Workshop Manual

Copyright © New Holland
E485
WORKSHOP MANUAL
R0077
All the information and data contained in this manual are based upon most recent information available at the
time of its publication.
NEW HOLLAND KOBELCO has the right to implement, at any time, any modification without providing any
communication.
NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

Print No. 604.13.472
Edition - March 2005
E485 IN-1
INTRODUCTION
TO THE READER
• This manual is written for an experienced techni- - If you have any questions or comments, or if you
cian to provide technical information needed to found any errors regarding the contents of this
maintain and repair this machine. manual, please contact:
- Be sure to thoroughly read this manual for correct NEW HOLLAND KOBELCO
information concerning the service procedures. CONSTRUCTION MACHINERY S.p.A.
Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition

to this service manual:
- Operation and Maintenance Instruction

Manual
- Parts Catalog
WORKSHOP MANUAL COMPOSITION
• The Workshop Manual consists of five parts: - The “Operational Performance Test” part includes
- “Safety Precautions” the information needed to carry out the machine
- “Operational Principle” operational performance test.
- “Operational Performance Test”
- “Troubleshouting”
- “Repair Instructions” - The “Troubleshooting” part includes the technical
information needed for troubleshooting and mal-
- The “Safety Precaution” part includes the recom- function detection.
mended procedures that, if followed, can avoid the
risk of accident for operator and for staff related to
the work and maintenance machine operations. - The “Repair Instruction” part includes information
needed for maintenance and repair of the machine,
- The “Operational Principle” part includes the tech- tools and devices needed for maintenance and
nical information concerning the operation of main repair, maintenance standards, removal/installa-
devices and systems. tion and assembly/disassembly procedures.
IN-2 E485
INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist)
Section number
T : Technical Manual
W : Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.
This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.
UNITS USED
SI Units (International System of Units) are used in this manual.

MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 MPa (250 kgf/cm2)
A table for conversion from SI units to other system units is shown below for reference purposes.
To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW CV-PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N.m kgf.m 0.10197 mL/rev cc/rev 1.0
N.m lbf.ft 0.7375
E485 INDEX
INDEX
MANUAL INDEX
SAFETY PRECAUTIONS Pag.
Section 1 GENERALITIES .................................................................... S1
Section 2 SAFETY PRECAUTIONS .................................................. S2
Section 3 SAFETY PLATES ................................................................ S3
OPERATIONAL PRINCIPLE
Section 1 GENERAL
Group 1 Specifications ........................................................................... T1-1
Group 2 Component Layout ................................................................... T1-2
Section 2 SYSTEM
Group 1 Mechatro Control System ........................................................ T2-1
Group 2 Mechatro Controller ................................................................. T2-2
Group 3 Hydraulic System .................................................................... T2-3
Group 4 Electrical System .................................................................... T2-4
Section 3 COMPONENT OPERATION

Group 1 Hydraulic Pump Assy .............................................................. T3-1
Group 2 Pilot Valve ............................................................................... T3-2
Group 3 Control Valve ........................................................................... T3-3
Group 4 Swing Device ........................................................................... T3-4
Group 5 Travel Device ........................................................................... T3-5
Group 6 Swivel Joint ............................................................................. T3-6
Group 7 Cylinders ................................................................................. T3-7
Group 8 Air Conditioner ......................................................................... T3-8
Group 9 Attachment Automatic Lubrication System .............................. T3-9
OPERATIONAL PERFORMANCE TEST

Section 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction .............................................................................. T4-1
Group 2 Standard Performances............................................................ T4-2
Group 3 Test Procedures ....................................................................... T4-3
Group 4 Mechatro Controller Adjustment ............................................... T4-4
TROUBLESHOOTING
Section 5 TROUBLESHOOTING
Group 1 Mechatro Control ..................................................................... T5-1
Group 2 Hydraulic System .................................................................... T5-2
Group 3 Electrical System .................................................................... T5-3
Group 4 Engine ..................................................................................... T5-4
INDEX E485
INDEX
REPAIR INSTRUCTIONS
Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly ......................... W1-1
Group 2 Tightening Torque .................................................................. W1-2
Section 2 UPPERSTRUCTURE
Group 1 Cab ....................................................................................... W2-1
Group 2 Air Conditioner ...................................................................... W2-2
Group 3 Counterweight ....................................................................... W2-3
Group 4 Main Frame ........................................................................... W2-4
Group 5 Pump Device ........................................................................ W2-5
Group 6 Control Valve ........................................................................ W2-6
Group 7 Swing Device ........................................................................ W2-7
Group 8 Pilot Valve ............................................................................ W2-8
Group 9 Solenoid Valve Unit ............................................................... W2-9
Section 3 UNDERCARRIAGE
Group 1 Swing Bearing ....................................................................... W3-1
Group 2 Travel Device ........................................................................ W3-2
Group 3 Swivel Joint .......................................................................... W3-3
Group 4 Track Adjuster ....................................................................... W3-4
Group 5 Front Idler ............................................................................. W3-5
Group 6 Upper and Lower Roller ......................................................... W3-6
Group 7 Tracks ................................................................................... W3-7
Section 4 FRONT ATTACHMENT

Group 1 Front Attachment .................................................................. W4-1
Group 2 Cylinders .............................................................................. W4-2
E485 INDEX
INDEX
Section 5 ENGINE AND ACCESSORY

Group 1 General Information .............................................................. W5-1
Group 2 Maintenance ......................................................................... W5-2
Group 3 Engine I (Disassembly) ......................................................... W5-3
Group 4 Engine II (Inspection and Repair) .......................................... W5-4
Group 5 Engine III (Assembly) ........................................................... W5-5
Group 6 Lubrication System ............................................................... W5-6
Group 7 Cooling System .................................................................... W5-7
Group 8 Fuel System ......................................................................... W5-8
Group 9 Turbocharger ......................................................................... W5-9
Group 10 Engine Electrical ................................................................. W5-10
Group 11 Troubleshooting ................................................................... W5-11
Group 12 Special Tools ...................................................................... W5-12
Group 13 Repair Standard .................................................................. W5-13
Group 14 Electronic Control System .................................................. W5-14
SAFETY PRECAUTIONS
R0077
E215-E235 W1-1-1
SAFETY PRECAUTIONS E485
INDEX
Section 1 GENERALITIES
Section 2 SAFETY PRECAUTIONS
Section 3 SAFETY PLATES

E485 S1-1
GENERALITIES
GENERALITIES Such paths should be opportunely defined by compe-

tent Authorities. If necessary, require that the service
Read the Operation and Maintenance Instruction is interrupted or said installations are moved prior to
Manual carefully before starting, operating, maintain- starting the work.
ing, fuelling or servicing the machine. You must know the working capacity of the machine.
Carefully read the explanation to each and all safety Define the rear upperstructure swing area and provide
signs in the special section of this Manual before start- for opportune barriers to prevent access into it.
ing, operating, maintaining, fuelling or servicing the Never exceed machine lifting capacity.
machine. Remain within the limits shown in the loading capac-
Machine-mounted safety plates are colour coded yel- ity chart which located on the machine.
low with black borders when they refer to points where
special ATTENTION must be paid and failure to ob-
serve them may cause a serious DANGER to the in-
tegrity of machine operators. They are white with red
borders and black lettering when they refer to a FOR- STARTING
BIDDEN practice.
It is fundamental that all machine operators know very Never start or operate a failed machine. Walk all
well the meaning of each safety plate as this consid- around the machine before mounting.
erably decreases operating hazards and accidents. Before operating the machine, make sure that any
Do not allow unauthorised personnel to operate or possible dangerous condition has been properly re-
service this machine. moved. Before starting machine, check that steering
Do not wear rings, wrist watches, jewellery, loose or and attachment controls are in the neutral position
hanging garments, such as ties, torn clothing, and the safety lever is in the LOCK position. Immedi-
scarves, unbuttoned or unzipped jackets that can get ately report any malfunction of parts or systems to
caught in moving parts. Wear certified safety clothes the maintenance managers for proper action.
such as: hard hat, no-slip footwear, heavy gloves, ear Prior to starting the engine, check, adjust and lock
protection, safety glasses , reflector vests, respira- the driver’s seat for maximum riding comfort and con-
tors every time the job requires it. Ask your employer trol accessibility. Prior to operating the machine and/
about safety regulations in force and protective equip- or its attachments, check that bystanders are out-
ment. side the machine operating range. Sound the horn.
Always keep the operator’s compartment, step plates, Obey all hand signals, safety indications and signs.
grab-rails and handles clean and clear of foreign ob- Due to the presence of flammable fluids, never check
jects, oil, grease, mud or snow to minimise the dan- fuel level, refuel, charge the batteries in the presence
ger of slipping or stumbling. Remove mud or grease of smoking materials, open flames or sparks.
from your shoes before operating the machine. Ensure that nobody is within the excavator operat-
Do not jump on or off the machine. Always keep both ing area before starting the machine, swinging the
hands and one foot, or both feet and one hand in upper structure or moving in any direction.
contact with steps and/or grab rails. Adjust all rear-view mirrors for maximum visibility of
Do not use controls or hoses as hand holds. Hoses the area behind the machine.
and controls are movable parts and do not provide Ensure that engine speed is appropriate to the job to
solid support. Besides, controls may be inadvert- be carried out.
ently moved and cause unexpected movement of the If any hydraulic control or system exhibits erratic per-
machine or its attachments. formance or responds abnormally, have the machine
Never operate the machine or its attachments from checked for air in the system.
any position other than sitting in the driver’s seat. Keep Air in these circuits may cause incorrect movements
head, body, limbs, hands and feet inside the opera- with consequent accident hazard. Refer to the Opera-
tor’s compartment at all times to reduce exposure to tion and Maintenance Instruction Manual about cor-
external hazards. rective action to be taken.
Be careful of possible slippery conditions of the steps
and hand rails as well as of the ground around the
machine. Wear protective boots or shoes with the soles
made of highly no-slip rubber
Do not leave the machine until it has come to a OPERATING
complete stop.
Always check height, width and weight limitations Do not run the engine of this machine in closed
which may be encountered in the working site and buildings without proper ventilation capable to re-
ensure the machine does not exceed them. move harmful exhaust gases which concentrate in
Assess exact paths of gas ducts, water mains, tel- the air.
ephone lines, sewers, overhead and underground elec- Keep the operator’s compartment free of foreign ob-
tric lines and all other possible obstacles. jects, especially if not firmly secured. Never use the
S1-2 E485
GENERALITIES
machine to transport objects, unless proper securing If noise level is high and exceeds 90 dB (A) over 8
points are provided. hours at the operator’s ear, wear approved ear protec-
Do not carry riders on the machine. tion in compliance with local regulations.
Study and familiarise with escape routes alternative Do not operate the machine if you are extremely tired
to normal exit routes. or feel ill.
For your personal safety, do not climb on or off the Be especially careful towards the end of the working
machine while it is in motion. shift.
Make sure that bystanders are clear of the machine Where removable counterweights are provided, do not
operating range before starting the engine and oper- operate the machine if they have been removed.
ating the attachment. Sound the horn. When operating the machine, keep in mind height lim-
Obey all hand signals, safety indications and signs. its of overhead doors, arches, overhead cables and
When backing, always look to where the machine is lines as well as width limits of corridors, roads and
to be moved. Be alert of the position of bystanders. narrow passages. Also, get to know load limits of the
Should someone enter the work area, stop the ma- ground and paving type of the ramps you are to work
chine. on.
Maintain a safe distance from other machines or ob- Beware of fog, smoke or dust that obscure visibility.
stacles to ensure required visibility conditions. Always inspect the working area to identify potential
Always give way to loaded machines. risks such as: inclines, overhangs, trees, demolition
Maintain a clear vision of the surroundings of the rubble, fires, ravines, steep slopes, rough terrain,
travel or work area at all times. ditches, crowns, ridge trenches,diggings in traffic
Keep cab windows clean and repaired. areas, crowded parking lots, crowded service areas,
When pulling loads or towing through a cable or chain, fenced zones. In such conditions, proceed with ex-
do not start suddenly at full throttle. Take-up slack treme care.
carefully. Whenever possible, avoid crossing over obstacles
Avoid kinking or twisting chains or cables. such as very rough terrain, rocks, logs, steps,
Carefully inspect the towing items for flaws or prob- ditches, railroad tracks. When obstructions must
lems before proceeding. be crossed, do so with extreme care and at a
Do not pull through a kinked chain or cable as the square angle, if possible. Slow down. Ease up to
high anomalous stresses existing in this condition may the break-over point, pass the balance point slowly
induce failures in the kinked portion. and ease down the other side also using the at-
Always wear heavy gloves when handling chains or tachment, if necessary.
cables. To overcome deep trenches or sinking ground,
Chains and cables should be securely anchored us- place the machine perpendicular to the obsta-
ing suitable hooks. Anchor points should be strong cle, drastically reduce ground speed and start
enough to withstand the expected load. crossing using also the attachment if necessary,
Keep anyone clear of anchor points and cables or only after assessing that ground conditions al-
chains. Do not pull or tow unless the operator’s low the traverse safely and without risks.
compartments of the machines involved are prop- The gradient you may attempt to overcome is limited
erly protected against possible backlash in case by factors such as ground conditions, load being han-
of cable or chain failure or detachment. dled, machine type and speed, and visibility.
Be alert of soft ground conditions close to newly There is no substitute for good judgement and experi-
constructed walls. The fill material and machine ence when working on slopes.
weight may cause the wall to collapse under Avoid operating the attachment too close to an over-
the machine. hang or high wall, either above or below the machine.
In darkness, check area of operation carefully Beware of caving edges, falling objects and land-
before moving in with the machine. Use all lights slides. Remember that such hazards are likely to be
provided. Do not move into low visibility areas. concealed by bushes, undergrowth and such.
If the engine tends to slow down and stall for what- Avoid faggots, bushes, logs and rocks. Never drive
ever reason under load or at idle, immediately report over them, nor over any other surface irregularities
this problem to the maintenance managers for proper that discontinue adherence or traction with the ground,
action. Do not operate the machine until this condi- especially near slopes or drop-offs.
tion is corrected. Be alert to avoid changes in adherence conditions
Regularly check all exhaust system components, as that could cause loss of control. Work with extreme
exhaust fumes are toxic for the operator. care on ice or frozen ground and on stepped slopes
Operators must know the performance of the ma- or near drop-offs.
chine they are driving. The word “bulldozing” generally refers to work in
When working on slopes or near sudden level drops virgin rough terrain, characterised by the presence
in the terrain, pay attention not to lose adherence of all the perils and risks listed above. We empha-
and avoid loose soft ground since overturn or loss of sise the danger represented in these conditions by
machine control could result. large tree limbs (possibly falling on the machine)
E485 S1-3
GENERALITIES
and large roots (which may act as a leverage un- Avoid travelling across slopes. Proceed from uphill
der the machine when up-rooted and cause the unit downhill and vice-versa. If machine starts slipping
to overturn). sideways when on a slope, lower the bucket and thrust
Position the machine dependent upon the loading bucket teeth into the ground.
and unloading areas in order to swing leftwards to Working on slopes is dangerous. Grade the working
load to obtain best visibility. area if possible. Reduce work cycle time if it is not
Never use the bucket or attachment as a man lift or possible to grade the working area.
carry riders.Never use the machine as a work platform Do not move full bucket or a load from uphill downhill
or scaffolding. The machine must not be improperly as this would reduce machine stability. Do not work
used for works not consistent with its features (such as with the bucket turned to the uphill side.
pushing railway cars, trucks or other machines). Do not work with the bucket turned uphill as coun-
Always pay attention to people within the machine terweights protruding downhill would reduce machine
operating range. stability on the slope and increase risk of overturn-
Never move or stop the bucket, other loads or the ing.
attachment above ground personnel or truck cabs. We recommend to work on slopes with the bucket
Ensure the truck driver is in a safe place before load- downhill, after checking machine stability with the
ing the truck. bucket empty and attachment retracted, by slowly
Load trucks from side or rear. swinging the upper structure by 360°.
Use only the type of bucket recommended consider- Position the carriage at a right angle relative to slopes,
ing machine type, materials to be handled, material hanging walls, etc. to exit the working area easily.
piling up and loading characteristics, ground type and Standard use, provides for the travel controls at the
other typical conditions of the work to be performed. front and travel motors at the back. Should travel
When transporting a loaded bucket, keep it as rolled- motors be positioned at the front with regard to the
back as possible. Keep boom and arm as low as actual travel direction. Remind relative to travel di-
possible. rection that controls are reversed.
Ground speed should be adequate to the load and Always check travel motor position before moving off.
ground conditions. Properly judge ground conditions with particular at-
The load must always be properly arranged in the tention to consistency of the area you are going to
bucket; move with extreme care when transporting work on.
oversize loads. Keep the machine sufficiently far from the ditch edge.
Do not lift and move the bucket overhead where per- Never dig under the machine.
sons are standing or working, nor downhill when work- Should it be necessary to dig under the machine, al-
ing on a slope as this would decrease machine sta- ways ensure that digging walls are opportunely
bility. Load the bucket from the uphill side. propped up against landslide to prevent the machine
Loads to be raised using the machine should be ex- from falling into the trench.
clusively hooked to the hitch specially provided. Do not swing the upperstructure, raise the load or
The excavator is no lifting and transportation means, brake abruptly if not required. This may cause acci-
therefore it should not be used to position loads ac- dents.
curately. Should it be exceptionally used to lift and Prior to beginning the work near gas distribution mains
lay building components, special caution must be or other public utilities:
taken as follows: - Contact the company owner of the gas mains or
- The machine must be equipped without failure with its nearest branch before starting the work. Look
the appropriate variant supplied, upon request, by up the number in the telephone directory.
NEW HOLLAND KOBELCO. Also, totally comply - Define together which precautions should be taken
with the safety precautions for the operation of the to guarantee work safety.
excavator as a lifting equipment. - Decrease work speed. Reaction time could be too
- Secure the loads to be raised using cables or chains slow and distance evaluation wrong.
fastened with appropriate hooking mechanisms. - When working near gas mains or other public utili-
- Nobody should be allowed to remain under the ties installations, appoint a person in charge of sig-
raised load or within the excavator operating range nalling duties. This person will have the responsi-
for any reason whatever. bility of observing the machine, any part of it and/or
Never exceed specified loading capacity. Incorrect the load approaching the gas mains from a stand-
fastening of slings or chains may cause boom/arm point more favourable than the Operator’s. This sig-
failure or failure of the lifting means with consequent nal man (flag-man) must be in direct communica-
bodily injuries and even death. tion with the Operator and the Operator must pay
Always ensure that slings and chains used for lifting undivided attention to the signals supplied.
are adequate to the load and in good condition. - The gas distributing Company, if previously advised
All loading capacities are referred to the machine and involved in the work, as well as machine Opera-
on a level surface and should be disregarded tor, Owner and/or any natural person or legal entity
when working on a slope. having rent or leased the machine or being responsi-
S1-4 E485
GENERALITIES
ble at the time by contract or by law, are liable for the STOPPING
adoption of the necessary precautions.
Working near electric lines can be very dangerous, When the machine is to be stopped for whatever reason,
therefore some special precautions must be ob- always check that all controls are in the neutral position
served. and that the safety lever is on the lock position to guaran-
Within this Manual, “work near electric lines” means tee risk-free start-up.
when the attachment or load raised by the excava- Never leave the machine unattended with the engine run-
tor (in any position) may reach the minimum safety ning.
distance established by local or international Safety Prior to leaving the driver’s seat, and after making
Regulations. sure that all people are clear of the machine, slowly
To work without risks, keep maximum possible dis- lower the attachment until resting it safely to the
tance from electric lines and never trespass minimum ground. Retract possible auxiliary tools to the closed
safety distance. safety position.
- Contact the Company owner of the electric lines or Check that all controls are in the neutral position. Move
its nearest branch before starting the work. engine controls to the shut-down position. Switch off
Look up the in the telephone directory. the key-start switch. Consult the Operation and Main-
- Define together with the Company representative tenance Instruction Manual.
which precautions should be taken to guarantee work Park the machine in a non-operating and no-traffic area.
safety. Park on firm level ground. If this is not possible, posi-
- All electric lines should be considered as operative tion the machine at a right angle to the slope, making
live lines even though it might be well known that sure there is no danger of uncontrolled sliding.
the line in question is out of work and visibly con- If parking in traffic lanes cannot be avoided, provide
nected to the ground. appropriate flags, barriers, flares and other signals as
- The Electric Power Company, if previously advised required to adequately warn the oncoming drivers.
and involved in the work, as well as machine Op- Always switch off the key-start switch before clean-
erator, Owner and/or any natural person or legal ing, repairing, or parking the machine to prevent acci-
entity having rent orleased the machine or being dental unauthorised start-up.
responsible at the time by contract or by law, are Never lower the attachment or auxiliary tools other
liable for the adoption of the necessary precautions. than from sitting in the operator’s seat. Sound the horn.
- Decrease work speed. Reaction time could be too Make sure that nobody is within the machine operat-
slow and distance evaluation wrong. ing range. Lower the attachment slowly.
- Warn all ground personnel to keep clear of the ma- Securely block and lock the machine every time you
chine and/or load at all times. If the load has to be leave it unattended. Return keys to the safe place
guided down for laying, consult the Electric Power previously agreed upon. Perform all necessary opera-
Company to know which precautions should be tions for stopping as detailed in the Operation and
taken. Maintenance Instruction Manual.
- Appoint a person in charge of signalling duties. Drive the machine far from pits, trenches, rocky hang-
This person will have the responsibility of observing walls, areas with overhead electric lines, and slopes
ing the machine, any part of it and/or the load ap- before stopping it at the end of the working day.
proaching the electric lines from a standpoint more Align the upperstructure to the tracks in order to allow
favourable than the Operator’s. This signal man (flag- to easily get on and off the driver’s compartment.
man) must be in direct communication with the Move all controls to the position specified for machine
Operator and the Operator must pay undivided at- stopping. Refer the Operation and Maintenance In-
tention to the signals supplied. struction Manual.
When working in or near pits, in ditches or very high Never park on an incline without accurately blocking
walls, check that the walls are sufficiently propped up the machine to prevent unexpected movement.
to avoid cave-in hazards. Follow stopping instructions contained in the Opera-
Pay the utmost attention when working near overhang tion and Maintenance Instruction Manual.
walls or where landslides may take place. Make sure
that the support surface is strong enough to prevent
landslides.
When digging, there is the risk of cave-ins and land-
slides. MAINTENANCE
Always check ground conditions and conditions of the
material to be removed. Support everywhere it is re- GENERALITIES
quired to prevent possible cave-ins or landslides when:
- digging near previous trenches filled with material Carefully read the Operation and Maintenance Instruc-
- digging in bad ground conditions tion Manual before starting, operating, maintaining,
- digging trenches subject to vibration from railroads, fuelling or servicing the machine in any manner.
working machines or highway traffic. Read all safety plates mounted on the machine and
E485 S1-5
GENERALITIES
observe instructions they contain before starting, op- When service or maintenance require access to ar-
erating, repairing, fuelling or servicing the machine. eas that cannot be reached from the ground, use a
Do not allow unauthorised personnel to repair or serv- ladder or step platform conforming to local or national
ice the machine. regulations to reach the working area. If such means
Follow all recommended maintenance and service are not available, use machine grab rails and steps.
procedures. Always perform all service or maintenance work with
Do not wear rings, wrist watches, jewellery, loose or the greatest care and attention.
hanging garments, such as ties, torn clothing, Shop and/or field service platforms or ladders should
scarves, unbuttoned or unzipped jackets that can get be manufactured and maintained in accordance with
caught in moving parts. Wear certified safety clothes local or national safety regulations in force.
such as: hard hat, no-slip footwear, heavy gloves, ear Disconnect batteries and label all controls to warn that
protection, safety glasses, reflector vests, respirators service work is in progress, according to local and
when required. Ask your employer about safety regu- national safety regulation requirements
lations in force and protective equipment. Block the machine and all attachments to be raised
Do not use controls or hoses as hand holds. Hoses according to local and national safety regulation re-
and controls are movable parts and do not provide quirements.
solid support. Besides, controls may be inadvert- Do not check or fill fuel tanks or install batteries near
ently moved and cause unexpected movement of the burning or smoking materials and open flames due to
machine or its attachments. the presence of flammable vapours.
Do not jump on or off the machine. Always keep both The fuel filler pipe nozzle must be constantly kept in
hands and one foot, or both feet and one hand in contact with the filler neck and this even before fuel
contact with steps and/or grab rails. starts flowing in. Keep this contact from the begin-
Never service the machine with someone sitting in ning to the end of the fuelling operation to avoid pos-
the driver’s seat, unless this person is an authorised sible generation of sparks due to static electricity.
operator assisting in the maintenance being carried Use a truck or trailer to haul a failed machine. Should
out. it be necessary to tow it, provide for suitable danger
Keep the operator’s compartment, step plates, grab signals as required by the local norms and regula-
rails and handles clear of foreign objects, oil, grease, tions and observe recommendations given in the Op-
mud orsnow to minimise the danger of slipping or stum- eration and Maintenance Instruction Manual. Load/
bling. unload the machine on firm level ground providing safe
Clean mud or grease from your shoes before climbing support to the wheels of the truck or trailer. Use strong
on the machine or driving it. access ramps, with adequate height and angle. Keep
Never attempt to operate the machine or its attach- the trailer flatbed free of mud, oil or slippery materi-
ments from any position other than sitting in the op- als. Tie the machine securely to the trailer and block
erator’s seat. carriages and upperstructure.
Keep the driver’s seat free from foreign objects, espe- Never align holes or slots using your fingers;
cially if these are not secured. alwaysuse appropriate aligning tools.
Should it be necessary to move the attachment for Remove all sharp edges and burrs from re-worked
maintenance purposes, do not raise or lower the at- parts.
tachment from any other position than sitting in the Use only approved and effectively grounded auxiliary
operator’s seat. Before starting the machine or mov- power sources for heaters, battery chargers, pumps
ing its attachment, sound the horn and require that and similar equipment to reduce electrical shock haz-
nobody remains near the machine. ard.
Raise the attachment slowly. Lift and handle heavy components using hoisting de-
Always lock all moving components or parts of the vices of appropriate capacity. Ensure the parts are
machine that must be lifted for maintenance purposes supported by appropriate straps and hooks.
using adequate external means as required by local Use lifting eyes provided to this aim.
and national regulations. Do not allow anyone to pass Pay attention to bystanders near the lifting area.
or stay near or below a raised attachment. If you are Never pour gasoline or diesel fuel into open contain-
not absolutely sure about your safety, do not stay or ers. Never use gasoline, solvents or other flammable
walk under a raised attachment. fluids to clean parts. Use proprietary certified non-
Do not place head, body, limbs, hands, feet or fingers flammable, non-toxic solvents only.
near articulated cutting edges deprived of the neces- When using compressed air to clean parts, wear safety
sary guards, unless they are suitably and safely glasses with side shields. Limit pressure to max. 2
locked. bars, in accordance with local and national safety regu-
Never lubricate, repair or adjust the machine with the lations in force.
engine running, except when this is specifically re- Do not run the engine of this machine in closed build-
quired by the Operation and Maintenance Instruction ings without proper forced ventilation capable to re-
Manual. move toxic exhaust gases concentrating in the air.
Do not wear loose clothing, jewellery near rotating parts. Do not smoke, nor allow open flames or sparks nearby
S1-6 E485
GENERALITIES
while refuelling the unit or handling highly flammable arc-cutting. Wear dark safety glasses when you are
materials. near a welding in progress. Do not look the welding
Do not use open flames as light sources to look for arc without proper eye protection.
leaks or inspect anywhere on the machine. Become acquainted with all your jacking equipment
Make sure that all mechanical tools provided are in and their capacity.
good condition at all times. Never use tools with mush- Ensure that the jacking point on the machine is ap-
roomed or damaged heads. Always wear eye protec- propriate for the load applied. Also, be sure the sup-
tions with side shields. ports under the jack and between the jack and the
Move with extreme care when working under, on or machine are appropriate and stable.
near the machine or its attachments. Any equipment supported by a jack represents a pos-
In case of attachment tests during which the engine sible hazard. Always support the load onto appropri-
should be kept running, a qualified operator must sit ate blocking means as a safety measure before pro-
in the driver’s seat at all times while the mechanic is ceeding with service or maintenance work, in compli-
at work. ance with local or national safety regulations.
Keep hands and clothes far OFF moving parts. Metal cables produce steel splinters. Always wear
Stop the engine and move the safey lever to the lock certified protection clothes such as safety gloves and
position before starting adjusting or repairing an as- glasses while handling them.
sembly. Do not use makeshift jacks to adjust track sag. Fol-
Do not carry out any work on the attachment without low instructions given in the Repair Manual.
prior authorisation. Observe maintenance and repair Handle all parts carefully. Keep hands and fingers
procedures. away from gaps, gears, and similar. Always use and
In case of field service, move the machine to level wear certified safety clothes such as safety glasses,
ground and block it. If work on an incline cannot be gloves and footwear.
avoided, securely block the machine and its attach- The attachment is kept constantly in position by an
ments. Move the machine to level ground as soon as oil column trapped into the high pressure circuit. Lower
possible. Do not twist chains and cables. Never use a the attachment to the ground and relieve pressure from
twisted chain or cable for lifting or pulling. Always wear all circuits prior to carrying out any type of mainte-
safety gloves to handle chains or cables. nance or repair work.
Be sure chains and cables are firmly fastened and Do not service or repair the machine if it is parked
that the anchor point is strong enough to withstand downhill. If this is unavoidable, in case of emergency,
the expected load. Keep all bystanders clear of the block the carriages to prevent unexpected movement,
anchor point, cables or chains. Do not pull or tow particularly if the work is to be carried out on the final
unless the operator’s compartments of the ma- reduction units or travel motors.
chines involved are fitted with proper guards Consult the Operation and Maintenance Instruction
against cable or chain backlash. Manual for correct maintenance procedure.
Keep the maintenance area clean and dry at all times. Areas near articulated cutting edges where mechani-
Clean immediately all water and oil spillage. cal parts are in motion are where personal injuries are
Do not pile up oily or greasy rags as they represent a most likely to occur. Pay attention to prevent possible
major fire hazard. Always store them in closed metal part movements by means of blocks or by keeping
containers. clear of such zones when motion may take place dur-
Before starting the machine or its attachment, check, ing maintenance or repair.
adjust and lock the operator’s seat. Also ensure that Move the hydraulic system lock safety lever to the
nobody is within the machine or attachment operating lock position when stopping the machine for what-
range before starting or operating the machine and/or ever reason.
its attachments. Always install the safety stays for the hood and other
Sound the horn. hinged covers before performing any maintenance or
Rust inhibitors are volatile and flammable. repair work in the engine compartment.
Prepare parts in well ventilated areas. Keep open flames
away.
Do not smoke. Store containers in a cool well venti-
lated place where they could not be reached by unau-
thorised people. TRANSFERS AND TRANSPORTATION
Do not carry loose objects in your pockets that might
fall unnoticed into open compartments. Before moving or transporting the machine, block
Wear appropriate safety clothing such as hard hat, upperstructure swing to prevent accidental move-
safety shoes and gloves, safety glasses when splin- ment.
ters or other particles may be ejected. Pay particular attention during transfer on inclines,
Wear the appropriate welder’s equipment such as dark both uphill and downhill. Keep the bucket in a posi-
safety glasses or mask, hard hat, protective clothing, tion to provide a possible anchor point into the
safety gloves and footwear always while welding or ground in case of slipping.
E485 S1-7
GENERALITIES
During transfers on inclines, both uphill and downhill, Do not lubricate the machine with the engine running.
keep the upperstructure aligned with the carriages. Do not run the engine with the air intakes open and
Do not travel across the slope. not protected. If this cannot be avoided for service
Never transfer the machine in the working site, in a reasons, place protection meshes on all intakes be-
crowded area, or near people without having at least fore servicing the engine.
one person charged with hand-signals who could guide
the Operator.
Sound the horn to inform that you are about to move off.
It is necessary to know load limits of bridges and di-
mensional limits of tunnels. Such limits must never ELECTRICAL SYSTEM
be exceeded. You should also know machine height,
width, and weight. Have a signal-man help you when Pay attention to connect connecting cables to cor-
clearances are limited. rect poles (+ to +) and (- to -) at both ends. Do not
Check distance between boom/arm and dimensional short-circuit terminals. Thoroughly follow instruc-
limits during transfer or transportation. tions given in Operation and Maintenance Instruc-
Rough terrain may cause the machine to sway and tion Manual.
roll to such an extent that boom/arm could get to con- Always move the key-start switch in the lock posi-
tact electric lines or other obstacles. Cross obstacles tion before servicing or repairing the machine.
at a right angle at low speed. Pay attention to ma- Batteries contain SULPHURIC ACID. Protect the
chine shaking when the centre of gravity overcomes eyes when working near the batteries against pos-
the obstacle. sible sprays of the acid solution. Should acid con-
Keep the bucket down at all times during transfers. tact skin, eyes, or clothes, RINSE IMMEDIATELY
Drive with the lights on and use appropriate signals IN WATER FOR AT LEAST 15 MINUTES. Immedi-
and flags. ately seek medical attention.
Get to know and respect local and national regula- Battery released gas is highly flammable. Leave
tions. the battery compartment cover open during recharg-
Consider boom/arm and upperstructure dimensions ing to improve ventilation. Never check battery
while turning. charge by placing metal objects across the posts.
Use a ramp to load the machine on a trailer. If a ramp Keep sparks or open flames away from batteries.
is not available, fabricate one using blocks. The ramp Do not smoke near the battery to prevent explo-
should be sufficiently strong to support machine sion hazard.
weight. Always load and unload on level surface. Before any maintenance or repair, make sure that
Tow the machine following the instructions contained there are no fuel or electrolyte leaks from the bat-
in the Operation and Maintenance Instruction Manual. teries. If any, correct prior to proceeding with fur-
ther work. Do not recharge batteries in confined
spaces. Ensure proper ventilation is provided to
avoid accidental explosions due to build-up of ex-
plosive gas released during charging.
ENGINE Disconnect batteries before working on the electri-
cal system or carrying out any other type of work.
Do not run the engine in closed buildings without proper
ventilation capable to remove harmful exhaust fumes.
Do not place head, body, limbs, feet, hands or fingers
near rotating fans or belts. Be especially careful near
blower fans. HYDRAULIC SYSTEM
Loosen the radiator cap very slowly to relieve system
pressure before removing it. Always top-up coolant Pressure fluid escaping from a very small hole can
level with the engine off or idling if hot. See the Op- be almost invisible and still have sufficient force to
eration and Maintenance Instruction Manual. penetrate the skin. Always check any suspected
Keep the exhaust manifold and tube free from com- pressure leaks using a piece of cardboard or wood.
bustible matters. Fit the machine with shields and Do not use hands. If injured by escaping fluid, ob-
guards when working in the presence of combustible tain medical attention immediately or serious in-
matter free in the air. fection or reaction may develop.Stop the engine
Do not refuel with the engine running, especially if and ensure pressure is relieved from all systems
hot, as this increases fire hazard in case of fuel spill- before removing side panels, housings, guards and
age. covers. See the Operation and Maintenance In-
Never attempt to check or adjust fan belt tensions struction Manual.
when the engine is running. Always use gauges of adequate capacity for pres-
Do not adjust the fuel injection pump when the ma- sure testing. Refer to the Operation and Mainte-
chine is operating. nance Instruction Manual or Repair Manual.
S1-8 E485
GENERALITIES
TOOLS ting in the driver’s seat. Sound the horn before start-
ing the machine or moving the attachment. Require
Always keep head, body, limbs, feet, hands, and fin- that nobody remain near the machine. Raise the at-
gers away from the bucket and attachments, when in tachment slowly.
the raised position. Do not use the machine to transport loose objects,
Prior to any maintenance or repair work, install all unless proper securing devices are provided.
supports necessary to this aim according to local and Never use gases other than nitrogen to charge the
national safety regulations. accumulators.
In case the attachment is to be operated for mainte- Refer to the Operation and Maintenance Instruction
nance or repair purposes, do so exclusively while sit- Manual.
E485 S2-1
SAFETY PRECAUTIONS
RECOGNISE SAFETY INFORMATION
• This is your SAFETY ALERT SYMBOL.
- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe oper-
ating practices.
S0021
UNDERSTAND SIGNAL WORDS
• In this Manual you will find the following words:

- DANGER;
- WARNING;
- CAUTION.
Referring to different hazard risks. DANGER
These words are always accompanied by the safety
alert symbol.
DANGER: Indicates an imminent hazardous situation

WARNING
which, if not avoided, will result in death or serious
injury.
CAUTION
WARNING: Indicated a potential hazardous situation
which, if not avoided, could result in death or serious
injury.
IMPORTANT
CAUTION: Indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate
injury. NOTE
IMPORTANT: Indicates a situation which, if not
avoided, may cause damage to the machine.
NOTE: Indicates an additional explanation for informa-

tion purposes.
ENVIRONMENTAL PROTECTION
• This Manual also contains this symbol accompany-

ing instructions for correct behaviour as regards
environmental protection.
S0024
S2-2 E485
SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS
• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.
• Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your NEW
HOLLAND KOBELCO Dealer in the same way
you order a spare part (be sure to detail machine
model and serial number upon ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorised personnel to S0022
operate the machine.
• Keep the machine in proper working conditions.
- Unauthorised changes to the machine may impair
function and/or safety and affect machine life.
• Safety messages in this Chapter “SAFETY PRE-
CAUTIONS”, are intended to illustrate basic safety
procedures of the machine. However, it is impossi-
ble for these safety messages to cover every
hazardous situation you may encounter. If you have
any doubts, consult your direct supervisor prior to
operating or servicing the machine.
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on hand.
- Thoroughly read and understand the label at-
tached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors, ambulance
service, hospitals and fire department posted near
the telephone.
S0023
E485 S2-3
SAFETY PRECAUTIONS
WEAR PROTECTIVE CLOTHING
• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask.
Be sure to correctly wear equipment and clothing for
the job.
- Do not take any chances. S0025
- Avoid wearing loose clothing, jewellery, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause impair-

ment or loss of hearing.
- Wear a suitable hearing protection such as ear-
muffs or earplugs to protect objectionable or un-
comfortably loud noise.
S0026
INSPECT THE MACHINE
• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.
- In the walk-around inspection, be sure to cover all

points detailed in the Chapter "MAINTENANCE",
paragraph "EXTERNAL VISUAL INSPECTION"
of the OPERATION AND MAINTENANCE IN- S0027
STRUCTION MANUAL.
S2-4 E485
SAFETY PRECAUTIONS
USE HAND HOLDS AND STEPS
• Falling is one of the major causes of personal injury.
- When you get on and off the machine, always face

the machine and maintain a three-point contact
with the steps and handrails.
- Do not use any control as a handhold.
- Never jump off the machine. Never get on and off

a moving machine.
S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.
ADJUST THE OPERATOR'S SEAT
• A seat poorly adjusted for operator or work require-

ments may quickly fatigue the operator leading to
improper operations.
- The seat should be adjusted whenever machine

operator changes.
- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.
- If not, move the seat fore and aft, and check again.
S0029
E485 S2-5
SAFETY PRECAUTIONS
FASTEN SEAT BELT
• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the overturning
machine resulting in serious injury or even death.
- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn, replace
the seat belt or component before operating the
machine.
S0030
- Be sure to remain seated with the seat belt
securely fastened at all times when the machine
is in operation to minimise injury hazard in case of
accident.
- After a significant accident, replace the seat belts

even though they do not look damaged.
MOVE AND OPERATE

MACHINE SAFELY
• Bystanders can be run over.
- Pay the utmost attention not to run over bystand-

ers.
- Be sure and aware of the location of bystanders

before moving, swinging or operating the machine.
- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.
- When operating, swinging, or moving the machine S0031
in a congested area use a signal man.
- Co-ordinate hand signals before starting the

machine.
S2-6 E485
SAFETY PRECAUTIONS
OPERATE ONLY FROM

THE DRIVER'S SEAT
• Inappropriate engine starting procedures may cause

the machine unexpected movement, possibly
resulting in serious injury and even death.
- Start the engine only from the operator’s seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across starter
motor terminals.
- Before starting the engine, ensure that all control
levers are in the neutral position.
S0032
KEEP RIDERS OFF THE MACHINE
• Riders on the machine are subject to injuries such as

being struck by foreign objects and being thrown off
the machine.
- Only machine operator is allowed on the machine.

Keep riders off.
- Riders also obstruct the operator’s visibility,

resulting in the machine being operated unsafely.
S0033
CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN
• Incorrect travel controls operation may result in

serious injury and even death.
- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front of
the cab, the machine will move reverse when travel
controls are moved towards cab front.
S0037
E485 S2-7
SAFETY PRECAUTIONS
AVOID INJURY FROM BACK-OVER

AND SWING ACCIDENTS
• If any person is present near the machine when

backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- Keep the travel alarm in working condition (if

equipped).
- ALWAYS BE ALERT FOR BYSTANDERS S0042

MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
- Use hand signals, which conform to your local

regulations, when work conditions require a signal
person.
S0043
- No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.
- Keep windows, mirrors, and lights clean and in

good condition.
- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.
- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE IN-
STRUCTION MANUAL.
S2-8 E485
SAFETY PRECAUTIONS
DRIVE MACHINE SAFELY
• Before starting the machine carefully read the OP-

ERATION AND MAINTENANCE INSTRUCTION
MANUAL. (Refer to the OPERATING INSTRUC-
TIONS chapter).
• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.
- Pushing down on the front of the travel pedals or

S0038
pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND MAINTENANCE INSTRUCTION MANUAL).
• Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.
- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.
- If machine starts to skid or becomes unstable,

lower the bucket immediately.
S0039
- Traveling across the face of a slope may cause

the machine to skid or to overturn. When travelling
(ascending/descending) on a slope, be sure to
point the tracks uphill/downhill.
- Turning on an incline may cause the machine to tip

over. If turning on an incline is absolutely unavoid-
able, do so at a place where the slope is gentle and S0004
the surface is firm.
- When operating on a grade and the fuel reserve

indicator light lights, immediately refuel.
WRONG
S0005
E485 S2-9
SAFETY PRECAUTIONS
AVOID OVERTURNING
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.
• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to the
machine.
- Reduce machine operating speed to avoid tipping
or slipping.
- Avoid changing direction when travelling on
S0002
grades.
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when swinging
loads.
• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.
S0047
PARK MACHINE SAFELY
• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
- Lock all access doors and compartments. S0049
S2-10 E485
SAFETY PRECAUTIONS
AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT
• Death or serious injury may result if you attempt to

get on or off a moving machine.
• To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
S0040
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.
S0041
PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES
• For jobs involving several machines, provide signals

commonly known by all personnel involved. Also,
appoint a signal person to co-ordinate the job site.
Make sure that all personnel obey the signal per-
son’s directions.
S0036
E485 S2-11
SAFETY PRECAUTIONS
INVESTIGATE JOB SITE

BEFORE HAND
• When working at the edge of an excavation or on a

road shoulder, the machine could overturn, possibly
resulting in serious injury or death.
- Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from overturning and prevent the ground,
stockpiles, or banks from collapsing.
- Make a work plan. Use machines appropriate to
the work and job site.
- Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
- When working on an incline or road shoulder, S0034
employ a signal person as required.
Confirm that your machine is equipped with a
F.O.P.S. (Falling Object Protective Structure)
cab before working in areas where there is the
possibility of falling stones or landslides.
- When footing is weak, reinforce the ground before
starting the work.
- When working on frozen ground, be extremely
alert. As ambient temperature rises, footing be-
comes loose and slipped.
PROTECT AGAINST FALLING STONES

AND LANDSLIDES
• Confirm that your machine is equipped with a

F.O.P.S. (Falling Object Protective Structure) cab
before working in areas where there is the possibility
of falling stones.
S0035
S2-12 E485
SAFETY PRECAUTIONS
DIG WITH CAUTION
• Accidental severing of underground cables or gas

lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
- Before digging, check the location of cables, gas
lines, and water lines.
- Keep the minimum distance required by law from
cables, gas lines, and water lines. If a fiber optic
cable should be accidentally severed, do not look
into the end. Doing so may result in serious eye
injury.
- Contact local authorities and/or the utility compa-
nies directly (electric power, gas, telephone, wa-
ter, sewers, telecommunications, etc.) to obtain
information about underground utility lines. S0009
OPERATE WITH CAUTION
• If the front attachment or any other part of the

machine hits against an overhead obstacle, such as
a bridge, both the machine and the overhead
obstacle will be damaged, and personal injury may
results as well.
- Take care to avoid hitting overhead obstacles with
the boom or arm.
S0008
AVOID ELECTRIC LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines. L
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length (L).
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.
S0205
E485 S2-13
SAFETY PRECAUTIONS
KEEP PERSONNEL CLEAR FROM

WORKING AREA
• A person may be hit severely by the swinging front

attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
- Keep all persons clear from the area of operation

and machine movement.
- Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.
S0044
NEVER MOVE THE BUCKET OVER

ANY ONE
• Never lift, move, or swing bucket above anyone or a

truck cab. Serious injury or machine damage may
result due to bucket load spill or due to collision with
the bucket.
S0045
AVOID UNDERCUTTING
• In order to retreat from the edge of an excavation if

the footing should collapse, always position the
undercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.
- If the footing starts to collapse and if sufficient

retreat is not possible, do not panic. Often, the
machine can be secured by lowering the front
attachment, in such cases.
S0011
S2-14 E485
SAFETY PRECAUTIONS
NEVER UNDERCUT A HIGH BANK
• The edges could collapse or a land slide could occur

causing serious injury or death.
S0048
SAFETY LOADS MOVING
• The excavator is no lifting and transportation means,

therefore it should not be used to position loads
accurately. Should it be exceptionally used to lift and
lay building components, special caution must be
taken as follows:
- The machine must be equipped without failure with
the appropriate variant supplied, upon request, by
NEW HOLLAND KOBELCO. Also, totally comply
with the safety precautions for the operation of the
excavator as a lifting equipment.
- Secure the loads to be raised using cables or
chains fastened with appropriate hooking mecha-
nisms.
- Never hook cables or chains to the bucket teeth.
- Nobody should be allowed to remain under the
raised load or within the excavator operating range
for any reason whatever.
- Never exceed specified loading capacity. Incor-
rect fastening of slings or chains may cause
boom/arm failure or failure of the lifting means with
consequent bodily injuries and even death.
S0165
- Always ensure that slings and chains used for
lifting are adequate to the load and in good condi-
tion.
- All loading capacities are referred to the ma-
chine on a level surface and should be disre-
garded when working on a slope.
E485 S2-15
SAFETY PRECAUTIONS
SAFETY TRANSPORTING
• The danger of tipping is present when loading/

unloading the machine onto/from a truck or trailer
bed.
- Be sure to observe local regulations when
transporting the machine on public roads.
- Provide an appropriate truck or trailer for
transporting the machine.
• Take the following precautions when loading/

unloading the machine:
1. Select firm level ground.
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when loading/ S0052
unloading the machine.

4. Always turn the auto-idle (A/I) switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintention-
al operation of a control lever.
5. Always select the slow speed mode with the
travel speed selector. In the high speed mode,
travel speed may automatically increase.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify travelling direction, and begin to
drive again.
7. Do not operate any levers besides the travel
levers when driving up or down the ramp.
8. The top end of the ramp where it meets the
flatbed is a sudden jolt. Take care when
traveling over it.
9. Prevent possible injury from machine tipping
while the upperstructure is rotating.
10. Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11. Securely fasten machine frame using chains or
cables. Refer to “TRANSPORT” chapter in the
OPERATION AND MAINTENANCE IN-
STRUCTION MANUAL for details.
S2-16 E485
SAFETY PRECAUTIONS
SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
S0053
6. Remove the ignition key from the start switch.
7. Apply the "Maintenance in progress" tag .
This tag can be applied o the left-hand control
lever, safety lever or cab door.
8. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
9. Let the engine cool down.
- Do not leave the machine unattended if servicing

requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or S0054
replace as necessary.
Refer to the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
- Keep all components in good condition and properly
install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable (-) from the battery
before carry out any work on the electrical system or
arc-welding on the machine.
E485 S2-17
SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
- Before performing any work on the machine,

attach a maintenance in progress tag. This tag can
be applied o the left-hand control lever, safety
lever or cab door.
S0055
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or attach-
ment, securely support the machine or attach-
ment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load.
- Do not work under a machine that is supported S0054
solely by a jack.
STAY CLEAR OF MOVING PARTS
• Entanglements in moving parts can cause serious

injury.
• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair do
not become entangled when working near rotating
parts.
S0056
S2-18 E485
SAFETY PRECAUTIONS
DISPOSE OF WASTE IN THE

APPROPRIATE MANNER
• Waste improperly disposed of represents a danger

for the envinronment. Potentially dangerous waste
used on the NEW HOLLAND KOBELCO excava-
tors includes lubricants, fuel, coolant, brake fluid,
filters and batteries.
- Used sealed containers when discharging fluids.

Do not use containers for food or beverages which
may induce drinking.
- Do not spill waste over the ground, into drains, or

water beds.
S0064
- Obtain information about the correct methods to

recycle or dispose of waste from local Authorities,
collection centres or your Dealer.
WORK IN A CLEAN AREA
• Before starting an operation, clean the working area.

Clear the area from all the objects that can be
dangerous for mechanics or people in the working
area.
S0166
PROPERLY LIGHT THE WORKING AREA
• Properly and safely light the working area.

- Use safe portable lamps in order to work inside
and under the machine.
- Make sure that the lamp is shielded by a cage;
the incandescent filament of a lamp, accidentally
broken, can cause fuel or oil fire.
S0167
E485 S2-19
SAFETY PRECAUTIONS
REGULARLY WASH THE MACHINE
• Remove all the traces of grease, oil and deposits,

in order to avoid people accidents or damages to
things.
- Do not spray water or steam in the cab.
S0153
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

breakers and blades can fall and cause serious injury
or death.
- Securely store attachments and implements to
prevent falling.
- Keep bystanders away from storage areas.
S0058
PREVENT ACID SCALDS

• The sulphuric acid, contained in the battery, is
poisonous.
It is strong enough to scald the skin, corrode clothes
and cause blindness, if it is sprayed into the eyes.
To avoid dangers:
- Fill the batteries in airy areas.
- Wear eye protections and rubber gloves.
- Avoid breathing the electrolyte vapours when
topping up.
- Avoid spilling or dripping the electrolyte.
- Use proper emergency starting techniques.
If you are touched with acid sprays:
- Rinse your skin well with water.
- Put on your skin sodium bicarbonate or clay to S0168
help the acid neutralization.
- Rinse your eyes with water for 10-15 minutes.
- Immediately see a doctor.
If you have swallowed the acid:
- Drink a big quantity of water or milk, swallow milk
of magnesia, scrabbled ‘eggs or vegetal oil.
- Immediately see a doctor.
S2-20 E485
SAFETY PRECAUTIONS
STARTING THE ENGINE WITH

BOOSTER BATTERIES
• Battery gas may explode causing serious damages

and injuries.
- If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed in the chapter “OPERATING
INSTRUCTIONS” of the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.
- The operator should be sitting in the driver’s seat
to keep the machine under control when the engine
starts. Starting the engine with booster batteries
is a two man operation.
S0001
- Do not use batteries that have been stored in the
cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may cause
the batteries to explode or machine to move
unexpectedly.
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
- Keep sparks, lighted matches, and flames away

from the top of battery.
- Never check battery charge by placing a metal

object across the posts. Use a voltmeter or
hydrometer.
- Do not charge a frozen battery; it may explode.

Warm battery to 16 °C.
• Battery electrolyte is poisonous. If the battery S0001

should explode, battery electrolyte may be splashed
into eyes, possibly resulting in blindness.
- Be sure to wear eye protection when checking

electrolyte specific gravity.
E485 S2-21
SAFETY PRECAUTIONS
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
- To prevent possible injury from hot spraying

water. Do not remove the radiator cap until the
engine is cool. When opening, turn the cap slowly
to the stop. Allow all pressure to be released
before removing the cap.
S0019
- The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation.
The engine, hoses, lines and other parts become
hot as well.
- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.
S0059
KEEP CLEAN THE MACHINE
Keep clean the engine compartment, radiator,

batteries, hydraulic pipes, fuel tank and operator's
position.
The engine compartment temperature can quickly
rise, after stopping the engine.
IN THESE CASES, BE CAREFUL TO POSSIBLE
FIRES.
Open the access doors in order to quicken the engine
cooling process and clean the compartment.
S0177
S2-22 E485
SAFETY PRECAUTIONS
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
SA0016
- Tighten all connections before applying pressure.
- Search for leaks with a piece of cardboard; take

care to protect hands and body from high-pressure
fluids. Wear a face shield or goggles for eye
protection.
- In an accident occurs, see a doctor familiar with

SA0017
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA0018
PREVENT PARTS FROM FLYING OFF
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
- NEVER attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.

S0178
- As pieces may fly off, be sure to keep body and
face away from air release plug to avoid injury.
reduction gear oil is hot. Wait for gear oil to cool
down, then gradually loosen the air release plug to
release pressure.
E485 S2-23
SAFETY PRECAUTIONS
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
- Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.
S0046
HANDLE FLUIDS SAFELY - AVOID

FIRES
• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur, possi-
bly resulting in serious injury or death.
- Do not refuel the machine while smoking or when

near open flame or sparks.
- Always stop the engine before refuelling the ma-
chine.
- Fill the tank outdoors.
S0050
• All fuels, most lubrificants, and some antifreeze

fluids are flammable.
- Store flammable fluids well away from fire haz-

ards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.
S0051
S2-24 E485
SAFETY PRECAUTIONS
PREVENT FIRES
• Check for Oil Leaks:
- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil- S0051
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
• Check for Shorts circuits which could cause fires:
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10) hour
operation for missing or damaged terminal caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc.
• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
• Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position to
confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
• Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the machine.
E485 S2-25
SAFETY PRECAUTIONS
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
- Stop the engine by turning the key-start switch to

the OFF position if there is time.
- Use a fire extinguisher if there is time.
- Exit the machine.
S0060
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
- If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air into
the area.
S0061
USE APPROPRIATE TOOLS
• Use tools appropriate for the job to be performed.
- Inappropriate tools, parts and procedures might

generate dangerous conditions.
- Use tools of correct size to tighten or loosening

securing elements, in order to avoid injuries
caused by a wrench getting out of control.
- Do not use U.S. Standard or British Standard tools

on metric fasteners and vice versa.
• Use only FIAT KOBELCO genuine spare parts

(please refer to the PARTS CATALOG). S0120
S2-26 E485
SAFETY PRECAUTIONS
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials when welding, soldering, etc.
AVOID APPLYING HEAT TO LINES

S0062
CONTAINING FLAMMABLE FLUIDS
- Do not weld or flame cut pipes or tubes that contain

flammable fluids.
- Clean them thoroughly with non-flammable solvent
before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING

OR HEATING
• Hazardous fumes can be generated when paints is

heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove S0063
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
E485 S3-1
SAFETY PLATES
BEH version
M0533
BEH version
M0534
1 - Attachment operating range safety plate

2 - Track adjuster plate
S3-2 E485
SAFETY PLATES
5 10 4
6
M0538
13
11
12
M0539
3 - Counterweight operating range safety plate 9- Controls lock/unlock plate (safety lever)
4 - Read-your-manual plate 10 - Biodegradable hydraulic oil level check plate (opt.)
5 - Boom and arm movement warning plate 11 - Burns warning plate
6 - Open windscreen warning plate (inside the cab) 12 - Safety distance plate
7 - Tag indicating maintenance in progress 13 - No-stepping warning plate
8 - Engine hood warning plate
E485 S3-3
SAFETY PLATES
1 - Attachment operating range safety plate
Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the attachments.
Sound the horn.
Yellow background
Black border and icons
S0074
2 - Track adjuster plate
It shows that obligation is made to consult the

Operation and Maintenance Instruction Manual
prior to acting on the track adjust valve.
Danger of severe injuries.
Yellow background
S0076
3 - Counterweight operating range safety plate
Ensure that any person near the working site is

outside the machine operating range before
starting the machine or operating the attachments.
Sound the horn.
Yellow background
S0075
S3-4 E485
SAFETY PLATES
4 - Read-your-manual plate
It is positioned in the cab to recommend to care-

fully read the Operation and Maintenance Instruc-
tion Manual prior to starting, operating, servicing,
refuelling or carrying out any other work on the
machine.
Yellow background
S0077
5 - Boom and arm movement warning plate
It indicates a danger represented by a contact

between bucket and boom.
Pay special attention as no stops are provided to
prevent this problem.
Yellow background
M0537
6 - Open windscreen warning plate (inside the

cab)
It indicates the risk of injuries deriving from the

windscreen not being locked or being improperly
locked in the open position.
Yellow background
S0079
E485 S3-5
SAFETY PLATES
7 - Tag indicating maintenance in progress
Maintenance staff is obliged to apply the tag that

indicates that the machine is not fully efficient
and warns about maintenance staff being located
in not visible positions. This tag should be applied
to the left-hand control lever, safety lever or cab
door.
Yellow background
S0080
8 - Engine hood warning plate
It highlights the obligation to stop the engine be-

fore opening engine hood.
Danger of severe injuries following the presence
of rotating parts such as fan, pulleys, and belts.
Yellow background
S0081
9 - Controls lock/unlock plate (safety lever)
It shows the position that the safety lever can

assume when the engine is running.
When the operator is about to leave the cab with
the engine running, even if for a short time, he
must move the safety lever to the LOCK posi-
LOCK
tion. Controls are disabled and therefore no acci-
dental machine or attachment movement is pos-
sible. S0083
White background
S3-6 E485
SAFETY PLATES
10 - Biodegradable hydraulic oil level check plate

(optional)
It shows that the machine is filled with

biodegradable hydraulic oil and that it is
necessary to consult this manual for correct
practices (oil level check, sampling, and change).
Yellow background
S0088
11 - Burns danger plate
It indicates that a burns danger exists, since the

zone is characterised by high temperature.
Background: yellow
S0095
12 - Safety distance plate
It instructs to keep at a safe distance from a zone

dangerous for personal safety.
Background: yellow
S0096
13 - No-stepping warning plate
It instructs not to step on the zone where this decal

is attached.
Background: yellow
Cross: red
S0097
OPERATIONAL PRINCIPLE
R0077
OPERATIONAL PRINCIPLE E485
SECTION AND GROUP CONTENTS
Section 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Section 2 SYSTEM
Group 1 Mechatro Control System
Group 2 Mechatro Controller
Group 3 Hydraulic System
Group 4 Electrical System
Section 3 COMPONENT OPERATION

Group 1 Hydraulic Pump Assy
Group 2 Pilot Valve
Group 3 Control Valve
Group 4 Swing Device
Group 5 Travel Device
Group 6 Swing Joint
Group 7 Cylinders
Group 8 Air Conditioner
Group 9 Attachment Automatic Lubrication System
SECTION 1 E485
GENERAL
CONTENTS
Group 1 - Specifications Group 2 - Component Layout
Transporting Dimensions Main Components ................................... T1-2-1

(Monoblock Version) ................................ T1-1-1 Electrical System
Digging Data (Overall System) ..................................... T1-2-2
(Monoblock Version) ................................ T1-1-2 Electrical System (Control Cab,
Transporting Dimensions Instrument and Switches) ....................... T1-2-3
(BEH Version) ......................................... T1-1-3 Electrical System
Digging Data (Cluster Gauge and Indicator Lights) ....... T1-2-4
(BEH Version) ......................................... T1-1-4 Electrical System (Fuse Box,
Excavator Performance ........................... T1-1-5 Mechatro Controller and Relays) ............. T1-2-5
Engine Data ............................................ T1-1-5 Electrical System
Hydraulic Components ............................ T1-1-6 (Fuse Box) .............................................. T1-2-6
Electrical System
(Batteries, Fuse Link, Relays) ................. T1-2-7
Electrical System
(Engine Electrical Components) .............. T1-2-8
Electrical System (Hydraulic
System Electrical Components) .............. T1-2-9
Electrical System
(Lights, Horn) ........................................ T1-2-10
E485 T1-1-1
SPECIFICATIONS
TRANSPORTING DIMENSIONS
(Monoblock version)
M0695
VERSIONS A B C D E F G H I L
(1) 12 175 (1) 3 730
E485LCH 4 400 5 470 1 394 3 700 (2) 12 110 (2) 3 590 3 000 3 310 1 203 775
(3) 12 120 (3) 3 610
Arm: (Dimensions in mm)

(1) 2 900 mm
(2) 3 450 mm
(3) 4 040 mm
E485LCH
M Track shoe width (mm) 600 700 800 900
N Width (reduced width for transportation) (mm) 2 990 3 090 3 190 3 290
O Frame width (mm) 3 200 3 200 3 200 3 200
N' Width (width in operational position) (mm) 3 490 3 590 3 690 3 790
Working weight (kg) 48 600 49 150 49 700 50 250
Specific ground pressure (bar) 0.90 0.78 0.70 0.62
T1-1-2 E485
SPECIFICATIONS
DIGGING DATA
(Monoblock version)
M0520
(Dimensions in mm)
Arm 2 900 3 450 4 040

A 11 553 12 079 12 577
A’ 11 308 11 845 12 353
B 7 226 7 770 8 366
B’ 7 061 7 626 8 237
C 10 707 10 969 11 032
D 7 531 7 767 7 884
E 5 237 5 173 5 187
F 4 701 4 230 3 706
G 7 777 8 246 8 897
E485 T1-1-3
SPECIFICATIONS
TRANSPORTING DIMENSIONS
(BEH version)
M0696
VERSIONS A B C D E F G H I L
E485BEH 4 400 5 470 1 394 3 700 11 500 3 980 3 000 3 310 1 203 775
(Dimensions in mm)
E485BEH
M Track shoe width (mm) 600 700 800 900
N Width (reduced width for transportation) (mm) 2 990 3 090 3 190 3 290
O Frame width (mm) 3 200 3 200 3 200 3 200
N' Width (width in operational position) (mm) 3 490 3 590 3 690 3 790
Working weight (kg) 47 950 48 500 49 050 49 600
Specific ground pressure (bar) 0.89 0.77 0.68 0.61
T1-1-4 E485
SPECIFICATIONS
DIGGING DATA
(BEH version)
M0523
(Dimensions in mm)
Arm 2 600
A 10 633
A’ 10 366
B 6 343
B’ 6 171
C 9 997
D 6 856
E 4 721
F 4 176
G 7 292
E485 T1-1-5
SPECIFICATIONS
EXCAVATOR PERFORMANCE
GRADEABILITY ......................................................................................................................................... 70%
TRAVEL SPEED
Excavator
E485
Speed
First speed 3.5 km/h
Second speed 5.6 km/h
ENGINE DATA
MAIN SPECIFICATIONS
- Manufacturer ISUZU
- Model AA-6SD1XQY
Four cycle, water cooled vertical, in-line-overhead camshaft,
- Type
direct injection
- Number of cylinder 6 in-line
- Bore 120 mm
- Stroke 145 mm
- Total displacement 9 839 cm3
- Compression ratio 16.8:1
- Net power at flywheel 235.4 ± 3.77 kW
-1
- Torque (at 1600 min ) 1275 Nm
- Engine idle at no-load 1050 ± 25 min-1
INJECTION PUMP
- Type ........................................................................................................................................... In-line Bosch
- Injection order ................................................................................................................................. 1-5-3-6-2-4
- Injection nozzle opening pressure ..................................................................................... 1st stage: 17.7 MPa
2st stage: 22.1 MPa
- Governor .......................................................................... Variable speed, electrically controlled type (Red IV)
BATTERY
- Voltage - Capacity ............................................................................................................... 2 x 12 V - 160 Ah
STARTER MOTOR
- Voltage - Output .......................................................................................................................... 24V - 5.5 kW
ALTERNATOR
- Voltage - Output ............................................................................................................................... 28V - 50A
T1-1-6 E485
SPECIFICATIONS
HYDRAULIC COMPONENTS
HYDRAULIC PUMP
Item Main pump Gear pump for pilot

