3.5 (22~25) 69 PIN GUIDE 1
32 SPRING HOLDER 2 70 SPRING (For swing priority) 1
Detail of lock valve (boom & arm)
33 PISTON GUIDE 2 71 O-RING 1
34 PISTON A 2 72 O-RING 1
35 LOCK VALVE SPRING A 2 4.0~5.0 (29~36) 73 PLUG : GPF3/8 2
4.0~5.0 (29~36) 36 PISTON C 2 1.0~1.1 (7.2~8.0) 74 SOCKET BOLT: M6 X 55 2
37 SHUTTLE VALVE SOCKET 1 75 BACKUP RING 2
38 SHUTTLE VALVE SEAT 1
F16970
Tightening
31102 60413252
torque:
1.2~1.4 kgf·m
(8.7~10 lbf·ft)
Lock it with
Loctite #270.
Detail of shuttle valve
Fig. 4-3 Constuction of control valve (2 / 2)
24-21
ELECTRICAL SYSTEM
4.3 HYDRAULIC CIRCUIT Table 4-2

(1) Hydraulic circuit and designation of main parts No. PARTS
7 Travel straight spool
8 Travel spool
9 Swing spool
61
10 Boom spool
7 TRAVEL 11 Arm spool
STRAIGHT
VALVE 12 Bucket spool
P1 PARALLEL 13 Boom conflux spool
P1 MAIN PASSAGE 51 PASSAGE 53 P2 PARALLEL 14 P2 bypass cut spool
TRAVEL 56 PASSAGE
54 P2 MAIN
15 P1 bypass cut spool
RIGHT 8
PASSAGE 21 Load check valve
8 28 Lock valve (boom, arm)
49 Load check valve
51 P1 main passage
FORWARD FORWARD 52 P1 bypass passage
21
53 P1 parallel passage
REVERSE P1 BYPASS REVERSE
PASSAGE 54 P2 main passage
52
9 55 P2 bypass passage
BOOM 10 SWING
56 P2 parallel passage
21 58 Boom conflux passage
59 Arm conflux passage
52 LEFT
P2 BYPASS 60 Tank passage
PASSAGE 55 RIGHT
61 Main relief valve assy
UP
62 Over load relief valve assy
28 49
F16969
DOWN
P1 BYPASS 11 ARM
PASSAGE 52 21
BUCKET 12 62
28
62
DIGGING OUT
DUMP IN
BOOM
BYPASS CUT CONFLUX 14 P2 BYPASS CUT
13
TANK BOOM
ARM CONFLUX PASSAGE PASSAGE 60 CONFLUX
PASSAGE 58
31102 60413252
Fig. 4-4 Hydraulic circuit and designation of main parts
24-22
COMPONENTS SYSTEM
4.4 FUNCTIONAL EXPLANATION

(1) Neutral
The oil discharged from port A1 of the hydraulic not shut off by travel straight spool (7). Therefore,
pump enters port P1. It then flows into the control the oil passes through the travel (right) boom
valve (C/V), passes through the land of travel bucket the bypass path (52) of the P1 side
straight spool (7) and flows into the P1 parallel of the P1 bypass cut spool, in that order, and flows
path (53) and the travel spool. In the neutral out of the T1 port past the tank passage (60)
position, the bypass path (52) on the P1 side is (Fig.4-5).
TRAVEL STRAIGHT SPOOL (7) P1 PORT PASSAGE
T1 PORT PASSAGE
P1 SIDE BYPASS PASSAGE (52)
P1 SIDE PARALLEL PASSAGE (53)

SECTION AA
P1 SIDE MAIN PASSAGE (51)

P1 PORT
TRAVEL (R)
BOOM
BUCKET
P1 BYPASS
CUT VALVE
31102 60413252

P1 SIDE BYPASS PASSAGE (52) TANK PASSAGE (60)
SECTION BB
Fig. 4-5 Operation (1) at neutral
24-23
COMPONENTS SYSTEM
The oil which entered the P2 port from the A2 port Therefore, the oil passes through the travel (left)
of the hydraulic pump flows into the C/V, passes swing arm the P2 bypass path (55) of the
through the land of travel straight spool (7), and P2 bypass cut spool, and flows out of the T1 port
flows into the P2 parallel path (56) and the travel past tank path (60) (Fig.4-6).
spool. In the neutral position, the P2 bypass path
(55) is not shut off by the travel straight spool (7).
P2 PORT PASSAGE
P2 PARALLEL PASSAGE (56)
T1 PORT
SECTION AA
T2 PORT P2 MAIN PASSAGE (54)
TRAVEL STRAIGHT (7)
TRAVEL (L)
SWING
ARM
BOOM
CONFLUX CUT VALVE 2
VALVE
31102 60413252
P2 SIDE BYPASS PASSAGE (55) P2 PARALLEL PASSAGE (60) TANK PASSAGE (60)
SECTION BB
Fig.4-6 Operation (2) at neutral
24-24
COMPONENTS SYSTEM
(2) Travel operation supplied to the travel motor from the A1 and D1
1) Travel forward operation ports which are now open because the bypass
If the travel straight operation is performed the paths (52, 55) are shut off by the spool (8) which
secondary pilot pressure enters the spring chamber is shifted.
of the Pal and Pd1 ports of the C/V from the travel In the meantime, the oil returning from the travel
pilot valve, and shifts the travel spool (8). The oil motor flows into the C/V from the B1 and C1 ports
which flows in from the pump port passes through and flows into the tank path (60) which is now
the land of travel straight spool (7) and flows into open as the travel spool (8) has been shifted.
the main paths (51), (54) of travel spool (8). The oil
which flows into the main paths (51, 54) is then
LEFT TRAVEL MOTOR
TRAVEL SPOOL (8)
P2 SIDE
BYPASS PASSAGE (55)
P2 SIDE
MAIN PASSAGE (54)
FROM PILOT
VALVE FOR TRAVEL
TRAVEL (L)
TRAVEL (R)
FROM PILOT
VALVE FOR TRAVEL
TANK PASSAGE (60)
P1 SIDE MAIN PASSAGE (51)

RIGHT TRAVEL MOTOR
Fig.4-7 Functions at travel straight operation

31102 60413252
24-25
COMPONENTS SYSTEM
2) Travel reverse operation The oil which flows from the main paths (51), (54)
If the travel reverse operation is carried out, the is supplied to the travel motor from the B1 and C1
secondary pilot pressure enters the opposite side ports which are now open, because the bypass
of the chamber of the Pb1 and Pc1 ports from the paths (52), (55) are shut off by the spool (8) now
travel pilot valve, and shifts the travel spool (8). shifted.
The oil which has flowed in from the pump port In the meantime, the oil returning from the travel
passes through the land of the travel spool (7) and motor flows into the C/V from the A1 and D1 ports
flows to the main paths (51), (54) of travel spool and flows to the tank path (60) which is now open
(8). as the travel spool (8) has been shifted.
P2 SIDE MAIN PASSAGE (54) LEFT TRAVEL MOTOR

TRAVE SPOOL (8)
FROM
PILOT VALVE
FOR TORAVEL
TRAVEL (L)
TRAVEL (R)
FROM
PILOT VALVE
FOR TRAVEL
P1 SIDE MAIN PASSAGE (51) TANK PASSAGE (60)
RIGHT TRAVEL MOTOR
Fig. 4-8 Functions at travel reverse operation

31102 60413252
24-26
COMPONENTS SYSTEM
(3) Bucket operation section, and is fed to the head of the bucket
1) Bucket digging operation cylinder by way of the bridge path and the A3 port.
If the bucket digging operation is performed, the Meanwhile, the oil which has returned from the
secondary pilot pressure enters the spring chamber cylinder rod flows into the B3 port, passes through
of the Pa3 port of the C/V from the pilot valve and the spool notch which is opened as the bucket
moves the bucket spool (12). When the bucket spool (12) is shifted, and flows out to the tank
spool has been shifted, the P1 bypass path (52) is passage (60). As the result, the bucket cylinder
shut off by the bucket spool (12). Therefore, the oil operates in the extending direction whereby the
which has flowed in from the P1 port flows into the bucket performs digging operation.
P1 parallel path (53) arranged in the travel straight
part. Now the passage betweean the A3 port and
the bridge path is opened as the bucket spool (12)
has been shifted. Therefore, the oil which has
flowed into the P1 parallel path (53) passes through
the load check valve (21) in the bucket select
ARM SPOOL (11)
TANK PASSAGE (60) P1 SIDE BYPASS PASSAGE (52)
BUCKET SPOOL (12)
FROM
PILOT VALVE
NOTCH
LOAD CHECK VALVE (21)

BRIDGE PASSAGE BRIDGE PASSAGE
BUCKET CYLINDER
Fig. 4-9 Functions at bucket digging operation

31102 60413252
24-27
COMPONENTS SYSTEM
2) Bucket dump operation Therefore, the oil which flows into the P1 parallel
If the bucket dump operation is performed, the path (53) passes through the load check valve
secondary pilot pressure enters the opposite side (21) of the bucket select part, and is fed to the rod
of the spring chamber of the Pb3 port of the C/V of the bucket cylinder by way of the bridge path
from the pilot valve and shifts the bucket spool and the B3 port.
(12). In the meantime, the oil returning from the cylinder
If the spool is shifted, the P1 bypass path (52) is head flows into the A3 port and flows out to the
shut off by the bucket spool (12). Therefore, the oil tank passage (60) which is now open as the
which has flowed in from the P1 port flows into the bucket spool (12) has been shifted. Therefore, the
P1 parallel path (53) provided in the travel straight bucket cylinder operates in the contracting direction
spool. in order to dump the bucket.
When the bucket spool (12) is shifted, the line
between the B3 port and the bridge path is opened.
ARM SPOOL (11)
P1 SIDE BYPASS PASSAGE (57) CUT OFF

TANK PASSAGE (60)
BUCKET SPOOL (12)
FROM
PILOT VALVE

BRIDGE PASSAGE P1 SIDE PARALLEL PASSAGE (53)
BUCKET CYLINDER
Fig. 4-10 Function at bucket dump operation

31102 60413252
24-28
COMPONENTS SYSTEM
(4) Boom operation The line between the A2 port and the bridge path
1) Boom up operation is opened as the boom spool is shifted. Therefore,
If the boom up operation is performed, the the oil which has flowed into the P1 parallel path
secondary pilot pressure enters the spring chamber (53) passes through the load check valve (21) of
of the Pa2 port of the C/V from the pilot valve and the boom select part and is fed to the head of the
shifts the boom spool (10). boom cylinder from the A2 port via the bridge path
The P1 bypass path (52) is shut off by the boom and the lock valve (28) (free flowing condition)
spool (10) as the spool has been shifted. Therefore, (Fig.4-11).
the oil which has flowed in from the P1 port flows
into the P1 parallel path (53) provided in the travel
straight spool.
SWING SPOOL (9)

LOCK VALVE (28)
BOOM SPOOL (10)
FROM
PILOaT VALVE
LOAD BRIDGE PASSAGE

CHECK VALVE (21)
BOOM CONFLUX PASSAGE (58) P1 SIDE PARALLEL PASSAGE (53)
BOOM CYLINDER
Fig. 4-11 Boom up opperation

31102 60413252
24-29
COMPONENTS SYSTEM
The secondary pilot pressure for boom up The oil which has flowed into the boom conflux
operation is branched off. At the same time, path (58) passes through the load check valve
secondary pilot pressure enters the spring (21) of the boom select part and is fed to the boom
chambers of the boom conflux spool (13) and the cylinder head from the A2 port (Fig.4-11).
P2 bypass cut spool and shifts the boom conflux As the result, the oil flow at the P1 port is combined
spool (13) and the P2 bypass cut spool (14) (Fig.4- with that at the P2 port and is fed to the boom
12). cylinder head.
If the P2 bypass cut spool (14) is shifted the P2 In the meantime, the oil which has returned from
bypass path (55) is cut off by the P2 bypass cut the cylinder rod flows into the B2 port and flows to
spool (14). Therefore, the oil which has flowed in the tank path (60) which is now open as the boom
from the P2 port flows into the P2 parallel path (56) spool (10) is shifted.
provided upstream of the P2 bypass path (55). Consequently, the boom cylinder operates in the
The oil which has flowed into the P2 parallel path extending direction and raises the boom.
(56) flows into the boom conflux path (58) which is
now opened as the boom conflux spool (13) is
shifted.
P2 SIDE PARALLEL PASSAGE (56) P2 SIDE BYPASS PASSAGE (55) CUT OFF
P2 BYPASS
BOOM CONFLUX SPOOL (13) CUT SPOOL (14)
PILOT PILOT
PRESSURE PRESSURE
P1 BYPASS CUT
SPOOL (15)
BOOM CONFLUX PASSAGE (58)
Fig. 4-12 Functions of the boom conflux spool and the P2 bypass cut spool
31102 60413252
24-30
COMPONENTS SYSTEM
(5) Boom down operation In the meantime, the oil which has returned from
If the boom down operation is performed, the the cylinder head flows into the A2 port and flows
secondary pilot pressure enters the opposite side out to the tank path (60) from the spool notch
of the spring chamber of the Pb2 port of the C/V which is now open as the boom spool (10) is
from the pilot valve and shifts the boom spool (10). shifted. (Refer to Fig.4-15 for the functions of the
If the boom spool is shifted, the P1 bypass path lock valve).
(52) is cut off by the boom spool (10). The oil which As the result, the boom cylinder operates in the
has flowed in from the P1 port flows into the P1 contracting direction to lower the boom. (The
parallel path (53) provided in the travel straight boom cylinder rod is not subject to the combined
spool. flow of the flow from the P1 port and that from the
Part of the oil passes through the P1 bypass path P2 port.)
(52) past the notch of the boom spool (10) and
flows out to the tank path (60).
Transfer of the boom spool opens the line between
the B2 port and the bridge path. The oil which has
flowed into the P1 parallel path (53) passes through
the load check valve (21) in the boom select part
and is fed to the boom cylinder rod by way of the
bridge path and the B2 port.
SWING SPOOL (9) P1 SIDE BYPASS PASSAGE (52)

NOTCH
TANK PASSAGE (60)
BOOM SPOOL (10) LOCK VALVE (28)
FROM
PILOT VALVE
BOOM

BRIDGE PASSAGE
BOOM CYLINDER
31102 60413252
Fig. 4-13 Functions at boom down operation
24-31
COMPONENTS SYSTEM
(6) Function of lock valves (boom and arm) 2) The oil which has returned from the boom cylinder
1) When the boom spool (10) is in neutral position, passes through the lock valve (28) and fills up the
the pilot piston chamber C is connected with the lock valve chamber. Therefore, the needle valve
drain path via the pilot port Pb2 (for releasing the [poppet valve (29)] is positively seated against the
lock valve). The piston C (36) is therefore held by poppet seat, while the lock valve is also firmly
the spring. seated against the body seat.
PILOT PISTON PILOT PISTON
RETURN SPRING CHAMBER CHAMBER A CHAMBER C
BOOM SPOOL (10) TANK PASSAGE PILOT PORT FOR

SPOOL CHANGE
LOCK VALVE
CHAMBER
LOCK VALVE (28)
BODY SEAT
NEEDLE VALVE
[POPPET (29)] PISTON A (34) PISTON C (36)
CYLINDER PORT POPPET SEAT SPRING PILOT PORT FOR LOCK
VALVE RELEASE
Fig.4-14 The hold condition of lock valve
3) The moment the boom spool (10) is shifted to the 4) If the needle valve [poppet (29)] opens, the
spring chamber side, the Pb2 port of the lock valve pressure of the lock valve chamber falls. The
releasing pilot line is pressurized. The piston A result is that the oil returning from the cylinder
(34) is pressed by the piston C (36) and opens the opens the lock valve (28) and then runs directly
needle valve [poppet (29)]. On the occasion, the into the tank path via the boom spool (10).
oil passes through the lock valve lock valve 5) If the boom spool (10) is brought back to neutral,
chamber pilot piston chamber B drilled hole the lock valve returns to a state whereby the lock
A, in that order, and flows to the drain port DR5. valve is positively seated against the body seat.
BOOM SPOOL (10)
CHANGE
DIRECTION
OF THE SPOOL
31102 60413252
FROM CYLINDER TO DRAIN

PILOT PISTON PASSAGE
CHAMBER B DRILLED HOLE A PILOT PRESSURE
FOR LOCK VALVE RELEASE
Fig. 4-15 Lock valve in open condition DRAIN PORT DR5
24-32
COMPONENTS SYSTEM
(7) Swing operation Then, the proportional secondary pressure of the

1) Swing left operation P2 bypass cut solenoid valve shifts the P2 bypass
If the swing left operation is performed, the cut spool (14) in the lower stream and cuts off the
secondary pilot pressure from the pilot valve enters oil path. This causes all the oil flowing out to the P2
the spring chamber of the Pd2 port of the C/V and bypass path to be fed to the swing motor, in order
shifts the swing spool (9). to soften the swing speed.
At the same time, the secondary pressure from If the swing spool (9) is shifted, the line between
the pilot valve enters the Pd2 port through the the D2 port and the bridge path is opened by the
external piping and flows into the swing preference spool notch. As the result, the oil which has flowed
section via the shuttle valve. (Refer to Fig.4-23 for into the P2 parallel path (56) passes through the
the swing priority section). load check valve (21) in the swing select part, and
When the swing spool (9) is shifted, the P2 bypass is fed to the swing motor via the bridge path and
path (55) is shut off by the swing spool (9). The oil the D2 port.
which has flowed in from the P2 port flows into the In the meantime, the oil which has returned from
P2 parallel path (56) provided in the travel straight the swing motor flows into the C2 port and flows
spool. into the tank path (60) from the spool notch which
Part of the oil passes through the notch in the is now open as the swing spool (9) is shifted.
swing spool (9) and the P2 bypass path (55), and Consequently, the swing motor rotates
flows out to the tank passage. counterclockwise.
P2 SIDE PARALLEL PASSAGE (56) P2 SIDE BYPASS PASSAGE (55) CUT OFF
TANK PASSAGE (60) SWING MOTOR
TO SWING
PRIORITY
SECTION LOAD
CHECK VALVE (21) BRIDGE PASSAGE
FROM
PILOT VALVE NOTCH
FROM
SHUTTLE VALVE PILOT VALVE
SWING SPOOL (9)
BOOM SPOOL (10) NOTCH

31102 60413252
Fig. 4-16 Function at swing left operation
24-33
COMPONENTS SYSTEM
2) Swing right operation Next, the secondary proportional pressure of the

If the swing right operation is performed, the P2 bypass cut solenoid valve shifts the P2 bypass
secondary pilot pressure from the pilot valve cut spool (14) in the lower stream and cuts off the
enters the opposite side of the spring chamber of oil flowing out to the P2 bypass path. The result is
the Pc2 port of the C/V and shifts the swing spool that all the oil is fed to the swing motor to soften the
(9). At the same time, the secondary pressure swing speed.
from the pilot valve flows into the swing priority Shift of the swing spool (9) causes the line between
section via the shuttle valve. (Refer to Fig.4-23 for the C2 port and the bridge path to be opened by
the function of the swing priority section); the spool notch. The oil which has flowed into the
Shift of the swing spool (9) causes the P2 bypass P2 parallel path (56) passes through the load
path (55) to be cut off. Therefore, the oil which has check valve (21) in the swing select section and is
flowed in from the P2 port flows into the P2 parallel fed to the swing motor by way of the bridge path
path (56) provided in the travel straight spool. and the C2 port.
Part of the oil passes through the notch of the In the meantime, the oil returning from the swing
swing spool (9) and the P2 bypass path (55) and motor flows into the D2 port and flows out to the
flows out to the tank path (60). tank path (60) from the spool notch which is now
open by the shift of the swing spool (9).

TANK PASSAGE (60)
SWING MOTOR
TO SWING
PRIORITY
SECTION LOAD BRIDGE PASSAGE
CHECK VALVE (21)
SHUTTLE VALVE
FROM PILOT VALVE
SWING SPOOL (9)
BOOM SPOOL (10)

NOTCH
Fig. 4-17 Functions at swing right operation

31102 60413252
24-34
COMPONENTS SYSTEM
(8) Arm operation Since the shift of the arm spool (11) causes the
1) Arm in operation line between the C3 port and the bridge path to be
If the arm in operation is performed, the secondary open, the oil which has flowed into the P2 parallel
pilot pressure from the pilot valve enters the path (56) passes through the load check valve
opposite side of the spring chamber of the Pc3 (21) in the arm select part and is fed to the arm
port of the C/V and shifts the arm spool (11). cylinder head by way of the bridge path and the C3
Shift of the arm spool (11) causes the P2 bypass port (Fig.4-18).
path (55) to be cut off. Therefore, the oil which has
flowed in from the P2 port flows into the P2 parallel
path (56) provided in the travel straight spool.
ARM CYLINDER

ARM CONFLUX PASSAGE (59)

ARM LOCK VALVE (28)
BRIDGE PASSAGE
FROM PILOT VALVE
ARM SPOOL (11)
TANK PASSAGE (60)
BUCKET SPOOL (12)

Fig. 4-18 Function at arm in operation

31102 60413252
24-35
COMPONENTS SYSTEM
In the meantime, the mechatro control system Thus the arm cylinder head is subject to the oil
causes the secondary pilot pressure stream at P1 port and that at port P2 combined.
(electromagnetic proportional) to enter the spring The oil which has flowed into the arm conflux path
chamber of the P1 bypass cut spool (15) and shifts passes through the load check valve (21) in the
the spool (15) (Fig.4-19). arm select section and is fed to the arm cylinder
Shift of the P1 bypass cut spool (15) causes the head from the C3 port (Fig.4-18).
P1 bypass path to be shut off. The oil which has In the meantime, the oil which has returned from
flowed in from the P1 port flows into the P1 parallel the cylinder rod flows into the D3 port and flows
path (53) provided in the check valve built in the out to the tank path (60) from the spool notch
P1 bypass cut spool (15) and upstream of the P1 which is now open by the shift of the arm spool via
bypass path (52). the lock valve (28). (Refer to Fig.4-14 for the
The oil which has flowed into the check valve and functions of the lock valve).
the P1 parallel path (53) flows into the arm conflux Consequently, the arm cylinder operates in the
path (59) which is now open by the shift of the P1 extending direction to cause the arm to dig.
bypass cut spool (15) (Fig.4-19).
NOTCH
NOTCH
PILOT PRESSURE
SPRING
P1 BYPASS CUT SPOOL (15)
P1 SIDE
PARALLEL PASSAGE (53)
CHECK VALVE
Fig. 4-19 Functions of P1 bypass cut spool

31102 60413252
24-36
COMPONENTS SYSTEM
2) Arm out operation If the arm spool (11) is shifted, the line between
If the arm out operation is performed, the secondary the D3 port and the bridge path is opened. The oil
pilot pressure from the pilot valve enters the which has flowed into the P2 parallel path (56)
spring chamber of the Pd3 port of the C/V and passes through the load check valve (21) in the
shifts the arm spool (11). If the arm spool (11) is arm select section and is fed to the arm cylinder
shifted, the P2 bypass path (55) is cut off by the rod by way of the bridge path, the lock valve (28)
arm spool (11). The oil which has flowed in from and the D3 port (free flow state) (Fig.4-20).
the P2 port flows into the P2 parallel path (56)
provided in the travel straight spool.
ARM CYLINDER
P2 SIDE LOAD CHECK VALVE (21)

ARM LOCK VALVE (28)
BRIDGE PASSAGE
ARM SPOOL (11)
FROM PILOT VALVE
TANK PASSAGE (60)
BUCKET SPOOL (12)
P2 SIDE BYPASS
PASSAGE (56) CUT OFF
Fig. 4-20 Functions at arm out operation

31102 60413252
24-37
COMPONENTS SYSTEM
In the meantime, the electromagnetic proportional The oil which has flowed into the arm conflux path
secondary pilot pressure created by the mechatro (59) passes through the load check valve (21) in
control system enters the spring chamber of the the arm select section and is fed to the arm
P1 bypass cut spool (15). (Fig.4-21) cylinder rod from the D3 port (Fig.4-20).
Since the P1 bypass path (52) is cut off by the As the result, the arm cylinder rod is subject to the
shifted P1 bypass cut spool (15), the oil which has combination of the stream of the P1 port and the
flowed in from the P1 port flows into the check stream of the P2 port. In the meantime, the oil
valve built in the P1 bypass cut spool (15) and into returning from the cylinder head flows into the C3
the P1 parallel path (53) provided upstream of the port and flows out to the tank path (60) which is
P1 bypass path (52). now open by the shifted arm spool (11).
The oil which has flowed into the check valve and Consequently, the arm cylinder operates in the
the P1 parallel path (53) flows into the arm conflux retracting direction to cause the arm to out.
path (59) which is now opened by the shifted P1
bypass cut spool (15) (Fig.4-21).
NOTCH
NOTCH
SPRING
PILOT PRESSURE CHAMBER
P1 BYPASS CUT SPOOL (15)

P1 SIDE
CHECK VALVE
Fig. 4-21 Functions of P1 bypass cut spool

31102 60413252
24-38
COMPONENTS SYSTEM
(9) Combined operation The hydraulic oil supplied from the P2 port flows
1) Simultaneous operation of travel and attachment into both travel select sections and at the same
(travel straight function) time flows into the P1 and P2 parallel paths (53),
The pilot line for a change signal of the travel (56) leading to the attachment select part, by way
straight spool (7) is normally (at neutral) connected of the orifice of the travel straight spool (7).
with the drain path by means of the travel straight As the result, if the attachment select section is
solenoid valve. Therefore, the travel straight spool changed over when both travel select sections are
(7) is not changed over. changed, the hydraulic oil supplied to the P2 port
If a combined operation of travel and attachment acts mainly on both travel select sections, whereas
is performed, the travel straight solenoid valve is the hydraulic oil supplied to the P1 port acts mainly
excited by the mechatro control system. Therefore, on the attachment select section. Consequently,
the electromagnetic secondary pilot pressure the pressure variation of the P2 port is small with
enters the P0 port of the C/V and shifts the travel limited branching of oil to both travel select sections.
straight spool (7). Consequently, the machine runs straight without
If the travel straight spool (7) is shifted, the hydraulic deviation and provides proper attachment action.
oil supplied from the P1 port flows into the P1 and
P2 parallel paths (53), (56) leading to the
attachment select section. At the same time, the
hydraulic oil flows into both travel select sections
via the orifice of the travel straight spool (7)
P2 SIDE PARALLEL PASSAGE

(56)
(TO ATTACHMENT)
P1 PORT PASSAGE
P2 PORT PASSAGE
NOTCH
TRAVEL
STRAIGHT SPOOL (7)
PRESSURIZE BY A
CHANGEOVER SIGNAL
P2 SIDE
BYPASS PASSAGE (55)
(TO TRAVEL MOTOR)
P1 SIDE PARALLEL PASSAGE (53) P1 SIDE BYPASS PASSAGE (52)

(TO ATTACHMENT) (TO TRAVEL MOTOR)
Fig. 4-22 Functions of travel straight spool

31102 60413252
24-39
COMPONENTS SYSTEM
2) Simultaneous operation of arm and swing actions If the swing operation is stopped, the secondary
(swing priority function) pilot pressure from the swing pilot valve does not
If the arm and the swing actions are performed at flow into the Ps port. Therefore, the piston (67) is
the same time, the secondary pilot pressure from pushed up by spring (70). This releases the force
the swing pilot valve flows out again from the Ps' pressing the load check valve (21) located in the
port of the C/V and flows into the Ps port by way P2 parallel path (56) of the arm select section.
of the external piping.
The oil which has flowed into the Ps port pushes
in the piston D (67) that is held by the spring (70)
and presses the load check valve (21) provided in
the P2 parallel path (56) of the arm select section,
via the stopper pin (65). As the result, the hydraulic
oil from port P2 flows preferentially into the swing
system at all times, free from the size of the load
to the arm cylinder.
ARM CYLINDER
SWING PILOT
SECONDARY PRESSURE
STOPPER PIN (65)

PISTON D (67)
SPRING (70)
BRIDGE PASSAGE
ARM PILOT VALVE

FOR ARM IN
ARM SPOOL (11)
TANK PASSAGE (60)
BUCKET SPOOL (12)

31102 60413252
P2 SIDE BYPASS
PASSAGE (55) CUT OFF
Fig. 4-23 Closing the load check valve (49) by secondary swing pilot pressure
24-40
COMPONENTS SYSTEM
(10) Function of main relief valve ORIFICE B

1) The hydraulic oil P is filled up in the inner chamber SOCKET T POPPET F
PASSAGE
A past the inside of the piston built in the plunger
G and the orifice B. The poppet F is securely
seated against the socket which is also positively
sealed against the regulator body.
A CHAMBER
PLUNGER G
PISTON
Fig. 4-24
2) When the hydraulic pressure at port P reaches a ANNULAR ORIFICE D SPRING C

set pressure of the spring C, it acts upon the
poppet F via the piston and opens the poppet F.
On that occasion, the hydraulic oil flows out to the
tank passage past the piston inside the orifice
B the chamber A the annular orifice D, and
T PASSAGE
the passage E, in that order. PASSAGE E
Fig. 4-25
T PASSAGE
3) If the poppet F opens, the pressure of chamber A
falls. Then the plunger G opens and the pressure
of port P flows directly to the tank T passage
through drilled hole H.
DRILLED HOLE H
Fig. 4-26
4) If the pressure at port P falls below a set value of

spring C, the poppet F is pressed against the seat
by the action of spring C. As the result, the
pressure of chamber A equals that of port P. This
presses the plunger G against the socket seat and
brings it back where it was (Fig.4-24).
31102 60413252
24-41
COMPONENTS SYSTEM
(11) Function of over road relief valve

CHOKE B PISTON
1) Pressurized oil P is filled up in chamber A through
T PASSAGE
the inside of the piston built in the plunger G and
choke B.
The plunger G and the socket are sealed securely.
The socket is sealed securely against the poppet
BODY SEAT
as well.
SOCKET PLUNGER G POPPET F
CHAMBER A
Fig. 4-27
2) When the hydraulic pressure at port P arrives at a T PASSAGE

set value of spring C, it pushes the piston which in
turn opens the poppet F.
On that occasion, the hydraulic pressure goes
through the inside of the piston choke B
chamber A annular orifice D and drilled hole E
goes around the outer circumference of the socket ANNULAR DRILLED SPRING C
ORIFICE D HOLE E
and flows out to the tank passage
Fig. 4-28
3) If the poppet opens, the pressure of chamber A

falls. Then the plunger G opens and the pressure
of port P flows directly to the tank T passage
through drilled hole F.
T PASSAGE DRILLED HOLE F
Fig. 4-29
4) If the pressure at port P falls below a set value of

T PASSAGE
spring C, the poppet F is pressed against the seat
by the action of spring C. As the result, the
pressure of chamber A equals that of port P. This
presses the plunger G against the socket seat and
brings it back where it was (Fig.4-27).
Fig. 4-30
5) Function of anti-cavitation
This function supplies oil from the T (tank) path in
case negative pressure occurs at port P. When
the tank path pressure gets higher than that of port
31102 60413252
P, the socket is subject to a force that pushes it up.

This creates a space between the body seat and
the socket. The oil from the T path (tank) flows into
port P, and fills up the space.
24-42
COMPONENTS SYSTEM
5. SWING MOTOR UNIT
5.1 SPECIFICATION
(1) General view
REDUCTION UNIT LUBRICATION PORT
B PORT RELIEF VALVE REDUCTION UNIT OIL LEVEL GAUGE
PLUG FOR MEASURING PRESSURE

2-PT1/4
BLEED
PORT
PF3/8 (PLUG)
AIR BLEED PORT MU PORT RG
LUBRICATION
REDUCTION UNIT PORT
A PORT RELIEF VALVE DRAIN HOSE RG
PT3/8 DRAIN PORT
The air bleed port RG GREASE
PT1/2 REDUCTION UNIT when RG grease LUBRICATION
LUBRICATION PORT BYPASS VALVE is filled up. HYDRAULIC DIAGRAM PORT
P
(PG)
SYM PORT
PORT NAME
-BOL SIZE
A Main port PF 1/2
B Main port PF 1/2
MU Make-up port PF 3/4
Dr Drain port PF 3/8
Parking brake
P PF 1/4
release port (PG)
F17009
31102 60413252
PT1/8 (RELIEF NIPPLE)

FOR AIR BLEED AT
LUBRICATION PT1/8 (GREASE NIPPLE)
The air bleed port when RG grease is filled up.
Fig. 5-1 General view of swing motor unit
24-43
COMPONENTS SYSTEM
(2) Specifications
Table 5-1
Item
Swing unit
Specifications
Type Motor
Reduction unit
Working pressure kgf/cm2 (psi) 250 (3360)
Reduction ratio 1:15.54
Output torque kgf·m (lbf·ft) 236 (3360) at 250 kgf/cm2 (3360 psi)
Braking torque kgf·m (lbf·ft) 18.9 (1.4)
Brake release pressure kgf/cm2 (psi) 20 (280), Allowable 40 (570)
The rotating direction (as seen from the shaft end) A port in : Clockwise, B port in : Counterclockwise
Weight (Including reduction unit) kg (lbs) 67 (148)
Reduction unit lubricate oil Nisseki gearlube SP90 : 1.5L (0.40 gal)
Grease Shell alvania EP2 : 150cc (9.15 cu·in)
5.2 EXPLANATION OF CONSTRUCTION

1) The rotary group of the swing motor consists of a Swing unit
cylinder (M-19) which is integral with the drive
shaft and seven piston assy (M-21) arranged in
the cylinder bores. The cylinder (M-19) is supported Swash plate type Two-stage planetary
by bearings (M-1) (M-6) on both ends. axial piston motor gear reduction unit
Each piston assy (M-21) is guided by a return
plate (M-22) and retaining spring (M-20) so as to Mechanical brake
slide smoothly on the cam plate (M-23).
The balance plate (M-10) is forced against the end
Relife valve
of the cylinder by the force of the disc spring (M-
15) and the hydraulic force acting on the bushing
Make-up valve
(M-14).
A mechanical brake is installed between the
cylinder exterior and the housing (M-26). By-pass valve
F17008
A relief valve to cushion hydraulic shock and a
backup valve to prevent cavitation are built in to
the cover (M-39).
2)
31102 60413252
24-44
COMPONENTS SYSTEM
5.3 CONSTRUCTION
(1) Swing motor
31102 60413252
Fig. 5-2 Swing motor
24-45
COMPONENTS SYSTEM
M-1 TAPER ROLLER BEARING 1 M-22 RETURN PLATE 1
M-3 FRICTION PLATE 2 M-23 CAM PLATE 1
M-4 SEPARATOR PLATE 2 M-24 LEVEL GAUGE 1
M-5 SNAP RING 1 M-25 O-RING 1
M-6 NEEDLE BEARING 1 M-26 HOUSING 1
M-7 O-RING 1 M-27 COLLAR 1
M-8 O-RING 1 M-28 OIL SEAL 1
M-9 O-RING 1 M-30 BACKUP RING 2
M-10 BALANCE PLATE 1 M-31 O-RING: 1B P21 2
M-11 PISTON 2 M-33 BACKUP RING 2
M-12 TEFLON RING 2 M-34 O-RING: 1B P26 2
M-13 PLUG: PT 1/4 2 M-35 PARALLEL PIN 2
M-14 BUSHING 4 M-36 PLUG: PF 3/8 1
M-15 SCROWAVE 4 M-37 O-RING: 1B P14 1
M-16 TEFLON RING 4 M-38 SOCKET BOLT: M12 X 30 4
M-17 SPRING 13 M-39 COVER 1
M-18 PISTON 1 M-40 PLUG 1
M-19 CYLINDER 1 70 RELIEF VALVE ASSY 2
M-20 SUPPORT SPRING 1 100 BY-PASS VALVE ASSY 2
M-21 PISTON ASSY 7
F17007
1) Relief and check valve assy (70)

70 RELIEF AND 2 82 SEAT 2
CHECK VALVE ASSY 83 POPPET 2
71 LOCK NUT 2 84 SPRING 2
72 CAP 2 85 O-RING 2
76 BACKUP RING 2 86 SHIM 2
77 O-RING: 1B P26 2 87 PISTON 2
78 SPRING 2 88 SLEEVE 2
79 BUSHING 2 89 O-RING 2
Fig. 5.3 Detail of relief and check valve assy 80 CHECK 2 90 CAP 2
81 SLEEVE 2
F17000
2) By-pass valve assy (100)

100 BY-PASS VALVE ASSY 2 106 O-RING: 1B P21 2
101 SEAT 2 107 BACKUP RING 2
102 SLEEVE 2 108 CAP 2
103 POPPET 2 109 SPRING 2
31102 60413252
104 BACKUP RING 2 110 POPPET 2

105 O-RING: 1B P14 2 111 SPRING 2
F16999
Fig. 5-4 Detail of by-pass valve assy (swing shockless valve)
24-46
COMPONENTS SYSTEM
(2) Swing reduction unit
Fig. 5-5 Swing reduction unit
R-1 PINION SHAFT 1 R-15 HOLDER 2 ASSY 1
R-2 COLLAR 1 R-16 NEEDLE BEARING 6
R-3 PLATE 1 R-17 SHAFT 2 3
R-4 TAPER ROLLER BEARING 1 R-18 SPUR GEAR 5 3
R-5 GEAR CASE 1 R-19 THRUST PLATE 2 6
R-6 PLUG: PT1/8 1 R-20 SPRING PIN: 8 X 15 3
R-7 OIL SEAL 1 R-21 HOLDER 2 1
R-8 TAPER ROLLER BEARING 1 R-22 COLLAR 2
R-9 PIN 2 R-23 RELIEF NIPPLE 1
31102 60413252
R-10 RING GEAR 1 R-24 CONNECTOR 1

R-11 SPUR GEAR 4 1 R-25 ELBOW 1
R-12 SUN GEAR 1 R-26 HOSE 1
R-13 HOLDER 1 ASSY 1 R-27 PLUG 1
R-14 SOCKET BOLT: M12 X 95 6
F16998
24-47
COMPONENTS SYSTEM
5.4 OPERATION In this way, every piston assy (M-21) receives the
(1) Swing motor pressure oil within the stroke from top dead point
The pressure oil fed by the pump via the control to bottom dead point on a grade, the oil pressure
valve, etc. enters the motor through port A (or port is converted to rotating power to rotate cylinder
B) installed on cover (M-39), and is discharged assy (M-19), resulting in discharging oil in the
from port B (or port A). stroke from bottom dead end and top dead point.
Also the oil leaking through the sliding section or The discharge line function in reverse of the
clearance returns to the tank through drain port Dr supply line, and the oil is discharged from port B.
installed on cover (M-39). As described above, the hydraulic motor is
The pressure oil fed to port A goes through passage operated, and the output torque of hydraulic motor
(b) inside of cover (M-39) and to the passage on is determined by oil pressure, and speed of
bushing (M-11) section installed cover, then is fed revolution by supply flow rate.
to piston bore (f) on the cylinder through balance (2) Parking brake
plate (M-10) passage (b) which contains crescent Separator plate (M-4) is fitted to the external
shaped port switching supply and discharge by section of cylinder assy (M-19) with spline.
180 degree of core rotation of motor, and cylinder Friction plate (M-3) is fitted to housing (M-26).
(M-19) passage (e). When the primary pilot pressure of brake release
The pressure oil exerts on piston assy (M-21), port is Zero, brake piston (M-18) locks the cylinder
then the piston assy is pushed against cam plate (M-19) (output shaft) which is rotated by the force
(M-23) through a part of the shoe. Since the shoe of the spring (M-17) pushing separator plate and
sliding surface of cam plate (M-23) is inclined at a friction plate.
uniform angle, the pushing force of piston assy Conversely, when pressure of 20 to 40 kgf/cm2
(M-21) on which pressure oil is exerted is converted (280 to 570psi) exerted on the brake relief port,
into sliding power for the shoe on the swash plate. brake piston power exceeds the force of spring
In addition, the shoe bulb is similarly joined to and strokes to the contact with cover end. Then
universal joint. As a result, the shoe sliding power space is generated between mating parts, and the
on the swash plate is converted into rotating mechanical brake released.
power through piston assy (M-21) and cylinder
assy (M-19) and transmitted to the motor output
shaft section.
31102 60413252
Fig.5-6
24-48
COMPONENTS SYSTEM
(3) Relief valve 3) 2-step relief at braking

1) Starting (shockless relief action)
With operation of the lever, the oil fed to port A at The increased pressure at port B enters the piston
first escapes and is discharged to port B without chamber (L) past the path (t) of the poppet (83-B).
obtaining regular revolution because the force of The poppet begins to move to the right slowly by
inertia of the upper structure is larger. The hydraulic the throttling effect of the inlet path and stops
oil from port A to passage (i) of relief valve, opens when it hits the shoulder J of piston (87) and the
poppet (83), and is discharged to port B. stopper K of sleeve (88). It pushes the spring (84-
2) Braking (cushion) B), acting as 2-step relief that rises to a specified
By returning the lever to neutral position, the pressure. This absorbs impacts at starts and
return circuit of motor discharge oil close, and stops.
immediately after this operation, the motor is
rotated by the force of inertia resulting in pumping
function, and the oil is sucked from port A and
discharged to port B side. Then, since the return SHOULDER STOPPER K i PORT A SIDE
J OF PISTON OF SLEEVE g PORT B SIDE
circuit of the control valve is closed, the pressure B (A PORT)
of port B is raised. PASSAGE t
The raised pressure of port B opposes the spring
A
(84-B) force and opens poppet (83-B), and check (B PORT)
valve (80-B) through passage (g) (h), and flows
into passage (c). The movement stops while PISTON
absorbing the force of inertia in this process. CHAMBER
L
In the above-mentioned process of pressure At starting (port A side 80-A 84-A 83-A)
At braking (port B side 80-B 84-B 83-B)
increase, the oil at port B enters the piston (L)
chamber past the small orifice of poppet (83-A), Fig. 5-7 Detail of relief valve (70)
and causes the piston (87) to move till it hits the
cap (90). In this period, the poppet (83-A) is
already open, so that the cushion relief action
operates first at a little lower pressure.
(4) Make-up valve

1) Operation in half lever position 2) Braking
(When cushion relief valve does not function) (When cushion relief valve is functioned)
After accelerating slewing of the upper structure, When the lever is moved to neutral position rapidly
when the speed is being reduced by half-lever as described in item 1), the pump does not supply
with the function of control valve, the supply flow oil to port A, but the upper structure is slewed by
rate from pump to port A is lowered. But if the the force of inertia. In this case, the cushion relief
upper structure is slewed at a comparatively high valve on port B side functions, and the oil from
speed, the pressure in the (C) section is lowered relief valve goes through the passage (g) (h) and
to negative pressure making lubrication necessary. opens make-up check (80) valve on the port A
However, when the pressure of port B is equal to side to flow into passage (b) (c). But the oil
or lower than the working pressure of cushion quantity is insufficient due to the leakage.
relief valve the all oil of (C) section led through port Therefore oil opens make-up check valve (80)
B is discharged to the control valve. As a result, through the make-up port, and flows into passage
the flow rate from the control valve (Since the (b) (c) to prevent cavitation.
31102 60413252
valve is in the half-lever position, the flow rate from

pump is limited.) does not satisfy the specified oil
quantity. To prevent this, the make-up check
valve is installed to supply necessary oil into the
(C) section.
24-49
COMPONENTS SYSTEM
(5) By-pass valve (swing shockless valve) POPPET A

1) Accelerating
At the moment of swing operation, the high
pressure oil in the “A” side flows instantly into the
“B” side instantly, but the high pressure oil enters
the chamber on the back side of poppet A
simultaneously. Then poppet A moves rightward,
resulting in the poppet A "Close" condition shown
in Fig.5-9.
HIGH PRESSURE OIL
Fig. 5-8 Poppet A “open”
2) Braking
3) Reverse rotation
When braking, the pressure oil of B side is raised
After stopping the swing of the upper structure,
to high pressure, and the high pressure oil is
the motor is reverse-rotated by high pressure on
bypassed from B side to A side, but the high
the B side. But while the motor is rotated inversely,
pressure oil enters the chamber on the back side
the high pressure oil is by-pass from A side to B
of poppet B simultaneously.
side to hold the reverse rotation to one rotation or
The poppet B moves leftward, resulting in the
less, protecting the generation of reverse-rotation
poppet B "Close" condition.
pressure.
POPPET A
POPPET B
Fig. 5-9 Detail of poppet
SWING MOTOR
(6) Swing reduction gear
The power of the swing motor output shaft is
transmitted to spur gear 4 (R-11) on the 2nd stage RING GEAR
through sun gear (R-12) on the 1st stage and
holder assy (R-13).
Similarly, the power is transmitted to pinion shaft
(R-1) through spur gear 4 (R-11) on the 2nd stage
and holder assy 2 (R-15). The pinion shaft is
supported by two bearing (R-4) (R-8) in gear case
(R-5). A
CHAMBER
In addition, oil seal is installed at the center of gear
case (R-5) to protect the bearing on the pinion
31102 60413252
shaft side of which the load condition is difficult B

CHAMBER
from the gear friction power, and the A chamber
side is lubricated by oil in the gear case, and the
B chamber is lubricated by the grease sealed
inside.
Fig. 5-10 Function of reduction unit
24-50
COMPONENTS SYSTEM
6. TRAVEL MOTOR
6.1 CONSTRUCTION
(1) General view
OIL LEVEL CHECK PORT PF3/8 FILLING PORT PF3/8
DRAIN PORT PF3/8

VIEW Z
Fig. 6-1
6.2 HYDRAULIC CIRCUIT
HI LOW PORT NAME, SIZE
Table 6-1
No. PORTS SIZE
A Hydraulic oil filling / drain port
PF 1/2
B Hydraulic oil filling / drain port
D1 Drain port
PF 3/8
D2 Drain port
P 1st / 2nd speed select port PF 1/4
F17021
ROTATIONAL DIRECTION (Viewed from Z side)

31102 60413252
INLET B PORT, OUTLET A PORT, CW

INLET A PORT, OUTLET B PORT, CCW
Fig. 1-2
24-51
COMPONENTS SYSTEM
6.3 SPECIFICATIONS
Table 6-2
TYPE GM09VN-B-19/34-1
Reduction ratio 61.6
Reduction unit Output torque 1st / 2nd kgf·m (lbf·ft) 870 (6,300) / 472 (3,410)
Revolution speed 1st / 2nd rpm 30.5 / 53.8
Displacement 1st /2nd cc / rev (cu·in/rev) 34.4 (2.1) / 19.1 (1.17)
Operation press. kgf/cm2 (psi) 300 (4,270)
Revolution speed 1st / 2nd rpm 1877 / 3312
Hydraulic motor
1, 2 speed select press. kgf/cm2 (psi) 35 (500)
Auto 1, 2 speed select press. kgf/cm2 (psi) 225 (3,200)
Drain press. kgf/cm2 (psi) STD2 (28), MAX.7 (100)
Breaking torque kgf·m (lbf·ft) 9.9 (72)
Parking brake
Release press. kgf/cm2 (psi) 4.8 (68)
Lube oil SAE #90 GL-4 L (gal) Approx.1.3 (0.34)
Weight kg (lb) 81 (179)
F17022
31102 60413252
24-52
COMPONENTS SYSTEM
6.4 CONSTRUCTION
(1) Basic construction of motor
1ST REDUCTION
GEAR SECTION
BRAKE VALVE
PARKING BRAKE
REDUCTION UNIT
HYDRAULIC HIGH-LOW 2-STEP SPEED

MOTOR SELECT MECHANISM
2ND REDUCTION
GEAR SECTION
Fig. 6-3
• Reduction gear • Brake valve

The reduction gear consists of a spur gear device The brake valve is composed of different valves. It
(hereunder called 1st reduction gear) and a stops the hydraulic motor smoothly, prevents the
differential gear device (hereunder called 2nd hydraulic motor from over-running and prevents
reduction gear) that employs a peri-cycloid tooth abnormally high pressure surges from occurring as
profile. The reduction gear system reduces the high the hydraulic motor is stopped jerkily.
speed of the hydraulic motor and converts it to low-
speed high torque rotation. • High-low 2-step speed select mechanism
The mechanism consists of a selector valve and a
• Hydraulic motor piston and changes the displacement capacity of
The hydraulic motor is of swash-plate axial piston the hydraulic motor in two steps.
type and converts the hydraulic pressure delivered
by the pump to rotary motion. • Parking brake
This is a friction plate type braking mechanism that
is made integral with the hydraulic motor.
31102 60413252
24-53
COMPONENTS SYSTEM
(2) Construction
31102 60413252
SECTION A-A SECTION B-B
Fig. 6-4
24-54
COMPONENTS SYSTEM
(3) Parts list
Table 6-3
1 HUB 1 112 PISTON 1
113 SPRING 8
SPINDLE KIT 114 SPRING 1
• SPINDLE ASSY 1 115 FRICTION PLATE 2
2 • • SPINDLE 1 116 SEPARATOR PLATE 2
3 • • HOLD FLANGE 1 132 OIL SEAL 1
19 • REAMER BOLT 3 135 O-RING 1
141 O-RING 1
RV GEAR ASSEMBLING PARTS 1 146 SNAP RING 1
• RV GEAR KIT 1 149 BEARING 1
4 • • RV GEAR A 1 150 BEARING 1
5 • • RV GEAR B 1 151 BEARING (ROLLER) 3
9 • CRANK SHAFT 3 176 PIVOT 2
12 • SPACER 6 177 PARALLEL PIN 2
22 • BEARING 6 185 SPRING 1
23 • BEARING 6
REAR FLANGE ASSEMBLING PARTS 1
6 INPUT GEAR 1 • REAR FLANGE KIT 1
201 • • REAR FLANGE 1
SPUR GEAR KIT 1 223 • • SPOOL 1
7 • SPUR GEAR 3 252 • • SOCKET PLUG 2
268 • • STEEL BALL 1
FLOATING SEAL KIT 1 275 • • SOCKET PLUG 10
31 • FLOATING SEAL 2 279 • • FILTER 1
280 • • ORIFICE 4
8 COVER 1 283 • • PLUG (WITH FLANGE) 1
15 SHAFT 1 286 • • PISTON 2
17 PIN 28 299 • • NAME PLATE 1
18 RING 1
20 SNAP RING 3 • SPOOL KIT 1
21 BEARING 2 271 • • SPOOL 1
24 SNAP RING 1 272 • • OIL STOPPER 1
25 SNAP RING 6 221 • PLUG 2
28 O-RING 2 224 • PLUG 2
29 O-RING 1 225 • SPRING RETAINER 2
30 O-RING 1 227 • VALVE 2
33 PLUG (WITH FLANGE) 1 228 • SPRING 2
34 PLUG 2 230 • SPRING 2
35 O RING 3 236 • O-RING 2
36 STEEL BALL 1 238 • O-RING 6
43 PARALLEL PIN 2 281 • SPRING 1
282 • PLUG 4
PISTON KIT 1 284 • PLUG 2
• PISTON ASSEMBLING PARTS 9 285 • O-RING 2
105 • • PISTON 1 287 • VALVE 2
106 • • SHOE 1 288 • SLEEVE 2
289 • PLUG 2
• PISTON ASSEMBLING PARTS 1 290 • SPRING 2
161 • • PISTON 1 291 • O-RING 2
162 • • SHOE 1 292 • O-RING 4
293 • PISTON SEAL 2
102 SHAFT 1 294 • BACKUP RING 4
31102 60413252
103 SWASH PLATE 1 295 • BACKUP RING 4

104 CYLINDER BLOCK 1 296 • STEEL BALL 2
107 RETAINER PLATE 1 297 • ORIFICE 2
108 THRUST BALL 1
109 TIMING PLATE 1 242 PARALLEL PIN 2
110 WASHER 2 245 SOCKET BOLT 6
F17020
24-55
COMPONENTS SYSTEM
6.5 FUNCTIONAL EXPLANATION

(1) Reduction gear
1) Function
The reduction gear consists of a spur gear device SPUR GEAR (7) CRANK SHAFT (9)
(hereunder called 1st reduction gear) and a
differential gear device (hereunder called 2nd
reduction gear) that employs a peri-cycloid gear
tooth profile. The reduction gear reduces the high
speed rotation of the hydraulic motor and converts
SHAFT (15)
it to low-speed high torque rotation.
2) Functional explanation
2-1: 1st reduction gear
1. The rotary motion of the hydraulic motor is put
out of shaft (102). This rotation is transmitted to
input gear (6) that is linked to shaft (G) (15).
The input gear (6) meshes with three spur
gears (7).
INPUT GEAR (6)
The speed of spur gears (7) are reduced and
rotate in the opposite direction. The reduction Fig. 6-5
gear composed of input gear (6) and spur gear
(7) is called 1st reduction gear.
The reduction ratio [i1] is as below:
i1 = — Zi
Zs
i1= Reduction ratio of 1st reduction gear

NEEDLE BEARING (23) SPUR GEAR (7)
Zi= No. of teeth of input gear
Zs= No. of teeth of spur gear ECCENTRIC BODIES ROTATION
CRANK SHAFT (9)
ROTATION
2-2: 2nd reduction gear
1. Spur gears (7) (3 pieces) are connected to
respective crankshafts (9). If spur gear (7)
rotates, crankshaft (9) rotates in the same
direction and at the same revolution. This
causes the eccentric bodies A and B of
crankshaft (9) to make eccentric motion.
(revolution). This eccentric motion (revolution)
is transmitted to RV gears A (4) and B [5] via ECCENTRIC MOTION
RV GEAR B (5)
needle roller bearing (23).
RV GEAR A (4)
RV gears A (4) and B (5) make eccentric
motion in the same direction and at the same Fig. 6-6
revolution as the spur gears and the
crankshafts.
31102 60413252
24-56
COMPONENTS SYSTEM
2. The tooth face of RV gear A (4) and RV gear

HUB (1)
B (5) meshes constantly with pins (17)(pin PIN (17)
number Zp). If RV gears A and B make eccentric
motion, the meshing point moves in sequence
RV GEAR A (4)
as the gears turn. In a single eccentric motion, OR RV GEAR B (5)
pins (17) rotate with hub (1) by the difference
between the number of teeth Zr of RV gears A, CRANKSHAFT REVOLVING
BODY SECTION
B and the number of pins Zp i.e. the number of
pins. The rotating direction of hub (1) is the
same as that of the eccentric motion of the RV
gears.
The hub (1) makes output rotation. The section
that is decelerated by the crankshafts, RV
gears, pins and hubs is called 2nd reduction
gear. The reduction gear (i2) of the 2nd
reduction gear is as below :
(Zp-Zr)
i2 = At half rotation (180°) At one rotation
Zp
Fig. 6-7
i2 = Reduction ratio of 2nd reduction gear
Zr = No. of teeth of RV gear A, B
Zp = No. of pin
2-3: Entire reduction gear

The motion of the entire reduction gear equals the
product that is made by multiplying the 1st reduction
gear with the 2nd reduction gear. Therefore, if the
hydraulic motor shaft makes one turn, the total
revolution (reduction ratioi) of the reduction gear
is as follows:
i = i1 X i2
Zi (Zp-Zr)
=- X
Zs Zp
i1= Speed ratio of 1st reduction gear section
i2= Speed ratio of 2nd reduction gear section
31102 60413252
24-57
COMPONENTS SYSTEM
(2) Hydraulic drive

This article describes the hydraulic motor, the
brake valve and parking brake driven by hydraulic
pressure and the high-low 2-step select
mechanism of the hydraulic motor.
1) Functions
1. Hydraulic motor
The hydraulic motor is of swash-plate axial piston
type and converts the force of the pressurized oil
to rotary motion.
2. Brake valve
1. The brake valve controls inertia force to stop
the hydraulic motor smoothly.
2. The brake valve prevents the hydraulic motor
from over running by external force acting on
the hydraulic motor i.e. prevents hydraulic CYLINDER BLOCK (104)
cavitation.
3. The brake valve prevents abnormally high PISTON (105)
pressure surges that are generated as the SWASH PLATE (103)
hydraulic motor is stopped jerkily.
3. High-low 2-step speed select mechanism
SHAFT (102)
The mechanism changes the hydraulic motor
output in two steps; high-speed low-torque and
low-speed high-torque.
4. Parking brake
The parking brake prevents the hydraulic motor at
rest from being turned by external force. The
brake is of friction plate type that is assembled
integral with the hydraulic motor.
TIMING PLATE (109)
2) Functional explanation
1. Hydraulic motor
The pressurized oil supplied by the hydraulic
pumps enters the rear flange (201) of the hydraulic
motor. The pressurized oil passes through the
brake valve and the timing plate (109) and is
admitted into the cylinder block (104).
The pressurized oil is admitted only to the one side Fig. 6-8
of the line (Y1-Y2) that connects the top dead
point with the bottom dead point of the piston (105)
stroke.
The pressurized oil pushes each piston (105) and Out of them the radial component F3 generates
generates force F (= P X A). This force acts upon torque = (F3 X ri). The total force of torque of the
the tilted surface of swash plate (103). The force pistons (105) T= ∑ (F3 X ri) equals the rotary force
F is split into components F2, F3, depending upon of the hydraulic motor. This rotary force causes
31102 60413252
the angle of the tilted surface. the cylinder block (104) and the shaft (102) to
rotate via the pistons (105).
24-58
COMPONENTS SYSTEM
2. Brake valve
Ports A and B are the oil inlet and the outlet. The
following is an explanation in which hydraulic oil
(pressurized oil) is supplied to port A.
When hydraulic oil is supplied to port B, the PARKING
BRAKE
direction of flow and motion are reversed. The SPOOL (223)
rotating direction of the hydraulic motor is reversed
as well. SPRING a b
1. Normal action
If pressurized oil is supplied to port A by the
pumps, the hydraulic motor turns. Below is a
detailed explanation.
If the pressurized oil is supplied by the pumps,
the oil enters port A and opens the valve (227).
The oil then passes through valve (227), enters
the hydraulic motor via port C and gives rotating
force to the hydraulic motor.
In the meantime, the oil enters port A, passes
through the orifice of spool (223) and the VALVE (227)
pipeline (a) and enters chamber (b). Spool
Fig. 6-9
(223) moves to the left from its neutral position
by the hydraulic force of chamber (b). In that
case, a hydraulic oil passage is formed between
ports D and B by the groove provided on the
spool (223).
The hydraulic oil discharged by the hydraulic
motor flows from port D to port B. Thus the
hydraulic motor rotates, and the hydraulic oil
returns to the oil tank.
In the meantime, if spool (223) moves to the
left, the pressurized oil enters port E and the oil
flows into the parking brake and the 2-speed
select valve.
31102 60413252
24-59
COMPONENTS SYSTEM
2. Stop action (braking action)

If the oil supply is suspended, the hydraulic
motor stops. More detailed functions are
explained below:
If the oil being supplied to port A is suspended,
the pressure at port A and chamber (b) falls.
As the pressure falls, spool (223) begins to PISTON (286)
shift from left to right (toward the neutral

position) by the action of spring (228).
The passage between ports D and B is g
narrowed as the spool (223) moves and shut
off when the spool arrives at neutral. VALVE
(287)
In the meantime, the hydraulic motor keeps
rotating by inertia force even though the oil
supply from port A is suspended. The hydraulic
f
oil discharged by the hydraulic motor is
exhausted as there is no passage for oil flowing
out of port D. Thus, the hydraulic pressure from
port D rises. The hydraulic pressure thus b
SPOOL
boosted goes through the orifice of the right (223)
hand valve (287) and enters chamber (g) from
chamber (f). The piston (286) on the right
moves to the left in the illustration so the
pressure does not rise. While the piston is SPRING (228)
moving, the pressure of chamber (f) and (g) is

lower than that of port D by the orifice effect of
valve (287).
In the meantime, the pressure difference
causes the valve (287) on the right to open.
The hydraulic oil runs from port D to port C. Fig. 6-10
When the piston (286) reaches the stroke end,
the pressure in chamber (g) and (f) rises to be
equal to the pressure of port D. The valve (287)
on the right is closed again. Since the passage
that allows the oil to flow from port D is shut off,
the pressure rises further.
Then, the valve (287) on the left opens. The
hydraulic oil of port D flows to port C. The
pressure of port D falls as the inertia force
decreases.
The valve (287) on the left is closed again. The
hydraulic motor stops rotating.
In this way, controlling the pressure at port D
in two steps allows the hydraulic motor to stop
by smooth braking action
31102 60413252
24-60
COMPONENTS SYSTEM
3. Self (over) run prevention function

If the hydraulic motor is forced to turn by
external force during normal running, self run
(over run) occurs. For instance, it occurs while
the excavator is going down on a slope. PARKING BRAKE
(112)
Now let us explain about the mechanism that SPOOL (223)
prevents such phenomenon from occurring.
If the hydraulic motor is forced to rotate by SPRING a b
external force during normal run, the pressure (228)
of the hydraulic oil being supplied (port A or B)
falls. If the pressure rises close to a level at
which the machine begins to run by itself, the
spool (223) begins to move to its neutral in the
middle.
As the spool (223) moves, the area of the
passage that lets the hydraulic oil run from
outlet port D to port B of the hydraulic motor is
made smaller, with the result that the flow of
the hydraulic oil from port D to port B is restricted.
At the same time, the pressure at port D (back VALVE (227)
pressure) rise as well. Fig. 6-11
In this way, self run of the motor is prevented
by controlling the flow and the pressure of the
outlet port of the hydraulic motor.
31102 60413252
24-61
COMPONENTS SYSTEM
(3) High-low 2-step speed select mechanism (auto 2- SPOOL (271)

PISTON (161)
step speed select mode)
CHAMBER S
1) Low-speed step
The low-speed step is the status in which pilot
pressure is not being supplied from port P.
In this case, the spool (271) is pressed to the left DRAIN
by the force of spring (281) and by the pressure
from port A or B. The pressure of port F is shut off.
The hydraulic oil of chamber S is released to drain
SPRING
(motor casing) via spool (271). The thrust of piston (281) FULCRUM
(161) is small. The swash plate (103) is located
along the Y face. FACE Y
At that time, the swash plate (103) takes the
SWASH PLATE (103)
maximum tilting angle 1. That is to say, the
hydraulic motor takes the maximum displacement
capacity and rotates at low speed.
Fig. 6-12
2) High-speed step SPOOL (271)

The high-speed step is the status in which a pilot PISTON (161)
pressure of 35 kgf/cm2 (500 psi) is supplied from CHAMBER S
port P. In that case, the spool (271) is pressed to
the right, overcoming the force of spring (281) and
the pressure from port A or B. The pressure of port
F is led to chamber S via spool (271).
The thrust of piston (161) increases by the pressure
of chamber S. The piston (161) is pushed up and
held till swash plate (103) comes in contact with SPRING
(281) FULCRUM
face X.
On that occasion, the swash plate (103) takes the
minimum tilting angle 2. That is to say, the FACE X
hydraulic motor takes the minimum displacement

capacity and rotates at high speed. SWASH PLATE (103)
31102 60413252
Fig. 6-13
24-62
COMPONENTS SYSTEM
3) Functional explanation of automatic selection of SPOOL (271)

low-speed step while operating at high-speed PISTON (161)
CHAMBER S
step
The pressure of A or B increases as load increases
at high speed step. When the pressure reaches
225 kgf/cm2 (3200 psi), the spool (271) is pressed DRAIN
to the left, overcoming the pilot pressure 35 kgf/
cm2 (500 psi) of port P. The pressure of chamber
S is released to drain (motor casing) via spool
SPRING
(271). In that case, the swash plate (103) comes (281) FULCRUM
in contact with the Y face and takes the maximum FACE Y
tilting angle 1. The angle is held, with the result
that the hydraulic motor rotates at low speed.
SWASH PLATE (103)
Fig. 6-14
31102 60413252
24-63
COMPONENTS SYSTEM
(4) Parking brake CYLINDER BLOCK

1) Machine is running: (104) SEPARATOR PLATE
PISTON (112) (116)
If the pressure from the pumps is supplied to port FRICTION PLATE
(115)
A or B, the spool (223) of the brake valve moves
to the right or the left. Port E opens, and the
pressure is led from port E to cylinder chamber c.
When the pressure reaches 4.8kgf/cm2 (68psi) or
over, the thrust of piston (112) overcomes the
force of spring (113). The piston (112) moves
toward rear flange (201). If the piston (112) loses
its pressing force against separator plate (116)
and friction plate (115), the friction plate (115) is let
free.
The friction plate (115) is engaged with cylinder REAR
block (104) of the hydraulic motor. The result is FLANGE
(201)
that the cylinder block (104) is freed from the E
B/V SPOOL
braking force. The hydraulic motor is freed to run. (223)
C
SPRING (113)
Fig. 6-15
2) Machine is not running: CYLINDER BLOCK

(104) SEPARATOR PLATE
If the pressure to port A or B is suspended, the (116)
spool (223) of the brake valve moves to neutral. PISTON (112) FRICTION PLATE
(115)
Port E is shut off, and the pressure in cylinder
chamber C falls. When the pressure falls below
4.8kgf/cm2 (68psi), the hydraulic force of piston
(112) decreases below the force of spring (113).
Then the action of spring (113) causes the piston
(112) to be pressed against the separator plate
(116) and the friction plate (115). This pressing
force creates frictional force that makes braking
power. The friction plate (115) meshes with the
cylinder block (104) of the hydraulic motor. The
cylinder block (104) meshes with shaft (102) of the
hydraulic motor.
E
In this way, the hydraulic motor undergoes braking C
B/V SPOOL
torque while the machine is at rest. (223)
SPRING (113)
31102 60413252
Fig. 6-16
24-64
COMPONENTS SYSTEM
7. SWIVEL JOINT
7.1 GENERAL VIEW

D PORT PF1/2
B PORT PF1/2
C PORT PF1/2
E PORT PF3/8
A PORT PF1/2
H PORT PF1/4
PLUG PT1/8
H PORT PF 1/4
C PORT PF1/2
363 (14.3˝)
G PORT PF3/8
A PORT PF1/2
B PORT PF1/2
F PORT PF3/8 D PORT PF1/2
E PORT PF3/8
Fig. 7-1 General view of swivel joint
7.2 SPECIFICATIONS
Table 7-1
Travel main port Working pressure 260 kgf/cm2 (3700 psi)
A, B, C, D Max. impact pressure 390 kgf/cm2 (5550 psi)
Dozer port Working pressure 210 kgf/cm2 (2990 psi)
F, G Max. impact pressure 390 kgf/cm2 (5550 psi)
Drain port
Max. working pressure 5 kgf/cm2 (71 psi)
E
31102 60413252
Pilot port
Working pressure 50 kgf/cm2 (711 psi)
H
Revolution 15rpm
Weight 21kg (46 lbs)
F17038
24-65
COMPONENTS SYSTEM
7.3 CONSTRUCTION
T=Tightening torque: kgf·m (lbf·ft)
Note: fix seal (5) in

the perfectly
degreased seal
groove without
applying grease.
SECTION K-K
T =3.1 (22) (Loctite #290) T =3.1 (22) (Loctite #290) VIEW M

SECTION J-J
Fig. 7-2 Construction
Table 7-2
1 BODY 1 8 SOCKET BOLT: M8 X 20 2
2 STEM 1 9 SOCKET BOLT: M8 X 30 3
3 THRUST PLATE 1 12 PLUG: PT1/8 1
4 COVER 1 13 PLUG: PT3/8 2
5 SEAL ASSY 7 15 SEAL 2
7 O-RING: 1A G95 1
F17040
7.4 OPERATION
The swivel joint consists mainly of mutually rotating flowing in from body (1) or stem (2) keeps on flowing
body (1) and stem (2), thrust plate (3) that prevents to stem (2) or body (1) past the circumferential groove
them from coming off, cover (4) that plugs up one part between body (1) and stem (2) ; the oil flow is never
of body (1), seals (5) that partitioning circuits, and O shut off because of rotation. Further, an oil groove for
rings (6, 7) that prevents oil from leaking out. lubrication that connects with the drain port is provided,
31102 60413252
Four ports for the travel main circuits are provided on in order to prevent the body (1) from binding with the
body (1) and stem (2). Further, four oil passing grooves stem (2). Such construction of the swivel joint makes
are arranged in the inner surface of body (1), with seal it possible to connect circuits between the swing body
(5) fixed above and below the circumferential groove. and the lower travel body at all times.
The body (1) and the stem (2) rotate mutually. The oil
24-66
COMPONENTS SYSTEM
8. CYLINDER
8.1 SPECIFICATIONS
(1) General view
B
gth
en
dl
e
A
nd gth
e xte d len
lly te
Fu ac
r etr
lly
Fu
Part No. and Manufacturing No.

Stamp position
Fig. 8-1 General view of cylincer
(2) Specifications
Cylinder bore/ Center distance of mounting pins Dry weight

Use Stroke Cushion
Rod Dia. Full extend B / Full retract A Kg (lbs)
110 / 70 916 2,291 / 1,375 With cushion on 94
Boom
(4.33˝/2.76˝) (30.1˝) (7´6˝ / 4´6˝) rod side (200)
95 / 65 813 2,113 / 1,300 With cushion on 72
Arm
(3.74˝/2.56˝) (32.0˝) (6´11˝ / 4´3˝) both sides (160)
80 / 55 735 1,855 / 1,120 48
Bucket Without
(3.15˝/2.16˝) (28.9˝) (6´1˝ / 3´8˝) (100)
120 / 70 150 840 / 690 55
Dozer Without
(4.72˝/2.76˝) (5.91˝) (33.1˝ / 27.2˝) (120)
31102 60413252
F17041
24-67
COMPONENTS SYSTEM
8.2 CONSTRUCTION AND OPERATION

T=Tightening torque: kgf·m (lbf·ft) [screw size]
8.2.1 Construction
(1) Boom cylinder
Press it in from both ends Press it in from both ends

of the boss so R2.5 (0.10˝) 27 of the boss so R2.5 (0.10˝)
holes face with each other holes face with each other
in the grease hole position. in the grease hole position.
24 23
25 26 28, 29
T=3.2 ± 0.6 (23 ± 4.3) [M10 X 1.5]
F17042
VIEW A-A
T=5.8 ± 1.1 (42 ± 8.0) [M12 X 1.75]

After tightening,fit it with punch
caulking on two portions.
T=85 ± 19.5 (610 ± 140) [M117 X 2]
Apply Three-bond #1901 on the thread 12 14 9,15 13
T=286 (286) [M52 X 2,HEX80]
8 3 7 11 6 4 9,10 5 2 1 16 17 19 18 20 21,22
With Detail of S
one hole
S F17044
Fig. 8-2 Construction of boom cylinder
No. PARTS Q'TY No. PARTS Q'ty No. PARTS Q'TY

1 CYLINDER TUBE ASSY 1 11 O-RING 1 21 SET SCREW 1
2 PISTON ROD ASSY 1 12 O-RING 1 22 STEEL, BALL 1
3 ROD COVER 1 13 CUSHION SEAL 2 23 PIN BUSHING 2
4 BUSHING 1 14 COLLAR 1 24 WIPER RING 2
5 SNAP RING 1 15 BACKUP RING 1 25 PIN BUSHING 2
6 BUFFER RING 1 16 CUSHION BEARING 1 26 WIPER RING 2
7 U-RING 1 17 PISTON 1 27 BAND ASSY 2
31102 60413252
8 WIPER RING 1 18 SEAL RING ASSY 1 28 BOLT 2

9 O-RING 2 19 SLIDE RING 2 29 WASHER 2
10 BACKUP RING 1 20 NUT 1
F17045
24-68
COMPONENTS SYSTEM
(2) Arm cylinder


of the boss so R2.5 (0.10˝) of the boss so R2.5 (0.10˝)
33 34 32 29 31 holes face with each other
holes face with each other
T=4.1 ± 0.8
30
(30 ± 5.8)
[M12 X 1.75]
29
26 27 T=3.2 ± 0.6 (23 ± 4.3) [M10 X 1.5] 27 26

F17046
VIEW A-A
T=5.8 ± 1.1 (42 ± 8.0) [M12 X 1.75]

T=58 ± 13 (420 ± 94) [M100 X 2] caulking on two portions.
Apply Three-bond #1901 on the thread
T=283 (2000) [M45 X 2, HEX70]
9 3 12 7,8 6 10,11 4 5 11,13 2 1 14 15 19 17 18 16 20 21 25 23 22 24
With
one hole
Face the slit to the piston side.

F17048
Fig. 8-3 Construction of arm cylinder
No. Q'TY No.

PARTS PARTS Q'ty No. PARTS Q'TY
1 CYLINDER TUBE ASSY 1 13 O-RING 1 25 SNAP RING 1
2 PISTON ROD ASSY 1 14 CUSHION BEARING 1 26 PIN BUSHING 4
3 ROD COVER 1 15 CUSHION SEAL 1 27 WIPER RING 4
4 BUSHING 1 16 PISTON 1 28 BAND ASSY 1
5 SNAP RING 1 17 SEAL RING ASSY 1 29 BAND 1
6 BUFFER RING 1 18 SLIDE RING 2 30 BOLT 2
7 U-RING 1 19 SHIM 1 31 WASHER 2
31102 60413252
8 BACKUP RING 1 20 SET SCREW 1 32 PIPE HOLDER 1

9 WIPER RING 1 21 STEEL BALL 1 33 BOLT 1
10 O-RING 1 22 CUSHION BEARING 1 34 WASHER 1
11 BACKUP RING 3 23 CHSHION SEAL 1
12 O-RING 1 24 STOPPER 2
F17049
24-69
COMPONENTS SYSTEM
(3) Bucket cylinder

T=3.2 ± 0.3 (23 ± 2.2) [M10 X 1.5]
45° 45 °
VIEW B-B VIEW A-A
T=1.7 ± 0.3 (12 ± 2.2) [M8 X 1.25]

T=46 ± 10 (330 ± 72) [M82 X 2]
T=143 (1000) [M39 X 3,HEX60)
8 3 7 11 6 4 9,10 5 2 1 12 14 13 15,16
With
one hole
F17052
Fig. 8-4 Construction of bucket cylinder
No. PARTS Q'TY No. PARTS Q'TY No. PARTS Q'TY

1 CYLINDER TUBE ASSY 1 9 O-RING 1 17 PIN BUSHING 1
2 PISTON ROD ASSY 1 10 BACKUP RING 1 18 WIPER RING 4
3 ROD COVER 1 11 O-RING 1 19 PIN BUSHING 1
31102 60413252

7 U-RING 1 15 SET SCREW 1 23 WASHER 4
8 WIPER RING 1 16 STEEL BALL 1
F17053
24-70
COMPONENTS SYSTEM
(4) Dozer cylinder

T=5.8 ± 1.1 (42 ± 8.0) [M12 X 1.75]

T=108 ± 24 (780 ± 170) [M125 X 2]
Apply Three-bond #1901 on the thread T=290 (2100) [M52 X 2,HEX80]
8 3 7 11 6 4 9,10 5 2 1 12 13 14 15 16,17
With
one hole
F17055
Fig. 8-5 Construction of dozer cylinder

1 CYLINDER TUBE ASSY 1 8 WIPER RING 1 15 NUT 1
2 PISTON ROD ASSY 1 9 O-RING 1 16 SET SCREW 1
3 ROD COVER 1 10 BACKUP RING 1 17 STEEL BALL 1
4 BUSHING 1 11 O-RING 1 18 PIN BUSHING 2
31102 60413252
5 SNAP RING 1 12 PISTON 1 19 WIPER RING 4

6 BACKUP RING 1 13 SEAL RING ASSY 1 20 GREASE NIPPLE 2
7 U RING 1 14 SLIDE RING 2
F17056
24-71
COMPONENTS SYSTEM
Hydraulic cylinder construction (See Fig. 8-3)

The hydraulic cylinder is composed of three
sections, cylinder tube assy (1), piston rod assy to
transmit the motion of piston (16) stroke in the
tube, a rod cover (3) which serves as the cover
and guide. Also, the cylinder tube assy and piston
rod assy (2) have piston mounting section (clevis)
which are used to connect the other device. And,
in addition to these principal parts, seal ring assy
(17), slide ring (18) and piston rod assy (2), buffer
ring (6), U ring (7), backup ring (8), and wiper ring
(9) between piston rod assy (2) and rod cover (3),
and O ring and backup ring between cylinder tube
assy (1) and rod cover (3).
8.2.2 Operation CUSHION BEARING

By feeding pressure oil through oil inlet and outlet PISTON SECTION
on cylinder alternately, the oil pressure exerts on

the piston, and piston rod assy (2) starts moving
the telescopic motion (stroke).
Fig. 8-6 Cushion on the rod side
(1) Operation of cylinder with cushion
The hydraulic cylinder contains a shock absorber
to shock generated when the moving piston rod
assy (2) strikes rod cover (3) without speed
reduction.
(Cushion on rod side)

When pressurizing the rod cover side, the oil in (A)
Fig. 8-7 Cushion on the rod side
chamber returns to the tank in constant speed
through passage (B) in the midway of stroke (Fig.
CUSHION BEARING
8-6).
As the end of the stroke approaches, the cylinder
bearing enters into passage (B), and the passage
(B) is throttle reducing oil quantity. As a result, the
speed of piston rod is also lowered (Fig. 8-7).
Fig. 8-8 Cushion on the head side
(Cushion on head side)
CUSHION BEARING
Like the cushion on the rod side, the piston end of
the piston rod enters into the cushion bearing, and
passage (B) is throttled. As a result, as the return
oil level for (A) chamber lowers, the speed of
piston rod lowers, obtaining the effect of cushion
(Fig. 8-8 and 8-9).
31102 60413252
Fig. 8-9 Cushion on the head side
24-72
HYDRAULIC SYSTEM
Part II: ELECTRIC EQUIPMENT

1. ELECTRIC EQUIPMENT LIST
GROUP CODE NAME GROUP CODE NAME GROUP CODE NAME
PROPORTIONAL
C-1 MECHATRO CONTROLLER M-1 STARTER MOTOR PSV-B P2 BY-PASS CUT PROPOTIONAL SOL.
CONTROLLER
C-2 GAUGE CLUSTER M-2 GOVERNOR MOTOR PSV-C TRAVEL PRIORITY PROPOTIONAL SOL.
VALVE
MOTOR
C-2 GAUGE CLUSTER M-3 WIPER MOTOR PSV-D P1 BY-PASS CUT PROPOTIONAL SOL.
C-4 AIR CONDITIONER CONTROLLER M-4 WASHER MOTOR
M-8 ROOF WIPER MOTOR (OPT.)
M-9 FUEL PUMP SW-1 KEY SWITCH
R-1 BATTERY RELAY SW-2 SWITCH ASSY
D-1 DIODE R-3 GLOW RELAY SW-3 TWO-SPEED SELECT SWITCH
D-2 R-4 SAFETY RELAY SW-4 SWING PARKING RELEASE SWITCH
D-3 R-5 WIPER MOTOR RELAY SW-6 ENG. WATER TEMPERATURE SWITCH
DIODE
D-4 R-6 WASHER MOTOR RELAY SW-7 ENG. OIL PRESS SWITCH
D-5 R-7 HONE RELAY SW-8 AIR FILTER ALARM SWITCH
R-8 WORK LIGHT RELAY SW-10 HORN SWITCH (LEFT)
RELAY
R-10 CAB WORK LIGHT RELAY SW-11 LEVER LOCK SWITCH
E-1 FUSE BOX R-13 CAB WORK LIGHT RELAY 2 SW-13 AIR CONDITIONER SWITCH
E-2 ALTERNATOR R-20 TIMER SW-15 ROOF WIPER SWITCH (OPT.)
E-3 HOUR METER R-21 BREAKER RELAY (OPT.) SW-16 WORK LIGHT SWITCH (OPT.)
E-5 HORN R-22 CLOCKWISE RELAY (OPT.) SW-17 DOUBLE·SINGLE SELECT SWITCH
SWITCH
E-6 CIGALETTE LIGHTER R-23 COUNTERCLOCKWISE RELAY (OPT.) SW-18 OPT. PEDAL PRESSURE SWITCH ASSY 1
E-7 TUNER AM & FM R-24 CRUSHER OPEN RELAY (OPT.) SW-19 OPT. PEDAL PRESSURE SWITCH ASSY 2
ELECTRIC FITTINGS
E-8 SPEAKER LEFT R-25 CRUSHER CLOSE RELAY (OPT.) SW-20 HORN SWITCH (RIGHT) (OPT.)
E-9 SPEAKER RIGHT SE-1 PRESSURE SENSOR (LOW): BUCKET DIGGING SW-21 OPT. PEDAL PRESSURE SWITCH ASSY 3
E-10 RECEIVER DRIER SE-2 PRESSURE SENSOR (LOW): BUCKET DUMP SW-23 WIPER INTERLOCK SWITCH
E-11 AIR COMMPRESSOR CLUTCH SE-3 PRESSURE SENSOR (LOW): BOOM UP SW-24 OVER LOAD SWITCH
E-14 BATTERY SE-4 PRESSURE SENSOR (LOW): BOOM DOWN SW-25 HYD. FLUID TEMPERATURE SWITCH
E-15 POWER SOCKET SE-5 PRESSURE SENSOR (LOW): SWING LEFT SW-27 ENGINE ROOM LIGHT SWITCH
E-16 HYD.FLUID TEMPERATURE ALARM LAMP SE-6 PRESSURE SENSOR (LOW): SWING RIGHT SW-28 OVERLDAD INDICATE SWITCH
E-17 CONVERTER SE-7 PRESSURE SENSOR (LOW): ARM IN SW-29 ROTARY LIGHT SWITCH
SENSOR
SE-8 PRESSURE SENSOR (LOW): ARM OUT SW-30 AUTO ACCEL RELEASE SWITCH
SE-9 PRESSURE SENSOR (LOW): TRAVEL RIGHT SW-45 BREAKER SWITCH
SE-10 PRESSURE SENSOR (LOW): TRAVEL LEFT SW-46 CLOCKWISE SWITCH
SE-13 E/G SPEED SENSOR SW-47 COUNTERCLOCKWISE SWITCH
SE-14 E/G WATER TEMPERATURE SENSOR SW-48 CRUSHER OPEN SWITCH
L-1 BOOM WORKING LIGHT LEFT SE-15 FUEL SENSOR SW-49 CRUSHER CLOSE SSWITCH
L-1 BOOM WORKING LIGHT RIGHT SE-16 ACCEL POTENTIO METER
F17050
L-2 WORKING LIGHT RIGHT
L-3 ROOM LIGHT SV-1 SWING PARKING BRAKE SOL.
L-4 CAB WORKING LIGHT FRONT (OPT.) SV-2 DOUBLE·SINGLE SELECT SOL. (OPT.)
SOLENOID VALVE
LIGHT
L-5 CAB WORKING LIGHT FRONT (OPT.) SV-3 TWO-SPEED SELECT SOL.
L-6 CAB WORKING LIGHT (FRONT 3) SV-4 LEVER LOCK SOL.
L-7 ENGINE ROOM LIGHT SV-5 BREAKER SOL.
31102 60413252
L-8 CAB WORKING LIGHT (FRONT 4) SV-6 CLOCKWISE SOL.