Pump model K5V200DPH1BDR-9TAW-V ZX15LSLZ2-07D
Gear
Drive Driven
(Theoretic ratio
Max. displacement capacity side side
values) 32:31
cm3
190 184 15
Rated min-1 1950 ←

Revolution (Clockwise seen
Hi idle from shaft end) 2000 or less ←
Rated 31.4
Max. Pressure MPa 5.0
ATT boost 34.3
Max. flow L/min 370 × 2 29.3
Max. input Horse Power kW 236 3.1
Max. input torque N·m 1153 14.7
Model KR3D-9TAW-V
Regulator Control function Electric flow control, total horsepower control,
powershift control at back-up and positive
flow control
Others With solenoid proportional reducing valve

(KDRDE5K-31/30C50-102)
Mass kg 260
NOTE - The max. input power and the max. input torque of the main pump include those of the gear pump.
CONTROL VALVE
Item Data
Model UY36-110
Max. flow L/min 370 × 2
Main relief valve set pressure MPa 31.4 at 360 L/min
When power boost pressure 34.3 at 320 L/min
Over load relief valve set pressure MPa
Boom H, Bucket H, Arm R 36.3 at 30 L/min
Boom R, Bucket R, Arm H 34.8 at 30 L/min
OPT-1 H&R 34.8 at 30 L/min
E485 T1-1-7
SPECIFICATIONS
PILOT VALVE
FRONT ATTACHMENT TRAVEL
Model PV48K1126A 07291-00000
Primary pressure 5.0 MPa 4.9 MPa
Secondary pressure 0.6 ~ 3.2 MPa 0.54 ~ 2.35 MPa
Rated flow 20 L/min 10 L/min
Mass Approx. 2 kg Approx. 11 kg
SWING MOTORS RIGHT HAND LEFT HAND
Model MFC 160-063 MFC 160-062
Type Swash-plate type, fixed-displacement plunger motor
Displacement cm3 151

Hydraulic motor
Working pressure MPa 25
Max. flow L/min 253
Braking torque Nm 685~891
Release pressure MPa 3.1
Relief set pressure MPa 25
Mass kg 53
Speed reduction type Planetary 2-stage
Reduction ratio 16.8
Lubicate oil Gear oil SAE90 (API class GL–4 grade)

Reduction unit
Lubicate oil volume L 15.3
Grease Extreme pressure multipurpose grease
Grease volume A small amount
Mass kg 241
Total mass kg 294

T1-1-8 E485
SPECIFICATIONS
TRAVEL DEVICE
Item Data
Reduction gear unit Epicycloidal, three-stage planetary type
Model 715C3K
Reduction gear ratio 1:62.4
Travel motor Two speed, axial piston swash plate type
Model MSF340VPEL6
Max 271.5 cm3/rev

Displacement
Min 165.3 cm3/rev
Rated flow 370 L/min
low speed 92 474 Nm

Theoretical output torque
high speed 56 295 Nm
Parking brake torque 1120 Nm
Release pressure of parking brake 1.8 MPa
Relief valve set pressure cracking 36.8 MPa
Mass (with oil) 600 kg
CYLINDERS
Center distance
Cylinder bore / of pins
Use Stroke Cushion Dry Mass
Rod Dia. Full extend B /
Full retract A
mm mm mm kg
With cushion
Boom Ø 170 / Ø 115 1 590 3 790 / 2 200 415
on rod side
With cushion
Arm Ø 190 / Ø 130 1 970 4 600 / 2 630 591
on both sides
Bucket Ø 170 / Ø 120 1 300 3 325 / 2 025 With cushion 416

on rod side
E485 T1-2-1
COMPONENT LAYOUT
MAIN COMPONENTS
10
11
3 12
13
2 8
14
9
15
1
29
16
28
27 17
26
18
25
24 19
23
22 20
21
R2222
1 - Bucket 11 - Swing motors 21 - Track link

2 - Bucket link 12 - Fuel tank 22 - Batteries
3 - Idler link 13 - Hydraulic oil tank 23 - Upper roller
4 - Bucket cylinder 14 - Control valve 24 - Track guide
5 - Arm 15 - Engine muffler 25 - Lower roller
6 - Arm cylinder 16 - Hydraulic pump 26 - Air cleaner
7 - Boom 17 - Engine 27 - Crawler adjuster
8 - Boom cylinder 18 - Counterweight 28 - Front idler
9 - Cab 19 - Engine radiator 29 - Shoe plate
10 - Swivel joint 20 - Travel motor
T1-2-2 E485
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Overall system)
D
F
R3681
A - Control cab D - Batteries

B - Fuse Box, Mechatro controller, engine controller and relays E - Engine electrical components
C - Battery relay, Fuse link and solenoid valve F - Hydraulic system electrical components
assembly
E485 T1-2-3
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Control cab, Instrument and switches)
12
1
18 3
14
19
4
11 15
16 5
17 6
7
8
13 9
10
R2223
1- Cluster gauge (C-2) 11 - Air conditioning switch (SW-13)

2- Power boost pushbutton 12 - Swing parking release switch (SW-4)
3- Hand control accelerator (SE-16) 13 - Hydraulic Pressure release switch (SW-50)
4- Working light switch (SW-20) 14 - Key switch (SW-1)
5- Cab working light switch (SW-26) 15 - Cigarette lighter (E-14)
6- Load alarm select switch (SW-12) 16 - Diagnostic engine led (L-13)
7- Quick coupler operation switch (SW-40) 17 - Diagnostic engine request switch (SW-46)
8- Heavy lift switch (SW-35) 18 - Supplementary greasing switch (SW-57)
9- Tuner (E-7) 19 - Supplementary greasing led (L-57)
10 - Socket 12 V D.C. (E-23)
T1-2-4 E485
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Cluster gauge and indicator lights)
1
3
13
5
12
6
11
10 9 8 7
R0445
1 - Engine coolant temperature indicator 8 - Conflux select switch

2 - Working Mode Indicators 9 - Buzzer stop switch
3 - Fuel meter 10 - Auto Idle switch
4 - Display 11 - Travel speed select
5 - Washer switch 12 - Led
6 - Wiper switch 13 - Display select switch
7 - MODE switch
E485 T1-2-5
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Fuse box, Mechatro controller and relays)
8 9 11 12
5
4
R2224
1 - Mechatro controller (C-1) 8 - Horn relay (R-5)

2 - Fuse box (E-4) 9 - Engine stop relay (R-28)
3 - Engine controller (C-3) 11 - Rotary Bucket (Extra) Left relay (R-27) (opt.)
4 - Swing parking release switch (SW-4) 12 - Rotary Bucket (Extra) Right relay (R-26) (opt.)
5 - Wiper relay assy (R-7)
T1-2-6 E485
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Fuse Box)
FUSES IN THE BOX
PROTECTED Value
Fuse Label
CIRCUIT (A)
MECHATRO Mechatro
1 20
CONTROLLER controller
2 RELAY Relay 10
ENGINE
3 Engine controller 10
CONTROLLER
Converter
4 CONVERTER (Tuner-Soket 12 V) 10
5 HORN Horn 10
CIGARETTE Cigarette
6 10
LIGHTER Lighter
CONTROLLER Mechatro
7 10
BACK UP Controller Back up
8 FUEL SUPPLY Fuel supply 20

PUMP pump
9 ROOM LIGHT Room Light 10
10 KEY SWITCH Key Switch 20
ENGINE
11 Engine Controller 10
CONTROLLER
12 AUTO GREASE Auto Grease 10
CLUSTER Cluster Gauge

13 10
GAUGE
WIPER
14 Wiper Washer 20
WASHER
15 SOLENOID Solenoid Valve 10
WORKING Working Light

16 20
LIGHT
OPTIONAL Optional Working

17 WORKING 20
Light Room
LIGHT
AIR
18 Air Conditioner 20
CONDITIONER
AIR
Air Conditioner
19 CONDITIONER 20
Heater
HEATER
20 RESERVE Opt 24 V 20 R2225

E485 T1-2-7
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Batteries, Fuse link, Relays)
5 B L
1
4
3
2
R3682
FUSES IN THE AIR CLEANER COMPARTMENT

Fuse Protected Value
Decal N° circuit (A)
Supply
FUSE 1 Fuses (12-20) 60
FUSE 2 Alternator 60
BOX B
Engine
FUSE 3 Controller 30
Mechatro
FUSE 4 Controller 30
Glow
FUSE 5 Relay 30
Supply
FUSE 6 Fuses (7-10) 60
1 - Battery relay (R-1) 5 - Safety relay (R-4)

2 - Fuse link 6 60 A (E-27) 6 - Glow relay (R-6)
3 - Fuse Link 5 30 A (E-28) 7 - Batteries (E-1)
4 - Box B
T1-2-8 E485
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Engine electrical components)
15 3 4
16 2 8
6 5
7
13
14
12
10
11
R3683
1 - Air filter restriction switch (SW-8) 9 - To load momentum alarm switch (SW-39)
2 - Engine coolante level switch (SW-23) 10 - Engine oil level switch
3 - Fuel supply pump 11 - Fuel filter
4 - Hydraulic oil level switch (SW-25) 12 - Oil dipstick
5 - Engine revolution sensor 13 - Q-ADJ resistor
6 - Engine revolution sensor for back-up 14 - Oil drain-plug
7 - Earth cable 15 - Fuel level sensor
8 - Starter motor 16 - Boost sensor
E485 T1-2-9
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Hydraulic System electrical components)
27 26
2 3
28
25
24
23
22
21
20
4
19
18
17
16
14 11 10 9 8 7
15 6
12
5
R3684
2 - Pump P2 proportional solenoid valve (PSV-P2) 16 - P1 Opt. sensor valve (SE-20)

3 - Pump P1 proportional solenoid valve (PSV-P1) 17 - Travel right sensor (SE-9)
4 - Swing sensor (SE-5) 18 - Travel left sensor (SE-10)
5 - Operating lever lock solenoid valve (SV-4) 19 - P2 Opt. sensor valve (SE-11)
6 - Power boost solenoid valve (SV-2) 20 - Bucket digging sensor (SE-1)
7 - P2 By-pass cut proportional solenoid valve (PSV-B) 21 - Bucket dump sensor (SE-2)
8 - Travel priority proportional solenoid valve (PSV-C) 22 - Boom raising sensor (SE-3)
9 - P1 By-pass cut proportional solenoid valve (PSV-D) 23 - Boom lowering sensor (SE-4)
10 - Arm variable re-circulation proportional solenoid valve 24 - Arm in sensor (SE-7)
(PSV-A) 25 - Arm out sensor (SE-8)
11 - Two speed select solenoid valve (SV-3) 26 - Pump P1 sensor (SE-22)
12 - Swing parking brake solenoid valve (SV-1) 27 - Pump P2 sensor (SE-23)
14 - Rotary Bucket (Extra) solenoid valve (A) (SV-16) (opt) 28 - Press sensor swing (SE-5)
15 - Rotary Bucket (Extra) solenoid valve (B) (SV-15) (opt)
T1-2-10 E485
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Lights, Horn)
3
R3685
1 - Frame Working light (L-2) 3 - Engine room light (L-12)

2 - Boom Working lght (L-1) 4 - Horn
SECTION 2 E485
SYSTEM
CONTENTS
Group 1 - Mechatro Control System Group 3 - Hydraulic Circuit
Outline .................................................. T2-1-1 Summary .............................................. T2-3-1

Bucket Conflux Control ......................... T2-1-4 Neutral Circuit ....................................... T2-3-3
Conflux Control for Boom up ................. T2-1-6 Travel Circuit ......................................... T2-3-6
Recirculation Control at Light Load Bucket Circuit ....................................... T2-3-8
Arm in ................................................... T2-1-8 Boom Circuit ......................................... T2-3-12
Arm in Recirculation Cut and Conflux Swing Circuit ......................................... T2-3-16
Control .................................................. T2-1-10
Arm Circuit ............................................ T2-3-18
Arm out Conflux Control ........................ T2-1-12
Combined Operation ............................. T2-3-24
Travel Straight Control ........................... T2-1-14
Pressure Drain (releasing) Circuit .......... T2-3-28
Swing Priority Control ............................ T2-1-16
Crusher & Breaker Circuit ..................... T2-3-30
Pressure Draining (releasing)
Control .................................................. T2-1-18
Group 2 - Mechatro Controller Group 4 - Electrical System
Summary of Mechatro Controller .......... T2-2-1 Outline .................................................. T2-4-1

Self Diagnosis Display Function ............ T2-2-7 Electric Power Circuit
(Key switch in OFF position) ................. T2-4-2
Service Diagnosis ................................. T2-2-8
Accessory Circuit
Trouble History Diagnosis ...................... T2-2-10
(Key switch in ACC position) ................. T2-4-4
How to Correct the Cumulative
Electric Power Circuit
Time ..................................................... T2-2-12
(Key switch in ON position) ................... T2-4-6
Contrast of Display Adjusting
Starting Circuit
Procedure ............................................. T2-2-13
(Key switch in START position) ............. T2-4-8
Mechatro Control Equipment ................. T2-2-14
Charging Circuit
(Key switch in ON position) ................... T2-4-12
Preheating Circuit ................................. T2-4-14
Engine Stop Circuit ............................... T2-4-16
Emergency Operating Circuit ................ T2-4-18
E485 T2-1-1
MECHATRO CONTROL SYSTEM
OUTLINE
System summary Features Purposes

P1, P2 pump is control- P1 pump is controlled by proportional A) The power curve shall be an ideal
led by proportional 1 valve (PSV-P1). curve.
valve.
P2 pump is controlled by proportional B) Supply an optimum flow for each
2 valve (PSV-P2). operation.
The travel straight valve is controlled • Make the changeover soft.
3 by proportional valve (PSV-C).
Part of the The bypass cut valve P1 and P2 are • Make the changeover soft.
control valve 4 controlled by proportional valve
is controlled by the (PSV-D) and (PSV-B) respectively.
proportional valve. The arm 2-speed spool is controlled • Control the arm speed as you de-
5 by proportional valve (PSV-A). sire.
The main spool
is controlled ATT boost is controlled by solenoid
6
hydraulically. valve (SV-2).
The open and close actions of the
7 swing P/B are controlled by solenoid
valve (SV-1).
T2-1-2 E485
Line coding for control system circuit
ELECTRIC: CONTROLLER
INPUT SIGNAL
678
HYDRAULIC: PILOT SECONDARY
PRESSURE
SOLENOID PROPORTIONAL
VALVE SECONDARY PRESSURE
PILOT PRIMARY PRESSURE

MAIN CIRCUIT
: ELECTRONIC GOVERNOR
: ENGINE SPEED SENSOR
: HIGH PRESSURE SENSOR (P1, P2: 2 pcs)
: LOW PRESSURE SENSOR (ATT: 7 pcs, Travel: 2 pcs)
: ACCEL DIAL POTENTIOMETER
Pilot secondary pressure code

Travel 1 Reverse right
2 Forward right
3 Reverse left
4 Forward left
ATT ➀ Bucket digging
➁ Bucket dump
➂ Boom up
➃ Boom down
➄ Swing left
➅ Swing right
➆ Arm in
➇ Arm out
ATTACHMENT TRAVEL
OPERATION LEVER OPERATION LEVER
E485
LEFT RIGHT
LEFT RIGHT LOW PRESS.

PRESSURE SENSOR
(SE-10)
LOW PRESS.
PRESSURE SENSOR
SENSOR
BOOM CYLINDER
BLOCK
SWING
BOOM UP
BUCKET
OPTION 1
CONFLUX
TRAVEL LEFT
TRAVEL RIGHT
ARM 1st-SPEED
ARM 2nd-SPEED
BOOM 1st-SPEED
TRAVEL
STRAIGHT VALVE
BOOM 2nd-SPEED
P2 BYPASS CUT VALVE

P1 BYPASS CUT VALVE
GAUGE P1 P2 BOOM DOWN
RECIRCULATION
CLUSTER
A/W/HM ARM CYLINDER

DISPLAY
ARM PROPORT. VALVE ARM OUT
CONFLUX
PSV-A
ARM IN
PROPORTIONAL COMM. CURRENT RECIRCULATION
MODE
SELECT BUCKET CYLINDER
SWITCH
A/W/HM
SWING PARKING
SELECT OUT PUT BRAKE
VOLTAGE
E
ACCEL
POTENTIO TRAVEL SPEED
COMMAND HIGH PRESS.

VOLTAGE PRESSURE SENSOR
SPEED SENSOR
SERIAL NETWORK
A4
MECHATRO CONTROLLER
ENGINE
PUMP
ELECTRIC PROP.
VALVE
GOVERNOR
BLOCK
PROPORTIONAL
COMMAND CURRENT P1 PUMP
PROPORTIONAL VALVE
SWING P/B
TRAVEL 1-2 SPEED
P1 BYPASS CUT
P2 BYPASS CUT
POWER BOOST
LOCK LEVER
PROPORTIONAL
COMMAND CURRENT P2 PUMP
PROPORTIONAL VALVE
PSV-C TRAVEL STRAIGHT
LIMIT SW.
24V VOLTAGE
PROPORTIONAL COMMAND CURRENT
R3690
T2-1-3
T2-1-4 E485
BUCKET CONFLUX CONTROL
PILOT SIGNAL PROCESS
COMMAND
CURRENT i P1 PUMP
PUMP
FLOW
PROPORTIONAL
VALVE
TRAVEL RIGHT TRAVEL STRAIGHT VALVE
P1 POSITIVE CONTROL
DIFFERENTIAL PRESSURE
SWING TRAVEL LEFT
COMMAND OPTION 1 BUCKET

CURRENT i P2 PUMP
PUMP
FLOW
PROPORTIONAL
VALVE BOOM 2-SPEED BOOM 1-SPEED
ARM
P2 POSITIVE CONTROL ARM 1-SPEED ARM 2-SPEED PROPORTIONAL
DIFFEREATIAL PRESSURE VALVE
P2 BYPASS P1 BYPASS
CUT VALVE CUT VALVE
COMMAND
CURRENT i P2 BYPASS CUT
VALVE CURRENT
PROPORTIONAL
PROPORTIONAL
VALVE
PILOT SECONDARY
PRESSURE
MECHATRO CONTROLLER
R3691
E485 T2-1-5
Bucket conflux control (digging)
1. In single bucket operation, the secondary pilot 3. The secondary pressure Pi from the P2 bypass cut
pressure for bucket operation changes the bucket proportional valve changes the bypass cut valve.
spool. At the same time a signal is put into the The hydraulic oil pushes the bucket conflux valve
mechatro controller from the low pressure sensor (Q) open, flows into the high pressure passage for
for the bucket. the bucket and makes a 2-pump conflux flow.
2. The mechatro controller processes signals as

shown in the figure and puts out a command current •
• •
• Bucket out operation uses single flow control by
i to the P2 bypass cut proportional valve according only P1 pump.
to the input voltage.
T2-1-6 E485
CONFLUX CONTROL FOR BOOM UP
COMMAND
CURRENT i P1 PUMP TRAVEL RIGHT TRAVEL STRAIGHT VALVE
PUMP
FLOW
PROPORTIONAL
VALVE
SWING TRAVEL LEFT
P1 POSITIVE CONTROL
DIFFERENTIAL PRESSURE OPTION 1 BUCKET
COMMAND BOOM 2-SPEED BOOM 1-SPEED

CURRENT i P2 PUMP
PUMP
FLOW
PROPORTIONAL
VALVE ARM 1-SPEED ARM 2-SPEED
P2 POSITIVE CONTROL
P2 BYPASS P1 BYPASS
DIFFERENTIAL PRESSURE CUT VALVE CUT VALVE
MECHATRO CONTROLLER
R3692
E485 T2-1-7
Conflux control for boom up
1. If boom up is operated, the secondary pilot pressure bigger which in turn increases command current i to
for boom up changes the boom 1-speed spool and the P1 and P2 proportional valves.
the boom up 2-speed spool.
4. The proportional valves for the P1 and P2 pumps
2. The moment the boom 1-speed spool and the boom put out secondary pressure according to command
2-speed spool have been switched over, the hy- current from the mechatro controller to change the
draulic oil is put into the low pressure sensor for delivery rates of the P1, P2 pumps. When current i
positive control. of the proportional valves for the P1, P2 pumps
increases, the secondary pressure Pi of the pump's
3. The voltage outputs from the low pressure sensor is proportional valves increases. This increases the
put into the mechatro controller. The mechatro delivery rates of the pumps. (Positive control).
controller processes control signals as shown in the
figure and puts out current signals i to the P1 and P2 5. If the boom 1-speed spool and the boom 2-speed
pump proportional valves according to voltage in- spool are switched over by hydraulic commands,
puts. For instance, the positive control pressure the oil delivered by the P2 pump is combined with
equals the max pressure if the boom up lever is the oil delivered by the P1 pump during boom up.
turned to full stroke. This makes the voltage inputs
T2-1-8 E485
RECIRCULATION CONTROL AT LIGHT LOAD ARM IN
Pi
COMMAND
CURRENT i P2 PUMP TRAVEL RIGHT TRAVEL STRAIGHT VALVE
PROPORTIONAL
VALVE
SWING TRAVEL LEFT
P1 PILOT PRESSURE
OPTION 1 BUCKET
BOOM 2-SPEED BOOM 1-SPEED

Pi
ARM 1-SPEED ARM 2-SPEED
COMMAND
CURRENT i REGENERATION P2 BYPASS P1 BYPASS
PROPORTIONAL
CUT VALVE CUT VALVE
VALVE
PUMP PRESSURE
MECHATRO CONTROLLER
R3693
E485 T2-1-9
Recirculation control at light load arm in
1. If arm in operation is operated, the secondary pilot rate of the P2 pump. In the case of the arm in full
pressure for arm in is put into the low pressure lever, for instance, the delivery rate of the P2 pump
sensor and switches over the arm 1-speed spool. increases. (Positive control).
2. When the arm 1-speed spool is switched over, the 4. The regeneration proportional valve put out second-
P2 positive control pressure increases. The voltage ary pressure according to command current from
output from the low pressure sensor is put into the the mechatro controller to change the pilot pressure
mechatro controller which processes signal as of arm 2 speed spool.
shown in the figure. The mechatro controller puts
out a command current i according to the voltage 5. An hydraulic command switches over the arm
input and changes the proportional reducing valve 1-speed spool. A mechatro controller command
for the P2 pump. changes the delivery rate of the P2 pump. When the
pump pressure is less than a certain value, the oil
3. The proportional valve puts out the secondary returned from the arm cylinder rod is recirculated to
pressure Pi according to the command current from the head.
the mechatro controller and changes the delivery
T2-1-10 E485
ARM IN RECIRCULATION CUT AND CONFLUX CONTROL
HIGH PRESS. SENSOR
ARM IN Pi SECONDARY
PRESSURE SENSOR
COMMAND
CURRENT i REGENERATION
PROPORTIONAL TRAVEL RIGHT
PROPORTIONAL
TRAVEL STRAIGHT VALVE

VALVE
MPa
CURRENT
ARM IN Pi SWING TRAVEL LEFT

SECONDARY PRESSURE
VALVE
OPTION 1 BUCKET
Pi BOOM 2-SPEED BOOM 1-SPEED

COMMAND
CURRENT i P1 PUMP
PROPORTIONAL P1 BYPASS
P2 BYPASS
VALVE
CUT VALVE CUT VALVE
P2 PUMP PRESSURE COMMAND

CURRENT i P2 PUMP
PROPORTIONAL
VALVE
MECHATRO CONTROLLER
R3694
E485 T2-1-11
Arm in recirculation cut and conflux control
1. If both the pilot pressure and the P2 pump pressure pilot line for digging and switches over the arm 2-
rise above certain levels while arm in is being speed spool. This causes the oil delivered by the P1
operated, a command current is put out to the arm pump to combine with P2 flow as arm 2-speed
regeneration proportional valve from the mechatro pressure.
controller.
4. If arm in is operated, the swing parking brake is
2. The secondary pressure of the arm regeneration released. The solenoid valve for the swing parking
proportional valve changes the arm 2 speed spool brake is braked by the mechanical brake as the
to the recirculation cut position and permits the arm swing P/B and the solenoid are excited the moment
cylinder rod circuit to connect with the tank circuit. the key is turned on.
The swing P/B and the solenoid are released by
3. When the arm 2 speed spool is turned to the swing and arm in actions. The primary pilot pressure
recirculation cut position, the secondary pilot pres- passes through the mechanical brake and releases
sure for 1-speed arm in goes through the 2-speed the brake.
T2-1-12 E485
ARM OUT CONFLUX CONTROL
ATT
Pi/V
P1
P2
Q
Pi
COMMAND P2
P1 PUMP TRAVEL RIGHT
CURRENT i TRAVEL STRAIGHT VALVE
PUMP
FLOW
PROPORTIONAL
VALVE
SWING TRAVEL LEFT
P1 POSITIVE PRESSURE
MPa P1
OPTION 1 BUCKET
Q
COMMAND
P2 PUMP Pi
CURRENT i
PUMP
FLOW
PROPORTIONAL
VALVE
P2 BYPASS P1 BYPASS
MPa CUT VALVE CUT VALVE
R3695
E485 T2-1-13
Arm out conflux control
1. If arm out is operated, the secondary pilot pressure mand current i from the mechatro controller and
for arm out switches over the arm 1-speed spool and changes the delivery rates of the P1, P2 pumps. For
the arm 2-speed spool. example, command current i increases if the arm
out lever is turned to full stroke. This increases the
2. Voltage output from the low pressure sensor is put secondary pressure Pi of the proportional valves
into the mechatro controller. The controller then and increases the delivery rates of the P1, P2
processes control signal as shown in figure and pumps.
puts out command current to the proportional valve
according to voltage inputs. 4. An hydraulic command switches over the arm 1-
speed spool and the arm 2-speed spool. In arm out
3. The proportional valves for the P1 and P2 pumps action, the oil delivered by the P2 pump is confluxed
put out secondary pressure Pi according to com- with the P1 pump.
T2-1-14 E485
TRAVEL STRAIGHT CONTROL
TRAVEL ATT
Pi/V Pi/V
P1
P2
COMMAND P2 P1
TRAVEL P1
CURRENT i STRAIGHT pi TRAVEL RIGHT TRAVEL STRAIGHT VALVE
VALVE CURRENT
PROPORTIONAL
PROPORTIONAL
P1 P2
VALVE
SWING TRAVEL LEFT
PILOT SECONDARY
PRESSURE MPa OPTION 1 BUCKET
P2 BYPASS P1 BYPASS
CUT VALVE CUT VALVE
MECHATRO CONTROLLER
R3696
E485 T2-1-15
Travel straight control in a combined operation of

travel and ATT
1. If ATT-related operations (boom, arm, bucket and 3. When the travel straight solenoid proportional valve
swing) are operated during travel (right and left) is turned on, the higher of the pilot pressure and the
actions, the secondary pilot pressure switches over travel pilot pressure during ATT operation is put out
each spool and put into each low-pressure sensor. as the secondary pressure for the solenoid propor-
tional valve and switches over the travel straight
2. If the mechatro controller receives a signal from any valve, inner the control valve. This causes ATT to
low-pressure sensor that is included in the combina- be actuated by the P1 pump and causes the travel
tion in the below table, it determines it as travel action to be actuated by the P2 pump.
straight and puts out command current i to the main
straight solenoid proportional valve.
Boom Bucket Arm Swing

Travel right – – { {
Travel left { { – –
Travel both { { { {
T2-1-16 E485
SWING PRIORITY CONTROL
ATT
Pi/V
P1
P2
Q
pi
COMMAND P2 PUMP P2
CURRENT i PROPORTIONAL TRAVEL RIGHT TRAVEL STRAIGHT VALVE
PUMP
FLOW
VALVE
P1
SWING TRAVEL LEFT
MPa
OPTION 1 BUCKET
SWING
i BOOM 2-SPEED PRIORITY BOOM 1-SPEED
VALVE
COMMAND ARM
CURRENT i REGENERATION
VALVE CURRENT

PROPORTIONAL
PROPORTIONAL
VALVE
P2 BYPASS P1 BYPASS
ARM Pi SECONDARY CUT VALVE CUT VALVE
MPa
PRESSURE
MECHATRO CONTROLLER
R3697
E485 T2-1-17
Swing priority control in a combined operation of

arm in and swing
1. The moment the swing spool is switched over by the 2. Since the passage is throttled, the oil from the P2
secondary swing pilot pressure during a combined pump is used preferentially for swing action. The
operation of arm and swing, the pressure is led to arm cylinder is actuated by the conflux flow of
the swing priority valve. The passage from the P2 1-speed and 2-speed.
pump to the arm cylinder head is throttled.
At the same time, the oil from the regeneration
proportional valve is confluxed with that of the arm
2-speed.
T2-1-18 E485
PRESSURE DRAINING (RELEASING) CONTROL
5 1 3 2 4
PILOT
P2 BYPASS CUT VALVE
P1 BYPASS CUT VALVE

VALVE
BOOM 1st-SPEED
BOOM 2nd-SPEED
ARM 2nd-SPEED
STRAIGHT VALVE
ARM 1st-SPEED
TRAVEL RIGHT
TRAVEL LEFT
OPTION 1
BUCKET
SWING
TRAVEL
PILOT VALVE
FOR TRAVEL
(LEFT) (RIGHT)
P2 P1
6 2 4 1
7 PSV-A
3
SE - 23 SE - 22
HYDRAULIC
PRESSURE A2 A1
RELEASE ENGINE
SWITCH
PRESSURE
RELEASING
CONTROL
Pi
C-3 ENGINE
ENGINE SPEED CONTROL CONTROLLER
Pi
PILOT SIGNAL PROCESS TRAVEL STRAIGHT Pi

PROPORTIONAL
VALVE
PSV - C
Pi
PILOT SIGNAL PROCESS P2 PUMP Pi

PROPORTIONAL
VALVE
PSV - P2
Pi
PILOT SIGNAL PROCESS P1 PUMP Pi

PROPORTIONAL
VALVE
PSV - P1
Pi
PILOT SIGNAL PROCESS P2 BYPASS CUT Pi

PROPORTIONAL
VALVE
PSV - B
Pi
PILOT SIGNAL PROCESS P1 BYPASS CUT Pi

PROPORTIONAL
VALVE
PSV - D
MECHATRO CONTROLLER
Pi; PROPORTIONAL VALVE
SECONDARY PRESSURE
R3698
E485 T2-1-19
Pressure draining (releasing) control
The purpose of this circuit is to release the main circuit If the spools are switched by pilot operation, the
pressure for piping repair work. remaining pressure from the actuators may be
relieved via travel straight valve and relieved
1. When the hydraulic pressure release switch is from bypass passage of opposite side of drive
actuated, the mechatro controller puts out the pump to the tank circuit, consequently the main
following commands: circuit may be released.
In this situation, the right and left control levers
a. Puts out the minimum tilting angle command
not to be operated simultaneously, otherwise the
value to the P1 and P2 pump proportional valve
pressure can not be relieved because of blocking
(PSV-P1) and (PSV-P2). The pump proportional
of tank passage . Further, stroke the lever to the
valves minimize the delivery rates of the P1 and
slow motion range independently. If the move-
P2 pumps.
ment of stroke is too fast, the release of pressure
b. Puts out a pressure release control revolution is not performed due to the communicating pas-
command value to the electronic governor, sage of travel straight valve is narrow.
through the C-3 Engine controller.
c. Travel straight proportional valve (PSV-C) is 2. If the operating lever is shifted to neutral during
input the command value to change the pressure engine running when the hydraulic pressure release
release position. The secondary pilot pressure switch is actuated and the pressure is drained
for travel straight valve pressure release position (released), "DRAINING HYD PRESS" is displayed
selection comes out of the travel straight propor- on the gauge cluster and intermittent buzzer sound
tional valve (PSV-C), flows into Pz1 port of continuously.
Control Valve (2) and switches the travel straight Operate the levers of each motion of attachment
valve to its pressure release position. right and left four to five times independently to their
slow motion range, the release pressure is per-
d. Puts out a standby command value to the P1 formed.
bypass cut valve and the P2 bypass cut propor- After draining pressure is completed, turnoff the
tional valve (PSV-D) and (PSV-B) ( a command starter key, and buzzer sound stops. If the pump
that does not put out the secondary pressure of pressure is determined to be more than 970 kPa by
P1 and P2 bypass proportional valves). the output value of the high-pressure sensor or the
e. When the travel straight valve is switched to the high-pressure sensors (SE-22,23) are broken,
pressure release position, the oil delivered by "FAIL DRAIN HYD. PRESS" is displayed on the
each pump is unloaded to the tank passage. This gauge cluster and the buzzer sounds continuously.
delivered oil flows into tank passage through In that case, also the buzzer is not stopped unless
bypass passage, because the oil is communi- the engine key is turned to off. Repeat the pressure
cated to the tank passage through orifice in the releasing procedure once again.
travel straight valve.
T2-1-20 E485
NOTES:
E485 T2-2-1
MECHATRO CONTROLLER
SUMMARY OF MECHATRO CONTROLLER
Electro-hydraulic conversion information is displayed cation time may be changed over if the screen change
on the multi display of the gauge cluster. However, the switch is pressed.
mechatro display and the cumulative engine oil lubri-
5
R2234
1 - Safety lock lever 5 - Swing parking brake release switch

2 - Starter switch 7 - Pressure release switch
3 - Gauge cluster 8 - Power Boost button
4 - Accel dial
T2-2-2 E485
MECHATRO CONTROLLER
WORK MODE DISPLAY
The work mode selector switch contains the fol-

lowing functions
1. The work mode indicator lamp is switched W → HM

→ A... in order every time when the work mode
switch is pressed.
2. Scrolling up of indicating items in trouble history
display and canceling trouble history.
3. Scrolling up of time when changing E/G oil supply
total hours.
4. At A (Attachment) mode, flow rate is increased.
5. Time displays are roll upped when correcting fuel
6 LOW E/G
filter, hydraulic oil filter and hydraulic oil replace
OIL PRESS interval.
6. Time displays is roll upped when adjusting clock,
indicating time is increased.
The buzzer stop switch contains the following

functions
R0385 1. Stops the warning sounding.