L-9 CAB WORKING LIGHT (REAR) SV-7 COUNTERCLOCKWISE SOL.
L-10 ROTARY LIGHT SV-9 CRUSHER OPEN SOL.
SV-10 CRUSHER CLOSE SOL.
24-73
HYDRAULIC SYSTEM
2. SPECIFICATION OF ELECTRIC EQUIPMENTS

Code No.
Parts Name Specifications Description
Use
C-1 Maker TOKAI RIKA

Rated voltage DC 24 V
Controller
Mechatro controller
C-2 Maker KANSEI

Controller More than 3 MΩ at
Insulation
500 V megger
Gauge cluster
C-4 Maker TKS-C215AO CONTROLLER

Rated voltage DC 20~30 V
Controller
Air conditioner
controller
31102 60413252
F17059
24-74
COMPONENTS SYSTEM
Code No.
Use
D-1~4 Peak reverse voltage 400 V

Mean output current 3A
Diode
Surge current 200 A
Key switch relay
Battery relay
Gauge cluster
Pedal pressure switch
D-5 Rated current 2.5 A
Diode
Glow relay
E-1
Fuse capacity and circuit name
No. Capacity Name of circuit
Fuse box
1 10A Mechatro controller
2 10A Wiper washer relay
Fuse
3 10A Cigarette lighter
4 10A Tuner
5 10A Horn
6 — Blank
7 — Blank
8 20A Power window (back-up option)
9 10A Tuner (buck-up), room lamp
10 20A Key switch
11 5A Fuel pump (option)
12 — Blank
Gauge cluster
13 10A
Power window (option)
14 20A Wiper, washer
Solenoid valve
15 10A
(lever lock, option select)
16 20A Work light
17 20A Cab work light (option)
31102 60413252
18 20A Air conditioner, heater (option)

19 10A Air conditioner
20 20A Spare
F17060
24-75
COMPONENTS SYSTEM
Code No.
Use
E-2 Maker MITUBISHI DENKI

B TERMINAL CONNECTOR
Rated out put 24 V X 30 A YAZAKI 7322-2128
Alternator M5
Generator
E-3 Movement Quartz

Rated voltage 10~80 V CD
Hour meter TERMINAL
CONNECTOR
Service meter
E-5 Type
Horn
Operating voltage range DC 22~28 V
Sound level 110 ± 5 dB
Warning sound
Basic frequency 415 ± 20 Hz high sound
Insulation resistance More than 1 MΩ / DC 500 V
STAMP H
HIGH SOUND
Drain 2-Hple
E-6 Model 409112-0000

Cigar lighter Max. current 5A PULG COMPLETE
KNOB
Return time Less than 18 sec
Cigar lighter
More than 3 MΩ /
Insulation resistance 500 V megger
Fusing temp.180°C ~ 250°C
31102 60413252
Temperature fuse (356°F ~ 482°F) JIS CA104

CASE
SOCKET COMPLETE
F17061
24-76
COMPONENTS SYSTEM
Code No.
Use
E-7 1 OPEN
2 SPEAKER (+)
3 ACC (+B)
Tuner
4 OPEN
5 OPEN
Radio (AM) 6 SPEAKER (-)
7 GND (-)
8 BACK UP (+)
9 OPEN
Meted side YAZAKI 7318-3039
E-7 Rated voltage DC 24 V
Tuner
1 L SPEAKER (+)
Radio (AM&FM) 2 R SPEAKER (+)
3 ACC (+B)
4 OPEN
5 L SPEAKER (-)
6 R SPEAKER (-)
7 GND (-)
8 BACK UP (-)
9 OPEN
E-8, 9 Model SX-M1028K

Rated input 8W
Speaker
Impedance 8Ω
Frequency 33.3 Hz
Radio
E-10
Receiver drier
Air conditioner
31102 60413252
F17062
24-77
COMPONENTS SYSTEM
Code No.
Use
E-11 Rated voltage DC 24 V

Max. revolution 4000 rpm
Air compressor
V belt A type
Cooling R-134 a
Air conditioner
Oil SP-20 : 135 cc
Cover (clutch)
CP3.96MA
YAZAKI 7120-8019
AVX1.25 (BLACK)
AVX1.25 (GREEN)
E-12 Type WH20-R

Voltage / power
24 V / 35 W
Hot water heater consumption
Amount of heat
2000 kcal/h
For heating radiation
Air flow rate 150 m3/h
31102 60413252
F17063
24-78
COMPONENTS SYSTEM
Code No.
Use
E-13 Type BA3111A

Rated voltage DC 12 V~36 V
Alarm
HOUSING 174354-2
TERMINAL 171661-1
Travel alarm VIEW A
VINYL TUBE
E-14
Type 95D31R
Battery Capacity 12 V 64 Ah (5 h)
Weight About 20.5 kg (45 lb)
Power
31102 60413252
F17064
24-79
COMPONENTS SYSTEM
Code No.
Use
E-A Electrostatic capacity 80±7pF HT

ED LENG
More than 100 MΩ
EX TEND
Antenna Insulation resistance (DC 500 Vmegger)
Radio
ANTENNA JUMPER 30pF/m
L-1 Type NS-1183

Bulb DC 24 V, 70 W
Light (halogen) BULB
Effective area of lens 125 cm2
Boom work light
TORQUE
1.9 ± 0.1 kgf·m
(14 ± 0.72 lbf·ft)
L-2 Type NS-1184FF BRACKET

Bulb DC 24 V, 70 W
Light (halogen)
Effective area of lens 69.2 cm2
Work light (R)
L-3 Bulb 24 V, 5 W
BODY
Note) Equivalent to 2456Z322F1 LENS
Light
Room light
31102 60413252
BULB
SECTION AA DOOR
SWITCH
F17065
24-80
COMPONENTS SYSTEM
Code No.
Use
L-4, 5 Type BL84-200

Bulb DC 24 V, 70 W
Light (halogen)
Effective area of lens 71 cm2
Cab work light

(OPT)
BRACKET
M12
CB104
CA104
M-1 B TERMINAL : M8 X 1.25,

Reted output DC 24 V, 3.2 kW TORQUE 1 kgf·m (7.2 lbf·ft)
S TERMINAL
Motor
Starter motor
M-2 Drive voltage DC 24 V

Rated voltage DC 8.5 V
Motor
Rated current 1.5 A / phase
Number of phases 2 phase
Governr motor
Excitation method 2 Excitation
Step angle 1.8°
More than100 MΩ
Insulation resistance
(500 V megger)
Brown Red
(A) (B)
Orange Yellow
(A) (B)
31102 60413252
F17066
24-81
COMPONENTS SYSTEM
Code No.
Use
M-3 Type Ferrite magnet type

Motor
For wiper (STD)

Connection diagram
(Motor OFF)
M-4 Reted voltage DC 24 V

Injection pressure More than 780 cc / min
Motor (tank)
Tank capacity 1.5 L (0.4 gal)
Time rated Max.continuous 20 sec
Window washer
Injection nozzle Ø1 X 2 pcs.
M-8 Type Ferrite magnet type

Motor
For roof wiper (OPT)
G AUTOMATIC STOP
IN LE
W
S NG POSITION
A
SWITCH
CONNECTOR DIAGRAM EQUIVALENT YAZAKI 7322-2046
31102 60413252
(MOTOR STOP POSITION)
F17067
24-82
COMPONENTS SYSTEM
Code No.
Use
M-9 Rated voltage DC 24 V

Current Less than 1.5 A
Motor (pump)
Operating fluid Light oil
Discharge rate
Fuel pump (OPT) More than 200 cc/min
(open circuit)
31102 60413252
F17068
24-83
COMPONENTS SYSTEM
Code No.
Use
R-1 At start 24 V 2000 A

Reted valtage / (0.1 sec.)
current At charge 28 V120 A
Relay (continuous)
Exciting current Less than 0.4 A / 24 V
Battery relay F HOUSING:
Contact pressure More than3.8 kgf (8.4 lbf) YAZAKI
Closed circuit voltage 7123-4220-30
Less than 16 V F TERMINAL:
YAZAKI
Open circuit voltage Less than 7 V 7116-3251
REAR HOLDER:
More than 3 MΩ / YAZAKI
500 V megger 7157-6801-30
WATER RESISTANCE:
YAZAKI
7157-3580-60
B2 TERMINAL
Z
FLOWING DIRECTION MAIN CURRENT

EARTH TERMINAL
TERMINAL A TERMINAL B
LOCK HOUSING AMP

TERMINAL A SECTION L TERMINAL 174359-2
RETAINER AMP
1-174360-1
TERMINAL AMP
171661-1
B2 TERMINAL WIRE SEAL AMP
TERMINAL B EARTH TERMINAL 172888-2
CIRCUIT DIAGRAM BRACKET VIEW I VIEW Z

EARTH
R-3 Rated voltage DC 24 V

In-rush current 130 A
Rated load
Relay Breaking current 30 A
Operating current Less than DC 16 V
Glow relay Release voltage More than DC 2 V
Exciting current Less than 1 A
31102 60413252
INTERNAL CONNECTION DIAGRAM CONNECTOR ON CONNECTOR ON

MATED SIDE MATED SIDE
VIEW Z
F17069
24-84
COMPONENTS SYSTEM
Code No.
Use
R-4 Rated voltage DC 24V

S TERMINAL R TERMINAL
Relay
E TERMINAL
S.R.E TERMINAL
Safety relay (YAZAKI : 7322-2830) WITE LOCK
A
C TERMINAL VIEW A
(YAZAKI : 7323-3012)
B TERMINAL
(YAZAKI : 7322-3012)
UPPER
MOUNTING
DIRECTION
TO STARTER
TO STARTER SWITCH S B B TERMINAL
TO STARTER
C S TERMINAL
TO GENERATOR
R TERMINAL
R
TO BATTERY (-) SIDE
E
R-5, 6, 7, 8, 10, 11, 13

21, 22, 23, 24, 25 Reted valtage DC 24V
Coil resistance 360Ω ± 10%
Relay
Insulation resistance 1 MΩ (500 V megger)
Wiper motor, Washer motor,
Horn relay, Work light relay,
Cab work light relay (OPT),
Travel aram relay (OPT)
Breaker relay (OPT)
Hand control rotating relay
(OPT)
Crusher open / close relay
(OPT)
APPLICATE CONNECTOR
SUMITOMO
CONNECTION DIAGRAM 1500-0207
R-20 Rate voltage DC 24 V

Consumption current 0.1 A max.
Relay
Timer
31102 60413252
CIRCUIT DIAGRAM
F17070
24-85
COMPONENTS SYSTEM
Code No.
Use
SE-1~10 Pressure range 0~30 kgf/cm2(0~430 psi)

O-ring
Pressure sensor Max.allowable press. 250 kgf/cm2(3560 psi) (P11 1B)
(Iow pressure) Operating source voltage 5 ± 0.5 V DC
HEX24 Vout
More than 50 MΩ/
Bucket digging, Dump, Insulation resistance
DC 50 V megger
Boom up, down, Swing R,L
Arm in, out, Travel R,L (Body connector)
Vcc GND
PF 1/4
TIGHTENING TORQUE
3~3.5 kgf·m (21.7~25.3 lbf·ft)
SE-13 Rated
Output voltage More than 2.5 V
Speed sensor
Clearance 1.0 mm (0.04 in)
E/G Speed sensor
SE-14
Resistance characteristics
Water temperature
50°C 80 Ω
E/G Water temperature 60°C 56.3 Ω
80°C 29.5 Ω
100°C 16.5 Ω
106°C 14.3 Ω
120°C 10 Ω
31102 60413252
F17071
24-86
COMPONENTS SYSTEM
Code No.
Use
SE-15 Froat operating standard

Float Resistance value Ω
Fuel sensor FULL 10+0.1
-0.5
3/4 (19)
Fuel sending 1/2 32 }3
1/4 (49.5)
+12
EMPTY 80+2
AMP CONNECTOR 3MA-JM U+

HOUSING F174359-2
TERMINAL F171661-1
SE-16 Total resistance value 2 KΩ

Effective electric angle 120°
Potentio meter
Number of notches 10 (90°)
Source voltage 5V
Accel dial
3MA-JM U+AMP
HOUSING F174359-2
TERMINAL F171661-1
31102 60413252
F17072
24-87
COMPONENTS SYSTEM
Code No.
Use
TRAVEL PRIORITY
P2 BY-PASS CUT
P1 BY-PASS CUT
SV-1~4 Operating pressure 35 kgf/cm2 (500 psi)
Solenoid selector Rated voltage DC 24 V
Solenoid valve assy valve Coil resistance 34 ± 2Ω (at 20°C)
Refer to hydraulic symbol Solenoid proportionate Dither current 100 Hz,300 mA P-P
valve Coil resistance 17.5 Ω (at 20°C)
AMP Econoseal J Mark II
Connector Housing 174354-2
specification
Terminal 173706-1
SWING PARKING
CONFLUX·SINGLE
SOLECT (OPT)
LEVER LOCK
TRAVEL 1,2-SPEED
PSV-B, C, D
TRAVEL PRIORITY
P1 BY-PASS CUT
P2 BY-PASS CUT
Solenoid valve assy
Refer to hydraulic symbol

PSV-C
PSV-D
PSV-B
CONNECTOR : AMP Econoseal J Mark II (+)

CAP HOUSING : 174354-2
TERMINAL : 173706-1
T
T TIGHTENING TORQUE
0.75 kgf·m (5.5 lbf·ft)
P
(Directional Valve)
Emergency manual P
adjustable bolt
TORQUE FOR CONTACTING WITH BOTTOM
0.2 kgf·m (1.5 lbf·ft)
TIGHTENING TORQUE
0.71 kgf·m (5.2 lbf·ft)
(-) LEAD WIRE (+) LEAD WIRE
P
SWING PARKING
SV-1
31102 60413252
CONFLUX·SINGLE
SOLECT
SV-2
TRAVEL 1,2-SPEED
SV-3
LEVER LOCK
SV-4
DIRECTIONAL VALVE CONNECTING

CONNECTOR PROCEDURE
F17073
24-88
COMPONENTS SYSTEM
Code No.
Use
AUTO RETURN
SW-1
Connection table
Switch Terminal B G1 G2 ACC M ST
Position
AUTO RETURN
H
Starter switch
OFF
VIEW A
ACC
ON “K250” STAMPED
START
TERMINAL
ARRANGEMENT
SW-2 SW section DC 5 V No. Connection
Operating voltage 1 Power +5V
Lighting DC 22~32 V
Switch 2 Address input Di1 F16861
Bulb 24 V, 3 W 2 pcs. 3 Address input Di2 JAPANESE AMP MADE
CONNECTOR
Mode select 4 Address input Di3
CN22 070 MULTI LOCK
5 Date input DO1 VERTICAL MOUNTING
6 GND TYPE 8P BOARD
2-174955-1
7 NC
(GOLD PLATED)
8 NC
1 Back light +
CN23
2 Back light -
F16862
CN LOCK TYPE
2P MALE
MADE BY YAZAKI
7122-2228
SW-3 MARKS ON SWITCH PORTION

Type Buried in right travel lever
Switch
Travel 1,2-speed
31102 60413252
24-89
COMPONENTS SYSTEM
Code No.
Use
SW-4 Single-pole single-throw INSULATION TAPE

Type
(alternate)
Switch Rated DC 30 V, 10 A
Swing parking release
SW-6 Reted voltage DC 24 V, DC 12 V

Operating ON105 ± 2°C
Switch temperature (221 ± 35.6°F)
E/G Water Contact type A
temperature switch More than 10 MΩ
[105°C (221°F)] Insulation resistance (500 V megger)
VIEW Z
SW-7 Function type Normal open

Function pressure 0.3+0.2 2 +2.8
0 kgf/cm (4 0 psi)
Switch ADAPTER
E/G Oil pressure

Switch
SW-8 CLOGGING OF
INDICATOR
Switch
Air filter
alarm switch
31102 60413252
24-90
COMPONENTS SYSTEM
Code No.
Use
SW-10, 20 Type Buried in left grip
Switch
Horn
SUMITOMO DENSO
HOUSING ITEM No. : 6090-1031 (2P MALE)
SUMITOMO DENSO
TERMINAL ITEM No. : 8230-4282
SW-11 Roller pluger type

Type
D4MC-5020
Switch
Lock lever
YAZAKI HOUSING : 7122-2228

TERMINAL : 7114-2020
SW-12 Rated voltage DC 24V

Load used 135W DC motor
Switch
Heater Connection table HOUSING : 172133-4 (G)

TERMINAL : 170340-1
SW-13 Operating voltage range DC 20V~30V
Switch
Air conditioner
operation
31102 60413252
F17076
24-91
COMPONENTS SYSTEM
Code No.
Use
SW-15 Single-pole single-throw

Type (alternate)
Switch Rated voltage DC 24 V
More than 1 MΩ/
Insulation resistance 500 V megger
Roof wiper switch
NOTE:
Switch has a wiper label on it.
SW-16 Rated voltage DC 24 V

Single-pole single-throw
Type
Switch (alternate)
More than 1 MΩ/ CONNECTOR (WITH LOCK) RED (R)
Insulation resistance EQUIVALENT
Work light (OPT) 500 V megger
TERMINAL CONNECTOR
RED/WHITE (RW)
SW-17 Rated voltage DC 24V

Single-pole single-throw
Type
Switch (alternate)
More than 1 MΩ/ CONNECTOR (WITH LOCK)
Insulation resistance EQUIVALENT RED (R)
Operation select 500 V megger
TERMINAL CONNECTOR
RED/WHITE (RW)
SW-18, 19, 21 Type Normal open

ON : 6 ± 0.6 kgf/cm2
Switch (85.3 ± 8.5 psi)
Specification
OFF : 4 ± 0.4 kgf/cm2
Option pedal press (56.9 ± 5.7 psi)
More than 100 MΩ Econoseal J
Insulation resistance (500 V megger) CONNECTOR II (MALE) AMP
PT1/8
31102 60413252
HOUSHING : 174354-2
TORQUE
TERMINAL : 17166-1
1.7 kgf·m (12.3 lbf·ft)
Wind seal tape
on to thread
F17077
24-92
COMPONENTS SYSTEM
Code No.
Use
SW-23 SPST ON-(OFF)

Contact configuration
momentary
Switch Insulation resistance More than 100 MΩ
(500 V megger)
Wiper inter lock BLACK
RED

Type
(alternate)
Buzzer stop switch Rated voltage DC 24 V
Buzzer stop Insulation resistance EQUIVALENT RED (R)
500 V megger
(Travle aram)
TERMINAL CONNECTOR
RED/WHITE (RW)

Type
(alternate)
Auto accel release
switch Rated voltage DC 24 V
Insulation resistance EQUIVALENT RED (R)
500 V megger
Auto accel release
TERMINAL CONNECTOR
RED/WHITE (RW)
31102 60413252
F17078
24-93
COMPONENTS SYSTEM
NOTE
31102 60413252
24-94
SECTION 25 AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
1. Construction and piping ........................................................................................ 25-1

1.1 Construction ................................................................................................................................... 25-1
1.2 Piping ............................................................................................................................................. 25-2
2. Construction of main components ........................................................................ 25-4

2.1 Intake unit ....................................................................................................................................... 25-4
2.2 Air-conditioner unit ......................................................................................................................... 25-5
2.3 Receiver dryer ................................................................................................................................ 25-6
3. Function ................................................................................................................ 25-7

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

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

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

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

31102 60413252
AIR-CONDITIONER SYSTEM
1. CONSTRUCTION AND PIPING
1.1 CONSTRUCTION
Fig.1 Air-conditioner group
No. PART NAME Q'TY No. PART NAME Q'ty No. PART NAME Q'TY
1 AIR-CONDITIONER ASSY 1 5 FILTER ASSY 1 8-8 S TUBE: Ø16 1
1-1 AIR-CONDITIONER UNIT 1 8 AIR DRYER ASSY 1 9 CONDENSER 1
1-2 HARNESS 1 8-1 RECEIVER DRYER 1
1-3 SENSOR 1 8-2 BRACKET 1
1-4 PLATE 1 8-3 L HOSE 1
31102 60413252
1-5 MACHINE SCREW 1 8-4 D HOSE 1

1-7 CAP 1 8-5 S HOSE: Ø24.5 1
3 COMPRESSOR 1 8-6 L HOSE: Ø15.5 1
4 PANEL 1 8-7 D TUBE: Ø12 1
F17087
25-1
1.2 PIPING
19
2 COMPRESSOR ASSY
19
22 22
15 13
A
AIR-CONDITIONER UNIT
20 1
23
16
COMPRESSOR
CONDENSER
20
CONDENSER
23
11 17
14 32
26
9 21 RECEIVER TANK
33
8 36
OUT 35
4
27
28
B 7 25
37
10 IN
6
27
5
6
31 34
OUT
27
IN
5
4
26
19 29
15
30
B A 11
12
9 21
24
31102 60413252
10 38 F17147
8 20 21 7
24 9
18
Fig. 2 (1/2) Installing air conditioner and heater
25-2
Tightening torque Tightening torque

No. PART NAME Q'TY No. PART NAME Q'TY
1 SUPPORT 1 20 WASHER 8
2 BRACKET 1 21 WASHER 3
3 PULLEY 1 22 LOCK WASHER 6
4 HOSE: L=2500 1 23 LOCK WASHER 6
5 HOSE: L=1950 1 4.7 (34) 24 NUT 2
6 TUBE: L=1400 1 2.5 (18) 25 CONNECTOR 1
7 TUBE: L=1500 1 26 TUBE: L=2100 1
8 TUBE: L=400 1 27 CLIP 4
9 TUBE: L=1900 1 28 GROMMET 1
10 TUBE: L=1250 1 29 GROMMET 1
11 CLIP 3 30 V-BELT 1
12 CLIP 1 31 CLIP 1
1.1 (8.0) 13 CAPSCREW: M8 X 100 4 4.7 (34) 32 CAPSCREW : M10 X 16 1
4.0 (29) 14 SEMS BOLT: M8 X 25 2 1.0 (7.2) 33 CLIP 1
1.1 (8.0) 15 CAPSCREW: M8 X 16 4 34 PIPE 1
0.45 (3.3) 16 CAPSCREW: M6 X 50 3 35 HOSE: L=150 1
0.45 (3.3) 17 NUT: M6 3 36 TUBE: L=100 1
18 CAPSCREW F M6 X 20 2 37 CLIP 2
19 WASHER 7 38 CLIP 1
F17129
31102 60413252
25-3
2. CONSTRUCTION OF MAIN COMPONENTS
2.1 INTAKE UNIT
31102 60413252
Fig. 3 Intake unit
25-4
2.2 AIR-CONDITIONER UNIT

31102 60413252
Fig. 4 Air-conditioner unit
25-5
No. PART NAME Q'TY No. PART NAME Q'ty No. PART NAME Q'TY
1 ACTUATOR 3 24 LEVER 3 47 BLOWER MOTOR 1
2 VALVE 1 25 CAM 1 48 CASING 1
3 THERMISTOR 1 26 ROD 1 49 CASING 1
4 CLAMP 2 27 ROD 1 50 FILTER 1
5 ROD HOLDER 2 28 ROD 1 51 LEVER 1
6 SENSOR HOLDER 2 29 DAMPER 1 52 LEVER 1
7 CLAMP 1 30 DAMPER 1 53 DAMPER 1
8 EVAPORATOR 1 31 DAMPER 1 54 FLANGE PLATE 1
9 CASING 1 32 DAMPER 1 55 SENSOR 1
10 CASING 1 33 DAMPER 1 56 SEMS BOLT 1
11 CASING 1 34 DAMPER 1 57 GASKET 1
12 THERMAL INSULATION MATERIAL 1 35 HEATER CORE 1 58 O-RING 1
13 THERMAL INSULATION MATERIAL 1 36 CONTROLLER 1 59 O-RING 1
14 PACKING 1 37 RELAY 1 60 TAPPING SCREW 6
15 PACKING 1 38 CLAMP 1 61 TAPPING SCREW 13
16 PACKING 1 39 BAND 1 62 SCREW 30
17 BRACKET 1 40 DUCT CAP 1 63 SEMS BOLT 3
18 CLAMP 1 41 HARNESS 1 64 TAPPING SCREW 9
19 PLATE 1 42 RESISTER 1 65 SCREW 1
20 LEVER 2 43 CASING 1 66 CAPSCREW 2
21 LEVER 1 44 CASING 1 67 TAPPING SCREW 4
22 LEVER 1 45 BRACKET 2
23 LEVER 3 46 HOSE 1
2.3 RECEIVER DRYER
REFRIGERANT
INLET
REFRIGERANT
OUTLET
No. PRT NAME Q'TY

1 1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
3 DESICCANT 1
4 SUCTION PIPE 1
5 FILTER 1
6 RECEIVER TANK 1
F17130
31102 60413252
Fig. 5 Receiver dryer
25-6
3. FUNCTION
3.1 MECHANISM OF COOLING CIRCUIT Table 1

(1) 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
Molecular weight 102.03
from liquid to gas and vice versa during which
Boiling point -26.19°C (-15.14°F)
process heat is transferred from the low tempera-
Critical temperature 101.14°C (214.05°F)
ture part (compartment) to the high temperature
Critical pressure 4.065 MPa (41.45 kgf/cm2)*1
part (outside of the vehicle). Critical density 511 kg/m3 (31.9 lb/ft3)
1) Kind of Refrigerant Density of saturated
Many kinds of refrigerants that change in that way 1206 kg/m3 (75.3 lb/ft3)
liquid [25°C (77°F)]
are available, but the following requirements are Specific volume of
needed for use in such applications: saturated vapor 0.0310 m3/kg (0.496 ft3/lb)
• Latent heat of vaporization (heat of [25°C (77°F)]
vaporization) is large. Latent heat of
• It is easy to liquefy (condense). (It dose not vaporization 197.5 KJ/kg {47.19 kcal/kg}
require very high pressure for condensation). [0°C (32°F)]
• It is easy to gasify (evaporate). (It evaporates Flammabillty Nonflammable
sufficiently at not too low pressure, i.e. cools Ozone destruction coefficient 0
down an object). F17116
• 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 PRESSURE
MPa (Kgf/cm2)
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation. LIQUID
• It has small specific volume.
Out of refrigerants meeting the above-
mentioned requirements, ones having GAS
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant other TEMPE-
that those designated is used, sufficient RATURE
[°C (°F)]
refrigeration will not be performed or the
equipment in which the refrigerant is used may Fig.6 Pressure-temperature characteristics of R134a
be broken. Therefore, always use a designated
refrigerant for the cooling unit.
Table 1 shows the principal characteristics of
the R134a refrigerant that is used in this
machine.
31102 60413252
(2) Characteristics of Refrigerant (See Fig.6). take a liquid state. The temperature at which
In general, the fluid (general term of gas and condensation begins is unique to each substance
liquid) has the following qualities: (fluid) at a given pressure. The temperature
1) As a gas under certain pressure is cooled down, determined by a given pressure is called saturation
it begins to condensate at a certain temperature to temperature.
25-7
2) Inversely to 1) above, the pressure at which a gas evaporation heat from the air unless it evaporates
condenses for a temperature is determined. This at a temperature lower that 15°C (59°F). For that
pressure is called saturation pressure. purpose, it can be seen from Fig.6 that the pressure
Fig.6 illustrates the relationships between the of the refrigerant in the evaporator must be less
saturation temperature and the saturation pressure than 5.2 kfg/cm2 (74 psi).
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.6,
the refrigerant take a gaseous state, while at the
temperature and the pressure on the upper lefthand
side of the curve, the refrigerant takes a liquid
state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the refrigerant
evaporates, it absorbs evaporation heat from the
air of the compartment. In order to cool the inside
of the compartment down to 25°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.6 that R134a under a
pressure above the atmospheric pressure is
capable of cooling the inside of the compartment
sufficiently. (If a refrigerant that requires a pressure
below the atmospheric pressure to cool it to a
required temperature is used, air is mixed into the
circuits, thereby deteriorating the performance of
the cooling unit.) In the process in which gaseous
refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer
air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 10.2 kgf/cm2
(145 psi), as seen from Fig.6.
INSIDE OF COMPARTMENT
3.2 COOLING CIRCUIT
Fig.7 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air
of the compartment is the evaporator. The object EVAPORATOR EXPANSION
VALVE
air is cooled off by utilizing the fact the refrigerant BLOWER
takes heat off the surrounding area as evaporation
heat as it evaporates in the cooling circuit. Since INSIDE OF
S D ENGINE
the part at which vaporization of the refrigerant ROOM
COMPRESSOR COOLING FAN
takes place is the evaporator, cooled air is
constantly delivered to the circumference of the
31102 60413252
evaporator by the blower fan. In the meantime,

RECEIVER
liquid refrigerant (slightly wet vaporized refrigerant) DRYER
is fed into the evaporator, when "cooling" effect is CONDENSER
attained. For instance, in order to cool the air to
15°C (59°F), the refrigerant can not absorb Fig. 7 Construction of cooling circuit
25-8
Consequently, the cooling circuit is so constructed in deterioration of the cooling effect. If the feed
that the evaporator can cool down an object (air in rate is too high, unvaporized liquid refrigerant
this case) sufficiently (i.e. so as to decrease the returns to the compressor (liquid back). This not
pressure in the evaporator) and that an adequate only deteriorates the cooling effect, but also
amount of refrigerant can be fed to the evaporator. damages the compressor valves.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator
is held low by the throttling action of the expansion
valve and the suction action of the compressor.
The compressor acts as a pump that allows the
refrigerant to circulate. The compressive action of
the compressor and the heat exchange (heat
radiation) action of the condenser transform the
refrigerant in a dry vapor state back to a liquid
state.
3.3 COMPONENT PARTS

(1) Evaporator (See Fig.8.)
The evaporator is an important heat exchanger
that absorbs the heat of the compartment air
(object) by the utilization of the latent vaporization
heat of the low-temperature, low-pressure liquid-
state refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and EVAPORATOR
the refrigerant take place in the evaporator.
To that end, the evaporator is equipped with fins
on the air side in order to increase the heat
O-RING
transfer area of the air side and thereby perform EXPANSION
excellent thermal transfer between the refrigerant VALVE
and the air. SOCKET BOLT
The humidity in the air condenses as the air cools M5 X 40 (2 pcs.)
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if
EVAPORATION
the water drops freeze. Therefore, how to SENSOR
discharge water is an important point.
Fig. 8 Evaporator
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve
which is described in the following. In order to
attain proper control, it is necessary to reduce the
pressure drop of the refrigerant of the evaporator.
Accordingly, reducing the pressure drop is one
element that makes the evaporator attain its full
performances.
(2) Expansion valve
In order for the evaporator to fulfill its performances,
31102 60413252
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 refrigerant completes
vaporization early in the evaporator which results
25-9
The expansion valve feeds the flowing high-

pressure high-temperature liquid refrigerant to
the evaporator as low-pressure low-temperature
liquid refrigerant (damp vapor of low dryness). DIAPHRAGM
The expansion valve controls the feed rate of the
refrigerant at the same time.
Fig.9 shows how the block type expansion valve
is constructed. The temperature sensing part is REFRIGERANT
EVAPORATOR OUTLET
provided in the shaft of the expansion valve to SIDE
directly detect the refrigerant temperature at the
SHAFT
outlet of the evaporator.
The diaphragm contains R134a in saturated sta-
te. The pressure in the diaphragm changes
according to the temperature detected by the REFRIGERANT
sensor. The change in the pressure causes the INLET
force acting upon the diaphragm to vary
BALL
accordingly. BALVE
The high-pressure high-temperature liquid SPRING
refigerant that is fed from the receiver side reduces
the pressure abruptly as it passes through the Fig. 9 Block type expansion valve
valve (throttling action). On that occasion, part of
the refrigerant evaporates by the heat of the
refrigerant and cooled off. The result is that low-
pressure low-temperature damp refrigerant vapor
is fed to the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that under
the pressure in the evaporator, the refrigerant is
properly overheated (3~8°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
31102 60413252
temperature at the outlet of the evaporator and

controls the overheating of the refrigerant and the Fig. 10 Expansion valve outside view
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block
type expansion valve.
25-10
(3) Compressor (See Fig.11)

The compressor performs the following three
functions in the cooling circuit: D HOSE
1) Suction action
2) Pumping action
3) Compressive action S HOSE
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 continuous cooling.
3) The compressive action, as combined with the
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant back Fig. 11 Compressor
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.12)
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure
by the use of outer air and condenses the
refrigerant. The direction in which heat moves is
from the refrigerant to air, the opposite to the case
of the evaporator. Fins are equipped on the outer
air side to improve thermal transfer. If the refrigerant
is not cooled well by the condenser, the air in the
compartment can not be cooled sufficiently by the
evaporator. For that purpose, it is necessary to
secure ventilation required for cooling of the
31102 60413252
refrigerant.
Fig. 12 Condenser
25-11
(5) Receiver dryer (See Fig.13) REFRIGERANT

INLET SIGHT GLASS
1) Receiver tank
On the air-conditioner, the revolution of the
REFRIGERANT
compressor varies greatly which cause the proper OUTLET
flow of refrigerant in the cooling circuit to vary. It is
the receiver tank that receives the variations.
When the cooling circuit 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
PRESSURE SWITCH
much refrigerant. The receiver tank also stores an
extra amount of refrigerant to be used for filling
balance and supplement small amounts of leakage
of the refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it deteriorates
the compressor valves and oil, corrodes the DESICCANT
metallic parts of the circuit or clogs the circuit as
the water freezes in the expansion valve. It is
SUCTION PIPE
desirable that the amount of water mixed in the
refrigerant should be held below a concentration
of 30 ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in order to FILTER
absorb water content that intrudes into the circuit
when the dryer is installed or when refrigerant is
charged.
3) Sight glass
This is a window with which the refrigerant level in
the circuit is determined, the only means of RECEIVER TANK
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 cutting
off the power supply to the compressor when high
pressure increases abnormally high [more than Fig. 13 Receiver dryer
32 kgf/cm2 (460 psi)].
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 2 kgf/cm2 (28 psi).
31102 60413252
25-12
4. DISASSEMBLY AND ASSEMBLY
4.1 PRECAUTIONS TO BE EXERCISED IN Table 2 Unit: kgf·cm (lbf·ft)
OPERATION Pipe fastening part Tightening torque

(1) Special refrigerator oil
D hose and compressor (M8 bolt) 200~250 (14~18)
This air-conditioner uses special refrigerator oil
D hose and condenser 200~250 (14~18)
SP20 for use with new refrigerant R134a. Oils
L hose and condenser 120~150 (8.7~11)
other than SP20 may not be used. Since SP20
L hose and receiver dryer
tends to absorb moisture and may corrode paint 80~120 (5.8~8.7)
(M6 bolt)
and resin, the following points must be noted: L hose and air-conditioner unit 120~150 (8.7~11)
1) Keep open all pipe connections on a new S hose and air-conditioner unit 300~350 (22~25)
compressor and the component parts of the Inlet of expansion valve 120~150 (8.7~11)
installed refrigeration circuit. Outlet of expansion valve 200~250 (14~18)
(Remove valves and caps at the pipe openings of Pressure sensing part of
the compressor, just before connecting popes. If 70~90 (5.0~6.5)
expansion valve
you have removed a pipe joint for repair, put a cap
to both ports immediately).
Table 3 Unit: kgf·cm (lbf·ft)
2) Use care so SP20 does not adhere to the painted
surface and resin parts. In case SP20 has adhered Screw size Tightening torque
to such surfaces, wipe it off immediately. N4, T4, machine screw, M4 8~12 (0.58~0.87)
(2) The receiver dryer is filled with desiccant to absorb N5, T5, machine screw, M5 20~25 (1.4~1.8)
moisture in the circuit. Therefore, remove the M6 (mounting part of
80~120 (5.8~8.7)
valve at the pipe port immediately before L hose joint)
connecting pipes. M6 (except mounting part of
100~120 (7.2~8.7)
(3) Tightening torque L hose joint)
1) Pipe joints (See Table 2.) M8 (mounting parts of
200~120(14~18)
When connecting pipe joints, coat the O ring with S,D hose joints)
special oil (SP20) and fasten to the tightening M8 (mounting part of A/C unit) 100~120 (7.8~8.7)
torque indicated in the table, using a double M8 (other than those
120~160 (8.7~12)
spanner. mentioned above)
2) Screws and bolts (See Table 3.) N10 400~550 (29~40)
(4) Amount of oil for compressor (See Table 4.)
The compressor SD7H (HD type) is filled with Table 4
240cc (15 cu-in) of oil. If the oil volume is small,
Part to be replaced Amount to be filled in
seizure at high revolution and shortening of service
life will occur. If the oil volume is large, the cooling Evaporator 40 cc (2.4 cu·in)
ability will be deteriorated. Condenser 40 cc (2.4 cu·in)
Once the air-conditioner is operated, part of the oil Drain out the volume of oil left in
Compressor compressor to be replaced, from
is dispersed in the refrigeration circuit. Therefore,
the new cpmpressor.
when replacing the parts in Table 4, adjust the oil
F17117
level to that of table.
(5) Before performing operation, stop the engine and
turn off all power supplies to the equipment related
to the air-conditioner.
31102 60413252
(6) After the operation is over, confirm that all faults

have been repaired completely, by operating the
air-conditioner.
25-13
4.2 REMOVAL AND INSTALLATION OF THE

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

BLOWER
1) Disconnect the cooling hose that is connected CASING
between the blower motor and the blower casing.
2) Remove three cross-recessed screws N5 X 16

(W) fixed from the bottom of the blower unit
casing. Then draw out the blower motor. BLOWER MOTOR
BLOWER
CONTROLLER
• Do not separate the fan from the blower motor.
COOLING HOSE
3) Assembly is the reverse order of disassembly.
BLOWER MOTOR
(3) Replacing the blower controller MOUNTING
BLOWER
1) Remove two cross-recessed screws T4 X 14 (T1) CONTROLLER SCREWS (3 pcs.)
fixed from the bottom of the blower unit casing and MOUNTING
SCREWS (2 pcs.)
31102 60413252
draw out the blower controller.

Fig. 16
2) Install a new blower controller in the reverse order

of removal.
• Do not disassemble the blower controller in
any circumstances.
25-14
(4) Removing the heater core

1) After discharging the cooling water, disconnect
the heater hose from heater core. HEATER CORE
2) Remove one cross-recessed screw N5 X 16 (T2) PIPE CLAMP

each for the AHC bracket fixing the heater core to
the unit and for the pipe clamp. Then remove the
PIPE CLAMP
AHC bracket and the pipe clamp and draw out the MOUNTING
SCREW (1 pc.)
heater core from the unit casing.
AHC BRACKET AHC MOUNTING
SCREW (1 pc.)
3) Assembly is the reverse order of disassembly.
Fig. 17
(5) Removing the upper and lower parts of the air-

conditioner unit casing.
1) Draw out the connectors for the mode motor
ROD 120
actuator and the evaporation sensor.
REAR OF UNIT
ROD HOLDER CASING
2) Separate the rod 120 from the rod holder that is MOUNTING
fixed to the lever MAL1 on the mode motor actuator. LEVER MAL1 SCREW
MOUNTING BOTTOM OF
SCREW UNIT CASING
3) Remove three cross-recessed screws N4 X 22
(T2) fastening the mode motor actuator that install MOUNTING MODE MOTOR
the bottom of the unit casing to the back of the unit SCREW ACTUATOR
casing. Then separate the mode motor actuator.
Fig. 18
4) Remove eleven cross-recessed screws N5 X 16

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

EVAPORATOR ASSY
core off the unit casing.
EXPANSION
VALVE
EVAPORATION
SENSOR
BOTTOM OF
UNIT
CASING
TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11
pcs.)
31102 60413252
Fig. 19
25-15
(6) Replacing the evaporator and the expansion val-

ve EVAPORATOR
1) Remove the evaporator assy from the bottom of
the casing, together with the casing insulator and
the expansion valve.
O-RING EXPANSION
VALVE
2) Remove the upper and lower casing insulators
from the evaporator assy and draw out the SOCKET HEAD
CAPSCREW
evaporator sensor with the sensor holder. M5 X 40 (2 pcs.)
3) Remove the socket ahead cap screws M5 X 40 (2

pcs.) from the evaporator. Then separate the EVAPORATION
expansion valve from the evaporator. SENSOR
: 4 mm Fig. 20
4) Attach O-rings (NFO-ring 5/8 and 1/2, one piece

each) to a new evaporator. Then install the
expansion valve to it.
: 4 mm
Tightening torque 0.7 kgf/m (5.1 lbf·ft)
• When attaching O-rings, use care so the O-

rings are not caught. 3rd ROW
(7) Installing the evaporator sensor 5th and

Install the evaporation sensor as shown in Fig.21. 6th ROWS
• When installing the casing, exercise care so
13th and 14th
the sensor cord is not caught by the casing. ROWS
EVAPORATION
(8) Replacing the motor actuator SENSOR
1) Replacing the mode motor actuator
Fig. 21
Remove the connector fixed to the motor actuator.
Remove the rod 120 linking the motor actuator
with the mode cam, from the rod holder.
Remove three cross-recessed screws T4 X 14
(T1) fixing the motor actuator. Separate the motor
actuator from the unit, together with the rod holder
and the lever MAL1. Remove the rod holder and
ROD 120 REAR OF
the lever MAL1 from the motor actuator and install UNIT
them to a new motor actuator. Assembly is the ROD CASING
HOLDER MOUNTING
reverse order of disassembly.
SCREW
LEVER MAL1
BOTTOM OF
MOUNTING UNIT
SCREW CASING
MOUNTING MODE MOTOR
31102 60413252
SCREW ACTUATOR
Fig. 22
25-16
2) Replacing the air mix motor actuator

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

Disconnect the connector connected with the
motor actuator.
Separate the motor actuator with lever MAL2 from
the unit. LEVER MAL2
Remove the lever MAL2 from the motor actuator
and install it to a new motor actuator, in the
reverse order of disassembly.
INNER / OUTER
AIR MOTOR
ACTUATOR
Fig. 24
31102 60413252
25-17
5. CHARGING REFRIGERANT
5.1 PRECAUTIONS TO BE EXERCISED IN 6) Store cans beyond the reach of children.
OPERATION (3) Charging
(1) Always assign a person in charge of handling 1) When warming the can in which refrigerant is
refrigerant. charged, do not fail to open the service can valve
Refrigerant charge operation involves dangers as and the low pressure valve of the gauge manifold
it handles high pressure gas. Always assign a and warm the can in warm water of 40°C (104°F)
person familiar with how work is done for handling or below (to an extent that you do not feel hot when
refrigerant. you put your hand in the water.) If the can is put in
hot water or heated by a direct fire, the pressure
WARNING of the can may rise sharply, thereby blowing off
• Always wear protective goggles. (You may lose your the can.
sight if the refrigerant gets in your eyes). 2) When charging refrigerant while running the
• The refrigerant in liquid state is at very low tempera-
engine, do not open the high pressure valve (HI)
ture [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant of the gauge manifold in any case.
is sprayed over your skin). (4) Others
Re-use of service cans is prohibited by law; never
use them again. Do not allow foreign matter to
(2) Storage and Transportation enter the air-conditioner circuit. Air, water and
1) Hold the service can (hereinafter called can) less dust are detrimental to the refrigeration cycle.
than 40°C (104°F). Since high pressure gas of Install the components of the air-conditioner
R134a is filled in the can in a saturated liguefied correctly and speedily. Pay full attention to the
state, the pressure in the can increases sharply as entry of water and dust.
temperature rises.
The can may blast as the result.
It is for this reason why the can temperature must WARNING
be kept below 40°C (104°F). • Be careful about overcharge of gas.
• Fasten pipes to a specified torque.
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. Therefore, never bring
the can close to a fire.
4) The inside of the closed compartment gets very
hot as the radiation heat of the sunlight enters the
compartment. The areas of the compartment which
are exposed to direct sunlight may rise to a
dangerous temperature level. Therefore, do not
bring the can into the compartment. Also, the
inside of the trunk room may rise to a dangerous
temperature level even in the summer time. Use
sufficient care, therefore, taking the above into
account.
31102 60413252
5) Note that if the can has scratches, marks and

distortion, the strength of the can will deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans
and packages containing cans, do not throw or
drop them.
25-18
5.2 OPERATING PROCEDURE 2) The “gas charging operation” consists of filling

(1) Refrigerant charge into the air-conditioner consists refrigerant in the circuit after forming vacuum.
mainly of “vacuum making operation” and “gas Filling gas not only depends upon the cooling
charge operation”. performances of the air-conditioner, but also affects
1) The “vacuum making operation” consists of the service life of the component parts of the
removing water in the air-conditioner circuit. If circuit. Extreme overcharge will make the circuit
only a little water remains in the circuit, the small pressure extremely high and causes the cooling
holes of the expansion valve are frozen during performance to deteriorate. On the contrary,
operation. This causes the circuit to clog up or undercharge causes poor circulation of the
rust, resulting in a variety of malfunctions. lubricating oil of the compressor and causes
Therefore, before filling refrigerant in the circuit, seizure of the moving parts of the compressor.
make vacuum and allow the water in the circuit to The gas filling operation involves handling of high
boil and vaporize. Water in the circuit is thus pressure gas; filling gas according to incorrect
eliminated. 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 mim. for five minutes
Begin vacuum Stop vacuum Check Fill in Check for Fillin
making making air-tightness refrigerant gas leak refrigerant
Less than
-750mmHg
Gauge reading
wrong
Charge liquid gas to a gauge
Check and correct joints
pressure of 1 kgf/cm2 (14 psi)
(2) Tools
Table 5
No. PART NAME Q'TY SKETCH SERVICE No. PART NAME Q'TY SKETCH SERVICE
Gauge Quick joint Low pressure

4 1
manifold side
1 1
T joint For service can
5 1
valve
Red: high
pressure side
Blue: low
Charging pressure side Service can For service can
2 3 6 2
hose Yellow: valve
vacuum pump
side
31102 60413252
Quick joint Vacuum For vauum

pump pump
3 1 7 adapter 1
F17118
25-19
5.3 CHARGING PROCEDURE HIGH

5.3.1 Vacuum making operation LOW PRESSURE PRESSURE GAUGE
GAUGE GAUGE MANIFOLD
(1) Connecting gauge manifold (See Fig.25)
(CLOSED)LOW HIGH PRESSURE
1) Close the high pressure valve (HI) and the low PRESSURE VALVE (CLOSED)
VALVE
pressure valve (LO) of the gauge manifold. RED
BLUE
2) Connect the charging hoses (red and blue) with
the service valves of the compressor. HIGH
PRESSURE YELLOW
Red hose: High pressure side (HI) of the gauge SIDE
manifold high pressure side DIS
LOW
(DIS) of compressor PRESSURE
Blue hose: Low pressure side (LO) of gauge SIDE
manifold low pressure side (SUC) SUC
of compressor COMPRESSOR
VACUUM PUMP (STOP)
WARNING
Fig. 25 Connecting gauge manifold
• Take care so as not to mistake the high pressure side
for low pressure side and push it in till a click is heard.
Connect the end bent like “L” of the charging hose

with the service valve of the compressor.
BLUE
WARNING RED
If the charging hose is connected the opposite way, the
mini core valve of the compressor does not open. (See
CHARGING HOSE
Fig.26)
(MINI CORE VALVE)
3) Connect the middle valve of the gauge manifold
with the charging hose of the vacuum pump. Fig. 26 Connecting piping with compressor
Some kinds of gauge manifolds are not equipped

with an open/close valve in the center.
(2) Vacuum Making (See Fig.27.)

1) Open the high pressure valve (HI) and the low LOW PRESSURE VALVE (OPEN) (CLOSE)
HIGHT PRESSURE VALVE (OPEN) (CLOSE)
pressure valve (LO) of the gauge manifold.
2) Turn on the switch of the vacuum pump and make More than 30 min.
vacuum for more than 30 minutes.
3) When vacuum making for a specified duration is GAUGE MANIFOLD
over (degree of vacuum : less than - 750 mmHg),
close the high pressure valve and the low pressure
valve of the gauge manifold.
4) Then turn off the vacuum pump.
DIS
31102 60413252
SUC
Fig. 27 Vacuum making operation
25-20
(3) Air-tightness check

Close the high pressure valve and the low pressure
valve of the gauge manifold, leave it as it is for
more than five minutes and make sure that the
gauge indication does not return toward zero.
WARNING
If the gauge indication swings toward zero, there is
somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.
5.3.2 Gas charging operation

(1) Charging from high pressure side
(See Fig.28.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold from
the vacuum pump to the service can.
Open the service can valve. (However, close the AIR PURGE
high and low pressure valves of the gauge CLOSE
manifold). Then push the mini core valve of the RED
side service port on the low pressure side of the OPEN SERVICE CAN VALVE
SCREWDRIVER
gauge manifold, using a screwdriver or something, OR SOMETHING
in order to let out the air in the charging hose by the BLUE YELLOW
pressure of the refrigerant (see Fig.28). (The
operation ends when a hissing sound is heard).
3) Open the high pressure valve of the gauge manifold
Fig. 28 Gas charging operation
and charge in refrigerant. [Charge in gaseous
refrigerant to a gauge pressure of 1 kgf/cm2 (14
psi)].
After charging, close the high pressure valve of
the gauge manifold and the service can valve.
(see Fig.29.)
WARNING
Do not run the compressor in any case, (otherwise the
refrigerant flow in reverse direction which causes the LOW PRESSURE HIGH PRESSURE VALVE
service can and the hoses to rupture. This is very VALVE (CLOSE)
(OPEN) (CLOSE)
dangerous). RED
FILL IN 1~1.5 CANS
BLUE OF REFRIGERANT
DIS YELLOW
(2) Checking for gas leakage
Check for gas leakage in the cycle, using a gas SERVICE CAN
leak detector (electric type). Retighten and correct VALVE
leaking points. (OPEN) (CLOSE)
SUC CHARGE
31102 60413252
WARNING
Always use R134a for the leak tester (the presently
used from gas affects the sensitivity adversely). Fig. 29 Gas charging operation (high pressure side)
25-21
(3) Charging from low pressure side (see Fig.30).

1) Make sure that the high-pressure and low-pressure
valve of the gauge manifold and the service can HIGH PRESSURE
LOW PRESSURE VALVE (CLOSE)
valve are closed. VALVE (MUST BE CLOSED
2) Start the engine and run the revolution to 1500 ± (OPEN) (CLOSE) POSITIVELY)
100 rpm and fully open the cab door and the WHEN AIR BUBBLES RED
IN THE SIGHT GLASS
windows. DISAPPEAR YELLOW
3) Turn on the air-conditioner switch to Max and the
DIS BLUE
temperature control switch to cool Max.
SERVICE CAN
4) When charging gas, set the discharge pressure of VALVE (OPEN)
the compressor to 14~16 kgf/cm2 (200~230 psi). SUC
5) Open the low pressure valve of the gauge manifold
and the service can valve and fill in refrigerant till COMPRESSOR
air bubbles of the sight glass of the receiver go OPERATION SERVICE CAN
(DO NOT TURN IT OVER)
away (see Fig.31).
[Total amount of gas to be charged: 800 +50 0 g Fig. 30 Gas charging operation (low pressure side)
+0.1
(1.8 0 lbs)].
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve. SIGHT GLASS
WARNING
• Do not open the high pressure valve of the gauge
manifold in any circumstances.
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state).
Fig. 31 Receiver dryer
31102 60413252
25-22
(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, no air

Overcharge
bubbles are seen.
After A/C is turned on, continuous

Undercharge
air bubbles are seen.
F17151
WARNING
• If the air-conditioner is run with scant 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) Detaching gauge manifold

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner.
1) Press the “L” shape metal fitting of the charging
hose (blue) on the low pressure side against the
service valve of the compressor so the refrigerant
does not leak out and loosen the nut. As soon as
the nut has been removed, disconnect the charging
hose from the service valve.
2) Leave the high pressure side as it is till the high
pressure gauge reading falls [below 10 kg/cm2
(140 psi)].
3) Disconnect the charge hose (red) on the high
pressure side the same way as on the low pressure
side.
31102 60413252
25-23
6. ELECTRIC CIRCUIT
6.1 WIRING DIAGRAM AND CONNECTORS
NOTE:
1.The double chain lines indicate the wiring on the excavator side.
2.The connector colors indicate the cord colors seen from the
connection part.
31102 60413252
Fig. 32 Electric diagram
25-24
6.2 INSPECTING FUNCTIONAL PARTS

(1)Relay (24-4PE)
1)Coil resistance: 320 Ω (across 1 and 2)
2)Operating voltage: DC20~30V As viewed from A
3)The coil of the relay has polarity: care is needed.
4)Turn on and off the power to the blower motor by
controlling the controller.
5) Check: check conductance across 3 and 4 in the
following condition:
Apply 20~30V across terminals 1 and 2: continue
No voltage applied across terminals 1 and 2:
discontinue
Fig. 33 Relay
(2) Inner air sensor (C44)

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

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

1) Operating voltage: DC20~30V
2) Operating temperature range: -30°C (-22°F) to
+75°C (167°F)
31102 60413252
The motor is controlled by signals (pulses) put out

by the controller.
Fig. 36 Motor actuator
25-25
(5) Pressure switch (attached to receiver dryer) PRESSURE SWITCH

1) Contents of checking (specification)
Low pressure side OFF pressure:
2.0 ± 0.2 kgf/cm2 (28 ± 3 psi)
Low pressure side return pressure:
OFF pressure + 0.3 kgf/cm2 (4.3 psi) or below
High pressure side OFF pressure:
32 ± 2 kgf/cm2 (455 ± 28 psi)
High pressure side return pressure:
OFF pressure -6 ± 0.2 kgf/cm2 (-85 ± 2.8psi)
Fig. 37 Pressure switch
LOW PRESSURE RETURN HIGH PRESSURE RETURN kgf/cm2 (psi)

(26) (30) (31) (36) (310) (430) (480)
1.8 2.1 2.2 2.5 22 30 34
F17152
LOW PRESSURE OFF HIGH PRESSURE OFF
2) Performance
• Low pressure side: to prevent actuation of the
compressor clutch where refrigerant is
deficient.
• High pressure side: to prevent actuation of the
compressor clutch where pressure rises
abnormally because of the clogging of the
refrigeration circuit, etc.
(6) Thermistor (C19)

1) Contents of checking (specification)
Resistance across terminals
at 0°C (32°F): 7.2 KΩ
at 25°C (77°F): 2.2 KΩ
NOTE:
Normally check that there is no shortcircuit or
disconnection.
Fig. 38 Thermistor
2) Performance
In order to prevent freezing of the evaporator, the
blowoff air temperature of the evaporator is
31102 60413252
controlled by turning the compressor clutch ON

and OFF. The thermistor operates as the sensor
of the control.
25-26
7. TROUBLESHOOTING
NOTE:
[ Temperature does not fall ]. M/A: Motor Actuator
If A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel.
NO YES
• Connector for air mix M/A is

*
"HL. " is shown on the set temp. display of the panel.
disconnected or in poor contact.
NOTE: is any of the
NO YES *
numbers 0 ~ 9. • M/A is broken.
• Main harness shows poor conductance.
** E on display.
A snow mark on the A snow mark on panel is flickering.
panel is flickering. Inspect and correct or replace parts.
NO YES NO YES
• Inner air sensor or harness • Both inner air sensor and

is disconnected or shorted. evaporation sensor are
• Inner air sensor connector is disconnected or sohrted.
disconnected or in poor contact. • Controller failed.
Inspect and correct or replace parts.
Blowout temp. falls if temp. is set

at 18.0 (64.4°F) (COOLMAX) and the
• Evaporation sensor connector
is disconnected or in poor contact.
blowout mode is changed to vent mode.
• Evaporation sensor is
NO YES disconnected or sohrted.
*1 Air mix damper is

in COOLMAX.
Chilly air flowing
into inner air sensor
NO YES NO YES
If M/A is at stop Turn compressor clutch Controller is faulty Inspect duct or

halfway, eliminate on and off. Inspect and or inner air eliminate cause for
cause, correct and correct electric circuits. sensor is faulty. chilly air intrusion.
measure operating
force. (less than Refer to Troubleshooting Inspect and replace.
1.5 kgf : OK) for refrigeration cycle.
1 COOL-MAX
*acting condition
NO YES
• Inspect, correct or replace M/A is faulty or controller

M/A lever link. is out of order.
31102 60413252
• After cleaning lever link,

apply grease.
Replace.
F17153
25-27
[ Temperature does not rise ].
HL.E is shown on the set temp. display of panel.
NO YES
*
"HL. " is shown on the set temp. display of the panel. NOTE:
* is any of the numbers 0 ~ 9
NO YES
*2Blowout temp. rises at blowout

• Inner air sensor or harness
mode if temp. is set at is disconnected or shorted. • Air mix M/A connector is off.
HOTMAX 32.0°C (89.6°F). • Inner air sensor connector • M/A is broken.
is off or in poor contact. • Main harness shows
poor continuity.

Inspect and correct
NO YES
or replace parts.
*2 Air mix damper is Warm air is flowing into

at HOT MAX. inner sensor.
NO YES
NO YES
If M/A action is at Inspect warm water piping.
stop, eliminate cause, Controller or Inspect duct or
correct and measure inner air sensor eliminate causes
operating force. is out of order. for warm air entry.
(less than 1.5kgf: OK)
Inspect and replace.
NO YES
• Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
• Clean lever link and apply grease.
2 HOT-MAX
Replace. *operating condition
F17154
31102 60413252
25-28
[ Blower motor does not run ].
At air flow HI, battery voltage acts across NOTE: Measure with
both terminals (+) and (-) of blower motor. connector set.
NO YES
Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
Replace.
NOTE1):Always turn off air- NO YES
conditioner, starter
key switch and light
switch before work.
Inspect blower motor relay. Approx. 10V acts across

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

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

or replace controller.
[ Blower motor speed does not change ].
HL.
* is shown on the set temp. display of panel. NOTE:
* is any of the
numbers 0 ~ 9.
NO YES
Air flow rate is constant regardless of readings. • Inner air sensor and harness
are disconnected or shorted.
31102 60413252
• Inner sensor connector is

disconnected or in poor contact.
Replace blower
amplifier or controller. Inspect and correct or replace parts.
F17156
25-29
[ Magnet clutch does not engage ].
Snow mark lights if A/C switch is pressed
NO YES
Snow mark flickers and E is Voltage acts upon clutch.

shown on panel display.
NO YES
to B Terminal voltage present across Clutch faulty.

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

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

and vehicle connector. harness. No fault.
Also clutch fuses.
NO YES
Replace harness. Replace controller.
[ Inner air and outer air do not change over ].
Inner / outer air mode display on

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

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

and replace parts.
31102 60413252
F17157
Replace
25-30
[ Modes do not change ].
Mode display on operating

panel is flickering.
NO YES
M/A rod is linked. Mode M/A connector is not linked or

in poor contact or M/A failed or main
harness is faulty.
NO YES
Inspect or replace.
Repair. Each damper lever is linked.
NO YES
When rod is removed and cam is operated

Repair. by hand, it is heavy. (more than 2kgf.)
NO YES
M/A or controller is out of order. • Cam or damper shaft includes

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

• Clean cam and apply new grease.
F17158
31102 60413252
25-31
[ Trouble with refrigeration cycle ].
Both high and low pressures are lower. Low pressure is lower.
Air bubbles are seen in sight glass. Air bubbles are High pressure
seen in sight glass. is lower.
NO YES
Cooling does not work Oil oozes out from Compressor Hot air Compressor
if run at high speed. piping and parts. cylinder does comes out of cylinder gets
not get hot. heater unit. very hot.
NO YES NO YES
Expansion Expansion Natural Gas leaks Expansion Water cock Compressor

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

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

it does not cool down or air flow decreases.
Air bubbles are seen in sight glass. Frost deposits.
NO YES
High pressure gets Condenser is Thermistor does

lower gradually. fouled or clogged. not cool off.
YES NO YES
NO
High pressure
circuit before Air bubbles are hard to Thermostat is Thermistor position
receiver is go out even if water not turned off. is normal.
clogged up. is poured on condenser.
NO YES NO YES
31102 60413252
Remove Clean Air is mixed. Functions and Thermistor Thermistor Air

clogging condenser. Make vacuum performances is faulty or position is leaks
or replace and refill are normal. cord is faulty. out of
parts. refrigerant. Familiarize disconnected. Correct casing.
the user with position. F17155
how to use it.
25-32
SECTION 31 WHOLE DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
1. Explaining chapter of whole disassembly and assembly...................................... 31-1

1.1 Form for chapter of disassembly and assembly ............................................................................ 31-1
1.2 Indication of tightening torque ....................................................................................................... 31-1
31102 60413252
WHOLE DISASSEMBLY AND ASSEMBLY
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY AND ASSEMBLY
1.1 FORM FOR CHAPTER OF DISASSEMBLY AND ASSEMBLY

This chapter is consist of 3-section as follows.
(1) ATTACHMENT ............................................................................................................................ SEC. 32

Part I; Removing and installing assy
Part II; Disassembling and assembling components
1) Hydraulic cylinder
(2) UPPER SLEWING STRUCTURE ................................................................................................ SEC. 33

1) Hydraulic pump 2) Control valve 3) Pilot valve (ATT)
4) Pilot valve (Travel) 5) Slewing motor 6) Swivel joint
(3) TRAVEL SYSTEM ....................................................................................................................... SEC. 34

1) Travel motor
1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example;
T = 10 kgf·m (72 lbf·ft)
Tolerance is ± 10% unless specified.
• Refer SEC. 11 TOOLS for standard tightening torque.
31102 60413252
31-1
WHOLE DISASSEMBLY AND ASSEMBLY
NOTE
31102 60413252
31-2
SECTION 32 ATTACHMENTS
TABLE OF CONTENTS
Part I: Disassembling and assembling components

1. Attachment and component ................................................................................. 32-1
2. Bucket................................................................................................................... 32-1
2.1 Removing bucket ............................................................................................................................ 32-1
2.2 Attaching bucket ............................................................................................................................. 32-2
2.3 Procedure for adjusting clearance ................................................................................................. 32-3
3. Arm ....................................................................................................................... 32-4

3.1 Removing arm ................................................................................................................................ 32-4
3.2 Attaching arm ................................................................................................................................. 32-5
4. Boom .................................................................................................................... 32-6

4.1 Preparation for removing and attaching boom ............................................................................... 32-6
4.2 Removing boom ............................................................................................................................. 32-6
4.3 Attaching boom .............................................................................................................................. 32-9
Part II: Disassembling and assembling components

1. Cylinder .............................................................................................................. 32-11
1.1 Preparation before disassemble ................................................................................................... 32-11
1.2 Construction of cylinder (an example of arm cylinder) ................................................................. 32-13
1.3 Disassembling .............................................................................................................................. 32-14
1.4 Install ............................................................................................................................................ 32-20
1.5 Maintenance standards ................................................................................................................ 32-26
1.6 General tool .................................................................................................................................. 32-27
1.7 Tightening torque ......................................................................................................................... 32-28
1.8 Tool and jigs list ............................................................................................................................ 32-29
1.9 Troubleshooting ............................................................................................................................ 32-33
31102 60413252
ATTACHMENTS
Part I: DISASSEMBLING AND ASSEMBLING COMPONENTS

1. ATTACHMENT AND COMPONENT
BOOM CYLINDER ROD PIN (C)
ARM CYLINDER HEAD PIN (D)
4. BOOM BOOM INSTALL (FOOT) PIN (A)

ARM CYLINDER
BOOM TOP PIN (F)
ARM CYLINDER
ROD PIN (E)
BOOM CYLINDER
2. BUCKET
BUCKET CYLINDER
HEAD PIN (G)
BUCKET CYLINDER
3. ARM
F17202
IDLER LINK PIN (I) BUCKET DRIVE PIN (J)
BOOM CYLINDER HEAD PIN (B)
IDLER LINK
BUCKET LINK
BUCKET CYLINDER ROD PIN (H) BUCKET ATTACHING PIN (K)
Fig. 1-1 Front attachment and position
2. BUCKET
2.1 REMOVING BUCKET

(1) Put the machine in position to remove bucket.
F17203
Fig. 2-1 Position to remove bucket
(2) Removing pin (2)

Expand slit of ring (1) with driver, and remove it.
Push out the pin (2) with driver (-).
31102 60413252
SECTION AA
Fig. 2-2 Removing pin (2)
32-1
ATTACHMENTS
(3) Removing bucket attaching pin (K).

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

Put bucket on the ground, position it so that the
bucket drive pin (J) is not loaded, adjust bucket
link, and pull out pin (J).
Fig. 2-4 Removing bucket drive pin
2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in
the reverse procedure of the pulling out.
WARNING
• When aligning the pin holes, do not put your finger in
the pin holes in any circumstances, but align them
visually.
• Check that the seals are not scored and replace a
faulty one if necessary.
• When inserting the pin, coat the shaft with grease.
Fig. 2-5 Attaching bucket
31102 60413252
32-2
ATTACHMENTS
2.3 PROCEDURE FOR ADJUSTING BUCKET

CLEARANCE
Adjustment of clearance between bucket and arm
1) Shift O-ring (3) toward the bucket boss, using a
spatula (a b).
2) When adjusting clearance (B), bring the non-

adjusting side of the bucket in contact with the
arm. ARM
3) Measure clearance (B) and check that it is within

1.0 mm (0.04 in).
BUCKET ATTACHING PIN
4) Adjust clearance (B) where it is more that 1.0 mm

(0.04 in).
5) An average of 5 shims (8) of 1mm (0.04 in)

thickness are set in each of the three M12 x 45
bolts (10). The clearance can be adjusted by 1mm
(0.04 in) if one shim is removed.
: 19 mm Fig. 5 Adjusting clearance between bucket and arm
6) After adjustment, tighten the bolts evenly.

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

of both clearances are within 1.0 mm (0.04 in).
8) Refit O-ring (3) to its original position.
WARNING
• When shifting O-ring (3) by means of a spatula, use
care so as not to score O-ring (3).
• Remove shims (8), push out bushing (7) rightwards
by means of three bolts (10) and adjust clearance (B)
so it falls within the standard value evenly all round.
• Check the clearance at 120 hours' intervals in normal
operation. Shorten these intervals in special hard
operation. Adjust the intervals as necessary.
31102 60413252
32-3
ATTACHMENTS
3. ARM
3.1 REMOVING ARM

(1) Put the machine in position to remove arm.
Fold arm, and the bucket cylinder is retracted and
the arm is put on the ground.
F17204
Fig. 3-1 Position to remove arm
(2) Separating piping of bucket cylinder

Release pressure of hydraulic tank, place oil pan
to prepare for oil leaking, and separate pipes.
WARNING
Plug both section of separated pipes.
Plug: M30
When the removal of bucket cylinder is not required Fig. 3-2 Separating piping of bucket cylinder
skip to procedure (6). (Illustration shows E75SR EVOLUTION)
Insert resin shim into bucket link side.

(3) Removing bucket cylinder rod pin (H) SHIM RESIN SHIM
1) Loosen nut (9), remove capscrew M12 X 100 (8), After adjustment of shim, the total gap
and push out pin (H). should be within 0.6~1.0 mm (0.02~0.04 in).
: 19 mm SHIM
2) Retract cylinder rod.
DUST SEAL
SECTION DD
SHIM RESIN SHIM
Insert resin shim into bucket link side.
Fig. 3-3 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G) Insert resin shim into bucket link side.
SHIM RESIN SHIM
Loosen nut (3), remove capscrew M12 X 100 (2),
After adjustment of shim, the total gap
and push out pin (G). should be within 0.6~2.0 mm (0.02~0.08 in).
: 19 mm SHIM
31102 60413252
SECTION AA
Fig. 3-4 Detail of bucket cylinder rod pin (H)
32-4
ATTACHMENTS
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight: 44 kg (97 lbs)
Fig. 3-5 Slinging bucket cylinder
(6) Removing arm cylinder rod pin (E) Insert resin shim into cylinder side.
SHIM RESIN SHIM
Loosen nut (4), remove capscrew (3), and push
out arm cylinder rod pin (E). After adjustment of shim, the total gap
should be within 0.6~2.0 mm (0.02~0.08 in).
: 22 mm SHIM
Retract arm cylinder rod, and return pin (E) to the
original position (hole).
SECTION BB
Fig. 3-6 Detail of arm cylinder rod pin (E)
(7) Removing boom top pin (F) Insert resin shim into cylinder side.
SHIM RESIN SHIM
Loosen remove capscrew (12), and pull out boom,
top pin (F).
Put block between arm cylinder and boom. After adjustment of shim, the total gap
: 19 mm should be within 0.5 mm (0.02 in).
Insert pin (F) into the original hole. SHIM
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight:
200 kg (440 lbs) (with bucket cylinder)
SECTION AA
150 kg (330 lbs) (without bucket cylinder)
Fig. 3-7 Detail of boom top pin (F)
3.2 ATTACHING ARM
1) Attaching boom top pin (F)
Attach boom top pin (F) first, and continue in the
reverse procedure of the removing.
WARNING
31102 60413252

visually.
• Check that the dust seals is not scored and replace
a faulty one if necessary.
Fig. 3-8 Slinging arm assy
32-5
ATTACHMENTS
4. BOOM
4.1 PREPARATION FOR REMOVING AND

A
ATTACHING BOOM
When removing and attaching boom in the position
shown in Fig.4-1, to remove and attach boom foot pin
(A), removing and attaching of cab and guard are
required.
Wood blocks
4.2 REMOVING BOOM
(1) Put the machine in position to remove boom. F17205
Place top end of boom down on block, etc. giving

attention for arm cylinder rod not to be extracted. Fig. 4-1 Position to remove boom
(2) Lifting up boom cylinder temporarily Wood blocks

Lift up boom cylinder temporarily to prevent it from
dropping.
Fig. 4-2 Lifting up boom cylinder temporarily
(3) Removing boom cylinder rod pin (C)

Loosen nut (7), remove capscrew (3), and push
out pin (C). Insert resin shim into bucket link side.
RESIN SHIM
IRON SHIM
After adjustment of shim, the
total gap should be within
0.6~2.0 mm (0.02~0.08 in).
SHIM
(4) Preparing for separating cylinder pipes

Retract boom cylinder rod side, and place one
side of cylinder on block (See Fig.4-2).
31102 60413252
SECTION AA
Fig.4-3 Detail of boom cylinder rod pin (C)
32-6
ATTACHMENTS
(5) Separating piping of arm cylinder and bucket

cylinder
Release pressure in hydraulic tank, and separate
pipe at section EE.
: 36 mm
After separation of pipe, plug every pipe.
Plug: M30
ARM - R
BUCKET - R
ARM - H
BUCKET - H
SECTION EE Fig. 4-4 Boom piping separation
(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom
foot pin (A) is not loaded.
Weight of boom assy: 400 kg (880 lbs)
Fig. 4-5 Boom assy temporarily lift up procedure

(7) Removing boom foot pin (A)
Insert resin shim into
1) Remove snap ring (3) and washer (4) and pull out boom side.
RESIN SHIM t = 2 (0.08 in)
pin (2).
2) Tools to Thread M16 X 54 for pin (1): screw slide
hammer in.
Refer to Tool 10. Tools for boom attaching pin.
3) Force slide hammer in until the pin is out.
SECTION AA
Fig.4-6 Details of boom foot pin (A)section
31102 60413252
Fig. 4-7 Removing pin (A) using slide hammer
32-7
ATTACHMENTS
(8) Slinging boom assy

Sling and remove boom assy.
Weight of boom assy: 400 kg (880 lbs)
Fig. 4-8 Boom assy slinging procedure
(9) Completion of removal of front attachments

When the removing and attaching of cylinder are
Opposing flats 27
not required, the work is finished.
A
Opposing flats 27
(10) Removing arm cylinder
Insert resin shim Opposing
Disconnect hose at A section, and plug both ends. into cylinder side. flats 36
RESIN SHIM Opposing flats 36
Plug 4-1
IRON SHIM
: 36 mm
Tightening torque : 22.0 kgf·m (160 lbf·ft)
: 27 mm
Tightening torque : 11.0 kgf·m (80 lbf·ft)
(11) Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew (2)and pull out SHIM
pin (D) After adjustment of shim, the
total gap should be within
0.6~1.0 mm (0.02~0.04 in)
Fig. 4-9 Removing arm cylinder
(12) Removing boom cylinder

Disconnect hose at B section. Plug both ends.
Opposing flats 36
plug 4-1
: 36 mm
Tightening torque: 220 kgf·m (160 lbf·ft)
31102 60413252
(13) Removing boom cylinder foot pin (B)

Loosen capscrew (4) and pull out pin (B).
Opposing flats 36
Fig. 4-10 Removing boom cylinder
32-8
ATTACHMENTS
4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
Screw tool 10. slide hammer M16 into boom foot
pin (A) first, and fit boom assy.
Attach it in the reverse procedure of removing
paying attention to the following points.
WARNING
visually. Fig. 4-11 Boom cylinder head pin (B)
• Check that the dust seals is not scored and replace
a faulty one if necessary.
• M12 Tightening torque: 11.7 kgf·m Insert resin shim into
cylinder side.
(85 lbf·ft) RESIN SHIM t = 2 (0.08 in)
• Pin lock nut handling procedure. SHIM After adjustment of shim, the total gap
should be within 0.6~1.0 mm (0.02~0.04 in)
(0~0.02)
0~0.5
IRON SHIM
F17206
• To attach shim, fit resin shim on operating side and

iron shim on the outside, and reduce the space.
SECTION BB
Fig. 4-12 Attaching boom cylinder head pin

31102 60413252
32-9
ATTACHMENTS
NOTE
31102 60413252
32-10
ATTACHMENTS
Part II: DISASSEMBLING AND ASSEMBLING COMPONENTS

1. CYLINDER
1.1 PREPARATION BEFORE torques of the cylinder head and the piston nut.
DISASSEMBLE Since a vise is attached to the bench, the width of
Before disassembly, it is necessary to keep a dustfree the work bench must be sufficiently large.
workshop and facilities.
(3) Support stand
1.1.1 Work area If the clevis part of the piston rod is fully extended
The following working area is required for disassembly: in a free condition, the bushing and the seals may
(1) Ample space be damaged as the rod bushing and the piston are
For disassembly of the hydraulic cylinder, the twisted due to the weight of the rod. A stand is
cylinder tube and the piston rod must be extracted. required to support the rod to prevent such.
Therefore, the first prerequisite is that the working
area must have sufficient space for such work. It (4) Hydraulic source
is also necessary that the space have amply A hydraulic source is required for disassembly
space widthwise to accommodate disassembly, and assembly of the cylinder head and piston nut
cleaning and measuring facilities. and for oil leak tests after completion of assembly.
(2) Suitable working environment (5) Jet air source

The hydraulic cylinder is a precision-machined It is used for drying after oil draining and cleaning
product incorporating seals and packings made of of the cylinder.
rubber and plastic materials. For this reason, care
should be used so that the hydraulic cylinder is (6) Cleaning bath, cleaning oil and detergent
free from dust, dirt, sand, metal chips weld slag
and other hard substance. If the hydraulic cylinder (7) Oil pan and oil reservoir
is assembled without being aware of hard particles An oil pan is necessary to contain oil drained from
stuck on the cylinder tube and the piston rod, the the cylinder and oil spilt during work.
tube inner surface and the rod surface may be An oil reservoir is required to collect oil spilt on the
scratched as the cylinder operates, thereby floor and waste oil.
disabling it in worst cases. Damage to the piston
seals and the rod seals will result in oil leaks. For (8) Others
this reason, grinding and welding operation should Oil extracting hoses, wooden skids, rag and
be avoided near the working area to keep it clean. sawdust in which oil soaked are also necessary.
1.1.2 Apparatus
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the
cylinder in an assembled condition. It must also be
capable of marking level and liner movement
under load for inserting and extracting the piston
rod and the tube.
31102 60413252
(2) Work bench

The work bench must have strength and rigidity
capable of accommodating the total length of the
cylinder in its most retracted condition and of
withstanding the repulsive force of the tightening
32-11
ATTACHMENTS
1.1.3 TOOLS NEEDED

Tools and jigs vary with types of cylinder, but it is
necessary to prepare the tools in Table 1-1 as a
guideline.
Table 1-1
TOOL / JIG REMARKS TOOL / JIG REMARKS
1.Steel hammer A sharp-point tool may be used in
Hammer Gimlet
2.Wooden or plastic mallet place of a gimlet.
Screwdriver A few types of large and small sizes 1. For fitting seal ring
Chisel Flat chisel 2. For pushing seal ring
Jig
One having an operation wide enough 3. For inserting bushing
Vise to hold cylinder head O.D. and tube 4. For press-fitting wiper ring
mounting pins (clevis) 1. Slide calipers
1.Hook wrench Measuring 2. Micrometer
Wrench 2.Extension pipe for wrenches instruments 3. Cylinder gauge (Fig.1-1)
4. V-block
F17232
• For the details of special tools and jigs, refer to the

back pages of this manual.
1.1.4 External cleaning

The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to the
clevis part. For this reason, remove external soil and
Fig. 1-1 Cylinder gauge
contamination from the cylinder with water and steam
before bringing it into the workshop.
• The following describes the construction of arm

cylinder (with cushions on both sides). When
disassembling and servicing the cylinder, confirm
the construction of cylinder referring to Parts Manual.
1.1.5 Discharging oil

Place a wooden-block on the work bench and mount
the cylinder on it to prevent it from rotating. Charge air
into ports A and B alternately to actuate the piston rod
till the hydraulic oil in the cylinder is drained out. At
this time, connect a suitable hose to each port so that
the hydraulic oil may not gush out.
31102 60413252
Fig. 1-2 Discharging oil
32-12
ATTACHMENTS
1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF ARM CYLINDER)
T = Torqu : kgf·m (lbf·ft) (Thread)

of the boss so R2.5 (0.10˝) of the boss so R2.5 (0.10˝)
33 34 32 29 31 holes face with each other
holes face with each other
T=4.1 ± 0.8
30
(30 ± 5.8)
[M12 X 1.75]
29
26 27 T=3.2 ± 0.6 (23 ± 4.3) [M10 X 1.5] 27 26

F17046
VIEW A-A
T=5.8 ± 1.1 (42 ± 8.0) [M12 X 1.75]

T=58 ± 13 (420 ± 94) [M100 X 2] caulking on two portions.
T=283 (2000) [M45 X 2, HEX70]
9 3 12 7,8 6 10,11 4 5 11,13 2 1 14 15 19 17 18 16 20 21 25 23 22 24
With
one hole
Face the slit to the piston side.

F17048
Fig.1-3 Construction of cylinder (An example of arm cylinder)

1 CYLINDER TUBE ASSY 1 13 O-RING 1 25 SNAP RING 1
2 PISTON ROD ASSY 1 14 CUSHION BEARING 1 26 PIN BUSHING 4
3 ROD COVER 1 15 CUSHION SEAL 1 27 WIPER RING 4
7 U-RING 1 19 SHIM 1 31 WASHER 2
8 BACKUP RING 1 20 SET SCREW 1 32 PIPE HOLDER 1
9 WIPER RING 1 21 STEEL BALL 1 33 BOLT 1
10 O-RING 1 22 CUSHION BEARING 1 34 WASHER 1
11 BACKUP RING 3 23 CHSHION SEAL 1
31102 60413252
12 O-RING 1 24 STOPPER 2
F17049
32-13
ATTACHMENTS
1.3 DISASSEMBLING
• Before starting disassembling and servicing, confirm m
0m
ox . 20
the construction and supply parts referring to Parts r ”)
App (8
Manual in the separate volume, and also required
tools and jig.
• Figures noted just after the "Part name" correspond
to the number stated in Fig. 1-3 Arm cylinder. Other
cylinders may have some different parts.
Fig. 1-4 Removing piston rod
1.3.1 Removing rod cover and piston rod

(1) Fix the tube installing pin side using a vise (Fig. 1-
2). CHISEL
(Meet the width of chisel
with the groove width,
flatten the lock washer)
WARNING
Take care not to damage the cylinder tube and
machined surface.
Never use external pipe to stop turning.
HAMMER
(2) Pull piston rod (2) out about 200 mm (8 in). BENT-UP PORTION
ON THE ROD COVER
Use air to push piston rod (2) out after draining the
oil because of the weight of piston rod (2). Fig. 1-5 Flatten the slit lock
(3) Flatten the lock on slit section installed between

rod cover (3) and cylinder tube (1) with chisel and
hammer. If pipe does not
found, strike this
portion with
(4) Lift up cylinder rod section with nylon sling hammer. Turn
counter
temporarily. clockwise
(5) Then, hook a hook wrench to rod cover (3), turn it

Cover this
counterclockwise and remove it. portion with
Special tool: Refer to Table 1-15. cloth.
(6) After putting threads out of mesh, remove the end

of rod cover (3) using plastic hammer. Fig. 1-6 Removing rod cover
WARNING
In this case, apply the hoisting force equivalent to the
weight of piston rod, because the weight of piston rod
weights upon the rod cover.
SLING
Pull it straight
31102 60413252
out horizontally
OIL PAN
Fig. 1-7 Pulling piston rod out
32-14
ATTACHMENTS
(7) Place pulled out piston rod assy (2) on the wooden
V-block horizontally.
WOODEN V-BLOCK
(cover with cloth.)
Fig. 1-8 Placing piston rod assy
(8) Remove slide ring (18)

Expand the slit portion in 45°
degrees and remove.
Fig. 1-9 Removing slide ring
1.3.2 Removing piston assy WOODEN

(1) Fix piston rod (2) grasping the installing pin portions BLOCK
with vise. Then fix it in strength so that it can

withstand the tightening torque for piston rod (2)
because the piston rod (2) is secured with large
tightening torque.
WOODEN V-BLOCK
Cover with cloth.
Fig. 1-10 Fixing piston rod assy
(2) Shave off the caulked section on set screw (20) DRILL
with hand drill, loosen setscrew and take out steel

ball (21).
31102 60413252
STEEL BALL
Fig. 1-11 Removing setscrew
32-15
ATTACHMENTS
(3) Remove nut section of piston with a closed wrench. EYE WRENCH
Special tool: see Table 1-16
1.0
(3’3 ~1.5
”~4 m
• Since the piston section (16) is tightened by ’11
”)
high torque, use the closed wrench closely
fitted to the width across flat.
Turn counter
• Approx. 1.5 times or higher of torque is required clockwise
to loosen piston nut. So prepare power wrench
equipped with hydraulic jack or hydraulic
cylinder, if possible.
PLATE
PISTON ROD WIPER RING
PIN
BUSHING
Fig. 1-12 Removing piston nut
THREADED
(4) Removing cushion bearing on the retraction side. PART CUSHION BEARING (22)
1) Remove snap ring (25). Strike it lightly being
STOPPER
careful not to damage cushion bearing and piston (24) (DIVIDE
INTO 2
rod. PORTIONS)
2) Move cushion bearing (22) to threaded side, and

remove stopper (24) (two pieces type). CUSHION SEAL (23)
SNAP RING (25)

3) Pull out cushion bearing (22).
PISTON ROD (2)
SLITTING
(1 PLACE)
4) Expand slit (1 place) of cushion seal (23) and
remove it. Fig. 1-13 Disassembling cushioning bearing
31102 60413252
32-16
ATTACHMENTS
(5) Removing cushion bearing on extension side.

1) Pull out cushion bearing (14).
2) Expand slit (1 place) on cushion seal (15) and
CUSHION SEAL (15) CUSHION BEARING (14)
remove it.
SLITTING (1 PLACE)
Fig. Disassembling cushioning bearing
1.3.3 Disassembling piston assy SEAL RING (17)

Removing piston seal SLIDE RING (18)
1) Remove slide ring (18) by hand.
WOODEN PIECE
2) Cut seal ring (17) with driver (-) and hammer as VISE
shown in the right figure.
3) Pull out O-ring with spatula.
O-RING
4) Strictly prohibited to use pulled out seal parts.
Fig. 1-15 Disassembling piston assy
1.3.4 Removing rod cover assy Strike with a

plastic mallet Lift here
Remove rod cover assy from piston rod (2). If it is too
difficult to remove, strike flange section of rod cover
(3) with plastic hammer.
Hang the rod cover assy with crane and remove it
straight horizontally.
Pull straight
WARNING
Care should be taken not to damage the bushing (4) lip
section of link and seal with screw of piston rod (2)
when puling out rod cover (3).
Fig. 1-16 Removing rod cover assy
31102 60413252
32-17
ATTACHMENTS
1.3.5 Disassembling rod cover assy O-RING AND

BUFFER RING (6) BACK-UP RING
(1) Removing buffer ring
(10, 11) (11, 13)
1) Buffer ring (6) (Teflon made seal) is fitted on the
WIPER
inside of rod cover (3). Pierce with pointed tool on RING (9)
the seal, raise it, insert spatula and take it out.
• Strictly prohibited to use the removed seal.
BUSHING (4)
SNAP RING (5)
O-RING (7) AND BACK-UP RING (8)
Fig. 1-17 Construction of rod cover assy
(2) Removing O-ring (7), backup ring (8) and wiper

BUFFER RING ASSY
ring (9)
(SQUARE RING + SLIDE RING)
1) Remove O-ring (7) and backup ring (8) with driver,
etc. SQUARE RING
(PROJECTION)
2) The wiper ring (9) is press-fitted.

Pierce with driver, etc. on rubber and strike and
remove it with driver. SLIDE RING
(SLITTING)
• Strictly prohibited to use removed seal. SNAP RING
Fig. 1-18 Direction of buffer ring
(3) Removing bushing (4)

Raise snap ring (5) with hooked bar and take it out Push with a press
from cylinder rod cover. And press out bushing (4)
with jig. If it is too difficult to take it out with jig, use JIG
lathe to remove it.
ROD COVER (3)
BUSHING (4)
31102 60413252
JIG
Fig. 1-19 Removing bushing
32-18
ATTACHMENTS
(4) Removing pin bushing WIPER RING (27)

1) Remove wiper ring (27).
2) The pin bushing (26) of piston rod (2) is press- Push with a press
fitted, so press it out with a press applying a plate PLATE
to the section.
WARNING
Where it is impossible to press it out, cut it with gas BASE
burner.
Fig. 1-20 Drawing out pin bushing (rod and tube)
(5) Cleaning
1) completion of cylinder disassembly, clean all the
parts with detergent.
Apply hydraulic oil on them and cover them to
store.
Leaving them in the as-disassembled condition
causes rust, adherence of dust, etc., which may
cause malfunction after assembling.
WARNING
Do not use volatile agents (gasoline and thinner) as
they deteriorate rubber.
2) Replace all of O-ring, wiper ring, O-ring and backup

ring as a general rule.
31102 60413252
32-19
ATTACHMENTS
1.4 INSTALL Push with a press

Start install with the sub assy listed below :
• Cylinder tube assy
• Piston rod assy
• Rod cover assy
• Piston assy
1.4.1 Assembling cylinder tube assy, piston rod assy

1) Apply hydraulic oil on the head in which pin
bushing is inserted and on the pin bushing hole of
OIL HOLE LOCATION
rod.
2) Press pin bushing (26) into cylinder tube (1) and

piston rod (2), using a press.
PLATE
3) Insert wiper ring (27) in both side. PISTON ROD WIPER RING
PIN BUSHING
1.4.2 Assembling rod cover assy Fig. 1-21 Pressing in pin bushing (rod and tube)
(1) Press fit bushing (4) in rod cover (3) applying plate
on the section. After press-fitting, check that the Push with a press straight down
bushing is not projected from the end surface (A)
(See Fig. 1-22)
PLATE
(2) Fit snap ring (5)
(3) Fit backup ring (8) on U-ring groove.
(4) Apply hydraulic oil on U-ring (7) and fit it on the O-

ring groove.
WARNING
• The U-ring is harder than other seals, so fit it in the Fig. 1-22 Pressing in bushing
groove by hand first, then press in with pushing bar
until it is fitted with a click.
• Fitting U-ring paying attention to the direction. PUSH BAR
• After fitting backup ring (8) and U-ring (7), check that
they are free from the permanent set.
31102 60413252
Fig. 1-23 Fitting O-ring
32-20
ATTACHMENTS
(5) Installing buffer ring assy SLIDE RING SQUARE RING

Buffer ring assy (6) is equipped with square ring Depress slide ring in
U shape to fit.
and slide ring.
1) Fit square ring on the groove.
2) Depress slide ring in U shape by hand to house it

in groove, and fit it pushing out to periphery.
BUFFER RING ASSY (6)

(SQUARE RING + SLIDE RING)
WARNING
• Depress it R 6 mm (0.24 in) or more, because if the SQUARE RING
(PROJECTION)
depressed R is too small, it may remain wrinkled.
• After fitting, check that it is free from wrinkles.
• Fit it giving attention to the seal fitting direction. SLIDE RING
Reverse fitting produces high pressure between U (SLITTING)
SNAP RING (5)
ring and seal and may cause the deformation of rod
cover. Fig. 1-24 Installing buffer ring assy (6)
• Fit slide ring so that the groove matches to the root
section of square ring.
(6) Press fit wiper ring (9) by means of jig Table 1-12 Push with a press
on page 32-II-1-20.
JIG
RUBBER
METAL RING CLIP
Fig. 1-25 Pressing in wiper ring
(7) Fit backup ring (11) and O-rings (10), (13) (attention O-RING AND
BACK-UP RING
should be paid to the fitting order). (10, 11) (11, 13)
Fig. 1-26 Fixing back-up ring and O-ring

31102 60413252
32-21
ATTACHMENTS
1.4.3 Assembling piston assy

(1) Installing seal ring assy SEAL RING PRESSING JIG SEAL RING (17)
1) Fit O-ring so as not to be distorted.
PISTON (16)
2) Press in seal ring (17) referring to jig Table 1-9, 1-

10.
PUSH
O-RING
Fig.1-27 Installing the seal ring (17)
CORRECTION JIG
3) Since the seal ring (17) is extended when fitting,
press it referring to correction jig Table 1-13.
PUSH
Fig. 1-28 Correcting the seal ring (17)
4) Fitting slide ring (18) Expand 45°deg. slit section in

Fit it from rod side expanding slit by both hands. direction specified by arrow
and fit the ring.
• Expand slit in minimum.

If expansion is exceeded, the ring cannot be
fitted.
• Slit is mutually shifted 90°degree.
Fig. 1-29 Installing the slide ring (18)

31102 60413252
32-22
ATTACHMENTS
1.4.4 Installing rod cover assy on rod

(1) Fix piston rod assy on work bench.
(2) Apply grease (or hydraulic oil) on outside of piston

rod (2), inner surface of buffer ring (6), U-ring (7),
backup ring (8), wiper ring (9) and bushing (4), and
slide rod cover assy on piston rod (2) taking care
not to damage the lip of wiper ring (9).
Fig. 1-30 Installing rod cover assy
It may not slide smoothly due to frictional resistance
of O-ring. In this case, sling rod cover assy
horizontally with crane, and push it striking flange
of rod cover with mallet.
ROD COVER PRESSING JIG

WARNING
While pushing, be careful that the rod cover assy is not PISTON ROD ROD COVER
rotated to piston rod (2).
PUSH
1.4.5 Installing piston assy on rod Fig.1-31 Pressing rod cover

(1) Fitting cushion bearing (14) on the extension side.
WARNING
Before attaching piston (nut ) (16), fit cushion bearing
(14). If the piston nut is attached, the bearing can not
be fitted.
1) Expand slit of cushion seal (15) and insert it into

groove piston rod (2).
WARNING CUSHIONING BEARING (14)

CUSHIONING SEAL (15)
Insert cushion seal (15) directing the cut out toward the
thread side of rod as shown in Figure. CUT OUT
FLAT SECTION
2) Fit cushion bearing (14). SLITTING (1 PLACE)
Fig. 1-32 Fitting cushion bearing (14) on the extension side

WARNING
Fit cushion bearing (14) directing the flat section toward
as shown in Figure.
31102 60413252
32-23
ATTACHMENTS
(2) Fitting cushion bearing (22) on retraction side

1) Fit cushion seal (23) in groove directing the cutout CUSHION BEARING (22)
THRE-
toward the thread side. ADED STOPPER (24)
PART (DIVIDE INTO
2 PORTIONS)
2) Assemble cushion bearing (22) directing the flat FLAT
SECTION
section toward as shown in Figure.
PISTON CUSHION SEAL (23)

3) Fit stopper (24) in groove. ROD (2)
CUT
SNAP OUT
RING SLITTING
4) Push cushion bearing (22) to stopper (24) fully, (25) (1 PLACE)
and strike and fit snap ring (25).
Fig. 1-33 Fitting cushion bearing (22) on retraction side
WARNING
Strike snap ring with plastic hammer being careful not
to damage rod (2) and cushion bearing (22).
(3) Tightening piston nut

EYE WRENCH
1) Insert piston (nut) (16) into rod, and tighten it to the
specified torque.
Special tool: see Table 1-16
Tightening torque: see Table 1-5.
Fig. 1-34 Tightening piston nut (16)
CAULK
2) Put steel ball (21) in and tighten setscrew (20).
: Tightening torque: see Table 1-6.
PUNCH
3) Caulk 2 places on outer surface with punch.
SETSCREW (20)
31102 60413252
STEEL BALL
Fig. 1-35 Caulking set screw of piston nut
32-24
ATTACHMENTS
1.4.6 Overrall install Bar used to prevent rotation

(Wood is preferable) or fix with vise
(1) Place a V-block on a rigid work bench (A wooden
V block is preferable.) Mount the cylinder tube
assy (1) on it and fix the assy by barring a bar
through the attaching pin hole to lock the assy Lift it lever
(Fig. 1-36).
(2) Insert piston rod (2) into cylinder tube (1 while

hanging and moving it with crane. Then, apply
hydraulic oil on tube lip inner side and piston outer
surface and insert horizontally aligning the center PISTON
of piston rod and center of cylinder tube. Apply Three-Bond #1901
Fig.1-36 Installing piston rod

• Also, the use of fork lift makes inserting easier.
• Insert piston into tube being careful that seal
ring and slide ring are not caught in the stepped
section of tube.
SLIT
ROD COVER (3)
(3) Apply three bond #1901 on thread section of rod

cover and hydraulic oil on O-ring (12), rotate rod CHISEL
cover assy (3) by hand. Screw in 2 or 3 threads Fig. 1-37 Bending lock of slit
first, then tighten it to the specified torque with
hook spanner wrench.
(4) Bend slit of cylinder tube toward cutout of rod

cover (3) to lock. SET SPACE
(5) Tighten band for piping on both sides equally to

the specified torque in order not to have a set
space.
Tightening torque: see II-1-18.
• Fix port section of cylinder pipe with wrench, PIPE HOLDER

etc. on main body and install pipe for cylinder,
and rubber hose, nipple, etc. Installation without SET SPACE BAND BOLT
fixation may cause bending of port plate,
consequently oil leakage, and interference with
body.
31102 60413252
SET SPACE
SET SPACE
Fig. 1-38 Installing band for piping
32-25
ATTACHMENTS
1.5 MAINTENANCE STANDARDS

(1) Inspection after disassembly
1) Inspection
Table 1-2
PART NAME INSPECTING SECTION INSPECTION ITEM REMEDY
Piston rod 1. Neck of rod pin Presence of crack Replace.
2. Stepped part to which Presence of crack Replace.
piston is attached
3. Threads Presence of seizure Recondition or replace
4. Bend Measure degree of bend Refer to rod bend
5. Plated surface Check that:
1) Plating is not worn off to 1) Replace.
base metal
2) Rust is not present on 2) Replace.
plating.
3) Scratches are not present. 3) Recondition or replace
6. Rod Wear of O. D. Recondition or replace
7. Bushing at mounting part Wear of I. D. Replace.
Cylinder tube 1. Weld on bottom Presence of crack Replace.
2. Tube at mounting part Presence of crack Replace.
3. Tube interior Scratches are not present. Replace if oil leak is seen.
4. Bushing at mounting part Wear of I. D. Replace.
Rod cover 1. Bushing 1) Wear of I. D. Replace.
2) Flaw on inner surface
F17233
(2) Maintenance standards

Replace sliding parts and seal parts according to the following.
1 Bushing ................................................................. where 1/4 of circumference is worn in red copper color
2 Seals and slide ring ............................................................... replace them when cylinder is disassembled
3 Pin bushing ........................................................................................... where severe scuffing is produced
4 Piston rod ............................................................................ where the bent 0.5mm/m or more is produced
(3) Inspection after assembling
Table 1-3
No-load performance When operating 5 time or more in full stroke at no-load, it operates smoothly with
inspection no abnormality.
Dimensional Check the fully retracted length and stroke specified in drawing.
inspection
Pressure inspection After applying test pressure specified in drawing to each stroke end for 3 minutes
or more, it is free from loosening, permanent set and oil leaking.
No-load performance Check rod section for oil leaking.
inspection (Refer to Criterion of oil leak quantity on rod section in proceeding page.)
Oil leak quantity unit mL (cc) / 10min
I. D. mm (in) Oil leak I. D. mm (in) Oil leak I. D. mm (in) Oil leak
quantity quantity quantity
31102 60413252
Internal leakage 32 (1.26) 0.4 100 (3.94) 4.0 160 (6.30) 10.0
inspection 40 (1.57) 0.6 125 (4.92) 5.6 180 (7.09) 12.6
50 (1.97) 1.0 140 (5.51) 6.0 200 (7.87) 15.6
63 (2.48) 1.6 220 (8.66) 20.0
80 (3.15) 2.3 250 (9.84) 22.0
F17234
32-26
ATTACHMENTS
(4) Criterion of oil leak quantity on rod section

Determine according to the oil ring condition
produced on rod after 20 strokes in oil temperatu-
re 20°C (68°F) to 40°C (104°F).
When oil ring is changed to A condition, it is in
abnormality. Refer to 1.6 Troubleshooting, and
take a measure.
OIL RING
Reject Accept
Fig. 1-39 Oil ring condition on rod section
1.6 GENERAL TOOL
Table 1-4
No. TOOLS NAME Q'TY
1 Flat-bladed screw driver 1
2 Allen key wrench 1 set
3 Vise 1
Spanner (see page II-1-18)

4 1 set
(for piston nut)
5 Punch 1
6 Torque wrench 1 set
Hammer
7 1
(Plastic mallet)
31102 60413252
8 Adjustable wrench 1
9 Spatula 1 pair
F17235
32-27
ATTACHMENTS
1.7 TIGHTENING TORQUE

(1) Piston nut
Table 1-5
Cylinder name Opposing flat A Tightening torque

Boom 80 mm 286 kgf·m (2070 lbf·ft)
Arm 70 mm 283 kgf·m (2050 lbf·ft)
Bucket 60 mm 143 kgf·m (1030 lbf·ft)
Dozer 80 mm 291 kgf·m (2100 lbf·ft) Fig. 1-40

F17236
CAULK
(2) Setscrew
Table 1-6 PUNCH
Cylinder name Opposing flat Tightening torque

Boom
6 mm 5.8 kgf·m (42 lbf·ft) SETSCREW
Arm
Bucket 4 mm 1.6 kgf·m (12 lbf·ft)
Dozer 6 mm 5.8 kgf·m (42 lbf·ft)

STEEL BALL
F17237
Fig. 1-41
(3) Rod cover

Table 1-7
HOOK WRENCH PIPE
Cylinder name Tightening torque
Boom 85 ± 19.5 kgf·m (610 ± 140 lbf·ft)
Arm 58 ± 13.2 kgf·m (420 ± 95 lbf·ft)
Bucket 46 ± 10.6 kgf·m (330 ± 77 lbf·ft)
Dozer 108 ± 24 kgf·m (780 ± 174 lbf·ft)

F17238
Fig. 1-42
(4) For piping

Table 1-8
Piping band Pipe holder

Cylinder
name Opposing flat Tightening Opposing flat Tightening
torque torque
Boom
31102 60413252
Arm 17 mm 19 mm
3.21 kgf·m 4.06 kgf·m
(23 lbf·ft) (29 lbf·ft)
Bucket
PIPE HOLDER PIPING BAND BOLT
Dozer
Fig.1-43
F17239
32-28
ATTACHMENTS
1.8 TOOL AND JIGS LIST

(1) Seal ring fitting jig ( I ) Material: mild steel
Fig.1-44
Table 1-9
APPLICABLE
CYLINDER D0 D1 (D2) D3 L0 (L1) L2
Boom 111 (4.3701) 110 (4.3307) 86 (3.39) 96 (3.78) 100 (3.94) 72 (2.83) 24 (0.9449)
Arm 96 (3.7795) 95 (3.7401) 71 (2.80) 81 (3.19) 100 (3.94) 72 (2.83) 23 (0.9055)
Bucket 81 (3.1890) 80 (3.1496) 56 (2.20) 66 (2.60) 100 (3.94) 72 (2.83) 20 (0.7874)
Dozer 121 (4.7638) 120 (4.7244) 96 (3.78) 106 (4.17) 100 (3.94) 72 (2.83) 24 (0.9449)
F17240
(2) Seal ring fitting jig ( II ) Material: nylon or acrylic resin
Fig. 1-45

APPLICABLE D0 D1 L
CYLINDER
31102 60413252
Boom 112 (4.41) 104 (4.09) 100 (3.9370)

Arm 97 (3.82) 89 (3.51) 100 (3.9370)
Bucket 82 (3.23) 74 (2.91) 100 (3.9370)
Dozer 122 (4.80) 114 (4.49) 100 (3.9370)
F17241
32-29
ATTACHMENTS
(3) Bushing press-fit jig Material: mild steel
Fig. 1-46

APPLICABLE
CYLINDER D0 D1 (D2) D3 L0 (L1)
Boom 75(2.9528) 69.5(2.74) 68(2.68) 95(3.74) 65.5(2.58) 59.5(2.3425)
Arm 70(2.7559) 64.5(2.54) 63(2.48) 90(3.54) 65.3(2.57) 53.3(2.0984)
Bucket 60(2.3622) 54.5(2.15) 53(2.09) 80(3.15) 20.5(0.807) 8.5(0.3346)
Dozer 75(2.9528) 69.5(2.74) 68(2.68) 95(3.74) 25.5(1.00) 13.5(0.5315)
F17242
(4) Wiper ring (rod cover) press-fit jig Material: mild steel
∇ finishing unless otherwise specified.
Fig. 1-47
31102 60413252
APPLICABLE
CYLINDER D0 D1 D3
Boom, Dozer 70 (2.7559) 78.5 (3.0905) 95 (3.74)
Bucket 55 (2.1654) 63.5 (2.5000) 80 (3.15)
Arm 65 (2.5591) 73.5 (2.8937) 90 (3.54)
F17243
32-30
ATTACHMENTS
(5) Seal ring straightening jig Material: mild steel
∇ finishing unless
otherwise specified.
Fig. 1-48
APPLICABLE D0 (D1) L0 (L1)

CYLINDER
Boom 110 (4.3307) 130 (5.12) 120 (4.72) 40 (1.57)
Arm 95 (3.7401) 115 (4.53) 120 (4.72) 40 (1.57)
Bucket 80 (3.1496) 100 (3.94) 120 (4.72) 40 (1.57)
Dozer 120 (4.7244) 140 (5.51) 120 (4.72) 40 (1.57)
F17244
(6) Piston insert jig Material: mild steel
Split into 2 portions with

2 to 3 mm (0.08~0.12˝) cutter.
∇ finishing unless otherwise specified.

Fig. 1-49

APPLICABLE D0 (D1) L0 (L1)
CYLINDER
31102 60413252
Boom 110 (4.3307) 130 (5.12) 120 (4.72) 40 (1.57)

Arm 95 (3.7401) 115 (4.53) 120 (4.72) 40 (1.57)
Bucket 80 (3.1496) 100 (3.94) 120 (4.72) 40 (1.57)
Dozer 120 (4.7244) 140 (5.51) 120 (4.72) 40 (1.57)
F17244
32-31
ATTACHMENTS
(7) Hook wrench
Material: chromium-vanadium steel, hardness HRc 36 ± 4
Fig. 1-50

APPLICABLE A B C t D r f L
CYLINDER
Boom 130 (5.1181) 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 86 (3.39) 12 (0.472) 380 (15.0)
Arm 120 (4.7244) 12 (0.4724) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 80 (3.15) 12 (0.472) 380 (15.0)
Bucket 100 (3.9370) 10 (0.3937) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 68 (2.68) 9 (0.354) 320 (12.6)
Dozer 140 (5.5118) 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 93 (3.66) 12 (0.472) 460 (18.1)
F17246
(8) Eye wrench
Tolerance of A: 0.3 mm~0.8 mm Straight in Material: mild steel, fInish by grinding after gas cutting
(0.0118˝~0.0315˝) this area
Fig. 1-51
APPLICABLE SIZE L=300 (11.8) L=500 (19.7)

CYLINDER A B1 B2 t B1 B2 B3 t
31102 60413252
Boom 80 (3.1496) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)
Arm 70 (2.7559) 95 (3.74) 67 (2.64) 25 (0.984) 104 (4.09) 90 (3.54) 78 (3.07) 25 (0.984)
Bucket 60 (2.3622) 95 (3.74) 67 (2.64) 16 (0.630) 104 (4.09) 90 (3.54) 78 (3.07) 16 (0.630)
Dozer 80 (3.1496) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)
F17247
32-32
ATTACHMENTS
1.9 TROUBLESHOOTING
Failure on hydraulic cylinder and corrective action
It is very difficult to find defective section. The following table explains general phenomenon, estimated causes
and corrective actions. For repair, refer to the 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 Table is often required. Please contact us to pursue the
problems and causes further and to take appropriate corrective action.
ITEMS PHENOMENON
1 Oil leakage from piston rod sliding section
(For criterion, refer to 1.5 (3) "Inspection after assembly".)
2 Oil leakage from rod cover set section
3 Oil leakage from pipe and cylinder tube weld zone
4 Malfunction
F17248
ITEMS PHENOMENON RELATED PARTS ABNOMALITIES MEASURES AND CORRECTIVE ACTIONS

1 Remove flaws with oil stone to make the
surface smooth. If oil is leaking after
making rod surface smooth (1.5S or less),
disassemble it and check seals of O-ring,
Flaw and rust on
etc. that it is free from flaw.
sliding surface.
2 In case the flaw is too wide to repair
Piston rod with oilstone, replace seals of O-ring and

wiper ring, etc. and bearing parts of
piston rod.
1 Plate it again, or replace piston rod.

2 At the same time, check seals and
Oil leakage Plating is peeled.
bearing parts of piston rod for possible
1 from piston rod damage, if damaged, replace it.
sliding section
Foreign matter is
1 Remove foreign matter.
caught in inner bore
2 Replace defective packing.
and outer surface.
Flaw on inner bore
1 Replace it.
Rod packing and outer surface.
(Buffer ring,
1 May be a burning caused by adiabatic
U ring)
31102 60413252
compression due to the remained air.

A part of lip and
2 After replacement of packing, release air
groove is carbonized
completely through operation in low
(burned).
pressure and low speed and start
cylinder operating.
F17249
32-33
ATTACHMENTS

1 Replace it.
2 May be service life expired, deterioration
Rubber packing is of hydraulic oil and high temperature.
deteriorated. a Change hydraulic oil with new one.
Or lip section is b Check hydraulic oil temperature.
damaged. (Temperature 80˚C or less is preferable.)
Rod packing c Be certain that temperature is not
(Buffer ring, locally raised.
U ring) 1 Replace it.
2 Extraordinary high pressure may be
The protrusion of applied to packing.
packing heel section a Check pressure at operating.
is too large. b Where buffer ring is fitted, it may be
damaged.
Check buffer ring for possible damage.
1 Replace rod packing at the same time as
a rule. (Where buffer ring is fitted, it is
preferable to replace it at the same
time.)
Backup ring Large deformation
2 It may be caused by extraordinary high
Oil leakage
pressure. In this case, check it using the
1 from piston rod
same procedure as the above packing
sliding section
heel.
Foreign matter is
caught on lip section
Wiper ring Lip is damaged.
Or there is another 1 Replace it.
abnormal damage.
Worn, and the space
between bearing and
piston rod exceeds the
maximum clearance. 1 Replace it.
Bearing (Refer Item 1.5 (2)
(Bushing) "Maintenance
Standard".)
1 Replace it.
Large flaw on sliding
2 Check piston rod for possible damage at
surface
the same time.
1 Remove flaw and rust with oilstone.
Flaw and rust on seal
Rod cover 2 In case it is too large to repair, replace
fitting surface
rod cover.
31102 60413252
F17250
32-34
ATTACHMENTS

2 Replace damaged O-ring.
3 Inspect inner surface of tube.
If flaw and rust are detected, make it
smooth with oil stone.
Foreign matter is
4 Inspect groove of rod cover.
O-ring caught in inner bore
- do -
and outer surface.
5 Inspect backup ring.
Replace deformed or incompletely fit O-ring.
Check O-ring for above failure. If failed,
replace it.
Deformed and
Backup ring 1 Replace it with O-ring
incomplete fitting
Oil leakage
1 Disassemble rod cover, check O-ring and
2 from rod cover
backup ring for possible damage.
set section
If damaged, replace it.
2 Check thread ridges of tube and rod
Rod cover Loosen
cover for possible damage.
3 After inspection, tighten it to the
specified torque.
(See Item 1.4 "Assembling Procedure".)
Loosen, elongation 1 Replace all bolts, and tighten them to

Bolt
and damage the specified torque.
1 Replace it with new one.

The oil leakage from set section may be
caused by the production of
Cylinder tube Abnormal expansion
extraordinary high pressure. Check tube
for expansion and deformation, and also
circuit pressure for possible error.
1 Replace it.
• Crack is progressed and ruptured

Oil leakage mechanically.
Cylinder tube, • The rupture is very dangerous. So
from pipe and
3 pipe (hollow Crack on weld zone when crack has been detected, stop
cylinder tube
piston rod) operating immediately and replace
weld zone
the parts with new one.
• The weld on crack for repair is
ineffective.
F17251
31102 60413252
32-35
ATTACHMENTS

Bending exceed the
specified deformation.
Piston rod Seal and sliding parts may be damaged.
(See Item 1.5 (2)
Cylinder tube Check for possible damage. If damaged,
"Maintenance
replace it.
Standard".)
Malfunction
Cylinder tube Dent Check seal and sliding parts for possible
damage same as the above.
Unsmooth
Wear or damage on 1 Replace it with new one.
operation
sliding parts Check seal and sliding parts for possible
Piston rod
Foreign matter is damage same as the above.
Cylinder tube
caught in piston and 2 Remove foreign matter.
sliding parts
cylinder head sliding Check seal and sliding parts for possible
section. damage same as the above.

Piston seal Flaw, wear, etc. Check inner surface of cylinder tube for
4 possible damage.
1 Remove flaw and rust with horning and

Internal
oilstone to make it flat.
leakage Flaw and rust on
Cylinder tube If it is too large to repair, replace
Piston rod is inner surface
cylinder tube with new one.
extended and
2 Replace piston seal with new one.
retracted of
itself or 1 Tighten it to the specified torque.
abnormally Piston nut Insufficient tightening (See Item 1.4.5 "Installing piston assy on
drops in rod".)
operation.
1 Inspect the leaking quantity and repair
And the speed Valves Leakage from valve
does not rise it.
to the specified
Hydraulic oil is expanded and contracted with change of temperature
speed.
and pressure. Consequently the cylinder is also extended and
retracted, so care must be taken in order not to mistake this for
internal leakage. Check it for internal oil leakage in the constant
temperature and pressure conditions
F17252
31102 60413252
32-36
ATTACHMENTS

1 Remove air.
a If cylinder is not equipped with air bleed
port ;
Release air by extending and retracting
it at low speed several times.
b If cylinder is equipped with air bleed
port ;
Unload so that the internal pressure is
The operation Air is remained in
Air not raised, loosen air breather and
is unstable. cylinder.
release air completely.
(Reference)
When cylinder has stopped in an
emergency, cylinder may be extended
and contracted slightly. This phenomenon
is caused by the pressure of hydraulic
oil, and easily occurs on the cylinder of
which the stroke is longer.
4 Great shock
when changed
The space between 1 Measure dimension of pin and pin
from / to Pin bushing
fitting section and pin bushing, if it exceeds the specified
extension to / Pin
bushing is too large. dimension, replace it with new one.
from
retraction.
Insufficient
Noise when Lubrication 1 Lubricate.
lubrication
cylinder is
worked. Pin bushing Scuffing on engaged
1 Replace it with new one, and lubricate.
Pin section
Hydraulic oil is expanded and contracted with change of temperature

and pressure. Consequently the cylinder is also extended and
retracted, so care must be taken in order not to mistake this for
internal leakage. Check it for internal oil leakage in the constant
temperature and pressure conditions.
F17253
31102 60413252
32-37
ATTACHMENTS
NOTE
31102 60413252
32-38
SECTION 33 UPPER SWING BODY
TABLE OF CONTENTS
Part I: Removing and installing assembly.................................................................. 33-1

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

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

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

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

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

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

7.1 Removal ......................................................................................................................................... 33-9
31102 60413252
7.2 Installation ...................................................................................................................................... 33-9
8. Air cleaner .......................................................................................................... 33-10

8.1 Preparation for removal ................................................................................................................ 33-10
8.2 Removval ..................................................................................................................................... 33-10
8.3 Installation .................................................................................................................................... 33-10
INDEX
9. Muffler ................................................................................................................ 33-11

9.1 Preparation for removal ................................................................................................................ 33-11
9.2 Removal ....................................................................................................................................... 33-11
9.3 Installation .................................................................................................................................... 33-11
10. Fuel tank ........................................................................................................... 33-12

10.1 Preparation for removal .............................................................................................................. 33-12
10.2 Removal ..................................................................................................................................... 33-12
10.3 Installation .................................................................................................................................. 33-12
11. Hydraulic tank .................................................................................................... 33-13

11.1 Peparation for removal ............................................................................................................... 33-13
11.2 Removal ..................................................................................................................................... 33-14
11.3 Installation .................................................................................................................................. 33-15
12. Pump ................................................................................................................ 33-16

12.2 Removal ..................................................................................................................................... 33-16
12.3 Installation .................................................................................................................................. 33-18
13. Radiator and oil cooler ..................................................................................... 33-20

13.2 Removal ..................................................................................................................................... 33-21
13.3 Installation .................................................................................................................................. 33-23
14. Engine .............................................................................................................. 33-24

14.1 Preparation for removing ............................................................................................................ 33-24
14.2 Removal ..................................................................................................................................... 33-26
14.3 Installation .................................................................................................................................. 33-26
15. Multi control valve ............................................................................................. 33-27

15.2 Removal ..................................................................................................................................... 33-27
15.3 Installation .................................................................................................................................. 33-27
15.4 Multi control lever remodeling procedure ................................................................................... 33-28
16. Control valve ..................................................................................................... 33-29

16.2 Removal ..................................................................................................................................... 33-29
16.3 Installation .................................................................................................................................. 33-30
17. Pilot valve (for att) .............................................................................................. 33-31

17.2 Removal ..................................................................................................................................... 33-31
17.3 Installation .................................................................................................................................. 33-31
18. Pilot valve (for travel) ........................................................................................ 33-32

18.2 Removal ..................................................................................................................................... 33-32
18.3 Installation .................................................................................................................................. 33-32
31102 60413252
19. Swing unit ......................................................................................................... 33-33

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

20.1 Preparation for remove ............................................................................................................... 33-35
20.2 Removal ..................................................................................................................................... 33-35
20.3 Installation .................................................................................................................................. 33-36
21. Upper frame ..................................................................................................... 33-37

21.2 Removal ..................................................................................................................................... 33-37
21.3 Installation .................................................................................................................................. 33-38
Part II: Disassembling and assembling components ............................................... 33-39

1. Hydraulic pump - regulator ................................................................................. 33-39
1.1 Structural exploded view .............................................................................................................. 33-39
1.2 Removal and installation .............................................................................................................. 33-42
1.3 Maintenance standard .................................................................................................................. 33-50
2. Control valve ....................................................................................................... 33-51

2.1 Preparation for construction ......................................................................................................... 33-51
2.2 Disassembly ................................................................................................................................. 33-52
2.3 Assembly ...................................................................................................................................... 33-57
3. Pilot valve (attachment) ...................................................................................... 33-62

3.1 Construction ................................................................................................................................. 33-62
3.2 Disassembly and assembly .......................................................................................................... 33-63
4. Pilot valve (travel) ............................................................................................... 33-67

4.1 Construction ................................................................................................................................. 33-67
4.3 Cause of failures and corrective action ........................................................................................ 33-71
5. Swing motor unit ................................................................................................. 33-72

5.1 Construction ................................................................................................................................. 33-72
5.2 Disassembly and assembly of swing motor ................................................................................. 33-75
5.3 Disassembly and assembly of swing reduction unit ..................................................................... 33-81
6. Swivel ................................................................................................................. 33-86

6.1 Construction ................................................................................................................................. 33-86
6.2 Disassembly and assmbly ............................................................................................................ 33-87
6.3 Maintenance satandards .............................................................................................................. 33-91
31102 60413252
UPPER SWING BODY
Part I: REMOVING AND INSTALLING ASSEMBLY

1. CAB Rotate 90
24 degrees
to remove.
1.1 REMOVAL
BOLT (24)
(1) Remove floor mat GROMMET
COVER
(2) Remove the following parts for air-con cover. 14
1) 5 bolts for catch (24)
2) Cover (1)
1 BRACKET
3) Grille under front seat GRILLE
CATCH
4) Duct from duct (14) to under right duct on cab
inside.
: Cross recessed screw driver
FLOOR MAT
: 13 mm
(3) Remove the following parts for harness and Fig. 1-1 Detaching and attaching air conditioner cover
connector. CURL
FOR ROOM LAMP CODE
1) Antenna cable from back side of tuner
2) Harness for room lamp GROMMET FOR WINDOW
3) Harness on cab front right side WASHER
4) Harness for gauge cluster DOOR SW
5) Harness on front right side of cab for power ANTENNA
window (OPT).
(4) Remove window washer tube
(5) Remove the following parts for cab mounting bolt GROMMET
1) 5 capscrews (A1) M10 To instrument panel
2) 4 nuts M16
3) Sems-bolt (B2) M10, 2 pcs on lower section of TO TUNER GROMMET
hand rail Remove
A1 M10 X 5 pcs. TUBE washer tube
(6) Slinging cab at floor
1) Remove 2 plastic plugs on front side of cab ceiling, TUBE
and attach eye bolts M10, and hook wire 3 places,
2 bolts and lifting eye, on rear left side.
2) Then lift up slowly avoiding interference with NUT M16 X 4 pcs.
surroundings. Ø30 (1.18˝)
HOLE FOR HAND RAIL
Wire with hook:
Length 1.5 m (4ft 11 in) X Dia. 8 mm (0.315 in) X Fig. 1-2 Removing and attaching harness connector and
3 pcs. cab mounting bolts
Weight of cab: Approx 200 kg (440 lbs)
1.2 INSTALLATION
Mount it in reverse procedure of dismouting according M10 EYE BOLT LIFTING EYE
to the tightening torque table.
31102 60413252
Fig. 1-3 Slinging cab
33-1
UPPER SWING BODY
2. OPERATOR SEAT
2.1 REMOVAL SEAT ASSY

(1) Remove seat (include upper slide). (Rails are located on back
face.)
1) Remove 4 sems-bolts (A17) M6.
2) Remove bracket (A8).
A17
3) Remove 4 cap screws (A16) M8 of bracket (A5).
A8
4) Remove seat
[Approx.22 kg (49 lbs) with bracket]
: 8 mm, 13 mm
A16
NOTE:
When required to disassemble seat lower section,
remove control box. A4 A5
A13
(2) Remove slide on lower side of seat.

1) Remove 4 socket bolts (A15) M8.
2) Remove support (A4).
A3
3) Remove 4 socket bolts (A15) M8. A15
4) Remove rail (A3).
: 6 mm
A18
(3) Remove seat stand
1) Remove 4 socket bolts (A18) M8. A15
A2
Support the controller assy by inserting wood
block under the support (A2). A1
2) Remove 4 socket bolts (A9) M10.
3) Remove seat stand (1). A18
A9
: 8 mm
Weight of seat stand: 17 kg (37 lbs) A2
2.2 INSTALLATION
Install it in reverse procedure of removing according
FLOOR PLATE
Fig. 2-1 Dismounting and mounting seat

31102 60413252
33-2
UPPER SWING BODY
3. BATTERY
3.1 REMOVE RIGHT FRONT COVER

(1) Open right front cover.
1) Open it with engine key.
2) Open cover.
3) Fix it with stay
(2) Remove 3 battery cables

1) Cable (between ground and battery ) (always
remove terminal first and install it at last). Fig. 3-1
2) Cable (between battery and ).
3) Cable (between battery and battery relay).
: 13 mm
STAY
WARNING
Follow the battery removal order.
Start removing battery from grounding side, and finish
attaching to grounding side. If this order is missed, BATTERY RELAY
short-circuits may occur.
(3) Remove battery (B1)

1) Remove 2 attaching bolts (A2) M10.
: 17 mm
2) Remove cover (A1) 1) 2) 3)
3) Remove battery (B1)
Fig. 3-2 Grounding cable for main body
3.2 INSTALL
(1) Install counterweight in the reverse procedure of
removing.
A2
Battery attaching bolt
: 17 mm
Tightening torque: 1.1 kgf·m (8.0 lbf·ft) A1
B1
(2) Installing grounding cable
Install grounding cable last. Especially care must
be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
31102 60413252
Fig. 3-3 Removing battery
33-3
UPPER SWING BODY
4. INSTRUMENT PANEL
4.1 PREPARATION FOR REMOVAL

Remove terminal (-) from battery.
4.2 REMOVAL 12 12
(1) Remove RH, LH instrument panel
1) Remove 8 sems-bolts (12) M5.
12
12
2) Lift instrument panel
3) Remove two connectors and antenna cable on
rear side of left instrument panel
1. 8P connector for air-con panel
2. 9P connector for tuner.
4) Remove four connectors on rear side of right

Fig. 4-1 Around of instrument panel
panel
1. 6P connector for key switch
2. 3P connector for accel dial
LH instrument panel RH instrument panel
3. 2P & 8P connectors for switch panel
CAP
12
12 M5 X 16
12
12
(2) Remove control box

28 12
1) Remove four (4) sems-bolts (19) M8 on right and
left sides.
2) Separate control box from support.
28
: 13 mm 28
Weight: Left control box 8.5 kg (19 lbs) and right M5 X 10
control box 7 kg (15 lbs) including pilot valve. ANTENNA CABLE
TUNER
Fig. 4-2 Removing instrument panel

4.3 INSTALLATION
Install it in reverse procedure of removing according
A13
M8 X 25 PILOT VALVE
SUPPORT
PILOT ASSY
VALVE
19 M8 X 25
20
M6 X 16
31102 60413252
SUPPORT
SEAT STAND
Fig. 4-3 Removing control box
33-4
UPPER SWING BODY
5. COUNTERWEIGHT
5.1 PREPATATION FOR REMOVAL

(1) Removing bonnet assy.
Remove bonnet on engine (see Fig. 6-7)
(2) Remove cover (3) (see GUARD Fig. 6-8)
(3) Preparing slinging jig
Remove C7 plug, and attach weight slinging jig
(see chapter Tools) to counterweight.
: 36 mm
Fig. 5-1 Lifting up counterweight
5.2 REMOVAL
(1) Lifting up counterweight temporarily A1
Hook wire rope to slinging jig, and lift it and stretch LIFTING HOLE
wire rope to the degree where it is providing no
C7
slack temporarily.
Weight of counterweight:
Approx. 850 kg (1870 lbs) C3 C3
SHIM
Wire more than Ø10 (0.394˝): C2
1.5 m (4 ft 11 in) X 2 pcs.
(2) Removing counterweight
SHIM
1) Remove 1 capscrew (C1) M20 X 70.
2) Remove 2 capscrews (C3) M20 X 130.
: 30 mm
3) Remove shim.
C2
C3
Fig. 5-2 Removing counterweight
5.3 INSTALLATION
(1) Install counterweight in the reverse procedure of
removing.
(2) Install shim as it was
(3) Slinging counterweight
Check that 3 attaching bolts can be screwed in by
hand.
31102 60413252
(4) Apply Loctite #262 on capscrews (C1, C3), and

tighten them with washers (C2).
: 30 mm
(5) Remove slinging tools, and attach plugs (C7).
Fig. 5-3 Attaching bolts counterweight
33-5
UPPER SWING BODY
6. GUARD 1
7 2
5
6.1 PREPARATION FOR REMOVAL 41
(1) Remove guard in the following procedure.
40 3
For removing equipment
Items (1) to (8).
For dismounting engine,
Items (9) to (13).
(2) All the locked equipment, open them using starter
key. 8, 9
Fig. 6-1 Guard assy

6.2 REMOVE GUARD
1 COVER ASSY
(1) Remove cover assy (1)
1) Open cover assy (1) and lift it up.
2) Pull out snap pin (23) and remove gas cylinder
(87).
3) Remove two nuts (26) M12.
4) Remove cover assy (1).
: 19 mm 26 23
23
Weight: 11 kg (24 lbs) 87
Fig. 6-2 Removing cover assy (1)
(2) Remove panel assy (2) 24

1) Remove two sems-bolts (24) M12 X 25.
2) Remove two nuts (26).
3) Remove panel assy (2).
: 19 mm 2
Weight: 11 kg (24 lbs) 24 PANEL ASSY
26
SHIM
Fig. 6-3.Removing panel assy (2)

(3) Remove cover assy (6)
1) Remove two capscrews (38) M12 X 45. 25
2) Remove a sems-bolts (24) M12 X 25. COVER ASSY
6 24
3) Remove three sems-bolts (25) M12 X 30. SEMS-BOLT
M20 X 30 SEMS-BOLT
4) Remove cover assy (6). 25 M12 X 25
31102 60413252
: 19 mm
38
Fig. 6-4.Removing cover assy (6)
33-6
UPPER SWING BODY
(4) Remove guard assy (40) GUARD ASSY

40
1) Remove three capscrews (64) M8 X 20.
2) Remove guard assy (40).
64
: 13 mm
Fig. 6-5 Removing guard assy (40)
41
(5) Remove guard assy (41) 24
1) Remove four sems-bolts (24) M12 X2 5.
2) Remove guard assy (41).
: 19 mm
24
(6) Remove bonnet assy (5)

1) Open bonnet assy (5) and lift it up with nylon 5
slings.
2) Pull out snap pin (23) and remove gas cylinder
(21).
3) Remove four sems-bolts (24) M12 X 25.
4) Remove bonnet assy (5).
: 19 mm
23
Weight: 32 kg (71 lbs) 24
23
21
Fig. 6-7 Removing bonnet assy (5)
COUNTERWEIGHT
(7) Remove cover (1A)
3 COVER 66
1) Remove four capscrws (3) M10X25.
2) Remove cover (1A).
: 17 mm
• Then remove counterweigtht (A1).
(See Article 5. Counterweight). The removing
procedures (1) through (7) for guards and
counterweight is available for removing
hydraulic equipment, but to remove engine
31102 60413252
and all guards together, the performance of

procedures (8) through (13) are required.
(A1)
Fig. 6-8 Removing cover (3)
33-7
UPPER SWING BODY
(8) Remove bracket (44) 24

1) Remove a sems-bolt (25) M12 X 30.
3) Remove bracket (44).
: 19 mm 44
BRACKET
25
24
Fig. 6-9 Removing bracket (44)
(9) Remove guard assy (7) 25 7 GUARD ASSY

1) Remove a sems-bolt (25) M12 X 30. 73
: 19 mm
2) Remove a capscrew (73) M12 x 25.
3) Remove guard saay (7).
(10) Remove cover assy (60) 24
Remove two capscrews (64) M8 X 20, then cover

assy (60).
: 13 mm
60 COVER ASSY
(11) Remove guard assy (11)
Remove a sems-bolts (25) M12 X 30 and a sems-
bolt (24) M12 X 25. 64
: 19 mm
11
GUARD ASSY
25
Fig. 6-11 Removing guard and cover assy (11), (60)
(12) Remove guard assy (9) GUARD ASSY

41 24
Remove four sems-bolts (24) M12 X 25 and guard
assy (9).
: 19 mm
GUARD ASSY
9
24
Remove four sems-bolts (24) M12 X 25 and guard 24
assy (41).
31102 60413252
Fig. 6-12 Removing guard assy (9), (41)
33-8
UPPER SWING BODY

1) Remove 3 sems-bolts (25) M12 X 30
2) Lift up guard assy (8) with nylon sling.
: 17 mm
8
6.3 INSTALLATION 25 25
(1) Installing is done in the reverse order of removing. SEMS-BOLT
M20 X 30
(2) Tightening torque
: 19 mm M12 8.1 kgf·m (59 lbf·ft)
: 17 mm M10 6.7 kgf·m (48 lbf·ft)
7. UNDER COVER
7.1 REMOVAL
(1) Remove under cover (1, 2, 3, 4, 5, 6)
1) Remove sems-bolts (7) M12 X 25.
2) Remove covers
:19 mm
COVER 1
6 COVER
COVER 2 7
1
SEMS-BOLT
M12 X 25 3 COVER
7
7
7.2 INSTALLATION
(1) Install under cover (1, 2, 3, 4, 5, 6) 4 COVER
31102 60413252
: 19 mm 7
COVER 5
Tightening torque: 8.1 kgf·m (59 lbf·ft)
7
33-9
UPPER SWING BODY
8. AIR CLEANER 5

(1) Opening bonnet assy (5)
15
1) Unlock it with starter key.
2) Open bonnet (5) and support it with stay (15).
(2) Opening cover assy (4) Fig. 8-1 Opening bonnet assy (5)
STAY 15
(3) Unplug terminals on indicator lines (5-5)
(see Fig. 8-4)
8.2 REMOVVAL
(1) Pulling out hose (2)
1) Loosen clip (8) on air cleaner side.
2) Pulling out hose (2) 4 COVER ASSY
: Flat-blade screw driver
(2) Pulling out hose (1)

Fig. 8-2 Opening cover assy (4)
1) Loosen clip (8) on air cleaner side.
2) Pulling out hose (1) 8 CLIP
: Flat-blade screw driver
(3) Remove air cleaner assy (5)

3) Remove 2 capscrews (14) M8X20
4) Remove air cleaner assy (5) together with bracket 2 HOSE
(4).
: 13 mm
8.3 INSTALLATION Fig. 8-3 Pulling out hose (2)

(1) Installing is done in the reverse order of removing.
(2) Spare parts for deteriorated elements
1 HOSE
5-5 8 CLIP
5 AIR CLEANER ASSY

FILTER ELEMENT TERMINAL
31102 60413252
4 BRACKET
O-RING
14 M8 X 20
Fig. 8-4 Pulling out hose (1)
33-10
UPPER SWING BODY
9. MUFFLER
9.1 PREPARATION FOR REMOVAL 68

(1) Open bonnet assy (5) (see Fig. 6-7)
(2) Remove cover (3) (see Fig. 6-8)
(3) Remove sems-bolt (68), then cover (42).

42 COVER
Fig. 9-1 U-bolt · nut (As seen from pump)
9.2 REMOVAL
5 U-BOLT
(1) Remove U-bolt (5).
1) Remove four nuts (9) M8.
2 MUFFLER
2) Remove two U- bolts (5). A
E/G parts
: 13 mm 9 CAPSCREW
LOCK NUT M8
T=1.1 kgf·m Fasten in with
(8.0 lbf·ft) pump together
9
NUT M8
T=0.9 kgf·m
(6.5 lbf·ft) 9
Fig. 9-2 Removing U-bolt (5)
(2) Remove clamp assy (6) CAPSCREW M10 X 35

1) Remove two capscrews (7) M10 X 35 T=8.5 kgf·m (61 lbf·ft)
7
2) Separate clamp assy (6) from muffler (2).
CLAMP
: 17 mm ASSY 6
NUT M8 9 A
WASHER
EX TUBE 3 NUT
GASKET 4
9.3 INSTALLATION
(1) Done in the reverse order of removing
M8 lock nut - Tightening torque: 1.1 kgf·m (8.0 lbf·ft)
M8 nut - Tightening torque: 0.9 kgf·m (6.5 lbf·ft)
M10 - Tightening torque: 8.5 kgf·m (61 lbf·ft)
31102 60413252
(2) Deteriorated parts Fig. 9-3 Removing clamp assy (6)

2. Muffler assy
33-11
UPPER SWING BODY
10. FUEL TANK
10.1 PREPARATION FOR REMOVAL A3

(1) Draining fuel.
1) Open cap (A3).
12
2) Loosen plug assy (A4) under the tank.
11
Installing position (See Fig. 10-3)
3) Draining fuel 15
Capacity of tank: 85 L (22 gal) 7
(2) Remove hose (6, 7)

1) Loosen band and pull out hoses (6, 7)
2) Plug hoses.
(3) Remove water separator (2) 6

Water separator Injection pump
1) Remove two capscrews (15) M8 X 25
2) Remove water separator (1). Fig. 10-1 Removing fuel hose (6, 7)
: 13 mm
1 WATER SEPARATOR
(4) Remove tube (11)
Loosen clip (12) and pull out tube (11).
10.2 REMOVAL
(1) Removing bracket (B3) used to secure two tanks.
1) Remove two sems bolts (B4) M12 X 25.
2) Remove bracket (B3).
: 17 mm
(2) Remove fuel tank assy (A1) Fig. 10-2 Removing water separator (1)
1) Remove four capscrews (B1) M16 X 30.
2) Sling and remove fuel tank assy. M12 X 25
Weight: 54 kg (119 lbs) B4 SEMS-BOLT
: 24 mm
B3
10.3 INSTALLATION
Tank attaching bolt M16 X 30
: 24 mm Apply Loctite #262
Special attention must be paid not to drop tightening B1
T=22 kgf·m
tools in far side when tightening bolts. (160 lbf·ft) B1
CAPSCREW
M16 X 30
31102 60413252
Capacity of tank:
A1 85 L (22 gal)
Weight:
PLUG ASSY A4 54 kg (119 lbs)
Fig. 10-3 Removing fuel tank
33-12
UPPER SWING BODY
11. HYDRAULIC TANK

(1) Swinging upper structure 45 degrees.
Swing upper structure to make the removal of
suction hose for pump installed under tank easier.
Fig. 11-1 Swinging upper structure 45 degrees

(2) Bleeding internal air of tank
Press cap by finger to bleed internal air.
Push
WARNING
Keep pressing until the hissing sound stops.
(3) Removing hydraulic pipe on the upper cover of

tank. Fig. 11-2 Bleeding internal air of tank
1) Remove two nuts M8 for coupling (17).
2) Open the gap and remove the coupling.
(4) Remove hose (4)

: 22 mm
(5) Remove hose (6)

: 27 mm
4
17
6
Fig. 11-3 Removing hydraulic pipe on the upper cover of tank
(6) Remove cover (8)

1) Remove six cpscrews (14) M10 X2 0
8
2) Remove cover (8).
: 17 mm
31102 60413252
14
WASHER
33-13
UPPER SWING BODY
(7) Emptying hydraulic oil

Place pump in tank and drain hydraulic oil.
Capacity of tank: Approx. 78 L (21 gal)
WARNING
Care should be taken that pump does not damage
suction strainer.
Fig. 11-5 Emptying hydraulic oil
11.2 REMOVAL
(1) Draw out the suction hose (4)
1) Remove two (2) clips (9) on tank side through
under side of swing frame.
2) Pulling out hose (4).
: Flat-blade screwdriver
HYDRAULIC OIL TANK
9
4
Fig. 11-6 Draw out the suction hose (4)
(2) Disconnecting pilot return hose (DR)

Disconnect 7 pilot drain hoses on rear side of tank.
31102 60413252
Fig. 11-7 Disconnecting pilot return hose (DR)
33-14
UPPER SWING BODY
(3) Remove hydraulic tank attaching bolt Tightening torque:

Remove four capscrews (1) M16 X 40. 22 kgf·m (160 lbf·ft)
Apply Loctite #262
: 24 mm equivalent
1 1
(4) Slinging hydraulic oil tank Tightening torque:
22 kgf·m (160 lbf·ft)
Hook wire to neck of tank upper cover. Apply Loctite #262
equivalent
Tank weight: Approx. 65 kg (143 lbs)
BOOM FOOT PIN HOLE

Fig. 11-8 Removing hydraulic tank attaching bolt
11.3 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) Attaching bolt

Apply Loctite #262
: 24 mm
(5) Connection of suction hose

Apply PERMATEX on pipe side of hose connection Fig. 11-9 Slinging hydraulic oil tank
and insert it.
(6) Clip (9), O-RING

Tightening torque: 0.55 kgf·m (4.0 lbf·ft)
(7) Tank cover attaching bolt

M10 Tightening torque: 4.7 kgf·m (34 lbf·ft)
SUCTION
STRAINER
31102 60413252
O-RING
RETURN FILTER
Fig. 11-10 Element and filter
33-15
UPPER SWING BODY
12. PUMP
BREATHER
12.1 PREPARATION FOR REMOVAL A8 14 CAPSCREW
(1) Remove counterweight. T=4.7 kgf·m (34 lbf·ft )
(2) Release pressure in hydraulic oil tank (see item

"Hydraulic oil tank"). SUCTION
SUCTION
STRAINER STOPPER
(3) Remove six capscrews (A14) M10.
(4) Remove cover (A8).
(5) Take out suction strainer.
(6) Install suction stopper.

For suction stopper, see Chapter "Tools". HYDRAULIC
OIL TANK
Note : Pump can be removed even when counterweight
is not removed. But removal of counterweight facilitates
Fig. 12-1 Hydraulic oil tank
working, and the working time is also reduced.
(7) Remove two capscrews (64) M8.

(8) Remove cover (60).
COVER
24 SEMS-BOLT
(9) Remove a sems bolt (25) M12 and two sems bolts
60
(24) M12.
64
(10) Remove guard (11) assy. 11
: 13 mm, 19 mm
25
(11) Disconnect drain down pipe installed under engine

Fig. 12-2 Removing guard
muffler.
12.2 REMOVAL 6
(1) Loosen cap nuts (5), (6) and remove 2 hoses from
delivery sides (A1), (A2).
: 36 mm
5
HYDRAULIC OIL
(2) Remove suction flange TANK
1) Remove four socket bolts (10) M12.
2) Remove flange (3) of suction hose (4) from pump PUMP B1
(B1).
: Special service tool No.6-1 of opposing 3

31102 60413252
frats 10 mm
40 mm
(1.57 in) 10
CLIP CLIP
4
Fig. 12-3
33-16
UPPER SWING BODY
(3) Removing other hoses

1) Disconnect hoses of the following ports
(see Fig. 12-4). A3
*A5
A1
A2 A5
PORT SIZE CONNECTED REMARKS Dr1
TOOL TO
Dr1 PF1/2 27 Tank Drain
Dr2 PF1/2 27 Plug HOSE
Pf PF1/4 19 Tank Air-con power

shift port A4
P3 PF1/4 19 A5 Do not have B2
to remove it.
Pf
A3 PF3/8 22 Inlet of Delivery port
in-line filter
A4 PF3/8 22 Outlet of Relief port
in-line filter B1
Dozer Delivery port Dr2
*A5 PF1/2 27
C/V-P for dozer (PLUG)
Suction port
B2 PF1 41 Tank for dozer Fig. 12-4 Pump port (with dozer)
F17316
2) Attach tags to hoses to identify. CLOCKWISE
(4) Remove main pump

1) Attach eye bolt (M8) on upper surface of pump.
2) Lift it with wire lightly.
3) Remove 2 socket bolts (7) M16.

4) Pull pump horizontally and remove it. EYE BOLT
45 mm
(1.77 in) : Special service tool No.6-2 of 14 mm
I
(For bolts on upper side)
Weight of pump: approx. 45 kg (99 lbs)
31102 60413252
7 Tightening torque:
19.5 kgf·m (140 lbf·ft)
Apply Loctite #262
Fig. 12-5 Removing pump
33-17
UPPER SWING BODY
12.3 INSTALLATION
Installing pump in the reverse procedure of removal
following the specification for tightening torque and
sealant.
(1) Apply grease on spline of input shaft.
Grease; Shell Retinax AM (General-purpose
Apply grease
extreme-pressure molybdenum disulfide grease)
(2) Hook wire to eye bolts (M8) on upper surface of

pump and lift it.
(3) Insert pump spline section.
7
(4) Apply sealant on suction port (B2) for dozer and fix
Fig. 12-6 Installing pump
it with hose connecting clip.
Sealant: Permatex
Socket screw driver 7 mm
6
(5) Apply sealant on socket bolt (7) and mount pump B2 port is omitted
in this Drawing
with it.
Sealant: Locktite #262
: 14 mm
(* Special service tool No.6-2)
Tightening torque =19.5 kgf·m (140 lbf·ft)
5
HYDRAULIC
(6) Install the suction flange mounting socket bolts OIL TANK
(10) M12 (4 pcs.)
: 10 mm
(* Special service tool No.6-1) PUMP
Tightening torque =10 kgf·m (72 lbf·ft)
(7) Installation
3
Tightening
TIGHTENING POSITION TOOL torque
kgf·m (lbf·ft)
Cap nut A1, A2 36 12.0 (87)
Cap nut Dr1 27 8.0 (58)
10
Cap nut Pf 19 3.0 (22)
Cap nut A3 22 5.0 (36) CLIP CLIP
Cap nut A4 22 5.0 (36)
4
Cap nut A5 27 8.0 (58)
* F17317 Fig. 12-7 Hose installing
(8) Install a water drain pipe under the engine muffler.

31102 60413252
33-18
UPPER SWING BODY
(9) Remove suction stopper

a2 a1
(10) Mounting suction strainer
(11) To bleed air in pump, loosen plugs on pressure

measuring ports a1 , a2 and a3 .
: 19 mm
a3
(12) Check hydraulic oil level.
(13) Start engine and check it for oil leakage and noise.
(14) Install guards

Fig. 12-8 Release air in pump
Tightening
TIGHTENING POSITION TOOL torque
kgf·m (lbf·ft)
Capscrew (64) 17 6.7 (48)
Sems-bolt (24), (25) 19 8.1 (59)
F17318
WARNING
After replacing pump, be sure to fill hydraulic oil of 1L COVER
(0.26 gal) or more. 24 64
64
11
25
Fig. 12-9 Guard installing

31102 60413252
33-19
UPPER SWING BODY
13. RADIATOR AND OIL COOLER
B9 SUB TANK
WARNING
Connection of hoses for air-con should not be loosened
HOSE
and removed. Refrigerant may be leaked.
B6 RADIATOR HOSE (UPPER)
SHROUD · BRACKET
B5 RADIATOR HOSE (LOWER)

CAP
M8 X 20
4 GUARD
4-M12 X 30
Loctite #262
T=12.2 kgf·m (88 lbf·ft) DRAIN COCK
STAY
M10 X 25
Fig. 13-1 Relative drawing of radiator
(1) Remove counterweight 3 HOSE
(2) Bleeding internal air of hydraulic oil tank
2 HOSE
(3) Remove cover of suction strainer, and adjust oil
quantity so that oil level becomes lower than the 7
return tube level.
7
(4) Remove air cleaner hose
1) Loosen two bands (7).
33-I-10
2) Pulling out hose (2). Refer to Fig. 13-2 Removing hose
3) Pulling out hose (3). air cleaner
(5) Removing under cover installed on lower side of

radiator.
1) Remove four sems bolts (A7) M12 X 25.
31102 60413252
2) Remove cover (A5).

: 19 mm COVER A5
A7
Fig. 13-3 Removing under cover
33-20
UPPER SWING BODY
(6) Drain down of radiator 9

D HOSE
Put container 18 L (4.8 gal) under drain cock hose (AIR-CON) A6 Tightening torque:
0.45 kgf·m
for draining water. (3.3 lbf·ft)
17, 20, 23
(7) Remove washer tank Tightening torque:
0.45 kgf·m (3.3 lbf·ft) Tightening torque:
1) Pulling out hose. 16, 20, 23 4.0 kgf·m
2) Move washer tank. CAPSCREW (29 lbf·ft)
M6 X 60 3 pcs. 14
CONDENSER
SEMS-BOLT
(8) Move air-con condenser (A6) RECEIVER M8 X 25 2 pcs.
1) Remove three capscrews (16) M6 X 60. TANK
1
WASHER
3) Move A/C condenser (A6) 11 TANK
: 10 mm, 13 mm
S HOSE
(AIR-CON)
8
(9) Move receiver tank
L HOSE (AIR-CON)
1) Remove two capscrews M8 X 16 which are used 10
to install regulator tank with bracket. Fig. 13-4 Removing air condenser
2) Move receiver tank
: 13 mm
13.2 REMOVAL CAP

(1) Remove radiator stay
1) Remove two capscrews (2) M10 X 25.
2) Remove stay (A1). STAY
: 13 mm
A1
T=12.2 kgf·m CAPSCREW
(2) Remove bracket (B2) (88 lbf·ft) M10 X 25
1) Remove four capscrews (B17) M8 X 20. B17 T=5.87 kgf·m
2) Remove bracket (B2). A2 (42 lbf·ft)
: 13 mm DRAIN COCK
4-M8
B2 COOLER MOUNTING BOLT
Fig. 13-5 Removing radiator stay (A1) and bracket
(3) Remove sub tank (B9) B9 SUB TANK

1) Loosen clip on one side of hose (B11) and pull out
hose.
2) Lift sub tank (B9) directing upward, and remove it BRACKET
from bracket (B3). B11 HOSE
TO RADIATOR
31102 60413252
Fig. 13-6 Removing sub tank
33-21
UPPER SWING BODY
(4) Remove guard (B4) B19 CAPSCREW

1) Remove three capscrews (B19) M8. B4
2) Remove guard (B4).

B6
: 13 mm
B12
(5) Remove water hose (B6)
1) Loosen the hose band (B12).
2) Remove hose (B6).
C1
(6) Remove main radiator (C1)
Remove four capscrews (A3) M12 X 30.
: 19 mm
: 19 mm
CAPSCREW
M12 X 30
Loctite #262
T=12.2 kgf·m
(88 lbf·ft)
A3
Fig. 13-7 Removing radiator

(7) Removing connection coupling for hydraulic oil
(oil cooler)
1) Remove 4 bolts M8 of coupling (17) just below the
radiator.
17
2) Put oil pan under the coupling (17), remove M8
coupling and let oil out.
(8) Disconnecting hydraulic oil pipe

1) Shift radiator outward.
2) Plug up pipe ends with rag, etc.
Fig. 13-8 Removing coupling

(9) Disconnecting water lower hose (B5)
1) Loosen the hose band (B13).
2) Pulling out hose (B5).
WARNING
Remove the hose while sliding the radiator little by
little.
RADIATOR
OIL COOLER
(10) Removing radiator

B5
Remove radiator assy by power of men or with B13
crane.
31102 60413252

F17319
Fig. 13-9 Removing water lower hose (B5)
33-22
UPPER SWING BODY
13.3 INSTALLATION
(2) Install radiator assy
Lift up radiator by power of men or with crane,
match the holes for water hose and hydraulic oil
pipe and also the position respectively, and
assemble them temporarily.
Tighten it with
However, water hose insert standard 30 ± 2 mm attaching bolts
of radiator
(1.18 ± 0.08 in) shroud.
3
Hydraulic oil pipe insert standard 30 ± 2 mm (1.18 T=0.83 kgf·m
± 0.08 in) (6.0 lbf·ft)
(3) Radiator attaching bolt
Apply Loctite #262 on 4 cap screws (A3) M12, and
tighten it with washer respectively.
: 19 mm
Weight of seat stand: 12.2 kgf·m (88 lbf·ft)
Fig. 13-10 Installing radiator
(4) Making up hydraulic oil and LLC
After completion of other installation, make up
hydraulic oil and water.
31102 60413252
33-23
UPPER SWING BODY
14. ENGINE
14.1 PREPARATION FOR REMOVING

(1) Remove guard (see Fig. 6-1~6-13). (7) If necessary, remove pump, air cleaner, muffler
and radiator.
(2) Remove counterweight (see Fig. 5-1~5-3).
(8) Remove harness and connector
(3) Remove battery ground (see Fig. 3-3). 1) Starter cable Starter B terminal
E/G sub harness terminal
(4) Remove air cleaner hose (see Fig. 8-3). CN357M
M-2
(5) Remove radiator hose (see Fig. 13-7~13-9). 2) Main harness CN-351F E/G sub
CN-352M harness
(6) Remove fuel hose and heater hose, and if CN-363F
necessary air-con hose. 3) Engine grounding cable
E/G LIFTING
FITTING
WARNING
Prepare a stand which withstands the weight of the
engine assy and can place the removed engine firmly.
I
GROUND
E/G OIL
PRESSURE SW
E/G OIL FILTER
E/G SPEED SENSOR
8 PIN CONNECTOR
CN-352M
BRACKET 2 E/G SUB HARNESS
E/G GROUND CABLE T=8.1 kgf·m
TO ALTERNATOR (59 lbf·ft)
1 PIN CONNECTOR
TO E/G SPEED CN-351F
SENSOR TIGHTEN CABLE TOGETHER WITH
CAPSCREW OF GROUND
Torque: 4.1 kgf·m (30 lbf·ft)
E/G OIL PRESSURE SW

Torque: 4.1 kgf·m (30 lbf·ft)
Apply Loctite #262
8 PIN CONNECTOR
31102 60413252
CN-363F
SEMS-BOLT
Torque: 0.98 kgf·m (7.1 lbf·ft)
SAFETY RELAY
CLIP
TO MAIN HARNESS DETAIL I
33-24
UPPER SWING BODY
PT3/8 (PLUG)
FOR HEATER HOSE
Clamp the white 4-M10 x 1.25

E/G WATER tape portion
TEMPERATURE
SW [105°C (221°F)]
WATER
TEMPERTURE FUEL FILTER
SENSOR FUEL RETURN (OUT)
M16 X 1.5 E/G LIFTING FITTING
Clamp the white tape portion
M-1
STARTER MOTOR
A/C COMPRESSOR
FUEL FEED (IN) STARTER CABLE

M-2
STEPPING (GOVERNOR) MOTOR
Connect with
the starter motor RUBBER CAP S
CN-357M STARTER CABLE
1PAM-58Y
B
TO E/G SUB
HARNESS M
31102 60413252
DETAIL OF STARTER MOTOR TERMINAL
33-25
UPPER SWING BODY
14.2 REMOVAL
6 6 CAPSCREW
M18 X 90
T=23 kgf·m (170 lbf·ft)
1 Apply Loctite #271
2 BRACKET
10 CAPSCREW
M10 X 35
Apply Loctite #271
3
4
4 RUBBER MOUNT
12
5
5
12 SHIM
7 5
5 RUBBER
7
7 7 NUT
(1) Removing attaching bolt to frame 14.3 INSTALLATION

1) Remove four nuts (7) M18. (1) Installing is done in the reverse order of removing.
2) Remove rubber mount (5) and shim (12). For tightening torque and Loctite, refer to above
3) Remove four capscrews (6) M18 X 90. figure.
: 27 mm
(2) Slinging engine body

1) Sling engine hooking wire to lifting lugs on the front
31102 60413252
and rear sides.