2. Display item rollbacked in service diagnosis opera-
Screen change switch tion.
3. Display item rollbacked in trouble history opera-
1. Indicated items are scrolled up, when service
tion.
diagnosis is displayed.
4. Time display rollbacked when correcting E/G oil
2. In A (Attachment) mode, adjusting mode is taken.
supply cumulative time.
5. At A (Attachment) mode, flow rate is decreased.
6. Time display are rollbacked when correcting fuel
filter, hydraulic oil filter and hydraulic oil replace
interval.
7. Time display is rollbacked when adjusting clock,
indicating time is decreased.
E485 T2-2-3
MECHATRO CONTROLLER
1. Display on LCD by the work mode switch
Work mode Pattern System summary

HM (Heavy and Mechatro) mode Display lamp 1. Digging The mode is suited for heavy load
HM ON Ditch digging work in which operating lever actions
Trench box are recognized sensitively and the
digging machine is operated at high speed
with its priority laid on the rate of
2. Leveling operation.
Slope finishing The system recognizes the operator's
action, automatically adjusts the ma-
chine into four patterns shown on the
3. Spreading left and causes the mode to flash.
The below controls are performed as
the result of judgment.
• Engine revolution control
4. Tamping • Pump control
• Arm variable recirculation control
• Boom conflux control
5. Others • In all modes(standby and travel)

10 : 05
W (Working) mode Display The most suitable mode for keeping

lamp balance between fuel consumption
W ON and work efficiency.
A (Attachment) mode Display Where the breaker and other require

lamp a limit to the max. flow rate
A ON • Operation in flow adjust mode
1. After the engine stops, turn the
starter switch to (ON) and the
mode switch to "A" and turn the
screen change switch to (ON) for
3 to 10 sec. Then the adjust mode
is available.
2. When the engine starts, 210 L/min
is indicated in the primary stage.
After that, the previous value is
indicated. The value increases by
10 L/min each time the mode
switch is pushed one time and
decreases by 10 L/min each time
the buzzer stop switch is pressed.
3. To release the adjust mode, turn
the screen change switch to (ON)
again.
T2-2-4 E485
MECHATRO CONTROLLER
2. Display on LCD by the screen change switch

The engine revolution and the cumulative hours from the engine oil change are indicated.
LCD display Operating procedure Buzzer sound
10 : 05
(After the key switch is in ON (After 5 seconds,

position, "FK" mark is displayed "Clock is displayed")
on the multidisplay)
256Hr AFT
1515 RPM
E/G OIL CH
256Hr AFT
FUEL FIL CH
Normal
None
display
256Hr AFT
HYD FIL CH
256Hr AFT
HYD OIL CH
Note:
If the screen change switch is pressed, the above six screen may be
changed over.
E485 T2-2-5
MECHATRO CONTROLLER
The functions displayed on the multidisplay are 5. Trouble history display

classified roughly into the following 8 types. Stores and displays the contents of the troubles
detected through the mechatro self diagnosis.
1. Clock display
After the engine starts, "NH" mark is displayed 6. Mechatro A adjustment display
on the multidisplay and 5 seconds later it Displays it by procedure during the mechatro A
changes to clock (In normal condition). adjustment.
•
• •
• 2. CPU error display 7. Oil/filter supply cumulative time
Display the error of the mechatro controller, etc. Displays the oil/filter supply cumulative time:
1. E/G oil 2. Fuel fiter 3. Hyd. oil filter 4. Hyd. oil.
•
• •
• 3. Self-diagnosis display
Displays the failure of the I/O (Input/Output) 8. Warning displays
•
system of the mechatro controller such as the In case the self diagnosis ( ) is normal but the
• •
•
low pressure sensor, governor motor, propor- machine is faulty, or if the machine condition must
tional valve, solenoid valve, etc. be notified to the operator, the below warning items
are indicated each time it is necessary.
4. Service diagnosis display
Displays the information output by the mechatro
controller such as the pressure sensor detec-
tion, proportional valve, solenoid valve, etc.
T2-2-6 E485
MECHATRO CONTROLLER
Warning displays item
1 10 29
CPU !
2 11 32
PR
4 12 37
5 13 38
!
6 14
NOTE - The buzzer sounds on display # 2, # 5, # 6
and 7.
15
In the case of # 5 and # 6, the buzzer is not stopped
7
even if the buzzer stop switch is pushed.
In case of # 7, the buzzer is stopped if the buzzer
stop switch is pressed.
9 19 In the case of # 2, the buzzer stops five seconds
later automatically.
1- Mechatro controller fail 12 - Low fuel level

2- Swing parking disengaged 13 - Low hydraulic oil level
3- E/G Preheat 14 - Low E/G cool level
5- Preheat fail 15 - Low E/G oil level
6- Low E/G oil press 19 - Power boost on
7- High E/G cool temp 29 - Change E/G oil
9- Air cleaner dirty 32 - Hydraulic system pressure discharge
10 - Overload boom oil pressure 37 - Warming up fuel filter
11 - Charging problem 38 - Presence of water in the fuel pre filter
E485 T2-2-7
MECHATRO CONTROLLER
SELF DIAGNOSIS DISPLAY FUNCTION
1. Summary
It performs self diagnosis of control inputs and the connector numbers and the pin numbers, refer
outputs of pressure sensors and proportional to the C-1 Mechatro Controller which describes
valves while the machine is in operation. Errors later. Wire numbers and colors may be confirmed
coming out of the self diagnosis are displayed on on the electric circuit diagram or on the harnesses
the multi display of the gauge cluster. Regarding diagram.
2. I/O configuration
INPUT
Pressure sensor
SERIAL COMMUNICATION
Control
Proportional valve
Gauge cluster
Selector valve (SOL)
(Buzzer alarm)
Governor motor
Battery relay
3. Self diagnosis display item
No. Contents Display of monitor No. Contents Display of monitor

1 Mechatro controller fail 1. MECHATRO 18 P2 bypass cut D-2 P2 BYPASS
CPU CONT. FAIL propo-valve fail PSV PROPO-VALVE
2 Gauge cluster → Mechatro con- I-1 RECEIVE 19 Travel priority D-3 TRAVEL
troller communication failure ERROR propo-valve fail PSV PROPO-VALVE
3 Battery relay fail I-2 BAT. 20 Arm variable recirculation D-6 RECIRCULAT
RELAY propo-valve fail PSV PROPO-VALVE
4 ROM data A-1 ROM DATA 21
CPU FAILURE
5 Mechatro set error A-2 MECHATRO 22
CPU SET ERROR
6 Boom raising pressue B-1 BOOM RAISE 23 P1 pump propo-valve E-1 PUMP P1
sensor fail SE SENSOR fail PSV PROPO-VALVE
7 Boom lowering pressue B-2 BOOM LOWER 24 P2 pump propo-valve E-2 PUMP P2
sensor fail
SE SENSOR fail PSV PROPO-VALVE
8 Arm in pressure B-4 ARM IN 25 Power up solenoid F-1 POWER BOOST
sensor fail
SE SENSOR valve fail SV SOLENOID
9 Arm out pressure B-3 ARM OUT 26 Travel 2-speed solenoid F-3 TWO-SPEED
sensor fail
10 Bucket digging pressure B-5 BUCKET DIG 27 Swing parking solenoid F-2 SWING BRAKE
sensor fail
11 Bucket dump pressure B-6 BUCKET DUMP 30 E/G speed sensor fail G-3 E/G REV.
sensor fail
SE SENSOR RPM SENSOR
12 Swing pressure sensor B-7 SWING (R) 31 Accel potentio meter fail H-1 ACCELERATOR
fail
SE SENSOR
POT
POTENTIO
13 Travel right pressure B-9 TRAVEL (R) 32 Hydraulic pressure 32 DRAINING
SE PR
sensor fail SENSOR release stand by HYD. PRESS
14 Travel left pressure B-10 TRAVEL (L) 33 Hydraulic pressure 33 FAIL DRAIN
SE PR
sensor fail SENSOR release fail HYD. PRESS
15 P1 pump pressure C-1 PUMP P1
sensor fail SE SENSOR
16 P2 pump pressure C-2 PUMP P2
sensor fail SE SENSOR
17 P1 bypass cut D-1 P1 BYPASS
propo-valve fail PSV PROPO-VALVE
T2-2-8 E485
MECHATRO CONTROLLER
SERVICE DIAGNOSIS
The present service diagnosis in items is displayed on 3. Each time the screen change switch on
the multidisplay according to the data received from the gauge cluster is pressed, the number
the mechatro controller. runs like No. 2, No. 3 ... in order.
4. Each time the buzzer stop switch on the
How to display switch panel is pressed, the number re-
1. Keep the buzzer stop switch pressing, turn the turns like No. 25, No. 24 ... in order.
starter switch (ON) and starts the engine. 5. The display disappears only when the starter
2. The 1st item Parts No. of Mechatro controller and switch is turned OFF.
the program version are displayed.
(Example)
No. 1
MAIN CONTROLLER P/No.
LS22E...............
PROGRAM VERSION
VER...............
Service diagnosis indication
Display Remarks Display Remarks
No. 1 No. 7
MAIN CONT. P/No. SOL. VALVE
LS22E.................. P/No. indication F-1 POWER BOOST
PROGRAM VER Version indication COMP. OFF ON/OFF indication
VER.................. MEAS. OFF ON/OFF indication
SWITCH OFF ON/OFF indication
No. 2
E/G SET 1850 No load set rpm No. 8
MEAS 1850 Actual rpm RELAY
E/G PRS. LIVE LIVE/DEAD indication I-2 BAT. RELAY Sensor voltage /
KPSS SW W W / H / A indication COMP. ON Pressure converted value
MEAS. ON Sensor voltage /
KEY SWITCH ON Pressure converted value
No. 3 No. 9
H-1 PRESS. SENSOR
ACCEL VOLT. 4.4V Potentio voltage B-1 BOOM RAISE Sensor voltage /
POS. 100% Voltage position 4.5V 3.0M Pressure converted value
MOTOR STEP 216 No of motor steps B-2 BOOM LOWER Sensor voltage /
POS. 100% Step position 4.5V 3.0M Pressure converted value
No. 5 No. 10
SOL. VALVE PRESS. SENSOR Sensor voltage /
F-2 SWING-BRAKE B-3 ARM OUT Pressure converted value
COMP. ON ON/OFF indication 4.5V 3.0M Sensor voltage /
MEAS. ON ON/OFF indication B-4 ARM IN Pressure converted value
RELEASE SW OFF ON/OFF indication 4.5V 3.0M
No. 6
SOL. VALVE
F-3 1/2-TRAVEL
COMP. OFF ON/OFF indication
MEAS. OFF ON/OFF indication
SWITCH OFF ON/OFF indication
E485 T2-2-9
MECHATRO CONTROLLER
Display Remarks Display Remarks
No. 11 No. 23
PRESS. SENSOR PROPO-VALVE
B-5 BUCKET DIG Sensor voltage / D-6 A-RECIRCULAT Command current /
4.5V 3.0M Pressure converted value COMP. 400mA 1.7M Pressure converted value
B-6 BUCKET DUMP Sensor voltage / MEAS. 400mA 1.7M Feedback current /
4.5V 3.0M Pressure converted value Pressure converted value
(Arm in at no load)
No. 12 No. 24
B-7 SWING (R) Sensor voltage / E-1 P1 PUMP Command current /
B-8 SWING (L) Sensor voltage / MEAS. 750mA 3.1M Feedback current /
0V 0M Pressure converted value POWER SHIFT 0mA Pressure converted value
No. 13 No. 25
B-9 TRAVEL (R) Sensor voltage / E-2 P2 PUMP Command current /
B-10 TRAVEL (L) Sensor voltage / MEAS. 750mA 3.1M Feedback current /
4.5V 3.0M Pressure converted value POWER SHIFT 0mA Pressure converted value
No. 14 No. 39
PRESS. SENSOR MECHATRO ADJT.
C-1 PUMP P1 Sensor voltage / CONT. SW TEST RUN/TEST indication
3.3V 3.5M Pressure converted value CONT. VOL 50% 50% fixed indication
C-2 PUMP P2 Sensor voltage / PROG. SW OFF ON/OFF indication
3.3V 3.5M Pressure converted value
No. 15 No. 40
PRESS. SENSOR RELEASE SW
B-16 P1 OPT. Sensor voltage / KPSS OFF ON/OFF indication
4.5V 3.0M Pressure converted value SWING BRAKE OFF ON/OFF indication
B-17 P2 OPT. Sensor voltage /
4.5V 3.0M Pressure converted value
No. 20
PROPO-VALVE
D-1 P1 CUT Command current /
COMP. 745mA 3.0M Pressure converted value
MEAS. 745mA 3.0M Feedback current /
Pressure converted value
(Arm out relief)
No. 21
PROPO-VALVE
D-2 P2 CUT Command current /
(Boom up relief)
No. 22
PROPO-VALVE
D-3 S-TRAVEL Command current /
(Arm in relief)
NOTE - The examples of displays are in the W mode with the engine at Hi and with the operating lever to full stroke.
T2-2-10 E485
MECHATRO CONTROLLER
TROUBLE HISTORY DIAGNOSIS
The error item detected by the self-diagnosis is stored 5. To erase the display, turn the starter switch to
in the mechatro controller as a history and is displayed (OFF).
on the multidisplay.
How to cancel the contents of the trouble history

How to display
1. Display the trouble history mode.
1. Turn the starter switch (ON).
2. Press the work mode select switch and the buzzer
2. Press the buzzer stop switch 5 times in sequence stop switch for 10 seconds or more concurrently.
for 10 seconds.
3. When the erasing is completed, the "NO ERROR"
(Example) is displayed.
Contents Display 4. Turn the starter switch (OFF).
No errors NO ERROR
NOTE - All the stored items are erased.
00025H It is impossible to erase data partially.
Error detected B-10 TRAVEL LEFT
in the past D-2 P2 BYPASS CUT
F-3 TRAVEL 1.2-SPEED
3. Transmits the error data (one or many) and hour

meter to the gauge cluster.
• Hour meter and 3 error data are displayed on the

screen.
• If three error data or more exist, display the data

three by three in order for every 5 seconds.
4. Scrolling pages (Item number)
• The item number increases each time the work

mode select switch is pushed.
• The item number decreases each time the

buzzer stop switch is pushed.
NOTE - The system stores all error items at each hour

meter reading. To check error items at different hour
meter readings, push the work mode select switch or
the buzzer stop switch.
E485 T2-2-11
MECHATRO CONTROLLER
Contents of the trouble history
Symbol Display
A Controller relation A-1 PUMP P1 SENSOR

A-2 PUMP P2 SENSOR
B-1 BOOM RAISE SENSOR

B-2 BOOM LOWER SENSOR
B-3 ARM OUT SENSOR
B-4 ARM IN SENSOR
B Low pressure sensor B-5 BUCKET DIG SENSOR
B-6 BUCKET DUMP SENSOR
B-7 SWING (R) SENSOR
B-9 TRAVEL (R) SENSOR
B-10 TRAVEL (L) SENSOR
High pressure sensor C-1 PUMP P1 SENSOR

C
(Hydraulic pump) C-2 PUMP P2 SENSOR
D-1 P1 BYPASS PROPO-VALVE

Proportional valve D-2 P2 BYPASS PROPO-VALVE
D
(Control valve) D-3 TRAVEL PROPO-VALVE
D-6 RECIRCULAT PROPO-VALVE
Proportional valve E-1 PUMP P1 PROPO-VALVE

E
(Hydraulic pump) E-2 PUMP P2 PROPO-VALVE
F-1 POWER BOOST SOLENOID

F Solenoid valve F-2 SWING BRAKE SOLENOID
F-3 TWO-SPEED SOLENOID
G-3 E/G REV. SENSOR

G E/G Accessory G-4 E/G COOL.
G-5 E/G OIL PRS
H Potentio relation H-1 ACCELERATOR POTENTIOMETER
I-1 RECEIVE ERROR

I I-2 BAT. RELAY
I-3 NO. 4 CABLE DISCONNECTED
MONITOR SYSTEM OK
T2-2-12 E485
MECHATRO CONTROLLER
HOW TO CORRECT THE CUMULATIVE TIME
1. The method of cumulative time indication change 2. Corrective action

is described on page T2-2-4. For example, correction method of engine oil sup-
ply cumulative time is described in following.
Procedure Operating procedure Display on multidisplay

(Normal)
A Turn the starter switch on. is displayed, and after 5 seconds
display changes to clock.
Press the gauge cluster screen change

Press once
B switch once, and the E/G speed (rpm) is 10 : 05 2000 RPM
displayed.
E/G speed is displayed

Press once more, and the engine oil sup-
C Press once 100 Hr AFT
ply cumulative time screen is displayed. 2000
10 :RPM
05 10 : 05
E/G OIL CH
Press the screen change switch and re-

100 Hr AFT 100 Hr AFT 100 Hr AFT
D lease in the range of 3 to 10 seconds, it
E/G OIL CH FUEL FIL CH E/G OIL CH
returns to the correction mode.
Press the work mode selector switch and 100 Hr AFT Cumulative time 101 Hr AFT
E
the cumulative time increases. (once 1 Hr) E/G OIL CH increases E/G OIL CH
Press the Buzzer stop switch, the cumula- 100 Hr AFT Cumulative time 99 Hr AFT
F
tive time decreases. (once 1 Hr) E/G OIL CH decreases E/G OIL CH
Press the gauge cluster screen change

switch once, the correcting time is stored, Complete the
99 Hr AFT 100 Hr AFT
G and exits from the correction mode and
E/G OIL CH correction FUEL FIL CH
"Fuel filter supply cumulative time" is dis-
played to complete the correction.
NOTES
1. Press screen change switch on the procedure D or later once, and the status is stored and the correction is
finished.
2. When altering the accumulated elapsed time of fuel filter, hydraulic oil filter and hydraulic oil respectively, press
the screen change switch and display the accumulated time screen corresponding to items required to be
altered, then repeat the procedures D to G.
3. The engine oil change time is displayed by 500 hours for warning on the display, but no buzzer sounds.
4. For fuel filter, hydraulic oil filter and hydraulic oil, press the screen change switch, and the "Hours elapsed after
change" is displayed on the display, but no warning displays and no buzzer sounds.
5. The display time is 4 digits for hydraulic oil, and 3 digits for others.
•
• •
• The display time can be returned to zero by simultaneously pressing " " selector switch and " " buz-
zer stop switch.
E485 T2-2-13
MECHATRO CONTROLLER
CONTRAST OF DISPLAY ADJUSTING

PROCEDURE
If buzzer stop switch and mode switch are pressed at

the same time for 5 to 10 seconds, the contrast
adjusting mode is appeared and the contrast of dis-
play becomes adjustable, but except the following
conditions:
Under (Adjustment) and (Service diagnosis)
1. Contrast enhancement
Press the mode switch:
LCD indication is enhanced.
Press the buzzer stop switch:
LCD indication becomes dim.
2. Contrast complete
Press the screen change switch, consequently the

mode is set for required contrast level.
22 : 00
CONTRAST 50
T2-2-14 E485
MECHATRO CONTROLLER
MECHATRO CONTROL EQUIPMENT
C-1 Mechatro controller

1. Outside view
2 1 6 21 4 2 18 2 1
10
16
26
34
27 22 18 16 12 28 22
1 (CN35F) 2 (CN36F) 3 (CN37F) 4 (CN38F)
13 2 18 2 1 11 2 1
1 2 3 4
5 6 7
(CN35F) (CN36F) (CN37F) (CN38F)
(CN39F) (CN40F) (CN41 F)
26 14 16 9 22 12
5 (CN39F) 6 (CN40F) 7 (CN41F)
R0386
2. List of connectors
HARNESS MECHATRO CONTROLLER
Wire Code Connector Pin Specification IN/OUT Signal level
No. No. No. PUT
952 1 Ground 0V
502 2 Boom up pressure sensor (SE-3) IN 0.5~4.5V
902 3 Power source 5V
503 5 Boom down pressure sensor (SE-4) IN 0.5~4.5V
953 6 Ground 0V
954 7 Ground 0V
504 8 Arm in pressure sensor (SE-7) IN 0.5~4.5V
505 11 Arm out pressure sensor (SE-8) IN 0.5~4.5V
955 12 Ground 0V
950 13 Ground 0V
500 14 Bucket digging pressure sensor (SE-1) IN 0.5~4.5V
901 1 16 Power source 5V
501 (CN35F) 17 Bucket dump pressure sensor (SE-2) IN 0.5~4.5V
951 18 Ground 0V
957 19 Ground 0V
507 20 Swing pressure sensor (SE-5) IN 0.5~4.5V
– 22 – –
– 23 – –
– 24 – –
958 25 Ground 0V
508 26 Travel right pressure sensor (SE-9) IN 0.5~4.5V
509 29 Travel left pressure sensor (SE-10) IN 0.5~4.5V
959 30 Ground 0V
– 31 – –
– 32 – –
– 33 – –
– 34 – –
E485 T2-2-15
MECHATRO CONTROLLER

No. No. No. PUT
967 1 Ground 0V
517 2 Accel potentiometer (SE-16) IN 0.5~4.5V
515 5 P1 pump pressure sensor (SE-22) IN 0.5~4.5V
965 6 Ground 0V
966 7 Ground 0V
516 8 P2 pump pressure sensor (SE-23) IN 0.5~4.5V
913 2 10 Power source 5V
513 (CN36F) 11 P1 OPT. pressure sensor (SE-20) IN 0.5~4.5V
963 12 Ground 0V
964 13 Ground 0V
514 14 P2 OPT. pressure sensor (SE-11) IN 0.5~4.5V
– 16 – –
– 17 – –
– 18 – –
– 19 – –
580 20
581 21 Engine revolution sensor (SE-13) OUT GND
SH-2 22 Shield
– 1 – –
600 2 Key SW. (ON) IN +24V / OPEN
34 3 Glow relay (ON) IN +24V / OPEN
– 4 – – –
545 5 Swing P/B release SW. (SW-4) IN GND / OPEN
65B 6 Alternator voltage IN ~12V/12V~
540 7 Load momentum alarm (SW-39) IN GND / OPEN
3
547 8 Overheat signal to engine controller IN GND / OPEN
(CN37F)
548 9 E/G oil pressure SW. (SW-7) IN GND / OPEN
549 10 Air filter clogger SW. (SW-8) IN GND / OPEN
591 11 OPT. press. (SW-44) IN GND / OPEN
550 12 Engine oil level SW (SW-23) IN Constant current circuit
551 13 E/G coolant level (SW-24) IN GND / OPEN
552 14 Hyd. oil level (SW-25) IN GND / OPEN
553 15 Fuel level (SE-15) IN 670/1140(Ω)
557 16 Wiper rise-up limit switch IN GND / OPEN
558 1 Wiper reverse limit switch IN GND / OPEN
542A 2 ATT power boost SW. (SW-21) IN GND / OPEN
130 3 Heavy lift SW. (SW-35) IN GND / OPEN
120 4 Quick coupler SW. (SW-40) IN GND / OPEN
E27 5 No. 4 connector detect signal IN GND / OPEN
87A 6 Safety lever lock SW. (SW-11) IN +24V / OPEN
622A 7 Extra switch (SW-55/56) IN GND / OPEN
559 8 Wiper inter-lock (SW-19) IN GND / OPEN
– 9 – – –
– 10 – – –
– 11 – – –
– 12 – – –
– 13 – – –
4
– 14 – – –
(CN38F)
572 15 Pressure drain SW. (SW-50) IN GND / OPEN
708 16 Wiper spark relay OUT GND / OPEN
709 17 Wiper forward relay OUT GND / OPEN
710 18 Wiper reverse relay OUT GND / OPEN
711 19 Washer motor relay OUT GND / OPEN
– 20 – – –
– 21 – – –
– 22 – – –
– 23 – – –
– 24 – – –
91 25 Engine stop relay (R-28) contr. OUT GND / OPEN
– 26 – – –
781 27 OUT 0~4.5V
Accell 1 to engine controller
780B 28 IN GND
T2-2-16 E485
MECHATRO CONTROLLER

No. No. No. PUT
– 1 – – –
– 2 – – –
– 3 – – –
744 4 OUT –
745 5 P1 bypass cut proportional valve D (PSV-D) OUT –
740 6 OUT –
741 7 P2 bypass cut proportional valve B (PSV-B) OUT –
742 8 OUT –
743 9 Travel straight proportional valve C (PSV-C) OUT –
746 10 Arm variable regeneration proportional OUT –
747 11 valve A (PSV-A) OUT –
1A 12 IN 20~32V
1B 13 Power supply + 24V IN 20~32V
5
7 14 Battery back up IN 20~32V
(CN39F)
– 15 – – –
– 16 – – –
748A 17 OUT –
749A 18 P1 pump proportional valve (PSV-P1) OUT –
750A 19 OUT –
751A 20 P2 pump proportional valve (PSV-P2) OUT –
702 21 Travel 1,2-speed selector valve 2 speed/ OUT +24V / OPEN
1 speed (SV-3)
701 22 Swing parking selector valve P /Release (SV1) OUT +24V / OPEN
703 23 ATT boost pressure solenoid valve (SV2) OUT +24V / OPEN
700 24 Battery relay Operation/Stop OUT +24V / OPEN
E2 25 Power input 0V
E3 26 Power supply (GND) Power input 0V
770 1 Cluster TXD OUT TTL level communication
582 2 Cluster RXD IN TTL level communication
980 3 – GND
SH-3 4 Cluster – Shield
– 5 – – –
– 6 – – –
– 7 – – –
– 6 8 – – –
– (CN40F) 9 – – –
– 10 – – –
– 11 – – –
– 12 – – –
13 – – –
– 14 – – –
782 15 OUT 0~4.5V
780C 16 IN GND
– 1 – – –
– 2 – – –
– 3 – – –
– 4 – – –
– 5 – – –
– 6 – – –
– 7 – – –
– 8 – – –
– 9 – – –
623 10 Hammer connect signal IN GND / OPEN
7
– 11 IN GND / OPEN
(CN41F)
590 12 P2 CPT. press. SW. (SW-43) IN GND / OPEN
– 13 IN GND / OPEN
770 14 (Orbcomm power) (CN-6M conn) OUT GND / OPEN
752 15 – – –
753 16 – – –
754 17 – – –
755 18 – – –
616 19 Download change SW. (CN-6M conn) OUT GND / OPEN
776 20 – RS-232C communication
615 21 Download/Orbcomm (CN-6M conn) – RS-232C communication
984 22 OUT GND
E485 T2-2-17
MECHATRO CONTROLLER
ENGINE CONTROL UNIT
Connector Pin Assignment and Connections
ECU Connector Pin Assignment
1 2 3 4 5 6 7 8 9 10 11 33 34 35 36 37 38 39 40 58 59 60 61 62 63 64 65 66 67 89 90 91 92 93
12 13 14 15 16 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 68 69 70 71 72 73 74 75 76 77 78 79 94 95 96 97 98 99 100
25 26 27 28 29 30 31 32 51 52 53 54 55 56 57 80 81 82 83 84 85 86 87 88 101 102 103 104
32-pin connector 25-pin connector 31-pin connector 16-pin connector
1 Glow relay output 27 TW SENSOR (GND) 53 RED4 SIG GND 79 -

2 - 28 - 54 RED4 SHILD GND 80 -
3 - 29 - 55 - 81 -
4 TDC SENSOR (SIG) 30 - 56 - 82 Memory clear SW input
5 BACKUP SENSOR (SIG) 31 - 57 - 83 SIG. GND
6 - 32 GND (M/V) 58 - 84 Boost sensor GND
7 - 33 RED4 + VB OUT 59 - 85 -
8 - 34 RED4 + VB OUT 60 IG SW input 86 -
9 PULL DOWN SIG 35 PWM SOLL 61 IG SW input 87 -
10 + VB (MV/VB) 36 RED4 + 5V 62 - 88 -
11 + VB (RED POWER) 37 Q-adj. resistance (SIG) input 63 Boost sensor (+5V) 89 TECH2, DDS (TXD)
12 - 38 - 64 - 90 -
13 - 39 - 65 Start SW input 91 Diag. lamp output
14 - 40 - 66 - 92 ECU POWER
15 TDC SENSOR (GND) 41 - 67 Limp Home 93 ECU POWER
16 - 42 GND (M/V) 68 - 94 -
17 BACKUP SENSOR (GND) 43 RED4 V-IST 69 - 95 -
18 - 44 RED4 PWM SOLL 70 - 96 -
19 - 45 RED4 + 5V 71 Diag. selector SW 97 -
20 - 46 Q-adj. resistance (GND) input 72 - 98 -
21 - 47 - 73 ACCEL 1 SIG 99 ECU GND
22 RED4 LIMP HOME (SIG) 48 - 74 ACCEL 2 SIG 100 ECU GND
23 - 49 - 75 TW (SIG) 101 -
24 - 50 Boost sensor input 76 Overheat signal output 102 -
25 - 51 RED4 GND 77 - 103 -
26 - 52 RED4 GND 78 - 104 -
R2446
T2-2-18 E485
MECHATRO CONTROLLER
NOTES:
E485 T2-3-1
HYDRAULIC CIRCUIT
SUMMARY
The hydraulic circuits are built up with the following ability, safety, mass volume handling and low fuel
functions and features in order to achieve easy oper- consumption.
Perfor-
mance Device Function Features
• Travel straight • Travel straight at combined operation

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

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

(simultaneous operation of arm in arm slanted leveling, swing press digging
and swing motions)
• Automatic swing parking brake • Swing parking when operating at on a slope
• Hydraulic pilot control system • Light action with operating lever

Attachment
• Timer-operated pilot safety lock type • Shut-off of pilot circuit one second after the
safety lock lever is operated
• Lock valve (boom/arm) • Protect boom and arm from unexpected drop
(Natural fall)
• Pressurized hydraulic oil tank • To prevent hydraulic oil from entering dust and
to promote self suction ability of pump
• Suction strainer • Remove dust on suction side
• Line filter; pilot circuit • To prevent pilot operating circuit from malfunc-
Others
tioning
• Return circuit • To prevent hydraulic oil from contamination
• Cooling hydraulic oil by oil cooler • To prevent hydraulic oil from being deteriorated
• Pressure draining circuit • To release the main circuit pressure for piping
repair work
T2-3-2 E485
HYDRAULIC CIRCUIT
Perfor-
mance Device Function Features
• Electric flow controlled variable • Pump delivery rate control by a current com-
displacement pump mand to the solenoid proportional valve of the
Mass handling capability
Pump
variable displacement pump

• Positive flow rate control • Flow control by positive pilot control pressure
• Back-up control • Back-up control when the solenoid proportional
valve of the pump fails
• Boom up conflux circuit • Speed up of boom raise operation

Attachment
• Arm conflux circuit • Speed up of arm operation

• Bucket digging conflux circuit • Speed up of bucket digging operation
• Optimum operation by work mode • Efficient operation in all work modes
select (A,W,HM)
consumption
• Auto accel (Auto/Idle) • Reduce fuel consumption and noise by lowering

computer
Micro
engine speed when control lever is in neutral

Low
fuel
position
Line Coding for Hydraulic Circuits
( ) Feed, drain, tank circuit: oil pressure less than 250 kPa
( ) Return, make up circuit: oil pressure 250 kPa to 500 kPa
( ) Secondary pilot pressure: oil pressure 0.59 MPa to 5 MPa
( ) Primary pilot pressure: oil pressure 3.4 MPa to 5 MPa
( ) Main pump drive pressure: oil pressure 5 MPa to 34.3 MPa

With power boost operating: oil pressure 37.7 MPa
Hydraulic circuit components reading key
1 - Hydraulic pump assy 16 - Boost check valve

2 - Main control valve 17 - Return filter
3 - Swing motor unit (RH) 18 - By-pass valve
4 - Swing motor unit (LH) 19 - Air breather
5 - Boom cylinder (LH) 20 - Solenoid valve assy
6 - Boom cylinder (RH) 21 - Restrictor
7 - Arm cylinder 22 - Restrictor
8 - Bucket cylinder 23 - Arm Regeneration proportional valve
9 - Swivel joint 24 - Restrictor
10 - Pilot valve (ATT) 25 - Restrictor
11 - Pilot valve (TRAVEL) 26 - Travel straight valve
12 - Travel motor 28 - By-pass cut valve P1
13 - Pilot filter 29 - By-pass cut valve P2
14 - Suction strainer 30 - Hydraulic accumulator
15 - By-pass check valve 31 - Check valve
NOTE - Regarding the electrical symbols in this manual, refer to the electric circuit diagram.
E485 T2-3-3
HYDRAULIC CIRCUIT
NEUTRAL CIRCUIT: Positive control system with safety lever turned forward (unlock position)
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
14
18
R3600
T2-3-4 E485
HYDRAULIC CIRCUIT
NEUTRAL CIRCUIT
This section describes the following: Operation:

1. Safety lock lever and pilot circuit. By changing the pilot pressure Pi, the pump tilting
angle (delivery flow) is regulated, as shown in the
2. Control of main pumps.
figure.
This regulator is of the positive flow control in which
the delivery flow Q increases as the pilot pressure
1. SAFETY LOCK LEVER AND PILOT CIRCUIT
Pi rises.
With this mechanism, when the pilot pressure
Purpose:
corresponding to the flow required for the work is
To protect attachment from unexpected motion for commanded, the pump deliveries the required flow
safety. only, and so il does not consume the power use-
lessly.
Principle:
Cut pressure source of pilot valve for operation.
Operation:
If the safety lock lever is turned forward after the
engine starts, the limit switch (SW-11) is turned on.
The timer relay is actuated one second later which
causes the solenoid (SV-4) of the solenoid valve
block (14) to be energized and makes the pilot
operating circuit to stand by.
2. CONTROL OF MAIN PUMPS
Hydraulic ↔ Electric (Mechatro) flow control:
1. Mechatro positive flow control.