Weight: Approx. 250 kg (550 lbs)
Wire: Ø6 (0.236˝) X 1 m (3 ft 3 in)-2 pcs.
(3) Position engine on the mount stable.
33-26
UPPER SWING BODY
15. MULTI CONTROL VALVE
15.1 PREPARATION FOR REMOVAL 5 MULTI CONTROL VALVE

(1) Bleed pressure air in hydraulic oil tank
(see Fig. 11-2.) 20 SUPPORT
(2) Remove cover assy (1) (see Fig. 6-2) 21
(3) Remove cover assy (2) (see Fig. 6-3)
(4) Remove cover assy (6) (see Fig. 6-4) 11
(5) Shift bracket (11) for multi control valve if necessary
(see Fig. 15-1). 10
VIEW III
(6) Tag harness and remove it.
(7)sAttach tag to hose between multi control valve and
Fig. 15-1 Removing bracket for multi control valve
main C/V, and write numbers C1 to C8 on it.
Remove hose on multi control valve side, and plug
connection. Plug No. 4-3
15.2 REMOVAL
(1) Attach tag on which hose name is entered to the
remote control hoses between multi control valve
and pilot V, and write numbers P1 to P8 on it.
(2) Remove hoses P1 to P8 on multi control valve side
and plug connection, Plug No.4-3
(3) Remove four capscrews (7) M8 X 20.
(4) Remove multi control valve (5).
: 13 mm
(5) Removing and shifting bracket (11) for multi control
valve.
1) Remove two capscrews (21) M10 X 20.
2) Remove support (20).
3) Remove three capscrews (20) M10 X 30. 7
4) Move bracket (11). Fig. 15-2 Connection between multi control valve and main C/V
15.3 INSTALLATION
(1) Installing is done in the reverse order of removing
(2) Relations between pilot valve and multi control
valve hose.
HOSE ISO MULTI MARK-

P/V PORT Operation pattern PORT ING
Size Collar
1 1/4 Red Bucket digging P1 BK
2 1/4 Blue Bucket dump P2 BA
Right 3 1/4 Green Boom up P3 BR
side 4 1/4 Gray Boom down P4 B
P 1/4 Black Pilot primary — —
T 3/8 Black Drain — —
5 1/4 Gray Swing left P5 SL
31102 60413252
6 1/4 Red Swing right P6 SR

Left 7 1/4 Blue Arm in P7 AK
side 8 1/4 Gray Arm out P8 AR
P 1/4 Black Pilot primary — —
T 3/8 Black Drain — —
F17320
Fig. 15-3 Connection between P/V and multi control valve
33-27
UPPER SWING BODY
Specification with multi control valve

15.4 MULTI CONTROL LEVER
352 353 271 472 471 401 261 201 273 274
REMODELING PROCEDURE
(1) Changing from "with multi valve" to "multiless
valve"
1) Be certain that the engine stops.
M
2) Set multi control valve to ISO (Y) pattern.
3) Remove four socket bolts (271) and two socket 275 O-RING
bolts (273). (161)
462
: 6 mm S SENSOR
461 BLOCK
4) Remove repair kit "with multi valve" and attach
repair kit "multiless valve".
Fig. 15-4
5) Then check that the inside O-ring (161) is free
from distortion.
C/V assy with multi
6) Check that whirl stop pin (355) and spring pin
No. Parts Q'ty
(356) are fitted on cover of valve "multiless control",
S SENSOR BLOCK 1S
and install it on sensor block (S). M REPAIR KIT WITH MULTI 1S
7) Fit socket bolt (271) and tighten it to the specified 161 • O-RING 1
torque. 201 • COVER FOR MULTI 1
: 6 mm 261 • DUST SEAL 1
Tightening torque: 4.3 kgf·m (31 lbf·ft) 271 • SOCKET BOLT 4
273 • SOCKET BOLT 2
274 • SPACER 2
(2) Changing from "multiless valve" to "with multi
275 • SLEEVE 4
valve" 352 • KNOB 1
1) Stop engine, and remove repair kit for "multiless 353 • LEVER 1
valve" in the reverse procedure of the said proce- 401 • PIN 1
dure, and attach repair kit for "with multi valve". 461 • O-RING 1
462 • BACK-UP RING 1
471 • SPRING PIN 1
472 • WING BOLT 1
F17321
Specification of multi less control valve

271 355 356 354
Y
O-RING (161)
S SENSOR
BLOCK
Fig. 15-5
Multi less control block assy

No. Parts Q'ty
S SENSOR BLOCK 1S
31102 60413252
Y MULTI LESS REPAIR KIT 1S

161 • O-RING 1
271 • SOCKET BOLT 6
354 • COVER 1
355 • PIN 1
356 • SPRING PIN 1
F17322
33-28
UPPER SWING BODY
16. CONTROL VALVE

(1) Remove cover assy (1) (see Fig.6-2).
(2) Remove panel assy (2) (see Fig.6-3).
(3) Remove cover assy (6) (see Fig.6-4).
(4) Release air in hydraulic oil tank, open cover of

suction element of hydraulic oil, and lower the
level (see Fig.12-1).
(5) Move bracket for multi control valve (11)

(see Fig. 15-1).
16.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name on it, then
remove hoses.
PORTS FUNCTIONS PORTS ON UPPER SIDES (ON MACHINE) PORTS FUNCTIONS
P0 Travel straight FAR SIDE
T1 Tank TRAVEL
STRAIGHT
TRAVEL
Pd1 Travel left forward (LEFT) Pa1 Travel right forward
Pd2 Swing left SWING Pa2 Boom up

REAR FRONT
ARM
Pd3 Arm extending Pa3 Bucket digging
Pd4 P2 by-pass cut CUT DR6 Drain

VALVE-2
DR4 Drain
NEAR SIDE
PORTS FUNCTIONS PORTS ON REAR SIDES (ON MACHINE) PORTS FUNCTIONS
BOTTOM FAR SIDE TOP
P2 P2 pump P1 P1 pump
C1 Travel left backward D1 Travel left forward
C2 Swing right D2 Swing left

31102 60413252
C3 Arm in D3 Arm out
PS Swing priority PC3´ Lock valve
DR2 Drain NEAR SIDE DR3 Drain

F17323
33-29
UPPER SWING BODY
PORTS FUNCTIONS PORTS ON FRONT SIDES (ON MACHINE) PORTS FUNCTIONS

TOP BOTTOM
A1 Travel right forward
A2 Boom up B1 Travel right reverse
A3 Bucket digging B2 Boom down
Pb2´ Boom lock release B3 Bucket dump
DR5 Drain
PORTS FUNCTIONS PORTS ON BOTTOM SIDES (ON MACHINE) PORTS FUNCTIONS

FAR SIDE DR1 Drain
PC1 Travel left reverse
Pb1 Travel right reverse PC2 Swing right

FRONT REAR
Pb2 Boom down PC3 Arm in
Pb3 Bucket dump PC4 Boom conflux
Pb4 P1 by-pass cut PS´ Swing priority output

(Arm conflux)
NEAR SIDE Pd2´ Swing priority input
F17324
(2) Remove control valve

1) Remove 4 capscrews (2) M12 X 30 from upper
frame.
2) Remove bracket (1) together with control valve.
3) Three cap screws (2) M12 X 30 from bracket.
: 19 mm
4) Weight: 42 kg (93 lbs)
16.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
: 19 mm
Weight of seat stand: 12.3 kgf·m (89 lbf·ft)
(2) Make certain that attachment moves normally in
1
operation.
31102 60413252
(3) Check oil level and that it is free from oil leakage.
2
2
Fig. 16-1 Removing main control valve
33-30
UPPER SWING BODY
17. PILOT VALVE (FOR ATT)

The removing procedure for right and left is the same, PANEL ASSY
so the preparation for left side is described here.
26
(1) Put attachment on ground, stop engine and release 25
pressure in tank.
(2) Remove panel assy referring to Section 4.

Instrument Panel.
(3) Remove one sems-bolt (12) M5 from lower side of

control box.
12
(4) Remove cover on outer surface. Fig. 17-1 Removing instrument panel
(5) Remove sems-bolt (25) and rubber sheet (26)

securing cover and control box on inner surface. BOOTS
16
(6) Remove cover on inner surface.
PILOT VALVE
(7) Remove harness connector for horn.
T=3.0 kgf·m
(8) Attach tag to hoses for identification. (22 lbf·ft) PF1/4
PF1/4
VALVE SIDE Opposing
Opposing flats 19
17.2 REMOVAL flats 22
(1) Remove hoses from your side to far side in order. MARK “F”
PF3/8
: 19 mm, 22 mm PF1/4
HOSE SIDE 1~4, 5~8 PORT AND
T PORT CONNECTOR P PORT (WITH FILTER)
(2) Shift boots. CONNECTOR
Fig. 17-2 Pilot valve connector

(3) Remove four socket bolts (A1) M6.
: 5 mm
(4) Remove pilot valve. FRONT OF THE MACHINE
(5) Plug hose ends. Plug PF1/4 T 8 ARM (R) 4 BOOM (R)
(GREEN) T (GRAY)
17.3 INSTALLATION 2 BUCKET (R)

6 SWING (R) (BLUE)
Install it in the reverse order of removal and tighten it (RED)
to the below tightening torque. 1
5 SWING (L) BUCKET (H)
31102 60413252
: 5 mm T=1.1 kgf·m (8.0 lbf·ft) (GRAY) (RED)

P
: 19 mm T=3.0 kgf·m (22 lbf·ft) 7 ARM (H) P
: 22 mm T=5.0 kgf·m (36 lbf·ft) (BLUE) 3 BOOM (H)
(GREEN)
LEFT SIDE RIGHT SIDE
Fig. 17-3 Pilot valve port position (for upper side)
33-31
UPPER SWING BODY
18. PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank
(2) Remove under cover (see 33-9 page)
(3) Remove floor mat
18.2 REMOVAL 7
(1) Disconnect pressure sensor connectors at two
places from under floor harness.
(2) Remove two pressure sensors. Lead cable for
travel 1,2 speed
: 19 mm 10
Connect to under
(3) Disconnect lead cable CA103 for travel 1,2 speed floor harness
at two places from under floor harness. PF1/4 with CA103 plug
(4) Attach tag, and disconnect connectors and hoses.
PRESSURE SENSOR
: 19 mm (P port) PRESSURE
: 19 mm (T port, 1~4 port) SENSOR
T
(5) Plug hose ends CONNECTORS
P
Plug PF1/4
(6) Remove four capscrews (7) M10 4
(7) Remove right and left levers.
3
(8) Remove four socket bolts (10) M10. 2
: 8 mm GROMMET
1
(9) Remove four sems-bolts (9) M10 and remove two 25 24
plate (18)
: 17 mm
(10) Remove pilot valve lifting it upward.
(11) Stop up holes with blank plugs PF1/4, 3/8.
18.3 INSTALLATION Opposing

PF3/8 flats 22
Install it in the reverse order of removal and tighten it PF1/4
to the below tightening torque.
: 19 mm, 22 mm T=3.0 kgf·m (22 lbf·ft)
: 8 mm T=4.7 kgf·m (34 lbf·ft)
VALVE SIDE HOSE SIDE
: 17mm T=4.7 kgf·m (34 lbf·ft) T port connector
Pressure sensor VALVE SIDE
: 19 mm T=3.5 kgf·m (25 lbf·ft) PF3/8 Opposing
flats 22 MARK “F”
Opposing
flats 22 PF1/4 PF1/4
31102 60413252
PF1/4
HOSE SIDE P port connector

1~4 port connector
Fig. 18-1 Installing and removing pilot V
33-32
UPPER SWING BODY
19. SWING UNIT

(1) Park machine on flat and solid ground and put CONTROL VALVE
FOR DOZER
attachment and dozer on ground.
(2) Stop engine and release pressure in circuit
operating dozer lever.
(3) Release internal pressure through bleeder of
hydraulic oil tank.
T
(4) Remove boom as necessary to make work easier P
(refer to chapter of Attachment).
(5) Remove cab if necessary to make work easier.
(refer to chapter of Upper structure). MU
Dr
(6) Remove cover under engine. P
(7) Attach tag to hose. B
A
19.2 REMOVAL
(1) Remove hose.
1) Two hoses from connectors of T, P ports on
control valve for dozer
: 27 mm Fig. 19-1 Swing unit piping
2) One hose from tee of MU port.
: 36 mm
3) One hose from tee of Dr port. B1
: 22 mm
SPECIAL EYE BOLT
4) One hose from elbow of P port (for swing parking
brake).
: 19 mm
M10
Tightening torque: 3.0 kgf·m (22 lbf·ft) B9
5) One hose from tee of A, B ports.
: 32 mm B10
(* Special service tool No. 6-3) B11
Tightening torque: 15.0 kgf·m (110 lbf·ft) B8

6) Install PF1/2 plug
Plug No.4-2-1
31102 60413252
Fig. 19-2 Removing swing unit
33-33
UPPER SWING BODY
(2) Loosen one nut (B9) M10 from under side of upper 19.3 PREPARATION FOR INSTALL
frame and remove drain hose clip for reduction (1) Clean mating surfaces of swing unit and upper
unit. frame.
: 17 mm Tools: spatula, cleaning fluid
Tightening torque: 7.2 kgf·m (52 lbf·ft) (2) Apply sealant on entire mounting surface of swing
(3) Remove eight the swing unit mounting socket bolt unit.
(B1) M16. Sealant: Loctite # 515 (Three Bond #1215)
Allen key socket wrench : 14 mm
Loctite #262 (Three Bond #1350) 19.4 INSTALLATION
(4) Remove tee of swing motor MU port and plug up Installing is done in the reverse order of removing
holes with plug used as eye bolt.
: 36 mm
Tightening torque: 16.5 kgf·m (120 lbf·ft) 19.5 PREPARATION FOR DRIVE
Plug No. 6-4, Eye bolt No. 6-5 (1) Before starting operation, check that engine oil
(5) Hook sling to eye bolts attached on MU port. level of swing reduction is sufficient. Amount of
Weight of swing unit: Approx. 70 kg (150 lbs) charge: 1.5 L (0.40 gal)
(2) Confirm no oil leaks
(3) Confirm proper functions.
31102 60413252
33-34
UPPER SWING BODY
20. SWIVEL JOINT

17 24 16-1
20.1 PREPARATION FOR REMOVE
(1) Remove attachment assy
(refer to 1. chapter: Attachment)
(2) Remove cab (see 1. CAB)
SWIVEL
(3) Remove guard (see 6. GUARD) JOINT
(4) Removig hoses on undercarriage
(see chapter: Undercarriage)
(5) Remove swing reduction unit if necessary.
(see 19. SWING MOTOR UNIT)
20.2 REMOVAL SWING MOTOR

Fig. 20-1 Removing piping
(1) Remove travel motor hose
1) Remove hose (24). (D port)
2) Remove hose (16-1). (A port)
C3 CAPSCREW
3) Remove hose (17). (C port)
4) Remove hose (16-2). (B port)
C5 M16
T=16 kgf·m
(2) Disconnect drain hose from pipe (6). (120 lbf·ft)
(3) Disconnect 2-speed travel hose from joint 1.
(4) Remove dozer hose. (OPT) (Port F, G)
(5) Remove whirl-stop of swivel joint.
Fig. 20-2 Removing whirl-stop nut and the capscrew
1) Loosen the nut (C5) M16.
2) Remove a capscrew (C3) M16 X 90.
: 24 mm
(6) Remove joint for piping CAPSCREW B4 M8 X 25
1) Remove three elbows (3). T=0.9 kgf·m
B7 (6.5 lbf·ft)
2) Remove tube (7).
3) Remove connector for travel 2-speed change PLATE B2
over (1).
: 27 mm, 19 mm DUST COVER B1
4) Remove plug (10) if attached. (Machine not
equipped with dozer)
Fig. 20-3 Removing dust cover (B1)
: 22 mm
(7) Remove dust cover (1)

1) Remove four capscrews (4) M8 X 25. 6 T=11.0 kgf·m (80 lbf·ft)
2) Remove plate (B2).

3) Remove dust cover (B1).
: 13 mm
31102 60413252
1
T=3.7 kgf·m 10
(27 lbf·ft) T=7.5 kgf·m
(54 lbf·ft)
VIEW I
Fig. 20-4 Removing joint for piping
33-35
UPPER SWING BODY
(8) Remove socket bolt for installation

Attach eye bolt on pipe (6), lift it up temporarily,
and remove three (3) socket bolts (2) M8 X 20.
BALL POINT
ALLEN KEY
WRENCH
2
SOCKET BOLT
M8 X 20
Loctite #262
T=3.6 kgf·m
(26 lbf·ft)
1
SWIVEL JOINT
Fig. 20-5 Removing socket bolt for installation
(9) Slinging the swivel joint

Weight: Approx. 21kg (46 lbs)
20.3 INSTALLATION
Piping tightening torque
THREAD DIA. TOOL TIGHTENING TORQUE

PF HEX O-ring type Hydraulic hose
3.7 kgf·m 3.0 kgf·m
1/4 19 Fig. 20-6 Slinging swivel joint
3/8 22
1/2 27
31102 60413252

F17325
(2) Check for oil leakage and the hydraulic oil level.
(3) Check for operating.
33-36
UPPER SWING BODY
21. UPPER FRAME

(1) Remove attachment
(refer to 1. chapter: Attachment) WIRE ROPE
Ø16 X 2.5 m
(2) Remove cab (see 1. CAB) (0.630˝) (8 ft 2 in)
(3) Remove guard (see 6. GUARD)
(4) Remove counterweight CHAIN BLOCK
(see 5. COUNTERWEIGHT)
(5) Remove swivel joint
(perform the steps (1) thru (7) of 20. SWIVEL
JOINT)
21.2 REMOVAL
(1) Lifting up upper frame temporarily
Hook upper structure sling tools to boom foot rear
hole and position two chain blocks on boom foot LIFTING JIG No.12 FOR UPPER SWING BODY
side, and raise it up temporarily at three points. Fig. 21-1 Temporarily lift upper frame
Wire rope: Ø16 (0.630˝) X 2.5 m (8 ft 2 in),1 pcs.
Ø16 (0.630˝) X 1.5 m (4 ft 11 in),2 pcs.
Chain block: 750 kg (1650 lbs) 2 pcs.
(2) Marking match marks on swing bearing
MATCH
Mark match marks on upper frame and swing MARK
bearing.
(3) Removing upper frame mounting bolts
Remove twenty capscrews M16 X 90 and three
reamer bolts used to install swing bearing and
upper frame.
: 24 mm
(4) Slinging upper frame Fig. 21-2 Matching mark on swing bearing and upper frame
Sling according to Fig. 21-1, and remove upper
frame and put it on a stand resistant to the weight.
Weight: Approx. 1,500 kg (3310 lbs)
31102 60413252
Fig. 21-3 Removing upper frame mounting bolts
33-37
UPPER SWING BODY
21.3 INSTALLATION Apply Loctite # 515 or equivalent

to race surface of the inside
(1) Installing is done in the reverse order of removing. of capscrew to only perimeter
specified by slanting lines.
(2) Cleaning mating surfaces of upper frame and
swing bearing.
(3) Applying Loctite #515 on mating surface.
(4) Slinging upper frame
Match marks and install it with three reamer bolts
temporarily.
WARNING Fig. 21-4 Bearing mount

Confirm the reamer bolt positions referring to Fig. 21-5.

OUTER S ZONE POSITION

(5) Install swing bearing
Install twenty capscrews (5) M16 X 90.
Fig. 21-5 Reamer bolt position (*)

Apply Loctite on section specified by slanting lines
31102 60413252
33-38
UPPER SWING BODY

1. HYDRAULIC PUMP - REGULATOR
1.1 STRUCTURAL EXPLODED VIEW
F17432
31102 60413252
Fig. 1-1 Hydraulic pump - regulator
33-39
UPPER SWING BODY
NOTE
31102 60413252
33-40
UPPER SWING BODY
Table 1-1
: Apply loctite #222
torque No. NAME Q'TY torque No. NAME Q'TY
111 SHAFT 1 621 COMPENSATION PISTON 1
114 COUPLING 1 624 SPRING SEAT 1
115 COLLAR 1 625 SPRING 1
123 ROLLER BEARING 1 626 SPRING 1
124 NEEDLE BEARING 1 627 PLUNGER 1
127 SPACER 1 628 ADJUST SCREW (C) 1
141 CYLINDER BLOCK 1 16 (120) 630 LOCK NUT: M30 1
151 PISTON 10 641 SPRING COVER 1
152 SHOE 10 651 SLEEVE 1
153 PLATE 1 652 SPOOL 1
156 SPHERICAL BUSHING 1 653 PIN 1
157 SPRING 10 654 PIN 1
212 SWASH PLATE 1 655 PIN (Pf PISTON) 1
214 BUSHING 1 656 PIN 1
215 PIVOT BALL 1 660 ADJUST SCRW (R) 1
216 PIVOT BALL 1 661 LOCK NUT: M14 X 1.5 1
271 CASING 1 3 (22) 662 SPRING SEAT 1
273 COVER 1 663 SPRING 1
312 VALVE COVER 1 664 POPPET 1
313 VALVE PLATE 1 665 SEAT (R) 1
24 (170) 401 SOCKET BOLT: M16 X 40 4 700 O-RING: 1B G35 1
3 (22) 402 FLANGE SOCKET BOLT: M8 X 16 2 701 O-RING: 1B G55 1
24 (170) 403 SOCKET BOLT: M16 X 70 1 702 O-RING: 1B G135 1
1.2 (8.7) 404 SOCKET BOLT: M6 X 20 9 705 O-RING: 1B P16 2
11 (80) 467 DRAIN PLUG: PF 1/2 1 706 O-RING: 1B P11 10
3.7 (27) 468 PLUG: PF1/4 6 707 O-RING: 1B P18 1
0.9 (6.5) 490 PLUG: NPTF1/16, Meck coated 14 708 O-RING 1
10 (72) 492 PLUG: PT1/8, Meck coated 1 709 O-RING: 1B P26 1
4.5 (33) 493 PLUG: PT3/8 1 710 O-RING 1
751 GASKET 1
0.9 (6.5) 508 ORIFICE THREAD: NPTF1/16 4 774 OIL SEAL 1
10 (72) 531 TILTING PIN: M16 X 1.5 1 787 BACKUP RING 1
10 (72) 532 SERVO PISTON: M16 X 1.5 1 789 BACKUP RING 2
534 SET SCREW: M27 X 1.5 1 801 LOCK NUT: M8 1
535 STOPPER 1 1.6 (12) 803 LOCK NUT: M27 X 1.5 1
541 SEAT 2 13 (94) 824 SNAP RING 1
543 STOPPER 2 825 SNAP RING 1
545 BALL 2 885 SPRING PIN 2
548 FEED BACK PIN 1 901 EYE BOLT: M8 1
611 FEED BACK LEVER 1 924 SET SCREW: M8 X 25 1
F17433
Marks in shows adjusting screw and nut. Don't touch these parts. Turning these parts causes losing of
31102 60413252
proper adjustment.
33-41
UPPER SWING BODY
1.2 REMOVAL AND INSTALLATION Table 1-2

(1) Tools TOOL NAME DIMENSION
The following list shows the tools required for
Allen wrench Opposing flats 4, 5, 6, 8, 10, 14 mm
remove and install. Eye wrench
Socket wrench Opposing flats 27 mm
Wrench with double
(2) General precautions for remove heads (single head)
1) Work in clean area. Adjust wrench Medium size 1 pc.
2) Spread rubber sheet or cloth on work bench to Screw driver Flat-bladed screw driver 1 pc.
protect parts from damaging. Hammer Plastic mallet 1 pc.
3) Remove dust and rust, etc. on pump surface with Plier For snap ring TSR-160
wash oil. Steel bar for key
Steel bar Approx. 10 X 8 x 200
(0.40˝ X 0.31 X 0.79˝)
One that may be fastened to
Torque wrench
specified torque
F17434
(3) Removal GEAR PUMP

1) Letting oil out
Remove drain plug (467) and let oil out of casing 402
(271).
: 27 mm 312
2) Remove coupling (114)
Remove socket bolts (402) used to fasten valve
cover (312) and gear pump, remove gear pump,
and remove coupling (114) from inside of valve
cover (312).
: 6 mm
3) Remove valve cover (312)
1. Remove socket bolt (401) used to fasten valve
Fig. 1-2 Remove coupling (114)
cover (312) and casing (271).
: 14 mm
401
271
31102 60413252
312
Fig. 1-3 Remove socket bolt (401)
33-42
UPPER SWING BODY
2. Remove valve cover (312) from casing (271). 271
312
4) Remove valve plate (313) Fig. 1-4 Remove valve cover (312)
Remove valve plate (313) from inside of casing
(271).
271
313
Fig. 1-5 Remove valve plate (313)
5) Remove cylinder assy and swash plate (212)

Remove cylinder block (141), piston (151), plate 271
(153), spherical bushing (157) and swash plate
151
(212) from casing (271). 212
• Also, special attention must be paid not to
damage sliding surface of cylinder block (141),
spherical bushing (156), shoe (152), swash
plate (212), etc.
153 141 (156,157)

Fig. 1-6 Remove cylinder assy and swash plate (212)
6) Remove pivot ball (215), (216)
Remove pivot ball (215), (216) from casing (271).
271
215
31102 60413252
216
Fig. 1-7 Remove pivot ball (215), (216)
33-43
UPPER SWING BODY
7) Remove shaft (111)

Remove snap ring (825) from casing (271) and 271
remove shaft (111) striking shaft end with plastic
hammer.
• Then, special attention must be paid not to 111
damage oil seal (774) fitted on casing (271). (825)
Fig. 1-8 Remove shaft (111)
8) Remove spring (625), (626) and spring seat (624)

Remove socket bolt (404), then remove spring 641 (624,625,626)
cover (641), spring (625) spring (626) and spring
seat (624).
: 5 mm
WARNING
• Never loosen lock nuts (630), (801) of spring cover
(641). If loosened, the set value of regulator may be
changed.
• The regulator is made up of small precision parts, so
care should be taken not to lose and damage any of
Fig. 1-9 Remove spring (625),(626) and spring seat (624)
them when remove and install.
9) Remove feed back lever (611) 611

Remove socket bolt (404) and cover (273). Then
remove feed back lever (611) from casing (271).
: 5 mm
271
Fig. 1-10 Remove feed back lever (611)
10) Remove spool sub assy and compensation piston

(621) 651 (621),(652)
Remove sleeve (651), spool (652), and
compensation piston (621).
31102 60413252
Fig. 1-11 Remove spool sub assy and compensation piston (621)
33-44
UPPER SWING BODY
11) Remove pin (655)

Remove plug (468), then remove pin (655). 468 (655)
: 6 mm
12) Remove servo piston sub assy
Since the set screw (534) installed on servo piston
sub-assy is screw used to regulate flow rate of
regulator, it should not be removal if not required.
If required to removal, remove set screw (534)
with lock nut (803), stopper (535), servo piston
(532) and tilt pin (531).
: 19 mm, : 41 mm
Fig. 1-12 Remove pin (655)

WARNING
• Lock nut (803) and set screw (534) are not allowed
to be removal unnecessarily. A set flow rate changes.
• Since servo piston (532) and tilt pin (531) are applied 271 531 532 535 803
Three Bond, it is not allowed to removal them.
• Care must be taken not to damage servo piston
534
fixing tilt pin when remove.
13) Remove valve cover (312)

If necessary, remove relief valve lock nut (661),
adjusting screw (660), spring seat (662), spring
(663), poppet (664), seat (665) and needle bearing
(124). Fig. 1-13 Remove servo piston sub assy
: 22 mm
• Relief valve are not allowed to be removal
unnecessarily. A set pressure relief rate 661
660
changes. 705
662
• Strictly prohibited to pull out needle bearing 663
664
other than when the life time is exceeded. CHECK VALVE SUB 665
RELIEF VALVE
541
14) Remove check valve sub and orifice thread (508) 545 706
Remove check valve sub (541), (543), (545) and 543 508
706
orifice thread (508) from casing (271) 508
508
: 4 mm 706
508
• Use wrench taking care not to damage orifice 706
541
thread (508) when remove. 545
543
271 124
312
31102 60413252
Fig. 1-14 Remove valve cover (312), and remove check

valve sub-assy and orifice thread (508).
33-45
UPPER SWING BODY
(4) General precautions to be exercised in installation

Installation is basically the reverse order of
removal, but exercise care of the following.
1) Repair scored parts at disassembly, Get
replacement ready beforehand.
2) Clean every parts with wash oil, and dry them
before attaching.
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,
oil seals, and gasket.
5) Tighten bolt and plugs to specified torques in
Service Standard, using a torque wrench.
(5) Install
1) Installing servo piston sub assy
When lock nut (803), set screw (534), stopper
(535), servo piston (532) and tilt pin (531) have
been removed, attach those parts on casing (271)
first.
WARNING
• Fasten servo piston (532) and tilt pin (531) stopping
tilt pin. And apply Three Bond #1303B on threaded
section.
: 14 mm
271 531 532 535 803
• After tightening, check that servo piston (532) moves
smoothly. 534
2) Installing drain plug (467)

Attach drain plug (467) and O-ring (707) first on
casing (271).
: 27 mm
Tightening torque: 11 kgf·m (80 lbf·ft) Fig. 1-15 Installing servo piston sub assy
707
467
31102 60413252
Fig. 1-16 Installing drain plug (467)
33-46
UPPER SWING BODY
3) Installing shaft (111)

Set shaft (111) on which bearing (123), spacer
111
(127) and snap ring (824) are fitted on casing
(271), and fit snap ring (825) on it. 123 (127,824)
WARNING 271
• Insert shaft (111) completely striking outer race of
bearing (123) with plastic hammer using steel bar.
Be careful not to strike shaft (111) with plastic hammer.
• Fit shaft taking care not to damage oil seal (774)
Fig. 1-17 Installing shaft (111)
4) Assembling pivot ball (215), (216)

215
Fit pivot ball (215) on right side and pivot ball (216)
on left side directing top cover installing surface of 216
casing (271) upward.
• Diameter of pivot ball (215) is smaller, and 271
equipped with O-ring (710) and backup ring
(787).
Fig. 1-18 Assembling pivot ball (215), (216)
5) Installing swash plate (212)

Fit tilt bushing (214) to tilt pin (531) top end and
install the swash plate (212) on casing (271).
212
• Before installing swash plate (212), apply 214
grease on the surface where pivot balls (215),
(216) side.
271
Fig. 1-19 Installing swash plate (212)
655
6) Installing pin (655)
271
Fit pin (655) on casing (271) and attach plug (468)
with O-ring (706).
: 6 mm
31102 60413252
Fig. 1-20 Installing pin (655)
33-47
UPPER SWING BODY
7) Assembling compensation piston (621)

Install compensation piston (621) on casing (271).
621
271
Fig. 1-21 Assembling compensation piston (621)
8) Assembling sleeve (651) and spool (652)

Install sleeve (651) and spool (652) on casing
271
(271). 651 (652)
Fig. 1-22 Assembling sleeve (651) and apool (652)

9) Installing feed back lever (611) and cover (273)
Install feed back lever (611) to tilt pin (531), install 611
cover (273) aligning with pin and tighten socket
bolt (404).
: 5 mm
271
Fig. 1-23 Installing feed back lever (611) and cover (273)
10) Installing spring cover (641)
Install spring (625), spring (626) and spring seat
(624), and install spring cover (641) on casing
271
(271) with socket bolt (404).
641 (624,625,626)
: 5 mm
31102 60413252
Fig. 1-24 Installing spring cover (641)
33-48
UPPER SWING BODY
11) Installing piston cylinder sub assy

271
Assemble cylinder assy [cylinder block (141),
piston (151), shoe (152) plate (153), spherical
151,152
bushing (156) and spring (157),] and install it on
casing (271) meeting the spline phases of spherical
bushing (156) and cylinder block (141).
153 141
(156,157)
Fig. 1-25 Installing piston cylinder sub assy
12) Installing needle bearing (124) and relief valve
When needle bearing (124) and relief valve have
been removed, attach those parts on valve cover
(312) first.
13) Installing check valve sub and orifice thread (508)

When check valve sub assy [seat (541), stopper
(543), ball (545)] and two orifice threads (508)
have removed, attach those parts on casing (271)
and valve cover (312) first.
14) Installing valve cover (312)

Install valve equipped with valve plate (313) on
401
casing (271) and tighten socket bolt (401). 271
: 14 mm
• Then, apply grease on installing surface of
valve cover (312) and valve plate (313) to
protect it from slipping out.
312
(313)
Fig. 1-26 Installing valve cover (312)
15) Installing gear pump

Set coupling (114) from rear side of pump to the
inside, install gear pump, and tighten flange socket
bolt (402).
: 6 mm
31102 60413252
402
Fig. 1-27 Installing gear pump
33-49
UPPER SWING BODY
1.3 MAINTENANCE STANDARD

(1) Replacement standards for parts
RECCOMENDED
PART NAME AND INSPECTION ITEM STANDARD VALUE FOR REMEDY
DIMENSION REPLACEMENT
Clearance between
piston (151) and 0.036 0.056
d D Replace piston or cylinder.
cylinder (141) bore (0.0014˝) (0.0022˝)
(D-d)
Gap between piston

0~0.1 0.3
(151) and caulked Replace piston shoe assy.
(0.004˝) (0.012˝)
part of shoe (152) ( )
Thickness of shoe 3.9 3.7

t Replace piston shoe assy.
(152) (t) (0.154˝) (0.146˝)
Free height of spring 31.0 29.9

Replace spring.
(157) (L) (1.22˝) (1.14˝)
L
Combined height of
plate (153) and 19.0 18.3 Replace or spherical
H
spherical bushing h (0.748˝) (0.720˝) bushing and plate.
(156) (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
Cylincer (sliding section) Roughness Standard surface roughness
Less than 0.4Z (lapping)
of each surface (correction value)
F17435
31102 60413252
33-50
UPPER SWING BODY
2. CONTROL VALVE
For part names and marks used in this explanation, (2) Tools (excluding general tools.)
refer to section "Construction of Control valve" Prepare the following tools before disassembling
explained in chapter "Equipment System" in attached the control valve.
sheet. Table 2-1
2.1 PREPARATION FOR CONSTRUCTION No. TOOL NAME Q'TY REMARKS
(1) General precautions a Vise 1
The disassembling and assembling should be b Mouth plate 2 For vise (Copper plate)
performed in shop as a rule. If it is unavoidably c 1 of each
size 4, 5, 8, 10, 12 mm
necessary to disassemble, it must be carried out
d 1 of each 19, 21, 22, 30 mm
by authorized personnel following the precautions
described below. e 1 of each 13,19, 21, 22, 30 mm
1) Place f Tweezers 1
The hydraulic equipment is machined in precision, g Magnet 1
and space in each section is very narrow. So h Torque For 0~7 kgf·m
wrench 1 (0~51 lbf·ft)
select clean place and be careful so that dust,
Wash oil, hydraulic
sand, etc. are not entered inside when Proper
i Others oil,grease, tag, oil
disassembling and assembling. Q'ty
marking ink, etc.
2) Preliminary investigation F17460
Before disassembling, understand the construction (3) Placing on work bench

and operation of control valve thoroughly. Place it on work bench directing swing priority
3) Cleaning section upward.
Cap each port of the control valve before removing Swing priority section
the valve from the machine. Before disassembly,
confirm that each cap is in place ad then clean the
exterior of the control valve assy. X X
Use an appropriate workbench. Lay a clean sheet Z
Y Y
of paper, rubber mat, or the like over the workbench.
4) Rust prevention and sealing
After disassembling, apply rust preventives on all Work bench
parts or seal to protect them from rusting. Top of machine
TRAVEL
5) Transportation STRAIGHT A A
SPOOL
In case control valve is required to carry or TRAVEL (L) B B
SPOOL
transport, it is prohibited to support control valve SWING C C
SPOOL
by applying support to pilot cover section, relief ARM D D
SPOOL
valve and overload relief valve. E
6) Handling BOOM CONFLUX P2 BY-PASS
Even if movement of control valve parts is not SPOOL CUT SPOOL
SECTION XX (Back of machine)
smooth, never strike it or handle forcibly.
7) Hydraulic testing device
After completion of assembly, various tests (relief Top of machine
characteristic, leak test, overload pressure setting,
TRAVEL (R) B B
performance test, etc.) are required. Hydraulic SPOOL
BOOM C C
testing device is therefore required. But it is not
31102 60413252
SPOOL
BUCKET D D
allowed to disassemble equipment which can be SPOOL
disassembled mechanically, but can not be P1 BY-PASS E E
CUT SPOOL
adjusted through test.
SECTION YY (Front of machine)
Fig. 2-1 Placing on work bench and cross-section
33-51
UPPER SWING BODY
2.2 DISASSEMBLY SWING PRIORITY SECTION PILOT COVER D (16) FOR ARM
TRAVEL (L)
(1) Pulling out travel straight spool (7), travel right and BOOM SPOOL (8)
CONFLUX SWING TRAVEL
left spool (8), swing spool (9) and bucket spool SPOOL (13) SPOOL (9) STRAIGHT
(12) (spool without lock valve) (see Fig. 2-2, 2-3). SPOOL (7)
1) Remove two socket bolts (47) of each spool, then P2 BY-PASS
CUT SPOOL
washer (49) and pilot cover C (18) (see Fig. 2-3) (14) (REVERSE
: 5 mm SIDE)
WARNING
Then, special care must be taken that O-ring (52) of
pilot cover C (18) does not slip out.
2) Hold each spool with spring (26) section, pull it out

slowly in parallel to spool hole, and remove spool P1 BY-PASS PILOT COVER D
assy from body (1). CUT SPOOL (15) (16) FOR BOOM TRAVEL (R)
BUCKET SPOOL (12) SPOOL (8)
• Don't disassemble spool assy. If it is damaged,
VIEW Z of Fig. 2-1
replace it.
• When two types of spool have been removed, Fig. 2-2 Position of spool without lock valve
attach tag and record the position before
disassembling.
(2) Pulling out P2 by-pass cut spool (14), P1 by-pass

TRAVEL SPOOL RIGHT (8) O-RING (52) SOCKET BOLT (47)
cut spool (15) and boom conflux spool (13) (spool
TRAVEL SPOOL LEFT (8) SPRING (26)
without lock valve) (see Fig. 2-2, 2-4).
1) Remove two socket bolts (47) of each spool, then
washer (49) and pilot cover C (18) (see Fig. 2-4).
: 5 mm
WARNING PILOT
Then, special care must be taken that O-ring (52) of COVER C (18)
pilot cover C (18) does not slip out.
Fig. 2-3 Pulling out travel right and left spool (section BB)
2) Hold each spool with spring (26) section, pull it out
slowly in parallel to spool hole, and remove spool
assy from body (1).
3) Pull out boom conflux spool (13) in the reverse P2 BY-PASS
direction. CUT SPOOL (14)
BOOM CONFIUX O-RING (52)
SPOOL (13)
SOCKET
WARNING BOLT (47)
• Don't disassemble spool assy. If it is damaged, PILOT
replace it. COVER C (18)
• When two types of spool have been removed, attach
tag and record the position before disassembling.
31102 60413252
P1 BY-PASS CUT SPOOL (15)

Fig. 2-4 Pulling out P2 by-pass cut spool, P1 by-pass cut
spool and boom conflux spool (section EE)
33-52
UPPER SWING BODY
(3) Pulling out boom spool (10) BOOM SPOOL (10) SPRING (26)
(spool with lock valve) (see Fig. 2-5). PILOT COVER D (16)
1) Remove three (3) socket bolts (48). PISTON A (34)

: 5 mm
2) Remove pilot cover D (16). Since pilot cover D is
equipped with piston guide (33), piston A (34), SOCKET BOLT (48)
piton C (36), and lock valve spring A (35), remove
O-RING
as equipped-pilot cover D. (52)
O-RING PISTON C (36)
WARNING (59)
POPPET PISTON
• Special care must be taken that O-rings (52), (53), (29) O-RING GUIDE (33) LOCK VALVE
(59) on bottom of pilot cover D (16) and poppet (29) (53) SPRING A (35)
do not slip out.
Fig. 2-5 Example of pulling out boom spool (section CC)
• Take care not to damage piston guide (33) protruded
from the bottom of pilot cover D (16).
3) Spring section (26) of each spool is disposed, so

hold spool with the spring (26) section, pull it out
slowly in parallel to spool hole, and remove spool
assy from body (1).
WARNING
• Don't fail to pull spool assy out from spring side.
• If spool assy is damaged, don't disassemble it.
Replace it.
ARM SPOOL (11)

(4) Pulling out arm spool (11) (see Fig. 2-6).
Same procedure as boom spool (10). PILOT COVER D (16)
1) Remove three (3) socket bolts (48).
: 5 mm
2) Remove pilot cover D (16). Since pilot cover D is
equipped with piston guide (33), piston A (34),
piston C (36), and lock valve spring A (35), remove
as equipped-pilot cover D.
Fig. 2-6 Pulling out arm spool

31102 60413252
33-53
UPPER SWING BODY
(5) Disassembling lock valve pilot cover D (16) PILOT COVER D (16)
PISTON C (36)
(see Fig. 2-7).
O-RING (58)
1) Remove pilot cover D (16).
WARNING
Keep poppet (29) carefully because it is slipped out
easily. LOCK VALVE (28) PISTON A (34)
RESTRICTOR (30),
PISTON GUIDE (33) PLUG (20)
2) Hold pilot cover D (16) with vise, and remove plug
(20).
( SPRING B (31),
)
SPRING HOLDER (32) POPPET (29)
RETAINER RING (51)
SPRING A (35)
: 8 mm
Fig. 2-7 Disassembling lock valve pilot cover D (16)
WARNING
• Don't hold on port surface with vise.
• Take care not to damage piston guide (33) projected
from the bottom of pilot cover D (16).
3) Take out piston C (36), spring A (35) and piston A

(34) with pin set or magnet through the plug hole
where it has been removed.
WARNING
• Record the direction Piston C (36) has been installed.
• Don't disassemble piston guide C (33). If it is
damaged, replace a set of pilot cover D (16).
4) Take out a set of lock valve (28), restrictor (30),

spring B (31) spring holder (32) and retainer ring
(51) from control valve body with magnet.
WARNING
Don't disassemble lock valve (28). If it is damaged,
replace a set of lock valve body.
(6) Disassembling shuttle valve (See Fig. 2-8)

1) Remove two places socket bolts (47).
: 5 mm
2) Remove pilot cover E (17). SHUTTLE VALVE STEEL SHUTTLE VALVE
SOCKET (37) BALL (46) SEAL (38) O-RING (52)
WARNING
Then, special care must be taken that O-ring (52) of
pilot cover E (17) does not slip out.
3) Fix pilot cover E (17) in a vise and remove shuttle

valve socket (37).
: 21 mm
SOCKET BOLT (47)
WARNING
• When pilot cover E (17) is required to be held, don't PILOT COVER E (17)
31102 60413252
hold on port surface with vise.

• Don't disassemble shuttle valve socket (37). If it is
damaged, replace a set of shuttle valve socket (37),
shuttle valve seat (38) and steel ball (46).
Fig. 2-8 Disassembling shuttle valve
33-54
UPPER SWING BODY
(7) Disassembling swing priority section (see Fig. 2-

SOCKET BOLT (74)
9.)
1) Remove two places socket bolts (74). PILOT
O-RING (71) COVER (66)
: 5 mm PILOT BODY (68)
2) Remove pilot cover F (66), spring (70), piston D PISTON GUIDE (69)
(67) and pilot body (68).
STOPPER PIN (65)
WARNING PISTON
SPRING (22) D (67)
Then, special care must be taken that O-ring (71) and
piston D (67) of pilot caver F (66) does not slip out.
LOAD CHECK
VALVE (49)
3) Take out stopper pin (65) with tweezers or magnet.
4) Removing pin guide (69).
: 13 mm
SPRING (70)
5) Take out load check valve (49) and spring (22)
with tweezers or magnet. O-RING (72)
O-RING (58)
(8) Disassembling load check valve (21) (see Fig. 2-
10)
Fig. 2-9 Disassembling swing priority section
1) Hold control valve body and remove 10 plugs (20).
: 8 mm
2) Take out load check valve (21) and spring (22) O-RING (58)
with tweezers or magnet.
PLUG (20)
LOAD CHECK
WARNING VALVE (21) SPRING (22)
For load check valve (21) of arm switching section,
disassemble swing priority section first. [Refer to (7)
Disassembling swing priority section]
LOAD CHECK SPRING (22)

VALVE (21) PLUG (20)
Fig. 2-10 Removing load check valve

(Example of section BB)
31102 60413252
33-55
UPPER SWING BODY
(9) Remove main relief valve (60) and over load relief
valve (61)
1) Hold control valve body and remove a main relief
valve (60) (see Fig. 2-11).
Opposing flats 30
: 30 mm
2) Remove six places over load relief valves (61).
(see Fig. 2-12).
: 22 mm MAIN RELIEF
VALVE (60)
Fig. 2-11 Removing main relief valve (section AA)
WARNING
• Remove main relief valve (60) and overload relief
valve (61) taking care not to apply tools on hexagonal
section in opposing flats 19 mm. Opposing flats 22
• Attach tag on removed overload relief valve (61), and
record the position before disassembling.
• Handle the removed main relief valve and overload
relief valve taking care not to damage on the seat. OVER LOAD
• Main relief valve and overload relief valve are very RELIEF VALVE
(61)
essential for safety operation, and also readjustment
of pressure is very difficult, so don't disassemble
them. If damaged, replace the assy.
OVER LOAD RELIEF
VALVE (61)
(10) Remove end cover (see Fig. 2-13). Fig. 2-12 Removing over load relief valve
1) Hold control valve body (1) directing the end cover (Example of section CC)
(5) upward, and mark between end cover (5) and
body (1) with marking ink.
2) Remove four socket bolts (6).
: 10 mm
3) Remove end cover (5). Mark on the O-RING (3) SOCKET BOLT (6)
• Remove end cover taking care so that O-rings surface
END COVER (5)
(2), (3) on mating surface are not slipped out.
• Handle it taking care not to cause damage, O-RING (2)
such as flaws and dents, on mating surface. O-RING (3)
(11) Removing other parts

In addition, remove pilot cover B1 (19), plugs (41),
(43), (45), (50), (62), (64) and (73), backup ring
(75), etc. as required.
BODY (1)
31102 60413252
Fig. 2-13 Removing end cover
33-56
UPPER SWING BODY
2.3 ASSEMBLY (3) Assembling Main relief valve and over load relief
Here, only the assembly procedures are described. valve (see Fig. 2-11, 2-12).
Regarding drawings, refer to the disassembly 1) Hold body (1), and tighten main relief valve (60) to
procedures. the specified torque.
(1) Precautions on installing : 30 mm
1) Cleaning the parts Tightening torque: 6.0~7.0 kgf·m (43~51 lbf·ft)
Before using parts for assembly, clean all of them 2) Tighten six over load relief valve (61) to the
with clean cleaning oil. specified torque.
2) O-ring, seals : 22 mm
1. Confirm that O-ring and seals are free of forming Tightening torque: 4.0~5.0 kgf·m (29~36 lbf·ft)
defects or defects caused by poor handling.
2. Lubricate O-ring, seals and sealing surfaces WARNING
• Install over load relief valve (61) to the original
with sufficient grease or hydraulic oil.
position with reference to the tag attached when
3. Fit O-ring taking care not to make a distortion. disassembling.
If it is distorted, it may cause oil leakage. • Install main relief valve (60) and overload relief valve
3) Handling (61) taking care not to apply tools on hexagonal
Even if sliding parts and engaging parts are not section in opposing flats 19 mm.
operated smoothly, never strike them and handle
forcibly.
(4) Assembling ten load check valves (see Fig. 2-10).
4) Preliminary preparation
1) Hold body (1) to the position where every load
Before assembling, prepare structural drawing
check valve (21) can be inserted, and install load
and check number of parts to avoid mistakes and
check valve (21) and spring (22).
missing of parts.
2) Fit O-ring (58) on plug (20) and tighten it to the
5) Tightening torque
specified torque.
Tighten socket bolts and screws in each section to
: 8 mm
the specified torque with torque wrench.
Tightening torque: 4.0~5.0 kgf·m (29~36 lbf·ft)
(2) Assembling end cover (see Fig. 2-13).

1) Hold body (1) directing mating surface upward,
and fit O-rings (2), (3).
WARNING
• Check that mating surface is free from dust and O-
ring is securely fitted on the groove.
• Don't apply hydraulic oil or grease on O-rings (2), (3)
fitted on mating surface.
2) Install end cover (5) meeting positions marked

when disassembling.
3) Tighten four socket bolts (6) to the specified
torque.
: 10 mm
Tightening torque: 6.8~7.0 kgf·m (49~51 lbf·ft)
WARNING
31102 60413252
• Don't tighten four socket bolts (6) at a time, but

tighten them evenly in order by separating in several
times.
• Check that body (1) and end cover (5) are fitted
rightly.
33-57
UPPER SWING BODY
(5) Assembling swing priority section (see Fig. 2-9). Tightening torque: 4.0~5.0 kgf·m
1) Hold body (1) directing swing priority section (29~36 lbf·ft)
upward, an install load check valve (49) and 3) Hold body (1) on side face other than port surface
spring (22). with vise directing lock valve (28) upward, and
2) Tighten pin guide (69) on which O-rings (58), (72) insert a set of lock valve (28) and needle valve
are installed to the specified torque. [poppet (29)] into body (1).
: 13 mm
Tightening torque: 3.0~3.5 kgf·m (22~25 lbf·ft) (8) Assembling boom spool and arm spool
3) Insert stopper pin (65) into piston guide (69). (spool with lock valve) (see Fig.2-5, 2-6).
4) Insert pilot body (68) on piston guide (69) and fit O- 1) Hold body (1) on side face other than port surface
ring (71) to the groove. with vise in the condition where spool assy can be
Insert pilot body (68) into piston guide (69) taking installed through upper side, and insert boom
care not to damage O-ring (72). spool assy and arm spool assy into body (1)
5) Install piston (67) and spring (70) on pilot cover F paying attention to the directions.
(66), and tighten two socket bolts (74) together When it is hard to insert spools into body, insert it
with washers (49) to the specified torque. getting in and out slowly.
: 5 mm 2) Install pilot cover D (16) on body (1) slowly mee-
Tightening torque: 1.0~1.1 kgf·m (7.2~8.0 lbf·ft) ting piston guide (33) protruded from the bottom
Check that the O-ring is securely fitted on the with needle valve [poppet (29)].
groove. Then, check that O-rings (52), (53), (59) are
(6) Assembling shuttle valve (see Fig. 2-8). securely fitted on the groove.
1) Hold pilot cover E (17) on the side face other than 3) Tighten three socket bolts (48) together with
the port surface with vise, tighten shuttle valve washer (49) to the specified torque.
socket (37) on which O-rings (55), (57) are fitted : 5 mm
to the specified torque. Tightening torque: 1.0~1.1 kgf·m (7.2~8.0 lbf·ft)
: 21 mm
Tightening torque: 4.0~5.0 kgf·m (29~36 lbf·ft) (9) Assembling P2 by-pass cut spool, P1 by-pass cut
Then, Tighten it slowly taking care not to damage spool and boom conflux spool
O-rings (55), (57) of shuttle valve socket (37). (spool without lock valve) (see Fig. 2-4).
2) Fit O-ring (52) on faucet joint, install pilot cover E 1) Insert every spool assy into body (1) taking care
(17) on which shuttle valve socket (37) is installed the directions.
on the faucet joint of body (1). When it is hard to insert spools into body, insert it
Check that the O-ring is securely fitted on the getting in and out slowly.
faucet joint. 2) Fit pilot cover C (18) on faucet joint of body (1).
3) Tighten two socket bolts (47) together with washer Then, check that O-ring (52) is securely fitted to
(49) to the specified torque. the faucet joint.
: 5 mm 3) Tighten two socket bolts (47) together with washer
Tightening torque: 1.0~1.1 kgf·m (7.2~8.0 lbf·ft) (49) to the specified torque.
(7) Assembling lock valve pilot caver D (see Fig. 2-7). : 5 mm
1) Hold pilot cover D (16) on the side face other than Tightening torque: 1.0~1.1 kgf·m (7.2~8.0 lbf·ft)
the port surface with vise, insert piston A (34),
spring A (35) and piston C (36).
• Place the groove side face of piston C (36) into
the piston A (34).
31102 60413252
• Care should be taken not to damage piston

guide (33) protruded from pilot cover D (16).
2) Tighten plug (20) on which O-ring (58) are installed
to the specified torque.
: 8 mm
33-58
UPPER SWING BODY
(10) Assembling travel straight spool, travel R/L spool,

swing spool, and bucket spool
(spool without lock valve) (see Fig. 2-3).
1) Insert every spool assy into body (1) taking care
the directions.
When it is hard to insert spools into body, insert it
getting in and out slowly.
2) Fit pilot cover C (18) on faucet joint of body (1).
Then, check that O-ring (52) is securely fitted to
the faucet joint.
3) Tighten two places socket bolts (47) together with
washer (49) to the specified torque.
: 5 mm
Tightening torque: 1.0~1.1 kgf·m (7.2~8.0 lbf·ft)
(11) Installation of other parts

In addition, install all the removed parts such as
pilot cover B1 (19), plugs (41), (43), (45), (50),
(62), (64) and (73), backup ring (75), etc.
31102 60413252
33-59
UPPER SWING BODY
INSPECTION OF COMPONENTS
PART NAME INSPECTION ITEM CRITERION AND REMEDY

Body 1) Check scratches, rusting, corrosion. 1) If any of the following parts are damaged,
replace the component as a unit.
• Sliding part of spool, particularly the
land, to which holding pressure is
applied.
• Part of seal pocket or flange through
which spool is inserted.
• Area of sealing part that is in contact
with O-ring.
• Seat of main relief valve, overload relief
valve and lock valve.
• Defects of other parts that seem to harm
normal function.
Spool 1) Check scratches, galling rusting, 1) Replace if there are scratches (which
corrosion. can be caught by your nail) on the outer
surface.
2) Insert the spool in the body, and 2) If the spool does not move smoothly,
move it while turning it. repair or replace the spool.
Load check valve 1) Damage to the load check valve or 1) Correct or replace if the seat is
the load check valve spring incomplete.
Spring and related 1) Check rust, corrosion, deformation, 1) If damaged severely, replace.
parts and breakage of the spring, spring
seat, plug and cover.
Spool seal and 1) Check external oil leakage. 1) Replace.

related parts
Main relief valve 1) Check rust and damage on outer 1) Replace.
Over load relief surface.
valve 2) Inspect the contact face of the valve 2) If damaged, replace.
seat.
F17461 31102 60413252
33-60
UPPER SWING BODY
2.5 TROUBLESHOOTING
1) When you find a malfunction or a fault, inspect whether or not it comes from the control valve, pump, motor
or hydraulic circuits. For this purpose it is necessary to measure pilot pressure, pump discharge pressure and
load pressure. If any part of the control valve is removed and inspected, do it according to the above mentioned
removing and installing procedures.
2) Dust is extremely harmful to hydraulic components.
Use care so as not to allow dust from intruding inside. Take dustproofing measures in case any part of the
control valve is to be removed.
3) Handle the moving part prudently. If a flaw is detected, even a small flaw, remove it with oilstone, or replace
it with new one. After repair, clean it.
4) Handle surfaces of O-rings so as not to score them as scoring will result in oil leakage.
TROUBLE CAUSE REMEDY

1. ATT does not 1) Malfunctioning relief valve 1) Measure relief valve pressure
move. • Foreign matter between plunger • Replace assy.
Slow to start up and seat.
(or poor power). • Foreign matter between poppet • Replace assy.
Slow response. and seat.
* •
Sticking plunger.
* • Replace assy.
• Broken or deformed spring. • Replace assy.
• Clogged piston orifice. • Replace assy.
• Loosened adjusting screw. • Replace it and tighten lock nut to the
specified torque.
2)Foreign matter caught between body • Disassemble and clean. If the flaw is
and spool or sticking. severe, replace body and spool with
new ones.
2. Excessive 1) Excessive clearance between control 1) Replace spool.

natural fall of body and spool.
cylinder under 2) Spool is not completely in neutral 2) Measure secondary pilot pressure.
its own weight position.
when spool is in • Foreign matter between body and • Remove and clean. If it is stuck,
neutral. spool, or sticking spool. replace both the control body and the
spool as a pair.
• Broken or deformed spring. • Replace spring.
3) Malfunctioning over load relief valve. 3) Measure over load relief valve
Refer to item above. pressure. Refer to item above.
* *
3. When extending 1) Malfunctioning load check valve. 1)
boom cylinder, at •
Foreign matter caught between • Disassemble and clean. If the flaw is
first it retracts. load check valve and body. severe, replace body and load check
valve with new ones.
• Sticking load check valve. • Disassemble and clean. If the flaw is
severe, replace body and load check
valve with new ones.
• Broken or deformed spring. • Replace spring.
If such faults as those marked should occur, always replace the relief valve assy. F17462
*
31102 60413252
33-61
UPPER SWING BODY
3. PILOT VALVE (ATTACHMENT)
3.1 CONSTRUCTION
Rotating sliding part, 312

apply grease. 301
302 501
212 Apply grease to top
213 151
211
218-2 246
214
218-1
216-2 216-1
241-2 241-1
221-2 221-1
Secondary pressure
217 adjusting shim
201-2 201-1
131 101
126 122
111
121 Not to be reused
F17478
PORT 2, 4 PORT 1, 3 125
Fig. 3-1 Pilot valve (Attachment)
Unit: kgf·m (lbf·ft)

No. THREAD SIZE TIGHTENING TORQUE
125 M8 2.1 (15.2)
301 M14 4.8 (34.7)
302,312 M14 7 (50.6)
F17479
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

101 CASING 1 211 PLUG 4 221-2 SPRING 2
111 PORT PLATE 1 212 PUSH ROD 4 241-1 SPRING 2
121 SEAL WASHER 2 213 SEAL 4 241-2 SPRING 2
122 O-RING 1 214 O-RING ; 1B P20 4 246 SPRING 4
125 SOCKET BOLT 2 216-1 SPRING SEAT 2 301 JOINT ; M14 1
31102 60413252
126 SPRING PIN ø 5 X 10 1 216-2 SPRING SEAT 2 302 DISK 1

131 BUSHING 1 217 WASHER 2 4 312 ADJUSTING NUT ; M14 1
151 PLATE 1 218-1 SPRING SEAT 2 2 501 BELLOWS (BOOTS) 1
201-1 SPOOL 2 218-2 SPRING SEAT 2 2
201-2 SPOOL 2 221-1 SPRING 2
F17480
33-62
UPPER SWING BODY
3.2 DISASSEMBLY AND ASSEMBLY

(1) Tools
No. TOOL NAME REMARKS

1.5~10 kgf·m class
a Torque wrench HANDLE LEVER
(10~75 lbf·ft)
W= 2~3mm, 4~5mm
b Screw driver ( )
(0.08~0.12in, 0.16~0.20in)
c Screw driver ( )
Spanner and Allen BELLOWS
d General tools (BOOTS)
wrench
F17481
LEAD WIRE
(2) Caution for disassembly and assembly
1) Exercise sufficient care to prevent entry of dust
when disassembling and assembling components.
2) Handle the parts with sufficient care, preventing
defect. Fig. 3-2 Disassembling handle lever
3) The spools, spring seats and springs used in ports
1, 3 and ports 2, 4 of this pilot valve differ slightly
in dimensions. Before removing those parts, re-
cord the locations so they are installed in correct
positions. 312
(3) Disassembly 301
1) Remove the handle lever assy, boots and lead
wires from valve body (101) (see Fig. 3-2). 302 501
2) Fix the pilot valve with a vise, placing copper 212
213 151
plates (or lead plates).
211
3) Place a wrench in the opposing flats of the disk 218-2 246
(302) and turn counterclockwise till joint (301)gets 214
loosened.
218-1
: 22 mm 216-2 216-1
4) Remove the operating part of the handle (301,
302, 312) from the valve body (101). 241-2 241-1
221-2 221-1
5) Remove plate (151)
217
6) Remove plug (211) with push rod (212) from valve 201-2 201-1
body (101) so as not to exert uneven load upon it,
utilizing the groove in the outer circumference of 131 101
plug (211) and using a screw driver (b). 126 122
111
WARNING 121
F17482
Take care that the plug (211) may jump out by spring PORT 2, 4 PORT1, 3 125
force of the springs (221-1, 221-2, 241-1, 241-2) while
the plug is pulling out. Fig. 3-3 Disassembling pilot valve
7) Remove push rods (212-1, 212-2) and spring

31102 60413252
seats (216-1, 216-2). 10) Loosen socket bolt (125), using an allen wrench
8) Record the related location of the holes in the and remove port plate (111) from valve body
spool assy and valve body (101). Remove the (101).
spool assy from valve body (101). : 6 mm
9) Take off springs (221-1, 221-2). 11) Remove bushing (131) from casing (101).
33-63
UPPER SWING BODY
12) Disassemble the spool (201-1, 201-2), spring

seat (216-1, 216-2), spring (241-1, 242-2) and 216-1, 216-2
washer 2 (217).
• These parts to be treated as assy until
assembling. 241-1, 241-2
13) Remove spring for 2nd stage (246) and spring
217
seat (218-1, 218-2) from push rod (212).
14) Remove push rod (212) from plug (211). 201-1, 201-2
15) Remove O-ring (214) and seal (213) from plug
(211)
16) Loosen disk (302), adjusting nut (312) and lock
nut on the handle operating parts, using spanner,
and disassemble joint (301).
: 22 mm Fig. 3-4 Spool assy
(4) Assembling
1) Before assembling, wash parts with cleaning
solvent and dry them with compressed air, avoid
312
using cloth if possible. 301
• Before assembling correct all defects made
during disassembling, clean parts, coat moving 302 501
parts with oil and refit parts back in original
212
place. 213 151
2) Replace O-rings with new ones. 211
218-2 246
Replace seal washers (121) with new ones, also.
214
3) Fit bushing (131)and O-rings (122) into valve
body (101). 218-1
216-2 216-1
4) Install port plate (111) to valve body (101).
In that case, beware of the mounting position so 241-2 241-1
that spring pin (126) can be set in the hole of valve 221-2 221-1
body (101) side. 217
201-2 201-1
5) Tighten slowly, with specified torque, two socket
bolts (125) with seal washers (121). 131 101
: 6 mm 126 122
T=2.1 ± 0.15 kgf·m (15.2 ± 1.1 lbf·ft) 111
121
F17482
PORT 2, 4 PORT1, 3 125
Fig. 3-5 Assembling

31102 60413252
33-64
UPPER SWING BODY
6) Install washer (217), spring (241-1, 241-2) and 211

spring seat (216-1, 216-2) into spool (201-1, 201-
2) in that order (see Fig. 3-4).
7) Assemble spring (221-1, 221-2) into valve body 213
(101) so it was located before removal. APPLY HYDRAULIC OIL
8) Install the reducing valve assy into valve body
(101).
212
9) Assemble seal (213) in plug (211) so its lip faces
as Fig. 3-6.
10) Install spring for 2nd stage (246) and spring seat Fig. 3-6 Inserting push rod
(218-1, 218-2) into push rod (212).
11) Insert the push rod (212) with seat spring (216-1,
216-2) into plug (211).Coat the surface of push
rod (212) with hydraulic oil. (See Fig. 3-6)
12) Assemble O-ring (214) to plug (211).
13) Assemble the plug assy into valve body (101).
(It stops because of the sliding resistance of the O-
ring).
14) Attach plate (151) to valve body (101).
15) Fasten joint (301) to valve body (101) with specified
torque.
: 22 mm
T=4.8 ± 0.3 kgf·m (35 ± 2 lbf·ft)
16) Install disk (302) to joint (301), and fasten adjusing
nut (312) in a position where the disk contacts the
tip of four push rods (212), to specified torque.
: 22 mm
T=7 ± 0.5 kgf·m (51 ± 4 lbf·ft)
17) Pass a lead wire through the hole of the valve
body, and through the side hole in the adjusting
nut located between 60° and 120°, and pull it out.
18) Assemble grommet (457) into plate (151) and
pass lead wire through it. Slacken the lead wire to
an extent that is required for moving when operation
is performed.
19) Apply heat resistant grease over the contact
surface of the joint rotating part, the plate and the
push rod.
20) Install the handle lever assy and the boots (bellows)
to valve body (101).
31102 60413252
33-65
UPPER SWING BODY

(1) Parts replacement standards
1) Replace O-ring and other seals at each
disassembly and assembly.
2) Replace worn parts if leaks affects the operating
system.
3) Replace spools having excessive wear on their
sliding portion. Fig. 3-7 Wear of push rod
4) Replace a push rod that is worn to 1mm (0.04in)
or over on its top end (see Fig. 3-7).
5) Replace operating lever and handle pins that
have a play of 2mm (0.08 in) or over.
6) Replace such parts that arise abnormal sounds,
hunting and drops in the primary pressure.
3.4 TROUBLESHOOTING
TROUBLE POSIBLE CAUSE REMEDY

Secondary pressure 1) Primary pressure is insufficient. 1) Secure primary pressure.
does not rise. 2) Springs (241-1, 241-2) are broken or 2) Replace with new ones.
fatigued.
3) Clearance between spool (201-1, 201-2) 3) Replace assembly.
and valve body (101) is abnormally large. 4) Disassembly and reassembly or
4) Play of handle portion is too much. replace handle portion.
Secondary pressure is 1) Sliding parts are caught. 1) Correct.
unstable. 2) Tank line pressure varies. 2) Return directly to oil tank.
3) Air has contained into pipeline. 3) Release air.
Secondary pressure is 1) Tank line pressure is high. 1) Return directly to oil tank.
high. 2) Sliding parts are caught. 2) Correct.
F17483 31102 60413252
33-66
UPPER SWING BODY
4. PILOT VALVE (TRAVEL)
4.1 CONSTRUCTION
APPLY GREASE
TO BEARING
APPLY GREASE
TO TOP
APPLY GREASE
TO TOP
SECTION CC
Fig. 4-1 Pilot valve (travel)
TORQUE TORQUE
kgf·m (lbf·ft) No. NAME Q'TY kgf·m (lbf·ft) No. NAME Q'TY
101 CASING 1 3.0 (22) 251 RO PLUG 3

102 CASING (DAMPER) 1 0.7 (5.1) 252 PLUG 6
191 SEAT 1 2 253 RO PLUG 2
192 SEAT 2 2 261 O-RING 3
193 BUSHING 2 2 263 O-RING 2
194 STEEL BALL 2 9.0 (65) 271 SOCKET BOLT 4
201 COVER 2 301 SPOOL 4
202 PLUG 4 311 SPRING SEAT 4
203 GREASE CUP 4 313 WASHER 4
210 PACKING 4 324 SPRING 4
31102 60413252
213 O-RING 2 413 CAM SHAFT 2

214 PUSH ROD 4 414 BUSHING 4
217 SHIM 4 420 CAM 2
218 SPRING SEAT 4 471 STEEL BALL 4
224 PISTON 4 0.7 (5.1) 472 SET SCREW 2
225 STEEL BALL 12 501 BELLOWS (BOOTS) 2
F17488
33-67
UPPER SWING BODY
4.2 DISASSEMBLY AND ASSEMBLY CENTERING HOLE IS ALLOWABLE

(SMALLER THAN Ø2 mm)
-0.0157˝ )
(Ø0.3937˝ -0.0118˝
(1) Special jig for disassembly and assembly
-0.0118˝)
(Ø0.315˝ -0.008˝
Special jig 1(for removal of bushing)
Ø10 -0.3
-0.4
(2) Precautions for disassembly and assembly
Ø8 -0.2
-0.3
1) Disassemble and assemble the pilot valve paying
attention to the rust protection fordust, dirt, etc. in
order not to allow them to enter in.
30°
2) Handle parts carefully not to damage
3) Write down the installing positions of respective
(0.787˝)
part during disassembly, and assemble respective 20 2 (0.008˝)
part to the position as they were before.
30
(1.181˝) F17489
(3) Disassembly
Fig. 4-2 Special jig 1
1) Stop respective port (P, T, 1, 2, 3, 4, 5 and 6) of the
valve with plugs and clean the outer surface.
2) Fix the cleaned valve with vise.
3) Remove bellows (501) from cover (201).
4) Remove set screw (472).
: 6 mm
5) Contact pry bar (ø7 or less) to one end of cam
shaft (413), and strike it slightly with a hammer.
6) Remove cam (420).
7) Remove socket bolt (271).
: 6 mm
8) Remove cover (201).
9) Remove the casing upper assy, and fix the assy
with vise, again.
10) Draw push rod (214) out of plug (202).
11) Remove plug (202) with grease cup (203), packing
(210) and O-ring (212).
12) Remove piston (224).
13) Remove damping spring (336) from the casing.
14) Take out spring seat (218) from casing (102) with F17490
pincette. Fig. 4-3

15) Take out steel ball (225) using magnet.
16) Fix the lower casing assy with vise, and take out
O-rings (211,213) from casing (101).
17) Remove reduction unit valve assy and return
spring (335) from casing (101).
18) Place cover (201) on the flat bench transverse,
apply bushing (414) to special jig 1, strike it lightly
with hammer, and draw the bushing out.
31102 60413252
33-68
UPPER SWING BODY
(4) Assembly 8) Place spring seat (218) in casing (102) with

1) Clean all parts before assembly, and dry them by tweezers.
means of compressed air. Don’t use rag. 9) Place damping spring (336) in casing (102).
• Repair the parts damaged when being 10) Install piston (224).
disassembled, clean them, apply oil to the 11) Place O-ring (212) in plug (202).
moving section, and install the same parts on 12) Place packing (210) in plug (202).
the positions where they are before. • Pay attention to the direction when placing the
• Replace every O-ring and packing with new packing in.
ones. • Apply grease slightly before placing packing
2) Install washer (313), shim (217), spring (324) for in.
resetting the secondary pressure, and spring seat
on spool (301) in order.
3) Pass spool (301) through the larger hole of spring
seat (311), push the spring seat in , and install it
PACKING
making the spring for the secondary pressure flex
and shifting the spring seat crosswise.
4) Fix casing (101) with vise, and place spring (335)
for return in casing (101).
F17491
5) Place the reduction unit subassy described in
Articles 2) and 3) in casing (101). Fig. 4-5
• Install them on the positions as they were

before.
• When placing the reduction unit subassy in,
pay attention to the spool lower end so as not 13) Place grease cup (203) in plug (202).
to bring into contact with the corner of the 14) Install push rod (214) on plug (202).
casing. 15) Place the push rod subassy which is sub-
6) Place O-rings (211,213) in casing (101). assembled by the procedures in Articles 11) to 14)
7) Fix upper casing (102) with vise and place the in casing (102).
steel ball in it. 16) Put cover (201) on the flat work bench, press
bushing (414) with special jig 1, and press fit the
bushing striking lightly.
17) Fix the lower cover assy which is assembled by
Pay attention to the the procedures in Articles 2) to 6) with vise, and
corner of the casing
install the upper cover assy which is assembled
by the procedures in Articles 7 to 15) on it.
18) Install cover (201) on casing (102).
19) Tighten socket bolt (271) to the specified torque.
20) Install cam (420) on cover (201).
21) Insert cam shaft (413) from the outside pressing
cam (420).
F17492
Fig. 4-4
31102 60413252
33-69
UPPER SWING BODY
22) Apply Loctite #241 or equivalent to the thread of

socket bolt.
23) Tighten socket set bolt (472) to the specified
torque.
24) Incline cam (420), apply grease to the top end of
push rod (214), and fill grease cup (203) of plug
(202) with grease.
25) After fitting the top end of bellows (501) in cam
(402), fit the lower side in the groove of cover
(201).
31102 60413252
33-70
UPPER SWING BODY
4.3 CAUSE OF FAILURES AND CORRECTIVE ACTION
PHENOMENON CAUSES CORRECTIVE ACTION

Secondary 1) Insufficient primary pressure 1) Secure primary pressure.
pressure does 2) Permanent set of spring (324) for setting 2) Replace it with new one.
not rise. of secondary pressure
3) The gap between spool and casing is 3) Replace it with complete remote
too large. control valve.
4) The control section is loosened. 4) Replace parts of control section.
Secondary 1) Sliding part is not smooth. 1) Repair unsmooth section.
pressure is 2) Variation of pressure of tank line 2) Return oil to oil tank directly.
unstable. 3) Air contamination in piping 3) Bleed air by operating several times.
Secondary 1) Pressure of tank line is high. 1) Return oil to oil tank directly.
pressure is high. 2) Sliding part is not smooth. 2) Repair unsmooth section.
Damping does 1) Air is accumulated in piston chamber. 1) Bleed air by operating several times.
not work. 2) Sliding part is not smooth. 2) Repair unsmooth section.
3) Permanent set of damping spring (336) 3) Replace it with new one.
4) Gap between damping piston (224) and 4) Replace it with complete remote
casing (damper) (102) is too large. control valve.
5) Malfunction of check valve 5) Disassemble and check on check
valve section.
6) Orifice of damping piston (224) is too 6) Replace damping piston.
large.
Damping torque 1) Sliding part is not smooth. 1) Repair unsmooth section.

is heavy. 2) Orifice of damping piston (224) is clogged. 2) Repair or replace damping piston.
F17493
31102 60413252
33-71
UPPER SWING BODY
5. SWING MOTOR UNIT
5.1 CONSTRUCTION
(1) Swing motor
Slewing motor assy
Composition
Swash plate type Two-stage planetary

axial piston gear reduction unit
motor
Mechanical brake
Relief valve
Makeup valve
Bypass valve
F17495
31102 60413252
Fig. 5-1 Swing motor
33-72
UPPER SWING BODY
TORQUE TORQUE
kgf·m (lbf·ft) No. PARTS Q'TY kgf·m (lbf·ft) No. PARTS Q'TY
1 TAPERED ROLLER BEARING 1 22 RETURN PLATE 1

3 FRICTION PLATE 1 23 CAM PLATE 1
4 SEPARATOR PALATE 2 24 LEVEL GAUGE 1
5 SNAP SING 2 25 O-RING 1
6 NEEDLE BEARING 1 26 HOUSING 1
7 O-RING 1 27 COLLAR 1
8 O-RING 1 28 OIL SEAL 1
9 O-RING 1 30 BACK UP RING 2
10 BALANCE PLATE 1 31 O-RING : 1B P21 2
11 PISTON 1 33 BACK UP RING 2
12 TEFLON RING 2 34 O-RING : 1B P26 2
13 PLUG ; PT 1/4 2 35 PARALLEL PIN 2
14 BUSHING 2 36 PLUG : PF3/8 1
15 SCROLL WAVE 4 37 O-RING : 1B P14 1
16 TEFLON RING 4 38 SOCKET BOLT : M12 X 30 4
17 SPRING 4 39 COVER 1
18 PISTON 13 40 PLUG 1
19 CYLINDER 1 70 RELIEF VALVE ASSY 2
20 RETAINING SPRING 1 100 BY-BASS VALVE ASSY 2
21 PISTON ASSY 1
F17496
1) Relief and check valve assy (70)

70 RELIEF AND 2 82 SEAT 2
CHECK VALVE ASSY 83 POPPET 2
71 LOCK NUT 2 84 SPRING 2
72 CAP 2 85 O-RING 2
76 BACK UP RING 2 86 SHIM 2
77 O-RING; 1B P26 2 87 PISTON 2
78 SPRING 2 88 SLEEVE 2
79 BUSHING 2 89 O-RING 2
Detail view of relief and check valve assy 80 CHECK SEAT 2 90 CAP 2
81 SLEEVE 2
F17497
2) By-pass valve assy (100)

100 BY-PASS VALVE ASSY 2 106 O-RING: 1B P21 2
101 SEAT 2 107 BACK UP RING 2
102 SLEEVE 2 108 CAP 2
103 POPPET 2 109 SPRING 2
104 BACK UP RING 2 110 POPPET 2
31102 60413252
105 O-RING: 1B P14 2 111 SPRING 2

F17498
Detail view of by-pass valve assy (swing shockless valve)
33-73
UPPER SWING BODY
(2) Swing reduction unit
Fig. 5-2 Swing reduction unit
TORQUE TORQUE
kgf·m (lbf·ft) No. PARTS Q'TY kgf·m (lbf·ft) No. PARTS Q'TY
1 PINION SHAFT 1 15 HOLDER 2 ASSY 1

2 COLLAR 1 16 NEEDLE BEARING 6
3 PLATE 1 17 SHAFT 2 3
4 TAPER ROLLER BEARING 1 18 SPUR GEAR 5 3
5 GEAR CASE 1 19 THRUST PLATE 2 6
6 GREASE NIPPLE 1 20 SPRING PIN: 8 X 5 3
7 OIL SEAL 1 21 HOLDER 2 1
8 TAPER ROLLER BEARING 1 22 COLLAR 2
9 PIN 2 23 RELIEF NIPPLE 1
31102 60413252
10 RING GEAR 1 24 CONNECTOR 1

11 SPUR GEAR 4 1 25 ELBOW 1
12 SUN GEAR 1 26 HOSE 1
13 HOLDER 1 ASSY 1 27 PLUG 1
14 SOCKET BOLT: M12 X 95 6
F17499
33-74
UPPER SWING BODY
70
5.2 DISASSEMBLY AND ASSEMBLY OF
SWING MOTOR
(1) Disassembly
1) Remove the relief assy (70).
: 27 mm
2) Remove the by-pass valve (100). 100

: 8 mm
Install it in the original position.
Fig. 5-3 Removing relief valve assy and by-pass valve
3) Apply match mark on cover (39) and housing (26). 39
26
MATCHING
MARK
Fig. 5-4 Maching marks on cover and housing
4) Remove socket bolt (38). 39

: 10 mm
26
38
Fig. 5-5 Removing cover mounting bolts
5) Lift up and remove cover (39).
39
31102 60413252
Fig. 5-6 Removing cover
33-75
UPPER SWING BODY
6) Remove snap ring (5) with plier.
7) Remove inner race of needle bearing (6).
Fig.5-7 Removing bearing (6) inner race
8) Remove the O-ring (9).
Fig.5-8 Removing O-ring (9)
9) Remove the balance plate (10).
10
Fig. 5-9 Removing balance plate
10) Remove the bushing (14) with a teflon ring (16) on

it, and the scroll wave (15).
31102 60413252
14
Fig. 5-10 Removing bushing (14) and scrollwave (15)
33-76
UPPER SWING BODY
11) Remove spring (17) from brake piston (18).
WARNING
Fit spring in the original position.
17
18
Fig. 5-11 Removing spring (17)
12) Remove brake piston (18). 18
WARNING
The O-ring (7) (8) make it difficult to slide the piston
(18) easily from the housing (26). For this reason, use
tapped hole (M6) provided in the piston (18) to remove
it, as shown in the Fig.5-12.
Fig. 5-12 Removing brake piston (18)
13) Remove the separator plate (4) and friction plate

(3).
Fig. 5-13 Removing separator plate (4) and friction plate (3)
14) Remove cylinder assy (19) from housing (26).