Delivery flow, Q
2. Mechatro total-power control.

3. Back up control.
1. Mechatro positive flow control
Purpose:
To decrease the pump delivery at neutral and
Pilot pressure, Pi
increase delivery when lever is operated.
R3601
Principle:
The mechatro controller executes flow control in
direct proportion to pilot pressure by operation of
levers.
E485 T2-3-5
HYDRAULIC CIRCUIT
2. Mechatro total-power control 3. Backup control
Purpose: Purpose:
To use the engine power effectively and to prevent Engine stall prevention at back up operated.
engine stall.
Principle:
Principle:
Brings down the power further below the P-Q curve
The delivery of the pump is controlled by the pump of the pumps controlled by mechatro
solenoid proportional valve as the pump power does
not exceed the engine power. Operation:
Two back up pistons are switched, and then the pilot
Operation:
primary pressure acts on positive control port and
If the ATT or travel actuator is operated, the delivery power shift control port, consequently the P-Q
pressure P1 of pump or the delivery pressure P2 of caracteristic are controlled by restrained input
pump increases. The P1 & P2 pump circuit is torque.
provided with a high-pressure sensor. The pressure
sensor converts pressure to voltage and puts it into
the controller.
The mechatro controller executes P-Q control op-
eration according to voltage outputs from the high-
pressure sensor and the low-pressure sensor and
puts out command current i to the solenoid propor-
tional valves for the pumps according to the delivery
rates of the pumps. Namely, if the pressure of the
P1 and P2 pumps increases, the command current
i to the pump solenoid proportional valves increases
also. This increases the secondary pressure Pi of
the pump solenoid proportional valves which in turn
increase or decrease the delivery of the pumps P1
and P2 in order to avoid the pumps power summa-
tion does not exceed the engine power.
T2-3-6 E485
HYDRAULIC CIRCUIT
TRAVEL CIRCUIT: 2nd speed travel, simultaneous operations
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
14
18
R3602
E485 T2-3-7
HYDRAULIC CIRCUIT
TRAVEL CIRCUIT Principle:

If the switch is turned, an electric signal is issued.
This section describes the following: It excites the travel 1-2 speed changeover solenoid
(SV-3) which in turn converts the primary pilot
1. Mechatro positive flow increase control pressure and the self pressure to a tilting angle of
2. Travel forward pilot simultaneous operation circuit. the variable displacement motor.
3. 2nd speed travel solenoid command circuit and auto
1st speed return function. Operation:
4. Travel main circuit. If the rabbit marked switch on the gauge cluster is
5. Travel motor function. pressed, the solenoid (SV-3) of the proportional
valve block (20) is excited and changes the propor-
tional valve. Then the solenoid command pressure
1. MECHATRO POSITIVE FLOW INCREASE is issued from A7 port, enters the Pi port of the travel
CONTROL motor (4), opens the oil passage to the 2nd speed
select piston, and causes the motor to run in the
Purpose: 2nd speed tilting mode by its self pressure. However,
To increase the pump delivery during travel opera- when the main circuit pressure rises above
tion. 27.4 MPa, the motor's self pressure pushes the
2nd speed select piston back to the 1st speed.
Principle:
The mechatro controller executes flow control in 4. TRAVEL MAIN CIRCUIT
direct proportion to pilot pressure by operation of
lever. Operation:
1) Positive flow control at travel action
Operation: When the travel spool is changed by travel pilot
If either ATT or travel action is executed, the action, the pilot pressure rises, consequently the
secondary pilot pressure shifts the spool of the flow of pump increased.
control valve (C/V). That is the pump flow increase The solenoid proportional valves of the pumps
as the secondary pilot pressure increases. are actuated by both condition of flow rise at
positive control and flow fall at power limitation.
2. TRAVEL FORWARD PILOT

SIMULTANEOUS OPERATION CIRCUIT NOTE - Coloring of pump circuit is execute only
according to operation of positive controlled solenoid.
Purpose:
Light operating force and shockless operation. 2) When the travel spool is shifted, the delivered oil
from the A1 and A2 ports of the main pump
Mechatronics passes through the 5B1 and 4A1 ports of Control
1. If the travel lever with damping mechanism is Valve and the C and A ports of the swivel joint (9),
operated for travel right, left and forward motions, enters the P2 and P1 ports of the travel motor (4)
the secondary pilot proportional pressure comes and performs the following functions in the travel
out of the 2 and 4 ports of pilot valve (11). The higher motor.
of the pressures is selected, comes out of the 5 and
6 ports and acts upon the low pressure sensors (SE-
5. TRAVEL MOTOR FUNCTION
9) and (SE-10).
2. The pilot secondary pressure flows to 5pb1 and Function:
4pa1 ports of the control valve (2), moves the travel
1. Prevents the motor from over running on a slope.
spool, and switches the main circuit.
2. Check valve that prevents cavitation of the hydrau-
lic motor.
3. 2nd SPEED TRAVEL SOLENOID
COMMAND CIRCUIT AND AUTO 3. Shockless relief valve and anti cavitation valve
1st SPEED RETURN FUNCTION when inertia force stops.
4. High/Low 2 step speed change mechanism and
Purpose: auto 1st speed return at high load.
Change travel motor speed with switch. 5. Travel parking brake.
T2-3-8 E485
HYDRAULIC CIRCUIT
BUCKET CIRCUIT: Bucket digging, confluence and ATT boost
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
14
18
1
R3603
E485 T2-3-9
HYDRAULIC CIRCUIT
BUCKET CIRCUIT
This section describes the following: 3. BUCKET DIGGING (CONFLUX) MAIN

1. Bucket digging pilot circuit. CIRCUIT
2. Auto accel operation. Operation:
3. Bucket digging (conflux) main circuit. 1. Increase of P1 & P2 pump flow rates.
With pilot operation, bucket spool and P2 bypass
cut valve are switched, consequently the pilot
1. BUCKET DIGGING PILOT CIRCUIT pressures and P1 and P2 pump flow rates increase
Refer to "Control of main pumps".
1. When the operation for bucket digging is performed, 2. After switching of P2 bypass cut valve, the flow rate
the pilot proportional secondary pressure is deliv- of P2 pump flows into bucket spool through load
ered through port 1 of the right pilot valve (10), flows check valves.
to 4pa2 port of the control valve (2), and acts on the In the meantime, the flow rate of P1 pump opens
low pressure sensor (SE-1), and at the same time load check valve, and flows into bucket spool
the bucket spool is switched. through parallel passage.
2. A voltage signal is input from low pressure sensor 3. When the bucket spool is shifted, pressure is
(SE-1) into mechatro controller, and the mechatro supplied to the bucket cylinder (H) from the 4A2 port
controller outputs command current used to switch of C/V (2).
P2 bypass cut solenoid proportional valve (PSV-B). Meantime, the oil returned from the cylinder R side
3. The secondary pressure from solenoid proportional returns to the tank line from the 4B2 port of C/V (2),
valve flows into 5pc2 port of P2 bypass cut valve while being restricted by the bucket spool.
and P2 unload passage is blocked.
2. AUTO ACCEL OPERATION
Principle:
Start operating with signal output by low pressure
sensor.
Operation:
<Lever in neutral position>
If no signal is sent out to the low pressure sensor for
more than 4 seconds even if the accel dial is turned
to MAX, the engine revolution is set to 1050 rpm.
<Lever in operation position>
If a pressure signal of 0.56 MPa or over enters the
low pressure sensor of the machine with standard
specifications (travel, bucket, boom, swing and
arm), a proportional voltage signal from the low
pressure sensor enters the mechatro controller
and brings the engine revolution back to the accel
dial setting according to the lever strokes.
T2-3-10 E485
HYDRAULIC CIRCUIT
BUCKET CIRCUIT: Bucket dump and Backup operation
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
14
1
18
R3604
E485 T2-3-11
HYDRAULIC CIRCUIT
The following functions are described: 2) The oil delivered by the P1 pump opens load check
4. Bucket dump pilot circuit valve, and arrives at the bucket spool by way of the
5. Bucket dump main circuit parallel passage.
6. Power shift control at back-up operation
3) When the bucket spool is shifted, the oil from port
4B2 of control valve (2) is supplied to bucket
cylinder (R). Meanwhile, the oil which has returned
4. BUCKET DUMP PILOT CIRCUIT from the cylinder (H) side returns to the tank line by
way of port 4A2 and the bucket spool.
Operation:
Hydraulic 6. POWER SHIFT CONTROL AT BACK-UP

1) If bucket dump is operated, the secondary pilot
OPERATION
proportional pressure is issued from port 3 of right
pilot valve (10), enters port 4pb2 of control valve (2) Operation:
and shifts the bucket spool. At the same time, the <Pilot circuit>
pressure acts upon low-pressure sensor (SE-2).
1) When the mechatro control system is out of order,
the rods of both pump regulators can be loosened
completely to shut off the pilot piston circuit from
5. BUCKET DUMP MAIN CIRCUIT
the solenoid proportional valve of the pump. The
primary pilot pressure acts upon the back pressure
Operation:
of compensation piston and executes power shift
1) P1 pump flow increase (reduced power) control along ghe P-Q curve of
If the bucket spool is changed over by pilot opera- mechatro control pump.
tion, the pilot pressure rises and the delivery rates
of the P1 pump increase. Refer to "Control of main
pumps".
T2-3-12 E485
HYDRAULIC CIRCUIT
BOOM CIRCUIT: boom up operation, confluence function
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
14
18
R3605
E485 T2-3-13
HYDRAULIC CIRCUIT
BOOM CIRCUIT
This section describes the boom raise conflux opera- 2. BOOM UP 2 PUMPS CONFLUX MAIN
tion: CIRCUIT IN CONTROL VALVE
1. Boom up pilot circuit.
Purpose:
2. Boom up 2 pumps conflux main circuit in control
valve. Boom up speed up.
Principle:
Confluxing oil from 2 pumps.
1. BOOM UP PILOT CIRCUIT
Operation:
Mechatronics:
1. If the boom spools 1st speed and 2nd speed are
1. If boom up operation is performed, the secondary changed over by pilot operation, the oil delivered
pilot proportional pressure from the right pilot valve through A1 port of P1 pump flows into control valve
(10) gets out of port 4 and acts upon the low (2) P1 port and the travel straight section (center),
pressure sensor (SE-3). At the same time, the and branches into bypass circuit and parallel circuit.
pressure acts upon the 4pa3 and 5pb4 ports of However since the boom spool is moved and
control valve (2), and changes over the boom 1st bypass circuit is closed, the oil opens load check
speed spool and the boom 2nd speed spool. valve through parallel circuit and flows into boom
2. When the boom 1st speed spool and boom 2nd speed spool.
spool are changed over, pilot pressure rises, conse- 2. Then the oil passes through boom spool, opens lock
quently the flow rate of the P1 and P2 pumps are valve of boom lock valve, and is led into (H) side of
increased. boom cylinders through control valve (2) 4A3 port.
3. Meanwhile, the oil delivered from the A2 port of the
P2 pump enters the P2 port of control valve (2) and
is branched to the bypass circuit and the parallel
circuit but, since the boom 2nd-speed spool has
been changed over, the center bypass circuit is
closed. Therefore, the oil pushes open load check
valve, by way of the parallel circuit, passes through
the boom 2nd-speed spool, push load check valve
open via boom conflux circuit, and allows the oil to
conflux internally with the oil delivered by the P1
pump.
4. The return oil from boom cylinder (R) side flows into
tank circuit through boom spool from control valve
(2) 4B3 port.
T2-3-14 E485
HYDRAULIC CIRCUIT
BOOM CIRCUIT: boom down operation & prevention of natural boom falling
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
14
18
R3606
E485 T2-3-15
HYDRAULIC CIRCUIT
This section describes boom down operation: When the boom spool is at neutral position, the drain
line on the lock valve poppet spring chamber is
3. Boom down pilot circuit.
closed which causes the poppet closed.
4. Prevention of natural fall by lock valve, and actua- The result is that the oil returning from the boom
tion at boom down. cylinder head (H) to the boom spool is held and
5. Constant recirculation function of boom down main makes the leakage from the boom spool zero.
circuit. Thus the boom cylinder is prevented from making
a natural fall.
3. BOOM DOWN PILOT CIRCUIT

5. CONSTANT RECIRCULATION
Mechatronics: FUNCTION OF BOOM DOWN MAIN
CIRCUIT
1. If the boom down operation is performed, the sec-
ondary pilot proportional pressure comes out of port Purpose:
2 of the right pilot valve (10) and acts upon the low
pressure sensor (SE-4). Prevention of cavitation during boom
At the same time, the pressure acts upon the 4pb3 lowering motion.
port, 5pa4 port and the 4pc1 port of control valve (2).
Principle:
2. Then, the proportional secondary pressure fed into
control valve (2) 4pb3 port switches boom 1st speed The oil returning from the boom cylinder head (H)
spool. The proportional secondary pressure flown is recirculated to the rod (R).
into control valve (2) 4pc1 port release the lock of
the boom lock valve. Operation:
The secondary pressure led into 5pa4 port switches When the oil is supplied to the boom cylinder rod
the boom 2nd speed spool. (R) side during boom down operation, the boom
3. The voltage output of the low pressure sensor moves faster than it should do in some cases by the
(SE-4) enters the mechatro controller and proc- self weight of the attachment.
essed in it. On that occasion, the circuit pressure on the rod
According to increasing of pilot pressure, the flow (R) side is on the negative side.
rate of P1 pump increases. The P2 pump delivery The oil supplied to the boom cylinder rod (R) flows
flow rate does not increase. into the A1 port of the P1 pump and the P1 port of
control valve. The oil then passes through the
boom spool and goes out of the 4B3 port.
On that occasion, the oil returning from the head
4. PREVENTION OF NATURAL FALL BY (H) goes through the recirculation path in the boom
LOCK VALVE spool, pushes the check valve in the spool open, is
recirculated to the 4A3 port and is supplied to the rod
Purpose: (R). When the (R) pressure is larger than the (H)
pressure, the check valve closes. Thereupon, the
Prevention of natural fall when the lever is neutral. recirculation is stopped.
The spool for 2nd speed strokes to the position the
Principle: passage to tank open, in order to make lowering
The oil is prevented from returning to the boom speed higher.
spool by the poppet seat of the boom lock valve.
Operation:
In the boom down action, the selector valve is
changed over by the boom down pilot pressure.
Then the poppet spring chamber of the lock valve
gets through the drain line and makes the lock valve
poppet open.
12
T2-3-16
1
PSV-P1 PSV-P2
3 4
26
21
19
SWING CIRCUIT: swing operation (LH)
18 22
14 15 16
17 8
13 24
5
6
31
25
HYDRAULIC CIRCUIT
10
29 28
7
23
11
30
SV-4 SV-2 PSV-B PSV-C PSV-D PSV-A SV-3 SV-1
20
E485
R3607
E485 T2-3-17
HYDRAULIC CIRCUIT
SWING CIRCUIT
This section describes the following operations: 3. SWING MAIN CIRCUIT

1. Swing left pilot circuit.
Operation:
2. Swing auto parking brake.
The delivery oil through A2 port of P2 pump flows
3. Swing main circuit. into P2 port of the C/V (2) and is branched into the
4. Swing motor circuit. bypass circuit and parallel circuit, but the bypass
circuit is restricted with the movement of the swing
spool, the pressure opens load check valve through
the parallel circuit flows into A and B ports of the
1. SWING LEFT PILOT CIRCUIT swing motors through 5A2 port of the C/V (2) and
rotates the swing motors counterclockwise.
Mechatronics:
1. If the swing left action is performed, the secondary
pilot pressure goes out of port 1 of left pilot valve 4. SWING MOTOR CIRCUIT
(10) and acts upon the low pressure sensor (SE-5).
At the same time, the pressure acts upon the 5pa2 1. Anti cavitation circuit at swing deceleration.
port of C/V (2).
2. Shockless relief valve that prevents the swing
motor from being reversed.
2. SWING AUTO PARKING BRAKE
Purpose:
Swing lock in neutral position and parking.
Principle:
Release mechanical brake only when required to
operate swing and arm in.
Operation:
1. The swing parking system excites the swing park-
ing soleniod (SV-1) usually if the key switch is
turned in ON position and works by the action of the
mechanical brake.
2. The mechanical brake is released if the swing
parking solenoid is de-excited only when the sec-
ondary operating pressure in the swing and arm in
actions acts upon any of the low pressure sensors
(SE-5) or (SE-7).
3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low pres-
sure sensor (SE-5) is reduced to zero.
In the case of arm in operation, the swing parking
solenoid (SV-1) is excited the moment the pres-
sure of the arm in low pressure sensor (SE-7) is
reduced to zero. This causes the mechanical brake
to operate.
T2-3-18 E485
HYDRAULIC CIRCUIT
ARM CIRCUIT: Arm in operation (light load), arm variable recirculation and anticavitation function
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
14
18
R3608
E485 T2-3-19
HYDRAULIC CIRCUIT
ARM CIRCUIT
This section describes the following operations: 2. ARM IN, LIGHT-LOAD VARIABLE NORMAL
RECIRCULATION MAIN CIRCUIT
1. Arm in, light-load operating pilot circuit.
2. Arm in, light-load variable normal recirculation main Operation:
circuit.
1. The oil returning from the arm cylinder (R) pushes
the arm lock valve open and enters the arm spool.
2. Since the passage to the tank from arm spool is
1. ARM IN, LIGHT-LOAD OPERATING PILOT shut off, the oil returning from the arm cylinder (R)
CIRCUIT is combined with the oil on the supply side of the arm
cylinder (H) via the check valve in the arm spool.
Purpose:
3. When load is light, the pressure on the cylinder (R)
Speed-up and Anticavitation when the arm is at light is higher than that on the cylinder (H). This pushes
loaded. the load check valve open. The oil is then
recirculated to the cylinder (H) side to speed up
Principle: digging at light duty.
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at inside of arm
spool 1st speed of control valve.
Operation:
1. If the arm in (digging) operation is performed, the
secondary pilot proportional pressure gets out of
port 4 of the left pilot valve (10) and acts upon the
low pressure sensor (SE-7).
At the same time, the pressure is branched off into
three circuits, acts upon the 5pb5 port, the 5pc1 port
and the recirculation proportional reducing valve
(23) P port, changes over the arm spool 1st speed
and the arm lock valve selector.
2. The voltage output by the low pressure sensor for
the arm in operation pilot is put into mechatro
controller and processed. Then, a current com-
mand, which is direct proportional to the pilot input
voltage, outputs to pump solenoid controlled pres-
sure reducing valve and recirculation proportional
pressure reducing valve. Then P2 pump delivery
flow rate increases.
T2-3-20 E485
HYDRAULIC CIRCUIT
ARM CIRCUIT: Arm in operation (heavy load) sequence confluence function
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
14
1
18
R3609
E485 T2-3-21
HYDRAULIC CIRCUIT
This section describes the following operations:

3. Arm in, heavy load operating confluxed main circuit.
3. ARM IN, HEAVY LOAD OPERATING

CONFLUX CIRCUIT (RECIRCULATION
CUT AND CONFLUXED)
Purpose:
Speed-up for arm in operation.
Principle:
The oil flow delivered by the P1 pump is confluxed,
in the C/V (2), with that by the P2 pump.
Operation:
If the arm is heavily loaded during arm in, a com-
mand current is put out to the arm recirculation
proportional valve (23).
The secondary pressure of arm recirculation propor-
tional reducing valve moves the arm spool 2nd speed
to the recirculation cut position; consequently the
arm cylinder rod circuit and tank circuit are con-
nected.
As soon as the arm spool for 2nd speed switches, P1
pump delivery oil confluxes with it for the arm
2nd speed.
T2-3-22 E485
HYDRAULIC CIRCUIT
ARM CIRCUIT: Arm out operation, confluence function
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
14
18
R3610
E485 T2-3-23
HYDRAULIC CIRCUIT
This section describes the following operations: 5. NATURAL FALL PROTECTION WITH
4. Arm out conflux control. ARM LOCK VALVE
5. Natural fall protection with arm lock valve. Purpose:
To prevent the arm from falling naturally by the
weight of the arm & bucket.
4. ARM OUT CONFLUX CONTROL
Principle:
Operation:
Complete seat of the return circuit against the arm
1. If the arm out operation is performed, the second- spool of the arm cylinder (R) side circuit.
ary pilot proportional pressure gets out of port 2 of
the left pilot valve (10), and acts upon the low Operation:
pressure sensor (SE-8). At the same time, the oil is
branched off into two flows and acts upon the 5pa5, 1. When the arm cylinder stops as the secondary
and 4pb4 ports of C/V (2). pressure for arm action is reduced to zero, the
pressure on the rod (R) side acts upon the back
2. Then, the secondary pilot pressure which has en- pressure of the lock valve via the 5A5 port of the C/V
tered the 5pa5 port of C/V (2) changes over the arm (2) and seats the lock valve.
spool 1st speed. In the meantime, the secondary
pilot pressure which has entered the 4pb4 port 2. Since the oil flow into the arm spool from the lock
changes over the arm spool 2nd speed. valve is shut off completely, natural fall of the arm
due to oil leaks through the arm spool is prevented.
3. If 1st speed and 2nd speed arm spools are operated
at the same time, the oil flows to arm cylinder are
confluxed.
The voltage output of low-pressure sensor (SE-8)
enters the mechatro controller. The controller in-
creases the delivery rates of the P1 and P2 pumps
by related control when the arm spools 1st speed
and 2nd speed are changed over.
T2-3-24 E485
HYDRAULIC CIRCUIT
COMBINED OPERATION: Boom up/Travel forward 1st speed operation, travel straight function
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
18
14
R3611
E485 T2-3-25
HYDRAULIC CIRCUIT
COMBINED OPERATION
This section describes only the difference in com- 2. BOOM UP/TRAVEL, TRAVEL STRAIGHT
bined operation: CIRCUIT
1. Boom up/travel, pilot circuit.
Purpose:
2. Boom up/travel.
Functions of travel straight circuit. The machine can execute travel straight and at-
tachment actions at the same time even if the
attachment is operated during travel action.
1. BOOM UP/TRAVEL, PILOT CIRCUIT Principle:
Operation: The travel action and the attachment action are

actuated by respective pumps.
<Pilot circuit other than independent operation>
1. If ATT and travel actions are performed at the same Operation:
time, the secondary pilot pressure enters the travel 1. When the travel straight valve is changed over, the
low-pressure sensors (SE-9), (SE-10), and the ATT oil delivered by the P2 pump enters the P2 port of
low-pressure sensors (SE-1 to SE-8). The C/V (2) and the right and left of the travel spool, and
mechatro controller processes the signals and puts is supplied to the travel motor by way of the swivel
out a current command to the travel straight sole- joint (9).
noid proportional valve (PSV-C) to energize it.
Then the secondary pressure of the solenoid pro- 2. When the travel straight valve is changed over, the
portional valve goes out of port A4 and enters port oil delivered by the P1 pump connects with all the
Pz1 of the C/V. ATT spools and the parallel circuits.
2. Then the pressure of the Pz1 port changes over the 3. If boom up is executed, for instance, the oil deliv-
travel straight valve. ered by the P1 pump opens load check valve,
enters the boom spool 1st speed, opens load check
valve, enters the boom spool 2nd speed, pushes
open lock valve via both spools and is supplied to
the boom cylinder (H).
T2-3-26 E485
HYDRAULIC CIRCUIT
COMBINED OPERATION: Swing/Arm in operation, Swing priority function
22
11
10
4
7
6
5
8
3
25
23
28
26
12
30
9
29
2
20
21
24
SV-1
SV-3
PSV-A
PSV-D
PSV-P2
PSV-C
13
16
PSV-B
15
17
SV-2
31
SV-4
19
PSV-P1
1
14
18
R3612
E485 T2-3-27
HYDRAULIC CIRCUIT
This section describes difference in combined opera- Operation:

tion:
1. Since the swing and the arm circuits make up a
3. Swing/Arm in, pilot circuit. parallel passage, the oil delivered by the P2 pump
runs into the swing and arm lines at the same time.
4. Swing/Arm in, swing priority main circuit.
If swing pilot action is executed, the secondary pilot
pressure for swing action enters the spool of swing
priority lock valve. The oil delivered by the P2 pump
3. SWING/ARM IN, PILOT CIRCUIT regulates the oil flowing into the arm spool 1st speed.
This makes the oil easy to flow into the swing spool.
Operation: The oil then pushes load check valve open and
1. The secondary pilot pressure for swing action supplies the oil preferentially to the swing spool.
changes over the swing spool in the C/V (2) and acts
upon the spool of the check valve, the same way as
the swing independent action. The secondary pilot
pressure for arm in changes over the arm spool
1st speed and the arm lock selector valve.
4. SWING/ARM IN, SWING PRIORITY MAIN

CIRCUIT
Purpose:
Stable swing speed.
Principle:
The system regulates the oil flow into the arm and
turns the oil flow by P2 pump preferentially for use
in the swing action.
1 12
T2-3-28
PSV-P1 PSV-P2
3 4
26
21
19
18 22
14 15 16
8
PRESSURE DRAIN (RELEASING) CIRCUIT
17
13 24
5
6
31
25
HYDRAULIC CIRCUIT
10
29 28
7
23
11
30
20
R3613
E485
E485 T2-3-29
HYDRAULIC CIRCUIT
PRESSURE DRAINING (RELEASING)

CIRCUIT
This section describes the following operations: pressure is completed, turn off the starter key, and
buzzer stops. If the pump pressure is determined to
1. Pressure drain (releasing) pilot circuit.
be more than 970 KPa by the output value of the
2. Pressure drain (releasing) main circuit. high-pressure sensor or the high-pressure sensors
(SE-22,23) are broken, "FAIL DRAIN HYD.
PRESS" is displayed on the gauge cluster and the
buzzer sounds continuously. In that case, also the
1. PRESSURE RELEASE PILOT CIRCUIT
buzzer is not stopped unless the engine key is
turned to off. Repeat the pressure releasing proce-
Purpose:
dure once again.
To release the main circuit pressure for piping
repair work. If the travel straight valve is switched to the pres-
sure release position, the oil delivered by each
Principle: pump is unloaded to the tank passage. This deliv-
ered oil flows into tank passage through bypass
When the hydraulic pressure release switch is
passage, because the oil is communicated to tank
switched, mechatro controller judges this is pres-
passage through orifice in travel straight valve.
sure release control and outputs the following com-
If the spools are switched by pilot operation, the
mand:
remaining pressure from the actuators may be
1. Puts out the minimum tilting command value to the relieved via travel straight valve and relieved from
pump proportional valves (PSV-P1, PSV-P2). bypass passage of opposite side of drive pump to
the tank circuit, consequently the main circuit
2. Puts out a pressure release control revolution
pressure may be released.
command value to the engine electronic control.
• Don't operate right and left control levers simul-
3. Travel straight solenoid proportional valve (PSV-C)
taneously, the pressure can't relieve because of
is input the command value to change the pressure
blocking of tank passage.
release position.
• Stroke the lever to the slow motion range inde-
4. Puts out a standby command value to the P1, P2
pendently. If the movement of stroke is too far,
bypass cut proportional valves. (a command that
the release of pressure isn't performed due to the
does not put out the secondary pressure of the P1,
communicating passage of travel straight valve
P2 bypass proportional valves).
is narrow.
Operation:
1. The pump proportional valve minimizes the deliv- NOTE - The pressure release position is middle
ery rates of the P1, P2 pumps. stroked position between normal position and travel
straight position (See following fig.), this condition is
2. The secondary pilot pressure for the travel straight
so-called pressure release position.
valve pressure release position selection comes
out of the travel straight proportional valve (PSV-C),
flows into the Pz1 port of C/V (2) and switches the
travel straight valve to its pressure release position.
2. PRESSURE RELEASE MAIN CIRCUIT
Operation:
When the operating lever is shifted to neutral, during Travel straight valve
engine running, if the pressure is drained (released) Pressure
release
as already mentioned, "DRAINING HYD. PRESS" position
is displayed on the gauge cluster and intermittent
buzzer sound continuously. Operate the levers of
each motion of attachment right and left four to five
Travel straight Normal
times independently to their slow motion range, the position position
release of pressure is performed. After draining
R3614
T2-3-30 E485
HYDRAULIC CIRCUIT
CRUSHER & BREAKER CIRCUIT
Outline
2
1 3 4
5
6
8 7
10 11
Replacing the
breaker with the
crusher is possible.
12
15
13
14
R3615
1 - Arm hydraulic piping 9 - Arm

2 - Hydraulic piping for boom 10 - Hydraulic breaker
3 - Upper hydraulic piping return hydraulic piping 11 - Arm top piping
4 - Selector valve 12 - Operating pedal
5 - Control valve option spool 13 - Single/conflux flow select switch
6 - Main control valve 14 - Remote control piping
7 - Hydraulic tank 15 - Crusher
8 - Stop valve
E485 T2-3-31
HYDRAULIC CIRCUIT
FOREWORD
• When using breaker, set the selector valve (item 2) • When using Crusher, according to specification of
to return to hydraulic tank directly hydraulic oil from Crusher installed, choose conflux or single flow by
breaker. conflux flow changeover switch.
• Adjust overload relief valve of opt. port to custom-

ize specification ordinary set pressure.
To tank To tank
To breaker To crusher
To control To control
valve valve
M0545 M0546
Selection condition and proportional valve command when any of Crusher single & conflux flow or breaker is
service.
COMMAND SIGNAL OF SOLENOID

SELECTION PROPORTIONAL VALVE
(W: {, W/{: –)
CONFLUX / SELECTOR
P1 P2 TRAVEL P1 P2
SINGLE SELECT VALVE MODE
SW. (ITEM 2) PUMP PUMP STRAIGHT CUT CUT
CRUSHER { { { { { A
CONFLUX ON
CONFLUX
CRUSHER – { – – { A
CONFLUX OFF
SINGLE
BREAKER CONFLUX OFF – { – – { A

T2-3-32 E485
HYDRAULIC CIRCUIT
HYDRAULIC DIAGRAM FOR CRUSHER & BREAKER: at crusher single flow operating
NOTE - This hydraulic circuit is used by adding to

the STD circuit diagram.
6
R
H
3
4
2
16
12
8
PSV-D
13
11
SV-4
10
5
R3616
1 - Option spool 9 - P1 bypass cut valve

2 - Selector valve 10 - P2 bypass cut valve
3 - Stop valve 11 - P2 main circuit
4 - Pilot valve 12 - P1 bypass circuit
5 - Return filter 13 - P2 bypass circuit
6 - Crusher cylinder 16 - Solenoid valve block
8 - Travel straight valve
E485 T2-3-33
HYDRAULIC CIRCUIT
CRUSHER & BREAKER CIRCUIT
Set the single/conflux flow select switch, according to 2) Main circuit

the specifications of the Crusher to be used. • The oil delivered by the P2 pump runs through the
straight valve (not switched) on the P1 side from
1. SINGLE FLOW FOR CRUSHER the main circuit (11) on the P2 side as the option
1) Pilot circuit spool is switched. Therefore the oil pushes open
the load check valve and runs to the option spool
• Change the single/conflux flow select switch to (1).
single. • The oil passes through the spool, is supplied to
• Depress the pilot valve (4) for the Crusher & the head (H) of the crusher cylinder (6) by way of
Breaker on your tiptoe. Then the secondary pilot the 5A3 port.
pressure enters the 5pa3 port of the control valve • The oil that comes back from the rod (R) of the
from the B port and changes over the spool of the crusher cylinder returns to the oil tank by way of
option spool (1). the 5B3 port of the option spool (1), and the oil
• Concurrently, the secondary pilot pressure en- cooler.
ters the low-pressure sensor (SE-11) from the
C2 port. The voltage output of the pressure
sensor enters the mechatro controller where
pilot signal processing takes place. The
mechatro controller then puts out current com-
mands, according to the voltage input to the P2
pump proportional valve.
• The P2 pump proportional valve puts out second-
ary pressure to the pump regulator to change the
delivery rate of the P2 pump.
T2-3-34 E485
HYDRAULIC CIRCUIT
HYDRAULIC DIAGRAM FOR CRUSHER & BREAKER: at crusher conflux flow circuit operating

6
R
H
3
4
2
16
12
8
PSV-D
13
1
SV-4
10
11
R3617
1 - Option spool 9 - P1 bypass cut valve

2 - Selector valve 10 - P2 bypass cut valve
3 - Stop valve 11 - P2 main circuit
4 - Pilot valve 12 - P1 bypass circuit
6 - Crusher cylinder 16 - Solenoid valve block
E485 T2-3-35
HYDRAULIC CIRCUIT
2. CONFLUX CIRCUIT FOR CRUSHER

1) Pilot circuit 2) Main circuit
• Change the single/conflux flow select switch to • The oil delivered by the P1 pump enters the
conflux. control valve, but since the P1 bypass cut spool
• Depress the pilot valve (4) for the Crusher & (9) has been changed over, the oil pushes the
Breaker on your tiptoe. The secondary pilot load check valve open and runs into the P2
pressure enters to the 5pa3 port of control valve bypass circuit (13).
(1) from the B port of pilot valve (4) and changes • The oil delivered by the P2 pump enters the
over the option spool (1). control valve, but since the spool of the travel
• Concurrently, the secondary pilot pressure en- straight valve (8), is not changed over, the oil
ters the low-pressure sensor (SE-11) from the C2 pushes the load check valve open, runs into the
port. The voltage output from the low-pressure P2 parallel circuit, and combines with the oil
sensor (SE-11) enters the mechatro controller delivered by the P1 pump.
where pilot signal processing takes place. The • The oil runs through the option spool and (1), is
mechatro controller then puts out current com- fed to the head (H) of the crusher cylinder (6) via
mands according to the voltage inputs, to the the spool and the 5A3 port, and causes the
proportional valves for the P1 pump and the P2 crusher to take close action.
pump, the P1 bypass cut proportional valve. • The oil that comes back from the rod (R) of the
• The P1 and P2 pump proportional valves put out crusher cylinder returns to the hydraulic tank, by
secondary pressure to the pump regulators to way of the 5B3 port of the option spool (1), and the
change delivery rates of the pumps. oil cooler.
• The P1 bypass cut proportional valve (PSV-D)
puts out secondary pressure to the 4pc2 port of
the control valve and changes over the P1
bypass cut spool (9).
T2-3-36 E485
HYDRAULIC CIRCUIT
HYDRAULIC DIAGRAM FOR CRUSHER & BREAKER: at breaker operating

7
3
4
2
12
8
PSV-D
13
1
11
SV-4
10
5
R3618
1 - Option spool 8- Travel straight valve

2 - Selector valve 9- P1 bypass cut valve
3 - Stop valve 10 - P2 bypass cut valve
4 - Pilot valve 11 - P2 main circuit
6 - Crusher cylinder 13 - P2 bypass circuit
7 - Breaker 16 - Solenoid valve block
E485 T2-3-37
HYDRAULIC CIRCUIT
3. BREAKER
• Bring the selector valve (2) to the position so as Procedure of setting the maximum flow:
to return the oil from the breaker directly to the oil
1. Turn ON the starter switch (without starting the
tank.
engine) and bring the machine to the breaker A
• Adjust the pressure of the port relief valve in the mode. If the screen change switch on the gauge
option valve, according to the specifications of cluster is pressed between 3 seconds and 10
the breaker to be mounted to the machine. seconds, the machine is brought to the adjust
mode.
1. Pilot circuit
• If the operating pedal (4) for the Crusher &
Breaker is depressed on your heel, secondary NOTE - The adjust mode is not available if the above
pilot pressure enters the 5pb3 port of the control step is taken after the engine has been started up.
valve (1) from the A port and changes over the
option spool. 2. A previously stored flow rate is displayed on the
• Concurrently, the secondary pilot pressure en- multi display.
ters the low-pressure sensor (SE-11) from the
C2 port. The voltage output from the pressure 3. The flow increases as the operation mode select
sensor enters the mechatro controller where switch is pressed, while it decreases as the buzzer
pilot signal processing takes place. The stop switch is pressed.
mechatro controller then puts out current com- 4. The flow changes two seconds after either switch
mands according to the voltage inputs, to the P2 is kept pressed. It changes by the 10 L min-1
pump. (20 L min-1 with conflux selected); let the switch go
• The proportional valve for the P2 pump puts out at a desired reading.
secondary pressure to the pump regulator to
5. The flow may be set in the range of the max. to min.
change the delivery rate of it.
values.
2. Main circuit 6. If the screen change switch is turned ON again, the
• The oil delivered by the P2 pump runs into the adjusted max. flow is stored, and the machine is
main circuit on the P2 side (11), but since the released from the adjust mode.
option spool (1) has been changed over, the oil
runs into the parallel circuit on the P1 side.
• The oil runs through the travel straight valve (not
switched) and pushes open the check valve and
is fed to the breaker by way of the option spool (1)
and the 5B3 port, and causes the breaker to
make blow action.
• The oil that comes back from the breaker returns
directly to the oil tank via the selector valve (2).
T2-3-38 E485
HYDRAULIC CIRCUIT
NOTES:
E485 T2-4-1
ELECTRICAL SYSTEM
OUTLINE
The electrical system is classified into the main circuit, 3. Starting Circuit: starts the engine. (Key Switch,
control circuit, and monitor circuit. Safety Relay, Starter motor)
• Main circuit operates the engine and accesso- 4. Charging Circuit: recharges the batteries and
ries. supplies consumption electricity. (Alternator,
• Control circuit functions to control operations of Regulator, Batteries)
the engine, hydraulic pumps, and valves (includ- 5. Preheating Circuit: automatically controlled by
ing actuators such as solenoid valves, Mechatro Engine Control Unit, helps the start of the engine
Controller, Engine Control Unit, switch panel, in cold weather. (Engine Control Unit, glow relay
sensors, and pressure switches). and glow plugs).
• Monitor circuit operates the monitoring devices 6. Engine Stop Circuit: stops the engine throught
consisting in indicators, indicators lights and Engine Control Unit (Key Switch, Engine stop
switches. relay, Engine Control Unit).
7. Engine Emergency Stop Circuit: In case of oil
In this group, the functions of the main circuit are
pressure drop, or in case of coolant engine
shown:
overheating, the buzzer is activated. With oil low
1. Electric Power Circuit: supplies electric power to pressure persisting, the engine will be automati-
all electric system on the machine. (Key Switch, cally stopped. (Engine oil pressure switch, En-
Batteries, Fuses, Battery Relay) gine coolant temperature sensor, Engine stop
2. Accessory Circuit: works with the key switch relay, Mechatro controller, Engine controller).
placed in the ACC position. (Key Switch, Bat-
tery, Fuses)
T2-4-2 E485
ELECTRICAL SYSTEM
ELECTRIC POWER CIRCUIT

(Key switch in OFF position)
The battery negative terminal is grounded to the

vehicle.
Current from the battery positive terminal flows as

follows with the key switch in OFF position:
Battery (7) Fuse link 6 (60 A) (2)

Terminal 7
• Mechatro controller
Backup
Battery
Relay (R-1) (8)
Terminal 8
• Fuel pump
Terminal 9
• Room light
• Engine room light
Terminal 10
Fuse
box (E-4) (1) • Key Switch terminal B
• Fleet link (Optional)
1 - Fuse box (E-4) 16 - Safety relay (R-4)

2 - Fuse Link 6 (60 A) (E-27) 17 - Alternator assembly (E-2)
3 - Fuse Link 5 (30 A) (E-28) 18 - Glow plugs (E-12)
4 - Glow relay (R-6) 29 - Diode 17
5 - Mechatro controller C-1 30 - Fuse link box A
7 - Battery (E-1) 139 - Engine room light switch (SW-16)
8 - Battery relay (R-1) 140 - Engine room light (L-12)
9 - Key switch (SW-1) 141 - Fuel supply pump
10 - Starter motor assembly 148 - Engine diagnosis request switch (SW-46)
12 - Engine emergency stop relay (R-28) 149 - Engine controller (C-3)
Key switch in OFF position
E485
149
1 4 148
18
2
3
12
7 5
8
30 1A
1B
9 7
29
10
ELECTRICAL SYSTEM
17
16
27
140 141
139
T2-4-3
R2210
T2-4-4 E485
ELECTRICAL SYSTEM
ACCESSORY CIRCUIT
(Key Switch in ACC position)
When the key switch (9) is turned to the ACC position, switch (9) in OFF position), from terminal ACC can
the terminal ACC is connected to terminal B inside the reach the fuse box (1) and from this, thought the
key switch (9). relate fuses, can supply the following accessory:
horn, cigar lighter, and power converter 24 V/12 V
Therefore, the battery (7) current, already existing on D.C. that in turn, supplies the radio and 12 V D.C.
the terminal B (refer to Electric Power Circuit with Key power socket.
1 - Fuse box (E-4) 23 - Antenna

2 - Fuse Link 6 (60 A) (E-27) 24 - Speakers
3 - Fuse Link 5 (30 A) (E-28) 25 - 12V D.C. Socket
4 - Glow relay (R-6) 26 - Converter (E-22)
5 - Mechatro controller C-1 29 - Diode 17
7 - Battery (E-1) 30 - Fuse link box A
8 - Battery relay (R-1) 56 - Tuner (E-7)
9 - Key switch (SW-1) 128 - Cigarette lighter (E-14)
10 - Starter motor assembly 131 - Horn relay (R-5)
12 - Engine emergency stop relay (R-28) 132 - Horn
16 - Safety relay (R-4) 133 - Horn switch (SW-10)
17 - Alternator assembly (E-2) 148 - Engine diagnosis request switch (SW-46)
18 - Glow plugs (E-12) 149 - Engine controller (C-3)
Key Switch in ACC position
E485
149
1 4 148
18
2
3
12
7 5
8
30 1A
1B
9 7
29
10
17
ELECTRICAL SYSTEM
16
27
23
128
56
26
24
131 132
25
T2-4-5
133 R2211
T2-4-6 E485
ELECTRICAL SYSTEM
ELECTRIC POWER CIRCUIT

(Key switch in ON position)
When the key switch (9) is turned to the ON position, By means of the fuse link 1 the fuses from 12 to 20 in
the terminal B is connected to terminals ACC and M. the fuse box (1) are powered. From these fuses, power
supply are fed to the control of solenoid valves, work
The current, beside to supply the accessory circuits lights, air condition, heater, wiper, auto grease system
connect to terminal ACC, from terminal M is routed to and further optional circuits.
the terminal 13-2 of Mechatro Controller C-1 (5) and to
the terminals 6-60, and 6-61 of Engine Control Unit C-3 By means of the fuse link 2, the terminals B and R of
(149) (via Engine Emerg. Stop Relay R-28) to feed the alternator (17) are connected to power supply line of
"key on" signal (Key switch (9) in ON position). the batteries (7).
Further, from the same terminal M, the current through By means of the fuse link 3, the Engine Control Unit
the Diode 16 (28), supplies the coil (terminal L) of the (149) are supplied throught terminals 6-93, 6-92, and
Battery relay R-1 (8). 6-10, 6-11.
The Battery relay R-1 (8) therefore is actuated and By means of the fuse link 4 the power supply is applied
connects the current of the batteries (7) to: to the Engine Emergency stop relay (R-28) (12),
Mechatro Controller C-1 (5) and Wiper relay box (111).
• Fuse link 1, 2 and 3, 4 (E-25) (30)
• Fuse link 5 (E-28) (3) By means of the fuse link 5 (E-28) (3), the power supply
• Power supply to starter motor (10) is applied to the Glow relay (R-6) (4).
• Safety relay R-4 (terminal B) (16)
1- Fuse box (E-4) 100 - Cluster gauge (C-2)

2- Fuse Link 6 (60 A) (E-27) 118 - Working light switch (SW-20)
3- Fuse Link 5 (30 A) (E-28) 119 - Frame working light (L-2)
4- Glow relay (R-6) 120 - Boom working right light (L-6)
5- Mechatro controller C-1 121 - Boom working left light (L-1)
7- Battery (E-1) 129 - Auto grease controller
8- Battery relay (R-1) 130 - Auto grease system switch (SW-57)
9- Key switch (SW-1) 135 - Air conditioner (C-4)
10 - Starter motor assembly 136 - Receiver drier (E-10)
12 - Engine emergency stop relay (R-28) 137 - Air compressor Clutch. (E-11)
16 - Safety relay (R-4) 138 - Air conditioner Switch (SW-13)
17 - Alternator assembly (E-2) 145 - Auto grease system connector
18 - Glow plugs (E-12) 146 - Auto grease working light (L-57)
28 - Diode 16 148 - Engine diagnosis request switch (SW-46)
29 - Diode 17 149 - Engine controller (C-3)
30 - Fuse link box A (E-25)
E485 T2-4-7
ELECTRICAL SYSTEM
R3763
Key switch in ON position
T2-4-8 E485
ELECTRICAL SYSTEM
STARTING CIRCUIT
(Key Switch in START position)
When the key switch (9) is turned to the START As soon the starter motor (10) puts in turn the engine,
position, terminal B on the key switch is connected to the alternator generates an output voltage, than the
terminals G2, M, and ST in the switch. current flows toward the contact 13-6 of Mechatro
Controller and actuates the safety relay R-4 (16). The
In this position, other than to maintain the power relay R-4, opens its contact, shut down the power
supply on the terminal M (refer to circuit with key supply of starter motor. The starter disengages from
switch in ON position), the power on terminal ST of the engine flywheel completing in this way the starting
key switch is connected to terminal S of the Safety sequence.
relay (R-4) (16) and to terminal 6-65 "Engine start" of
Engine Control Unit (149). The activation of the safety relay R-4 (16) occurs in
any case, even if the key switch (9) is hold on START
The battery (7) current can then flow through the position, avoiding in this way a possible dragging of
Safety relay (R-4) (16). With activation of relay, the starter motor (10) or a further starter coupling with
closed contacts allow the battery (7) current to flow engine already running.
toward the terminal C of the starter motor (10).
The inner relay of starter will close and allow to power

the starter motor (10). Thereby, the starter begins to
rotate.
1 - Fuse box (E-4) 12 - Engine emergency stop relay (R-28)

2 - Fuse Link 6 (60 A) (E-27) 16 - Safety relay (R-4)
4 - Glow relay (R-6) 18 - Glow plugs (E-12)
5 - Mechatro controller C-1 27 - Hour meter (E-3)
7 - Battery (E-1) 29 - Diode 17
8 - Battery relay (R-1) 30 - Fuse link box A
9 - Key switch (SW-1) 148 - Engine diagnosis request switch (SW-46)
10 - Starter motor assembly (M-1) 149 - Engine controller (C-3)
E485 T2-4-9
ELECTRICAL SYSTEM
Key Switch in START position
T2-4-10 E485
ELECTRICAL SYSTEM
Safety Relay Operation
• When the key switch is turned to the START relay terminal R rises. When the voltage at terminal
position, key switch terminal B and ST have conti- R reaches 21 to 22 V, zener diode (Z) comes ON.
nuity in the key switch. Then, the current flows to Accordingly, transistor (Q1) is switched ON so that
the base of transistor (Q2) via resistance R4 in the the base current to transistor (Q2) is cut, switching
starter relay, switching transistor (Q2) ON. transistor (Q2) OFF. At this time, continuity be-
Thereby, the current flows through coil (L) of relay, tween starter terminal B and C is opened. Then, the
closing the circuit between starter terminals B and starter is switched OFF. Capacitor C1 shown in the
C. Then, the starter begins to rotate. figure is used to stabilize the operating voltage.
Diode D4 protects the circuit from damage when the
• Once the engine is started, the alternator begins to batteries are inversely connected.
charge the batteries so that the voltage at starter
Safety Relay Operation
E485
24 V Dc from battery relay R-1
To fuse box E-4
R4 L Key-on signal to mechatro controller C-1

D3
R2 R3
ELECTRICAL SYSTEM
Q2
Z D2 Engine start signal to engine controller C-3
Q1
C1 C D4
Charge signal from alternator E-2

T2-4-11
R2218
T2-4-12 E485
ELECTRICAL SYSTEM
CHARGING CIRCUIT
(Key Switch in ON position)
After the engine starts and the key switch is released, In addition, through the terminal L of the alternator (17),
the key switch (9) is returned to the ON position. a "charge " signal is supplied to the Mechatro Control-
ler (5), terminal 13-6.
After the engine starts, the alternator (17) begins to In case of lack of voltage output from alternator (17)
deliver voltage output. side, the Mechatro Controller (5) will feed to the cluster
gauge a no charge signal.
Current from terminal B of the alternator (17) flows to
the batteries (7) through the fuse link 2 of 40 A and Further, from the terminal L of the alternator (17) the
through the battery relay R-1 (8) actuated. Therefore, "charge" signal is also supplied to the Safety Relay
with engine running, the alternator (17) will power all (R-4) (16) (Refer to Starting Circuit) and to the Hour
utility of the machine and will maintain the batteries (7) meter (E-3) (27) for the counting of operating hours.
in charge.

10 - Starter motor assembly 149 - Engine controller (C-3)
Charging circuit
E485
149
1 4 148
18
2
3
12
7 5
8
30 1A
1B
9 7
29
ELECTRICAL SYSTEM
10
17
16
27
T2-4-13
R2214
T2-4-14 E485
ELECTRICAL SYSTEM
PREHEATING CIRCUIT
When the key switch (9) is turned to ON position, the actuated and, as it receives power supply from fuse
battery relay R-1 (8) is activated and a "key on "signal link 5 (E-28) (3), by its closing contact, allows the
is fed to the Mechatro Controller (5) and to Engine powered of glow plugs (E-12) (18) on the engine.
Controller (149).
Further, for the period on which the glow plugs are
Further, the current of the batteries (7), through the powered, a signal flows from glow relay R-6 (4) to
battery relay R-1 (8) is routing to the 30 A fuse link 5 terminal 13-3 of Mechatro Controller (5). This sends to
(E-28) (3), reaches the terminal of Glow relay R-6 (4). the cluster gauge a signal for the indication to the
The coil of the Glow relay (R-6) is powered through the operator of preheating time.
fuse box E-4 (1).
After elapsing time, the Engine Controller (149) re-
In these conditions and with engine coolant tempera- moves the ground from terminal 6-1, then the glow
ture low, automatically the Engine Controller (149) relay R-6 (4) deactivates and consequently shut down
supplies, through the terminal 6-1, a ground to the glow the power supply to the glow plugs (18) on engine.
relay R-6 (4). Therefore the glow relay R-6 (4) that is

4 - Glow relay (R-6) 27 - Hour meter (E-3)
8 - Battery relay (R-1) 59 - Water temperature sensor
12 - Engine emergency stop relay (R-28)
Preheating circuit
E485
149
1 4 148
18
2
3
12
7 5
8
30 1A
1B
9 7
29
ELECTRICAL SYSTEM
59
Water temperature
10 sensor
17
16
27
T2-4-15
R2215
T2-4-16 E485
ELECTRICAL SYSTEM
ENGINE STOP CIRCUIT
When the key switch (9) from the ON position is turned Then, the Engine Controller, without "key on" signal,
to the OFF position, the signal "key on" that is sends information to governor on injection pump that,
connected from terminal M of the key switch (9) to the in turn, shut-off the fuel to the engine, that stops.
Mechatro Controller (5) and Engine Controller (149), is
cut off.

Engine stop circuit
E485
149
1 4 148
18
2
3
12
7 5
8
30 1A
1B
9 7
29
ELECTRICAL SYSTEM
10
17
16
27
T2-4-17
R2216
T2-4-18 E485
ELECTRICAL SYSTEM
EMERGENCY OPERATING CIRCUIT
With key switch (9) on ON position and with engine Only in case a persisting drop of engine oil is oc-
running, if a drop of engine oil pressure occurs or if the curred, the Mechatro Controller (5) controls the activa-
temperature of engine coolant raises, the related tion of the engine stop relay R-28 (12).
sensors send signals to the Mechatro Controller (5)
and Engine controller (149). Therefore in these conditions, the signal "key-on" sent
toward the terminals 6-60, 61 of Engine Controller is
On the cluster gauge will be displayed the indication cut-off. The Engine controller, without "key on" signal,
of engine oil low pressure or the overheating of engine sends information to the governor on injection pump
coolant, and in the mean time will be activated the and the engine will stop for lack of fuel supply.
warning buzzer.

4 - Glow relay (R-6) 27 - Hour meter (E-3)
8 - Battery relay (R-1) 59 - Water temperature controller
9 - Key switch (SW-1) 60 - Oil press switch (SW-7)
10 - Starter motor assembly (M-1) 148 - Engine diagnosis request switch (SW-46)
12 - Engine emergency stop relay (R-28) 149 - Engine controller (C-3)
Emergency operating circuit
E485
149
1 4 148
18
2
3
12
7 5
8
30 1A
1B
9 7
29
59
Water temperature
ELECTRICAL SYSTEM
10 sensor
17
60
16
27
T2-4-19
R2217
T2-4-20 E485
ELECTRICAL SYSTEM
NOTES:
SECTION 3 E485
COMPONENT OPERATION
CONTENTS
Group 1 - Hydraulic Pump Assy Group 6 - Swivel Joint
Outline ...................................................... T3-1-1 Outline ...................................................... T3-6-1

Hydraulic Pump ........................................ T3-1-4 Construction .............................................. T3-6-2
Regulator .................................................. T3-1-9 Operation .................................................. T3-6-3
Control Curve of Pump ............................ T3-1-18
Group 7 - Cylinders
Group 2 - Pilot Valve
Outline ...................................................... T3-7-1
Outline (ATT) ............................................ T3-2-1 Construction ............................................. T3-7-2
Construction, Function and Operation .................................................. T3-7-5
Operation (ATT) ........................................ T3-2-2
Outline (Travel) ......................................... T3-2-7
Construction (Travel) ................................ T3-2-8 Group 8 - Air Conditioner
Operation (Travel) ..................................... T3-2-9
Construction and Piping ........................... T3-8-1
Main Components .................................... T3-8-4
Group 3 - Control Valve Function .................................................... T3-8-8
Outline ...................................................... T3-3-1

Construction ............................................. T3-3-4
Group 9 - Attachment Automatic
Hydraulic Circuit ...................................... T3-3-18 Lubrication System
Operation ................................................ T3-3-19
Attachment Centralised Lubrication
System ..................................................... T3-9-1
Group 4 - Swing Device Operation .................................................. T3-9-4
Main Distributor SXE-2 ............................. T3-9-5
Outline ...................................................... T3-4-1
Secondary Distributor MX-F ...................... T3-9-8
Construction .............................................. T3-4-4
Controls .................................................. T3-9-11
Description ................................................ T3-4-8
Maintenance ........................................... T3-9-14
Operation .................................................. T3-4-9
Troubleshooting ....................................... T3-9-15
Group 5 - Travel Device
Outline ...................................................... T3-5-1

Construction .............................................. T3-5-5
E485 T3-1-1
HYDRAULIC PUMP ASSY
OUTLINE
General view and hydraulic ports
Dr1 D1 A2 4 PH1 a3 Dr3

4 M16-DEPTH-24
B1
Pr2
Pi2
PB
Pr1
PSV
Pi1
Dr2 a1 A1
4
3
PH2
1
Dr2
A3
B3
a1, a2
D0
R3506
No. Parts Q.ty Code Port name Port size
1 Main pump assy 1 A1,2 Delivery port SAE 6000 psi 1"
2 Regulator assy 2 B1 Suction port SAE 2500 psi 3"
3 Gear pump assy(for pilot) 1
Dr1,2 Drain port G 3/4 - 20
4 Solenoid proportional reducing valve 2
Propotional press.-reducing
Pr1,2 G 1/4 - 15
valve primary press. port
Pi1,2 Pressure sensor ports G 1/4 - 15
PH1,2 Pressure sensor ports G 3/8 - 15
PSV Servo assist port G 1/4 - 15
a1,2 Gauge port G 1/4 - 15
D1 Oil filling port G 3/4 - 20
D0 Outlet port G 3/4 - 20
PB Gauge port RC 1/8
A3 Gear pump delivery port G 1/2 - 19
B3 Gear pump suction port G 3-4 - 20.5
Dr3 Gear pump drain port G 3-8 - 15
a3 Gauge port G 1/4 - 14
T3-1-2 E485
HYDRAULIC PUMP ASSY
Hydraulic circuit diagram
(DRIVE) (DRIVEN)
(KR3D-9TAW-V) (KR3D-9TAW-V)
Pump Pr1 PH1 a1 A1 PSV A2 a2 PH2 Pr2 Pump
proportional proportional
valve (KDRDE5K) (KDRDE5K) valve
Regulator Regulator
Pi1 Pi2
Main pump
D1
Dr1,2
Dr3
D0 B1
Gear pump B3 A3 a3
R3507
E485 T3-1-3
HYDRAULIC PUMP ASSY
Specifications
Item Main pump Gear pump for pilot

Pump model K5V200DPH1BDR-9TAW-V ZX15LSLZ2-07D
Gear
Drive Driven
(Theoretic ratio
Max. displacement capacity side side
values) 32:31
cm3
190 184 15
Rated min-1 1950 ←

Revolution (Clockwise seen
Hi idle from shaft end) 2000 or less ←
Rated 31.4
Max. Pressure MPa 5.0
ATT boost 34.3
Max. flow L/min 370 × 2 29.3
Max. input Horse Power kW 236 3.1
Max. input torque N·m 1153 14.7
Model KR3D-9TAW-V
Regulator Control function Electric flow control, total horsepower control,
powershift control at back-up and positive
flow control
Others With solenoid proportional reducing valve

(KDRDE5K-31/30C50-102)
Mass kg 260
NOTE: The max. input power and the max. input torque of the main pump include those of the gear pump.
T3-1-4 E485
HYDRAULIC PUMP ASSY
HYDRAULIC PUMP
Construction
MAIN PUMP
Apply adhesive
Apply adhesive
N° 1305N of Threehond MAKE
N° 1305N of Threehond MAKE
R3508
111 - Drive Shaft 211 - Shoe Plate (Q.ty 2)

113 - Driven shaft 212 - Swash Plate (Q.ty 2)
123 - Roller bearing (Q.ty 2) 214 - Tilting Bushing (Q.ty 2)
124 - Needle bearing (Q.ty 2) 251 - Swash plate support (Q.ty 2)
126 - Spacer (Q.ty 2) 261 - Front Cover
127 - Spacer 262 - Cover
128 - Bearing Spacer (Q.ty 3) 271 - Pump casing
129 - Bearing Spacer (Q.ty 2) 312 - Valve Cover
130 - Booster 313 - Right valve plate
131 - Booster Cover 314 - Left valve plate
141 - Cylinder Block (Q.ty 2) 325 - Casing
151 - Piston (Q.ty 18) 405 - Capscrew M8x30, 29 Nm; (Q.ty 8)
152 - Shoe (Q.ty 18) 406 - Capscrew M12x35, 98 Nm; (Q.ty 8)
153 - Set Plate (Q.ty 2) 408 - Capscrew M12x55, 98 Nm; (Q.ty 11)
156 - Spherical Bush (Q.ty 2) 409 - Capscrew M10x16, 56 Nm; (Q.ty 2)
157 - Cylinder Spring (Q.ty 18) 410 - Capscrew M22x60, 630 Nm; (Q.ty 9)
171 - Front Casing 411 - Capscrew M22x95, 630 Nm; (Q.ty 2)
191 - Drive Gear 412 - Capscrew M22x180, 630 Nm
192 - Driven Gear 413 - Capscrew M10x25, 56 Nm; (Q.ty 5)
E485 T3-1-5
HYDRAULIC PUMP ASSY
Valve plate for c. clockwise rotation
Apply sealub L101

to the oil seal
surface
circunferential
Valve plate for

clockwise rotation
SECTION A-A SECTION X-X

R3509
414 - Capscrew M6x65, 12 Nm; (Q.ty 3) 726 - O-Ring (Q.ty 2)