• Oil seal (28) and outer race of taper roller
bearing (1) are left in housing.
19
• Take care not to damage the sliding surface on
upper section of cylinder housing.
• Assemble piston bore of cylinder (19) and
31102 60413252
piston assy (21) in the same original

combination. 26
Fig. 5-14 Removing cylinder assy (19)
33-77
UPPER SWING BODY
15) Remove the outer race of tapered roller bearing

1
(1) from the housing.
Fig. 5-15 Removing outer race of tapered roller bearing (1)
16) Remove oil seal (28) from housing (26) with driver
and hammer.
• The reuse of the removed oil seal is not allowed.
28
26
Fig. 5-16 Removing oil seal (28)
17) Removing the cylinder assy.

1. Attach an gear puller to two positions of the
inner race of the tapered roller bearing (1) and
to the splined end of the cylinder (19), and pull
out the inner race along with the collar (27).
27
Fig. 5-17 Pulling inner race of tapered roller bearing (1)
2. Remove the cam plate (23), piston assy (21)

and return plate (22) together from the cylinder
(19).
23
31102 60413252
22
21
Fig. 5-18 Removing cam plate (23), piston assy (21) and
return plate (22)
33-78
UPPER SWING BODY
3. Remove cam plate (23) from the piston assy (21)

as is by sliding it on sliding surface of piston assy
(21).
21
23
WARNING
Handle cam plate with care so as not to damage its
sliding surface.
Fig. 5-19 Removing cam plate (23)
4. Remove retaining spring (20) from cylinder (19).
19 20
Fig. 5-20 Removing retaining spring (20)
(2) Installation
Install swing motor unit in the reverse procedure
of disassembling.
1) Jigs
Jig used for installing is not provided with part
number.
JIGS DIMENSIONS JIGS DIMENSIONS

(1.1909˝±0.0039˝)
C1
(1.0039±0.0039)
Ø35 (1.38˝)
(0.04˝)
Ø30.25±0.1
Ø25.5±0.1
(1.9488˝±0.0039˝)
(2.4350˝ ± 00.00591˝ )
Press-fitting jig
(1.1417˝±0.0039˝)
61.85 ± 0.15
Ø49.5±0.1
Ø29±0.2
°
for inner race Press-fitting jig 30
of tapered 3 for oil seal (28)

(0.008˝) (0.08˝) 2
roller bearing (1) 60 (2.36˝) 10.5 (0.413˝)
75 (2.95˝) (0.5315˝ +0.0039
-0 ) 155 (6.10˝)
13.5 ± 00.1
3 ˝)
()R 118
.
)
(0
Ø30.3 (1.19˝)
(0.9921˝ +0.0039
31102 60413252
(0.8720˝)
(0.689˝)
Ø22.15
25.2 ± 0.1
(1.06˝)
)
Ø17.5
(±0.0059
0
-0
Ø27
± 0.15
0
0
Press-fitting jig
Seal protector 5°
for collar (27) 7
(0.276˝) 50 (1.97˝) 25 (0.984˝)
60 (2.36˝) 45 (1.77˝)
F17500
33-79
UPPER SWING BODY
70
2) Assembling relief assy
Fit relief assy (70) to cover (39). 39
: 27 mm
3) Confirming correct assembly Fig. 5-21 Assembling relief assy (70)

Open the brake release port, apply a pilot pressure
Rotate spline A,B release
of 20 kgf/cm2 (280 psi) to the P port and confirm by 2 to 3 kgf·m (inlet / outlet ports)
that the output shaft rotates more than 1 turn (14 to 22 lbf·ft)
with torque
smoothly by 2~3 kgf·m (14~22 lbf·ft) torque. In wrench.
case the output shaft does not rotate, disassemble
it again and readjust.
Apply pressure 20 kgf/cm2

(280 psi) to brake release
port (PF 1/4)
Fig. 5-22 Confirming correct assembly
31102 60413252
33-80
UPPER SWING BODY
5.3 DISASSEMBLY AND ASSEMBLY OF

SWING REDUCTION UNIT
(1) Removal
15
1) Remove the sun gear (12) and then remove the
holder 1 assy (13).
• Because the shafts in the holder 1 assy (13)
are press-fit in the holder (1), and caulked at
the end, further removal of the assy is
20
impossible.
Fig. 5-23 Removing spring pin (20)
2) Remove spur gear 4 (11) and then remove the

holder 2 assy (15).
3) Removing the holder 2 assy (15).
1. Drive the spring pin (20) through the holder 2
assy (15).
• The spring pin (20) cannot be reused.
2. Holding spur gear 5 (18) with your hand, remove
the shaft 2 (17) from holder 2 (15).
18
17
Fig. 5-24 Removing shaft (17)
4) Remove the ring gear (10).
• The mating surface between the ring gear (10)
and the gear case (5) is coated with liquid
packing (Three Bond #1215, gray) to prevent
oil leakage. Use the notch in the gear case (5) 10
to remove the ring gear (10).
5) Removing the collar (16). 5
Remove the collar (16) from the shaft (1) by
tapping the collar with a screwdriver and hammer.
Fig. 5-25 Removing ring gear (10)
6) Removing the shaft (1) assy.

Place blocks about 300 mm high under the flange
of the gear case (5) to allow removal of the shaft
PRESS
(1) and push the end of the shaft with a hydraulic
press to remove the shaft (1), collar (2), plate (3)
and taper roller bearing (4) as an assy.
31102 60413252
5
WARNING
Do not remove any further, unless the bearings etc. are
abnormal.
7) Remove the oil seals (7) from the gear case (5).
• Do not reuse the oil seals. Fig. 5-26 Removing shaft (1) assy
33-81
UPPER SWING BODY
(2) Installation
• The jigs to be used for installation are shown below. Unit: mm
OIL SEAL (7) PRESS-FITTING JIG SEAL PROTECTOR REMARKS
Ø50 15°
(1.97˝)
• Heat vinyl chloride tube in hot
(0.591˝) (0.272˝) (0.591˝) (1.18˝)

15 6.9 15 30
water and inset it onto the pinion
±0.1 (0.00394˝)
shaft to from a seal protector.
150 (5.91˝)
C2
(0.08˝)
85 (3.34˝)
(0.118˝) 3
0˝
(2.5512˝ -0.0079˝ )
0
Ø64.8-0.2 15°
Ø89 -0.2 -0.0079˝

-0.5 (3.5039˝ -0.0197˝ )
Ø119 (4.69˝) Ø65

(2.56˝)
F17501
1) Apply grease to the rollers of the taper roller

bearing (4).
• Grade: SHELL ALVANA EP2 or equivalent
GREASE
(grease for extreme pressure duty)
• Quantity: About 150cc
Fig. 5-27 Applying grease to taper roller bearing (4)
2) Press-fitting the oil seal (7) 5 SEAL

Degrease the oil seal position on the gear case (5) PRESS-
FITTINGH
and the oil seal (7). Apply liquid packing (Three JIG
7
Bond #1211, white) to the outside of the oil seal.
Using the seal press-fitting jig and a hand press,
install the oil seal (7) on the gear case (5).
• After press-fitting, apply grease to the oil seal
lips.
Fig. 5-28 Press-fitting oil seal (7)
3) Place the gear case (5) with the output shaft side 1
facing upward, and install the pinion shaft (1) assy
4
into the gear case (5).
• Use the seal protector to prevent the spline of
SEAL
the pinion shaft (1) from damaging the lips of PROTECTOR
the oil seal (7).
5
31102 60413252
Fig. 5-29 Installing pinion shaft (1) assy
33-82
UPPER SWING BODY
4) Installing the taper roller bearing (8)

Place gear case (5) directing pinion shaft
downward, warm collar (22) of taper roller bearing
to temperature adding +50°C (122°F) to the room
temperature and fit it.
22
Fig. 5-30 Installing taper roller bearing (8)
5) Installing the collar (22) Adjust the clearance

0.06 mm (0.0024 in)
The nominal thickness of the collar (22) is 7.0 mm
(0.2756 in). Adjust this thickness so that the
clearance between the collar (22) and the groove COLLAR (22)
in the shaft (1) is 0.06 mm (0.0024 in). TAPER ROLLER
BEARING (8)
SHAFT (1)
Fig. 5-31 Adjusting clearance between collar (22) and shaft (1)
6) Installing the ring gear (10).

• Degrease the mating surface between the
gear case (5) and the ring gear (10) and the pin
(9).
• Apply liquid packing (Three Bond #1215, gray)
to the area of the gear case (5) inside the bolt
circle, and install the ring gear (10) on the gear
case (5).
• Apply sealant equally so that the thickness
projecting from nozzle is about 1.5 mm (0.06 Fig. 5-32 Applying liquid packing to gear case (5)
in) in diameter.
10
31102 60413252
Fig. 5-33 Installing ring gear (10)
33-83
UPPER SWING BODY
7) Installing the holder 2 assy (15)

1. Install the needle bearing (16) in spur gear 5
(18). Install this assy together with the thrust
plate 2 (19) into holder 2 (21), and insert the
shaft 2 (17) into the spur gear.
• Apply hydraulic oil to the inside diameter of 15
spur gear 5 (18), needle bearing (16) and the
outside diameter of the shaft 2 (17).
17
Fig. 5-34 Installing holder assy 2 (15)
2. Drive the spring pin (20)
WARNING
Drive spring pin facing the split to gear side.
Beware of the direction

of spring pin.
GEAR SIDE 20
Caulk two point with a punch. 15

Fig. 5-35 Driving spring pin (20)
8) Carefully mesh the holder 2 assy (15) in the

internal teeth of the ring gear (10), and the spline
of the pinion shaft (1) with its mating part. In this
condition, insert the holder 2 assy (15) while 15
turning it.
9) Carefully mesh spur gear 4 (11) in the spur gear
5 (18).
11
Fig. 5-36 Inserting holder 2 assy (15)
10) Installing the holder 1 assy (13)

1. Carefully mesh the holder 1 assy (13) in the
internal teeth of the ring gear (10), and holder
1 (13) in the teeth of sun gear (12). In this
condition, insert the holder 1 assy (13) while
turning it slowly.
31102 60413252
2. Place sun gear (12) in while engaging with

13
planet gear of holder 1 assy (13) slowly.
11) Turn the holder 1 assy (13) with your hand to
confirm that the pinion shaft rotates smoothly.
Fig. 5-37 Inserting holder 1 assy (13)
33-84
UPPER SWING BODY
PARTS MAINTENANCE
Replace if harmful wear, pitting, peeling, scratch, etc. are found on the
Gear, Pinion
tooth face.
Replace if harmful wear, indentation, etc. are found on the spline
portion, there is a backlash on the pin portion (For holder 1 assy,
Holder 1, 2 assy
loosening of caulking, for holder 2 assy, wear of pin bore), or the needle
bearing is worn making a backlash.
Even if the bearing works normally, when the "Hour meter" arrives to
the time in 3000 hours, replace them with new ones.
Even through the "Hour meter" is within 3000 hours, when the rolling
Taper roller bearing,
contact surface of needle bearing is flawed while removing, replace
Needle bearing
them with new ones.
And if possible we will recommend that you replace bearings with new
ones because they will often be damaged during removing.
When the lip is damaged, replace it with a new one.
Oil seal And even if there is no leak, replace seal every 3000 hours.
Also, replace it with new ones without fail while installation.
Other parts Replace parts worn or damaged with new ones.
F17502
31102 60413252
33-85
UPPER SWING BODY
6. SWIVEL
6.1 CONSTRUCTION
T=Tightening torque: kgf·m (lbf·ft)
NOTE:
Fit completely-
degreased seal
assy (5) and seal
(15) in seal groove
without application
SECTION K-K of oil and grease.
T = 3.1 (22) T = 3.1 (22)

(Loctite #290) (Loctite #290) VIEW M
SECTION J-J
Fig. 6-1 Construction
Table 6-1
1 BODY 1 5 SEAL ASSY 7 12 PLUG: PT1/8 1
2 STEM 1 7 O-RING; 1A G95 1 13 PLUG: PT3/8 2
3 THRUST PLATE 1 8 SOCKET BOLT: M8 X 20 2 15 SEAL 2
31102 60413252
4 COVER 1 9 SOCKET BOLT: M8 X 30 3

F16863
33-86
UPPER SWING BODY
6.2 DISASSEMBLY AND ASSMBLY

6.2.1 Tools
Table 6-2
CODE TOOL NAME USED FOR REMARKS

1. Steel hammer
a Hammer
2. Wooden or plastic hammer
b Rubber mat Disassembly 500 mm (20 in) square or more
Assembly 1. Allen wrench
c Wrench 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 10 kgf·m (72 lbf·ft)
Grind the tip of "a nail"
to shape as a screwdriver.
e Pin Disassembly
Made from a hack-saw blade
Disassembly Approx. 120 mm (5 in)

f Spatula
Assembly
Remove the edge completely

Vinyl tape and make corner round smooth.
Disassembly
g V block or vise Vises movable over 150 mm (6 in)
Assembly
Thrust plate,
h Loctite #290
Cover
i Lubricating oil Hydraulic oil or Vaseline
j Cleaning oil
F17543
6.2.2 Apparatus 6.2.3 Cleaning

(1) Hoist or crane Clean the swivel joint to remove dirt, dust, etc. using
The lifting device should be capable of lifting the steam, wash oil, etc.
swivel joint assembly. • Never fail to plug up every port before starting
cleaning
(2) Work bench
The work bench should have an area of 1.2 m X
1.5 m (4ft X 5ft)
(3) Others
Also prepare rag, wooden block and oil container.
31102 60413252
33-87
UPPER SWING BODY
1
6.2.4 Disassembly
The part numbers used in this disassembly procedu- MATCHING MARK
re correspond to those of a construction drawing in 9
Fig. 6-1. 4
(1) Removing cover

1) Place a V-block on a work bench, mount a swivel
joint set on the side, fix it and loosen capscrew (9)
by means of allen wrench.
: 6 mm ALLEN
WRENCH
• Apply match mark on cover (4) and body (1). V-BLOCK
PIPE
• Alternately the swivel joint may be fixed by
holding stem (2) in a vise.
2) Remove cover (4) from body (1) and draw out O-
ring (7) from cover (4).
7 O-RING
WARNING
When removing thrust plate (3) by fixing body (1),
support stem (2) so it may not fall dawn.
(2) Removing thrust plate

Loosen socket bolts (8) fastening thrust plate (3),
4 COVER
in the same manner as the removing of the above-
mentioned cover. Fig. 6-3 Removing O-ring (7)
: 6 mm
1 BODY
3 THRUST PLATE
8 CAPSCREW
PIPE
2 STEM
Fig. 6-4 Removing thrust plate (3)
1 BODY
(3) Extraction of stem
Place body (1) on a V-block. Put a wooden block
against stem (2), then knock it out using a hammer.
By hitting out the stem over about 1/2 from the
31102 60413252
body, it can be easily pulled out by hand. Weight

of stem; about 11kg (24 lbs) WOODEN V-BLOCK
BLOCK 2 STEM
Work bench
F17544
Fig. 6-5 Drawing out stem (2)
33-88
UPPER SWING BODY
(4) Removing seals

1) Stick pin (e) to seal (15) and remove seal (15).
Fig.6-6 shows the use of one pin, but by using two
pins, this can be extracted with more sureness.
15
(SEAL RING)
PIN (e)
F17545
Fig. 6-6 Taking out seal (15)

2) Pull out back-up ring from the O ring groove with
SPATULA (f)
the aid of a spatula.
WARNING 1 BODY
Use the tip of the spatula taking not to harm the body (BACK-UP RING)
(1).
3) Stick pin (e) to slipper ring and remove seal assy F17546
(5) in the same procedure as seal (15). Then

remove back-up ring by means of spatula (f). Fig. 6-7 Taking out seal (15)
SLIPPER RING
BACK-UP RING
Detail of seal assy (5)
GROOVES
6.2.5 Assembly FOR SEAL ASSY
Prior to assembly, clean each parts (excluding the O- PIN (e) GROOVES FOR
ring and seal), and arrange in the sequence of SEAL HYDRAULIC OIL
ASSY
assembly. 5
GROOVES
FOR
SEAL ASSY
(1) Assembling seals to body
1) Install seal (15) (back-up ring and seal ring in
Fig. 6-8 Taking out seal assy (5)
order) into the seal groove. In this time, deform
and fit the seal ring as shown in Fig.6-9. And after
inserting entire seal section, fit it in seal groove
completely with spatula.
2) After deform slipper ring of seal assy (5) as shown
in Fig.6-9, install back-up ring. And after inserting
entire seal section, fit it in seal groove completely
with spatula.
31102 60413252
WARNING
Before fitting seal (15) and seal assy (5), check that
seal groove is free from hydraulic oil, vaseline, grease,
etc.
Fig. 6-9 Inserting seal ring (15)
33-89
UPPER SWING BODY
(2) Assembling stem Press in by applying your weight

by your both 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
WARNING
• If stem (2) is pressed in too fast, the seal may be
damaged. Do it slowly.
SEAL 15
• The clearance between body (1) and stem (2) is
about 0.1 mm (0.004 in). Push stem straight along 1 BODY
the shaft center.
SEAL ASSY 5
WORK BENCH
Fig. 6-10 Inserting stem (2)
(3) Assembling thrust plate

8 3 2
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 bolts (8), coat it with Loctite #290 and
tighten to stem (2).
: 6 mm
Fig. 6-11 Tightening socket bolts (8)
1
(4) Assembling cover
MATCHING MARK
After installing O-ring (7) to cover (4) and aligning
9
the matching marks of the cover (4) and body (1),
and tighten socket bolts (9) it which will then 4
complete assembly.
: 6 mm
31102 60413252
ALLEN WRENCH
V-BLOCK
PIPE
Fig. 6-12 Tightening socket bolts (9)
33-90
UPPER SWING BODY
6.3 MAINTENANCE SATANDARDS

6.3.1 Usable limit of parts
Table 6-3
PARTS MAINTENANCE STANDARDS REMEDY
Sliding surface with Plating worn or peeled due to seizure or
Replace
sealing sections contamination.
Sliding surface 1) Worn abnormality or damaged more than 0.1 mm

Replace
between body and (0.004 in) in depth due to seizure contamination.
stem other than 2) Damaged more than 0.1 mm (0.004 in) in depth. Smooth with oil
Body, Stem sealing sections stone.
1) Worn more than 0.5 mm (0.02 in) or abnormality. Replace
Sliding surface with 2) Worn less than 0.5 mm (0.02 in). Smooth
thrust plate
3) Damage due to seizure or contamination
Smooth
remediable within wear limit 0.5 mm (0.02 in).
1) Worn more than 0.5 mm (0.02 in) or abnormality. Replace
Sliding surface with 2) Worn less than 0.5 mm (0.02 in). Smooth
Cover
thrust plate
3) Damage due to seizure or contamination
Smooth
remediable within wear limit 0.5 mm (0.02 in).
1) Extruded EXTRUSION
excessively from
Replace
seal groove square
(With back-up
ring.
ring)
BACK-UP RING
2) Slipper ring
1.5 mm (0.06 in)
Replace
Slipper ring narrower than seal
(With back-up
Seal ring groove, or 1.5 mm (max.)
ring)
narrower than (0.06 in)
back-up ring.
BACK-UP RING
3) Worn more than

0.5 mm (0.02 in).
0.5 mm (max.) Replace
(0.02 in) (With back-up
ring)
F17547
31102 60413252
33-91
UPPER SWING BODY
1
6.3.2 Inspection after assembly
After completion of assembly, inspection for oil leakage,
pressure resistance, etc., using a device as shown in
9 Connect to
the figure right. body side
(1) High pressure port

Install a changeover valve and pressure gauge to 2
the stem side port and body side port respectively, Connect to
and while watching the pressure gauge (for high stem side
pressure) installed on the body side and also by 3
regulating high pressure relief valve (7), gradually
increase the pressure and when the pressure has 8
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 7
relief valve side closed at this time.
Apply high pressure for 3 minutes, and check the
looseness, deformation and breakage on every
parts.
Pressure down should be within 10% of closing
pressure. 6 5
These inspections are performed on every circuit.
Fig. 6-13 Hydraulic circuit for inspection equipment
(2) Low pressure port (drain port, return port, etc.).

Similar to the high pressure port, install a
changeover 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 Table 6-4
side and also by regulating low pressure relief
ITEM DESCRIPTION REMARKS
valve (5), gradually increase the pressure and
1 Pressure gauge High and low pressures
check for outside leakage with a color check at a are required.
pressure of 5kgf/cm2 (71 psi). 2 Swivel joint
• The maximum working pressure stands for 3 Stop valve
pressure of hydraulic excavator equipped with 5 Relief valve for Setting pressure:
low pressure 5 kgf/cm2 (71 psi)
swivel joint.
6 Stop valve
Setting pressure:
7 Relief valve for [Max. operating pressure
high pressure 260 kgf/cm2
(3700 psi) X 1.5 times]
8 Directional valve
9 Piping, etc.
F17548
31102 60413252
33-92
UPPER SWING BODY
6.4 TROUBLESHOOTING
Table 6-5
TROUBLE CAUSE REMEDY
1. External leakage of Defective O-ring Replace all seals.
hydraulic oil
2. Internal leakage of 1) Defective slipper seal 1) Replace all seals.

hydraulic oil 2) Sliding face worn 2) Replace assy.
excessively
3. Swivel joint seized 1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body
are too loose and causing oil
leakage.
2) Setting failure of swivel 2) Reinstall
stopper bracket Secure 2~3 mm (0.08~0.12 in)
allowance for bolt stopper.
4. Loose swivel stem and Socket bolt tightened Retighten to specified torque.
cover insufficiently.
F17549
31102 60413252
33-93
UPPER SWING BODY
NOTE
31102 60413252
33-94
SECTION 34 TRAVEL SYSTEM
TABLE OF CONTENTS
Part I: Removing and installing assy ................................................................34-1

1. Components of travel system ............................................................................... 34-1
2. Crawler ................................................................................................................. 34-1

2.1 Removing crawler ........................................................................................................................... 34-1
2.2 Installing ......................................................................................................................................... 34-2
2.3 Construction ................................................................................................................................... 34-3
2.4 Maintenance standard .................................................................................................................... 34-4
2.5 Tools and jigs .................................................................................................................................. 34-4
3. Upper roller ........................................................................................................... 34-5

3.1 Upper roller assy ............................................................................................................................ 34-5
3.2 Removing ....................................................................................................................................... 34-5
3.3 Installing ......................................................................................................................................... 34-5
3.4 Construction ................................................................................................................................... 34-6
3.5 Disassembly and assembly ............................................................................................................ 34-6
3.6 Maintenance standard .................................................................................................................... 34-9
3.7 Tool and jigs ................................................................................................................................... 34-9
4. Lower roller (track roller) ..................................................................................... 34-10

4.1 Lower roller assy .......................................................................................................................... 34-10
4.2 Removal ....................................................................................................................................... 34-10
4.3 Installation .................................................................................................................................... 34-10
4.4 Construction ................................................................................................................................. 34-11
4.7 Tool and jigs ................................................................................................................................. 34-16
5. Front idler (idler adjuster assy) ........................................................................... 34-17

5.1 Front idler assy ............................................................................................................................. 34-17
31102 60413252
5.2 Removing ..................................................................................................................................... 34-17

5.3 Idler assy ...................................................................................................................................... 34-18
6. Sprocket ............................................................................................................. 34-22

6.1 Removing ..................................................................................................................................... 34-22
6.2 Installing ....................................................................................................................................... 34-22
INDEX
6.3 Maintenance standard (2404N267) .............................................................................................. 34-23

6.4 Sprocket tooth profile gauge ........................................................................................................ 34-23
7. Travel motor ........................................................................................................ 34-24

7.1 Travel motor .................................................................................................................................. 34-24
7.2 Removing ..................................................................................................................................... 34-24
7.3 Installing ....................................................................................................................................... 34-25
8. Swing bearing ..................................................................................................... 34-26

8.1 Swing bearing assy ...................................................................................................................... 34-26
8.2 Removing ..................................................................................................................................... 34-26
8.3 Installing ....................................................................................................................................... 34-27
8.4 Construction ................................................................................................................................. 34-27
Part II: Disassembling and assembling components ......................................34-29

1. Travel motor ........................................................................................................ 34-29
1.1 Construction ................................................................................................................................. 34-29
1.2 Tools and jigs ................................................................................................................................ 34-32
1.3 Tightening torque ......................................................................................................................... 34-38
1.4 Weight .......................................................................................................................................... 34-38
1.5 Disassembly ................................................................................................................................. 34-39
1.6 Assembly ...................................................................................................................................... 34-59
1.8 Dimensions of snap ring .............................................................................................................. 34-81
1.7 Performance inspection ................................................................................................................ 34-82
1.9 Service standards ........................................................................................................................ 34-83
29002 00000000
TRAVEL SYSTEM
Part I: REMOVING AND INSTALLING ASSY

1. COMPONENTS OF TRAVEL SYSTEM
8
2
7
F17561
5
6
10
9
11 3
Fig. 1-1 Designation and location of undercarriage 4
2. Crawler 7. Travel motor

3. Upper roller 8. Swing bearing
4. Lower roller 9. Lower frame
5. Front idler 10. Guard
6. Sprocket 11. Grease nipple of the track spring adjuster
2. CRAWLER
2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Set master pin to positions shown in the figure.
2) Slacken crawler
: 19 mm
WARNING
• When loosening the grease nipple of the adjuster, do F17562
not loosen it more than one turn. Fig. 2-1 Crawler removing position
• 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 PROTECTION
MASTER
danger of injury. So be careful not to over loosen the PIN
grease nipple.
3) Pushing out master pin

Apply jig on master pin and strike it out with a
31102 60413252
mallet.
WARNING
If you use a big hammer, wear a long-sleeved garment MASTER PIN
DRAWING JIG
and protective goggles to protect yourself from flying
objects.
Fig. 2-2 Pushing out master pin
34-1
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.
WARNING
Crawler end section may fall on the ground just before
extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
Fig. 2-3 Removing crawler
2.2 INSTALLING
Installing is done in the reverse order of removing. Front
(1) Checking crawler installation direction. idler side
Place the track links on the ground so they conver-
ge, facing the front idler, as shown in the figure on
the right.
Fig. 2-4 Installing direction of crawler
(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
2) Winding crawler
Insert bar into master pin hole, lift lower frame up
1 or 2 cm (0.4 in~0.8 in) using attachment and hold
it, then turn sprocket in rearward positioning the
machine so that the weight is not loaded to shoe.
Fig. 2-5 Winding crawler
(3) Preparation for press fitting master pin

1) Preparing for installation
Put wood block under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine adjustment
turning sprocket.
31102 60413252
Connecting
position of master pin
Fig. 2-6 Preparation for press fitting master pin
34-2
TRAVEL SYSTEM
(4) Press fitting of master pin

Apply press fitting jig on master pin, and
strike it with a mallet to press fit.
WARNING
• If you use a big hammer, wear a long-sleeved
garment and protective goggles to protect yourself
from flying objects.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in.
Fig. 2-7 Rress fitting of master pin
(5) Adjusting crawler tension (See Fig. 2-8.)

After installing, adjust tension of crawler.
: 19 mm
MODEL A DIMENSION
Proper tensioning E70SR 200~230 mm
of the iron crawler EVOLUTION (8 in~9 in)
Proper tensioning E70SR 140~150 mm
of the rubber crewler EVOLUTION (5 in~6 in)
F17563
Fig. 2-8 Adjusting crawler tension
2.3 CONSTRUCTION
7
No. NAME Q'TY 4
3
SHOE ASSY 2
7
• TRACK LINK ASSY 1X2 8
1 • • TRACK LINK (R.H) 39 X 2
2 • • TRACK LINK (L.H) 39 X 2
3 • • BUSHING 38 X 2 11 1
5
4 • • PIN 38 X 2
5 • • MASTER BUSHING 1X2 8
2
6 • • MASTER PIN 1X2 6
7 • • SEAL 76 X 2 9
8 • • MASTER COLLAR 2X2
9 • SHOE 39 X 2
10 • SHOE BOLT 156 X 2
11 • SHOE NUT 156 X 2
31102 60413252
F17564
10
Fig. 2-9 Shoe assy
34-3
TRAVEL SYSTEM

Track link assy
E F
G
(3.50˝)
(2.87˝)
B D
89
73
57 (2.24˝)
A
Fig. 2-10 I
No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY

A Link pitch 155.6±0.1(6.126±0.0039) 160 (6.30) 164 (6.46) Replace the link
ass'y if the
B O.D. of bushing Ø41 +0.214 +0.0084
+0.174 (1.6142 +0.0069 ) Ø37 (1.46) Ø36 (1.42) service limit is
C Height of link 75±0.15 (2.9528±0.0059) 69 (2.72) 67 (2.64) exceeded.
Basic Tolerance Fit Fit
dimension
D Interference between +0.214
bushing and link Ø41 +0.714 Interference Interference
(1.6142) Shaft +0.0084 0.05 (0.0020) 0 Replace
+0.0069
+0.15
E Interference between Ø24 0 Interference Interference
track pin and link (0.9449) Shaft +0.008 0.05 (0.0020) 0
0
-0.05
F Interference between Ø24 -0.08 Interference Interference Replace
master pin and link (0.9449) Shaft -0.0020 0.05 (0.0020) 0 Link
-0.0032
G Clearance between 1.6 (0.06) 8 (0.32) 10 (0.39) Replace
links (both sides)
H STD shoe plate 26 (1.02) 15 (0.59) 13 (0.51) Replace
I Tightening torque of 30 kgf·m (220 lbt·ft) Retighten
shoe bolt
F17566
2.5 TOOLS AND JIGS

No. JIGS SHAPE
31102 60413252
Master pin
a
fixing jig
F17565
34-4
TRAVEL SYSTEM
3. UPPER ROLLER
3.1 UPPER ROLLER ASSY
No. PARTS Q'TY REMARKS IDLER SIDE

1 CAPSCREW 2 M16 X 80
2 NUT 2 M16 2 1
3 ROLLER ASSY 2 -
F17567
3
Fig. 3-1 Upper roller assy
3.2 REMOVING
(1) Preparation for removal
Remove crawler (2).
(2) Removing upper roller (3)
1) Remove nuts on support tightening section, and
also remove cap screw M16 X 80.
: 24 mm (1)
M16 X 80
Fig. 3-2 Removing upper roller
3.3 INSTALLING IDLER SIDE

3 Countersinking
(1) Inspection
2
Before reassembling, check it that it rotates
smooth manually and for leakage.
Up
(2)Installing upper roller (3)
1)Fit it directing nut toward idler side.
2)Insert it until collar comes in contact with support.
3)Fit it directing the countersinking mark of shaft 1 Apply Loctite #262
SUPPORT
end upward. COLLAR T=28.5 kgf·m (210 lbf·ft)
4) Apply Loctite #262 on capscrew M16 X 80, and
Fig. 3-3 Installing upper roller
tighten it to the specified torque.
: 24 mm
31102 60413252
Fig. 3-4 Installing upper roller (3)
34-5
TRAVEL SYSTEM
3.4 CONSTRUCTION 10 7 8 1 5 6 11
2
1 ROLLER 1 7 O-RING; G45 1A 1
2 SHAFT 1 8 SOCKET BOLT;
3 PLATE 1 M8 X M16 2
4 COVER 1 9 SNAP RING 1
5 BUSHING 1 10 PLUG 1
6 FLOATING SEAL 1 11 COLLAR 1
F17568
9 4 3
Fig. 3-5 Construction of upper roller
3.5 DISASSEMBLY AND ASSEMBLY 8 9

(1) Disassembly 3
10
1) Draining out oil
7
Remove plug (10) and drain out oil. 4
: 5 mm
1
2) Removing snap ring (9)
Mount the end face inside upper roller (1) on stand
jig (f) and separate snap ring (9), using snap ring
pliers. f
3) Removing cover (4)

Take off cover (4) upwards, utilizing the screwed
hole for the plug.
4) Removing O-ring (7) Fig. 3-6 Removing snap ring (9), cover (4), O-ring (7),
plate (3)
Separate O-ring (7) from cover (4).
5) Removing plate (3)

Loosen two socket bolts (8) and draw out plate (3) Push with press
from upper roller (1).
: 6 mm
g
6) Removing shaft (2)
Put the extrusion jig (g) against the end face of 2
shaft (2) and lightly extrude shaft (2) with retainer
for floating seal (6), using a press or hammer.
Press machine capacity: 10 ton class. 6
31102 60413252
Fig. 3-7 Extruding shaft (2)
34-6
TRAVEL SYSTEM
7) Removing floating seal (6).

Take out floating seal (6) from upper roller (1).
6
Fig. 3-8 Taking out floating seal (6)
8) Removing floating seal (6).

Take out, from retainer, floating seal (6) that is 2
located on the side from which shaft (2) was

disparted. 6
WARNING RETAINER
Retainer is press fitted into shaft (2). Therefore do not
disassemble it.
9) Removing bushing (5).

Since the thickness of bushing is thin, remove it
Push-out bar
through lathe or strip it. When the wear of bushing
is too small, place upper roller (1) on jig (f) for
repair stand and apply push-out bar on the end
face of busing (5), and push it out by striking it with 5
mallet.
1
(2) Assembly
Fig. 3-10 Extruding bushing (5)
Assembly of the upper roller is done in the reverse
order of disassembly.
1) Pressing the bushing (5).
Push with press
Align inner hole of roller (1) and bushing (5) and
press fit it vertically with press so that jig (h) for h
bushing push-in jig (h) is inserted into bushing (5).
5
31102 60413252
WARNING
If you fail in this operation by pressing the bushing 5
f
unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing
as it may develop malfunctioning after assembly.
Fig. 3-11 Pushing in bushing (5)
34-7
TRAVEL SYSTEM
2) Installing floating seals (6). 6

2
Two floating seals (6) make a pair. Attach one
6 1
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1).
• Prior to placing floating seal (6) in, apply engine
COLLAR
oil lightly to seal surface.
Fig. 3-12 Fixing floating seal (6)
3) Inserting shaft (2).

Coat shaft (2) with a thin film of oil and insert it into
2
upper roller (1).
4) Installing plate (3).
Mount upper roller (1) on the stand jig (f) and
attach plate (3) to the end face of the shaft with
socket bolt (8). In that case, coat the screwed part 1
of socket bolt (8) with Loctite #242 beforehand.

: 6 mm
Fig. 3-13 Pressing the shaft (2)
5) Installing O-ring (7). 9

8
Fit O-ring (7) to the groove of cover (4). 7
4
• Apply grease to O-ring.
3
6) Installing cover (4). 1
Attach cover (4) to upper roller (1). Use a press in
this operation as a press fit is used.
7) Installing snap ring (9).
Fix snap ring (9) into upper roller (1), using snap
f
ring pliers.
Fig. 3-14 Installing plate (3), O-ring (7), cover (4),snap ring (9)
8) Filling oil
Fill in 20 cc (1.22 cu-in) of engine oil API grade
10
CD#30 through the plug hole in cover (4).
9) Installing plug (10). 4
Place seal tape around plug (10) and screw it into 1
the plug hole of cover (4).
: 5 mm
31102 60413252

• After assembling the upper roller, confirm that
f
oil is not leaking from it and that it rotates
smoothly by hand.
Fig. 3-15 Filling oil
34-8
TRAVEL SYSTEM
(1.34˝)
A
Ø34
D C
E
Fig. 2-15 Upper roller
Table 2-1

A Tread dia. Ø82 (3.23) Ø73 (2.87) Ø70 (2.76)
B Tread width 102 (4.02) 95 (3.74) 92 (3.62)
Replace
dimension
C Clearance between -0.025
shaft and bushing Ø32 -0.050 Clearance Clearance
(1.2598) Shaft -0.00098 0.7 (0.028) 1.0 (0.04)
-0.00197 Replace
0 bushing
D Interference between Ø36 Hole -0.03 Interference Clearance
roller and bushing (1.4173) 0 0 0.01 (0.0004)
-0.0012
E Tightening torque of 3.4 kgf·m (25 lbt·ft) Apply Loctite
socket bolt #242
Oil Engine oil API grade CD #30, 20 cc (1.22 cu·in) Replenish.
Roller rotation Roller rotates smoothly by hand. Reassembly.
3.7 TOOL AND JIGS

Table 2-2
No. JIGS SHAPE No. JIGS SHAPE
For extruding
g
shaft
f Stand jig
Bushing fixing
31102 60413252
h
jig
34-9
TRAVEL SYSTEM
4. LOWER ROLLER (TRACK ROLLER)
4.1 LOWER ROLLER ASSY
1 4
Apply Loctite #262
T=18.5 kgf·mm (130 lbf·ft)
Fig. 4-1 Lower roller assy
4.2 REMOVAL
(1) Where crawler (2) is removed
1) Preparation for removal
Loosen grease nipple to slacken the link. Put
wood blocks on the front and rear sides of under
section of lower frame, and stabilize the machine.
2) Removing lower roller
Remove capscrew (1) M14 X 55.
: 22 mm
Weight of lower roller: Approx.15 kg (33 lbs) F17570
Fig. 4-2 Holding up the lower frame
(2) Where crawler (2) is installed.

1) Preparation for removal
Slacken crawler (2), and stop engine keeping
lower frame lifted up with front attachment.
2) Put safe blocks under the front and rear sides of
lower frame.
3) Remove lower roller
Remove cap screw (1) in the same procedure as
that shown in Fig. 4-1.
Fig. 4-3 Removing lower roller
4.3 INSTALLATION
(1) Securing lower roller temporarily GREASE NIPPLE
Apply Loctite #262 on 4 capscrews (1) and tighten
them temporarily.
: 22 mm
31102 60413252
(2) Securing lower roller regularly.

Tighten capscrews (1) to the specified torque.
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
Fig. 4-4 Adjusting tension of crawler
34-10
TRAVEL SYSTEM
4.4 CONSTRUCTION T=2.4 kgf·m (17 lbf·ft)

8
No. PARTS Q'TY
1 ROLLER 1
2 SHAFT 1
3 BUSHING 2
4 PIN 2
6 O-RING 2
7 COLLAR 2
8 PLUG 2
9 SEAL 2
F17571
1 2 3 9 6 4 7
Fig. 4-5 Construction of lower roller
4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
Ø14
1) Drain oil (0.551˝)
J
Remove plug (8) and drain out oil.
: 6 mm
4
2) Removing pin (4)

Put both ends of lower roller assy on the V-shaped
blocks (K), apply push-out bar (j) on upper end
K
face of pin (4), and push pin out striking with
mallet.
Fig. 4-6 Drawing out collar fixing pin (4)
3) Removing collar (7), O-ring (6) Push with press Push with press
Put lower roller on jig (m) for repair stand so that
the shaft is perpendicularly located, apply push- P P
out jig (P) on shaft end on upper side, and push
shaft (2) until the O-ring separate from collar (7) 7 7
with press or mallet, and take out collar (7) and O-
ring (6). 6 6
4) Removing shaft (2)

In addition, push out and remove shaft (2) together
2 2
with the lower collar (7) and O-ring (6).
m m
31102 60413252
WARNING
The shaft (2) extrusion operation may cause the
remaining lube oil to flow out and contaminate the
floor. Prepare an oil container beforehand.
Fig. 4-7 Removing shaft (2), collar (7), O-ring (6)
34-11
TRAVEL SYSTEM
5) Removing collar (7), O-ring (6) 9
Insert shaft (2) with collar (7) and O-ring (6)

removed in the said procedure into roller (1)
directing the collar (7) side upward, and take out 7
collar (7) and O-ring (6) from shaft (2) in the same
procedure as that described in Item 3).
6) Removing floating seal (9)
Take out floating seal (9) from collar (7).
7) Removing floating seal (9)

Take out floating seal (9) from roller (1).
9
8) Removing bushing (3)

a
Since thickness of bushing (3) is thin, remove it
n
through lathe or strip it with care not damage inner Ø16 (0.63˝)
200 (8˝)
hole of roller. When the wear of bushing is not

large, place 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
3
with mallet.
WARNING m
Hammer the inside surface of roller lightly so as not to
damage the surface. Put the extrusion jig (n) uniformly Fig. 4-10 Extruding bushing (3)
over the circumference of bushing (3) and extrude it
little by little.
31102 60413252
34-12
TRAVEL SYSTEM
(2) Installing 6 2
1) Attach O-ring (6) to one side

Install O-ring (6) to shaft groove.
• Replace O-ring with new one. Fig. 4-11 Attach O-ring (6) to one side
2) Press fitting bushing (3) Push with press q

Align inner hole of roller (1) and bushing (3) and
press fit it vertically in capacity of press fit load,
3600kg (7940 lbs), in the condition that bushing 3
push-in jig (g) is inserted into bushing (3).
• Apply molybdenum disulfide grease on press- 1
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. 4-12 Press fitting bushing (3)
3) Press fitting collar (7)

Fit O-ring to the one side of shaft (2) mating pin
9
hole of collar (7) on which floating seal (9) is fit with 4
pin hole of shaft (2) in advance.
• Care should be taken not to damage O-ring (6)
while press-fitting collar (7) to shaft.
2
4) Inserting pin (4)

Press-fit pin (4) to pin hole on aligning pin holes of
shaft (2) and collar (7).
7
6
Fig. 4-13 Inserting pin (4)
5) Attach floating seal (9) to roller side

Fit floating seal (9) to inner holes on both ends of
roller (1).
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
6) Inserting roller (1) 1
Insert roller (1) from the side where collar (7), O-

ring (6) is not press-fitted to the shaft (2).
31102 60413252
Fig. 4-14 Inserting roller (1)
34-13
TRAVEL SYSTEM
7) Installing O-ring (6) Press
Install O-ring (6) to shaft groove.

• Apply grease to O-ring. PIN
• Replace O-ring with new one. 7
6
8) Press fitting collar (7)
Press-fit collar (7) to shaft (2).
• Press-fit collar (7) on aligning pin (4) hole.
2
9) Inserting pin (4)

Press-fit pin (4) described in to the pin hole mating
pin hole of collar (7) with pin hole on the end side
of shaft (2).
Fig. 4-15 Installing O-ring (6), collar (7)
10) Filling oil 8

Tightening torque:
Remove plug (8) and fill in 90 cc (5.49 cu·in) of 2.4 kgf·m (17 lbf·ft)
engine oil API grade CD#30.
11) Check it for leakage

Before tightening plug (8), check it for leakage in
the condition of air pressure 2.0 kgf/cm2 (28 psi).
12) Installing plug (8)

7
Apply oil resistant sealant on plug (8), and tighten
it in the plug hole on the collar (7) end face.
: 6 mm
Fig. 4-16 Installing filling oil plug (8)
WARNING
After assembling the lower roller, confirm that oil is not
leaking and that the roller rotates smoothly by hand.
31102 60413252
34-14
TRAVEL SYSTEM
C 95 (3.74)
G
(0.945˝)
ØD
E
ØA
ØB
24
199 (7.83˝)
Before tightening plug,
apply oil resistant sealant on it.
Tightening torque 2.4 kgf·m (17 lbf·ft)
Fig. 4-17 Lower roller (Track roller)

A O.D. of flange Ø147 (5.79) Reinforcement
weld. repair or
B Tread dia. Ø120 (4.72) Ø110 (4.33) Ø106 (4.17) replace
C Flange width 17.5 (0.689) 12 (0.472) 10 (0.394)
dimension
Clearance between
D shaft and bushing -0.060
(Coiled bushing) Ø40 -0.090 Clearance Clearance Replace
(1.57480) Shaft
-0.00236 0.7 (0.028) 1.0 (0.39) bushing
-0.00354
+0.025
E Interference between Ø44 -0.020 Interference Clearance
roller and bushing (1.73228) Hole +0.00098 0 0.01 (0.0004)
-0.00079
Oil Engine oil API grade CD #30, 90 cc (5.49 cu·in) Replenish.
Roller rotation Rotates smoothly by hand. Reassembly.
G Clearance between Keep 2.5±0.5 (0.09843±0.01969) space.
roller and collar
F17572
31102 60413252
34-15
TRAVEL SYSTEM
4.7 TOOL AND JIGS
No. JIGS SHAPE
k V-block
100 (3.94˝)
Pin (4)
extrusion rod Ø14
(0.551˝)
200 (7.87˝)
Bushing
n Ø16
extrusion rod (0.630˝)
Ø150 (5.91˝)
Ø100 (3.94˝)
m Stand jig
230 (9.06˝)
250 (9.84˝)
Shaft
p
extrusion jig Ø36 (1.42˝)
Ø58 (2.28˝)
(0.394˝) 10
Bushing 46
q 36 (1.81˝)
fixing jig (1.42˝)
Ø39.6 +0.1
0
(1.559˝ +0.004
0 )
F17573
31102 60413252
34-16
TRAVEL SYSTEM
5. FRONT IDLER (IDLER ADJUSTER ASSY)

700 IRON SHOE (27.6˝)
5.1 FRONT IDLER ASSY
205 495 IRON SHOE (19.5˝)
No. PARTS Q'TY REMARKS (8.07˝)
1 IDLER ASSY 2 - 1 116 270+STROKE 35
2 IDLER ADJUSTER 2 - (4.57˝) (10.6˝) (1.38˝)
3 GREASE NIPPLE 2 -
F17574
4 2 3
Grease nipple is
positioned on the outside
Apply Loctite #262 T=6 kgf·m (43 lbf·ft)
or equivalent
Fig. 5-1 Front idler assy
5.2 REMOVING
Remove crawler. (Above meationed)
(2) Removing front idler assy

PRY-BAR
Sling idler assy, and push it forward with pry-bar.
Weight of front idler assy : 146 kg (320 lbs)
Keep away from the front side of front idler.
(3) Installing
Fig. 5-2 Removing and installation the front idler assy
(4) Where idling assy (1) has to be separated 1

Loosen capscrew (4), and separate idler assy (1)
from idler adjuster assy (2).
: 19 mm
Weight of idler assy: 45 kg (99 lbs)
2
Weight of idler adjuster assy: 49 kg (110 lbs)
• The separated idler assy should be placed on
wood blocks.
31102 60413252
4
3
Fig. 5-3 Separating idler assy (1) from idler adjuster assembly
34-17
TRAVEL SYSTEM
5.3 IDLER ASSY

5.3.1 Construction 1
4 8
3
2
5
7
6 Storage procedure
Fig. 5-4 Idler assy
5
5.3.2 Removing and installing R
(1) Removing
1) Drain oil
Remove plug (8) on the side of collar (3) to drain
idler assy of oil.
: 5 mm
2) Removing pin (5)

Apply pin push bar (jig R) to the top of pin, and take Fig. 5-5 Removing pin (5)
out striking bar (jig R) lightly by hammer.
3) Removing collar (3)

Push with press
Put idler (1) on repair stand (U), apply push-out jig
(S) on shaft (2), push out shaft (2) with collar (3),
S
then remove collar (3). 2
3
1
U
3
Fig. 5-6 Removing collar (3)
4) Removing collar (3) from shaft (2)

Push with press
If removal of collar (3) on the opposite side is
required, turn over front idler and proceed with the
procedure described in Item 3). S
2
3
31102 60413252
Fig. 5-7 Removing coller (3)
34-18
TRAVEL SYSTEM
5) Removing bushing (4) T 4

1
With idler (1) mounted on the stand, tap bushing
(4) lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing (2)
evenly all round, till it comes out.
6) Removing floating seals (6)

Take out floating seals (6) from idler (1), collar (3). U
If you intend to re-use floating seals (6), confirm
that there is no scoring and rusting on the contact Fig. 5-8 Removing bushing
surface and store the floating seals in pairs by
placing thick paper between the sealing faces.
7) Removing O-ring (7)

Separate O-ring (7) from shaft (2). Push with press
4 V 1
(2) Assembly
1) Pressing in bushing (4)
Align inner hole of idler (1) and bushing (4) and
press fit it vertically with press so that jig (V) for
bushing press-fitting jig (V) is inserted into bushing
(4). Fig. 5-9 Pressing in bushing (4)
2) Installing O-ring (7)

Fit O-ring (7) to O-ring groove on shaft (2).
Pressing
3) Installing collar (3) (see Fig. 5-10)
Press fit the O-ring installed side of shaft into collar 2
(3), and drive pin (5).
4) Installing floating seal (6) 3

Fit one piece of two (2) pieces type floating seal (6) 5
on each side of collar (3).
5) Inserting idler (1)

Fig. 5-10 Installing collar (3), shaft (2)
Insert floating seal (6) fitted side of idler (1) into
shaft (2).
6) Installing floating seal (6)

Fit floating seal (6) on the other side of idler (1).
2
6
1
31102 60413252
Fig. 5-11 Inserting idler (1) and installing floating seal (6)
34-19
TRAVEL SYSTEM
(2) Assembly W
Assembly is done in the reverse order of 1

disassembly.
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1) into spring (5) and 5
attach lifting eye nut (W) to screw M36 X 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. 5-21 Mounting spring (5) and grease cylinder (1) to the jig
2) Fixing idler adjuster assy Holding-down nut

Install bracket (2) on top of spring (5). Center the Retainer plate
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
2
the idler adjuster assy to the jig body.
4
: 46 mm
3
3) Compressing spring (5) and removing nut (3) 1

Extend the hydraulic jack, compress spring (5) to
Fig. 5-22 Compression of spring (5), and attaching nut (3)
a set length and screw in nut (3) to the screwed and spring pin (4)
part at the tip of grease cylinder (1).
Set length of the spring: 270 mm (10.63 in)
4) Installing spring pin (4)

Tighten nut (3) till the holes for locking spring pins
(4) are aligned. Then fit spring pin (4).
: 46 mm
: 55 mm
5) Removing idler adjuster assy

Remove idler adjuster assembly from jig.
31102 60413252
Fig. 5-23 Removing idler adjuster assy
34-20
TRAVEL SYSTEM
6) Installing oil seal (8), O-ring (7) 1
Fit oil seal (8) and O-ring (7) to grease cylinder (1).
8
• Apply grease to oil seal (8) and O-ring (7).
7
7) Filling grease cylinder (1) with grease. 6
Fill grease cylinder (1) with grease, remove grease
nipple from piston (6), and press piston by hand to
discharge air through grease nipple hole.
• Direct grease nipple hole downward to make
air discharge easier. 10
Fig. 5-24 Grease cylinder (1)

8) Installing grease nipple (10)
Tighten grease nipple (10) to piston (6).
: 19 mm
5.3.3 Maintenance standard
No. ITEM STANDARD

VALUE
A Installed length of spring mm 270 (10.63 in)
B Free length of spring mm About 320
(12.6 in)
C Stroke mm 35 (1.38 in)
D Set length mm 495 (19.49 in) E
E Outer circumference of piston Nor scoring
and rusting
A, B
F Tightening torque of grease nipple 6 kgf·m D F
(43 lbt·ft)
Close contact length of spring 235 (9.25 in)
F17579
Fill it with grease and bleed air.
31102 60413252
34-21
TRAVEL SYSTEM
6. SPROCKET
6.1 REMOVING
Remove crawler referring to Section 1. "Crawler",
lift up crawler frame with attachment, and put it on
wood blocks to float and stabilize.
(2) Removing sprocket

Loosen twelve capscrews (2) (M14) for the
mounting of the sprocket by means of a socket
and remove the sprocket. Fig. 6-1 Preparation for removal
Weight of sprocket: 28 kg (62 lbs)
: 22 mm
1
Fig. 6-2 Removing sprocket
6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction
gear and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.
(2) Securing sprocket temporarily.

Coat the sprocket mounting capscrews with Loctite
#262 and fasten the sprocket temporarily.
(3) Securing sprocket completely

Take out wood blocks placed under track frame,
and tighten capscrews to the specified torque. Fig. 6-3 Securing sprocket completely
31102 60413252
: 22 mm
34-22
TRAVEL SYSTEM
Table 6-1
PITCH 78.7 mm NUMBER OF 21

PRINCIPAL (3.10 in) TEETH
PARTICULARS ROLLER Ø41 527.9
DIA. (1.61 in) PITCH DIA. (20.78 in)
F17580
155.6±1 (6.1260˝±0.0394˝)
394˝)
± 1 (3.0984˝± 0.0 62°±
3´
78.7 4 (0.157˝)
94˝)
(0.3 0
4 (0.157˝)
1
(0
.3
10 ˝)
94
.64
(0.813˝)
20.64
20 13˝)
(0.8
(20.7834 7.9
˝)
P.C.D 52
Fig. 6-4 Sprocket

STANDARD
No. ITEM VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
Ø540 +30 534 532 Reinforcement weld,
A O.D. of sprocket repair or replace
(21.260 +0.118
0 ) (21.0) (20.9)
38 -30
B Width of sprocket teeth 0 32 (1.26) 30 (1.18) Replace.
(1.4961 -0.118 )
C I.D. of sprocket Ø487 (19.2) 481 (18.9) 479 (18.9) Reinforcement weld,
repair or replace
F17581
6.4 SPROCKET TOOTH PROFILE GAUGE

31102 60413252
Fig. 6-5 Tooth profile gauge
34-23
TRAVEL SYSTEM
7. TRAVEL MOTOR
Apply Loctite #262
2 T=18.5 kgf·m (130 lbf·ft)
7.1 TRAVEL MOTOR
TRAVEL MOTOR INSTALL
No. PARTS Q'TY REMARKS
1 SPROCKET 2 -
4 TRAVEL MOTOR ASSY 2 - 3
F17582 Apply Loctite #262
D2 (PF 3/8) or equivalent
B (PF 1/2)
P (PF 1/4)
A (PF 1/2)
D1 (PF 3/8) Fig. 7-1 Installing travel motor

VIEW I
7.2 REMOVING 1, 2
Remove crawler, lift up crawler frame using
attachment, and put it on wood blocks to float and
stabilize. 8
(2) Removing cover (1), (2)

Remove capscrew (8) and also remove covers
(1), (2).
: 19 mm
Fig. 7-2 Removing and installing capscrew (3),(8)
(3) Preparation of oil pan
(4) Removing hydraulic pipe

Bleed air in hydraulic oil tank, remove all pipes
connecting to travel motor. Then plug up all pipes
31102 60413252
and joint section to protect them from entry of dust.

: 19 mm, 22 mm, 24 mm, 27 mm, 32 mm
Plug 4-1
Fig. 7-3 Removing and installing hydraulic pipe
34-24
TRAVEL SYSTEM
(5) Removing sprocket

Removing twenty four capscrews (2) M14 X 35.
: 22 mm
Fig. 7-4 Removing and installing sprocket
(6) Loosening travel motor mounting bolts Remove pipes (disconnect)

Apply match marks on travel motor and lower
frame, and remove twenty four capscrews (3)
M16 X 40.
: 24 mm
Fig. 7-5 Removing and installing travel motor mounting bolts
(7) Slinging travel motor assy

Sling travel motor with nylon sling applied on the
the side close to sprocket installing section and
remove the motor.
Weight of motor Approx.90 kg (198 lbs)
Fig. 7-6 Slinging travel motor
TIGHTENING
7.3 INSTALLING PARTS SIZE TOOLS No. TORQUE REMARKS
Installing of the travel motor piping is performed in the kgf·m(lbf·ft)
reverse order of removal. M14 22 2 18.5 (134)

Capscrew
1) Cleaning M16 24 3 28.5 (210) Apply
loctite #262
Check that contact surface of travel motor and Flareless Ø10 X 1.5 19 - 5 (36)
31102 60413252
track frame is free from burr and stain. nut for Ø15 X 2.0 27 - 12 (87)
pipes,
2) Tightening torque sleeve Ø18 X 2.5 32 - 15 (110)
Tighten capscrew and hydraulic pipes to the PF1/4 19 P 3.7 (27)
specified torque. Connector PF3/8 22 D1,D2 7.5 (54)
PF1/2 27 A,B 11 (80)
F17583
34-25
TRAVEL SYSTEM
8. SWING BEARING
8.1 SWING BEARING ASSY
No. PARTS Q'TY REMARKS

1 SWING BEARING 1 -
F17584 FRONT
A A
2
Apply Loctite #262 or
equivalent to be applied
1
Inner S mark position
of swing bearing
Fig. 8-1 Swing bearing assy
SECTION A-A
NOTE:
Fill grease bath with 5 kg (11 lbs) of grease NLGI-2
(molybdenum disulfide grease) or equivalent
8.2 REMOVING SWING BEARING

(1) Matchmarks OUTER RACE
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. INNER RACE
MATCHMARKS
(2) Remove thirty capscrews (2) M16 X 90 for
installation inner race.
Fig. 8-2 Matchmarks
(3) Drawing out grease

Remove grease in grease bath.
(4) Removing swing bearing SWING BEARING

Attach eyebolt on swing bearing (1) and sling it. EYE BOLT
Weight of swing bearing: 110 kg (240 lbs)
31102 60413252
GREASE BATH
Fig. 8-3 Removing and installing swing bearing
34-26
TRAVEL SYSTEM
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and stain.
(2) Installing
Install swing bearing on lower frame meeting the FRONT
A A
matchmarks and positioning the S mark on inner
race as shown in the figure.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) (24 pcs) to
an extent that they are fastened temporarily.
: 24 mm
Inner S mark position
(4) Regular tightening of inner race of swing bearing
Fasten the capscrews (2) (24 pcs) at 180° intervals
Fig. 8-4 Location of S mark on swing bearing
alternately and tighten them up to a specified
torque.
: 24 mm 2
Tightening torque: 28.5 kgf·m (210 lbf·ft) Apply Loctite #262 or
equivalent to be applied
(5) Filling grease T=28.5 kgf·m (210 lbf·ft)
Fill grease bath with 5 kg (11 lbs) of grease NLGI-
2 (molybdenum disulfide grease) or equivalent.
1
SECTION A-A
Fig. 8-5 Removing and installing capscrew (2)
8.4 CONSTRUCTION
3, 4 6 2
1 OUTER RACE 1 6 SEAL 1 1
2 INNER RACE 1 7 GREASE NIPPLE 1 9
3 BALL 84 (PT1/8) 7
8
4 RETAINER 84 8 TAPER PIN 1
5
5 SEAL 1 9 PLUG 1
F17585
Fig. 8-6 Cross-section
8.5 DISASSEMBLY AND ASSEMBLY Eye bolt

6 2
(1) Disassembly
8
1) Take out seal (5) fitted in the groove in the outer
circumference under inner race (2) and seal (6) 1
fitted in the groove in the inner circumference on
Wood blocks
31102 60413252
top of outer race (1) and place them level on a

wood blocks or something.
2) Draw out taper pin (8), using a hammer and an
9
extrusion rod.
5
3) Draw out plug (9), inserting a pull bolt in the
screwed hole of the plug and using a puller. Fig. 8-7 Removing swing bearing
34-27
TRAVEL SYSTEM
3) While rotating outer race (1) little by little, take out 1

ball (3) and retainer (4) through plug hole, in that
order.
2
4
3
Fig. 8-8 Removing balls (3) and retainers (4)
(2) Installing
1) After cleaning grooves for seal (6) on inner surface
on the upper side of outer race (1), and for seal (5)
on the outer surface of inner race (2), apply
adhesive agent Cyano-bond PO-1, fit seal (5),
1
and place them on a surface plate.
2) Lower outer race (1) to the position where upper Push rod 6
surface of inner race (2) and lower portion of seal 2
groove are mated, put adjusting washer under 3
outer race (1) so that raceway surface of ball (3) Wood blocks 5
agrees, and support it.
Fig. 8-9 Fitting balls (3)
3) Insert ball (3) and retainer (4), on which grease is
applied, through plug (9) hole on outer race (1),
alternately.
Eye blte
WARNING
To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers
into plug hole. Hooked rod
4) Fit plug (9) to outer race (1) while checking it for 4

direction and position of taper pin hole.
Wood blocks
5) Apply adhesive agent Cyano-bond PO-1 to seal
(7), and fit it to groove of outer race (1).
6) Check that grease nipple (7) is properly fitted, and
Fig. 8-10 Fitting retainer (4)
fill it with grease. Then, check bearing for smooth
rotation and flaws on seal lip portion.

Maintenance standard concerning wear of swing
bearing is described in the item "Measuring Swing
31102 60413252
Performance" in the section "Maintenance Standard

and Test Procedure" in the separate volume.
34-28
TRAVEL SYSTEM

1. TRAVEL MOTOR
1.1 CONSTRUCTION
(1) General view
D1
D2
OIL LEVEL CHECK PORT PF3/8 FILLING PORT PF3/8
DRAIN PORT PF3/8

VIEW Z
Fig. 1-1
HYDRAULIC CIRCUIT
HI LOW
PORT NAME, SIZE
Table 1-1
No. PORTS SIZE
A Hydraulic oil filling / drain port
PF 1/2
B Hydraulic oil filling / drain port
D1 Drain port
PF 3/8
D2 Drain port
P 1st / 2nd speed select port PF 1/4
F17021
ROTATIONAL DIRECTION (viewed from Z side)

31102 60413252
INLET B PORT, OUTLET A PORT, CW

INLET A PORT, OUTLET B PORT, CCW
Fig. 1-2
34-29
TRAVEL SYSTEM
(1) Standard tools

1) Exploded view of reduction unit 1
21
31 19
3
2
21
30 5
43
12
23
9
23 18
12 34
4
8 35
22 29
28
6
7
25 15 F17683
25
20
22
3533
36
24
2) Exploded view of hydraulic motor

245
141 135
282 112
238 275
230 221 113
227 292
109
103
280 150 115
201 106
224 116 105
107
282
238 286
228 225 242 151
275 104
279
236 110
297 299 227
293 230 114
280 238
292 296 110
268 282 146 108
289 285
238 291 284 280 275
290 296 286 132
283 238 162 149
287 161
295 252 285 282
288 294 284
291 102 185
281 223
272 292
271 280 225
31102 60413252
293 177
292 275 297 228 176
221
294 236
288 224 F17684
295
287
290
238
289
34-30
TRAVEL SYSTEM
(3) Parts list

1 HUB 1 112 PISTON 1
113 SPRING 8
SPINDLE KIT 114 SPRING 1
• SPINDLE ASSY 1 115 FRICTION PLATE 2
2 • • SPINDLE 1 116 SEPARATOR PLATE 2
3 • • HOLD FLANGE 1 132 OIL SEAL 1
19 • REAMER BOLT 3 135 O-RING 1
141 O-RING 1
RV GEAR ASSEMBLING PARTS 1 146 SNAP RING 1
• RV GEAR KIT 1 149 BEARING 1
4 • • RV GEAR A 1 150 BEARING 1
5 • • RV GEAR B 1 151 BEARING (ROLLER) 3
9 • CRANK SHAFT 3 176 PIVOT 2
12 • SPACER 6 177 PARALLEL PIN 2
22 • BEARING 6 185 SPRING 1
23 • BEARING 6
REAR FLANGE ASSEMBLING PARTS 1
6 INPUT GEAR 1 • REAR FLANGE KIT 1
201 • • REAR FLANGE 1
SPUR GEAR KIT 1 223 • • SPOOL 1
7 • SPUR GEAR 3 252 • • SOCKET PLUG 2
268 • • STEEL BALL 1
FLOATING SEAL KIT 1 275 • • SOCKET PLUG 10
31 • FLOATING SEAL 2 279 • • FILTER 1
280 • • ORIFICE 4
8 COVER 1 283 • • PLUG (WITH FLANGE) 1
15 SHAFT 1 286 • • PISTON 2
17 PIN 28 299 • • NAME PLATE 1
18 RING 1
20 SNAP RING 3 • SPOOL KIT 1
21 BEARING 2 271 • • SPOOL 1
24 SNAP RING 1 272 • • OIL STOPPER 1
25 SNAP RING 6 221 • PLUG 2
28 O-RING 2 224 • PLUG 2
29 O-RING 1 225 • SPRING RETAINER 2
30 O-RING 1 227 • VALVE 2
33 PLUG (WITH FLANGE) 1 228 • SPRING 2
34 PLUG 2 230 • SPRING 2
35 O RING 3 236 • O-RING 2
36 STEEL BALL 1 238 • O-RING 6
43 PARALLEL PIN 2 281 • SPRING 1
282 • PLUG 4
PISTON KIT 1 284 • PLUG 2
• PISTON ASSEMBLING PARTS 9 285 • O-RING 2
105 • • PISTON 1 287 • VALVE 2
106 • • SHOE 1 288 • SLEEVE 2
289 • PLUG 2
• PISTON ASSEMBLING PARTS 1 290 • SPRING 2
161 • • PISTON 1 291 • O-RING 2
162 • • SHOE 1 292 • O-RING 4
293 • PISTON SEAL 2
102 SHAFT 1 294 • BACKUP RING 4
103 SWASH PLATE 1 295 • BACKUP RING 4
104 CYLINDER BLOCK 1 296 • STEEL BALL 2
31102 60413252
107 RETAINER PLATE 1 297 • ORIFICE 2

108 THRUST BALL 1
109 TIMING PLATE 1 242 PARALLEL PIN 2
110 WASHER 2 245 SOCKET BOLT 6
F17020
34-31
TRAVEL SYSTEM
1.2 TOOLS AND JIGS

(1) Standard tools
TOOLS SIZE Q'TY APPLICATION ITEM (No.)

Torque wrench Nominal 450 Dial type 1 284
Torque wrench Nominal 1800 Dial type 1 33, 34, 221, 245, 282, 289
Torque wrench Nominal 5500 Dial type 1 19, 224
Allen wrench Nominal 5 1 284
Allen wrench Nominal 6 1 34
Allen wrench Nominal 8 1 33, 34, 221
Allen wrench Nominal 10 1 245, 282
Socket Nominal 5 Inset square 12.7 1 284
Socket Nominal 8 Inset square 12.7 1 33, 34, 221
Socket Nominal 10 Inset square 12.7 1 245, 282
Socket Nominal 22 Inset square 12.7 1 289
Socket Nominal 36 Inset square 12.7 1 19, 224
Extention bar Inset square 12.7 1 19
Spanner Round shaped powerful spanner 36 1 224
Hammer Nominal 12 1 1, 21
Plastic hammer L=300 (12˝) or so 1 8, 102
Snap ring pliers For shaft 1 24, 25
Snap ring pliers For bore 1 20, 145
Center punch Ø9.5 X 100 (0.374˝ X 4˝ ) 1 1
Pin punch Ø3 X 150 (0.127˝ X 6˝ ) 1 21
Lifting tool Hook, wire rope 1 Set 1,2 for lifting
Car washing brush 1 Cleaning the parts
Wire brush 1 Cleaning the parts
Container Vat for general use
Lubricant, draining hydraulic oil
W450 X D300 X H120 3
ball (36, 268, 296) retainer
(W18˝ X D12˝ X H5˝ )
Paint marker Oil base white 1 For matching mark
Metal screen basket 1 17
Rubber mat 1
Leather gloves 1 Pair 149
Jug For hydraulic oil, For lubricant. 2 Oil filling
F17685
31102 60413252
34-32
TRAVEL SYSTEM
(2) Tools
TOOLS SIZE APPLICATION ITEM (No.) Q'TY

General work bench Disassembly and assembly 1 set
Cleaning bath For rough cleaning and finish cleaning Cleaning the parts 1 set
Work bench for press Pressing capacity 200 kg (441 lb) or over 104, 149 1 set
Heating bath Heating capacity 100°C (212°F) or over 149 1 set
Size 500 X 500 X 500 (20˝ X ~20˝ X ~20˝ X)
Electric drill Portable electric drill 1 1
[Max. drill depth Ø10 (0.394˝)]
Drill Ø2 (0.0787˝) 1 1
Compressed air Pressure 3~5 kgf/cm2 (43~71 psi) Disassembly 161,162,163, 112
Drying after cleaning
Lathe 3 1 set
(4) Measuring instrument
TOOLS SIZE APPLICATION ITEM (No.) Q'TY

Thickness gauge Measurement range: 0.04~0.3 mm For snap ring (20)
2
(0.0016~0.012 in) thickness adjustment
Outside micrometer Measured range: 0~25 mm (0~0.98 in) For snap ring (20)
1
Minimum graduation: 0.01 mm (0.0004 in) thickness adjustment
Single depth Measured range: 0~25 mm (0~0.98 in) For bearing (21) pre-load
1
micrometer Minimum graduation: 0.01 mm (0.0004 in) adjustment
F17686
31102 60413252
34-33
TRAVEL SYSTEM
1) Working bench for travel motor

This is used to carry out the work for assembly and
disassembly of travel motor easy and safe.
2) Fixing metal
This is used to connect spindle (2) and hub (1).
3) Retainer metal (I)

This is used to insert spring (114), washer (110),
snap ring (145) into cylinder block (104).
4) Retainer metal (II)

This is used to pull out bearing (149) from shaft
(102).
31102 60413252
34-34
TRAVEL SYSTEM
5) Retainer metal (III)

This is used to press fit oil seal (132) into oil seal
fitting hole of spindle (2).
6) Retainer metal (IV)

Apply it on outer race of bearing (22) fitted on
crankshaft (9) of RV gear assy, then strike it to
insert RV gear assy securely.
7) Jig for adjusting the preload to the bearing

This is used to press fit bearing (21) in hub (1), and
also used to measure clearance of bearing (21) in
shaft direction.
8) Steel rod (I)

This is used to remove ring (18) from hub (1).
31102 60413252
34-35
TRAVEL SYSTEM
9) Eye bolt for PF

This eye bolt is used to remove cover (8) from hub
(1) with wire and crane.
Screw size: PF3/8
10) Long eye bolt APPLICATION "A"

This eye bolt is used to sling up travel motor, Hub M14
spindle (2) and hub (1). Spindle M16
Travel motor M16
F17687
11) Spatula
This is used to remove timing plate (109) from rear
flange (201).
12) Pin punch

This is used to remove outer race of bearing (21).
31102 60413252
34-36
TRAVEL SYSTEM
13) Jig for removing cover

This is used to remove cover (8) from hub (1).
14) Floating seal fitting tool (I)

This is the tool that is used to assemble floating
seal (31) to hub (1).
15) Floating seal fitting tool (II)

seal (31) to spindle (2) and hub (1).
16) Floating seal fitting tool (III)

seal (31) to spindle (2).
31102 60413252
34-37
TRAVEL SYSTEM
1.3 TIGHTENING TORQUE

APPLICATION BOLT - NUT OPPOSING TIGHTENING TORQUE
ITEM
(No.) Parts Size FLATS (mm) kgf·m (lbf·ft)
19 Reamer bolt M24 P2.0 36 81 ± 5 (586 ± 36)
33 Plug (with flange) PF3/8 8 6.0 (43)
34 Plug PF3/8 8 6.0 (43)
221 Plug PF3/8 8 6.0 (43)
224 Plug M30 P1.5 36 36 (26)
245 Socket bolt M12 P1.75 10 10.4 (75)
282 Plug PF1/2 10 10 (72)
284 Plug PF1/8 5 1.25 (9.0)
289 Plug PF1/2 22 10 (72)
1.4 WEIGHT
PARTS WEIGHT [kg (lb)]
Travel motor assy Approx. 81 (179)
Hub 19 (41)
Spindle 27 (60)
Rear flange assy 9.7 (21)
F17688
31102 60413252
34-38
TRAVEL SYSTEM
1.5 DISASSEMBLY 7) It is a rule to replace seals once disassembled.

(1) Preparation (even though they are not scored on an
Prepare as below before disassembly : appearance) Get new seals ready before
1) Preparation of work bench disassembly.
Prepare a work bench for the travel motor. 8) Photos and illustrations shown are typical models.
The work bench must be sufficiently solid to Although they may differ from those in use, they
disassemble and assemble the internal do not affect the disassembly procedure.
components of the travel motor and sufficiently
spacious to place components so components do
not fall or move during operation.
Place a rubber or plastic sheet on the work bench.
2) Preparation of tools and materials
Prepare those tools and materials listed under
article 1.2.
(2) General precautions to be exercised at work
WARNING
• The internal components are wet with hydraulic oil
and slippery during disassembly : Handle them with
care because you may be injured by the fall of
components may or components may be damaged.
• Such flammables as clear kerosene are used to
clean components. Handle flammables as they are
easy to be caught a fire.
1) Before disassembly, decide inspection points and

check the nature of the trouble.
2) Handle the components with care as they are
finished to high precision. Take care so as not to
hit and drop the components.
3) If the components are struck or twisted by force
during disassembly, they develop burrs or broken
in some cases. This makes the components unable
to be reassembled or deteriorates the
performances. Therefore, handle them with care
and patience.
4) If components are left separated or in the midst of
disassembly, they develop rusting by humidity
and dust. Take rust and dust prevention treatment
in case work is suspended halfway.
5) During disassembly, leave a matching mark on
the mating face of each component.
6) Arrange disassembled components in order as
31102 60413252
the work proceeds so they are not damaged or lost

during work.
34-39
TRAVEL SYSTEM
(3) Removing
1) Cleaning travel motor
1. Tighten the eye bolts into the tapped holes of the
spindle (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.
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.
1 2
2) Installing travel motor

1. Fix travel motor with two socket bolts on working
bench.
• Align threaded holes of hub (1) and working
bench and place travel motor in fixing hole of
working bench slowly.
WARNING
Tighten up the socket bolts rigidly. Unless tightened
rigidly, the components drop as the travel motor is
turned over and cause bodily injuries.
31102 60413252
34-40
TRAVEL SYSTEM
3) Draining oil.
1. Turn over the travel motor.
2. Loosen one plug (33) and two plugs (34).
• If the plug (33), (34) is removed and the travel
motor is reversed, oil spills. Stop loosening the
plug when it can be turned by hand.

• When draining out the oil, place a container
under the work bench.
33
34
4. Remove one plug (33) and two plugs (34) from the OIL FILL PORT
(PF3/8)
cover (8) and drain out the oil.
5. Remove O-ring (35), one plug (33) and two plugs
(34).
6. Remove O-ring (35) from two plugs (34).
• Do not reuse removed O-ring (35).
33
DRAIN PORT (PF3/8)
4) Removing cover.
2. Mark on the mating surface between hub (1) and
cover (8), using marker paint.
8 1
18
3. Find the mating part of ring (18), and punch at a
point of the outside of the hub, approximately 20
mm (0.8 in) inward from the tip of ring (18) for
drilling purpose.
(Mating part)
31102 60413252
COVER (8) RING (18)
Ø2
(0.08˝)
HUB
34-41
TRAVEL SYSTEM
18
4. Drill through a 2mm (0.08 in) hole from the outside
of hub (1) toward ring (18) using electric drill.
• Put a drill against the punched hole and drill it
through so the ring takes off the cover as it is
pushed by the drill.
• Wipe off the metal chips produced by drilling so
they do not score the parts to be removed.
18
5. Put a steel bar into the hole and push ring (18).
• In that case, the tip of the ring (18) stands out
above the cover (8) as pressed by a steel bar.
8
8
6. Hold the tip of ring (18) sticking out of the cover (8)
and draw the ring (18) out of the ring groove of the
hub (1).
18 1
7. Fix two bolts inside of jig to the plug holes of drain

(33) (34).
• In case the cover (8) is hard to remove because
of the resistance of the O-ring (29), lift it up
while lightly tapping the outer rim of the cover
31102 60413252
by means of a plastic mallet.
8 COVER REMOVING JIG
34-42
TRAVEL SYSTEM
8. Tighten two bolts outside of jig then two bolts

(installed in plug holes) inside of jig float with cover
(8).
9. Remove O-ring (29) from cover (8).
8 (29)
15
5) Removing input gear.
1. Remove snap ring (24) from shaft (15).
• When the snap ring is removed, the tip of the
pliers slips from the snap ring hole and the
snap ring jumps up in some cases. Be careful
not to slip the pliers.
24
36 6
2. Remove input gear (6) from shaft (15).
15
9, 25
6) Removing spur gear
1. Remove two snap rings (25) from crank-shaft (9).
31102 60413252
34-43
TRAVEL SYSTEM
7
2. Remove three spur gears (7) from crank-shaft (9).
9
3. Remove three snap rings (25) from crank-shaft
(9).
25
15
7) Removing shaft
1. Remove shaft (15) from shaft (102).
289
8) Removing rear flange
1. Turn over the travel motor
• This work is intended to remove the plug easily
when removing the inside of the rear flange.
• On that occasion, loosen the plug so it can be
31102 60413252
removed by hand.
• Do not loosen the plug if you do not remove the
inside of the rear flange.
2. Loosen two plugs (282)

3. B Loosen two plugs (289)
34-44
TRAVEL SYSTEM
4. Loosen two plugs (224)

5. Loosen six socket bolts (245) from rear flange
(201).
245
201
6. Remove rear flange (201) from spindle (2).
• Hold the rear flange by both hands, hold it up
gently upright and remove it.
Forced prying or striking it may cause timing
plate (109) to fall and damage it.
7. Remove parallel pins (43) from spindle (2).
43
8. Remove O-ring (28),(30) from spindle (2).

• Do not reuse removed O-ring (28), (30).
31102 60413252
30 28
34-45
TRAVEL SYSTEM
9) Removing the rear flange fittings

1. Place rear flange (201) on a work bench, with the
mating surface for spindle (2) facing up.
2. Remove timing plate (109) from rear flange (201).
• 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 flange side and hold
the timing plate up. Then the rear 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. 210 109
3. Remove parallel pins (242) from rear flange (201).
242
201
4. Remove bearing (150) from rear flange (201).
150
201
10) Removing the shockless relief valve (SRV) from

the rear flange.
1. Remove two plugs (282) of rear flange (201).
2. Remove O-ring (238) from plug (282).
31102 60413252
282 210
34-46
TRAVEL SYSTEM
3. Remove piston (286) from rear flange (201).
201
238
4. Remove two plugs (289) from rear flange (201).

289 238
6. Remove spring (290), valve (287) and sleeve

(288) from rear flange (201) in that order.
287, 288, 290 201
7. Remove O-ring (292), backup ring (294) from

sleeve (288).
• Do not reuse removed O-ring (292) and backup
ring (294).
31102 60413252
294 288
34-47
TRAVEL SYSTEM
8. Remove piston seal (293) from valve (287).

• Do not reuse removed piston seal (293).
PISTON SEAL (293)
VALVE (287)
9. Remove plug (285) and steel ball (296) from rear

flange (201).
• Do not disassemble plug (285) except in case
necessary.
• Be careful to fall the steel ball (296).
201
285, 296
11) Removing the brake valve parts from the rear

flange.
1. Remove two plugs (224) of rear flange (201).
236, 224 201
3. Remove two spring retainer (225) and two springs

(228) from rear flange (201).
4. Remove spool (223) from rear flange (201).
• To remove spool (223), place your hand on
one part of the plug port of rear flange (201)
31102 60413252
and tilt it down. Then spool (223) falls down.

Hold the tip and remove it.
201
223, 225, 228
34-48
TRAVEL SYSTEM
5. Remove two plugs (282) from rear flange (201).

282
238
7. Remove two springs (230) and two valve (227)

from rear flange (201).
227, 230 201
12) Removing the pilot valve parts from the rear

flange.
1. Remove plug (221), spool (271) and spring (281)
from the rear flange (201).
221
• Do not reuse removed O-ring (292). 271
281
112
13) Removing the parking brake
WARNING
The sudden blowing of compressed air may cause
piston (112) to jump out of the spindle (2) incurring the
31102 60413252
danger of injury. Cover piston (112) for protection.
1. Blow jet air into the passage hole for the paring
brake of the spindle (2) and take out the piston
(112) from the spindle (2).
2
34-49
TRAVEL SYSTEM
112
2. Remove O-ring (135), (141) from piston (112).
• Do not reuse removed O-ring (135), (141).
135, 141
14) Removing the hydraulic motor section

• When placing the travel motor on its side, oil
spills; place a container under the travel motor.
1. Incline travel motor 90 degree. (Lay it down.)

2. Drain out the oil of the travel motor.
115
3. Remove two friction plate (115) and two separator 116
plate (116).
4. Hold cylinder block (104) by hand, remove shoe

(106) adhered on swash plate (103) turning 2 or 3
times alternately. 106
• If the cylinder block is pulled out without

separating shoe, the shoe (106) remained on
swash plate (103) (piston, shoe) may drop in
spindle (2).
5. Remove cylinder block (104) from shaft (102).

6. Remove piston assy [piston (105) and shoe (106)]
and retainer plate (107) from cylinder block (104).
164 102 2
• When removing the cylinder block, hold the

retainer plate (107) by both hands and remove
it with the piston assy.
• The piston (105) and the shoe (106) are made
in one piece as they are caulked by the spherical 106
surface of the piston. It is not possible to
31102 60413252
remove the piston from the shoe without 107

damaging the shoe. When replacement is
105
required, replace 9 sets of piston (105) and
shoe (106). (Hereafter called piston assy.)
104
34-50
TRAVEL SYSTEM
7. Remove the piston assy (105), (106) from retainer

plate (107). [Nine pistons]
105, 106
107
8. Remove thrust ball (108) from cylinder block (104).
108
104
151
9. Remove three rollers (151) from cylinder block
(104).
104
15) Remove spring (114) from inside of cylinder block.

1. Place cylinder block (104) on the press bench.
• Do not remove the spring except when PRESS
replaced.
• When removing the spring, align the Jig (I) with
the washer in order to prevent the cylinder
31102 60413252
block from being damaged by contact. Plastic sheet

• Put a plastic sheet over the cylinder block so as
not to score the surface of the cylinder block.
JIG 104
34-51
TRAVEL SYSTEM
2. Apply Jig (I) on washer (110), remove snap ring JIG (I)
PRESS
(146) from the groove with snap ring plier pressing
146
the metal with a press.
114
110 104
WARNING
Release press slowly. Sudden releasing may cause
spring to fly out incurring the danger of injury.
110
110
3. Remove the snap ring (146), washer (110), spring
(114), and washer (110) from inside the cylinder
block (104).
114
104
16) Removing out swash plate (103).

1. Removing swash plate (103) from shaft (102).
• When removing it, check that pivot (176) is not
adhered on swash plate (103).
102 103
2. Pull shaft (102) out of spindle (2). Then bearing

(149) is removed together.
• The shaft comes off easily if the tip of the shaft
on the reduction gear side is tapped lightly,
using a plastic mallet. If it is struck forcibly,
shaft may be projected. Strike it with care.
31102 60413252
3. Remove two pivots (176) and two parallel pins

(177) from the spindle (2).
149 102 176, 177 2
34-52
TRAVEL SYSTEM
161, 162
WARNING
The blowing of compressed air may cause two speed
piston assy projecting incurring the danger of injury.
Cover projection section for protection
4. Blow compressed air through passage of spindle,

and remove two speed switching piston assy
(piston, shoe) and spring (185) from spindle (2).
• Piston (161)
Piston assy
• Shoe (162)
• Compressed air.
Pressure: 3~5 kgf/cm2 (43~71 psi)
PRESS
17) Removing bearing.
149
1. Place the retainer metal (II) on a press bench
• Remove it only when replacing the ball bearing. RETAINER METAL (II)
2. Put the shaft (102) in it. Hold down the tip of the
shaft by press and remove the bearing (149) from
102
the shaft.
• Do not reuse the bearing.
18) Remove hold flange (3)

1. Turn over the travel motor. FIXING METAL
2. Fix hub (1) and spindle (2) with fixed metal. Then,
the fixed metals should be tightened on symmetrical
positions each other.
• If the hold flange (3) is removed without
attaching the fixing metal, the hub (1) separates
from the spindle (2), causing the spindle (2) to
fall from the work bench.
1 2
WARNING
When the snap ring is removed, the tip of the pliers slips
from the snap ring hole and the snap ring jumps up in
31102 60413252
some cases. Be careful not to slip the pliers.
4. Remove three snap rings (20) from the hold flange

(3).
20 1 3
34-53
TRAVEL SYSTEM
5. Put matching mark on snap ring (20) and hold

flange (3) with an oil paint marker.
• This is to place them in the same positions as
at installation.
3 20
6. Incline travel motor 90 degree.

7. Loosen three reamer bolts (19).
• The threaded portion of reamer bolt (19) is
provided with adhesive agent and may cause
the seizure on the reamer portion where the
adhesive agent is applied, leading to the
difficulty of disassembling. Therefore loosen
reamer bolt (19) slowly. If it turns tightly in the
middle way, tighten it one more time, then
loosen it again.
• The tightening torque is 81.0 ± 5.0 kgf·m (590
± 36 lbf·ft). A torque more than it is needed to
19
loosen the bolt because of adhesive.
8. Tilt the travel motor to 90 degrees once again to

bring it back where it was.
9. Remove holding flange (3) from spindle (2).
10. Put match marks on hold flange (3) and spindle (2)
with paint marker.
• This is intended to install the hold flange (3) in
the same position as the spindle (2).
• The three mounting holes for reamer bolts (19)
in the spindle (2) are machined together. In
31102 60413252
case of they must be replaced, replace the

spindle (2) and the hold flange (3) together as
a set (assy). [Hereafter called spindle assy]
34-54
TRAVEL SYSTEM
FIXING METAL
19) Removing fixing metal.
2. Remove three fixing metal.
20) Removing spindle.

1. Place a clean container under the travel motor.
2. Tighten two eye bolts into the tapped holes of

spindle (2) so they are located in diagonally
opposite positions.
3. Hook sling to eye bolt, lift spindle (2) up and

remove it from hub (1). Then, floating seal (31),
outer race of bearing (22), and oil seal (132) are
also removed together.
1 2, 31, 22, 132
21) Removing bearing, RV gear assy and pin

1. Remove floating seal (31) from hub (1).
2. Remove bearing (21) from hub (1) striking pin(17)

end face with punch and mallet. Then, RV gear
assy [RV gear A (4), RV gear B (5), crankshaft (9),
bearing (22) bearing (23), spacer (12)] and pin
(17) are also removed together.
• Remove bearing (21) striking 3 or 4 points of
perimeter evenly taking care for bearing not to
be inclined.
• When the fit section of outer race of bearing 31
(21) is separated, bearing (21), RV gear assy
and pin (17) drop from hub (1). So spread MALLET 1
rubber mat under the working bench to protect ALUMINUM ROD 21
them from damage.
22 4
31102 60413252
17
23
5
12
21
9
34-55
TRAVEL SYSTEM
3. Separate RV gear A (4) and RV gear B (5) from

crankshaft (9).
• Never remove bearing (22), bearing (23) and
spacer (12) from crankshaft (9) except for
21
replacement.

5. Remove bearing (21)
• Remove bearing (21) striking 3 or 4 points of 21
perimeter evenly taking care for bearing not to
be inclined.
22) Removing the spindle fittings.

1. Remove oil seal (132) from spindle (2). OIL SEAL (132)
• Never reuse remove oil seal (132).
SPINDLE (2)
2. Remove floating seal (31) from spindle (2).

31102 60413252
31
34-56
TRAVEL SYSTEM
3. Remove the outer races (3 pcs.) of bearing (22)

from spindle (2).
• It is sometimes hard to remove the outer race
of the bearing (22) as the outer race of the
taper roller bearing comes in close contact
with the mating surface of the spindle by oil
films of lubricating oil. In that case, tap the
center of the spindle (2) with aluminum rod.
Then the outer race is removed easily.
2 22
23) Disassembling holding flange

1. Remove outer race of bearing (22) from hold
flange (3).
3 22
24) Rough washing of parts.

1. Classify the parts as four groups; hub (1), spindle
(2), cover (8), and rear flange (201) and other
parts (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 and sand from the parts.
WARNING 1
Wash oil is flammable. Be careful not to catch fire.
3. Put the built-in parts in a rough cleaning bath and

clean the parts.
• Before cleaning stained parts, immerse them
in wash oil until dust and stain become soft and
31102 60413252
are floated to protect them from damaging

when cleaning.
34-57
TRAVEL SYSTEM
25) Finish cleaning

1. Put parts in a finish cleaning container and clean
them well, turning them slowly.
2. Wipe off the light oil adhered to the parts, using a

clean rag.
• 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.
• Inner surface of rear flange (1), hydraulic motor
parts, and RV gear assy are to be dried naturally 3
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
eight pins (17) or lose them while handling.
31102 60413252
34-58
TRAVEL SYSTEM
1.6 ASSEMBLY
(1) Assemble it by reversing the procedure of (3) Preparatory arrangement for assembly
disassembly. 1) After replacing parts with new ones, adjust the
pre-load of bearing and thickness of snap ring
(2) General precautions for assembly without fail.
1) Assemble it in clean air condition.
1. When the following parts are replaced, the pre-
2) Don’t use cloth gloves during assembly. load adjustment of bearing is required.
Hub (1)
3) Replace or repair the damaged parts during Spindle (2)
disassembly according to the instructions in the Hold flange (3)
“Maintenance standard”. Bearing (21)
Replace O-ring, oil seal, etc. with new one.
4) Clean every part sufficiently, and blow them with 2. When the following parts are replaced, the snap
compressed air don’t use rag. ring thickness adjustment is required.
5) Prior to assembling, apply clean hydraulic oil to Spindle kit (2)
moving and sliding portions of hydraulic motor Hold flange (3)
valve. Crankshaft (9)
6) Tighten bolt and plug to the specified torque using Spacer (12)
torque wrench. Bearing (22)
7) Replace reamer bolt with new ones. If it is
unavoidably reused, remove completely the (2) The assembling procedure varies according to
adhesive agent on reamer bolt, repair flaws on the procedure of the above described parts.
bolt seat surface with oilstone, and degrease it.
8) Prior to assembling, apply grease to lip portions of
O-ring, oil seal, and floating seal to protect it from WARNING
being damaged, and to moving section and sliding Where replacing the above parts, the previously
adjusted parts should be used. If unadjusted parts are
section.
used, the travel motor moves abnormally, causing
early breakage.
9) After assembly, plug every port to prevent the
entry of dust, etc.
31102 60413252
34-59
TRAVEL SYSTEM
1) Installing hub (1).
1. Install two eye bolts into the tapped holes of hub

(1) so they are located in diagonally opposite
positions.
2. Hook eye bolt of hub (1), and lift up and place it on
working bench.
• Align hub (1) to the mounting holes of the work
bench, while matching the holes in hub (1) with
those in the work bench.
3. Install hub (1) to the work bench and fasten socket

bolts so they are located in diagonal positions.
WARNING
Fasten the socket bolts securely. If the bolts are not
tightened sufficiently, the travel motor may fall when
turned over, which is dangerous.
4. Insert bearing (21) in hub (1).

• Place a pin punch against the outer race of
bearing (21), hammer it lightly all around and
press in the bearing little by little.
21
5. Assemble floating seal (31) to hub (1), using the

assembling jigs (I), (II).
31102 60413252
31 FLOATING SEAL INSERT JIG (I) (II)
34-60
TRAVEL SYSTEM
2) Assembling spindle section.

1. Coat the O-ring of floating seal (31) with hydraulic
oil and install the floating seal into the groove of
the floating seal groove in spindle (2), using
assembling jigs (II), (III).
• Remove O-ring from floating seal and apply
grease on its outside lightly.
• Fit floating seal so that spindle groove is in
parallel with floating seal surface after fitting O-
ring in spindle groove rightly. FLOATING SEAL
31 INSERT JIG (I) (II)
2
2. Insert three outer races of bearing (22) in holes of

spindle (2) respectively.
22
2
3. Tighten two eye bots in the threaded holes on

spindle (2) in symmetric situations.
4. Tighten eye bolt, and lift up spindle (2) and place

it in hub (1).
1 2
5. Fix hub (1) and spindle (2) with fixing metal in
symmetrical position.
• If the motor is turned over without attaching the
fixing metal, the hub (1) separates from the
spindle (2), causing the spindle (2) to fall from
31102 60413252
the work bench.
FIXING METAL 1 2
34-61
TRAVEL SYSTEM
3) Install RV gear assy.

1. Insert RV gear A (4) to hub (1).
1 4
2. Fit three crankshafts (9) in holes for bearing (22)

inside of spindle (2).
• Then, bearing (22), bearing (23) and spacer
(12) are already fitted in crankshaft.
9, 12, 22, 23
3. Insert RV gear B (5) to hub (1)

• Since teeth of RV gear A (4) and RV gear B
(5) are engaged in phase, match punched
point on the end, and fit it.
1 5
4. Insert twenty eight pins (17) between pin groove

of hub (1) and tooth groove of gear.
• Prior to inserting, apply lube oil to pin (17).
31102 60413252
17
34-62
TRAVEL SYSTEM
21
5. Insert bearing (21) to hub (1)
• Apply pin punch on outer race of bearing (21),
and strike it in all around with mallet to press fit.
4) Installing hold flange

1. Check that hub (1), spindle (2), hold flange (3), two
bearings (21) are not replaced with new ones.
• If they are not replaced, proceed the next
process.
• Even if one of them is replaced, adjust hold
flange (3) referring to Item “Pre-load adjustment
1
procedure of bearing 20)” in page II-1-49, and
proceed to next process.
2. Fit hold flange (3) to inner race of bearing (21) in

hub (1).
• Install hold flange (3) to bearing (21) on the
same position as it was, put matchmarks on
spindle (2) and crankshaft (9).
• If it is difficult to insert hold flange (3) in inner
race of bearing (21), strike hold flange (3)
lightly and equally with plastic mallet to insert
in bearing (21).
21 1 9 3
5) Tightening reamer bolt (19).
1. Coat the reamer part of reamer bolt (19) with
antiseize lubricant and coat the threaded part of
the reamer bolt with adhesive.
• In case oily matter is stuck to the reamer bolt,
degrease it and after cleaning, dry them in
natural condition. Coat the reamer bolts with
adhesive.
• Fasten three reamer bolts (19) equally little by
little. If you fasten one or two bolts first, hold
flange (3) tilts, making bearing (21) unable to
be pressed into hold flange (3). This causes
reamer bolts (19) to seize themselves.
Therefore, tighten them evenly all round.
2. Tighten three reamer bolts (19) until hold flange

(3) is fitted into bearing (21) evenly.
3. Tighten three reamer bolts (19) to the specified

torque.
31102 60413252
19 3
34-63
TRAVEL SYSTEM
22
5. Remove (two) fixing metal.
7. Fit the outer race of bearing (22) to hold flange (3).
6) Fixing snap ring.

1. Check that spindle (2), hold flange (3), crankshaft
(9), bearing (22) and spacer (12) are not replaced.
• Go to next process if nothing is replaced.
• Even if one of them is replaced, adjust clearance
in shaft direction of bearing (22) and proceed
to next process.
(Refer to “Clearance adjustment procedure of
bearing (21) in shaft direction”)
• When replacement of snap ring (20) only is
required, use the same snap ring as the
removed snap ring (20) or select one equivalent 3 20
to the removed one from 15 types.
2. Fix snap ring (20) to the snap ring groove in hold

flange (3).
• Install three snap rings (20) meeting to match
mark on hold flange (3).
When required to use new snap ring (20), use
snap ring selected according to the specified
thickness in the previous process.
3. Put three snap rings (25) to crankshaft (9).

31102 60413252
9 25
34-64
TRAVEL SYSTEM
7) Installing spur gear (7).

1. Install three spur gears (7) to crankshaft (9).
• Put the matching marks (punched) of three
spur gears (7) as shown below and fix them to
crankshaft (9).
Position the matching marks

(punched) on the spur gears
and install them.
HOLD FLANGE
2. Fix three snap rings (25) into the snap ring grooves
of crankshaft (9).
25
8) Install oil seal (132).

1. Turn over travel motor.
2. Coat the lip of the oil seal with lithium grease and
fix oil seal (132) into the oil seal hole in spindle (2),
using retainer metal and a hammer.
RETANER METAL 2 132

9) Fixing shaft (102).
1. Put bearing (149) in a heating bath and heat it at
100 ± 10°C (212 ± 18°F) for ten minutes and insert
it into shaft (102).
WARNING
31102 60413252
Carry out the insertion work with leather gloves. Use

care so as not to get burns.
• Insert bearing (149) into shaft (102) so it comes

in close contact with the flange of the shaft. 102 149
34-65
TRAVEL SYSTEM
2. Fix two parallel pins (177) into the pin holes of

spindle (2).
3. Coat two pivots (176) with lithium grease and fix it
into parallel pins (177) of spindle (2).
4. Install spring (185) and piston assy [piston shoe
(161), shoe (162)] on spindle (2).
5. Incline travel motor 90° (lay it down).
2 176, 176
6. Install shaft (102) into spindle (2).

• Install shaft (102) to spindle (2) taking care so
as not to score the lip of oil seal (132) placed in
spindle (2). Scoring of the lip causes oil leakage
which leads to early damage of the travel
motor.
2 102
103
7. Coat the spline of shaft (102) with lithium grease.
8. Install swash plate (103) to spindle (2).
• Apply grease on contact surface of swash
plate (103) with spindle (2).
• Meet two pivots (176) with pivot attaching
holes of swash plate and install swash plate
(103) in spindle (2).
10) Installing cylinder block

1. Place washer (110), spring (114), washer (110) 110
and snap ring (146), in that order into cylinder
block (104).
2. Place cylinder block (104) on the press bench. 114
31102 60413252
104
34-66
TRAVEL SYSTEM
3. Put retainer metal (I) on washer (110) and fit snap

ring (146) in the groove of cylinder block (104).
• Put a plastic sheet over cylinder block (104) so PRESS
the contact surface of cylinder block is not
scored in contact with timing plate (109).
Plastic sheet
RETAINER METAL (I) 104
11) Installing hydraulic motor parts.

1. Put three rollers (151) into the holes cylinder block 151
(104).
2. Put thrust ball (108) on cylinder block (104).
3. Fit nine piston assy to retainer plate (107). 108
• After fixing it, immerse the whole unit in hydraulic
oil.
104
4. Fit nine piston assy to cylinder block (104).
• Match retainer plate (107) with the spherical
part of thrust ball (108) and install them.
Piston assy
107
104
5. Install cylinder block (104) into shaft (102).
• Insert cylinder block (104) into the spline of
shaft (102) by aligning the spline hole with the
spline of the shaft.
• After installing the cylinder block, turn it by
hand and make sure that it does not loosen.
31102 60413252
34-67
TRAVEL SYSTEM
12) Installing parking brake.

• Immerse friction plate (115) in hydraulic oil
before fitting it.
1. Incline work bench 90 degree (lay it down.)
2. Install friction plate (115) and separator plate
(116) on groove outside of cylinder block
alternately. Then install friction plate first, and
then separator plate.
3. Fit O-rings (135),(141) to the O-ring grooves of
piston (112). In that case, coat O-rings (135),
(141) with a thin film of grease.
4. Incline the travel motor 90°. (Lay it down) 116
5. Install piston (112) into spindle (2).
• If it is hard to fit the piston (112) into the spindle
(2) due to the resistance of O-rings (135),(141),
lightly tap the end face of the piston (112),
using a plastic mallet.
• Take care so as not to score the O-rings when
installing the piston (112).
141 112
31102 60413252
34-68
TRAVEL SYSTEM
238
13) Installing the brake valve parts into rear flange
1. Fit two O-rings (238) to two plugs (282).
• Coat O-ring (238) with grease.
2. Install valve (227) and spring (230) on rear flange

(201). Apply grease on valve and spring in order
to adhere them to rear flange (201).
3. Install the plug (282) in rear flange (201).

• Place on the work bench by directing rear
flange (201) with its plug attaching face up.
Align the center of threaded hole with the plug
282
(282) center.
• Prevent spring (230) from falling from valve
(227). Note that if spring (230) falls from valve
(227), the valve does not contact with the seat
surface of rear flange (201) properly, causing
oil leaks.
4. After installing two plugs (282), temporarily fasten

rear flange (201) by means of allen wrench.
5. Install spool (223) into rear flange (201).

• Coat the spool with hydraulic oil and insert the 227 201
spool into the rear flange.

• Attach the spool by aligning the hole of the rear
flange with the spool and prevent the inner
surface of the rear flange and the outer surface
of the spool from being damaged by mutual
interference.
• In case damage resulting from interference
should occur to the holes in the rear flange and
the outer surface of the spool, internal leaks
will occur after assembly, ultimately
deteriorating the performances of the travel
motor.
6. Fit O-ring (236) to plug (224). 282

• Coat O-ring (236) with grease. 236
7. Fit spring retainer (225) and spring (228) to plug

(224).
31102 60413252
224
34-69
TRAVEL SYSTEM
224
8. Tighten two plugs (224) into rear flange (201).
• When tighten the plugs into the rear flange,
use care so as not to deform the spring.
9. Temporarily tighten two plugs (224) to rear flange

(201) by means of a spanner.
201
14) Into rear flange assembling shockless relief valve

(SRV).
1. Fit O-ring (291), O-ring (292) and backup ring
(294),(295) to sleeve (288).
2. Fit O-rings (238) to plug (289).
• Coat O-ring (291),(292),(238) with grease.
288
294, 295
3. Install piston seal (293) to valve (287).

• Piston seal (293) is made up of O-ring and
teflon ring, and apply grease on both rings and PISTON SEAL (293)
fit O-ring first, then teflon ring.
VALVE (287)
288
4. Insert sleeve (288), valve (287) and spring (290)
to rear frange (201)
• Apply hydraulic oil on valve (287) and insert it
in sleeve (288).
• Parts inside of sleeve are fitted in the factory as
a sleeve kit, so take care not to make a wrong
31102 60413252
combination.
201
34-70
TRAVEL SYSTEM
289
201
282
6. Fit O-ring (238) to plug (282).
• Coat O-ring (238) with grease.
7. Insert piston (286) to rear flange (201).

• Piston (286) and rear flange (201) are factory
fitted for assembly. Do not mistake the
combination.

9. Install steel ball (296) to rear flange (201).

• Assemble the steel balls into the rear flange by
caulking.
10. Tighten plug (284) to rear flange (201) and tighten

it to specified torque.
201
296
31102 60413252
34-71
TRAVEL SYSTEM
271
15) Installing fittings to rear flange.
1. Installing pilot valve into rear flange.
1) Place rear flange directing the contact surface
with spindle (2) upward.
2) Insert spring (281), spool (271) into rear flange

(201).
3) Fit O-ring (292) to plug (221)

• Coat O-ring (292) with grease. 201
221
4) Tighten plug (221) to rear flange (201) and tighten
it to specified torque.
Tightening torque: 6kgf·m (43 lbf·ft)
2. Apply hydraulic oil to bearing (150), and install it in

rear flange (201).
150
201
3. Drive two parallel pins (242) in pin holes of rear

flange (201).
31102 60413252
201
242
34-72
TRAVEL SYSTEM
4. Apply grease to the surface of timing plate (109)

in contact with rear flange (201).
5. Install timing plate (109) on rear flange(201) taking

parallel pin (242) as a guide.
• Install timing plate (109) until it is completely
contacted with rear flange (201). Grease film is
used to protect them from dropping.
109 210
16) Connecting rear flange with spindle.

1. Fix O-ring (28), (30) into the O-ring groove of
spindle (2).
• Fit O-ring (30) without application of grease.
Application of grease may cause taking the
oozed grease out of contact face of rear flange
and spindle for the leaking oil. So never apply
grease on O-ring (30).
2 30
43
2. Fix two parallel pins (43) to spindle (2).
3. Fill hydraulic oil 0.5 (0.13 gal) into spindle (2).
201
4. Align two parallel pins (43) set in spindle (2) with
the pin holes of the rear flange and install rear
flange (201) to spindle (2).
• At the time when rear flange (201) is installed
on spindle (2), fit eight springs (113) on the rear
flange side. Apply grease on spring (113) to
31102 60413252
prevent them from dropping.
34-73
TRAVEL SYSTEM
5. Install six socket bolts (245) to spindle (2) and

tighten them up.
245 2
282
6. Tighten plug (282).
224
Tightening torque: 36 kgfüm (260 lbf·ft)
282
31102 60413252
34-74
TRAVEL SYSTEM
289
17) Installing input gear.

1. Turn over travel motor.
2. Fit shaft (15) to shaft (102).
3. Fit input gear (6) to shaft (15).

• Fix input gear (6) to shaft (15) by matching the
teeth of three spur gears (7). When gear is not
engaged, check it for possible error.
15
36 6
4. Fix snap ring (24) into the snap ring groove of the
shaft (15).
5. Coat steel ball (36) with grease and put it on the

concave part of input gear (6).
15 24
18) Installing cover

1. Fill lubricating oil in hub (1).
Oil volume: 1.3 (0.34 gal)
2. Fit O-ring (29) into the O-ring groove of cover (8).

• Apply grease to O-ing (29).
31102 60413252
34-75
TRAVEL SYSTEM
3. Install hub (1) to cover (8).

• Align the matching marks on cover (8) and hub
(1) and install them.
• Install cover (8) in hub (1), tapping the outer
circumference of cover (8) lightly by means of
a plastic mallet. Use care that if the cover is
fixed jerkily by striking it hard, the O-ring is
scored and brings about an oil leakage.
4. Fix ring (18) into the ring groove of hub (1).
18 1
33
5. Fit the O-ring (35) to flange plug (33).
Tighten with flange plug (33) into the cover (8).
6. Fit the O-ring (35) to flange plug (34).

Tighten with flange plug (34) into the cover (8).
8 34
19) Removing travel motor

1. Remove the travel motor attaching bolts from the
work bench.
31102 60413252
34-76
TRAVEL SYSTEM
20) The specified pre-load must be applied to bearing

(21) to ensure the proper life.
• Therefore, when the parts exerting influences
on the pre-load are replaced, assemble it
temporarily in the following procedure and
check the pre-load. If it is assembled without
checking the pre-load, the malfunction of
hydraulic motor may be caused and the life
may be shortened.
• Parts exerting influences on the pre-load.
Hub (1), spindle (2), hold flange (3), bearing
(21).
• When the above parts are not replaced, omit
this procedure.
• Pre-load checking and pre-load adjusting pro-
cedure are described below.
BEARING PRELOAD
ADJUSTING JIG
1. Procedure of the pre-load to bearing.

1) Attach the bearing pre-load adjusting jig to spindle
(2) tighten the special nut, and press bearing (21)
into hub (1).
A specified tightening
Torque of special nut: 4 kgf·m (29 lbf·ft)
2) Determine the depth “A” through the measuring

hole of the bearing pre-load adjusting jig, using a
depth micrometer.
Depth micrometer
BEARING (21) Bearing pre-load
3) Since the dimension “B” of the bearing adjusting JIG
B
pre-load adjusting jig is known, determine the
clearance “C” by the following formula: A
A: Actual value C
31102 60413252
“C”=“A”-“B” HUB (1)

B: Dimensions of jig body
SPINDLE (2)
C: Specified dimension
34-77
TRAVEL SYSTEM
4) Then determine dimension “D” of hold flange (3). D

E
5) After measurement steps 2)~4), adjust hold flange
(3) as follows:
Dimension “C” is the specified dimension of the
hold flange.
3
I. When actual dimension “D” of hold flange (3) is
0.02 mm (0.0008 in) smaller than a specified
value “C”;
Remove surface E of hold flange (3) to a specified
value by lathe.
II. Where the actual dimension of the hold flange
falls within ± 0.02 mm (0.0008 in) of the specified
clearance “D”;
Use the hold flange (3) as it is.
III. When actual dimension “D” of the hold flange (3)
is 0.02 mm (0.0008 in) larger than a specified
value “C”;
Replace the flange with a new spindle assy.
The adjustment allowance for new hold flange (3)
is specified without fail.
• Since hold flange and spindle are drilled at the
same time, they are integrated in an assembly
unit. Therefore they can not be replaced BEARING PRELOAD
separately. Replace them as an assembly ADJUSTING JIG
unit, that is, together with spindle.
This assy is called as spindle assy.
• To replace the spindle assy, disassembling
and assembling works should be performed
again.
6) Remove bearing pre-load adjustment jig from

spindle (2).
7) After completion of hold flange adjustment in the

procedure shown in Sections I, II, and III, proceed
to the procedure shown in page II-35 4) “ 2 ”.
31102 60413252
34-78
TRAVEL SYSTEM
21) Procedure of axial clearance adjustment of bearing

(22)
• When the following parts have been replaced,

it is necessary to adjust the axial clearance of
taper roller bearing (22) to a specified value by
adjusting the thickness of snap ring (20).
If it is installed without adjustment, malfunction
of hydraulic motor may be caused and the life
may be shortened.
Spindle (2), hold flange (3),

crankshaft (9), spacer (12),
bearing (22).
• When the above parts are not replaced, the

adjustment of thickness of snap ring is
unnecessary. Proceed to the regular assembly.
• The clearance adjustment is described below.
1. Lightly tap the outer race with mallet and jig (IV) of
bearing (22) attached to crankshaft (9).
• Put the RV gear assy in spindle (2) securely.
RETAINER METAL (IV)

2. Fix the thinnest snap ring (20) into the snap ring
groove in hold flange (3).
31102 60413252
20 3
34-79
TRAVEL SYSTEM
3. Lightly tap the outer periphery of snap ring (20) via

jig (IV).
• Confirm that the RV gear assy is securely set
in spindle (2).
RETAINER METAL (IV)
4. Insert a thickness gauge between snap ring (20)

and bearing (22) and measure the clearance.
5. Thickness measurement of snap rings

• Set thickness of snap ring (max).
Thickness of Thickness of
MAX = thickness + presently set
gauge snap ring
THICKNESS
• Set thickness of snap ring (min). GAUGE
Thickness of Thickness of 0.05

MIN = thickness + presently set - mm
gauge snap ring (0.002 in)
6. When the thickness of the snap ring has been

determined, select one out of fifteen kinds A
through Z and fit it to the hold flange.
7. Install snap ring satisfying the set thickness.
31
31102 60413252
34-80
TRAVEL SYSTEM
1.8 DIMENSIONS OF SNAP RING
ITEM DIMENSION
Snap ring (20)
Class Dimension t mm (in)

A over 1.90 to 1.95 (0.075 to 0.077) incl.
B over 1.95 to 2.00 (0.077 to 0.078) incl.
C over 2.00 to 2.05 (0.078 to 0.081) incl.
D over 2.05 to 2.10 (0.081 to 0.083) incl.
E over 2.10 to 2.15 (0.083 to 0.085) incl.
F over 2.15 to 2.20 (0.085 to 0.087) incl.
G over 2.20 to 2.25 (0.087 to 0.089) incl.
H over 2.25 to 2.30 (0.089 to 0.091) incl.
I over 2.30 to 2.35 (0.091 to 0.093) incl.
J over 2.35 to 2.40 (0.093 to 0.094) incl.
K over 2.40 to 2.45 (0.094 to 0.096) incl.
L over 2.45 to 2.50 (0.096 to 0.098) incl.
X over 1.75 to 1.80 (0.069 to 0.071) incl.
Y over 1.80 to 1.85 (0.071 to 0.073) incl.
Z over 1.85 to 1.90 (0.073 to 0.075) incl.
F17689
31102 60413252
34-81
TRAVEL SYSTEM
1.7 PERFORMANCE INSPECTION

• After completing the maintenance, carry out the performance inspection in the following procedure
1) Required measuring instrument

1 Pressure gauge [35 kgf/cm2 (500 psi)] 2 pcs
2 Measuring cylinder [5L (1.3 gal)] 1 pc
3 Stop watch 1 pc
2) Test procedure
Mounting ·········· Install motor in body (sprocket section), and connect pipe.
1 hydraulic motor However, don't install crawler.
and piping
[To carry out performance test of motor (No load)]
NOTE:
1.Connect pipes so that pressure gauge is installed, and the drain rate of
hydraulic motor can be measured.
2.Never use hammer to mount motor, but mount it using bolts holes softly.
Running-in of
2 Hydraulic motor
hydraulic motor Condition Rotation direction Operating time
·········· Speed revolution
1 st 10 rpm Forward Every 1
No load
2 nd 20 rpm Reverse minute or more
Performance inspection
3
of motor
Warming up ··················· Warm up motor until the temperature rises to the following
temperature
1
• Hydraulic oil temp 45~55˚C (113~131˚F)
• Reduction unit outer temp. 40~80˚C (104~176˚F)
Performance test ··········· Measure the following items, and determine if it is allowable or
not.
2
Allowable standard Hydraulic motor drive pressure ··· 16 kgf/cm2 (228 psi) or less/10 rpm
(1-speed) Hydraulic motor drain level ··· 0.5 L (0.13 gal) /min. or less at 10 rpm
Allowable Not allowable
Install crawler Disassemble and adjust again

F17690
31102 60413252
34-82
TRAVEL SYSTEM
1.9 SERVICE STANDARDS

Disassemble and inspect the motors according to this standard. Handle each component carefully, exercising
particular care so the moving parts and the sliding parts are not scored.
(1) Seals
Replace all seals (O-ring, oil seal, floating seal) once used even if no damage is seen.
(2) Wear parts maintenance standard

1) Replace any part that shows damage on appearance.
2) Replace such parts that show the following abnormalities, as well.
ITEM ALLOWABLE
PARTS TROUBLE REFERENCE VALUE
No. VALUE
Spindle kit
(2) Spindle • Severe damage to appearance
(3) Hold flange • Abnormal wear such as scoring
(19) Reamer bolt is present.
RV gear assy
(4) RV gear (A) • The RV gear tooth surface
(5) RV gear (B) shows uneven wear.
(9) Crankshaft • Crankshaft-related parts do not
(22) Conical roller bearing move smoothly when crankshaft
(23) Needle roller bearing (9) is turned.
20 Snap ring • The end face of the circumference
is abnormally worn.
21 Bearing • Dent is present.
• Flaking is seen.
• Uneven wear is present.
Rear flange kit
(201) Rear flange • Part in contact with spool (223)
is scratched.
• Clearance with spool is large.
• Surface in contact with valve Clearance on diameter Clearance on
(227) is scratched. 9~15 diameter 35
• Depth to the contact surface (0.0003~0.0006 in) (0.0014 in)
with valve (227) is large.
(223) Spool • Outer circumference is scored.
• Outer circumference is worn
unevenly.
(286) Piston • Outer circumference is scored. Clearance on diameter Clearance on
• Outer circumference is worn 12~20 diameter 40
unevenly. (0.0005~0.0008 in) (0.0016 in)
F17691
31102 60413252
34-83
TRAVEL SYSTEM
ITEM ALLOWABLE
PARTS TROUBLE REFERENCE VALUE
No. VALUE
(102) Shaft • Contact surface with oil seal (132)
is worn.
• Spline is worn
(104) Cylinder block • Spline is worn.
• Bore surface is worn badly.
• Sliding surface with timing plate
(109) is scored or worn unevenly.
Piston Assy
(105) Piston • Clearance is present in the axial Clearance Clearance
(106) Shoe direction between piston (105) 0.04 mm 0.14 mm
and shoe (106). (0.0016 in) (0.0055 in)
• Shoe is worn abnormally.
• Shoe is worn unevenly.
• The end face of the circumference
(107) Retainer plate
is worn nuevenly.
(108) Thrust ball • Spherical sliding part with retainer
plate (107) is worn unevenly.
• Sliding surface is seized or worn

(109) Timing plate
unevenly.
(115) Friction plate • Both end faces are worn unevenly. Braking torque Braking torque
• Specified torque can not be 9.9 kgf·m 9.9 kgf·m
(116) Separator plate reached. (72 lbf·ft) (72 lbf·ft)
• Seizure is seen. or over
(227) Valve • Seat surface is scored.
(149) Bearing • Dent is present.

(150) Bearing • Flaking is seen.
• Uneven wear is present.
(287) Valve • Outer circumference is scored.
(288) Sleeve • Outer circumference is scored.
F17692
31102 60413252
34-84
SECTION 41 TROUBLESHOOTING (MECHATRO CONTROL)
TABLE OF CONTENTS
1. Outline .................................................................................................................. 41-1

1.1 Judgment of actual thing at site ..................................................................................................... 41-1
2. Table of actuator for troubleshooting: mechatro control ......................................... 41-2
3. Troubleshooting summarized: mechatro control .................................................... 41-3
4. Check point for mechatro system .......................................................................... 41-4

31102 60413252
TROUBLESHOOTING (MECHATRO CONTROL)
1. OUTLINE
Troubleshooting provides process locating for the

cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.
1.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Attending the field to verify actual thing
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 on the hour-meter.
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
additional works.
(3)How to diagnose trouble Verifying background of trouble occurred.

1)Verify defective part.
2)Make the condition of trouble again.
3)Where defective part 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 flaws on the
piston rod. And the method of using the machines
should be explained so that the same kind of
trouble not reoccur. Confirm the symptoms of the trouble.
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, soil, etc.
into port of hydraulic unit, etc. and return them.
31102 60413252
And also use care not to flaw and damage those

surfaces.
Diagnosing fail by means of troubleshooting
41-1
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING: MECHATRO CONTROL
ELECTRIC HYDRAULIC
Control valve Motor Cylinder Other
Low pressure sensor

ACTUATOR
proportional valve
proportional valve
proportional valve
Safety lock lever

Travel 1-2speed
solenoid valve
solenoid valve
solenoid valve
P2 bypass cut
P1 bypass cut
Travel straight
Swing P / B
P1 bypass cut valve
P2 bypass cut valve
Boom conflux valve
Travel right motor
Boom lock valve

Travel left motor
Arm lock valve

Swing motor
Travel right
Travel left
P2 Pump
S P P P S S S
P1 pump
E S S S V V V
Bucket
Bucket
Swing
Boom
Boom
-
-
1 V V V
Arm
Arm
OPERATING CONDITION 1 3 4
~
-
10 B C D
Boom up inching operation
Boom up full lever operation
Boom down operation
Arm out inching operation

Indenpendent operation
Arm out full lever operation
Arm in inching operation
Arm in full lever operation
Bucket digging
Bucket dump
Swing operation
Travel LH / RH operation
(1st. speed)
(2nd. speed)
Travel right operation
+ Boom operation
+ Bucket operation
Combined operation
+ Arm operation
+ Swing operation
Travel left operation
+ Boom operation
+ Bucket operation
+ Arm operation
31102 60413252
+ Swing operation
+ Boom up operation
F17821
41-2
3. TROUBLESHOOTING SUMMARIZED: MECHATRO CONTROL

ELECTRIC OR HYDRAULIC CAUSE HYDRAU- NORMAL CRITERION ELECTRIC OR HYDRAULIC CAUSE HYDRAU- NORMAL CRITERION
OPERATING LIC OR OPERATING LIC OR
No. TROUBLE No. TROUBLE
CONDITION ELECTRIC CONDITION ELECTRIC
Cause Check point 1 2 3 Cause Check point 1 2 3
1-1 No Safety lock Safety lock lever SOL (SV-4) 24V at SV-4 connector. 24V at SW-11. 24V at fuse box 4-3 Fine swing Swing left or Swing parking Swing parking Command voltage for swing Swing right/left
operation lever down solenoid (SV-4) does connector connector right and left right lever to solenoid is not solenoid (SV-1) Electric parking solenoid : 0V sensor values :
works at full not change over and (CN-14M) operations full stroke deenergized. connector more than 4.0V
Electric
stroke there is no hydraulic white & black impossible. Secondary pilot pressure for Secondary pilot pressure
source for pilot valve. Hydrau-
swing parking solenoid : for swing right/left :
lic
35kgf/cm2 (500psi) 35 kgf/cm2 (500psi)
Lever at P1 bypass cut P1 bypass cut Current for P1 bypass cut Arm in sensor and arm 4-4 Fine arm in Fine arm in or P2 bypass cut Connector of P2 Command current for P2 bypass Swing right/left sensor
neutral proportional valve proportional Electric proportional valve : 315mA. out sensor values : and out out operation proportional valve bypass cut Electric cut proportional valve : 315mA and boom raise sensor
moves freely and valve (PSV-D) less than 1.3V. motions moves freely and the proportional valve values : less than 1.3V
the P1 circuit connector Secondary pilot pressure for Secondary pilot impossible. P2 circuit pressure (PSV-B) Secondary pilot pressure for Secondary pressure for Unload pressure for
pressure rises. Hydrau- rises. Hydrau-
P1 bypass cut valve : pressure : P2 bypass cut valve : swing right, left and boom P2 pump : approx.
lic lic
5.5kgf/cm2 (78psi). 6kgf/cm2 (85psi). 5.5kgf/cm2 (78psi) raise actions : 6kgf/cm2 (85psi) 20kgf/cm2 (280psi)
1-2 Moves freely
Lever at P2 bypass cut P2 bypass cut Current for P2 bypass cut Boom raise sensor and 5 Travel 1-2 Travel 1-2 Travel 1-2 speed Connector for travel 24V across power supply for 100th is indicated as
neutral proportional valve proportional Electric proportional valve : 315mA. swing right/left sensor speed change speed select solenoid (SV-3) does 1-2 speed solenoid Electric travel 1-2 speed solenoid and 1 in controller service
moves freely and P2 valve (PSV-B) values : less than 1.3V. impossible. switch is on. not change over. earth. diagnosis 23.
circuit pressure rises. connector Secondary pilot pressure for Secondary pilot Secondary pilot pressure
Hydrau- Hydrau-
P2 bypass cut proportional pressure : for command travel 1-2 speed
lic lic
valve : 5.5kgf/cm2 (78psi). 6kgf/cm2 (85psi). select : 35kgf/cm2 (500psi)
2-2 Only bucket Bucket P2 bypass cut P2 bypass cut Current for P2 bypass cut Boom raise sensor and 6 Travel speed Travel lever at Travel straight valve Command current of Command current of travel 8 sensor values for
is slow lever and proportional valve proportional Electric proportional valve : 315mA. swing right/left sensor is low. full stroke. moves freely and the travel straight Electric straight proportional valve : bucket, boom, swing
other levers moves freely, valve (PSV-B) values : less than 1.3V. (single (Other levers machine travels only proportional valve 315mA and arm : less than 1.3V
at full P2 circuit pressure connector Secondary pilot pressure for Lever at neutral Secondary pilot operation) in neutral) by the delivery rate of (PSV-C) Secondary pilot pressure of PO 8 sensor values for Secondary pilot
stroke rises, and P1 circuit Hydrau- P1 pump. Hydrau-
P2 bypass cut valve : Secondary pilot pressure with pressure for bucket : port travel straight valve : bucket, boom, swing pressure for travel :
flow decreases. lic lic
5.5kgf/cm2 (78psi). lever neutral : 6kgf/cm (85psi). 35kgf/cm2 (500psi)
2
5.5kgf/cm2 (78psi) and arm : 6kgf/cm (85psi) 24kgf/cm2 (340psi)
2
2-3 Only boom Boom lever P2 bypass cut P2 bypass cut Feedback current for P2 Command current for P2 Boom raise sensor 8 Machine can Levers at full Travel straight valve Command current of Command current for travel Swing right/left sensor
raise speed at full proportional valve proportional Electric bypass cut proportional bypass cut proportional : more than 4.0V not travel stroke in does not change over travel straight Electric straight proportional valve : and arm in/out sensor :
is low stroke does not move and valve (PSV-B) valve : 700mA. valve : 700mA. straight. composite and the travel action proportional valve 315mA more than 4.0V
the boom conflux feedback current Secondary pilot pressure for Secondary pilot swing/travel or is affected by the (PSV-C) Secondary pilot pressure for PO Secondary pilot pressure
flow is not created. Hydrau- arm/travel delivery rate of P1 Hydrau-
P2 bypass cut valve : pressure for travel : port travel straight valve : for swing right/left and arm
lic actions. pump. lic
26kgf/cm2 (370psi) 24kgf/cm2 (340psi) 26kgf/cm2 (370psi) in/out : 35kgf/cm2 (500psi)
Travel lever Travel straight valve Travel straight Command current for P2 Travel right and left Levers at full Travel straight valve Command current of Command current for travel Boom raise/lower sensor
at neutral moves freely and proportional Electric bypass cut proportional sensors: less than stroke in does not change over travel straight Electric straight proportional valve : and bucket close/open
is actuated by P1 valve (PSV-C) valve : 315mA. 1.3V. composite and the travel action proportional valve 315mA sensor : more than 4.0V
pump flow. command current Secondary pilot pressure for Secondary pilot operations of is affected by the (PSV-C) Secondary pilot pressure for PO Secondary pilot pressure for
Hydrau- boom/travel or delivery rate of P1 Hydrau-
P2 bypass cut valve : pressure for travel : port travel straight valve : boom raise/lower and bucket
lic bucket/travel. pump. lic
5.5kgf/cm2 (78psi). 6kgf/cm2 (85psi). 26kgf/cm2 (370psi) close/open : 35kgf/cm2 (500psi)
Only speeds Travel lever Travel straight valve Travel straight Command current for travel Travel right and left 10 Swing power Swing lever at Swing parking Connector for swing 0V across power supply of swing Swing right/left
other than at neutral moves freely and proportional Electric straight proportional valve : sensor value : less is not available. full stroke. solenoid does not parking solenoid Electric parking solenoid and ground sensor : more than
boom raise, P2 pump flow to tank. valve (PSV-C) 315mA. than 1.3V. demagnetize. (SV-1) 4.0V
arm in and command current Secondary pilot pressure for Secondary pilot Secondary pilot pressure for Secondary pilot pressure
out are low Hydrau- Hydrau-
PO port travel straight valve : pressure for travel : swing parking solenoid for swing right/left :
lic lic
5.5kgf/cm2 (78psi). 6kgf/cm2 (85psi). : 35kgf/cm2 (500psi) 35kgf/cm2 (500psi)
2-4 Only arm in Arm lever Arm conflux flow is P1 bypass cut Command current for P1 Arm in sensor : 11 Swing speed Swing lever at P2 bypass cut Feedback current of Feedback current for P2 bypass Command current for P2 Swing right/left
speed is at full not created. proportional Electric bypass cut proportional valve : more than 4.0V is low. full stroke. proportional valve P2 bypass cut Electric cut proportional valve : 700mA bypass cut proportional sensor : more than
low stroke valve (PSV-D) 700mA. does not change over proportional valve valve : 700mA 4.0V
command current Secondary pilot pressure for Secondary pilot and part of the (PSV-B) Secondary pilot pressure for P2 Secondary pilot pressure
Hydrau- delivery of P2 pump Hydrau-
P1 bypass cut valve : pressure for arm in : bypass cut valve : 26kgf/cm2 for swing right/left :
lic flows to tank. lic
26kgf/cm2 (370psi). 35kgf/cm2 (500psi) (370psi) 35kgf/cm2 (500psi)
2-5 Only arm Arm lever Arm conflux flow is P1 bypass cut Command current for P1 Arm out sensor : 12 Swing power Swing lever at P2 bypass cut Feedback current of Command current for P2 bypass Command current for P2 Swing right/left
out speed is at full not created. proportional Electric bypass cut proportional valve : more than 4.0V. is poor. full stroke. proportional valve P2 bypass cut Electric cut proportional valve : 700mA bypass cut proportional sensor : more than
low stroke valve (PSV-D) 315mA does not change over proportional valve valve : 700mA 4.0V
command current Secondary pilot pressure for Secondary pilot and the P2 circuit (PSV-B) Secondary pilot pressure for P2 Secondary pilot pressure
Hydrau- pressure does not Hydrau-
P1 bypass cut valve : pressure for arm out : bypass cut valve : 26kgf/cm2 for swing right/left
lic rise. lic
5.5kgf/cm2 (78psi). 35kgf/cm2 (500psi) (370psi) 35kgf/cm2 (500psi)
4-1 Fine bucket Fine bucket P1 bypass cut P1 bypass cut Command current for P2 Arm in and arm out 13 Swing motion Swing lever at Swing parking brake Connector for swing 24V across power supply of Swing right/left sensor
close and operation proportional valve proportional Electric bypass cut proportional valve : sensor values : can not be neutral. is released. parking solenoid Electric swing parking solenoid and and arm in sensor
open moves freely and valve (PSV-D) 315mA less than 1.3V. held on a ground. values : more than 1.3V
operations the P1 circuit connector Secondary pilot pressure for Secondary pilot Unload pressure for slope. Secondary pilot pressure of Secondary pressure for
can not be pressure rises Hydrau- Hydrau-
P1 bypass cut valve : pressure for arm in and P1 pump : approx. swing parking solenoid : swing right/left and arm
done lic lic
5.5kgf/cm2 (78psi). out : 6kgf/cm (85psi) 20kgf/cm2 (280psi)
2
35kgf/cm2 (500psi) in : 6kgf/cm2 (85psi)
F17822
4-2 Fine boom Fine boom P1 bypass cut P1 bypass cut Command current for P2 Arm in and arm out
raise and raise and proportional valve proportional Electric bypass cut proportional valve : sensor values :
lower lower moves freely and valve (PSV-D) 315mA. more than 1.3V.
NOTE:
31102 60413252
operations operations the P1 circuit connector Secondary pilot pressure for Secondary pilot Unload pressure for
Hydrau-
can not be pressure rises.
lic
P2 bypass cut valve : pressure for arm in and P1 pump : approx. The upper table shows items to be highlighted in the electrical and hydraulic troubleshooting.
done 5.5kgf/cm2 (78psi). out : 6kgf/cm (85psi). 20kgf/cm2 (280psi)
2
“Normal criterion” is a list of figures which come up in the electrical and hydraulic troubleshooting.
4-3 Fine swing Fine swing P2 bypass cut P2 bypass cut Command current for P2 Swing right and left sensor
Electric bypass cut proportional valve : and boom raise sensor
Regarding the inspecting procedures, refer to each troubleshooting.
right and right and proportional valve proportional
left left moves freely and valve (PSV-D) 315mA. values : less than 1.3V.
operations operations the P2 circuit connector Secondary pilot pressure for Unload pressure for P2 Secondary pressure for
can not be pressure rises. Hydrau-
P2 bypass cut valve : pump : approx. 20kgf/cm2 swing right/left and boom
done lic
5.5kgf/cm2 (78psi). (280psi) or less. raise : 6kgf/cm2 (85psi)
41-3
4. CHECK POINT FOR MECHATRO SYSTEM
(1) Mounting position of connectors for solenoids (solenoid valves): SV-1, SV-3, SV-4 (SV-2 OPT)
(2) Mounting position of connectors for solenoid proportional valves: PSV-B, PSV-C, PSV-D
(3) Detail sensor connector: SE-1~SE-10
P2 BYPASS CUT
PROPORTIONAL
VALBE (PSV-B)
TRAVEL STRAIGHT
CONFLUX-SINGLE SWING PARLING SOL (SV-1) PROPORTIONAL
SELECT SOL (SV-2) VALVE (PSV-C) UNDER FLOOR HARNESS
Normal spec. does
not need connection.
TRAVEL
1,2-SPEED SOL (SV-3) TO INSTRUMENT
PANEL HARNESS
SAFETY LOCK LEVER SOL (SV-4)
PRESSURE SENSOR(TRAVEL LEFT) (SE-10)
P1 BYPASS CUT
PRESSURE SENSOR(TRAVEL RIGHT) (SE-9) PROPORTIONAL
VALVE (SPV-D)
OPT PEDAL
PRESSURE SWITCH 1
GND
Vout
F17823
TRAVEL 1,2-SPEED SWITCH GROUND CONNECTOR
GROUND CABLE
TRAVEL STRAIGHT
AMP MQS CONNECTOR (3P)
Vcc
P1 BY-PASS CUT
P2 BY-PASS CUT
PSV-C
PSV-D
PSV-B
HEX24
4, P, T PORT : PF 3/8
1, 2, 3, B, C D PORT : PF 1/4
PF1/4
T O-RING(P11, 1B)
F17914
Fig. 2 Detail sensor connector

CONNECTOR : AMP Econoseal J Mark II (+)
CAP HOUSING : 174354-2
TERMINAL : 173706-1
T T
TIGHTENING TORQUE
0.75 kgf·m (5.5 lbf·ft)
P
(Directional Valve)
Emergency manual P
adjustable bolt
TORQUE FOR CONTACTING WITH BOTTOM
0.2 kgf·m (1.5 lbf·ft)
TIGHTENING TORQUE
0.71 kgf·m (5.2 lbf·ft)
(-) SIDE (+) SIDE

READ CABLE READ CABLE
31102 60413252
P
F17913
SV-1
SWING PARKING
SV-2
CONFLUX·SINGLE
FLOW
SV-3
TRAVEL 2-SPEED
SV-4
SAFETY LOCK
LEVER
Selector valve Connection procedure
connector detail for selector valve
Fig. 1 Solenoid valve, solenoid proportional valve connector
41-4
SECTION 42 TROUBLESHOOTING (HYDRAULIC SYSTEM)
TABLE OF CONTENTS
1. Trouble diagnosis: Hydraulic .................................................................................. 42-1
2. Troubleshooting ..................................................................................................... 42-2

31102 60413252
31102 60413252
Hydraulic systems
CLASSIFICATION
Swing operation Travel operation Attachment operation
7
6
5
4
3
2
1
13
12
GROUP No.
Fine operation Power lacks. Speed is low.
impossible.
9 Machine
8 Machine
Boom
Boom
swing motion.
All actions
All motions
Arm in conflux
Bucket digging
Arm in and out

Arm in and out
Swing left, right

Arm out conflux
Travel power is low.

Travel speed is low.
TROUBLE
11 Swing speed is low.

Swing power is poor.
Boom raise conflux
No operation is possible.
though lever is in neutral.
10 Swing motion does not work.

Bucket digging and dump
Bucket digging and dump
does not stop still on a slope.

Machine operates freely even
Swing motion drifts very large.

COMPONENT
drifts on a downhill and

cannot travel straight or
An unusual sound is heard during

Raise
Raise
Lower
Lower
Raise
Device
Lower
Machine is not held still on a slope.

Travel 1,2 speed change impossible
deviates in one direction or zigzags.

No.
E/G revolution
P1 pump
1. TROUBLE DIAGNOSIS: HYDRAULIC
P2 pump
1
Pump
P3 pump
Pilot relief valve
Travel straight spool
Travel spool
Swing spool
Boom spool
Arm spool
Bucket spool
2
Conflux spool
P2 bypass cut valve
Control valve
P1 bypass cut valve

Load check valve
Lock valve
Shuttle valve
Check valve for relief
Parking brake
3
Bypass valve
Reduction parts
Swing motor
Motor
Counter balance valve
4
Parking brake
Counter balance check valve
Travel motor
Pilot valve (1-2speed select)

5
Boom cylinder
6
Arm cylinder
TROUBLESHOOTING (HYDRAULIC SYSTEM)
Cylinder
HYDRAULIC
Bukcet cylinder
8
Swivel joint
Pilot valve (ATT)
Pilot valve (travel)
Other valve
Multi control valve

9 10 12
Swing parking sol. valve

Travel 1-2speed sol. valve
Safety lock lever sol. valve
11
P2 bypass cut proportional valve

Proportional valve block
P1 bypass cut proportional valve

Inline filter
Suction strainer
Bypass check
Filter
Return filter
Breather
13 14 15 16 17
Main relief valve

Bucket digging
Bucket dump
Boom raising
Boom lowering
Main control valve
Arm in
Arm out
Relief valve
Left shockless
Right shockless
Left shockless
Travel Swing
Right shockless
F17915
42-1
2. TROUBLESHOOTING
(1)-1
No operation is possible.
24V is alive across white/blue and black terminals of connector NO To electric

(CN-256F) of lever lock solenoid (SV-4). troubleshooting
YES Is the main relief valve
Only the hydraulic pilot system NO pressure within a standard NO Pilot relief valve NO
(ATT and travel motion) not value? pressure is about Replace relief valve.
operative? [P1,P2 : 300kgf/cm2 (4270psi)] 35kgf/cm2 (500psi).
[P3 : 200kgf/cm2 (2840psi)] Inspect or replace pump.
YES YES
YES Also inspect pump
coupling.
Inspect if there is any other cause.

NO
The primary pressure of pilot pump is about 35kgf/cm2 (500psi). Inspect or replace pilot pump and pilot relief valve.
YES
NO
The pilot valve P port inlet pressure is approx. 35kgf/cm2 (500psi). Inspect or replace safety lock lever solenoid valve.
YES
NO
The secondary pressure of pilot valve is approx. 35kgf/cm2 (500psi). Inspect or replace pilot valve.
(1)-2
Machine moves freely with levers in neutral.
Machine stops moving freely if the connector (CN-253F) for YES To electrical
proportional valve P1 bypass cut is disconnected. troubleshooting
NO
Pump NO The secondary pilot pressure of the system that is YES Inspect or replace pilot
delivery moving freely is generated when the lever is in
valve.
pressure in neutral.
unloaded NO
condition is YES
approx. The spool returning spring of the circuit that is Inspect or replace spool
20kgf/cm2 moving freely is broken. assy and pilot cover.
(280psi). NO
NO The outer YES
The spool of the system that is operating freely
YES moves smoothly by hand. (Remove pilot cover.)
circumference of Replace spool assy.
spool is scratched.
NG
NO
YES Replace control valve
Pilot pressure at ports Pb4, Pb4 (P1, P2 bypass YES Inspect or replace the proportional valve for bypass
cut valve) is approx. 5.5kgf/cm2 (78psi). cut valve that is defective.
NO NG
Inspect or replace proportional valve block.
YES Inspect or replace bypass cut valve spool assy and

Return spring of bypass cut valve spool is broken.
pilot cover.
NO
Bypass cut valve spool moves smoothly by hand. NO Spool is scored YES Replace bypass cut valve
(together with P1 and P2 bypass cut valves) on inspection. spool assy.
YES NO NG
Replace control valve.
31102 60413252
Boom or YES Inspect or replace overload relief valve. Inspect lock
arm? valve parts and replace if faulty.
NO
YES
Spool of the circuit that operates freely is scored on. Replace spool assy.
NO Inspect or replace Inspect the cylinder of the circuit that Inspect or replace control
overload relief valve. operates freely and replace if faulty. valve.
(Inside leak) F17916
42-2
(2)-1
All attachment motions are slow.
Do motions get normal if the coupler for YES

tralve straight proportional valve is To electric troubleshooting.
disconnected?
NO
NO Inspect or replace pilot
Primary pilot pressure is 35kgf/cm2 (500psi).
pump and pilot relief valve.
YES
Secondary pilot pressure at PO port (travel YES Inspect or replace travel
straight) is approx. 5.5kgf/cm2 (78psi). straight proportional valve.
NO NG
Inspect or replace
proportional valve block.
NO Inspect or replace travel

Return spring of travel straight spool is
straight spool assy and pilot
broken.
cover.
YES
NO Outer circumference of YES
Travel straight spool moves smoothly by Replace travel straight spool
travel straight spool is
hand. (Remove the pilot cover.) assy.
scored.
YES NG
NO
Main relief pressure is approx. 300kgf/cm2 NO Inspect or replace main NG Replace control valve or
(4270psi) relief valve. pump.
(2)-2
Only the bucket motion is slow.
Is the motion normal if connector (CN-254F) YES

To electrical troubleshooting.
for proportional P2 bypass cut is disconnected?
NO
Secondary pilot pressure at Pa3, Pb3 ports (bucket NO Inspect or replace pilot
close and open ports) is 35kgf/cm2 (500psi). valve.
YES
Inspect overload relief valve
Relief pressure that selects bucket is approx. NO Relief pressures for both YES on the faulty pressure side
300kgf/cm2 (4270psi). Check the pressure for bucket close and open are
and replace valve if
bucket close and open as well. not at 300kgf/cm2 (4270psi).
defective.
YES NO Confirm the check valve
before relief valve for NG
control valve. Check the
seat of it as well.
YES
Return spring for bucket spool is broken. Replace bucket spool assy.
NO
Bucket spool moves smoothly by hand. NO Outer circumference of YES
Replace bucket spool assy.
(Remove pilot cover.) bucket spool is scored.
NO NG
YES
Is the motion slow if coupler for travel NO To electric troubleshooting.

straight proportional valve is disconnected? (to "All motions are slow.")
YES
Pilot pressure at port PO (travel straight) is NO Inspect or replace travel
31102 60413252
approx. 5.5kgf/cm2 (78psi). straight proportional valve.

YES NG
Inspect or replace
Return spring for travel straight spool is
broken.
NO YES
Inspect travel straight spool
assy and pilot cover and
Continued on next page.
replace them if faulty.
F17917
42-3
Continued from previous page.
NO
hand. assy.
scored.
YES NG
NO
Is the motion slow if pump delivery ports P1 NO

Inspect or replace pump.
and P2 are exchanged.
YES
Inspect bucket cylinder for

oil tightness and replace if
defective.
(2)-3 Diagnosis 29 ; mechatronic (C-1) controller service diagnosis 29

Only the boom raise motion is slow.
(Diagnosis 29)
Control current of P2 bypass cut proportional NO
valve is approx. 700mA when full lever To electric troubleshooting.
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port Pc4 (P2 NO Inspect or replace P2 bypass NG Inspect or replace
bypass cut valve) is approx. 26kgf/cm2 (370psi). cut proportionate valve. proportional valve block.
YES
Pilot pressure at Pa2, Pd4 ports (boom raise NO Inspect or replace ATT pilot
and boom conflux) is approx. 35kgf/cm2
valve.
(500psi).
YES
Relief pressure is approx. 300kgf/cm2 (4270psi) NO NG
Adjust boom port relief Replace overload relief valve
when full lever operation is performed for
pressure. at port A2 (boom head side).
boom raise motion.
YES
YES Inspect or replace P2 bypass
Return spring for P2 bypass cut valve spool is
cut spool assy and pilot
broken.
cover.
NO
NO Outer circumference of P2 YES
P2 bypass cut valve spool moves smoothly by Replace P2 bypass cut spool
bypass cut valve spool is
hand. (Remove pilot cover.) assy.
scored.
YES NG
NO
Return spring of boom spool is broken. YES Inspect or replace boom

(Remove pilot cover.) spool assy and pilot cover.
NO
Boom spool moves smoothly by hand. NO Outer circumference of YES
Replace boom spool assy.
(Remove pilot cover.) boom spool is scored.
YES NO NG
Return spring for boom conflux spool is YES Inspect or replace boom
broken. spool assy and Pilot cover.
NO
NO Outer circumference of YES Replace boom conflux spool
Boom conflux spool moves smoothly by hand.
boom conflux spool is scored. assy.
YES NG
NO
31102 60413252

F17918
42-4
(2)-4
Motions other than boom raise, arm in and out are slow.
(Diagnosis 30)
Control current for travel straight
proportional valve is approx. 315mA. NO
To electric troubleshooting
(Are the motions slow if coupler for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PO (travel straight) is YES Inspect or replace travel NG Inspect or replace
approx. 5.5kgf/cm2 (78psi). straight proportional valve. proportional valve block.
NO
Inspect or replace travel
Return spring for travel straight spool is broken. YES
cover.
NO
NO Outer circumference of YES Replace travel straight spool
Travel straight spool moves smoothly by
travel straight spool is assy.
hand. (Remove pilot cover.)
scored.
YES
NO Replace control vlave.
(2)-5
Only arm digging action is slow.
(Diagnosis 26)
Command current for P1 bypass cut NO
proportional valve is approx. 700mA when To electric troubleshooting.
boom raise lever is shifted to the full.
YES
Secondary pressure of P1 bypass cut
proportional valve at port Pb4 (P1 bypass
NO Inspect or replace P1 bypass NG IInspect or replace
cut proportional valve. proportional valve block.
cut) is approx. 26kgf/cm2 (370psi).
YES
Secondary pilot pressure at Pc3, Pc3 ports NO Inspect or replace pilot
(arm in, lock valve release) is approx.
valve.
35kgf/cm2 (500psi).
YES
NO Inspect or replace overload
Relief pressure is approx. 300kgf/cm2 (4270psi)
relief valve at port C3 (arm
when arm in lever is shifted to the full.
head side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken.
assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
Replace arm spool assy.
(Remove pilot cover.) spool is scored.
NO NG
YES

F17919
31102 60413252
42-5
(2)-6
Only arm out operation is slow.
(Diagnosis 26)
Command current for P1 bypass cut NO
proportional valve is approx. 700mA when To electrical troubleshooting
arm out lever is shifted to the full.
YES
Secondary pilot pressure at port Pb4 NO Inspect or replace P1 bypass NG Inspect or replace
(P1 bypass cut valve) is approx. 26kgf/cm2
(370psi).
YES
Secondary pilot pressure at port Pd3 (arm out) NO Inspect or replace pilot
is approx. 35kgf/cm2 (500psi) or over. valve.
YES
Inspect or replace overload
Relief pressure is approx. 300kgf/cm2 (4270psi) NO relief valve at port D3 (arm
when arm out lever is shifted to the full. rod side).
YES
NO
(Remove pilot cover.) spool is scored.
YES NO NG
(3)-1
All ATT operating power is poor.
Each independent operating speed is within a NO Refer to "All motions are

standard value. slow.".
YES
Relief pressures of P1, P2 pumps are approx. NO Adjust main relief pressure NG Replace the relief valve of
300kgf/cm2 (4270psi). of control valve. main control valve.
YES
Primary pilot pressure is approx. 35kgf/cm2 NO Replace pilot pump and
Adjust pilot relief pressure.
(500psi). relief valve.
YES
Travel straight spool return spring is broken. YES straight spool assy and pilot
cover.
NO
hand. (Remove pilot cover.) assy.
scored.
YES NG
NO
Inspect or replace control

valve or pump.
F17920
31102 60413252
42-6
(3)-2
Bucket close power is poor.
No-load independent operating speed is within NO Refer to "Only bucket

a standard value. motion is slow."
YES
NO Replace overload relief valve
Relief pressure is approx. 300kgf/cm2 (4270psi) Adjust overload relief valve NG
at port A3 (bucket head
when bucket close lever is shifted to the full. on bucket close side.
side).
YES
Secondary pilot pressureat port Pa3 (bucket NO Inspect or replace pilot
close) is approx. 35kgf/cm2 (500psi). valve.
YES
YES Inspect or replace bucket
Bucket spool return spring is broken. spool assy and pilot cover.
NO
Bucket spool moves smoothly by hand. NO Outer circumference of YES
(Remove pilot cover.) bucket spool is scored.
YES NO NG
Replace control valve or

pump.
(3)-3
Boom up operating power is poor.
No-load independent operating speed is within NO Refer to "Only boom raise

a standard value. motion is slow."
YES
Relief pressure of both P1 and P2 pumps is NO Inspect or replace overload
approx. 300kgf/cm2 (4270psi) when boom raise relief valve at port A2
lever is shifted to the full. (boom head side).
YES
Secondary pilot pressure at port Pa2 (boom NO Inspect or replace pilot
raise) is approx. 35kgf/cm2 (500psi). valve.
YES
YES Inspect or replace boom
Boom spool return spring is broken. spool assy and pilot cover.
NO
Boom spool moves smoothly by hand. Replace boom spool assy.
boom spool is scored.
YES NO NG
Inspect or replace control

valve or pump.
F17921
31102 60413252
42-7
(3)-4
Arm in power is poor.
No-load independent operating speed is within NO Refer to "Only arm in is

a standard value. slow.".
YES
Relief pressure of both P1 and P2 pumps is NO NG Replace overload relief valve
Adjust overload relief
approx. 300kgf/cm2 (4270psi) when arm in at port C2 (on arm head
pressure on arm head side.
lever is shifted to the full. side).
YES
Secondary pilot pressure at ports Pc3 and
PC3' (arm in and lock valve release) is
NO Inspect or replace pilot
approx. 35kgf/cm2 (500psi). valve.
YES
NO
(Remove pilot cover.) Replace arm spool assy.
spool is scored.
YES NO NG
Replace control valve or

pump.
(4)-1
Machine can not perform fine operation of bucket close and open.
Machine returns normal if connector of P1 bypass cut YES

To electric troubleshooting.
proportional valve (PSV-D) is disconnected.
NO
Unload pressure of P1 NO No-load independent operating NO Refer to "Only bucket
pump is less than speed is within a standard
motion is slow.".
20kgf/cm2 (280psi) when value.
bucket close lever is at
neutral. YES
Secondary pilot pressure at
YES Inspect or replace P1 NG
port Pb4 (P1 bypass cut valve) YES Inspect or replace
bypass cut
is approx. 5.5kgf/cm2 (78psi) proportional valve block.
proportional valve.
when lever is at neutral.
NO
P1 bypass cut spool return cut spool assy and pilot
spring is broken. cover.
NO
P1 bypass cut spool moves NO Outer circumference of YES Replace P1 bypass cut spool
smoothly by hand. (remove P1 bypass cut spool is
assy.
pilot cover.) scored.
NG
YES NO
Secondary pressure of pilot
valve is approx. 5.5kgf/cm2 Replace control valve.
(78psi) when bucket close
lever is just shifted a YES Inspect or replace pilot
little. valve.
NO
Pilot spool return spring is YES Inspect or replace bucket
broken. spool assy or pilot cover.
NO
Bucket spool moves NO Outer circumference of bucket YES
smoothly by hand. spool is scored.
31102 60413252
(Remove pilot cover.) NG

NO
YES Replace control valve.
F17922
42-8
(4)-2
Machine can not perform fine operation of boom raise and lower motions.
Machine gets normal if connector of P1 bypass cut proportional YES To electrical

valve (PSV-D) is disconnected. troubleshooting.
NO
Unload pressure of P1
pump is less than NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
port Pb4 (P1 bypass cut valve) proportional valve for
20kgf/cm2 (280psi) when proportional valve block.
is approx. 5.5kgf/cm2 (78psi). P1 bypass cut valve.
boom lever is at neutral.
YES NO
Return spring or P1 bypass
cut spool is broken.
cover.
NO Outer circumference of Replace P1 bypass cut spool
P1 bypass cut spool moves NO P1 bypass cut spool is YES assy.
smoothly by hand. scored.
NG
YES NO
Secondary boom pilot pressure is approx. YES To electrical

5.5kgf/cm2 (78psi) when lever is just shifted. troubleshooting.
NO
YES To electrical
Return spring of boom spool is broken.
troubleshooting.
NO
Boom spool moves NO Outer circumference of boom YES
Replace boom spool assy.
YES NO NG
Does boom lock valve NO Inspect or replace lock

move smoothly by hand? valve.
YES Replace control valve.
(4)-3
Machine can not perform fine swing operation.
Machine gets normal if connector of P2 bypass cut proportional YES To electrical

valve (PSV-B) is disconnected. troubleshooting.
NO
Machine gets normal if connector for swing parking brake YES
To electrical troubleshooting.
solenoid (SV-1) is disconnected.
NO
Secondary pressure of swing pilot valve is approx. 6kgf/cm2 YES Inspect or replace NG Inspect or replace
(85psi), while pilot pressure of parking brake soleonid valve is swing parking solenoid
0kgf/cm2 (0psi). valve.
NO
Unload pressure of P2 Pilot pressure of port Pd4 (P2
pump is approx. 20kgf/cm2 NO bypass cut valve) is approx. YES Inspect or replace NG Inspect or replace
proportional valve for
(280psi) or less when 5.5kgf/cm2 (78psi) when swing proportional valve block.
P2 bypass cut valve.
swing lever is at neutral. lever is at neutral.
YES NO
Return spring for P2 bypass YES Inspect or replace P2 bypass
cut spool is broken. cut spool and pilot cover.
NO
31102 60413252
P2 bypass cut spool moves NO Outer circumference of YES

Replace P2 bypass cut spool
smoothly by hand. (Remove P2 bypass cut spool is
assy.
pilot cover.) scored.
NG
YES NO
Continued on next page. Replace control valve.

F17923
42-9
Continued previous page.
Secondary pilot pressure of parking brake solenoid valve is NO Inspect or replace swing
0kgf/cm2 (0psi) when secondary pressure of pilot valve is
parking solenoid valve.
approx. 6kgf/cm2 (85psi).
NG
YES
Inspect or replace pilot
pump and pilot relief valve.
Secondary pressure of pilot
valve at start up is approx. NO Inspect or replace pilot
5.5kgf/cm2 (78psi). valve.
YES
NO Inspect or replace swing
Fine operation is possible
pilot shuttle valve of control
if Pd2 port is pluged.
valve.
YES
Return spring for swing YES
Replace swing spool assy.
spool is broken.
NO
Swing spool moves NO Outer circumference of swing YES
YES NO NG

(4)-4
Machine can not perform fine operation of arm in and out.
Machine gets normal if connector of P2 bypass cut proportional YES

To electrical troubleshooting
valve (PSV-B) is disconnected.
NO
P2 pump unload pressure NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
is less than 20kgf/cm2 port Pd4 (P2 bypass cut valve) proportional valve for
2 proportional valve block.
(280psi) when arm lever is is approx. 5.5kgf/cm (78psi). P2 bypass cut valve.
at neutral.
NO
YES YES Inspect or replace P2 bypass
Return spring of P2 bypass
cut spool is broken.
cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES
Replace P2 bypass cut spool
smoothly by hand. P2 bypass cut spool is
assy.
(Remove pilot cover.) scored.
NG
YES NO
Secondary pressure is Replace control valve.

approx. 5.5kgf/cm2 (78psi)
when arm lever is shifted YES Inspect or replace pilot
a little. valve.
NO
Return spring of arm spool YES
is broken.
NO
Arm spool moves smoothly NO Outer circumference of swing YES
by hand. spool is scored.
YES NO NG
Arm lock valve moves NO Inspect or replace lock

31102 60413252
smoothly by hand. valve.