467 - Plug G 1/4, 36 Nm; (Q.ty 2) 728 - O-Ring (Q.ty 4)
469 - Plug G 3/4, 170 Nm; (Q.ty 4) 732 - O-Ring (Q.ty 2)
490 - Plug NPTF 1/16, 8.8 Nm; (Q.ty 27) 752 - Seat Packing (Q.ty 2)
491 - Plug Re 1/8, 12 Nm (Q.ty 12) 774 - Oil seal
492 - Restrictor NPTF 1/16, (Q.ty 4) 789 - Backup ring (Q.ty 2)
493 - Plug Re 1/4, 22 Nm (Q.ty 2) 792 - Backup ring (Q.ty 2)
531 - Tilting Pin (Q.ty 2) 806 - Nut M20, 240 Nm; (Q.ty 2)
532 - Piston (Q.ty 2) 807 - Nut M20, 240 Nm; (Q.ty 2)
534 - Stopper (Q.ty 2) 823 - Snap Ring
535 - Stopper (Q.ty 2) 824 - Snap Ring (Q.ty 3)
536 - Cover (Q.ty 2) 825 - Snap Ring (Q.ty 2)
541 - Seat (Q.ty 4) 827 - Snap Ring
543 - Stopper (Q.ty 4) 828 - Snap Ring (Q.ty 2)
545 - Ball (Q.ty 4) 885 - Pin (Q.ty 2)
548 - Pin (Q.ty 2) 886 - Spring pin (Q.ty 4)
702 - O-Ring (Q.ty 2) 888 - Pin (Q.ty 2)
709 - O-Ring 901 - Eye bolt (Q.ty 2)
711 - O-Ring (Q.ty 2) 953 - Setscrew (Q.ty 2)
712 - O-Ring (Q.ty 2) 954 - Setscrew (Q.ty 2)
724 - O-Ring (Q.ty 13) 981 - Nameplate
725 - O-Ring (Q.ty 6) 983 - Pin (Q.ty 2)
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
T3-1-6 E485
HYDRAULIC PUMP ASSY
GEAR PUMP (FOR PILOT)
R3510
307 - Poppet 435 - Flange socket; M10 (Q.ty 2) 33 Nm

308 - Seat 466 - Vp plug; PF1/4 (Q.ty 2) 16 Nm
309 - Ring 467 - Adapter; PF1/2-PF3/8 53 Nm
310 - Spring 700 - Ring
311 - Adjust screw 709 - O-Ring
312 - Lock nut; M14×1.5 29 Nm 725 - O-Ring
351 - Gear case 728 - O-Ring
353 - Drive gear 732 - O-Ring
354 - Driven gear 850 - Locking ring
355 - Filter a3 - Gauge port; PF1/4 16 Nm
361 - Front case A3 - Delivery port; PF3/8 34 Nm
433 - Flange socket; M8 (Q.ty 2) 17 Nm B3 - Suction port; PF3/4 74 Nm
434 - Flange socket; M8 (Q.ty 2) 17 Nm Dr2 - Drain port; PF3/8 34 Nm
E485 T3-1-7
HYDRAULIC PUMP ASSY
Operation ROTARY GROUP

This pump assy consists of two pumps arranged in The rotary group consists of shaft (111), cylinder block
parallel with two gears (191), (192) for driving. The two (141), piston (151), shoe (152), plate (153), spherical
pumps can be driven simultaneously as the rotation of bushing (156), and cylinder spring (157).
the prime mover is transferred by the drive shaft (111). The shaft is supported by bearings (123) and (124) at
The suction and discharge port are integrated in valve its both ends. The shoe, which is caulked to the piston,
cover (312): the suction port serves for the both forms a spherical coupling.
pumps. It has a pocket to relieve thrust force generated by
loading pressure and to take hydraulic balance so that
The pumps may be classified roughly into the rotary it slides lightly over the shoe plate (211). The sub group
group performing a rotary motion and working as the composed by a piston and a shoe is pressed against the
major part of the whole pump function: the swash plate shoe plate by the action of the cylinder spring via a
group that varies the delivery rates: and the valve retainer and a spherical bush. Similarly, the cylinder
cover group that changes over oil suction and dis- block is pressed against valve plate (313) by the action
charge. of the cylinder spring.
R3515
T3-1-8 E485
HYDRAULIC PUMP ASSY
SWASH PLATE GROUP

The swash plate group consists of swash plate (212),
shoe plate (211), swash plate support (251), tilting
bushing (214), tilting pin (531),and servo piston (532).
The swash plate is the cylindrical part that is formed
on the opposite side of the shoe sliding surface and is
supported by the swash plate support.
If the servo piston moves to the right and left as
hydraulic force controlled by the regulator is admitted
to hydraulic chamber located on both sides of the
servo piston, the swash plate slides over the swash
plate support via the spherical part of the tilting angle
α).
(α
R3511
VALVE COVER GROUP

The valve cover group consists of valve cover (312),
valve plates (313) (314), booster (130) and valve plate
pin (885). The valve plates having two crescent-
shaped ports are installed to valve cover (312) to feed
and collects oil to and from cylinder block (141). The
oil switched over by the valve plate is connected with
the external pipe by way of the valve cover.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with respect
to the cylinder while rotating with the cylinder block. If
R3512
we keep an eye on a single piston, it makes a motion
away from the valve plate (oil suction process) in the
first 180° and a motion toward the valve plate (oil
delivery process) in the remaining 180°. If the swash
plate is not inclined (zero tilting angle), the piston does
not stroke i.e. delivers no oil.
R3513
E485 T3-1-9
HYDRAULIC PUMP ASSY
REGULATOR
Construction
B-B
C-C
SECTION B-B
VIEW C
A-A
SECTION A-A
R3514
T3-1-10 E485
HYDRAULIC PUMP ASSY
412 - Socket bolt; M8×50 (Q.ty 2) 29 Nm 653 - Spring seat

413 - Socket bolt; M8×70 (Q.ty 2) 29 Nm 654 - Return spring
418 - Socket bolt; M5×12 (Q.ty 2) 6.9 Nm 655 - Set spring
436 - Socket bolt; M6×40 (Q.ty 4) 12 Nm 656 - Block cover
438 - Socket bolt; M6×20 (Q.ty 8) 12 Nm 708 - O-Ring
467 - Plug; PF3/8×M8 34 Nm 722 - O-Ring (Q.ty 3)
496 - Plug; NPTF1/16 (Q.ty 15) 8.8 Nm 724 - O-Ring (Q.ty 9)
601 - Casing 725 - O-Ring
611 - Feed back lever 727 - O-Ring
612 - Lever 1 728 - O-Ring
613 - Lever 2 730 - O-Ring
614 - Fulcrum plug 732 - O-Ring
615 - Adjusting plug 733 - O-Ring
621 - Compensating piston 734 - O-Ring
622 - Piston case 753 - O-Ring
623 - Compensating rod 755 - O-Ring (Q.ty 5)
624 - (C) Spring seat 756 - O-Ring
625 - Outer spring 757 - O-Ring
626 - Inner spring 763 - O-Ring
627 - (C) Adjusting stem 801 - Nut; M8 (Q.ty 3) 16 Nm
628 - (C) Adjusting screw 814 - Snap ring
629 - (C) Cover 836 - Snap ring
630 - Lock nut; M30×1.5 160 Nm 858 - Snap ring (Q.ty 2)
631 - Sleeve 874 - Pin; Ø4×11.7L
641 - Pilot cover 875 - Pin; Ø4×8L (Q.ty 2)
642 - Rod 876 - Pin; Ø5×8L
643 - Pilot piston 887 - Pin
644 - (Q) Spring seat 897 - Pin; Ø5×19L
645 - (Q) Adjusting stem 898 - Pin; Ø8.5×10L
646 - Pilot spring 924 - Socket screw; M8×20
651 - Sleeve 925 - (Q) Adjusting screw
652 - Spool 079 - Solenoid proportional reducing valve
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
E485 T3-1-11
HYDRAULIC PUMP ASSY
Operation
CONTROL FUNCTION
The regulator for inline axial piston pump consists of
Delivery flow rate Q

the following control functions:
1. Positive Flow Control
2. Constant Horsepower Control
Pilot pressure Pi
R0154
POSITIVE FLOW CONTROL

By changing the pilot pressure Pi, the pump tilting
angle (delivery flow) is regulated as shown in the
figure.
This regulator is of the positive flow control in which the
delivery flow Q increase as the pilot pressure Pi rises.
With this mechanism, when the pilot pressure corre-
sponding to the flow required for the work is com-
manded, the pump discharges the required flow only,
and so it does not consume the power uselessly.
FUNCTIONAL EXPLANATION
Flow Reducing Function
As the pilot pressure Pi decreases, the pilot piston R3516
(643) moves to the left by the action of the pilot spring
(646) and causes Lever 2 (613) to rotate around the
fulcrum of Point G. Since the pin (897) is pressed
against the large-hole section (C) of Lever 2 by the
action of the return spring (654) via the spool (652), pin
(874), and feedback lever (611), the feedback lever
rotates around the fulcrum of Point D as Lever 2
rotates, and shifts the spool to the right.
The movement of the spool causes the delivery
pressure P1 to connect to Port CL throug the spool and
to be admitted to the large-diameter section of the
servo piston. The delivery pressure P1 that is con-
stantly admitted to the small-diameter section of the
servo piston moves the servo piston to the right due to
the area difference, resulting in decrease of the tilting
angle.
When the servo piston moves to the right, Point D also
moves to the right. The spool is fitted with the return
spring (654) and is tensioned to the left at all times, and
so the pin (897) is pressed against the large-hole
section (C) of Lever 2.
Therefore, as Point D moves, the feedback lever Servo piston
Tilting big Tilting small
rotates around the fulcrum of Point C, and the spool is
shifted to the left. This causes the opening between R3798
the sleeve (651) and spool (652) to close slowly, and

the servo piston comes to a complete stop when it
closes completely.
T3-1-12 E485
HYDRAULIC PUMP ASSY
Flow Increasing Function

As the pilot pressure Pi rises, the pilot piston (643)
moves to the right to a position where the force of the
pilot spring (646) balances with the hydraulic force.
The groove (A) in the pilot piston is fitted with the pin
(875) that is fixed to Lever 2 (613). Therefore, when the
pilot piston moves, Lever 2 rotates around the fulcrum
of Point G (fixed by the fulcrum plug (614) and pin
(875)). Since the large-hole section (C) of Lever 2
contains a protruding pin (897) fixed to the feedback
lever (611), the pin (897) moves to the left, as Lever 2
rotates. Port CL opens a way to the tank port as the
spool moves.
This deprives the large-diameter section of the servo
piston of pressure, and shifts the servo piston to the
left by the discharge pressure P1 in the small-diameter
section, resulting in an increase in the flow rate.
As the servo piston moves, Point D also moves to the
left, the feedback lever rotates around the fulcrum of
Point C, and the spool moves to the right till the
opening between the spool and sleeve is closed.
ADJUSTMENT OF FLOW CONTROL

CHARACTERISTIC
The flow control characteristic can be adjusted with
the adjusting screw.
Adjust it by loosening the hexagon nut (801) and by
Delivery flow, Q
tightening (or loosening) the hexagonal socket head

screw (924).
Tightening the screw shifts the control chart to the right
as shown in the figure.
Pilot pressure, Pi
R3795
E485 T3-1-13
HYDRAULIC PUMP ASSY
CONSTANT HORSEPOWER CONTROL

The regulator decrease the pump tilting angle (delivery
flow) automatically to limit the input torque within a
certain value with a rise in the delivery pressure P1 of

the self pump.
(The input horsepower is constant when the speed is
constant).
Delivery pressure
R3796
T3-1-14 E485
HYDRAULIC PUMP ASSY
FUNCTIONAL EXPLANATION LOW TILTING ANGLE (LOW FLOW) COMMAND

PREFERENTIAL FUNCTION
Overload Preventive Function
As mentioned above, flow control and horsepower
When the self pump delivery pressure P1 rises, it acts
control tilting angle commands are transmitted to the
on the stepped part of the compensating piston (621).
feedback lever and spool via the large-hole sections (C
It presses the compensating rod (623) to the right till
& F) of Levers 1 and 2. However, since Sections C and
the force of the outer spring (625) and inner spring (626)
F have the pins (ø4) protruding from the large hole (ø8),
balances with the hydraulic force. The movement of
only the lever lessening the tilting angle contacts the
the compensating rod is transmitted to Lever 1 via pin
pin (897); the hole (ø8) in the lever of a larger tilting
(875).
angle command is freed without contacting the pin
Lever 1 rotates around the pin (875) (E) fixed to the
(897). Such a mechanical selection method permits
casing (601).
preference of the lower tilting angle command of the
Since the large-hole section (F) of Lever 1 contains a
flow control and horsepower control.
protruding pin (897) fixed to the feedback lever (611),
the feedback lever rotates around the fulcrum of Point
D as Lever 1 rotates, and then the spool (652) is shifted
to the right. As the spool moves, the delivery pressure
P1 is admitted to the large-diameter section of the
servo piston via Port CL, causes the servo piston
move to the right, reduces the pump delivery flow rate,
and prevents the prime mover from being overloaded.
The movement of the servo piston is transmitted to the
feedback lever via Point D. Then the feedback lever
rotates around the fulcrum of Point F and the spool is
shifted to the left. The spool moves till the opening
between the spool and sleeve (651) is closed.
Flow Reset Function

As the self pump delivery pressure P1 the compensat-
ing rod (623) is pushed back by the action of the
springs (625 & 626) to rotate Lever 1 around Point E.
Rotating of Lever 1 causes the feedback lever to rotate
around the fulcrum of Point D and then the spool to
move to the left. As a result, Port CL opens a way to
the tank port. This causes the servo piston to move to
the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the
spool by the action of the feedback mechanism to
move it till the opening between the spool and sleeve
is closed.
E485 T3-1-15
HYDRAULIC PUMP ASSY
ADJUSTMENT OF INPUT HORSEPOWER

Adjustment of Outer Spring
tightening (or loosening) the adjusting screw C (628).

Tightening the screw shifts the control chart to the right
and increases the input horsepower as shown in the
figure. Since turning the adjusting screw C by N turns
changes the setting of the inner spring, return the
adjusting screw CI (925) by NxA turns at first.
Delivery pressure (P1+P2)

R0162
Adjustment of Inner Spring

tightening (or loosening) the adjusting screw CI (925).
Tightening the screw increases the flow and then the

input horsepower as slown in the figure.
Delivery pressure (P1+P2)

R0163
T3-1-16 E485
HYDRAULIC PUMP ASSY
Adjustment of maximum and minimum flows
The regulator can adjust the maximum and minimum

flows with the adjusting screws.

ADJUSTMENT OF MAXIMUM FLOW
tightening (or loosening) the set screw (954).
The maximum flow only is adjusted without changing
other control characteristics.
Input current I (Pilot pressure Pi)

R0160
ADJUSTMENT OF MINIMUM FLOW

Adjust it by loosening hexagon nut (806) and by
tightening (or loosening) the hexagonal socket head
set screw (953). Delivery flow rate Q
Similarly to the adjustment of the maximum flow, other
characteristics are not changed.
However, remember that, if tightened too much, the
required horsepower during the maximum delivery
pressure (or during relieving) may increase.
Input current I (Pilot pressure Pi)

R0161
E485 T3-1-17
HYDRAULIC PUMP ASSY
Fault finding and remedies on regulator
In case a functional fault probably resulting from the

regulator occurs, disassemble and inspect it.
PRIME MOVER IS OVERLOADED

Determine which is faulty, the front pump or rear pump,
by loading each pump independently. When both
pumps are found faulty, investigate the following (1)
and (2). Begin investigation with (3), when only one
pump is found faulty. (1) and (2) are only for cases of
the variable horsepower control.
(1) Check that the power shift command current I is

normal.
(2) The power shift pressure is low. Check the amplifier dither.
Replace the proportional pressure

reducing valve.
(3) The compensating piston (621) and compensating Disassemble and clean the regulator.
rod (623) are stuck with each other.
(4) The pin (898) is stuck. Disassemble and clean the regulator.
MAXIMUM FLOW IS NOT AVAILABLE

(1) Check that the pilot pressure Pi is normal.
(2) The pilot piston (643) is stuck. Disassemble and clean the regulator.
(3) The spool (652) is stuck. Disassemble and clean the regulator.
NOTE - Replace faulty parts that are deeply scored.

(1) and (2) are only for cases of the pilot control.
T3-1-18 E485
HYDRAULIC PUMP ASSY
CONTROL CURVE OF PUMP
Pump type: K5V200DPH1BDR-9TAW-V
Engine rated speed: 1950 min-1
Q
(L/min)
600
500
400
300
200
Two pumps loaded
100
0 5 10 15 20 25 30 35 P
(MPa)
R3797
NOTE - The curve does not include the power consumption of the gear pump.
E485 T3-2-1
PILOT VALVE
OUTLINE (ATT) Specifications
General view Model PV48K1126A
Operating torque Refer to the curve below

25° 19°
Max. primary pressure 6.9 MPa
SINGLE SINGLE
OPERATION OPERATION Primary pressure 5.0 MPa
ANGLE ANGLE
(PORT 2.4) (PORT 1.3) Rated flow 20 L/min
Weight Approx. 2 kg
The adjust nut Performance characteristics

(Opposing flats: 22)
Fix adjust nut
when the lever is PORT 1.3
installed by means of 4.0 4.0
spanner or the like.
Then tighten the
3.2
Secondary pressure (MPa)

mating lock nut to 3.0 3.0
Operations torque (Nm)

SINGLE OPERATING
41.2 ± 2.9 Nm TORQUE
2.58
R0167
2.0 2.0
34° 34°
SECONDARY
PRESSURE
1.0 1.0
0.85
0.6 1.15
0.96
0 0
0 1.1 2 4 6 7
PUSH-ROD STROKE mm
0 5 10 15 19
Operating angle (deg.)
R0170
PORT 2.4
4.0 4.0
34° 34° 3.2

Secondary pressure (MPa)
3.0 3.0 Operations torque (Nm)

R0168 SINGLE OPERATING
2.82
TORQUE
2.0 2.0
P T SECONDARY
PRESSURE
1.0 1.0
0.85
0.6
1.15
0.96
0 0
0 1.1 2 4 6 8 9.4
PUSH-ROD STROKE mm
1 3 2 4 0 5 10 15 20 25
Hydraulic symbol Operating angle (deg.)
R0169 R0171
Function
Port Tightening Port
size torque (Nm) name LH Pilot Valve RH Pilot Valve
1 Swing left Bucket digging
2 Arm out Boom down
PF 3/8 49 ± 4.9 3 Swing right Bucket dump
4 Arm in Boom up
T Tank port Tank port
PF 1/4 29.4 ± 2.9 P Pilot primary pressure port Pilot primary pressure port
T3-2-2 E485
PILOT VALVE
CONSTRUCTION, FUNCTION AND OPERATION (ATT)
Cross sectional view
312
501
302
Rotating sliding
part, apply
213 grease.
301 Beware of the
assembly
direction
151 212
Apply grease
•
to top
•
• •
• 246
• •
• 218–2
211
214
•
• •
• 218–1
216–2 216–1
241–1
241–2
201–2 201–1
221
231
217 122
Secondary
pressure 101
adjusting shim Not to
121
Designed value 126 be reused
t = 0.4 mm
q.ty 1 125
111
R0172
Apply Loctite #277 to areas marked ✩.
101 - Casing 216–2 - Spring seat 1 (Q.ty 2)

111 - Port plate 217 - Washer 2 (shim) (Q.ty 4)
•
121 - Seal washer (Q.ty 2) • •
• 218–1 - Spring seat 2 (Q.ty 2)
•
122 - O-Ring • •
• 218–2 - Spring seat 2 (Q.ty 2)
125 - Socket bolt; M8×35 (Q.ty 2) 20.6 ± 1.5 Nm 221 - Spring (Q.ty 4)
126 - Spring pin 241–1 - Spring (Q.ty 2)
131 - Bushing 241–2 - Spring (Q.ty 2)
•
151 - Plate • •
• 246 - Spring (Q.ty 4)
201–1 - Spool (Q.ty 2) 301 - Joint; M14 47.1 ± 2.9 Nm
201–2 - Spool (Q.ty 2) 302 - Circular plate
211 - Plug (Q.ty 4) 312 - Adjust nut; M14 ✩ 68.6 ± 4.9 Nm
212 - Push rod (Q.ty 4) 501 - Boots
213 - Seal (Q.ty 4)
214 - O-Ring (Q.ty 4)
216–1 - Spring seat 1 (Q.ty 2)
Note - The parts marked •

• •
• may not to be equipped depending on valve type.
E485 T3-2-3
PILOT VALVE
Construction MAIN FUNCTIONS

The function of spool (201) is to receive the supply
The pilot valve is constructed as shown in the cross-
pressure of the hydraulic pump by port P and admit
sectional view. The casing has a vertical shaft hole in
the hydraulic pressure at port P to output ports (1, 2,
which a reducing valve is assembled.
3, 4) or admit the hydraulic pressure at the output
The reducing valve consists of spool (201), spring
ports to port T. Spring (241) (for secondary pressure
(241) (for secondary pressure setting), spring (221)
setting) acts upon spool (201) and determines the
(for return), spring seat (216), and washer (217). The
output pressure.
spring (241) (for secondary pressure setting) is so set
Push rod (212) that changes the deflection of spring
as to achieve the secondary pressure conversion
(241) (for secondary pressure setting) is inserted in
0.49 ~ 0.98 MPa (varies with the model). The spool
plug (211) so as to enable smooth movement.
(201) is pressed against push rod (212) by spring
Spring (221) (for return) acts upon casing (101) and
(221) (for return).
spring seat (216) and brings push rod (212) toward
If push rod (212) is pushed down by tilting the control
zero displacement regardless of output pressure, in
part of the handle, the spring seat (216) falls at the
order to positively bring spool (201) back to neutral.
same time and changes a set pressure of spring (241)
The spring also acts as a reactive force that gives the
(for secondary pressure setting).
operator a proper operating feeling.
The casing (101) and the port plate (111) are
provided with an oil inlet (primary pressure) port P
and an outlet (tank) port T. They are further pro-
vided with ports 1, 2, 3, 4 from which secondary
pressure is discharged.
Function
BASIC FUNCTIONS
The pilot valve controls the stroke and the direction of
the control valve spool. This is achieved by applying
the output pressure of the pilot valve to the end of the
control valve spool.
In order to satisfy the functions, the pilot valve is
constructed with the following elements:
1. Inlet port (P) to which the oil of the hydraulic pump
is supplied.
2. Multiple output ports (1, 2, 3, 4) that exert the supply
pressure from the input port upon the end of the
spool of the control valve.
3. Tank port (T) to control the above mentioned output
pressure.
4. Spool that connects the output port with the inlet
port or the tank port.
5. The mechanical means including springs that act
upon the above-mentioned spool, in order to con-
trol the output pressure.
T3-2-4 E485
PILOT VALVE
Now, let us explain the function of the pilot valve, using

the hydraulic diagram (the figure on the right) and the
functional explanation drawing.
1 3
P T
1 Pilot valve 2 Pilot pump

R0173
LEVER IN NEUTRAL
The action of spring (241) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201). Therefore,
spool (201) (for return) is pushed up by spring (221)
[spring seat 1 (216)]. The output ports (2, 4) connect
with the T port. The result is that the output pressure
is equal to the tank pressure.
216
241
T
221
201 P
PORT (2, 4)
R0174
E485 T3-2-5
PILOT VALVE
WHEN THE PILOT LEVER IS TILTED

When the lever is tilted and the push rod (212)
strokes, the spool (201) spring seat (216) moves
downward to make the port P to connect with the port
2, 4, with the result that the oil of the pilot pump flows
to the port 2, 4 to produce a pressure.
212
216
T
201
PORT (2, 4) R0175
LEVER HELD
When the pressure at ports (2, 4) rises to a level
equivalent to the action of spring (241) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2, 4) rises
above a set value, ports (2, 4) and the P port close
while ports (2, 4) and the T port open. When the
pressure at ports (2, 4) falls below a set value, ports
(2, 4) and the P port open while ports (2, 4) and the T
port close. Thus the secondary pressure is kept
constant.
241
T
T PORT
P
P PORT
PORT (2, 4) R0176
OPERATION IN THE AREA WHERE THE

TILTING ANGLE OF THE HANDLE IS LARGE
(VARIES WITH THE MODEL)
If the handle is inclined beyond a certain angle on of the push rod contacts the spring if the handle is
certain models, the top end of the spool contacts the turned beyond a certain angle. This causes the sec-
bottom of the bore of the push rod. This keeps the ondary pressure gradient to change by the spring
output pressure connected with the P port pressure. action. Thereafter, the bottom of the bore of the push
Furthermore, on a model in which a spring seat and a rod contacts the top end of the spring seat, keeping
spring are built in the push rod, the bottom of the bore the output pressure connected with the P port.
T3-2-6 E485
PILOT VALVE
NOTES:
E485 T3-2-7
PILOT VALVE
OUTLINE (TRAVEL) 12.4° ± 0.5 12.4° ± 0.5
Outside view
VIEW FROM MACHINE FRONT SIDE 5
Tightening
Port torque Port Function 4 3
size name
Nm
1 RH travel reverse port

2 RH travel forward port
PF3/8 73.5 ± 4.9 3 LH travel reverse port
4 LH travel forward port
T Tank port
5 Travel pressure sensor port

PF1/4 36.3 ± 2 6 Travel pressure sensor port 2 1
P Pilot primary pressure port 4-Ø11
Through R0177
Specifications Performance characteristics
Type 07291-00000
Secondary pressure Operating torque
Primary pressure 4.9 MPa
MPa Nm
Secondary pressure 0.54 ~ 2.35 MPa 4.90 19.60
Rated flow 10 L/min 4.41 17.64
Mass Approx. 11 kg 3.92 15.68
3.42 13.72
12.7
2.94 11.76
LEFT RIGHT
2.45 9.8
2.35±0.15
1.96 7.84
7.7
1.47 5.83 6.4
0.98 3.92
0.54±0.1
T 0.49 1.96
P
0 0
0 2 4 6 8 10 12
4 6 3 2 5 1 Operating angle (deg.)
Hydraulic symbol Control diagram

R0178 R0179
T3-2-8 E485
PILOT VALVE
CONSTRUCTION (TRAVEL)
Z
13 12 28
36 14
B 33 2 36 33
19
PORT 5
37 26 42
1, 3 30
20 25
34
15
22
21
20 25
20
39
32 17 42
PORT 6
44, 16 40
6 7
33 36 33
18 8
24
A A 25, 42
41 SECTION AA
27
B
4 10, 11
9 31 5 29
35
4-M10
T = 42.1 ± 3.9 Nm
38
24, 41
VIEW Z SECTION BB
R0180
Apply Loctite #262 to areas marked ✩.
1- Orifice (shim) (Q.ty 4) 22 - Spring (Q.ty 4)

2- Seat (Q.ty 2) ✩ 14.7 Nm 24 - Plug: PF1/8 (Q.ty 3) 9.8 Nm
3- Orifice (shim) (Q.ty 4) 25 - Plug: PF1/4 (Q.ty 3) 24.5 Nm
4- Spool (Q.ty 4) 26 - Socket bolt: M10×60 (Q.ty 2) 58.8 Nm
5- Body 27 - Flange bolt (Q.ty 4) 4.9 Nm
6- Stopper (Q.ty 4) 28 - Setscrew: M8 (Q.ty 4) 14.7 Nm
7- Spring (Q.ty 4) 29 - Washer (Q.ty 4)
8- Spring (Q.ty 4) 30 - Washer (Q.ty 2)
9- Name plate 31 - Rivet (Q.ty 2)
10 - Shim t = 0.2 (Q.ty 4) 32 - Pin: Ø5 (Q.ty 4)
11 - Shim t = 0.1 (Q.ty 4) 33 - Ball (Q.ty 6)
12 - Cam (Q.ty 2) 34 - Ball (Q.ty 4)
13 - Boots (Q.ty 2) 35 - Ball (Q.ty 4)
14 - Pin (Q.ty 2) 36 - Ball (Q.ty 6)
15 - Cover (Q.ty 2) 37 - U-packing (Q.ty 4)
16 - Piston (Q.ty 4) 38 - O-Ring (Q.ty 4)
17 - Guide (Q.ty 4) 39 - O-Ring (Q.ty 4)
18 - Sleeve (Q.ty 4) 40 - O-Ring (Q.ty 4)
19 - Holder (Q.ty 4) 41 - O-Ring (Q.ty 3)
20 - Ring (Q.ty 12) 42 - O-Ring (Q.ty 3)
21 - Orifice(shim) (Q.ty 4) 44 - Piston assy (Q.ty 4)
E485 T3-2-9
PILOT VALVE
OPERATION (TRAVEL) • If the cam operates during travel operation, the oil
in the damper chamber is kept from flowing back by
Construction the check valve. Thus the oil flows to part E only
The valve consists of the following parts in terms of from the orifice. Damper action operates by the
hydraulic function: resistance that is built up as the oil passes through
A: Damper section the orifice.
B: Reducing valve section Let us explain the profile of the piston.
C: Shuttle section The upper part of the piston has a diameter of
12 mm, while the lower part of it has a diameter of
11 mm. This results in an areal difference, with the
Operation result that the piston is constantly subject to a
vertical force.
DAMPER SECTION For this reason, the orifice rises by the pressure
caused by the areal difference between the oper-
• If the primary pressure is supplied by P, it is flowed
ating part of the cam and the piston on the opposite
to the damper chamber by way of circuits D and
E . side i.e. the piston follows the cam.
That is to say, constant damper action operates
The pressure is then filled up in the damper cham-
wherever the cam is located.
ber via the orifice and the check valve.
Since the larger diameter of the piston, the cover,
In that case, the air present in the damper chamber
the 11mm diameter part of the piston and the guide
is pushed out to the T port from circuits F and G ,
are manufactured with minimal clearance, only a
in order to prevent the damper characteristics from
little leakage occurs. Consequently, the damper
fluctuating by air mixture.
performance is not affected at all.
CAM
PISTON G
CHECK
COVER
E VALVE
A. DAMPER SECTION
GUIDE
ORIFICE
SPRING FOR
SECONDARY DAMPER
PRESSURE CHAMBER
T
D
B. REDUCING VALVE SECTION
SPOOL P P
SECONDARY PRESSURE PORT

BODY
R0181
T3-2-10 E485
PILOT VALVE
REDUCING VALVE SECTION

At neutral
The primary pressure supplied by P is shut off by the If the pressure at the secondary pressure port rises
seal between the circumference of the spool and the above the action of the secondary pressure spring,
body hole. the spool is pushed up by the pressure. The result is
The secondary pressure port is connected with the T that the notch J enters the hole of the body, shuts
port through the vertical hole H and the horizon- off the circuit from the primary pressure port to the
tal hole I in the center of the spool. This causes the secondary pressure port, and causes the horizontal
pressure to be reduced to zero. hole I to connect with the T port to let the pressure
of the secondary pressure port out to the T port.
At operation If the above-mentioned action is repeated, the pres-
sure at the secondary pressure port becomes a level
If the cam tilts toward the operating direction, the
that balances the compressive load of the secondary
piston goes down. The spool sub assy moves down.
pressure spring proportional to the cam stroke.
If the notch J on the circumference of the spool
The return spring provides proper reactive force and
connects with the secondary pressure port, the pri-
positively brings the spool of the reducing valve back
mary pressure supplied by P enters the secondary
to its neutral position.
pressure port.
In that case, the horizontal hole I enters the hole
of the body and seals it. As the result, the circuit from
the secondary pressure port to the T port is shut off.
12
11
RETURN
SPRING
T
I
T
P J
P
J
H
SECONDARY
PRESSURE PORT
R0182
E485 T3-2-11
PILOT VALVE
SHUTTLE SECTION
If pressure is built up at port 1 or 3, the ball is pressed
against the seat by the pressure. The pressure goes
through from port 1 to port 5 (or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4 as the ball
is metallical sealed by the seat.
If pressure occurs at port 2 or 4, the ball is pressed
against the body by the pressure. The result is that the
pressure connects with port 5 from port 2 (with port 6
from port 4).
Only a little leakage occurs at port 1 or 3 as the ball is
metallical sealed against the body.
PORT 5
PORT 2 PORT 1
SEAT BALL
BODY
PORT 4 PORT 3
PORT 6
R0183
T3-2-12 E485
PILOT VALVE
NOTES:
E485 T3-3-1
CONTROL VALVE
OUTLINE
Specifications
Item
Model UY36-110
Max. flow L/min 370x2
Main relief valve set pressure MPa 31.4 at 360 L/min
When power boost pressure 34.3 at 320 L/min
Over load relief valve set pressure MPa
Boom H, Bucket H, Arm R 36.3 at 30 L/min
Boom R, Bucket R, Arm H 34.8 at 30 L/min
OPT1 H&R 34.8 at 30 L/min
T3-3-2 E485
CONTROL VALVE
Outside view and hydraulic ports
R3517
Abbreviation table
ARM-1 AM-1 AM-2 ARM-2
BOOM-2 BM-2 BM-1 BOOM-1
OPTION 1 OPT-1 BKT BUCKET
SWING SW TL TRAVEL LEFT
TRAVEL RIGHT TR TST TRAVEL STRAIGHT