YES
Piston in swing Confirm piston movement by disconnecting NO Inspect or replace swing
priority block connector at port Pc3' and pushing piston
priority block parts.
moves smoothly. through the port hole, using a rod.
YES
F17924
42-10
(5)
Travel 1 and 2 speeds can not be changed over.
24V is alive across light green/black and NO

black of connector for travel 1-2 speed To electrical troubleshooting
soleonid (SV-3).
YES
Pilot pressure of travel 1-2 speed select NO Inspect or replace travel 1-2 NG Inspect or replace
solenoid (SV-3) is approx. 35kgf/cm2 (500psi). speed select solenoid valve. proportional valve block.
YES
Travel 1-2 speed select can not be done in NO Inspect travel motor (ristrict in passage to 1-2 select valve, inclusion
heavy duty condition on a slope or on a muddy
of foreign matter in shuttle valve, etc.) or replace it.
land.
Since the delivery rate of pump is small at heavy duty, the difference
YES between 1 and 2 speeds gets smaller. This makes you feel sometimes
that speed is not changed. But this is normal.
(6)
Travel independent speed is low.
Are both travel speeds low? NO Refer to "Machine

(H-mode, Hi idle, 1-speed, sprocket
deviates."
revolution ; 31rpm)
YES
Command current of proportional
valve is approx. 315mA. (Is the speed NO To electrical
low if coupler of travel straight troubleshooting.
proportional valve is disconnected?)
YES
Secondary pressure for NO Inspect or replace travel
travel remote control is
2 remote control valve.
approx. 24kgf/cm (340psi).
YES
NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
Is the pivot turn possible?
port PO (travel straight valve) travel straight
(in both directions) proportional valve block.
is approx. 26kgf/cm2 (370psi). proportional valve.
YES
NO
YES Inspect or replace travel
Return spring of travel
straight spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of YES Replace travel straight spool
smoothly by hand. assy.
scored.
YES NG
NO
Return spring of travel YES Inspect or replace travel

spool is broken. spool assy and pilot cover.
NO
Travel spool moves NO Outer circumference of travel YES
Replace travel spool assy.
smoothly. spool is scored.
YES NO NG
Relief pressure in all NO
travel motions is approx. Inspect or replace travel
300kgf/cm2 (4270psi). motor relief valve.
YES
31102 60413252

motor.
F17925
42-11
(7)
Travel power is poor.
(Diagnosis 30)
Command current for travel straight NO To electrical
proportional valve is approx. 315mA. troubleshooting.
YES
Since the delivery rate of pump is small and travel speed
Power lack is felt on a slope or in muddy YES
is low in heavy duty condition, power lack is felt in some
fields.
cases, but it is normal.
NO
Is the secondary pilot NO Inspect or replace travel
pressure for travel approx.
pilot valve.
24kgf/cm2 (340psi)?
YES
Is a pivot turn possible? NO Pilot pressure at port PO NO Inspect or replace NG Inspect or replace travel
(travel straight valve) is travel straight
(in both directions) pilot valve.
approx. 5.5kgf/cm2 (78psi). proportional valve.
YES
YES
cover.
NO
Travel straight spool moves NO Outer circumference of YES Inspect or replace travel
smoothly by hand. pilot valve.
scored.
YES NG
NO
Return spring of travel YES Inspect or replace travel

spool is broken. straight spool and pilot
cover.
NO
Travel spool moves NO Outer circumference of travel YES
Replace travel spool assy.
YES NO NG
Relief pressure is approx. Replace control valve.
300kgf/cm2 (4270psi) when
travel lever is turned to NO IInspect or replace travel
the full. motor relief valve.
motor.
(8)-1
Machine does not travel straight.
Feed current for travel NO

straight proportional To electrical troubleshooting
valve (PSV-C) is 700mA.
YES
Secondary pilot pressure
at port PO (travel straight NO Secondary pressure of travel NO Inspect or replace travel
pilot valve is approx.
valve) is approx. 26kgf/cm2 pilot valve.
24kgf/cm2 (340psi).
(370psi).
YES Inspect or replace NG Inspect or replace
YES travel straight
proportional valve.

cover.
NO
Travel straight spool NO Outer circumference of travel YES Replace travel straight spool
31102 60413252
moves smoothly by hand. straight spool is scored. assy.

YES NO NG

F17926
42-12
(8)-2
Machine deviates in travel independent motion.
Does the machine deviates

In idle run, machine runs to the right and the NO in opposite direction if NO Inspect or replace control
left at different speeds. (H-mode, Hi idle, delivery ports are
valve.
1-speed, and sprocket rotation : 31rpm) exchanged?
YES YES
Inspect or replace pump.
Is the secondary pilot pressure for travel NO Inspect or replace travel
motions normal in both the right and the left
remote control valve.
directions? It is approx. 24kgf/cm2 (340psi).
YES
Relief pressure in right and
Does the machine deviates if the right and NO NO
left travel motions is Inspect or replace travel
left pipes between control valve and motor are
approx. 300kgf/cm2 motor rilief valve.
exchanged?
(4270psi).
YES YES Inspect or replace travel
motor.
Return spring of travel spool is broken.
spool assy and pilot cover.
NO
NO Outer circumference of NO
Travel spool moves smoothly by hand. Replace travel spool assy.
travel spool is scored.
YES YES
Confirm check valve and seat located before NO

the relief valve of control valve.
YES
(9)
Machine drifts on a slope. (Machine can not be held on a slope.)
Machine can not be held on a slope when YES Inspect or replace travel
engine is off. motor.
NO
Secondary pilot pressure for travel is 0kgf/cm2 NO Inspect or replace remote
(0psi). control valve.
YES
Return spring of travel spool is broken.
NO
NO Outer circumference of NO
Travel spool moves smoothly by hand. Replace travel spool.
travel spool is scored.
YES YES NG

F17927
31102 60413252
42-13
(10)
On disconnecting connector YES
Swing motion To troubleshooting for
(CN-259F) on swing parking
does not work. electric failures.
SOL (SV-1), it swings.
NO
Does the pilot pressure of
parking SOL rise to 0Mpa NO NG
Check or replace swing Check or replace
(0kgf/cm2) at the time when
parking solenoid valve. proportional valve block.
pilot valve secondary pressure
is 0.6MPa(6kgf/cm2)?
In case of a machine with a
YES multi control valve, check if the
condition returns normal by
changing swing lever back &
forth operation.
Swing pilot valve secondary NO

pressure on both right and left Check or replace pilot valve.
sides is 3.43MPa(35kgf/cm2).
YES
The return spring of swing YES Check or replace swing
spool is damaged. spool Assy and pilot cover.
NO
The swing spool moves
smoothly. (Remove pilot cover, NO The outer surface of swing YES
Replace swing spool Assy.
and check it for possible spool is damaged.
damage.) NG
NO
YES
Check or replace P2 by-pass

The return spring of P2 by-pass YES
cut valve spool Assy and
cut valve spool is damaged.
pilot cover.
NO
P2 by-pass cut valve spool
moves smoothly. (Remove NO The outer surface of P2 cut YES
Replace P2 by-pass cut Assy.
pilot cover, and check it for valve spool is damaged.
possible damage.) NG
NO
YES
The swing relief pressure is in

the range of reference value. NO Check or replace swing
(With P2 pump) 25.5 – 28.3 motor relief.
MPa(260-290kgf/cm2)
NG
YES
The swing motion can be held NO Check and replace swing

on a slope. reduction unit or swing motor.
YES
Machine drifts largely when the YES Check or replace swing

swing parking is released (arm
motor.
in fine operation) on a slope.
NO Check or replace swing

reduction unit or swing motor.
F17928
31102 60413252
42-14
(11)
Swing speed is low.
Feedback current of P2 bypass cut NO

proportional valve (PSV-B) is 700mA when To electrical troubleshooting
swing lever is turned to the full.
YES
Secondary pilot pressure at Pd4 port (P2 NO Inspect or replace P2 bypass NG Inspect or replace
bypass cut valve) is approx. 26kgf/cm2 (370psi)
when swing lever is shifted to the full.
YES
Return spring of P2 bypass cut spool is
broken.
cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut spool moves smoothly by hand.
bypass cut spool is scored. assy.
YES NO NG

multi control valve, check if the
forth operation.
Secondary pilot pressure for swing motion is NO Inspect or replace pilot

approx. 35kgf/cm2 (500psi) when lever is
valve.
turned to the full in either direction.
YES Inspect or replace swing
pilot shuttle valve of control
valve.
Swing relief pressure is 260 to 290kgf/cm2 NO Inspect or replace swing

(3700~4120psi). motor relief.
YES NG
Machine drifts very much when swing YES Inspect or replace swing
parking is released (arm in action) on a slope. motor.
NO
Swing motor port pressure is 35kgf/cm2 NO NG
Inspect or replace swing Inspect or replace
(500psi) when swing lever is shifted to the full
parking solenoid valve. proportional valve block.
or arm in operation.
NO
YES Inspect or replace swing
Return spring of swing spool is broken.
NO
Swing spool moves smoothly. (Confirm the NO Outer circumference of YES
action of spool by removing pilot cover) Replace swing spool assy.
swing spool is scored.
YES NO NG

F17929
31102 60413252
42-15
(12)-1 The swing speed is in the

Swing range of reference value. NO Refer to Article “Swing
power is poor. (12.5rpm or more at Hi idling in speed is slow.”
H mode.)
YES
The return spring of P2 YES Check or replace P2 by-pass
by-pass cut spool is damaged. cut spool Assy and pilot cover.
NO
P2 by-pass cut spool move NO The outer surface of P2 YES Replace P2 by-pass cut
smoothly by hand. by-pass cut spool is damaged. spool Assy.
YES NO NG
multi control valve, check if the
forth operation.
Swing pilot valve secondary

pressure is 3.43MPa NO
(35kgf/cm2) when the levers Check or replace pilot valve.
on both right and left sides are
to full position.
YES
The swing relief pressure is in
the range of reference value. NO Check or replace swing
(With P2 pump) 25.5 – 28.3
motor relief.
MPa(260-290kgf/cm2)
YES NG
Machine drifts largely when the YES Check or replace swing

swing parking is released
motor.
(arm-in operation) on a slope.
NO
Swing motor (PG) port pressure
is 3.43MPa(35kgf/cm2) when NO Check or replace swing NG Check or replace
the swing lever is to full position parking SOL valve. proportional valve block.
or to arm-in position.
YES
NO
The swing spool moves NO YES
The outer surface of swing
smoothly. (Remove pilot cover Replace swing spool Assy.
spool is damaged.
and check the operation.)
NO NG
YES

F17930
31102 60413252
42-16
(12)-2
Swing relief pressure is in the
Swing motion range of reference value. NO Check or replace swing
drifts very large. (With P2 pump) 25.5 – 28.3 motor relief valve.
MPa (260-290kgf/cm2)
YES
The swing motion can be held NO Replace swing motor
on a slope. parking brake lining.
YES
Machine drifts largely when the YES
swing parking is released Check and replace swing
(arm-in operation) on a slope. motor.
NO multi control valve, check if the
forth operation.
The swing pilot secondary

pressure lowers in 0.2 seconds NO
Check or replace pilot valve.
or less after the swing lever
returns to the neutral position.
YES
NO
The swing spool moves NO YES
Outer surface of swing spool
smoothly. (Remove pilot cover Replace swing spool Assy.
is damaged.
and check the operation.)
NO NG
YES
F17931
31102 60413252
42-17
(13)-1
The swing The command voltage for YES
To troubleshooting for
motion swing parking SOL. is
electric failures.
cannot be output.
held on a
slope. NO
Check or replace swing
motor reduction unit.
(13)-2
Noise when Make noise when swing YES Check or replace swing
swinging motion is released. motor relief valve.
NO
Make noise when swing YES Check swing shockless
motion stops. valve.
NO
Swing relief pressure is in The control current of
the range of reference value. NO proportional valve for P2 NO To troubleshooting for
(With P2 pump) 25.5–28.3 by-pass cut valve is electric failures.
Mpa (260-290kgf/cm2) approx.585mA.
YES YES
P2 by-pass cut port Pb4
pressure is approx. 2MPa NO Check or replace NG Check or replace
proportional valve
(20kgf/cm2) in swing proportional valve block.
for P2 by-pass cut.
operation.
YES
The main relief valve
pressure is in the range YES Check or replace NG Check or replace swing
swing motor
of reference value. motor.
relief valve.
(With P2 pump) 29.4MPa
(300kgf/cm2)
NO
The return spring of P2 YES Check or replace P2
cut valve spool is by-pass cut valve spool
damaged. Assy and pilot cover.
NO
spool moves smoothly. YES Check or replace main
(Remove pilot cover and
relief valve.
check it for possible
damage)
NO
Outer surface of P2 YES Replace P2 by-pass cut
by-pass cut valve spool
valve spool Assy.
is damaged.
NO NG

NO
The swing spool moves
smoothly by hand. NO Outer surface of P2 YES Replace swing spool
by-pass cut valve spool
(Remove pilot cover and Assy.
is damaged.
check it.)
NO NG
YES
The swing motion is held NO Check or replace swing

on a slope. motor or reduction unit.
YES
Check or replace swing
motor pinion gear,
31102 60413252
swing race, bearing.

F17932
42-18
SECTION 43 TROUBLESHOOTING (ELECTRIC)
TABLE OF CONTENTS
1. Trouble diagnosis table: electric ............................................................................. 43-1
2. Controller error code display ................................................................................. 43-2
3. Servise diagnosis .................................................................................................. 43-2

31102 60413252
TROUBLESHOOTING (ELECTRIC)
1. TROUBLE DIAGNOSIS TABLE: ELECTRIC

C1 MECHATRO CONTROLLER ELECTRICAL FITTINGS
Proportional valve Sensor Other Proportionate valve Sensor Solenoid Switch
Boom raising pressure sensor
Bucket digging pressure sensor
Bucket dump pressure sensor

Boom lowering pressure sensor


Travel 1-2-speed selector valve
Swing right pressure sensor

COMPONENTS
Travel right pressure sensor

Swing left pressure sensor
Travel left pressure sensor

Arm out pressure sensor
Travel 1-2speed select SW

Arm in pressure sensor
Swing P/B selector valve
Fuse blown, shortcircuit,
Swing P/B release SW

Safaty lock lever SOL
Travel 1-2speed SOL
Safety lock lever SW

Travel 1-2speed SW
Swing parking SOL
Bucket digging
Gauge cluster
disconnection
Bucket dump
Boom lower
Boom raise
Swing right
Travel right
Swing left
Travel left
Arm out
Arm in
GROUP No.
SYSTEM
G(A1)5V 5V(A2)G G(A3)5V 5V(A4)G G(A5)5V G(A6)5V 5V(A7)G G(A8)5V 5V(A9)G G(A10)5V
P P P S S S S S S S S S S S S S S S S
Pin 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 13 13 13 13 13 13 13 13 13 13 13 13 14 14 14 14 E C S S S
E E E E E E E E E E V V V W W W
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
TROUBLE No 2 11 12 13 14 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 4 5 6 10 1 V V V
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2
-
-
-
B C D 1 2 3 4 5 6 7 8 9 10 1 3 4 3 4 11
No motions operate
1
Machine moves freely
when lever is at neutral
All operation
Only bucket speed is
slow.
Speed is slow
Only boom raise

speed is slow.
2 Motions are slow
except boom raise
Attachment operation
and arm digging.

Only arm motion is slow.
Only arm out motion
is slow.
All operation
Power is poor
Bucket digging
3
Boom raising
Arm in
Electric systems
Bucket digging
Fine operation
Boom raising, lowering

impossible
4
Swing left, right
Arm in, out
5 not be 1-2
Travel speed can
changed
6 Travel independent
speed is low.
Travel operation
7 Travel power is poor

ATT travel combined and
8 travel straight are
impossible.
Machine drifts on a
9 downhill and does not
stop still on a slope
10 Swing
work
motion does not
Swing operation
11 Swing speed is slow

31102 60413252
Swing power is poor

12
Swing drifts too much
Swing can not be held
on a slope
13
An unusual sound is
heard during swing
F17933
43-1
2. CONTROLLER ERROR CODE DISPLAY 3. SERVISE DIAGNOSIS
When the hard check switch of the controller is set to "00" (The machine is tuned to "00" at shipment.), faults of devices and The following items are displayed if the hard ware check switch located in the controller is changed over.
harnesses connected to them are listed as below. Since the hard ware check switch is tuned to “00” at shipment, error codes are displayed.
When an error code is displayed, the CPU lamp on the gauge cluster flickers and the buzzer blows intermittently. In some HARDWARE
cases, the CPU lamp on the gauge cluster lights continuously and the buzzer sounds continuously. This is to indicate a fault CHECK NORMAL
SW SERVICE DIAGNOSIS ITEM CONTENTS OF DISPLAY
A B VALUE
on the controller itself.
0 0 Normal (no service diagnosis) Trouble diagnosis (error code)
1. Trouble diagnosis
0 1 A set value of engine rpm Displayed in 3 digits by 10 rpm. [230] at 2300 rpm. 1020~2250
ERROR ERROR 0 2 An actual engine rpm Displayed in 3 digits by 10 rpm. [230] at 2300 rpm. Approx. 1020 to
TROUBLE DIAGNOSIS ITEM CORRECTIVE ACTION TROUBLE DIAGNOSIS ITEM CORRECTIVE ACTION approx. 2250
CODE CODE
0 3 Key switch input / option switch input Statuses of key switch on 10th digit (ON [1] / OFF [0] ), and
E01 EEPROM data faulty Readjust engine speed or E16 Battery relay faulty Replace battery relay or battery relay on the 1st digit (ON [1] / OFF [0] ) are displayed.
E02 Mechatronic adjustment faulty replace controller inspect harness between 0 4 Mode switch / washer switch / work light Mode switch on the 10th digit ( [H] [S] [F] ) Status of option switch on
battery relay and controller. switch the 1st digit (ON [1] / OFF [0] ) is displayed.
E03 Fault on boom raise pressure sensor
0 5 Wiper switch / washer switch / work light The following statuses are displayed ; wiper SW on the 100th digit
E04 Fault on boom lower pressure sensor E17 Fault on P1 by-pass cut proportional valve Replace proportional valve swich (push [1] / [OFF] [0] ), washer SW on the 10th digit (push [1] /
E05 Fault on arm in pressure sensor E18 Fault on P2 by-pass cut proportional valve or inspect harness between [OFF] [0] ), work lamp SW on the 1st digit (push [1] / OFF [0] ).
E06 Fault on arm out pressure sensor E19 Fault on travel straight proportional valve proportional valve and controller. 0 6 Voltage of accel dial Displayed in whole numbers to the 2nd decimal points. 0.4~4.6
0 7 Accel dial position Governor motor position converted from accel dial voltage is displayed in per cents. 0~100
E07 Fault on bucket digging pressure sensor Replace sensor or inspect E20 Fault on governor motor current Replace governor motor or
0 8 Step number of governor motor Present step number of governor motor is displayed in three whole numbers. 0~630
E08 Fault on bucket dump pressure sensor harness between sensor E21 Fault on governor motor inspect harness between
0 9 Governor motor position What percent in position the present step number is between low 0~100
E09 Fault on swing right pressure sensor and controller. starting point governor motor and controller. idle and high idle is displayed.
E10 Fault on swing left pressure sensor E22 Reverse rotation of engine Replace engine hydraulic 1 0 Phase current of governor motor A Displayed in whole numbers to the 2nd decimal points. 2.34A is Approx. 150
switch or inspect harness 1 1 Phase current of governor motor B displayed in [234] .
E11 Fault on travel right pressure sensor
between engine oil switch 1 2 Governor motor limit switch Status of governor motor limit switch on the 1st digit (ON [1] /
E12 Fault on travel left pressure sensor and controller. OFF [0] ) is displayed.
E13 Accel dial faulty pressure sensor 1 3 Boom raise pressure sensor Displayed in whole numbers to the 2nd decimal points. 2.34V is 0.4~5.0
E14 Fault on 1-2-speed travel selector valve Replace selector valve or 1 4 Boom down pressure sensor displayed in [234] .
1 5 Arm out pressure sensor
E15 Fault on swing parking selector valve inspect harness between
1 6 Arm in pressure sensor
selector valve and controller.
1 7 Bucket digging pressure sensor
1 8 Bucket dump pressure sensor
SERVICE DIAGNOSIS DISPLAY 1 9 Swing right pressure sensor
2 0 Swing left pressure sensor
2 1 Travel right pressure sensor
2 2 Travel left pressure sensor
2 3 Travel 1-2 speed SW / selector valve Statuses of travel 1-2 speed SW in the 100th digit (push [1] / OFF
output command / feedback [0] ) output command in the 10th digit (ON [1] / OFF [0] ),
and feedback in the 1st digit (ON [1] / OFF [0] ) are displayed.
2 4 Output command of swing parking Statuses of output command on the 10th digit (ON [1] / OFF [0] ),
selector valve / feedback and feedback on the 1st digit (ON [1] / OFF [0] ) are displayed.
2 5 Battery relay output command / feedback
2 6 Command current for P1 bypass cut proportionate valve Current is displayed in mA. 280~760
2 7 Feedback current of P1 bypass cut proportionate valve
2 8 Command current of P2 bypass cut proportionate valve
2 9 Feedback current of P2 bypass cut proportionate valve
3 0 Command current of travel straight proportionate valve
3 1 Feedback current of tralve straight valve
3 2 Wiper motor rise-up LS / reverse LS Statuses of LS on the 10th digit (ON [1] / OFF [0] ), wiper motor
rise-up LS on the 1st digit (ON [1] / OFF [0] ) are displayed.
Wiper motor arc preventive relay / forward Statuses of wiper motor arc preventive relay command on the 100th
digit (ON [1] / OFF [0] ), forward relay command on the 10th digit
3 3 relay / reverse relay command
(ON [1] / OFF [0] ), and reverse relay command on the 1st digit
(ON [1] / OFF [0] ) are displayed.
HARDWARE CHECK SW A Washer motor relay / work light relay / Statuses of washer motor relay command on the 100th digit (ON [1]
Remove grommet, / OFF [0] ), work light relay command on the 10th digit (ON [1] /
3 4 CPU trouble lamp command
and the right OFF [0] ), CPU trouble lamp command on the 1st digit (ON [1] /
Hardware check SW (The left shows
31102 60413252
switches are appear. OFF [0] ) are displayed.
the “0.0” setting condition.)
3 5 Wiper operating command / power window Statuses of wiper operating command on the 10th digit (ON [1] /
Turn the arrow at the center of switch OFF [0] ), and wiper window operating input command on the 1st
and set it to numeric value. operating input
digit (ON [1] / OFF [0] ) are displayed
Insert precision driver (-) in to convex
indicated by arrow and turn the arrow Status of internal adjust switch on the 1st digit (TEST [1] / RUN
3 6 Internal adjust switch
to set to numeric values. [0] ) is displayed.
F17934
INTERNAL ADJUSTMENT JP SW
HARDWARE CHECK SW B
43-2
(1)-1
No motions operate.
Lever stand down

24V is alive across
white/blue and black of YES To hydraulic
connector (CN-256F) for troubleshooting
lever lock solenoid (SV-4).
NO
24V is alive across white Harness between lever

and blue of connector YES lock switch (SW-11) and YES
Inspect harness.
(CN-66F) for lever lock lever lock solenoid
switch (SW-11). (SV-4) is disconnected.
NO
Lever lock switch (SW-11) YES

Replace switch (SW-11).
is faulty.
24V is alive across white

and black of connector YES
(CN-66F) for lever lock
switch (SW-11).
NO Lever lock switch (SW-11) YES
Adjust and mount.
is mounted improperly.
YES YES Inspect the shorted point

Fuse No.15 is blown. Harness shorted to frame.
of harness.
NO
Inspect if there is no
disconnection in fuse box.
F17936
31102 60413252
43-3
(1)-2
Machine moves freely when lever is at neutral.
(Hard check SW00) ; error code E17 is indicated at this time.

Machine moves not freely when NO To hydraulic
connector (CN-253F) for P1 bypass cut
troubleshooting
proportional valve is disconnected.
YES
(Hard check SW15)
Arm out sensor (SE-8) shows more than YES Trouble disappears if arm out operation YES Arm out operation sensor
1.3V even when lever is at neutral. sensor (SE-8) is replaced. (SE-8) is faulty.
NO NO
Arm out pilot pressure is 6kgf/cm2 NO
Replace C-1 controller.
(85psi) when lever is at neutral.
YES
Inspect ATT pilot valve.
(Hard check SW16)
Arm in sensor (SE-7) shows more than NO
ReplaceC-1 controller.
1.3V when lever is at neutral.
YES
Trouble disappears if arm in sensor (SE-7) YES Arm in sensor (SE-7) is
is replaced. faulty.
NO
Arm in pilot pressure is more than NO
6kgf/cm2 (85psi) when lever is at neutral.
YES
(Hard check SW00) ; error code E18 comes out at this time.
Machine stops moving freely when NO To hydraulic
connector (CN-254F) for P2 bypass cut
troubleshooting
proportional valve is disconnected.
YES
(Hard check SW13)
Boom raise sensor (SE-3) shows more YES Trouble disappears when boom raise YES Boom raise sensor (SE-3)
than 1.3V when lever is at neutral. sensor (SE-3) is replaced. is faulty.
NO NO
Boom raise pilot pressure is more than NO
YES
(Hard check SW20)

Swing left sensor (SE-5) shows more YES Trouble disappears when swing left YES Swing left sensor (SE-5)
1.3V when lever is at neutral. sensor (SE-5) is replaced. is faulty.
NO NO
Swing left pilot pressure is more than NO
YES
(Hard check SW21)

Swing right sensor (SE-6) show more NO
than 1.3V when lever is at neutral.
YES
Trouble disappears if swing right sensor YES Swing right sensor (SE-6)
(SE-6) is replaced. is faulty.
NO
Swing right pilot pressure is more than NO
31102 60413252

YES
F17937
43-4
(2)-1
Only bucket motion is slow
(Hard check SW00) ; Error code E18 comes out on that occasion.
Is the motion normal after
connector (CN-254F) of P2 NO To hydraulic
bypass cut proportional troubleshooting
valve is disconnected.
YES (Hard check SW13)
Boom raise sensor (SE-3) YES Trouble disappears if boom YES Boom raise sensor (SE-3)
shows 1.3V when lever is raise sensor (SE-3) is
is faulty.
at neutral. replaced.
Boom raise pilot pressure
NO NO is more than 6kgf/cm2 NO
(85psi) when lever is at
neutral.
YES
(Hard check SW20)
Swing left sensor (SE-5) YES Trouble disappears if swing YES Swing left sensor (SE-5)
shows 1.3V when lever is left sensor (SE-5) is
is faulty.
at neutral. replaced.
NO NO Swing left pilot pressure is NO
more than 6kgf/cm2 (85psi) Replace C-1 controller.
YES
(Hard check SW21)
Swing right sensor (SE-6) shows 1.3V NO Replace C-1 controller.
YES
NO
Swing pilot pressure is more than NO
YES
(2)-2
Only boom raise speed motion is slow.
(Hard check SW29)

Feedback current for P2 bypass
cut proportional valve (PSV-B) YES To hydraulic
is approx. 700mA when boom troubleshooting
raise lever is shifted to the full.
NO (Hard check SW28) (Hard check SW13)

Command current for P2 bypass Boom raise sensor (SE-3)
cut proportionl valve (PSV-B) NO shows more than approx. 4.0V YES
is approx. 700mA when boom when boom raise lever is
raise lever is shifted to the full. shifted to the full.
YES NO
Trouble disappears when boom YES Boom raise operating
raise sensor (SE-3) is replaced. sensor (SE-3) is faulty.
NO
Boom raise pilot pressure is
more than approx. 35kgf/cm2 NO
(500psi) when boom raise lever Inspect ATT pilot valve.
is shifted to the full.
YES Harness between
Error code E03 is displayed on YES C-1 controller and YES
Inspect harness.
31102 60413252
C-1 controller. boom raise sensor

(SE-3) is shorted.
NO
Contact between C-1 controller YES
Continued on P6. and boom raise sensor (SE-3) Inspect harness.
is poor.
F17938
43-5
Continued from P5
YES Harness between C-1 controller Inspect harness between

Error code E18 is shown on C-1 YES and P2 bypass cut proportional YES C-1 controller and P2
controller. valve (PSV-B) is disconnected or bypass cut proportional
(Hard check SW30) shorted. valve (PSV-B).
NO
Command current for travel
straight proportional valve NO To hydraulic
(PSV-C) is more than approx.
troubleshooting
350mA only when boom raise
lever is shifted to the full.
YES
Travel right sensor (SE-9) shows NO
approx. 1.3V when travel right Replace C-1 controller.
lever is at neutral.
YES
Trouble disappears if travel right YES Travel right sensor (SE-9)
sensor (SE-9) is replaced. is faulty.
NO
Travel right pilot pressure is NO Inspect harness between
more than 6kgf/cm2 (85psi) when travel right sensor (SE-9)
lever is at neutral. and C-1 controller.
YES
Inspect travel pilot valve.
(2)-3
Only boom raise and arm in motions are slow.
YES (Hard check SW30) ; controller service diagnosis 30
Command current for
travel straight
proportional valve is NO To hydraulic
approx. 350mA or over at troubleshooting
boom raise or arm in
motions.
YES (Hard check SW21) (Hard check SW22)
Travel right sensor (SE-9) Travel left sensor (SE-10)
shows more than 1.3V NO shows approx. 1.3V or over NO
when travel right lever is when travel left lever is at
at neutral. neutral.
YES YES
Trouble disappears if travel NO Travel left pilot pressure is NO Inspect harness between
left sensor (SE-10) is more than 6kgf/cm2 (85psi) travel left sensor (SE-10)
replaced. when lever is at neutral. and C-1 controller.
YES YES
Replace swing left sensor

(SE-10).
Travel right pilot pressure

Trouble disappears when NO NO Inspect harness between
is more than 6kgf/cm2
travel right sensor (SE-9) travel right sensor (SE-9)
is replaced. and controller.
neutral.
YES
YES
31102 60413252
Inspect travel pilot valve.
Replace swing right

sensor (SE-9).
F17939
43-6
(2)-4
Only arm in motion is slow.
(Hard check SW26)
Command current for
bypass cut proportional YES To hydraulic
valve (PSV-D) is approx.
troubleshooting
700mA when arm in lever
NO (Diagnosis 16)
Arm in sensor (SE-7) shows (Hard check SW00)
approx. 4.0V or over when YES NO
Error code E17 is displayed. Replace C-1 controller.
arm in lever is shifted to
the full.
YES
NO Inspect harness between
P1 bypass cut
proportional valve (PSV-
D) and C-1 controller.
Trouble disappears if arm YES Arm in sensor (SE-7) is

in sensor (SE-7) is replaced. faulty.
NO
Arm in pilot pressure is
YES Inspect harness between
approx. 35kgf/cm2 (500psi)
arm in sensor (SE-7) and
or over when arm in lever
C-1 controller.
NO
(2)-5
Only arm out motion is slow.
(Hard check SW26)
Command current for P1
bypass cut proportional YES To hydraulic
valve (PSV-D) is approx.
troubleshooting
700mA when arm out lever
NO (Hard check SW15)
Arm out sensor (SE-8) (Hard check SW00)
shows approx. 4.0V or over YES NO
Error code E17 is displayed. Replace C-1 controller.
when arm out lever is
shifted to the full.
YES
P1 bypass cut
proportional valve (PSV-
D) and C-1 controller.
Trouble disappears if arm YES Arm out sensor (SE-8) is

out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is
or over when arm out lever
C-1 controller.
NO
F17940
31102 60413252
43-7
(4)-1
Fine operation of bucket digging and dump motions can not be performed.
YES
Trouble gets normal if
connector on P1 bypass cut NO To hydraulic
proportional valve (PSV-D) troubleshooting.
is disconnected.
Arm in sensor (SE-7) shows NO Arm out sensor (SE-8) NO
approx. 1.3V or over when shows approx. 1.3V or over Replace C-1 controller.
lever is at neutral. when lever is at neutral.
YES YES
Trouble gets normal if arm YES Arm out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is NO Inspect harness between
more than 6kgf/cm2 (85psi) arm out sensor (SE-8) and
when lever is at neutral. C-1 controller.
YES
Trouble is corrected if arm YES Arm in sensor (SE-7) is

NO
Arm in pilot pressure is NO Inspect harness between
more than 6kgf/cm2 (85psi) arm in sensor (SE-7) and
YES
(4)-2
Fine operation of boom raise and lower motions can not be performed.
YES (Hard check SW00) ; error code E17 is displayed at this time.
connector of P1 bypass cut NO To hydraulic
proportional valve (PSV-D) troubleshooting
is disconnected.
Arm out sensor (SE-7) shows YES Trouble disappears if arm YES Arm in sensor (SE-7) is
approx. 1.3V or over when
NO NO
6kgf/cm2 (85psi) or over arm in sensor (SE-7) and
YES

(Hard check SW15)
Arm out sensor (SE-8) NO
shows approx. 1.3V or over Replace C-1 controller.
YES
Trouble disappears if arm YES Arm out sensor (SE-8) is
faulty.
replaced.
NO
31102 60413252
Arm out pilot pressure is NO Inspect harness between

more than 6kgf/cm2 (85psi) arm out sensor (SE-8) and
YES
F17941
43-8
(4)-3
Fine operation of swing motion can not be performed.
(Hard check SW00) ;
error code E18 is
indicated at this time.
(Hard check SW20)
connector of P2 bypass cut YES Swing left sensor (SE-5) YES Trouble is corrected if YES Swing left sensor (SE-5)
shows approx. 1.5V or over swing left sensor (SE-5) is
proportional valve (PSV-B) if faulty.
when lever is at neutral. replaced.
is disconnected.
NO NO
NO
Swing left pilot pressure is NO Inspect harness between
more than 6kgf/cm2 (85psi) swing left sensor (SE-5)
when lever is at neutral. and C-1 controller.
YES
(Hard check SW19)
Swing right sensor (SE-6) YES Trouble disappears if swing YES Swing right sensor (SE-6)
shows approx. 1.3V or over right sensor (SE-6) is
is faulty.
NO NO
Swing right pilot pressure
is more than 6kgf/cm2 NO Inspect harness between
swing right sensor (SE-6)
and C-1 controller.
neutral.
YES
Boom raise sensor (SE-3) YES Trouble disappears if boom YES Boom raise sensor (SE-3)
shows approx. 1.3V or over raise sensor (SE-3) is
is faulty.
when lever is neutral. replaced.
NO NO
is more than 6kgf/cm2 NO Inspect harness between
boom raise sensor (SE-3)
and C-1 controller.
neutral.
YES

connector of swing parking NO To hydraulic
solenoid (SV-1) is troubleshooting
disconnected.
Swing left sensor (SE-5)
NO Trouble gets normal if YES
shows approx. 4.0V or over Swing left sensor (SE-5)
swing left sensor (SE-5) is
when lever is shifted to the is faulty.
replaced.
full.
NO
YES
Swing left pilot pressure is
swing left sensor (SE-5)
or over when lever is
and C-1 controller.
NO
(Hard check SW19) Inspect ATT pilot valve.
Swing right sensor (SE-6)
NO Trouble gets normal if swing YES
shows approx. 4.0V or over Swing right sensor (SE-6)
right sensor (SE-6) is
replaced.
full.
NO
YES
is approx. 35kgf/cm2
(500psi) or over when lever
31102 60413252
and C-1 controller.

NO

F17942
43-9
(4)-4
Fine operation of arm in and out motions is not possible.
(Hard check SW00) ; error code E18 is displayed at this time.
connector of P2 bypass cut NO To hydraulic
proportional valve (PSV-B) troubleshooting.
is disconnected.
YES
(Hard check SW20)
indicates approx. 1.3V or YES Trouble gets normal if YES Swing left sensor (SE-5)
swing left sensor (SE-5) is
over when lever is at is faulty.
replaced.
neutral.
NO
NO
YES
(Hard check SW19)

indicates approx. 1.3V or YES Trouble disappears if swing YES Swing right sensor (SE-6)
over when lever is at is faulty.
replaced.
neutral.
NO
NO
and C-1 controller.
neutral.
YES
(Hard check SW13)

Boom raise sensor (SE-3)
indicates approx. 1.3V or NO
over when lever is at
neutral.
YES
Trouble disappears if boom YES Boom raise sensor (SE-3)
raise sensor (SE-3) is
is faulty.
replaced.
NO
Boom raise pilot pressure is NO Inspect harness between
more than 6kgf/cm2 (85psi) boom raise sensor (SE-3)
YES
F17943
31102 60413252
43-10
(5)
Travel 1-2 speed can not be changed.
24V is alive across light

green/black and black wires of YES To hydraulic
connector (CN-258F) for travel 1-2 troubleshooting
speed select solenoid (SV-3).
NO
On service hard check SW23, if the
On service hard check SW23, if the
100th digit pushes travel 1-2 speed YES YES
100th digit displays 1 and 0 by
select switch (SW-3), "1" is Replace C-1 controller.
turns, the 10th digit and 1st digit
indicated and if it does not, "0" is
indicate 1 and 0 alternately.
indicated.
Inspect harness (light green
NO NO and black) between travel
1-2 speed select solenoid
On service hard check SW23, if (SV-3) and C-1 controller.
receptacles (2 females) connecting
the travel 1-2 speed select switch YES Replace travel 1-2 speed
(SW-3) with main harness are
select switch (SW-3).
connected, the 100th digit turns to
1 and if they are disconnected, 0 is
indicated.
NO
Harness (pink and blue) between
travel 1-2 speed select switch NO
(SW-3) and C-1 controller is
disconnected.
YES
Repair harness.
(6)
Travel independent speed is low.
(Hard check SW30)
Command current of travel
straight proportional (PSV-C) is NO To hydraulic
more than 350mA during troubleshooting
traveling.
Bucket digging sensor (SE-1) YES Trouble disappears if bucket digging YES Bucket digging sensor
indicates 1.3V when lever is at
sensor (SE-1) is replaced. (SE-1) is faulty.
neutral.
NO
NO
Bucket digging pilot pressure is NO
more than 6kgf/cm2 (85psi) when Replace C-1 controller.
YES
(Hard check SW18)
Bucket dump (SE-2) indicates more YES Trouble disappears if bucket dump YES Bucket dump sensor
than 1.3V when lever is at neutral. sensor (SE-2) is replaced. (SE-2) is faulty.
NO NO
Bucket dump pilot pressure is NO
more than 6kgf/cm2 (85psi) when Replace C-1 controller.
YES
(Hard check SW13)
Boom raise sensor (SE-3) indicates YES YES
Trouble disappears if boom raise Boom raise sensor (SE-3)
more than 1.3V when lever is at
neutral.
NO NO
31102 60413252
Boom raise pilot pressure is more NO

than 6kgf/cm2 (85psi) when lever is Replace C-1 controller.
at neutral.
YES
Continued on P12. Inspect ATT pilot valve.
F17944
43-11
Continued from P11.
NO (Hard check SW14)

Boom lower sensor (SE-4) indicates YES YES
Trouble disappears if boom lower Boom lower sensor (SE-4)
neutral.
NO NO
Boom lower pilot pressure is more NO
at neutral.
YES
(Hard check SW20)
Swing left sensor (SE-5) reads YES Trouble disappears if swing left YES Swing left sensor (SE-5)
neutral.
NO
NO
Swing left pilot pressure is more NO
at neutral.
YES
(Hard check SW19)
Swing right sensor (SE-6) reads YES Trouble disappears if swing right YES Swing right sensor (SE-6)
neutral.
NO
NO
Swing right pilot pressure is more NO
at neutral.
YES
(Hard check SW16)
Arm in sensor (SE-7) reads more YES Trouble disappears when arm in YES Arm in sensor (SE-7) is
than 1.3V when lever is at neutral. sensor (SE-7) is replaced. faulty.
NO NO
Arm in pilot pressure is more than NO
6kgf/cm2 (85psi) when lever is at Replace C-1 controller.
neutral.
YES
(Hard check SW15)
Arm out sensor (SE-8) reads more YES Trouble disappears if arm out YES Arm out sensor (SE-8) is
than 1.3V when lever is at neutral. sensor (SE-8) is replaced. faulty.
NO NO
Arm out pilot pressure is more NO
at neutral.
YES
Replace C-1 controller

F17945
31102 60413252
43-12
(8)
Machine does not travel straight.
(Hard check SW31)

Feedback current of travel YES To hydraulic
straight proportional
troubleshooting
valve (PSV-C) is 700mA.
NO
Check harness (green/
(Hard check SW00) black and gray/black)
Error code E19 is YES between travel straight
indicated. proportional valve
(PSV-C) and C-1
NO controller.
(Hard check SW20)
Machine deviates to the YES reads more than 4.0V NO Trouble disappears if swing YES Swing left sensor (SE-5)
left sensor (SE-5) is
left. when lever is shifted to the is faulty.
replaced.
full.
NO
NO
YES
more than approx. YES Check harness between
35kgf/cm2 (500psi) when
and C-1 controller.
NO
(Hard check SW19) Check ATT pilot valve.

indicates more than 4.0V NO Trouble disappears if swing YES Swing right sensor (SE-6)
when lever is shifted to the and C-1 controller.
replaced.
full.
NO
YES
is approx. 35kgf/cm2 YES Inspect harness between
and C-1 controller.
NO
Arm out sensor (SE-8)
indicates more than 4.0V NO Trouble disappears if arm YES Arm out sensor (SE-8) is
when lever is shifted to the faulty.
replaced.
full.
NO
YES
Arm out pilot pressure is
approx. 35kgf/cm2 (500psi) YES Inspect harness between
arm out sensor (SE-8) and
C-1 controller.
NO
(Hard check SW16)
Arm in sensor (SE-7) reads NO Trouble disappears if arm YES Arm in sensor (SE-7) is
more than 4.0V when lever in sensor (SE-7) is
faulty.
is shifted to the full. replaced.
YES NO
Replace controller. Arm in pilot pressure is
C-1 controller.
NO
Boom raise sensor (SE-3)
Trouble disappears if boom YES Boom raise sensor (SE-3)
reads more than 4.0V
raise sensor (SE-3) is
replaced.
full.
NO
YES
31102 60413252
boom raise sensor (SE-3)
and C-1 controller.
NO
Continued on P14 Inspect ATT pilot valve.
F17946
43-13
Continued from P13

Boom lower sensor (SE-4)
NO Trouble disappears if boom YES
reads approx. 4.0V or over Boom lower sensor (SE-4)
lower sensor (SE-4) is
replaced.
full.
NO
YES
Boom lower pilot pressure
boom lower sensor (SE-4)
and C-1 controller.
NO
Bucket digging sensor (SE-
NO Trouble disappears if YES
1) reads approx. 4.0V or Bucket digging sensor
bucket digging sensor (SE-
over when lever is shifted (SE-1) is faulty.
1) is replaced.
to the full.
NO
YES
Bucket digging pilot
Inspect harness between
pressure is approx. 35kgf/cm2 YES
bucket digging sensor
(SE-1) and C-1 controller.
NO
Bucket dump sensor (SE-2)
NO Trouble disappears if YES
reads approx. 4.0V or over Bucket dump sensor (SE-
bucket dump sensor (SE-2)
when lever is shifted to the 2) is faulty.
is replaced.
full.
NO
YES
Bucket dump pilot pressure
bucket dump sensor (SE-
2) and C-1 controller.
NO
(10)
Swing motion does not work.
Swing motion works if NO To hydraulic

connector of swing parking
troubleshooting
solenoid (SV-1) is disconnected.
Swing left sensor (SE-5) reads NO YES
Trouble disappears if swing left Swing left sensor (SE-5)
YES NO
approx. 35kgf/cm2 (500psi) or
over when lever is shifted to
and C-1 controller.
the full.
NO
(Hard check SW19)
Swing right sensor (SE-6) reads NO YES
Trouble disappears if swing Swing right sensor (SE-6)
right sensor (SE-6) is replaced. is faulty.
NO
YES
Swing right pilot pressure is
approx. 35kgf/cm2 (500psi) or
31102 60413252

over when lever is shifted to
and C-1 controller.
the full.
NO

F17947
43-14
(11)
Swing speed is low.
(Hard check SW29)

Feedback current of P2 bypass
is approx. 700mA when swing troubleshooting
Command current of P2 bypass Swing left sensor (SE-
cut proportional valve (PSV-B) NO 5) reads approx. 4.0V NO Trouble disappears if swing YES Swing left sensor (SE-5)
is approx. 700mA when swing when lever is shifted is faulty.
replaced.
lever is shifted to the full. to the full.
YES NO
YES
and C-1 controller.
NO
(Hard check SW19)
Swing right sensor (SE-6) reads approx. YES
4.0V when lever is shifted to the full.
NO
NO
Swing right pilot pressure is approx. YES Inspect harness between
35kgf/cm2 (500psi) or over when lever is swing right sensor (SE-6)
shifted to the full. and C-1 controller.
NO
Error code E18 is YES Inspect harness between P2 bypass cut

indicated. proportional valve (PSV-B) and C-1 controller.
NO
(12)
Swing power is poor.
(Hard check SW29)

Feedback current of P2 bypass
is approx. 700mA when swing troubleshooting
Command current of P2 bypass Swing left sensor (SE-
cut proportional valve (PSV-B) NO 5) reads approx. 4.0V NO Trouble disappears if swing YES Swing left sensor (SE-5)
is approx. 700mA when swing when lever is shifted is faulty.
replaced.
lever is shifted to the full. to the full.
YES NO
YES
and C-1 controller.
NO
(Hard check SW19)
Swing right sensor (SE-6) reads approx. YES
4.0V when lever is shifted to the full.
NO
31102 60413252
NO
Swing right pilot pressure is approx. YES Inspect harness between
35kgf/cm2 (500psi) or over when lever is swing right sensor (SE-6)
shifted to the full. and C-1 controller.
NO
Continued on P16. Inspect ATT pilot valve.
F17948
43-15
Continued from P15
YES
Error code E18 is NO
indicated.
YES Inspect harness between P2 bypass cut
proportional valve (PSV-B) and C-1 controller.
(13)-1
Swing motion can not be held on a slope.
YES
24V is alive across
pink/black and black wires YES To hydraulic
of connector for swing troubleshooting
parking solenoid (SV-1).
NO
Swing parking release NO
switch (SW-4) is at Turn to NORMAL.
NORMAL.
Swing right sensor (SE-6) YES Trouble gets normal if YES Swing right sensor (SE-6)
reads more than 1.3V swing right sensor (SE-6)
is faulty.
when lever is at neutral. is replaced.
NO NO
and C-1 controller.
neutral.
YES
(Hard check SW20)
Swing left sensor (SE-5) YES Trouble gets normal if YES Swing left sensor (SE-6)
reads more than 1.3V swing left sensor (SE-5) is
is faulty.
NO NO
is when lever is at neutral. and C-1 controller.
YES
Arm in sensor (SE-7) reads YES Trouble gets normal if arm YES Arm in sensor (SE-7) is
more than 1.3V when lever in sensor (SE-7) is
faulty.
is at neutral. replaced.
NO NO
more than 6kgf/cm2 (85psi) arm in sensor (SE-7) and
YES
Inspect that harness (pink

If swing right (or swing
YES and black) between swing
left, or arm in) lever is
parking brake solenoid
operated, error E15 is
(SV-1) and C-1 controller
indicated.
is not disconnected.
NO

31102 60413252
F17949
43-16
SECTION 44 TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS
1. Trouble diagnosis: engine ...................................................................................... 44-1
2. Troubleshooting ..................................................................................................... 44-2

31102 60413252
31102 60413252
Engine
SYSTEM
Other trouble Drop in output Rotation trouble Starting trouble
8
7
6
5
4
GROUP No.
11
not stop.
Over heat
Idling unsmooth
warming-up E/G
key is turned off.

not work properly.
TROUBLE
Exhaust gas is black

Exhaust gas is white
1 Starter does not run.
Knocking occurs after

3 High speed unsmooth
Medium speed hunting
E/G deficiency in output

Accel potentiometer does
work modes are changed.
not disappear after idling.)

COMPONENT
Max. revolution is too high.
9 Excessive oil consumption.
Engine does not stop when

Does not reach max revolution.
Revolution does ont change if
Power is off the moment the key

12 is turned to OFF, but engine does
(In cold state, white smoke does
10 Excessive fuel consumption.

2 Starter runs but does ont start.
Fuel not filled up or leaking.
1. TROUBLE DIAGNOSIS: ENGINE
Oil cooler element clogged.

Fuel system trouble (Air or water entered.)
Oil filter clogged.
Air cleaner clogged.
Gauze filter clogged.
Filters
Fuel filter clogged.

V-belt slips.
Inspection
Breather hose bent.

Cooling water level
Fuel is of poor quality or leaking.
Specific gravity of battery fluid
Fluid
Viscosity of engine oil is not suited, engine oil is

leaking, or the engine oil level not proper.
Poor quality fuel is used or heavy oil is used.
Blowby gas is much.
Gas leaks from valve and gasket.
Engine oil is too much.
Gas / Fluid
Visual check
Battery fluid level

SERVICE MAN
Fuse
Starter key
Battery relay
Mechatoronic controller
Mechatoro "A" adjust.
Shovel side
Electrical fittings
Stepping motor
Accel potentiometer
Connector and electric wiring
Safety relay
TROUBLESHOOTING (ENGINE)
Glow relay
Glow
Starter motor
Engine side
Electrical fittings
Starter relay
Alternator
Feed pump function
Check injection timing
Inspect nozzle.
Fuel system
Injection pump
Stop
Valve clearance
position
Valve spring is fatigued.

system
exhaust
Suction/
Air cleaner & muffler

Check if engine oil goes into combustion
chamber through piston or through valve guide.
Check relief valve.
Oil strainer clogged.
system
Lubrication
Fuel is mixed.
Check thermostat.
Oil cooler element damaged.
Cooling
Compression pressure low.

ENGINE DEALER
Control rack movement unsmooth.

Governor spring fatigued.
Crank shaft oil seal no good.
Piston liner worn.
Piston ring worn.
Valve spring fatigued.
Main structure
Internal parts stuck.

Check fuel feed.
Head gasket faulty.
Flywheel gear damaged.
F17950
44-1
2. TROUBLESHOOTING
(1)
Starter does not run.
NO Check battery fluid

Check battery voltage. level and specific Charge or replace battery.
gravity.
OK
The voltage at B1 NO
Check battery relay B1
terminal of battery is Replace fusible link 60A.
voltage.
24V ore more.
OK
The voltage at outlet
side of 20A fuse for NO
Check fuse box voltage. keyswitch is 24V or Replace fuse.
more.
OK OK
The voltage at fuse for YES Check electric wiring and
keyswitch is not 24V. or
connectors.
more.
Measure the voltage at

L terminal of battery NO Check electric wiring
relay instead of M
and connector.
terminal of keyswitch
to check the voltage of
Check key switch the M terminal.
Check key switch.
voltage.
Measure the voltage at
S terminal of safety relay
(Line No.63) instead of NO Check electric wiring
ST terminalof keyswitch and connector.
to check the voltage at
ST terminal. NO
Check electric wiring
OK and connector.
The voltage at L YES

Check IN side of battery
terimnal of battery Replace battery relay.
relay voltage.
relay is 24V or more.
OK
Check voltage of
battery relay A. Also 24V is alive on A side,
Replace fusible link 60A.
check voltage of battery but not on A1.
relay A1.
OK
24V is alive on
Check IN side voltage of
terminal B of starter
startermotor.
motor.
OK OK
Replace starter motor.
24V is alive on
Check IN side voltage of
terminal S of starter
starter motor.
motor.
OK
24V is alive on
Check IN side voltage YES
terminal S of safety
of safety relay.
relay.
OK
Replace safety relay.
F17951
Check OUT side voltage
24V is alive on NO
terminal C of safety
of safety relay.
relay.
31102 60413252
Condition: check keyswitch in START position;
emergency stop knob (engine stop) is back in position.
44-2
(2)
Starter turns but engine is hard to start.
Check starter power is strong WEAK Check battery fluid level and
Charge or replace battery.
or weak. specific gravity.
OK
Check engine itself. Check compression
pressure and valve
clearance. Check that
Check that air filter clogged valve spring is not
Check air suction system. fatigued, that piston liner
lamp lights.
is not worn, that piston
OK OK ring is not worn, that
head gasket is not faulty
Check that air cleaner clogged
and that flywheel gear is
lamp and sensor.
not damaged. Also check
radiator and thermostat.
E/G side Check gauze filter.

Check feed pump
OK performance, injection
Check fuel feed system.
pump, injection nozzle
Check fuel gauge and water and injection timing.
Machine
separator. Check that poor
side
quality fuel is not used.
YES
Check electric system. E/G side 24V is alive on glow plug. Glow plug is faulty.
NO
24V is alive on wire No.66 YES Harness between glow
(5W) of CN-153F on glow relay relay and glow plug is
(R-3). faulty.
NO
NO Harness between glow
24V is alive on wire No.55 (5Y)
relay and battery relay is
of CN--154F on glow relay (R-3).
faulty.
OK
24V is alive across wire No.62 YES
of CN-155F on glow relay (R-3) Replace glow relay.
and earth.
NO
NO Harness between glow
Ground connection is poor. relay and battery relay is
faulty.
Check E/G oil of viscosity if it NO

Check viscosity of E/G oil. is suited to atmospheric Replace engine oil.
temperature. F17952
Checking condition: E/G starter key is in ON position.

31102 60413252
Internal connection
Fig.1 Glow relay terminals and connector
44-3
(3)
E/G revolution is faulty.
Check high pressure pipe

and injection nozzle.
Check that compression
Idling not smooth.
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling is faulty.
1
Idling revolution is too *Adjust mechatro "A"
high.
Check control rack.

Medium revolution is Hunting occurs at
Change over governor
faulty. medium revolution.
spring.
Check that air is not YES

Bleed air.
mixed in fuel.
OK
Check that air cleaner is
Check air suction system.
not clogged.
OK
Check fuel gauge, water
separator and gauze filter.
Check fuel system.
Check also that poor
quality fuel is not used.
High idling is faulty. OK
Check injection nozzle,

injection pump and
injection timing.
E/G does ont reach max.

1
revolution.
*Adjust mechatro "A"
Max revolution is too F17954
high.
Checking condition; E/G water temperature is more than 50°C (122°F).

1; Refer to Electric Troubleshooting.
* 31102 60413252
44-4
NOTE:
(6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Check that E/G water OK Check the contents of
Overheat temperature lamp is on and
excavating.
that buzzer sounds.
NO Check E/G water
temperature switch,
Inspect electric system.
gauge cluster, electric
wiring and connectores.
OK
Check coolant level.
Inspect cooling system. Check that fan belt does
not slip.
OK Check thermostat.
Also check that radiator.
Oil cooler is not clogged.
Check that poor quality

Check fuel system.
fuel is not used.
OK
Check E/G oil system. Check E/G oil filter.
Check air suction Check that air filter clogged OK Check that air cleaner is
system. lamp lights. not clogged.
OK
Check that air is not mixed
Check fuel system. Bleed air.
in fuel.
OK OK
Check feed pump, injection
Check water separator and
pump, injection nozzle and
gauze filter. Check also that
injection timing.
poor quality fuel is not used.
Check viscosity of E/G oil if

Check E/G oil. it is suited to atmospheric Replace engine oil.
temperature.
OK
Check that blowby gas is not Check compression
much, that gas does not leak pressure and valve
from gasket, and that engine clearance. Check that
Check engine body oil goes into combustion valve spring is not
chamber through piston or fatigued. Check that
through valve guide control rack moves
smoothly. Check that
piston ring is not worn.
Checking condition; High idling Check also that head
gasket is net faulty.
(7)
Knocking occurs after warming-up E/G.
OK
Check that poor quality fuel
Check fuel system. Replace fuel.
is not used.
Check that engine oil goes into Judge it if oil is there on

Check E/G itself. combustion chamber through exhaust port.
piston.
OK
31102 60413252
Check that blowby gas is not Check compression

much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.
F17955
Checking condition; E/G water temperature is more than 50°C (122°F).
44-5
(8)
Exhaust is abnormal.
OK
Check that air cleaner is not
Exhaust gas is black. Replace air element.
clogged.
OK
Check engine oil viscosity.
Check that engine oil is not
too much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is
not fatigued and that piston
ring is not faulty.
Check that water is not

Exhaust gas is white. Check water separator.
mixed in fuel.
OK
Check that engine oil goes
into combustion chamber
through piston or through valve Check compression pressure
guide. Blowby gas is much. and injection timing.
A lot of gas leaks from gasket.
Checking condition; Engine water temperature is more than 50°C (122°F).
(9)
Excessive oil consumption.
Check leakage by checking

Check that engine oil is not Retighten.
the ground under E/G or by
leaking. Replace packing and seal.
placing an oil pan under E/G.
(Check that engine oil is not
filled up too much.) OK
Check that breather hose is
Replace breather hose.
not bent or clogged.
OK
Advise to replace fuel.
is not used.
OK
Check viscosity of engine oil. Advise to replace engine oil.
OK Check that ; CR shaft oil seal

Check that engine oil does is not faulty, piston liner is
not into combustion chamber not worn, or piston ring is
Checking condition; No engine oil leaks. through piston or through valve not worn.
guide.
(10)
Excessive fuel consumption.

Check fuel leakage. Advise to replace fuel.
is not used.
OK
Blowby gas is much.
Check that gas does not leak Check nozzle function.
from gasket.
OK
Check injection timing.
31102 60413252
Check compression pressure.

Checking condition; Use proper fuel.
F17956
44-6
(11)
Check that
E/G does not stop Confirm governor Check if governor
governor motor link
when starter key is lever stop bolt motor is not faulty
connecting bolts are
turned off. position. mechanically.
not loose.
OK
Check that Wire number 60 Check resistance
NG Replace starter key
terminal M of of instrument panel across terminals M
if resistance across
starter key switch harness CN-43F and B on starter
M and B is 0Ω.
shows 0V. shows 0V. key.
See Fig.3.
OK
Check that battery Does resistance
relay terminal B2 Wire No.857 of NG across C1 controller
Check C1
measures 0V four main harness CN- terminals 11-1 and
controller.
seconds after key is 150F measures 0V. 14-22 measure
turned off. 72Ω?
(12) OK
When starter key is Replace C1
Does battery NG
turned off, power is Check that battery Replace battery controller if
terminals A and B
cut off but engine relay operates. relay. resistance measures
measure 0Ω?
does not stop. 0Ω.
See Fig.2.
F17957
Checking condition; Starter key is off.
CN-152F
TERMINAL A1 LOCK
Flowing direction of main current

TERMINAL B1
TERMINAL A1, A B, B1 TERMINAL
VIEW I
FLW FLW TERMINAL A
2.0 sq 2.0 sq
FLW 2.0 sq
TERMINAL B FLW 2.0 sq
G B2
P COIL
H COIL
BRACKET EARTH
Circuit diagram TERMINAL L
TERMINAL L
TERMINAL B2
AVS 1.25L TERMINAL B2

AVS 1.25G GROUND
GROUND CABLE TERMINAL
AVS 1.25B
Fig.2 Battery relay CN-150M
31102 60413252
Fig.3 Key SW. terminal
44-7
NOTE
31102 60413252
44-8
SECTION 51 ENGINE
TABLE OF CONTENTS
Section 1. General information ...................................................................................... 1
Section 2. Maintenance ...............................................................................................17
Section 3. Engine assembly (1) (disassembly)............................................................ 29
Section 4. Engine assembly (2) (inspection and repair) .............................................. 47
Section 5. Engine assembly (3) (reassembly) ............................................................. 81
Section 6. Lubricating system ................................................................................... 109
Section 7. Cooling system ......................................................................................... 121
Section 8. Fuel system .............................................................................................. 127
Section 9. Engine electricals ..................................................................................... 141
Section 10. Troubleshooting ........................................................................................ 169
Section 11. Special tool list ......................................................................................... 195
Section 12. Repair standards ...................................................................................... 199
Section 13. Conversion table ....................................................................................... 213

31102 60413252
GENERAL INFORMATION
SECTION 1: GENERAL INFORMATION
TABLE OF CONTENTS
General repair instructions ................................................................................................................................ 2
Notes on the format of this manual ................................................................................................................... 2
Main data and specifications ............................................................................................................................. 6
Tightening torque specifications........................................................................................................................ 7

31102 60413252
51-1
GENERAL INFORMATION
31102 60413252
51-2
GENERAL INFORMATION
31102 60413252
51-3
GENERAL INFORMATION
31102 60413252
51-4
GENERAL INFORMATION
31102 60413252
51-5
GENERAL INFORMATION
31102 60413252
51-6
GENERAL INFORMATION
31102 60413252
51-7
GENERAL INFORMATION
31102 60413252
51-8
GENERAL INFORMATION
31102 60413252
51-9
GENERAL INFORMATION
31102 60413252
51-10
GENERAL INFORMATION
31102 60413252
51-11
GENERAL INFORMATION
31102 60413252
51-12
GENERAL INFORMATION
31102 60413252
51-13
GENERAL INFORMATION
31102 60413252
51-14
GENERAL INFORMATION
31102 60413252
51-15
GENERAL INFORMATION
NOTE
31102 60413252
51-16
MAINTENANCE
SECTION 2: MAINTENACE
TABLE OF CONTENTS
Model identification ......................................................................................................................................... 18
Injection ump identification .............................................................................................................................. 18
Lubricating system .......................................................................................................................................... 18
Fuel system ..................................................................................................................................................... 19
Cooling system ................................................................................................................................................ 22
Valve clearance adjustment ............................................................................................................................ 23
Injection timing ................................................................................................................................................ 24
Compression pressure measurement ............................................................................................................. 26
Recommended lubricants ............................................................................................................................... 27
Engine repair kit .............................................................................................................................................. 28

31102 60413252
51-17
MAINTENANCE
31102 60413252
51-18
MAINTENANCE
31102 60413252
51-19
MAINTENANCE
31102 60413252
51-20
MAINTENANCE
31102 60413252
51-21
MAINTENANCE
31102 60413252
51-22
MAINTENANCE
31102 60413252
51-23
MAINTENANCE
31102 60413252
51-24
MAINTENANCE
31102 60413252
51-25
MAINTENANCE
31102 60413252
51-26
MAINTENANCE
31102 60413252
51-27
MAINTENANCE
31102 60413252
51-28
ENGINE ASSEMBLY (1)
SECTION 3: ENGINE ASSEMBLY (1)
TABLE OF CONTENTS
General description ......................................................................................................................................... 30
Disassembly .................................................................................................................................................... 31
31102 60413252
51-29
ENGINE ASSEMBLY (1)
31102 60413252
51-30
ENGINE ASSEMBLY (1)
31102 60413252
51-31
ENGINE ASSEMBLY (1)
31102 60413252
51-32
ENGINE ASSEMBLY (1)
31102 60413252
51-33
ENGINE ASSEMBLY (1)
31102 60413252
51-34
ENGINE ASSEMBLY (1)
31102 60413252
51-35
ENGINE ASSEMBLY (1)
31102 60413252
51-36
ENGINE ASSEMBLY (1)
31102 60413252
51-37
ENGINE ASSEMBLY (1)
31102 60413252
51-38
ENGINE ASSEMBLY (1)
31102 60413252
51-39
ENGINE ASSEMBLY (1)
31102 60413252
51-40
ENGINE ASSEMBLY (1)
31102 60413252
51-41
ENGINE ASSEMBLY (1)
31102 60413252
51-42
ENGINE ASSEMBLY (1)
31102 60413252
51-43
ENGINE ASSEMBLY (1)
31102 60413252
51-44
ENGINE ASSEMBLY (1)
31102 60413252
51-45
ENGINE ASSEMBLY (1)
31102 60413252
51-46
ENGINE ASSEMBLY (2)
TABLE OF CONTENTS
Inspection and repair ....................................................................................................................................... 48

31102 60413252
51-47
ENGINE ASSEMBLY (2)
31102 60413252
51-48
ENGINE ASSEMBLY (2)
31102 60413252
51-49
ENGINE ASSEMBLY (2)
31102 60413252
51-50
ENGINE ASSEMBLY (2)
31102 60413252
51-51
ENGINE ASSEMBLY (2)
31102 60413252
51-52
ENGINE ASSEMBLY (2)
31102 60413252
51-53
ENGINE ASSEMBLY (2)
31102 60413252
51-54
ENGINE ASSEMBLY (2)
31102 60413252
51-55
ENGINE ASSEMBLY (2)
31102 60413252
51-56
ENGINE ASSEMBLY (2)
31102 60413252
51-57
ENGINE ASSEMBLY (2)
31102 60413252
51-58
ENGINE ASSEMBLY (2)
31102 60413252
51-59
ENGINE ASSEMBLY (2)
31102 60413252
51-60
ENGINE ASSEMBLY (2)
31102 60413252
51-61
ENGINE ASSEMBLY (2)
31102 60413252
51-62
ENGINE ASSEMBLY (2)
31102 60413252
51-63
ENGINE ASSEMBLY (2)
31102 60413252
51-64
ENGINE ASSEMBLY (2)
31102 60413252
51-65
ENGINE ASSEMBLY (2)
31102 60413252
51-66
ENGINE ASSEMBLY (2)
31102 60413252
51-67
ENGINE ASSEMBLY (2)
31102 60413252
51-68
ENGINE ASSEMBLY (2)
31102 60413252
51-69
ENGINE ASSEMBLY (2)
31102 60413252
51-70
ENGINE ASSEMBLY (2)
31102 60413252
51-71
ENGINE ASSEMBLY (2)
31102 60413252
51-72
ENGINE ASSEMBLY (2)
31102 60413252
51-73
ENGINE ASSEMBLY (2)
31102 60413252
51-74
ENGINE ASSEMBLY (2)
31102 60413252
51-75
ENGINE ASSEMBLY (2)
31102 60413252
51-76
ENGINE ASSEMBLY (2)
31102 60413252
51-77
ENGINE ASSEMBLY (2)
31102 60413252
51-78
ENGINE ASSEMBLY (2)
31102 60413252
51-79
ENGINE ASSEMBLY (2)
NOTE
31102 60413252
51-80
ENGINE ASSEMBLY (3)
TABLE OF CONTENTS
Model identification ......................................................................................................................................... 82

31102 60413252
51-81
ENGINE ASSEMBLY (3)
31102 60413252
51-82
ENGINE ASSEMBLY (3)
31102 60413252
51-83
ENGINE ASSEMBLY (3)
31102 60413252
51-84
ENGINE ASSEMBLY (3)
31102 60413252
51-85
ENGINE ASSEMBLY (3)
31102 60413252
51-86
ENGINE ASSEMBLY (3)
31102 60413252
51-87
ENGINE ASSEMBLY (3)
31102 60413252
51-88
ENGINE ASSEMBLY (3)
31102 60413252
51-89
ENGINE ASSEMBLY (3)
31102 60413252
51-90
ENGINE ASSEMBLY (3)
NOTE
31102 60413252
51-91
ENGINE ASSEMBLY (3)
31102 60413252
51-92
ENGINE ASSEMBLY (3)
31102 60413252
51-93
ENGINE ASSEMBLY (3)
31102 60413252
51-94
ENGINE ASSEMBLY (3)
31102 60413252
51-95
ENGINE ASSEMBLY (3)
31102 60413252
51-96
ENGINE ASSEMBLY (3)
31102 60413252
51-97
ENGINE ASSEMBLY (3)
31102 60413252
51-98
ENGINE ASSEMBLY (3)
31102 60413252
51-99
ENGINE ASSEMBLY (3)
31102 60413252
51-100
ENGINE ASSEMBLY (3)
31102 60413252
51-101
ENGINE ASSEMBLY (3)
31102 60413252
51-102
ENGINE ASSEMBLY (3)
31102 60413252
51-103
ENGINE ASSEMBLY (3)
31102 60413252
51-104
ENGINE ASSEMBLY (3)
31102 60413252
51-105
ENGINE ASSEMBLY (3)
31102 60413252
51-106
ENGINE ASSEMBLY (3)
31102 60413252
51-107
ENGINE ASSEMBLY (3)
31102 60413252
51-108
LUBRICATING SYSTEM
SECTION 6: LUBRICATING SYSTEM
TABLE OF CONTENTS
Main data and specifications .........................................................................................................................110
General description ....................................................................................................................................... 111
Oil pump ........................................................................................................................................................114
Oil filter with built-in oil cooler ........................................................................................................................117

31102 60413252
51-109
LUBRICATING SYSTEM
31102 60413252
51-110
LUBRICATING SYSTEM
31102 60413252
51-111
LUBRICATING SYSTEM
31102 60413252
51-112
LUBRICATING SYSTEM
31102 60413252
51-113
LUBRICATING SYSTEM
31102 60413252
51-114
LUBRICATING SYSTEM
31102 60413252
51-115
LUBRICATING SYSTEM
31102 60413252
51-116
LUBRICATING SYSTEM
31102 60413252
51-117
LUBRICATING SYSTEM
31102 60413252
51-118
LUBRICATING SYSTEM
31102 60413252
51-119
LUBRICATING SYSTEM
31102 60413252
51-120
COOLING SYSTEM
SECTION 7: COOLING SYSTEM
TABLE OF CONTENTS
Thermostat ....................................................................................................................................................125
31102 60413252
51-121
COOLING SYSTEM
31102 60413252
51-122
COOLING SYSTEM
31102 60413252
51-123
COOLING SYSTEM
31102 60413252
51-124
COOLING SYSTEM
31102 60413252
51-125
COOLING SYSTEM
NOTE
31102 60413252
51-126
FUEL SYSTEM
SECTION 8: FUEL SYSTEM
TABLE OF CONTENTS
Injection nozzle .............................................................................................................................................132
Injection pump calibration data ..................................................................................................................... 137

31102 60413252
51-127
FUEL SYSTEM
31102 60413252
51-128
FUEL SYSTEM
31102 60413252
51-129
FUEL SYSTEM
31102 60413252
51-130
FUEL SYSTEM
31102 60413252
51-131
FUEL SYSTEM
31102 60413252
51-132
FUEL SYSTEM
31102 60413252
51-133
FUEL SYSTEM
31102 60413252
51-134
FUEL SYSTEM
31102 60413252
51-135
FUEL SYSTEM
31102 60413252
51-136
FUEL SYSTEM
31102 60413252
51-137
FUEL SYSTEM
31102 60413252
51-138
FUEL SYSTEM
31102 60413252
51-139
FUEL SYSTEM
NOTE
31102 60413252
51-140
ENGINE ELECTRICALS
SECTION 9: ENGINE ELECTRICALS
TABLE OF CONTENTS
Starter ........................................................................................................................................................... 142
Alternator ......................................................................................................................................................157
31102 60413252
51-141
ENGINE ELECTRICALS
31102 60413252
51-142
ENGINE ELECTRICALS
31102 60413252
51-143
ENGINE ELECTRICALS
31102 60413252
51-144
ENGINE ELECTRICALS
31102 60413252
51-145
ENGINE ELECTRICALS
31102 60413252
51-146
ENGINE ELECTRICALS
31102 60413252
51-147
ENGINE ELECTRICALS
31102 60413252
51-148
ENGINE ELECTRICALS
31102 60413252
51-149
ENGINE ELECTRICALS
31102 60413252
51-150
ENGINE ELECTRICALS
31102 60413252
51-151
ENGINE ELECTRICALS
31102 60413252
51-152
ENGINE ELECTRICALS
31102 60413252
51-153
ENGINE ELECTRICALS
31102 60413252
51-154
ENGINE ELECTRICALS
31102 60413252
51-155
ENGINE ELECTRICALS
31102 60413252
51-156
ENGINE ELECTRICALS
31102 60413252
51-157
ENGINE ELECTRICALS
31102 60413252
51-158
ENGINE ELECTRICALS
31102 60413252
51-159
ENGINE ELECTRICALS
31102 60413252
51-160
ENGINE ELECTRICALS
31102 60413252
51-161
ENGINE ELECTRICALS
31102 60413252
51-162
ENGINE ELECTRICALS
31102 60413252
51-163
ENGINE ELECTRICALS
31102 60413252
51-164
ENGINE ELECTRICALS
31102 60413252
51-165
ENGINE ELECTRICALS
31102 60413252
51-166
ENGINE ELECTRICALS
31102 60413252
51-167
ENGINE ELECTRICALS
31102 60413252
51-168
TROUBLESHOOTING
SECTION 10: TROUBLESHOOTING
TABLE OF CONTENTS
Hard starting .................................................................................................................................................171
Undstable idling .............................................................................................................................................175
Insufficient power ..........................................................................................................................................178
Excessive fuel consumption .......................................................................................................................... 182
Excessive oil consumption ............................................................................................................................ 184
Overheating ................................................................................................................................................... 185
White exhaust smoke ....................................................................................................................................187
Dark exhaust smoke .....................................................................................................................................188
Oil pressure does not rise ............................................................................................................................. 189
Abnormal engine noise .................................................................................................................................191

31102 60413252
51-169
TROUBLESHOOTING
31102 60413252
51-170
TROUBLESHOOTING
31102 60413252
51-171
TROUBLESHOOTING
31102 60413252
51-172
TROUBLESHOOTING
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51-173
TROUBLESHOOTING
31102 60413252
51-174
TROUBLESHOOTING
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51-175
TROUBLESHOOTING
31102 60413252
51-176
TROUBLESHOOTING
31102 60413252
51-177
TROUBLESHOOTING
31102 60413252
51-178
TROUBLESHOOTING
31102 60413252
51-179
TROUBLESHOOTING
31102 60413252
51-180
TROUBLESHOOTING
31102 60413252
51-181
TROUBLESHOOTING
31102 60413252
51-182
TROUBLESHOOTING
31102 60413252
51-183
TROUBLESHOOTING
31102 60413252
51-184
TROUBLESHOOTING
31102 60413252
51-185
TROUBLESHOOTING
31102 60413252
51-186
TROUBLESHOOTING
31102 60413252
51-187
TROUBLESHOOTING
31102 60413252
51-188
TROUBLESHOOTING
31102 60413252
51-189
TROUBLESHOOTING
31102 60413252
51-190
TROUBLESHOOTING
31102 60413252
51-191
TROUBLESHOOTING
31102 60413252
51-192
TROUBLESHOOTING
31102 60413252
51-193
TROUBLESHOOTING
NOTE
31102 60413252
51-194
SPECIAL TOOLS LIST
SECTION 11: SPECIAL TOOLS LIST

31102 60413252
51-195
SPECIAL TOOLS LIST
31102 60413252
51-196
SPECIAL TOOLS LIST
31102 60413252
51-197
SPECIAL TOOLS LIST
NOTE
31102 60413252
51-198
REPAIR STANDARDS
SECTION 12: REPAIR STANDARDS
TABLE OF CONTENTS
General rules .................................................................................................................................................199
Repair standards chart .................................................................................................................................. 200

31102 60413252
51-199
REPAIR STANDARDS
31102 60413252
51-200
REPAIR STANDARDS
31102 60413252
51-201
REPAIR STANDARDS
31102 60413252
51-202
REPAIR STANDARDS
31102 60413252
51-203
REPAIR STANDARDS
31102 60413252
51-204
REPAIR STANDARDS
31102 60413252
51-205
REPAIR STANDARDS
31102 60413252
51-206
REPAIR STANDARDS
31102 60413252
51-207
REPAIR STANDARDS
31102 60413252
51-208
REPAIR STANDARDS
31102 60413252
51-209
REPAIR STANDARDS
31102 60413252
51-210
REPAIR STANDARDS
31102 60413252
51-211
REPAIR STANDARDS
NOTE
31102 60413252
51-212
CONVERSION TABLE
SECTION 13: CONVERSION TABLE
TABLE OF CONTENTS
Lenght ........................................................................................................................................................... 213
Area ...............................................................................................................................................................215
Volume .......................................................................................................................................................... 215
Mass ..............................................................................................................................................................217
Pressure ........................................................................................................................................................218
Torque ........................................................................................................................................................... 219
Temperature ..................................................................................................................................................220
31102 60413252
51-213
CONVERSION TABLE
31102 60413252
51-214
CONVERSION TABLE
31102 60413252
51-215
CONVERSION TABLE
31102 60413252
51-216
CONVERSION TABLE
31102 60413252
51-217
CONVERSION TABLE
31102 60413252
51-218
CONVERSION TABLE
31102 60413252
51-219
CONVERSION TABLE
31102 60413252
51-220
SECTION 63 MOUNTING THE BREAKER AND
NIBBLER AND BREAKER
TABLE OF CONTENTS
List of additional parts .......................................................................................................................... 63-1
1. Summary ............................................................................................................ 63-11

1.1 General precautions ..................................................................................................................... 63-11
1.2 Basic method to be taken when mounting ................................................................................... 63-11
1.3 Laying of piping ............................................................................................................................ 63-12
2. Hydraulic circuit diagram .................................................................................... 63-13

2.1 Function ....................................................................................................................................... 63-13
2.2 Hydraulic components .................................................................................................................. 63-16
3. Modification procedure for breaker ..................................................................... 63-17

3.1 Modification item .......................................................................................................................... 63-17
3.2 Floor mat ...................................................................................................................................... 63-17
3.3 Install of the cab guard ................................................................................................................. 63-18
3.4 Modification of the control valve ................................................................................................... 63-19
3.5 Control piping (breaker) ............................................................................................................... 63-20
3.6 Upper hydraulic piping (breaker) .................................................................................................. 63-28
4. Modification procedure for nibbler & breaker ...................................................... 63-30

4.2 Floor mat ...................................................................................................................................... 63-31
4.3 Control piping (nibbler & breaker) ................................................................................................ 63-32
4.4 Upper hydraulic piping (nibbler & breaker) ................................................................................... 63-38
4.5 Return hydraulic piping ................................................................................................................ 63-40
4.8 Install of the name plate (nibbler & breaker) ................................................................................ 63-42
5. Modification procedure for attachment ............................................................... 63-43

5.2 Modification of the 3.7 m (12 ft-2 in) boom ................................................................................... 63-44
31102 60413252
5.3 Modification of the std. arm (breaker, nibbler & breaker).............................................................. 63-47
5.4 Modification of the 2.07 m (6 ft-9 in) long arm (breaker, nibbler & breaker) ................................. 63-49
5.5 Connector assy (breaker) ............................................................................................................. 63-51
5.6 Connector assy (nibbler) .............................................................................................................. 63-51
5.6 Reinforcing the idler link (nibbler & breaker) ................................................................................ 63-52
INDEX
6. Reminders on the use of nibbler & breakers ...................................................... 63-53

6.1 Changing over the selector valve ................................................................................................. 63-53
6.2 Flushing method ........................................................................................................................... 63-54
6.3 Replacing hydraulic oil and return filter ........................................................................................ 63-54
6.4 Operating procedure .................................................................................................................... 63-54
7. Precautions to be exercised on breakers of different manufacturers.................. 63-56
8. Reference ........................................................................................................... 63-58
31102 60413252
MOUNTING THE BREAKER AND NIBBLER & BREAKER
LIST OF ADDITIONAL PARTS
How to utilize the list of additional parts.

This manual is compiled to change the standard machine to this specification on the basis of “Parts Manual” for
the standard machine. This list consists of additional parts and disused parts.
The manual consists roughly of two sections: Breaker and Nibbler & Breaker. Each of the section is divided into
four parts, 1. Upper structure, 2. Boom, 3. Standard arm, and 4. Long arm, each being assigned a kit number. The
cab guard should be ordered optionally. In the case of the arm, select a connector suited for the attachment
(Nibbler, Breaker) for ordering.
A. Additional parts for the modification of the breaker
CAB GUARD SAME AS BREAKER, NIBBLER & BREAKER

No. PARTS NAME Q'TY REMARKS
Since the cab guard is an option, it is not assigned
a kit number.
1 GUARD ASSY
1 • CAB ASSY (1)
1-1 • • PLATE ASSY 2
To be performed
1-2 • • PLATE ASSY 1 in service shop
3 • GUARD 1
8 • SEMS BOLT 4
2 GUARD ASSY
2 • CAB ASSY (1)
3 • GUARD 1
4 • GUARD 1
5 • PLATE ASSY 1 To be performed
6 • PLATE ASSY 1 in service shop
7 • CAPSCREW 4
8 • SEMS BOLT 7
9 • CAP SCREW 1
10 • WASHER 1
11 • LOCK WASHER 1
12 • LOCK WASHER 4
13 • WASHER 4
F17962
31102 60413252
63-1
A.1 UPPER STRUCTURE BREAKER

• MODIFICATION OF CONTROL VALVE
• • CONTROL VALVE (1)
0-1 • • OPTION VALVE ASSY (1) For Standard machine
0-1A • • • OPTION VALVE 1
0-1B • • • SOCKET BOLT 4
• MAIN CONTROL PIPING

1 •• ELBOW 3
2 •• TEE 1
3 •• CONNECTOR 4
22 •• HOSE 1
28 •• TEE 1
31 •• HOSE 1
•• CONTROL VALVE PIPING

2 •• ELBOW (1)
To be performed
13 •• HOSE (1) in factory.
16 •• SOLENOID VALVE (1)
•• REMOTE CONTROL PIPING

1 •• HOSE 1
2 •• HOSE 1
5 •• ELBOW 1
6 •• ELBOW 1
8 •• BRACKET 1 To be performed
9 •• SOLENOID VALVE 1 in service shop.
10 •• CAPSCREW 2
12 •• WASHER 2
13 •• WASHER 2
14 •• TEE 1
15 •• TEE 1
24 •• HOSE 1
F19457
31102 60413252
63-2

• REMOTE CONTROL PIPING
A1 • • HOSE 1
A2 • • HOSE 1
A3 • • HOSE 1
A4 • • NUT 1
A5 • • PIN 1
A6 • • WASHER 3
A7 • • CAPSCREW 2
A8 • • WASHER 2
A9 • • BRACKET 1
A10 • • PIN 1
A11 • • PIN 1
A12 • • CONNECTOR 1
A13 • • CUSHION RUBBER 1
A14 • • ELBOW 2
A15 • • PILOT VALVE 1
A16 • • ELBOW 1
A17 • • CAPSCREW 2
A18 • • LOCK ASSY 1
A19 • • PEDAL 1
A20 • • COVER 1
A21 • • WASHER 1
A22 • • PRESSURE SWITCH 1
A23 • • PLATE 2
• CONTROL BLOCK PIPING

B8 • • CONNECTOR 1
B11 • • ELBOW 1
• • UPPER HYDRAULIC PIPING

1 • • CONNECTOR 1
3 • • O-RING 1
4 • • BUSHING 2
5 • • ROD BOLT 1
6 • • WASHER 1
7 • • NUT 6
8 • • HOSE 1
9 • • BCLAMP 2
11 • • BUSHING 2
12 • • PLUG 1
• • RETURN HYDRAULIC PIPING

12 • • ELBOW 1
16 • • HOSE 1
26 • • HOSE 1
29 • • CLIP 1
35 • • GROMMET 1
F17964
31102 60413252
63-3
A.2 BOOM BREAKER

• BOOM HYDRAULIC PIPING
1 •• TUBE 1
2 •• TUBE 1
3 •• PLUG 2
4 •• CLAMP 6
5 •• CLAMP 3
6 •• CAPSCREW 8
7 •• CAPSCREW 1
8 •• NUT 1
9 •• LOCK WASHER 9
10 •• WASHER 1
A.3 BOOM BREAKER

• 1.65 M (5´5˝) ARM HYDRAULIC PIPING
1 •• TUBE 2 For STD Arm
2 •• HOSE 2
3 •• STOP VALVE 2
4 •• CLAMP 2
6 •• O-RING 2
7 •• CAPSCREW 8
8 •• CAPSCREW 2
F17965
31102 60413252
63-4
A.4 LONG ARM BREAKER Common to N&B

• CONNECTOR ASSY
•• CONNECTOR
1 •• PLUG 1
For NPK
2 •• O-RING 1
3 1
•• CONNECTOR ASSY
•• CONNECTOR 1
1 •• PLUG 1 For TOKU
2 •• O-RING 1 KRUPP
3 1
F17966
31102 60413252
63-5
B. Additional parts for the modification to the nibbler & breaker

B.1 UPPER STRUCTURE NIBBLER & BREAKER
Since the cab guard is an option, Common to the
it is not assigned a kit number. breaker: refer to
par. A
• MODIFICATION OF CONTROL VALVE
• • CONTROL VALVE (1) For Standard machine
1 • • OPTION VALVE ASSY (1)
1-1 • • • OPTION VALVE 1
1-2 • • • SOCKET BOLT 4
• INSTALL OF THE NAME PLATE

21 •• LABEL 1
22 •• LABEL 1
23 •• LABEL 1
• MAIN CONTROL PIPING

1 •• ELBOW 2
2 •• TEE 1
22 •• HOSE 1

2 •• ELBOW (1)
To be performed
13 •• HOSE (1)
in factory.
16 •• SOLENOID VALVE (1)

1 •• HOSE 1
2 •• HOSE 1
5 •• ELBOW 1
6 •• ELBOW 1
8 •• BRACKET 1 To be performed
9 •• SOLENOID VALVE 1 in service shop.
12 •• WASHER 2
13 •• WASHER 2
14 •• TEE 1
15 •• TEE 1
24 •• HOSE 1
F19458
31102 60413252
63-6

• HARNESS 1 For single / conflux
switching solenoid
•• REMOTE CONTROL PIPING
A1 •• HOSE 1
A2 •• HOSE 1
A3 •• HOSE 1
A4 •• HOSE 1
A5 •• NUT 1
A6 •• PIN 1
A7 • WASHER 3
A8 •• CAPSCREW 2
A9 •• LOCK WASHER 2
A12 •• CONNECTOR 1
A13 •• ELBOW 1
A14 •• ELBOW 1
A15 •• PILOT VALVE 1
A18 •• LOCK ASSY 1
A19 •• PEDAL 1
A20 •• RUBBER 1
A21 •• PRESSURE SWITCH 1
A23 •• CONNECTOR 1
A24 •• WASHER 4
A25 •• PLUG 1
• CONTROL BLOCK PIPING

B8 • • CONNECTOR 1
B11 • • ELBOW 1
• UPPER HYDRAULIC PIPING

3 •• O-RING 1
4 •• BUSHING 2
5 •• ROD BOLT 1
6 •• WASHER 1
7 •• NUT 6
8 •• HOSE 1
9 •• CLAMP 2
10 •• HOSE 1
• RETURN HYDRAULIC PIPING

12 •• ELBOW 1
16 •• HOSE GUARD 1
26 •• HOSE 1
27 •• BUSHING 1
29 •• CLIP 1
35 •• GROMMET 1
40 •• BUSHING 1
31102 60413252
F17968
63-7
B.2 BOOM NIBBLER & BREAKER

• BOOM HYDRAULIC PIPING
1 •• TUBE 1
2 •• TUBE 1
3 •• TUBE 1
4 •• TUBE 1
5 •• SELECTOR VALVE 1
6 •• SUPPORT 1
8 •• ELBOW 2
9 •• PLUG 2
10 •• O-RING 3
11 •• CLAMP 7
12 •• CLAMP 3
16 •• NUT 1
19 •• WASHER 1
F17969
31102 60413252
63-8
B.3 STD ARM NIBBLER & BREAKER

• 1.65 M (5´5˝) ARM HYDRAULIC PIPING
1 •• TUBE 2
2 •• HOSE 2
4 •• CLAMP 2
6 •• O-RING 2
7 •• CAPSCREW 8
8 •• CAPSCREW 2
B.4 LONG ARM BREAKER Common to Breaker

No. PARTS NAME Q'ty REMARKS
• 2.07 M (6´9˝) ARM ASSY HYDRAULIC PIPING
1 •• TUBE 2
2 •• HOSE 2
4 •• CLAMP 2
6 •• O-RING 2
7 •• CAPSCREW 8
8 •• CAPSCREW 2
F17970
31102 60413252
63-9

• CONNECTOR ASSY
For NPK
2 •• PLUG 1
3 •• O-RING 1
1 •• CONNECTOR 1 For TOKU,
2 •• PLUG 1 KRUPP
3 •• O-RING 1
1 •• CONNECTOR 1 For NIBBLER &
2 •• PLUG 1 BREAKER
3 •• O-RING 1
•• IDLER LINK (L.H)

•• IDLER LINK (R.H)
0 •• IDLER LINK (L.H) (1) For STD machine
0 •• IDLER LINK (R.H) (1) For STD machine
1 •• PLATE 2
F17971
31102 60413252
63-10
1. SUMMARY
1.1 GENERAL PRECAUTIONS

(1) Application of breaker or nibbler & breaker (2) Functions of the option valve:
Breaker piping ........ Applicable only when a breaker the option valve transmits oil pressure to the
is mounted. nibbler or the breaker. It contains a spool that
Nibbler & Breaker ... Applicable only when a nibbler changes the flow of the oil to the rod and the head
and breaker are mounted. of the nibbler cylinder. It also contains a single /
conflux flow spool that selects a single flow the A1
(2) Modifying breaker and a nibbler & breaker port of the main pump or conflux flow of the A1 and
There are specific procedures to be followed A2 ports of the main pump.
when modifying a breaker and nibbler & breaker.
Therefore, when they are to be modofied at our (3) Action of the single / conflux flow switch:
service shop, contact the nearest breaker and a solenoid valve is provided under the floor plate
nibbler manufacturer's office, and obtain and the single / conflux select switch in the
instructions, so that you install the pipes and instrument panel, in order to operate the single /
handle the machinery correctly. conflux change spool.
(3) Differences between a breaker circuit and a nibbler (4) Installing the operation pedal:
& breaker piping a pedal and a pilot valve are mounted to the floor
• Breaker piping plate and a remote control piping is placed between
There is a single oil flow from pump P1 to the the option valve and pedal, in order to operate the
breaker. The oil returns to the hydraulic tank breaker or the nibbler.
directly. The flow is single flow.
(5) Installing the selector valve:
on the nibbler & breaker attached machine, a
WARNING selector valve is mounted to the boom in order to
If the return oil from the breaker is fed back to the change the oil flow for the breaker and for the
control valve, the pulsation of the breaker is transmitted
nibbler.
to the oil cooler. This causes the machine to break
down.
(6) Reinforcement of the attachment: (if required)
reinforcement plates are welded to the standard
• Nibbler piping arm (civil engineering services: for general use)
The oil flows to the nibbler is conflux flow: the and to the idler links of the nibbler & breaker
oil flow is changed to the rod and the head of attached machine.
the nibbler cylinder.
1.2 BASIC METHOD TO BE TAKEN WHEN

MOUNTING
When mounting the breaker or nibbler, always execute
the following six items:
(1) Install an option valve to the main control valve, to

31102 60413252
use the pressure oil from pump P1 for the breaker

and nibbler.
63-11
1.3 LAYING OF PIPING

(1) Breaker specification
ARM HYDRAULIC
PIPING
HYDRAULIC PIPING FOR BOOM
STOP
VALVE
BRACKET UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
ARM
ARM TOP
HYDRAULIC PIPING
BREAKER OPTION VALVE
(ADD-ON VALVE)
MAIN CONTROL PIPING
OPERATING PEDAL
SOLENOID VALVE
(UNDER FLOOR)
FLOOR MAT REMOTE CONTROL PIPING
Fig. 1-1 Outside view of Breaker-attached machine
(2) Nibbler & breaker specification
HYDRAULIC PIPING FOR BOOM
ARM HYDRAULIC
PIPING
STOP
VALVE SELECTOR VALVE
BRACKET
ARM UPPER HYDRAULIC PIPING
HYDRAULIC RETURN HYDRAULIC PIPING
BREAKER ARM TOP
PIPING
Replacing the
breaker with the
nibbler is possible. OPTION VALVE
(ADD-ON VALVE)
MAIN CONTROL PIPING

OPERATING
PEDAL
SOLENOID VALVE
31102 60413252
(UNDER FLOOR)
FLOOR MAT REMOTE CONTROL

PIPING
SINGLE / CONFLUX FLOW SELECT SWITCH

Fig. 1-2 Outside view of nibbler & breaker-attached machine
63-12
2. HYDRAULIC CIRCUIT DIAGRAM 2.1 FUNCTION

2.1.1 Hydraulic circuit for breaker
The pressurized oil which enters port (P1) of the
A1 A2 BREAKER SPECIFICATION control valve (50) from port (A1) of the hydraulic
No. Parts Type pump flows into the nibbler & breaker spool of the
50 CONTROL VALVE ASSY BCV75-A2-1 option valve (50-1). Meanwhile, the pressurized
50-1 CONTROL VALVE (OPT) – oil which enters port (P2) of the control valve (50)
A3 51 SOLENOID VALVE ASSY To be performed in factory. from port (A2) of the hydraulic pump flows into the
52 PILOT VALVE 16030-00000 single / conflux flow switch spool of the option
M 53 STOP VALVE – valve (50-1). If the pilot valve (52) operates, the
61 SOLENOID VALVE SV-2 To be performed in service shop. secondary pilot pressure from the port (A) shifts
the nibbler & breaker spool. The spool transmits
NOTE:
Add this hydraulic circuit to the standard circuit of E70SR EVOLUTION for the pressurized oil from the pump port to the
completion. breaker and actuates the breaker. The oil returning
from the breaker returns directly to the hydraulic
oil tank through the return filter (12).
P1 P2
T1
12
50
BREAKER
DR2
51 53
B C D
P2 TRAVEL P1 NEUTRAL CUT
NEUTRAL CUT PRIORITY & ARM CONFLUX
SW18
T SINGLE FLOW
CONFLUX
52 P
NIBBLER & CHANGEOVER
P1 BREAKER Pd5
Pa5 32.9MPa DR7
Pb5 {336kgf/cm2}
SWING SINGLE FLOW TRAVEL LEVER A5 HEAD
PARKING CONFLUX 1-2SPEED LOCK B5 ROD T
BRAKE CHANGEOVER CHANGEOVER 32.9MPa A
1 2 3 4 {336kgf/cm2}
SV-2
SINGLE FLOW
CONFLUX To be performed P
CHANGEOVER in service shop.
To be performed
in factory. 61
A T 50-1
SINGLE FLOW
CONFLUX P
CHANGEOVER
31102 60413252
F17974
Fig. 2-1 Hydraulic circuit for breaker
63-13
NIBBLER & BREAKER SPECIFICATION 2.1.2 Hydraulic circuit for nibbler & breaker
A1 A2 No. Parts Type • Switch operating (Nibbler & Breaker)
50 CONTROL VALVE ASSY BCV75-A2-1
Specification Switch position Circuit
50-1 CONTROL VALVE (OPT) –
Breaker OFF Single flow
51 SOLENOID VALVE ASSY To be performed in factory.
52 PILOT VALVE 16030-00000 Nibbler ON Conflux flow
A3
53 STOP VALVE – • Nibbler operating
M 54 SELECTOR VALVE –
Foot pedal depressing section Operating condition
61 SOLENOID VALVE To be performed in service shop.
Depress toe section Nibbler close
NOTE: Depress heel section Nibbler open
Add this hydraulic circuit to the standard circuit of E70SR EVOLUTION for
F17975
completion.
(1) When the nibbler used
When the nibbler is used, the selector valve (54)
and the stop valve (53) are shifted in the illustrated
P1 P2
T1
position. The pressurized oil which centers port
(P1) of the control valve (50) from port (A1) of the
12 hydraulic pump flows into the nibbler & breaker
50 spool of the option valve (50-1). In the meantime,
the pressurized oil which center port (P2) of the
control valve (50) from port (A2) of the hydraulic
pump flows into the single / conflux flow switch
spool of the option valve (50-1). If the single /
DR2
conflux selector switch on the rear panel is turned
on, the solenoid valve (SV-2) in the solenoid
51 BREAKER
valve assy (51) operates. This causes the pilot
B C D
P2 TRAVEL P1 NEUTRAL CUT
pressure to change the single / conflux flow
NEUTRAL CUT PRIORITY & ARM CONFLUX switch spool. Then the hydraulic oil from port (P2)
NIBBLER is combined with the hydraulic oil from port (P1)
T SINGLE FLOW
P1
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER 53 and flows into the nibbler & breaker spool. If the
Pd5
Pa5 32.9MPa DR7 NIBBLER single / conflux selector switch is turned off, the
Pb5 {336kgf/cm2}
SWING
PARKING
SINGLE FLOW
CONFLUX
TRAVEL
1-2SPEED
LEVER
LOCK
A5 HEAD
BREAKER
52 pressurized oil from the pump port (A2) is shut off,
B5 ROD
BRAKE CHANGEOVER CHANGEOVER 32.9MPa with the result that only the single flow from the
1 2 3 4 {336kgf/cm2}
SV-2
SINGLE FLOW
54 pump port (A1) flows into the nibbler & breaker
CONFLUX To be performed T
CHANGEOVER in service shop. spool.
P
To be performed
in factory. 61
A T 50-1 Now if the toe of the pilot valve (52) is depressed,
B A the secondary pilot pressure from port (B) shifts
SINGLE FLOW C1 C2
CONFLUX P P SE11
CHANGEOVER the nibbler & breaker spool, which in turn causes
the hydraulic pressure to be transmitted to the
head (H) of the nibbler cylinder and actuates the
nibbler. The oil returning from the rod (R) of the
nibbler cylinder passes through the nibbler &
breaker spool and returns to the hydraulic oil tank
through the port (T1) of the control valve (50) and
the return filter (12). Action is reversed of you
31102 60413252
F17976 depress the heel of the pilot valve (52).
Fig. 2-2 Hydraulic circuit for Nibbler & breaker (When the Nibbler Used)
63-14
NIBBLER & BREAKER SPECIFICATION • Hydraulic breaker operating

No. Parts Type Foot pedal depressing section Operating condition
A1 A2
50 CONTROL VALVE ASSY BCV75-A2-1 Pedal in neutral position Breaker stops operating.
50-1 CONTROL VALVE (OPT) – Depress heel section Breaker starts operating
51 SOLENOID VALVE ASSY To be performed in factory. F17978
52 PILOT VALVE 16030-00000
A3
53 STOP VALVE – (2) When the Breaker Used
M 54 SELECTOR VALVE – When the breaker is used, the selector valve (54)
61 SOLENOID VALVE (SV-2) To be performed in service shop. and the stop valve (53) are shifted to the illustrated
position. The pressurized oil which enter port
NOTE: (P1) of the control valve (50) from the port (A1) of
Add this hydraulic circuit to the standard circuit of E70SR EVOLUTION for the hydraulic pump flows into the nibbler & breaker
completion. spool of the option valve (50-1). In the meantime,
the pressurized oil which enters port (P2) of the
control valve (50) from port (A2) of the hydraulic
P1 P2 pump flows into the single / conflux switch spool
T1 of the option vlave (50-1). If the single / conflux
selector switch on the rear panel is turned on, the
12 solenoid valve (SV-2) in the solenoid valve assy
50
(51) operates. This causes the pilot pressure to
shift the single / conflux switch spool. The result
is that the hydraulic oil from port (A2) combines
with that from port (A1) and flows into the nibbler
DR2 & breaker spool. If the single / conflux selector
switch is turned off, the oil pressure from the
51 BREAKER pump port (A2) is shut off, with the result that only
B C D the single flow from the pump port (A1) flows into
P2 TRAVEL P1 NEUTRAL CUT the nibbler & breaker spool. Now, if you depress
NEUTRAL CUT PRIORITY & ARM CONFLUX
NIBBLER
the heel of the pilot valve (52), the secondary pilot
T SINGLE FLOW
pressure from port (A) shifts the nibbler & breaker
P1
NIBBLER &
CONFLUX
CHANGEOVER 53
BREAKER Pd5 spool, cause the oil pressure from the pump port
Pa5 32.9MPa DR7 BREAKER
Pb5 {336kgf/cm2} to the breaker and actuates the breaker. The oil
SWING SINGLE FLOW TRAVEL LEVER A5 HEAD 52
PARKING CONFLUX 1-2SPEED LOCK B5 ROD NIBBLER which returns from the breaker returns directly to
BRAKE CHANGEOVER CHANGEOVER 32.9MPa
1 2 3 4 {336kgf/cm2} the hydraulic oil tank through the selector valve
SV-2
SINGLE FLOW
54 (54) and the return filter (12).
CONFLUX To be performed T
CHANGEOVER in service shop.
P
To be performed
in factory. 61
A T 50-1
B A
SINGLE FLOW C1 C2
CONFLUX P P SE11
CHANGEOVER
31102 60413252
F17977
Fig. 2-3 Hydraulic circuit for Nibbler & breaker (When the Breaker Used)
63-15
2.2 HYDRAULIC COMPONENTS

2.2.1 Control valve assy (50)
Option valve (breaker, nibbler & breaker) (50-1)
TRAVEL
STRAIGHT
ORV-A2 TRAVEL
ORV-B2 STRAIGHT TRAVEL (L.H) TRAVEL (L.H)
PF1/4 (Pd2’)
ORV-D3
TRAVEL (L.H) SWING BOOM
SWING
PF1/4 (Pd2’) ORV-C3 BUCKET
LOCK VALVE ARM ARM
RELEASE
CUT VALVE 1 &
ORV-A3 BOOM ARM CONFULX
PF1/4 (DR5) DRAIN PORT CONFLUX
ORV-B3 CUT VALVE 2
SINGLE / CONFLUX SINGLE / CONFLUX NIBBLER &

SWITCH SWITCH BREAKER
ORV-A5 ORV-B5
HEAD SIDE DR2
50-1
Fig. 2-4 Control valve (Breaker, Nibbler & Breaker)
2.2.2 Solenoid valve 2.2.3 Pilot valve 2.2.4 Pilot valve
(-) Black (+) Red

CIRCUIT DIAGRAM CIRCUIT DIAGRAM
AMP MARK 2 POLE SECONDARY

VIEW A PRESSURE OPERATING TORQUE
Houshing 174354-2 SECONDARY
PRESSURE OPERATING TORQUE
Plate 174355-7
Tab terminal 173706-1
Secondary pressure
Plug 172888-2
F17979
Secondary pressure
Operating torque
3-PF1/4
Operating torque
(JIS O-RING SEAL)
CIRCUIT DIAGRAM
31102 60413252
4-PF1/4 Operating angle
CONTROL DIAGRAM
Stroke
2-Ø11 CONTROL DIAGRAM
THROUGH
Fig. 2-5 Solenoid valve (Nibbler & Breaker) Fig. 2-6 Pilot valve (Nibbler & Breaker) Fig. 2-7 Pilot valve (Breaker)
63-16
3. MODIFICATION PROCEDURE FOR BREAKER
3.1 MODIFICATION ITEM

The main items that are needed to modify the standard
machine into a breaker-mounted machine are as
follows:
Table 3-1
MAIN ITEMS TO BE
No. ITEM MAIN MODIFICATION POINTS
ADDED AND CHANGE
3.2 Modification of floor mat Cutout of floor mat Floor mat
Install of 1 guard
Install of the bracket & guard
3.3 the cab 2 guard
guard 3 guard
3.4 Modification of the Install of the option valve Option valve
control valve Capscrew
Main control piping Control piping for option valve Hose
(Option valve) Hose
Control valve Install of the solenoid valve To be performed in factory.
piping Solenoid valve
Control Remote control The single / conflux flow switch solenoid added To be performed in service shop.
3.5
piping piping Solenoid valve
Remote control Pilot valve Pilot valve
Install of the pedal
piping pilot valve Control piping Pedal
Block control piping
Install of the block and piping Block
(Pedal block)
Control valve Hydraulic Hose
3.6 Upper hydraulic piping
piping for breaker Plug
Breaker Hydraulic Tube
3.7 Return hydraulic piping
piping for hydraulic tank Hose
F17990
3.2 FLOOR MAT CUT OUT

Make slits (notch) to face of the standard floor mat
according to Fig. 3-1 and cut out the hatching.
Floor mat for breaker.
31102 60413252
Fig. 3-1 Modification of floor mat
63-17
3.3 INSTALL OF THE CAB GUARD

3.3.1 1 guard & 2 guard
Install the additional parts listed in Table 3-2 to the 4 9
cab of the standard machine, as shown in Fig. 3-2. 11 7,12,13
10
6
8
Table 3-2 7,12, 13
CAB 1 GUARD 5
ASSY 2 GUARD
No. Parts Q'ty Remarks
1 CAB ASSY (1) –
1-1 •PLATE ASSY 2 – 3
1-2 •PLATE ASSY 1 –
1-3 •PLATE ASSY 1 –
2 CAB ASSY – (1)
2-1 •PLATE ASSY – 3
8
3 GUARD 1 1 Fig. 3-2 Install of the guard (1 guard, 2 guard)
4 GUARD – 1
5 PLATE ASSY – 1
6 PLATE ASSY – 1
7 SEMS BOLT – 4
8 SEMS BOLT 4 7
9 CAPSCREW – 1
10 WASHER – 1
11 LOCK WASHER – 1
12 LOCK WASHER – 4
13 WASHER – 4
F17991
2 (-1)
2 (-3)
1 (-1)
2 (-1) 1 (-3)
2 (-3)
31102 60413252
1 (-1)
2 (-1)
1 (-2)
2 (-2)
CAB ASSY
Fig. 3-3 Installing procedure for cab guard
63-18
3.4 MODIFICATION OF THE CONTROL 0-1

VALVE
3.4.1 Modification procedure
Install the additional parts listed in Table 3-3 to the
control valve of the standard machine, as shown in
Fig. 3-4. On that occasion, some parts become
unnecessary.
Table 3-3
MODIFICATION OF THE CONTROL VALVE 6
No. Parts Q'ty Remarks Tightening torque:

0 CONTROL VALVE (1) Standard
machine 6.8~7.0 kgf·m (49~51 lbf·ft)
1 OPTION VALVE ASSY (1) Fig. 3-4 Modification of control valve
1-1 OPTION VALVE 1
1-2 SOCKET BOLT 4 M12 X 65
F17992
3.4.2 Parts to be disused

When the option valve is installed, the parts shown in 5
Table 3-4 and Fig. 3-5 are disused from the standard
machine.
Table 3-4
CONTROL VALVE (STD)
5 END COVER 1
6 SOCKET BOLT 4 M12 X 30
F17993 6
Fig. 3-5 Parts to be disused

31102 60413252
63-19
3.5 CONTROL PIPING (BREAKER) TIGHTENING TORQUE

3.5.1 Main control piping (option valve) Installing parts on the control valve side
(1) Modification procedure O-ring type coupling Hydraulic hose
Install the additional parts listed in Table 3-5 to the Thread Spanner Tightening torque Tightening torque
size
main control piping of the standard machine , as (PF) (mm) kgf·m (lbf·ft) kgf·m (lbf·ft)
shown in Fig. 3-7 1/4 19 3.0 (22) 3.0 (22)
3/8 22 5.0 (36)
NOTE: Installing parts on the hydraulic tank side

• Before starting the modification work, check parts O-ring type coupling Hydraulic hose
according to the additional parts list. Thread Spanner Tightening torque Tightening torque
• When disconnecting and reconnecting pipes, take size
care, so as not to allow dirt and foreign matter to (PF) (mm) kgf·m (lbf·ft) kgf·m (lbf·ft)
enter. 1/4 19 3.7 (27) 3.0 (33)
3/8 22 7.5 (54)
F17994
(2) Connector mounting direction

As seen from the top of the control valve of the As seen from the bottom of the control valve of the
machine. machine.
DR7 Pb5
3 3
(1) 2, 3
BREAKER,
31 NIBBLER & BREAKER
TO TANK
20° 20°
BREAKER,
NIBBLER & BREAKER
1 Pa5 Pa5
1
Fig. 3-6 Control valve piping

31102 60413252
63-20
Fig. 3-5
MAIN CONTROL PIPING

SOL.V 2
TO TANK 1 ELBOW 3 PF1/4
2 TEE 1 PF1/4
3 CONNECTOR 4 PF1/4
31 PF1/4
22 HOSE 1 L=450
PF3/8-
28 TEE 1 PF1/4
1 PF1/4
31 HOSE 1 L=1500
F17995
28
3
C/V
Pa5
(1) 1 31
2 TANK
3 3
22 F17997
TANK
Fig. 3-7 Main control piping (Breaker)
(3) Part to be disused

When the main control piping, the part shown in
Table 3-6 and Fig. 3-8 is disused from the standard
machine.
Table 3-6
C21
C21 ELBOW 1 PF3/8 C/V
F17996 DR2
TANK
31102 60413252
F17998
Fig. 3-8 Part to be disused
63-21
3.5.2 Control valve piping (breaker) Table 3-7

(1) Modification procedure CONTROL VALVE PIPING
To be performed
in factory.
Install the additional parts listed in Table 3-7 to the No. Parts Q'ty Remarks
control piping of the standard machine, as shown 2 ELBOW 1 PF1/4
in Fig. 3-9. On that occasion, some parts become 13 HOSE 1 PF1/4
L=3200
unnecessary. 16 SOLENOID VALVE 1
F17999
NOTE: F
• Before starting the modification work, check parts
according to the additional parts list. CONTROL VALVE
• When disconnecting and reconnecting pipes, take
care so as not to allow dirt and foreign matter to
enter.
13
SWING MOTOR
A SWIVEL JOINT
S/V
C S/V
Pd4 B
INLINE FILTER
TANK
2 Pd5
PT PO S/V
P 2
13 S/J P1 13
4
H
CONTROL VALVE
3
2
C/V
Pd5 T
1
S/M D Pb4
PG
C
16 C/V
B Pb4
C/V
31102 60413252
Po
C/V S/V
Pd4
D
A F F18002
Fig. 3-9 Control valve piping (Breaker & Nibbler & Breaker)
63-22
TIGHTENING TORQUE
Installing parts on the control valve side
O-ring type coupling Hydraulic hose
Thread Spanner Tightening torque Tightening torque
size
(PF) (mm) kgf·m (lbf·ft) kgf·m (lbf·ft)
1/4 19 3.7 (27) 3.0 (22)
3/8 22 7.5 (54) 5.0 (36)
F18000
P T
(2) The procedure of adding the single / conflux

selector solenoid valve A
/V T
/V P
RP
R P
remote control piping of the standard machine, as
AK
E KE
shown in Fig. 3-10 E R EA
BR B
In this time, install simultaneously the P and T
ports connector of pilot valve for breaker. OPT S/V T
1 -PT T
(See Fig 3-12, 13)
OPT S/V T
2 -PT P
Table 3-8 (Add to solenoid valve)
A
To be performed
REMOTE CONTROL PIPING in service shop. P T
B
1 HOSE L=550 1 PF1/4
2 HOSE L=520 1 PF1/4
5 ELBOW 1 PF1/4 F19460
6 ELBOW 1 PF1/4
7 CONNECTOR 2 PF1/4
8 BRACKET 1 Remove plug
9 SOLENOID VALVE 1 14 15
10 CAPSCREW 2
11 CAPSCREW 2
Use existing parts B11(Fig. 3-12)
12 WASHER 2 P T
13 WASHER 2
14 TEE 1 PF1/4
15 TEE 1 PF3/8
PF3/8- 7 B8 (Fig. 3-12) 16
16 CONNECTOR 1 PF1/4 Remove plug
24 HOSE 1 PF1/4
L=3200 TO OPT S/V P TO OPT S/V T
F19459
DETAIL A
F19461
2 places
31102 60413252
DETAIL B VIEW I
Fig. 3-10 Addition 1-section solenoid valve
63-23
3.5.3 REMOTE CONTROL PIPING (BREAKER) &

NOTE:
BLOCK CONTROL PIPING (BREAKER,
NIBBLER & BREAKER)
according to the additional parts list.
(1) Modification procedure • When disconnecting and reconnecting pipes, take
Assemble the additional parts listed in Table 3-9 care so as not to allow dirt and foreign matter to
to the control valve of the standard machine, as enter.
shown in Fig. 3-11 On that occasion, some of the
existing parts must be used and some of them
become unnecessary.
Table 3-9
REMOTE CONTROL PIPING
No. Parts Q'ty Remarks No. Part No. Parts Q'ty Remarks
A1 HOSE 1 PF1/4
L=2150 A13 2416Z566 CUSHION RUBBER 1
A2 HOSE 1 PF1/4
L=400 A14 ZH42X04000 ELBOW 2 PF1/4
A3 HOSE 1 PF1/4
L=500 A15 YT30V00004F1 PILOT VALVE 1
A4 NUT 1 A16 2444Z3833 ELBOW 1 PF1/4-
PT1/8
A5 PIN 1 A17 ZS18C08020 CAPSCREW 2
A6 WASHER 3 A18 YT30M01002F1 LOCK ASSY 1 R.H
A7 CAPSCREW 2 A19 YN68H01039P2 PEDAL 1
A8 WASHER 2 A20 YR03M01134P1 COVER 1
A9 BRACKET 1 A21 ZW16X12000 WASHER 1
A10 PIN 1 A22 GB50S00049F2 PRESSURE SWITCH 1
A11 PIN 1 A23 2418T18004 PLATE 2
A12 CONNECTOR 1 PF1/4
L=23
F18003
A19
A20 TIGHTENING TORQUE
A5 Capscrew (10T)
A18-2
Thread Spanner Tightening torque
A6
A4
A7
A11
size
A18-4
A8 A21 (PF) (mm) kgf·m (lbf·ft)
A17
A6 M8 13 3.6 (26)
M10 17 7.2 (52)
A18-3 A9
A18
A18-1 A23
A18-5 O-ring type coupling Hydraulic hose
A10 A13
A18-6 Thread Spanner Tightening torque Tightening torque
size
A15 (PF) (mm) kgf·m (lbf·ft) kgf·m (lbf·ft)
A14 T
1/4 19 3.7 (27) 3.0 (22)
A12 F18004
P
A14
A3 A
T Pb5
A2
A22 A16 A1 CONTROL VALVE
P
A A Pb5
A1
31102 60413252
A2
A3 B
Fig. 3-11 Remote control piping (Breaker) F18005
63-24
Table 3-10
BLOCK CONTROL PIPING P

B8 CONNECTOR 1 PF1/4 P
B11 ELBOW 1 PF3/8-

PF1/4
T
F18007 P
T
P
T T
T
P/V B8
P
P/V
T B11
B
Fig. 3-12 Control block piping (Breaker, Nibbler & Breaker)
(2) Parts to be disused

Concerning the control block piping, the parts
P
listed in table 3-11 and Fig. 3-13 are disused from P
the standard machine. P/V T
P
P
Table 3-11 P

T
C9 PLUG 1 PF3/8 P
C13 PLUG 1 PF1/4 T

T
F18008
T
C13
C9
F18006
P/V
T
Fig. 3-13 Control block piping (STD)
(3) Parts to be disused A4

Concerning the remote control piping, the parts
A8
listed in table 3-12 and in Fig. 3-14 are disused A2
from the standard machine.
Table 3-12
A2 SUPPORT 1
A4 COVER 1
31102 60413252
A8 SEMS BOLT 2
F18009
63-25
3.6 UPPER HYDRAULIC PIPING NOTE:

(BREAKER) • Before starting the modification work, check parts
3.6.1 Modification procedure according to the additional parts list.
Fit the additional parts in the table 3-13, according to • When disconnecting and reconnecting pipes, take
care, so as not to allow dirt and foreign matter to
Fig. 3-15
enter.
• At assembly, use care of O-ring do not come off.
TIGHTENING TORQUE • Regarding the tightening torque of O-ring type joints,
O-ring type coupling hydraulic hoses and nut sleeve joints, refer to the
Thread Spanner Tightening torque remarks of Table 3-13 and the Tightening Torque
size
(PF) (mm) kgf·m (lbf·ft) Table.
1/2 27.32 11 (80)
Nut sleeve joint

Spanner Tightening torque
Tube size
(mm) kgf·m (lbf·ft)
Ø18 X t2.5 27.32 15 (110)

size
(PF) (mm) kgf·m (lbf·ft)
M 12 19 12.3 (89)
F18010
Table 3-13
UPPER HYDRAULIC PIPING
1 CONNECTOR 1 Ø18-PF1/2
3 O-RING 1
4 BUSHING 2
5 ROD BOLT 1 M12 X 200
6 WASHER 1
7 NUT 6
8 HOSE 1 Ø18,L=2500
9 CLAMP 2
11 BUSHING 2
12 PLUG 1 PF1/2
F18011
31102 60413252
63-26
TO BREAKER
A
CONTROL VALVE
7
6
11
7
12 4
12-1
9
A5
B5
1
8 3
CONTROL VALVE
BREAKER
31102 60413252
A B F18012
Fig. 3-15 Upper hydraulic piping (Breaker)
63-27
3.7 RETURN HYDRAULIC PIPING NOTE:

(BREAKER) • Before starting the modification work, check parts
Install the additional parts listed in Table 3-14 to the • When disconnecting and reconnecting pipes, take
return hydraulic piping of the standard machine, as
enter.
shown in Fig. 3-16. On that occasion, some parts • At assembly, use care of O-ring do not come off.
become unnecessary. • Regarding the tightening torque of O-ring type joints
and hydraulic hoses, refer to the remarks of Table 3-
14 and the Tightening Torque Table.
TIGHTENING TORQUE
size
3/8 22 7.5 (54) 5.0 (36)
1/2 27 11.0 (80) 5.0 (36)
3/4 36 16.5 (120) 12.0 (87)

size
M8 13 3.6 (27)
M 10 17 7.2 (110)
F18013
B
HYDRAULIC TANK
26
TO BREAKER T CONTROL VALVE

29
35
SWING MOTOR
16
HYDRAULIC PUMP
SWIVEL JOINT
UPPER HYDRAULIC RADIATOR

PIPING F18014
A
31102 60413252
Fig. 3-16 Upper hydraulic piping (Breaker)
63-28
Table 3-14
HYDRAULIC PIPING FOR RETURN

12 ELBOW 1 PF3/4
16 HOSE GUARD 1 L=1000
PF3/4
26 HOSE 1 L=3000
29 CLIP 1
35 GROMMET 1
F18015
3.7.2 Parts to be disused 44 44-1

Concerning the return hydraulic piping the part listed
in table 3-15 and Fig. 3-17 disused from the standard
machine.
Table 3-15
44 PLUG 1
F18016
HYDRAULIC TANK
F18017
12 12-1
26
BREAKER
T
31102 60413252
HYDRAULIC TANK
B F18018
63-29
4. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER

The main items that are needed to modify the standard
machine into a nibbler & breaker mounted machine
are as follows:
Table 4-1
MAIN ITEMS TO BE
No. ITEM MAIN MODIFICATION POINTS ADDED AND CHANGE
4.2 Modification of floor mat Cutout of floor mat Floor mat
Install of 1 guard
Refer the cab 2 guard Install of the bracket & guard
to guard 3 guard
sect 3 Modification of the Option valve
Install of the option valve
control valve Capscrew
Main control piping Control piping for option valve Hose
Control valve To be performed in factory.

Install of the solenoid valve
piping Solenoid valve
Remote control To be performed in service shop.
The single / conflux selector solenoid added
Control piping Solenoid valve
3.5 piping
Harness For single / conflux select solenoid Harness
Remote control Pilot valve Pilot valve

Install of the pedal
piping Control piping Pedal
Control block Connector
Change the connectors
piping Tee
Control valve Hydraulic
4.4 Upper hydraulic piping Hose
piping for breaker
Breaker Hydraulic Tube
4.5 Return hydraulic piping
piping for hydraulic tank Hose
4.6 Install of the name plate Add to label Label

F18036
31102 60413252
63-30
4.2 FLOOR MAT CUT OUT

Make slits (notch) to face the standard floor mat
according to Fig. 4-1 and cut out the hatching.
Floor mat for nibbler & breaker.
Fig. 4-1 Modification of floor mat

31102 60413252
63-31
4.3 CONTROL PIPING (NIBBLER &

BREAKER)
4.3.1 Main control piping
(1) Modification procedure
main control piping of the standard machine, as
shown in Fig. 4-2, 4-3
NOTE:
enter.
Table 4-2
(2) Connector mounting direction

As seen from the top of the control valve of the As seen from the bottom of the control valve of the
machine. machine.
DR7 Pb5
3 3
(1) 2, 3
BREAKER,
NIBBLER &
BREAKER
°
20
20°
BREAKER,
NIBBLER &
BREAKER
1 Pa5 1 Pd5
FIg. 4-2 Control valve piping (Nibbler & Breaker)

31102 60413252
63-32
(1)
2
3 3
22
TO TANK
Fig. 4-3 Main control piping (Nibbler & Breaker)

31102 60413252
63-33
4.3.2 Control valve piping (breaker, nibbler & Table 4-3

breaker) To be performed
CONTROL VALVE PIPING in factory.
(1) Modification procedure
2 ELBOW 1 PF1/4
main control piping of the standard machine, as
13 HOSE 1 PF1/4
L=3200
shown in Fig. 4-4. On that occasion, some parts
16 SOLENOID VALVE 1
become unnecessary. F17999
NOTE: F
according to the additional parts list. CONTROL VALVE
enter.
13
SWING MOTOR
A SWIVEL JOINT
S/V
C S/V
Pd4 B
INLINE FILTER
TANK
2 Pd5
PT PO S/V
P 2
13 S/J P1 13
4
H
CONTROL VALVE
3
2
C/V
Pd5 T
1
S/M D Pb4
PG
C
16 C/V
31102 60413252
B Pb4
C/V
Po
C/V S/V
Pd4
D
A F F18002
Fig. 4-4 Control valve piping (Breaker, Nibbler & Breaker)
63-34
TIGHTENING TORQUE
Installing parts on the control valve side
size
1/4 19 3.7 (27) 3.0 (22)
3/8 22 7.5 (54) 5.0 (36)
F18000
P T
(2) The procedure of adding the single / conflux
selector solenoid valve A
/V T
/V P
remote control piping of the standard machine, as
RP
R P
shown in Fig. 4-5 AK
E KE
E R EA
In this time, install simultaneously the P and T BR B
ports connector of pilot valve for N&B.
OPT S/V T
(See Fig 4-7, 8) 1 -PT T
Table 4-4 (Add to solenoid valve) OPT S/V T
To be performed 2 -PT P
REMOTE CONTROL PIPING in service shop.
A
No. Parts Q'ty Remarks T
P
1 HOSE L=550 1 PF1/4 B
2 HOSE L=520 1 PF1/4
5 ELBOW 1 PF1/4
6 ELBOW 1 PF1/4 F19460
7 CONNECTOR 2 PF1/4
8 BRACKET 1
9 SOLENOID VALVE 1 Remove plug
14 15
10 CAPSCREW 2
11 CAPSCREW 2
12 WASHER 2 Use existing parts B11(Fig. 4-7)
13 WASHER 2 P T
14 TEE 1 PF1/4
15 TEE 1 PF3/8
PF3/8-
16 CONNECTOR 1 PF1/4 7 B8 (Fig. 4-7) 16
24 HOSE 1 PF1/4 Remove plug
L=3200
F19463
TO OPT S/V P TO OPT S/V T
(3) Connect a harness to the single / conflux solenoid DETAIL A
F19464
valve.
Connect the existing connector (CN-266F) and
single / conflux flow selector solenoid that is
adding by above (2) procedure to the under floor
2 places
harnesses of the standard machine
Table 4-5
HARNESS
(FOR SINGLE CONFLUX SOL)
31102 60413252
1 HARNESS 1
F18037
DETAIL B VIEW I
Fig. 4-5 Addition of 1-section solenoid valve

2FA-JM II+ 2MA-JM II+
Single / conflux flow To under floor
select solenoid harness
63-35
4.3.3 Remote control piping (nibbler & breaker) TIGHTENING TORQUE Pilot valve attaching
& control block piping (breaker, nibbler & Capscrew (10T) connector
breaker) Thread Tightening torque (O-ring type coupling)
Assemble the additional parts listed in Table 4-6 to size
(PF) kgf·m (lbf·ft) Thread Spanner Tightening torque
the remote control piping of the standard machine, as size
M8 3.6 (26) (PF) (mm) kgf·m (lbf·ft)
shown in Fig.4-6. M10 7.2 (52) 1/4 19 30 (22)

NOTE: Thread Spanner Tightening torque Tightening torque
• Before starting the modification work, check parts size
• When disconnecting and reconnecting pipes, take 1/4 19 3.7 (27) 3.0 (2.2)
care so as not to allow dirt and foreign matter to 3/8 22 7.5 (54) 5.0 (36)
enter. F18038
Pa5
A
CONTROL VALVE
Pb5
A1
A3 B
A4
A2
A8
A9
A6 A24 A20
A18-2
A7
A5 A18-4
A17
A7 A19
A10 P
A24
A18-3
A25 A12 P
A18 T A13
T
A18-5 A18-1 P
A18-6
A4 P
P T
A15 P/T P
A23 T
T T
A21
P/T
P A14
B
A3 P/V B8
T
31102 60413252
C/V P
A P/V
Pa5 T B11
C/V
Pb5
A13 A1
A13 A2
A B F18040
FIg. 4-7 Remote control piping (Nibbler & breaker)
63-36
Table 4-6
REMOTE CONTROL PIPING
No. Parts Q'ty Remarks No. Parts Q'ty Remarks
A1 HOSE 1 PF1/4
L=2800 A13 ELBOW 3 PF1/4
A2 HOSE 1 PF1/4
L=2150 A14 ELBOW 1 PF1/4
WITH FILTER
A3 HOSE 1 PF1/4
L=400 A15 PILOT VALVE 1
A4 HOSE 1 PF1/4
L=500 A17 CAPSCREW 2
A5 NUT 1 A18 LOCK ASSY 1
A6 PIN 1 A19 PEDAL 1
A7 WASHER 3 A20 RUBBER 1
A8 CAPSCREW 2 A21 PRESSURE SWITCH 1
A9 LOCKWASHER 2 A23 CONNECTOR 1
A10 CAPSCREW 2 A24 WASHER 4
PF1/4
A12 CONNECTOR 1 L=23 A25 PLUG 1 PF1/4
F18039
Table 4-7
BLOCK CONTROL PIPING
P
B8 CONNECTOR 1 PF1/4 P
B11 ELBOW 1 PF3/8-
PF1/4 P/V T
F18007 P
P
(2) arts to be disused T

P
Concerning the control block piping, the parts
T
listed in Table 4-8 and Fig. 4-7 are disused from T
T
the standard machine.
C13
Table 4-8 C9
No. Parts Q'ty Remarks P/V
T
C9 PLUG 1 PF3/8 F18041
C13 PLUG 1 PF1/4

F18008 FIg. 4-7 Control block piping (Nibbler & Breaker)
(3) Parts to be disused A4

Concerning the remote control piping, the parts
listed in Table 4-9 and in Fig. 4-8 are disused from A8
A2
the standard machine.
Table 4-9
A2 SUPPORT 1
A4 COVER 1
A8 SEMS BOLT 2
F18009
31102 60413252
FIg. 4-8 Parts to be disused
63-37
4.4 UPPER HYDRAULIC PIPING NOTE:

(NIBBLER & BREAKER) • Before starting the modification work, check parts
Assemble the additional parts listed in Table 4-10 to according to the additional parts list.
the upper hydraulic piping of thr standard machine, as
shown in Fig. 4-9. enter.
• At assembly, use care of O-ring do not come off.
TIGHTENING TORQUE • Regarding the tightening torque of O-ring type joints,
O-ring type coupling hydraulic hoses and nut sleeve joints, refer to the
Thread remarks of Table 4-10 and the Tightening Torque
size Table.
1/2 27.32 11 (80)
Nut sleeve joint

Tube size
(mm) kgf·m (lbf·ft)
Ø18 X t2.5 32 15 (108)

size
M 12 19 12.3 (89)
F18042
Table 4-10
UPPER HYDRAULIC PIPING
3 O-RING :1B 18 1
4 BUSHING 2
5 ROD BOLT 1 M12 X 240
6 WASHER 1
7 NUT 6
8 HOSE 1 Ø18 L=2650
9 CLAMP 2
10 HOSE 1 Ø18 L=2500
F18043
31102 60413252
63-38
A
B
TO N&B H
CONTROL VALVE
TO N&B R
A
A
10
7
6
10
7
2
4
2-1
9
A5 7
N&B 1 B5
H 3
N&B CONTROL VALVE

R
31102 60413252
A B F18044
Fig. 4-9 Upper hydraulic piping (Nibbler & Breaker)
63-39
4.5 RETURN HYDRAULIC PIPING NOTE:

(NIBBLER & BREAKER) • Before starting the modification work, check parts
Install the additional parts listed in Table 4-11 to the • When disconnecting and reconnecting pipes, take
return hydraulic piping of the standard machine, as
enter.
shown in Fig. 4-10. On that occasion, some parts • At assembly, use care of O-ring do not come off.
become unnecessary. • Regarding the tightening torque of O-ring type joints,
hydraulic hoses and flareless joints, refer to the
TIGHTENING TORQUE remarks of Table 4-11 and the Tightening Torque
Table.
size
3/8 22 7.5 (54) 5.0 (36)
1/2 27 11.0 (80) 5.0 (36)
3/4 36 16.5 (120) 12.0 (87)

size
M8 13 3.6 (27)
H 10 17 7.2 (52)
F18045
B HYDRAULIC TANK
26
CONTROL VALVE
TO N&B T 29
35
TO N&B H
A
SWING MOTOR
16
HYDRAULIC PUMP
E
40
27 SWIVEL JOINT
RADIATOR
UPPER HYDRAULIC
PIPING
F18048
A
31102 60413252
Fig. 4-10 Return hydraulic piping (Nibbler & Breaker)
63-40
Table 4-11
RETURN HYDRAULIC PIPING
12 ELBOW 1 PF3/4
16 HOSE GUARD 1 L=1000
26 HOSE 1 PF3/4
L=3000
27 BUSHING 1
29 CLIP 1
35 GROMMET 1
40 BUSHING 1
F18046
4.5.2 Parts to be disused 44 44-1

Concerning the return hydraulic piping the part listed
in Table 4-12 and Fig. 4-11 are disused from the
standard machine.
Table 4-12
44 PLUG 1
F18016
HYDRAULIC TANK
F18017
12 12-1
26
TO N&B
T
31102 60413252
HYDRAULIC TANK
F18047
63-41
4.8 INSTALL OF THE NAME PLATE

(NIBBLER & BREAKER)
Fit the labels shown in Table 4-17 to the cab of the
standard machine, according to Fig. 4-16 and 4-17.
INSTALL OF THE NAME PLATE

20 LABEL 1
22 LABEL 1
23 LABEL 1
F18053
21
VIEW I
IMDICATES VIEW OF PEAR PANEL
Fig. 4-16 Labeling position
(20) (22)
Procedure to change MAINTENANCE Attachment operation by foot pedal.

selector valve (When using nibbler, breaker or extra) Always check the foot pedal control pattern
Mark SELECTION • Contamination and deterioration before operation.
N Nibbler of hydraulic oil may develop
B Breaker malfunctioning of control valves, Always read operators manual before operating
E EXTRA early wear and seizure of
hydraulic pumps, and consequential
machine.
Please adjust suitable damage of entire hydraulic
notch to capscrew. circuit.
(some mark may not be Replace filters and hydraulic oil, (23)
indicated) refering to the following table.
31102 60413252
CAPSCREW
Notch (1) Hydraulic oil change
: Every 600 HRS.
(2) Hydraulic line filter change Do not set this switch to nibbler combined flow
First : 50 HRS
Regular : Every 250 HRS operation position when using breaker.
Marks
F18061 F18062
Fig. 4-17 Additional
63-42
5. MODIFICATION PROCEDURE FOR ATTACHMENT
Table 5-1
No. ITEM
3.71 M (12 ft-2 in)

Boom
boom
1.65 M (5 ft-5 in)
Breaker
arm
Arm
2.07 M (6 ft-9 in)
arm
For NPK
Connector
assy For TOKU
For KRUPP
3.71 M (12 ft-2 in)
Nibbler Boom
boom
&
Breaker 1.65 M (5 ft-5 in)
arm
Arm
2.07M (6 ft-9 in)
arm
Connector assy
Breaker, L·H
Nibbler
Idler link
&
Breaker R·H
F18065
31102 60413252
63-43
5.2 MODIFICATION OF THE 3.7M (12 ft-2 in) NOTE:

BOOM • Use weld symbol B welding rod (mild steel 50kg
5.2.1 Modification of the 3.7m (12ft-2in) boom grade).
[breaker, nibbler & breaker] • Seal the unwelded areas of the tapped block.
Weld the additional parts listed in table 5-2 to the boom
of the standard specification, according to Fig. 5-1.
Table 5-2
BOOM ASSY (BREAKER)
1 •BOOM ASSY (1) With bushing
•BOOM STD
(Without bushing)
2 •TAPPED BLOCK 6
3 •TAPPED BLOCK 1
4 •PLATE 1
F18066
Seal the
unwelded areas
of the tapped
block.
SECTION AA
SECTION BB
31102 60413252
Fig. 5-1 Modification of the 3.7 m (12 ft-2 in) boom (Breaker, Nibbler & Breaker)
63-44
5.2.2 Hydraulic piping for 3.7m (12 ft-2 in) boom

(breaker)
3.7m (12 ft-2 in) boom modified under par. 5.2.1 as
shown in Fig. 5-2.
Table 5-3
HYDRAULIC PIPING
FOR BOOM (BREAKER)
1 TUBE 1
2 TUBE 1
3 PLUG 2
4 CLAMP 6
5 CLAMP 3
6 CAPSCREW 8
7 CAPSCREW 1
8 NUT 1
9 LOCK WASHER 9
10 WASHER 1
F18067
NOTE:
• Apply Loctite #242 to the clamp mounting bolts.
• For M-threads Tightening torque
Thread size
M10 6.7 kgf·m (48 lbf·ft)
• For PF,PT-threads Tightening torque
Thread size
1/2 11.0 kgf·m (80 lbf·ft)
3/4 16.5 kgf·m (120 lbf·ft)
• Tightening torque of nut-sleeve joint.
Piping size
Ø22 X 3.0 22.0 kgf·m (160 lbf·ft)
• At assembly, use care of O-rings do not come off.
• Remove item 3 plug as necessary, and install an
accumulator recommended by the breaker maker.
SECTION AA SECTION CC
SECTION EE
31102 60413252
SECTION BB SECTION DD
Fig. 5-2 Hydraulic piping for 3.7 M (12 ft-2 in) boom (Breaker)
63-45
5.2.3 Hydraulic piping for 3.7m (12ft-2in) boom

(nibbler & breaker)
Install the additional parts listed in table 5-4 to the 3.7m
(12ft-2in) boom modified under par.5.2.1 as shown in
Fig. 5-3.
Table 5-4
HYDRAULIC PIPING
FOR BOOM (BREAKER)
1 TUBE 1
2 TUBE 1
3 TUBE 1
4 TUBE 1
5 SELECTOR VALVE 1
6 SUPPORT 1
7 CONNECTOR 1
8 ELBOW 2
9 PLUG 2
10 O-RING 3
11 CLAMP 7
12 CLAMP 3
13 CAPSCREW 8
14 CAPSCREW 8
15 CAPSCREW 1
16 NUT 1
17 LOCK WASHER 8
18 LOCK WASHER 9
19 WASHER 1
F18068
NOTE:
Thread size
Thread size
1/2 11.0 kgf·m (80 lbf·ft)
3/4 16.5 kgf·m (120 lbf·ft) SECTION AA SECTION CC SECTION EE
• Tightening torque of nut-sleeve joint.
Piping size
Ø22 X 3.0 22.0 kgf·m (160 lbf·ft)
• Remove item 3 plug as necessary, and install an
accumulator recommended by the breaker maker.
31102 60413252
SECTION BB SECTION DD
Fig. 5-3 Hydraulic piping for 3.7 M (12 ft-2 in) boom (Nibbler & Breaker)
63-46
5.3 MODIFICATION OF THE STD. ARM NOTE:

(BREAKER, NIBBLER & BREAKER) • Sectional shape of fillet welding should be concave
but convex.
5.3.1 Modification of the 1.65m (5 ft-5 in) arm
• Use weld symbol B welding rods (mild steel 50 kg
(breaker, nibbler & breaker) grade).
When the additional parts listed in table 5-5 to the arm • Seal the unwelded areas of the tapped block.
of the standard specification, according to Fig. 5-4.
Table 5-5
1.65M(5ft-5in) ARM ASSY
(BREAKER)
No. Part No. Q'ty Remarks
1 •ARM ASSY (1) (1) With bushing
•ARM STD
(Without bushing)
2 •PLATE – 1
3 •PLATE – 1
4 •PLATE – 1
5 •BRACKET 2 2
6 •TAPPED BLOCK – 1
7 •TAPPED BLOCK 2 –
F18069
SECTION BB
SECTION AA
SECTION CC SECTION DD
Fig. 5-5 Modification of the 1.65 M (5 ft-5 in) arm (Nibbler & Breaker)
31102 60413252
SECTION AA
Fig. 5-4 Modification of the 1.65 M (5 ft-5 in) arm (Breaker)
63-47
5.3.2 Hydraulic piping for 1.65m (5 ft-5 in) arm NOTE:

(breaker, nibbler & breaker) • Apply Loctite #242 to the clamp mounting bolts.
This hydraulic piping applies to both the breaker
Thread size
machine and the nibbler & breaker machine. M8 3.4 kgf·m (25 lbf·ft)
Install the additional parts listed in table 5-6 to the M10 6.7 kgf·m (48 lbf·ft)
1.65m (5 ft-5 in) arm modified under par. 5.3.1 as • For PF,PT-threads Tightening torque
shown in Fig. 5-6. Thread size
3/4 16.5 kgf·m (120 lbf·ft)
Table 5-6 • Tightening torque of nut-sleeve joint.
Piping size
1.65M (5ft-5in) ARM HYDRAULIC
PIPING FOR Ø22 X 3.0 22.0 kgf·m (160 lbf·ft)
(BREAKER, NIBBLER & BREAKER) • At assembly, use care of O-rings do not come off.
1 TUBE 2
2 HOSE 2
3 STOP VALVE 2
4 CLAMP 2
5 CONNECTOR 2
6 O-RING 2 1B P24
7 CAPSCREW 8 M8 X M25
8 CAPSCREW 2 M10 X M45
9 LOCK WASHER 8
10 LOCK WASHER 2
F18070
31102 60413252
SECTION AA
SECTION BB
Fig. 5-6 Hydraulic piping for 1.65 M (5 ft-5 in) arm (Breaker, Nibbler & Breaker)
63-48
5.4 MODIFICATION OF THE 2.07M (6 ft-9 in) NOTE:

LONG ARM (BREAKER, NIBBLER & • Use weld symbol B welding rod (mild steel 50 kg
grade).
BREAKER)
• Seal the unwelded areas of the tapped block.
5.4.1 Modification of the 2.07m (6 ft-9 in) arm
Install the additional parts listed in Table 5-7 to the long
arm of the standard machine, as shown in Fig.5-7.
Table 5-7
2.07M(6ft-9in) LONG ARM
ASSY (BREAKER & N&B)
1 •LONG ARM ASSY (1) With bushing
•LONG ARM
2 •PLATE 1
3 •PLATE 1
4 •PLATE 1
5 •BRACKET 2
6 •TAPPED BLOCK 1
F18071
SECTION AA SECTION DD
31102 60413252
SECTION CC
SECTION BB
Fig. 5-7 Modification of the 2.07 M (6 ft-9 in) long arm (Nibbler & Breaker)
63-49
5.4.2 Hydraulic piping for 2.07m (6 ft-9 in) long

NOTE:
arm (breaker, n&b)
This hydraulic piping applies to both the breaker • For M-threads Tightening torque
machine and the nibbler & breaker machine. Thread size
Install the additional parts listed in table 5-8 to the M8 3.4 kgf·m (25 lbf·ft)
2.07m (6 ft-9 in) long arm under par. 5.4.1 as shown M10 6.7 kgf·m (48 lbf·ft)
in Fig. 5-8.
Thread size
3/4 16.5 kgf·m (120 lbf·ft)
Table 5-8 • Tightening torque of nut-sleeve joint.
HYDRAULIC PIPING FOR Piping size
2.07M (6ft-9in) ARM Ø22 X 3.0 22.0 kgf·m (160 lbf·ft)
(BREAKER, NIBBLER & BREAKER)
1 TUBE 2
2 HOSE 2 L=1450
3 STOP VALVE 2
4 CLAMP 2
5 CONNECTOR 2
6 O-RING 2 1B P24
9 LOCK WASHER 8
10 LOCK WASHER 2
F18072
31102 60413252
SECTION AA SECTION BB
Fig. 5-8 Hydraulic piping for 2.07 M (6 ft-9 in) long arm (Nibbler & Breaker)
63-50
5.5 CONNECTOR ASSY (BREAKER) 2 3 1

When using the machine with a breaker. Attach the 3/4-16UNF
below parts to the tip of the stop valve. for use with
NPK, TOKU and KRUPP breakers.
Table 5-9
CONNECTOR ASSY FOR NPK
PF3/4
1 CONNECTOR 1 PF3/4-3/4
16UNF
A: FOR NPK
2 PLUG 1
3 O-RING 1 1B P24
F18073
Fig. 5-9 Connector assy (NPK)
2 PF3/4 1 3 PF3/4
Table 5-10
CONNECTOR ASSY FOR
TOKU, KRUPP
1 CONNECTOR 1 PF3/4
2 PLUG 1
3 O-RING 1 1B P24
F18074
A : FOR TOKU,KRUPP
Fig. 5-10 Connector assy (TOKU, KRUPP)
5.6 CONNECTOR ASSY (NIBBLER) 2 M30 X 1.5 1 3
When using the machine with a nibbler. Attach the

below parts to the tip of the stop valve.
Table 5-11
CONNECTOR ASSY
1 CONNECTOR 1 PF3/4 PF3/4
2 PLUG 1
3 O-RING 1 1B P24
31102 60413252
F18075
Fig. 5-11 Connector assy (NIBBLER)
63-51
0
5.6 REINFORCING THE IDLER LINK
(NIBBLER & BREAKER)
When using the machine as a nibbler & breaker
machine, the right and left idler links need
reinforcement. Reinforce them according to table 5-
12 and Fig. 5-12.
Table 5-12
IDLER LINK (L.H)
IDLER LINK (R.H)
No. Parts Q'ty Pemarks
0 IDLER LINK (1) (RH) 1
0 IDLER LINK (1) (LH) IDLER LINK (L·H)
1 PLATE 2 RH and LH
in common
F18076
0
IDLER LINK (R·H)
Fig. 5-12 Reinforcing the idler link
31102 60413252
63-52
6. REMINDERS ON THE USE OF NIBBLER & BREAKERS
6.1 CHANGING OVER THE SELECTOR PLUG
VALVE
A nibbler & breaker-attached machine is equipped with
a selector valve in both the operation circuit and the
main circuit. When running the machine after
completion of modification, always set the selector
valves according to a nibbler or a breaker used.
NOTE:
Incorrect setting of the selector valves not only
deteriorates operating efficiency and decreases speed
but also causes failure of he machine. Therefore,
confirm completion of the modification and give proper
advice to the user.
SELECTOR VALVE
• Tool used
For main circuit changeover
: 5 mm BOOM
: 24 mm
Changing over procedure of the selector valve C/V C/V

1) Remove socket bolt with allen wrench. BREAKER BREAKER
2) Turn the nibbler or the breaker to its operating

position, using a spanner.
3) Stop it at a specified position and tighten the TANK TANK
setscrew.
WHEN USING WHEN USING
BREAKER NIBBLER
F18091
Fig. 6-2 Changing over procedure of the selector valve
ALLEN WRENCH (HEX 5 mm)
SPANNER (HEX 5 mm)

31102 60413252
Fig. 6-1 Changing over procedure of the selector valve
63-53
6.2 FLUSHING METHOD

After completion of piping work, connect the high
pressure side and the low pressure side, as shown in
Fig. 6-3, open the stop valves on both sides and
depress the operating pedal to perform flushing.
NOTE:
• Before beginning flushing, run the engine at low
speed, depress the breaker operating pedal and
then run the engine at high speed.
• Perform flushing operation for at least 40 minutes,
and during the operation, make sure of no oil leakage An example of flushing time (23 min) in a single process
from each of the connections of the newly attached
breaker circuit and the nibbler & breaker circuits.
6.3 REPLACING HYDRAULIC OIL AND

RETURN FILTER
Contamination and deterioration of hydraulic oil may
develop malfunctioning of the control valve, early wear
and seizure of the hydraulic pumps and malfunctioning
of the entire hydraulic circuits: always replace hydraulic
Fig. 6-3 Flushing method
oil at regular intervalvs, based on table 6-1.
Table 6-1
INSPECTION / REPLACEMENT INTERVALS

ITEM
MAINTENANCE POINTS First replacement 2 nd replacement Regular replacement
Hydraulic oil Hydraulic oil tank – – Every 600h
Return filter Hydraulic oil tank 25h 100h Every 200h
F18092
6.4 OPERATING PROCEDURE

This machine is provided with breaker single circuit
and nibbler and breaker combined (conflux) circuit. To
use breaker or nibbler, select circuit appropriate to the
specification through switch on the left rear side of
driver's seat.
6.4.1 Switch operating (nibbler & breaker

specification)
SPECIFICATION SWITCH POSITION CIRCUIT

F18094
Breaker OFF Single flow
Nibbler ON Conflux flow
31102 60413252
F18093
CAUTION NIBBLER & BREAKER SPECIFICATION

Never turn switch on (conflux) to operate breaker.
It may cause trouble of machine.
63-54
6.4.2 Throttle potentiometer

When operating the machine with a hydraulic breaker,
do the following operations:
Use the throttle potentiometer on the high idle side
(refer to Fig. 6-4).
Fig. 6-4 Throttle potentiometer position
6.4.3 control pedal RELEASE

(1) Hydraulic breaker single circuit
Release pedal lock on the right front side of LOCK
driver's seat to operate pedal. PUSH LOCK
ROD FORWARD PULL LOCK ROD
TO RELEASE BACKWARD
TO LOCK PEDAL
CAUTION
Precaution for pedal operation.
The operation varies in the specification, so before
operating, read the Operator Manual carefully. BREAKER ONLY
Foot pedal
Operating condition
depressing section
Depress heel section Breaker starts operation
Pedal in neutral position Breaker stops operating
(2) Nibbler and breaker combined (conflux) circuit.

Release pedal lock on the right front side of
driver's seat to operate pedal.
• Hydraulic breaker
Foot pedal
Operating condition
depressing section
Pedal in neutral position Breaker stops operating
Depress heel section Breaker starts operation
31102 60413252
• Nibbler
Foot pedal
Operating condition
depressing section
Depress toe section Nibbler close
Fig. 6-5 Operate pedal
Depress heel section Nibbler Open
F18095
63-55
7. PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT

MANUFACTURERS
There are some differences between manufactures as Low pressure side:
to the piping to breakers and the handling of breakers. Measure the inlet pressure of the line filter on the
For this reason, consult with the manufacturer when breaker side by actuating the breaker at full engine
mounting a breaker in the field. The following is a revolution in the H mode, and in case the maximum
summary of how breakers should be handled that is pressure exceeds 55kgf/cm2 (780 psi), install a low
extracted from manufacturers' catalog use and pressure accumulator.
operation manuals max. < 55 kgf/cm2 (780 psi)
Regarding the capacity and the charge pressure of
NOTE: accumulators, contact the breaker manufacturer before
This is a general outline of how breakers should be
installation.
used and may differ with excavator models. Always
contact the breaker manufacturer before field mounting.
(2) Installation of a relief valve
(1) Placing high and low pressure accumulators N P K Installation is not necessary.
(Contact the breaker
N P K They must be placed basically
manufacturer as it is necessary
(depending upon models).
depending upon models).
T O K U Check the oscillation of the
T O K U Installation is necessary.
K R U P P pulsation of the breaker
K R U P P A relief valve is specified by
O K A D A pressure and if pulsation is large,
O K A D A each breaker manufacturer.
FURUKAWA always install accumulators.
T A I S E I Since the method of pressure
Standard of judgment on the installation of FURUKAWA setting of the relief valve differs
F18176
accumulators. with breaker manufacturers,
install a relief valve according to
High pressure side: the manufacturer's instructions.
Measure the pulse oscillation by pressure on the high
NOTE:
pressure side of the breaker at the inspection port for Only the B series of TOKU machine requires a relief
the pump's delivery pressure by actuating the breaker valve to be installed.
at the full revolution of the engine in mode H and set
the maximum pressure difference to within 20% of he
excavator's system pressure 300 kgf/cm2 (4270 psi).
HIGH PRESSURE SIDE PLUG
In case it exceeds 20%, install a high pressure
accumulator. LOW PRESSURE SIDE PLUG
NOTE:
The pulse oscillation is 300 X 20% = 60kgf/cm2 (850
psi). Therefore, if it is more than this level, an
accumulator must be installed.
WARNING
Install the accumulator by referring to Table 8-2 result
of verfication test.
SELECTOR VALVE
31102 60413252
Max. press–Min press <system press X 20%> Fig.7-1 Relief valve mounting
63-56
6 (4) Changing over the breaker to high and low speeds

4
N P K
These breakers are not so
2 T O K U
constructed as to be switched
T A I S E I
3 over to high and low speed.
TO TANK FURUKAWA
K R U P P F18177
MKB1200 or larger breakers
RETURN SIDE
5 are constructed with a switching
1
function. It can be operated from
inside the cab by the installation
of a solenoid valve. For piping
work, consult with the breaker
TO BREAKER OIL SUPPLY SIDE
manufacturer.
1. HIGH PRESSURE 4. PLUG
NOTE:
2. NIPPLE 5. ELBOW
Piping work is not required in some cases if a high-low
3. ADAPTER 6. RELIEF VALVE cangeover function is not necessary at user's request.
On that occasion, it is necessary to fix the changeover
Fig. 7-2
valve contained in the breaker to the low speed side
beforehand. Consult with the breaker manufacturer in
that case. It is prohibited to use the high-low speed
(3) Restriction of engine revolution changeover valve without laying high-low speed piping
and without fixing the high-low speed changeover
N P K Full engine revolution may be valve.
used.
There are restriction on the
T O K U
engine revolution. Since a
K R U P P
specified revolution differs with HIGHT-LOW SPEED
O K A D A CHANGEOVER VALVE
breakers, follow the breaker
T A I S E I
manufacturer's instructions.
FURUKAWA
F18178
NOTE: RELIEF VALVE HYDRAULIC

In the case of a breaker for which the engine revolution BREAKER
is limited, the breaker does not increase impact power TO CONTROL VALVE
and cycles even at full engine revolution.
Since extra hydraulic oil returns to the hydraulic oil via
the relief valve, it causes the hydraulic oil temperature
to rise and the fuel consumption to increase. Plaster TO TANK
the label (furnished by the breaker maker) indicating
the revolution (check the engine revolution), to the
throttle potentiometer position. Always observe the CHECK VALVE
indicated revolution.
Fig. 7-3
31102 60413252
63-57
8. REFERENCE
Typical combinations are quoted from breaker When fitting a breaker, read through reminders on the
manufacturers' catalog use as below, but concerning use of breakers and cautions instructed by breaker
applicable breaker models, decide it after consultation manufacturers.
with the breaker manufacturer.
Table 8-1
Applicable Working press Oil volume Total weight Total length Bucket
Manufacturer used L/min capacity m3
breaker kgf/cm2 (psi) (gal/min) kg (lbs) mm (in) (cuyd)
H-10XB 120~140 160~200 1,450 2,156

(1,710~1,990) (42.2~52.8) (3,200) (84.9˝)
NPK
H-4XB 130~150 35~60 410 1,644
(1,850~2,130) (9.24~15.8) (900) (64.7˝)
TNB-10B 100~140 110~140 1,000 0.55~0.70

(1,420~1,990) (29.0~37.0) (2,210) (0.72~0.92)
TNB-14B 120~140 140~160 1,400 0.70~.090

(1,710~1,990) (37.0~42.2) (3,100) (0.92~1.18)
TOKU TNB-6B 100~160 45~80 391 1,476 0.25~0.35

(1,420~2,280) (11.9~21.1) (860) (58.1˝) (0.33~0.46)
TNB-10E 120~170 100~140 997 1,850 0.55~0.70

(1,710~2,420) (26.4~37.0) (2,200) (72.8˝) (0.72~0.92)
TNB-14E 130~170 130~170 1,500 2,190 0.70~0.90

(1,850~2,420) (34.3~44.9) (3,300) (86.2˝) (0.92~1.18)
MKB1100 150~160 80~110 1,100~1,250 2,278 0.50~0.90

(2,130~2,280) (21.1~29.0) (2,430~2,760) (89.7˝) (0.65~1.18)
KRUPP
NKB1200 150~180 90~130 1,120~1,200 0.55~1.00
(2,130~2,560) (23.8~34.3) (2,470~2,650) (0.72~1.31)
UB 11 150~180 110~ 1,450 2,240 0.70~

(2,130~2,560) (29.0~ ) (3,200) (88.2˝) (0.92~ )
OKADA
OUB 310 130~160 110~155 1,070 2,040 0.55~0.70
(1,850~2,280) (29.0~40.9) (2,360) (80.3˝) (0.72~0.92)
TAISEI 150~170 100~120 1,330 [1,596] 0.60~0.90

TF-150 (2,130~2,420) (26.4~31.7) (2,930) (62.8˝) (0.78~1.18)
FURUKAWA 160~180 125~150 1,400 2,119

HB20G (2,280~2,560) (33.0~39.6) (3,100) (83.4˝)
[ ] Excludes chisels.
General precautions to be exercised on the installation of breakers by different manufacturers.
Table 8-2
Installation of Installation of Restriction
Manufacturer accumulators engine
of
High-low speed changeover
a relief valve revolution
Manufacturer changeover type not available.
TOKU changeover type not available.
Series B
TOKU changeover type not available.
Series E
KRUPP changeover type available for
large machines.
OKADA changeover type available for
special request.
31102 60413252
HURUKAWA changeover type not available.

TAISEI changeover type not available.
F18179
One that must be installed. One that must be adjusted at installation.
One that does not need to be installed. Capacity 1 liter, pressure is 70 kgf/cm2 (1,000psi)
Adaptation test completed.
63-58

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INTRODUCTION

- Read this manual carefully for correct FIAT KOBELCO CONSTRUCTION

ADDITIONAL REFERENCE MANUALS

• In addition to this Workshop Manual, refer also to

- Operation and maintenance instruction

DESCRIPTION OF THE COMPLETE

• The complete repair manual consists of two equipment, information on maintenance

VOLUME MACHINE TYPE PRINT No.

Most accidents, whether they occur in industry, on the farm, at home or on

On machines having hydraulically, mechanically and/or cable

COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A.

All rights reserved. Reproduction of text and illustrations in whole or in part,

Section 1 - Preliminary remarks

Section 21 - Mechatro control system

Section 31 - Disassembling and assembling

Section 41 - Mechatro control

Section 63 - Mounting the breaker and nibbler & breaker

SAFETY PRECAUTIONS machine. Hang a “Do Not Operate” tag in the

WARNING 5. Do not work on any machine that is supported

Remove ignition keys.

12. Be careful when removing filler caps, breathers

16. Do not damage wiring during removal operations.

17. Be sure all protective devices including guards

18. The maintenance and repair work while holding

19. Loose or damaged fuel, lubricant and hydraulic

can result in a high velocity oil stream that will be

20. Tighten connections to the correct torque. Make

1. General precautions for repairs .............................................................................. 1-1

2. International unit conversion system ...................................................................... 1-4

1. GENERAL PRECAUTIONS FOR REPAIRS

3) Stop the engine before starting inspection and

1) Wear appropriate clothes with long sleeves, safety work.

(3) Move away the articles in advance that may cause

(3) Precautions for handling hydraulic oil

sive fluid, even if the size is same. sufficiently.

2. INTERNATIONAL UNIT CONVERSION SYSTEM

(6) Unit Conversion [ Table 3-6 ]

Area square metre m2

1. Name of components .............................................................................................. 2-1

2. Machine dimensions ................................................................................................ 2-2

3. Weight and components ......................................................................................... 2-3

4. Transportation dimension and weight ..................................................................... 2-4

5. Specifications and performance ............................................................................. 2-7

6. Type of crawler........................................................................................................ 2-8

7. Type of bucket ......................................................................................................... 2-9

8. Combinations of attachment ................................................................................. 2-10

9. Engine specification ............................................................................................. 2-11

1. Arm 16. Travel motor

10. Rotary multi control valve (option) 25. Bucket link

2.1 2.07 m (6 ft-9 in) ARM

5,510 (18´1˝) Unit: mm (ft-in)

2.2 1.65 m (5 ft-5 in) ARM

1,440 (4´9˝) 450 (17.7˝)

3. WEIGHT AND COMPONENTS

2.07 M (6 ft-9 in) Arm 1.65 M (5 ft-5 in) Arm

4.3 Fuel 71 (157)

4. TRANSPORTATION DIMENSION AND WEIGHT

• OVERALL DIMENSIONS OF WITHOUT ARM AND CUCKET

• OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

• OVERALL DIMENSIONS OF BOOM

Weight kg (lb) 500 (1,100)

• OVERALL DIMENSIONS OF ARM + BUCKET

Weight kg (lb) 450 (990) 480 (1,060)