E485 T3-3-3
CONTROL VALVE
Port size Tightening torque Nm Port name Description

P1 Pump P1 port
P2 Pump P2 port
4A2 Bucket digging port
4B2 Bucket dump port
Ø 32 4A3 Boom up side port
148 4B3 Boom down side port
(M14)
5A3 Option 1 port
5B3 Option 1 port
5A5 Arm out port
5B5 Arm in port
4A1 Travel left forward port
4B1 Travel left reverse port
Ø 26 5A1 Travel right reverse port
100 5B1 Travel right forward port
(M12)
5A2 Swing left port
5B2 Swing right port
4pc1 Boom down lock valve release pilot port
4pc2 P1 bypass cut select port
5pc1 Arm in lock valve release pilot port
5pc2 P2 bypass cut valve select port
5pc3 Lock valve pilot port for swing priority
PF1/4 36 dr1 Drain port
dr4 Drain port
dr5 Drain port
pc ATT power boost pressure port
R3 Drain back pressure port
4pa1~4 Travel left, Bucket, Boom 1, Arm 2 pilot port
4pb1~4 Travel left, Bucket, Boom 1, Arm 2 pilot port
Pz1 Travel straight pilot port
dr5 Drain port
PF3/8 74 dr6 Drain port
5pa1~5s Travel right, Swing, OPT1, Boom 2, Arm 1 pilot port
5pb1~5 Travel right, Swing, OPT1, Boom 2, Arm 1 pilot port
dr3 Drain port
G1 255 RS Swing motor boost circuit port
T3-3-4 E485
CONTROL VALVE
CONSTRUCTION
R3518
VIEW Z
R3533
E485 T3-3-5
CONTROL VALVE
15 14 8 7 6 5 4 1
16
16
21
17
20
18
18
19
SECTION A-A
R3520
15 14 7 13 12 11 10 2
16
17 16
21
18 18
SECTION B-B
R3521
T3-3-6 E485
CONTROL VALVE
14 87
89 88
89 88 14 87
SECTION K-K
R3519
47 49 85 51, 52 86
75
76
AM HOLDING
VALVE
PRIORITY
VALVE
SECTION J-J
R3522
E485 T3-3-7
CONTROL VALVE
BM HOLDING VALVE
76
66
83
116, 117, 118
72
75
52, 51 50 49 47
SECTION H-H
R3523
47 49 50 51, 52
75 76
53, 54 54, 53
37 37
44, 46 44, 46
78 79 80
SECTION G-G
R3524
T3-3-8 E485
CONTROL VALVE
82 51, 52
52, 51 50 49 47
SECTION F-F
R3525
47 49 50 51, 52 52 81
SECTION E-E
R3526
E485 T3-3-9
CONTROL VALVE
Manifold assy
53 54 3 65 55 56 57, 58 59 60 61 59 60 61 62, 63
64, 63
19
19
JOINT JOINT
SECTION C-C SURFACE SURFACE
FOR SWING FOR BUCKET
SIDE SIDE
R3534
T3-3-10 E485
CONTROL VALVE
1- Housing 68 - Cap
2- Housing 69 - O-Ring
3- Manifold 70 - Cover
4- Plunger 71 - Cap (Q.ty 2)
5- Plunger 72 - O-Ring (Q.ty 3)
6- Plunger 75 - Port relief valve (Q.ty 3)
7- Plunger (Q.ty 2) 76 - Port relief valve (Q.ty 3)
8- Plunger 78 - Flange (Q.ty 2)
10 - Plunger 79 - Socket bolt (Q.ty 12)
11 - Plunger 80 - O-Ring (Q.ty 2)
12 - Plunger 81 - Main relief valve
13 - Plunger 82 - Cap
14 - O-Ring (Q.ty 4) 83 - Plug
15 - Cap (Q.ty 2) 85 - Cap
16 - O-Ring (Q.ty 20) 86 - Check valve
17 - Cover (Q.ty 10) 87 - Cap (Q.ty 2)
18 - Socket bolt (Q.ty 40) 88 - Spring (Q.ty 2)
19 - O-Ring (Q.ty 8) 89 - Spool (Q.ty 2)
20 - Cover 90 - Cover (Q.ty 2)
21 - Cover (Q.ty 9) 91 - Socket bolt M14x40 (Q.ty 8)
22 - Plunger 92 - Washer (Q.ty 12)
23 - Plunger 93 - Cap (Q.ty 4)
24 - Plunger 95 - O-Ring (Q.ty 2)
25 - Plunger (Q.ty 2) 97 - O-Ring (Q.ty 2)
26 - Plunger 98 - Poppet (Q.ty 2)
27 - Plunger 99 - Spring (Q.ty 2)
28 - Plunger 100 - Sleeve (Q.ty 2)
29 - Plunger 101 - Poppet (Q.ty 2)
30 - Plunger 102 - Spring (Q.ty 2)
31 - Plunger 103 - Back-up ring (Q.ty 2)
32 - Cap (Q.ty 10) 104 - O-Ring (Q.ty 2)
33 - Spring guide (Q.ty 20) 105 - Back-up ring (Q.ty 2)
34 - Sleeve (Q.ty 10) 106 - Piston (Q.ty 2)
35 - Spring 107 - Flange
36 - Spring 108 - Socket bolt M12x40 (Q.ty 4)
37 - Plug (Q.ty 2) 109 - Washer (Q.ty 4)
38 - Check valve 110 - O-Ring
39 - Spring (Q.ty 3) 113 - Back-up ring (Q.ty 3)
40 - Spacer (Q.ty 3) 114 - O-Ring (Q.ty 2)
41 - O-Ring (Q.ty 7) 115 - Sleeve
42 - Back-up ring (Q.ty 3) 116 - Cap
43 - Cap (Q.ty 3) 117 - Poppet
44 - Back-up ring (Q.ty 2) 118 - Spring
45 - Check valve (Q.ty 2) 120 - Cap
46 - O-Ring (Q.ty 2) 121 - Cap
47 - Check (Q.ty 10) 122 - O-Ring
48 - Spring (Q.ty 2) 123 - Cover
49 - Spring (Q.ty 10) 124 - Socket bolt (Q.ty 4)
50 - Cap (Q.ty 7) 125 - Piston
51 - Back-up ring (Q.ty 9) 126 - Spring
52 - O-Ring (Q.ty 13) 127 - Plate
53 - O-Ring (Q.ty 3) 128 - Back-up ring
54 - Cap (Q.ty 3) 129 - O-Ring
55 - O-Ring (Q.ty 2) 130 - Spring
56 - Cover (Q.ty 2) 131 - Spring guide
57 - Socket bolt (Q.ty 8) 132 - Sleeve
58 - Washer spring (Q.ty 8) 133 - Poppet
59 - O-Ring (Q.ty 2) 134 - Check valve
60 - O-Ring (Q.ty 12) 135 - Spring
61 - O-Ring (Q.ty 8) 136 - Cap
62 - Socket bolt (Q.ty 9) 137 - O-Ring
63 - Washer (Q.ty 26) 138 - Back-up ring
64 - Socket bolt (Q.ty 5) 139 - Back-up ring (Q.ty 6)
65 - Cap (Q.ty 2) 140 - O-Ring (Q.ty 6)
66 - O-Ring (Q.ty 4) 141 - Spring (Q.ty 6)
67 - Socket bolt (Q.ty 12) 142 - Poppet (Q.ty 2)
E485 T3-3-11
CONTROL VALVE
Main plunger
1 2 3 4 5
R3527
Arm plunger AM-1, AM-2
6 7, 8 9 10 11
R3528
Boom plunger BM-1
6 7, 8 9 10 11
R3529
Travel straight
R3530
1 - Plunger 7- Back-up ring

2 - Spring guide (Q.ty 2) 8- O-Ring
3 - Sleeve 9- Spacer
4 - Spring 10 - Spring
5 - Plunger cap 11 - Check valve
6 - Cap
T3-3-12 E485
CONTROL VALVE
Main relief valve
9 8 7, 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
R3531
1 - Sleeve 10 - Adjust screw

2 - Hexagon nut 11 - Hexagon nut
3 - Cap 12 - O-Ring
4 - O-Ring 13 - Piston
5 - O-Ring 14 - O-Ring
6 - Back-up ring 15 - Spring
7 - O-Ring 16 - Pilot seat
8 - Main poppet 17 - Pilot poppet
9 - Sleeve 18 - Spring
Port relief valve
1 2 3 4 5
14, 15 16 17
13 12 11, 10 9 8 7 6
R3532
1 - Relief sleeve 10 - Back-up ring (Q.ty 2)

2 - Pilot poppet 11 - O-Ring
3 - O-Ring 12 - Spring
4 - Relief seat 13 - Main poppet
5 - Hexagon nut 14 - O-Ring
6 - Adjust screw 15 - Back-up ring
7 - O-Ring 16 - Piston
8 - Spring 17 - O-Ring
9 - Spring
E485 T3-3-13
CONTROL VALVE
Selector valve (AM, BM Holding valve)
1, 2
Z VIEW
Z
3
4, 5
4, 5 6 7
8 9, 10 11, 12 13 14 15
R3535
1 - Socket bolt (Q.ty 4) 9- Back-up ring

2 - Washer (Q.ty 4) 10 - O-Ring
3 - Cover 11 - O-Ring
4 - Cap (Q.ty 2) 12 - Back-up ring
5 - O-Ring (Q.ty 2) 13 - Poppet
6 - O-Ring 14 - Sleeve
8 - Piston
T3-3-14 E485
CONTROL VALVE
Cover assembly (BM-1)
2, 3 R3536
1 - Cover
2 - Plug
3 - O-Ring
Center bypass valve (BKT Sum. - OPT. Sum)
1 2 3
R3537
1 - Spring
2 - O-Ring
3 - Cap
4 - Spool
E485 T3-3-15
CONTROL VALVE
Check valve (BKT. BM-1, BM-2, SW. OPT.)
2, 3
5
R3537BIS
1 - Cap
2 - Back-up ring
3 - O-Ring
4 - Check valve
5 - Spring
Check valve (AM-2)
2, 3
6
R3538
1 - Cap
2 - Back-up ring
3 - O-Ring
4 - Check valve
5 - Spring
6 - Check valve
T3-3-16 E485
CONTROL VALVE
Priority valve
1 2 3, 4
8, 9
18
17 10, 11
16
12
15
14 13
R3539
1 - Socket bolt (Q.ty 4) 10 - O-Ring

2 - Cover 11 - Back-up ring
3 - Cap 12 - Cap
5 - Piston 14 - Poppet
6 - Spring 15 - Check valve
7 - Plate 16 - Spring guide
8 - Back-up ring 17 - Sleeve
Port relief plug
1, 2
5, 4 3 R3540
1 - Cap 4 - Back-up ring

3 - Plug
E485 T3-3-17
CONTROL VALVE
Check valve (OPT. Sum)
1 2 3 4, 5 6
R3541
1 - Cap 4 - Back-up ring

3 - Spring 6 - Check valve
Check valve (BKT. Sum)
6 7
1 2 3, 4, 3 5
8, 9
R3542
1 - Check valve 6 - O-Ring

2 - Spring 7 - Flange
3 - Back-up ring (Q.ty 2) 8 - Socket bolt (Q.ty 4)
4 - O-Ring 9 - Washer (Q.ty 4)
5 - Sleeve
Check valve (BM Back pressure check)
1 2 3 4
R3543
1 - Spring 3 - Cap
2 - O-Ring 4 - Spool
T3-3-18 E485
CONTROL VALVE
HYDRAULIC CIRCUIT
13 4
15
5
14
11 3
12
7
10
2
7
R3544
1 - Main relief valve 9- Travel straight valve

2 - Port relief valve 10 - Check valve (Opt. Sum)
3 - Boom holding valve 11 - Check valve (BKT Sum)
4 - Selector valve (BM Holding/V) 12 - Priority valve
5 - Center Bypass valve (Opt. Sum) 13 - Bypass valve (BKT Sum)
6 - Check valve (Double type) 14 - Arm holding valve
7 - Check valve (Single type) 15 - Selector valve (AM Holding /V)
8 - Check valve (Main relief)
E485 T3-3-19
CONTROL VALVE
OPERATION
TRAVEL CIRCUIT (TR AND TL)
(e.g. TR-5pa1 port, TL-4pb1 port: ON, travel reverse is switched. Oil discharged from the pump "P1" flows
operation) into the control valve's inlet port "P1" and flows to the
The pilot port "5pa1" is pressurized and "TR" plunger cylinder port "4B1".
is switched. Oil discharged from the pump "P2" flows And oil from the actuator returns to the tank passage
into the control valve's inlet port "P2" and flows to the through the cylinder port "4A1".
cylinder port "5A1". The pilot port "Pz1" is not pressurized. The straight
And oil from the actuator returns to the tank passage travel plunger is in neutral position, each travel section
through the cylinder port "5B1". is operated independently.
The pilot port "4pb1" is pressurized and "TL" plunger
R3545
TRAVEL CIRCUIT
T3-3-20
Parallel
passage
Parallel
passage
CONTROL VALVE
R3546
E485
E485 T3-3-21
CONTROL VALVE
TRAVEL STRAIGHT CIRCUIT

"TR" and "TL" plungers operated. The other section is control valve's inlet port "P2" and flows to the "TR"
switched simultaneously (e.g. "SW"). section, and "TL" section through the straight travel
As the pilot port "5pb2" is pressurized "SW" plunger is plunger.
switched. At the same time, the pilot port "Pz1" is On the other hand, oil discharged from the pump "P1"
pressurized and the straigh travel plunger is switched flows into the control valve's inlet port "P1" and flows
make the connection between the high pressure pas- to "SW" section. Other in the case of actuator "SW" it
sage of "TR" and "TL". is the same.
Oil discharged from the pump "P2" flows into the
R3547
TRAVEL STRAIGHT CIRCUIT
T3-3-22
Parallel
passage
Parallel
passage
CONTROL VALVE
R3548
E485
E485 T3-3-23
CONTROL VALVE
BUCKET FLOW SUMMATION CIRCUIT

(e.g. 4pb2 port: ON, bucket digging operation) At the same time, the pilot port "5pc2" is pressurized
The pilot port "4pa2" is pressurized and "BKT" plunger and the center bypass spool (P2 bypass cut valve) is
is switched. Oil discharged from the pump "P1" flows switched.
into the control valve's inlet port "P1" and flows to the Oil discharged from the pump "P2" flows into the
cylinder port "4A2". control valve's inlet port "P2" and flows to the "BKT"
And oil from the actuator returns to the tank passage high pressure passage through the center bypass
through the cylinder port "4B2". passage and the internal summation line. And "P2"
joins "P1".
R3549
BUCKET FLOW SUMMATION CIRCUIT
T3-3-24
Center by-pass valve
Parallel
passage
Parallel
passage
BKT Summation check

CONTROL VALVE
R3550
E485
E485 T3-3-25
CONTROL VALVE
OPTION FLOW SUMMATION CIRCUIT

The pilot port "5pa3" is pressurized and "OPT" plunger and the center bypass spool (P1 bypass cut valve) is
is switched. Oil discharged from the pump "P2" flows switched.
into the control valve's inlet port "P2" and flows to the Oil discharged from the pump "P1" flows into the
cylinder port "5A3". control valve's inlet port "P1" and flows to the "OPT"
And oil from the actuator returns to the tank passage high pressure passage through the center bypass
through the cylinder port "5B3". passage and the internal summation line. And "P1"
At the same time, the pilot port "4pc2" is pressurized joins "P2".
R3551
OPTION FLOW SUMMATION CIRCUIT
T3-3-26
Center by-pass valve
Parallel
Parallel
passage
passage
CONTROL VALVE
OPT Summation check
R3552
E485
E485 T3-3-27
CONTROL VALVE
MAIN PLUNGER
High pressure Parallel

passage Cyl. "A" Cyl. "B" passage
Tank passage Tank passage

from Pump
to Tank (Center bypass)
(Center bypass)
R3553
1. When the main plunger is in neutral position. Oil The cylinder port "A" and "B" are shut off from the
from the pump flows to the tank through the center high pressure passage and tank passage by the
bypass line. main plunger.
Then the actuator keeps its situation as it is.
Check C
Cyl. "A" Cyl. "B" Parallel

High pressure
passage passage
Pilot pressure
Tank passage Tank passage

from Pump
to Tank (Center bypass)
(Center bypass) R3554
2. When pilot pressure is led to the port (e.g. "a" port), check valve and the return oil from the actuator
the main plunger is switched, and shuts off the flows to the tank passage. At this time, the load
center bypass passage, cylinder port "A" is con- pressure is higher than the pump pressure the
nected to the high pressure passage, and cylinder check "C" shuts off the passage between the high
port "B" is connected to the tank passage. pressure passage and the parallel passage and
Oil from the pump flows to the actuator through the prevents the reverse flow from the actuator.
T3-3-28 E485
CONTROL VALVE
MAIN RELIEF VALVE
High pressure setting

Pilot signal port
Pilot poppet B
Main poppet A
Spring C
Pc
Piston D
d1
d2
Pump port
1 2 3 4
Tank passage R3555
1. Standard Pressure Setting (Pc Pilot port: OFF, 1.1. Oil from the pump port enters into the chamber
proportional valve SV-2 ATT boost not operated). "3" through the orifice "2" of the main poppet
Piston "D" is positioned in right side by the spring "A". As d1 > d2, main poppet "A" is securely
"C". seated.
Pilot poppet B
Spring C
4
Tank passage
R3556
1.2. When the pressure reaches the preset force of flows around pilot poppet "B" and flows into the
the spring "C" the pilot poppet "B" opens. Oil tank passage through the side hole "4".
E485 T3-3-29
CONTROL VALVE
Main poppet A
Pump port
1 2 3
Tank passage
R3557
1.3. As oil flows from the pump port to the tank comes to lower than that of the pump port.
passage through the orifice "2" of the main Then the main poppet "A" is lifted and pres-
poppet "A", the pressure of the chamber "3" sured oil flows into the tank passage.
High pressure setting Pilot signal port
Spring C
Pc
Piston D
Pump port
Tank passage
R3558
2. High Pressure Setting (Pc Pilot port: ON, propor- The setting force of the spring "C" increases and the
tional valve SV-2 ATT boost operated) relief setting pressure changes to the high pressure.
Piston "D" is positioned in left side by the pilot
pressure "Pc".
T3-3-30 E485
CONTROL VALVE
PORT RELIEF VALVE
Pilot poppet D
Main poppet B
Spring C
Piston A
d2 d1
Cylinder port
1 2 3 5 4
Tank passage
R3559
1. Overload Relief Function As d1 > d2, main poppet "B" is securely

1.1. Oil from the cylinder port enters into the cham- seated.
ber "3" through the orifice "2" of the piston "A".
Pilot poppet D
Spring C
Cylinder port
5 4
Tank passage
R3560
1.2. When the pressure reaches the preset force of tank passage through the side hole "4" and the
the spring "C" the pilot poppet "D" opens. Oil passage "5".
flows around pilot poppet "D" and flows into the
E485 T3-3-31
CONTROL VALVE
Pilot poppet D
Piston A
Cylinder port
1 2 3 5 4
Tank passage
R3561
1.3. As oil flows from the cylinder port to the tank lower than that of the cylinder port. Then the
passage through the orifice "2" of the piston piston "A" is lifted and seated to the pilot
"A", the pressure of the chamber "3" comes to poppet "D".
Pilot poppet D
Main poppet B
Cylinder port
1 3 6
Tank passage
R3562
1.4. Oil from the cylinder port flows to the tank sure of the chamber "3" comes to lower still
passage through the orifice "6" of the pilot more, the main poppet "B" is lifted and pres-
poppet "D" and the chamber "3". As the pres- sured oil flows into the tank passage.
T3-3-32 E485
CONTROL VALVE
Main poppet B
d2 d1
Cylinder port
Tank passage
R3563
2. Make-up Function negative pressure), the main poppet "B" opens

2.1. As the cylinder port pressure is normally higher receiving the tank passage pressure for the
than the tank passage pressure and d1 > d2, difference in area between "d1" and "d2". Oil
the main poppet "B" is securely seated. florws from the tank passage flows to the
2.2. When the cylinder part pressure comes to cylinder port in order to prevent cavitation.
lower than the tank passage pressure(closer to
E485 T3-3-33
CONTROL VALVE
HOLDING VALVE
Drain port
Piston A dr2 Poppet B
Poppet C 5
d1
4pc1
Pilot signal port
1
d2
4
2 (Pc)
BM-1 Plunger
3 (Pv)
High pressure
to BM passage
cylinder (head)
Tank passage
R3564
BM holding valve is explained as a example. Therefore, the pressure of chamber "1" is same to
1. When the plunger is in neutral position (4pc1 pilot the pressure of "BM" cylinder (head), (equals to
signal: OFF). "Pc"), as it is connected with the core "2" through
Piston "A" and poppet "B" is in the status as shown. the orifice "4" of the poppet "C".
The passage "5" and drain port "dr2" is shut off by Since d1 > d2, the poppet "C" is seated and the core
the poppet "B". "2" and "3" are completely blocked.
T3-3-34 E485
CONTROL VALVE
Drain port
Piston A dr2 Poppet B
Poppet C 5
d1
4pc1
Pilot signal port
1
d2
4
2 (Pc)
BM-1 Plunger
3 (Pv)
to BM
cylinder (head) High pressure
passage
Tank passage
R3565
2. When the plunger is operated. "Pc"), as it is connected with the core "2"
2.1. Boom-up operation (Pv > Pc and pilot signal through the orifice "4".
4pc1: OFF). The poppet "C" is pushed up and oil from the
The pressure of the chamber "1" is same to the high pressure passage flows into the "BM"
pressure of "BM" cylinder (head), (equals to cylinder port.
E485 T3-3-35
CONTROL VALVE
Drain port
dr2
Piston A Poppet B
Poppet C
5
d1
4pc1
Pilot signal port
1
d2
4
2 (Pc)
BM-1 Plunger
3 (Pv)
from BM High pressure

cylinder (head) passage
Tank passage
R3566
2.2. Boom-down operation (pilot signal 4pc1: ON). lower than that of the core "2", and the pressure
Piston "A" and poppet "B" is switched by the of the core "2" acts on the differential area (d1,
pilot pressure, the passage "5" is connected to d2) to push up the poppet "C".
the drain port "dr2". Return oil from "BM" cylinder flows into the
Then the pressure of the chamber "1" comes to tank passage through the core "3".
T3-3-36 E485
CONTROL VALVE
PRIORITY VALVE
Drain port Pilot port (5pc3)

(dr4)
Piston 1
Spring A
Spring B
Spring C
Poppet 2
Check valve 3
High pressure passage
Parallel passage
R3567
The swing priority valve in an arm section. check valve "3" is in the position of a figure by
1. When not operating the swing plunger. each spring "A" , "B", "C". And the shear is
1.1. Parallel passage pressure ≤ High pressure carried out certainly.
passage pressure piston "1", poppet "2",
Spring C Spring B
Poppet 2
Check valve 3
Parallel passage
R3568
1.2. Parallel passage pressure > High pressure check valve "3" is carried out. The oil of a
passage pressure. Since the power of spring parallel passage flows the ARM cylinder from
"B" and "C" is small, the lift of poppet "2" and the high pressure passage.
E485 T3-3-37
CONTROL VALVE
Drain port Pilot port (5pc3)

(dr4)
Piston 1
Spring A
Spring guide
Spring B
Spring C
Poppet 2
Check valve 3
Parallel passage
R3569
The swing priority valve in an arm section. Check valve "3" is in the position of a figure by
2. When a swing plunger is operated. each spring "C". And the shear is carried out
2.1. Parallel passage pressure ≤ High pressure certainly.
passage pressure pilot pressure is pressurized
bye "5pc3" port, and piston "1" moves and
forces poppet "2".
Spring guide
Poppet 2
Check valve 3
d2
d1 Parallel passage
Orifice
R3570
2.2. Parallel passage pressure > High pressure At this time, the lift of the check valve "3" is
passage pressure diameter (d1) > diameter carried out, and oil controlled by the orifice and
(d2). flows in the arm cylinder. Oil flows with the
Therefore if pilot pressure is pressurized and priority to a swing motor.
poppet "2" cannot carry out a lift by compara-
tively low pressure either.
T3-3-38 E485
CONTROL VALVE
AM-1 REGENERATION
Poppet A
5B5 Parallel passage
5A5
5pb5
Check valve C
Center bypass passage
Sleeve B
Tank passage
R3571
Arm-in operation. Since, as for the return oil by the side of a rod, a tank
1. A plunger moves to the left and closes a center passage is blocked by sleeve "B", oil opens check
bypass passage. The oil from a pump opens poppet valve "C" in a plunger and is reproduced at a head
"A" from a parallel passage, and flows from a high side.
pressure passage to the head side of a cylinder.
E485 T3-3-39
CONTROL VALVE
AM-2 REGENERATION

Check valve A
Orifice B
4pa4
Tank passage from AM to AM

cylinder (rod) cylinder (head)
Check valve C
R3572
Arm-in operation. As for the return oil by the side of a rod, the pressuer
A plunger moves to the left and closes a center bypass is rose by orifice "B", and the oil opens check valve "C"
passage. in a plunger and is regenerated to the head side.
The oil froma pump opens check valve "A" and flows
from a high pressure passage to the head side of a
cylinder.
T3-3-40 E485
CONTROL VALVE
BM REGENERATION
Check valve A
4B3 Parallel passage
Check
valve B
4A3
4pb3

Back pressure
check valve
Tank passage
R3573
Boom-down operation. As for the return oil by the side of a head, the pressure
A plunger moves to the left and closes a center bypass is rose by back pressure check valve, and the oil
passage. opens check "B" in a plunger and is regenerated to the
The oil from a pump opens check "A", and flows from rod side.
a high pressure passage to the rod side of the cylinder.
E485 T3-4-1
SWING DEVICE
OUTLINE
General view
GIN L, AR
Dr
THREAD GB
2-M12
DEPHT26
B
A
GA
Au
P
Mu
R3034
A, B - Main port (PF3/4) 167 Nm PR - Parking brake release port (PF1/4) 36 Nm

Dr - Drain port (PF3/8) 73 Nm L - Gear oil level gauge (PT1/2) 65 Nm
Mu - Make-up port (PF1) 255 Nm AR - Air breather port (PT1/2) 65 Nm
GA, GB - Pressure measuring port (PF1/4) 36 Nm GIN - Gear oil filling port (PT3/4) 98 Nm
T3-4-2 E485
SWING DEVICE
Au Mu
GA (GB)
A (B)
R3035
DRAIN PORT
AIR VENT PORT IN CASE OF OIL FILLING
Hydraulic diagram
R3036
E485 T3-4-3
SWING DEVICE
Specifications
RIGHT HAND LEFT HAND
Model MFC160-063 MFC160-062
Type Swash-plate type, fixed-displacement plunger motor
Displacement cm3 151

Hydraulic motor
Working pressure MPa 25
Max. flow L/min 253
Braking torque Nm 685~891
Release pressure (stroke end) MPa 3.1
Relief valve setting pressure MPa 25
Mass kg 53
Speed reduction type Planetary 2-stage
Reduction ratio 16.8

Reduction unit
Lubicate oil Gear oil SAE90 (API class GL–4 grade)
Lubicate oil volume L 15.3
Grease Extreme pressure multipurpose grease
Grease volume A small amount
Mass kg 241
Total mass kg 294

T3-4-4 E485
SWING DEVICE
CONSTRUCTION
Swing motor (This drawing shows the left hand hydraulic swing motor)
15,16
33
32
17
35
28 39 38 37 36 SECTION A-A
15 16 17
18
14 19
13 20
21
12 22
11 23
10 24
9 25
8 26
7
6
5
3 2 1 27
R3574
E485 T3-4-5
SWING DEVICE
1- Inner ring 21 - Balance plate

2- Oil seal 22 - Needle bearing
3- Tapered roller bearing 23 - Retaining ring
4- Retaining spring 24 - Cylinder
5- Cam plate 25 - Housing
6- Return plate 26 - Collar
7- Piston assy (Q.ty 9) 27 - Retaining ring
8- Separator plate (Q.ty 3) 28 - By-pass hyd. valve (Q.ty 2), 78 Nm
9- Friction plate (Q.ty 3) 29 - Back-up ring (Q.ty 2)
10 - O-Ring 30 - O-Ring (Q.ty 2)
11 - Brake piston 31 - O-Ring
12 - O-Ring (Q.ty 2) 32 - Cover
13 - Spring (Q.ty 19) 33 - Relief valve (Q.ty 2), 78 Nm
14 - Piston (Q.ty 2) 34 - O-Ring (Q.ty 4)
15 - Plug (Q.ty 3) 35 - Capscrew M16x60 (Q.ty 4), 284 Nm
16 - O-Ring (Q.ty 3) 36 - Check valve (Q.ty 2)
17 - Pin (Q.ty 2) 37 - Spring (Q.ty 2)
18 - Disc spring (Q.ty 4) 38 - Plug (Q.ty 2)
19 - Teflon ring (Q.ty 4) 39 - Back-up ring (Q.ty 2)
20 - Bushing (Q.ty 4) 40 - Plug
T3-4-6 E485
SWING DEVICE
Swing reduction unit (This drawing shows the right swing reduction unit)
1 16 17 27 3 13 31 2 15 14 19 7 8 5 10 20 11
OIL FILLING PORT

PT 3/4
LEVEL PORT
PT 1/2
4 18
32 28 5 21 23 24 25 26
22 9 22 12 24
30 29
32
OIL FILLING PORT

PT 3/4
LEVEL PORT
PT 1/2
VIEW A
R3575
E485 T3-4-7
SWING DEVICE
1- Pinion shaft 17 - Oil seal

2- Housing 18 - Capscrew M10x30 (Q.ty 14)
3- Retainer 19 - Retaining ring
4- Sleeve 20 - Capscrew M14x150 (Q.ty 16)
5- Shaft (Q.ty 4) 21 - Spring pin (Q.ty 4)
6- Ring gear 22 - Thrust washer (Q.ty 8)
7- # 2 Spider 23 - Needle bearing (Q.ty 4)
8- # 2 Sun gear 24 - Trust washer (Q.ty 8)
9- # 2 Planetary pinion (Q.ty 4) 25 - Needle bearing (Q.ty 4)
10 - # 1 Spider assy 26 - Retaining ring (Q.ty 4)
11 - # 1 Sun gear 27 - Spacer
12 - # 1 Planetary pinion (Q.ty 4) 28 - Connector
13 - Bearing 29 - Hose
14 - Bearing 30 - Plug
15 - Spacer 31 - Plug
16 - O-Ring 32 - Set screw M20x30 (Q.ty 2)
T3-4-8 E485
SWING DEVICE
DESCRIPTION
1. The rotary group of the swing motor consists of a

cylinder (24) which is integral with the drive shaft Swing unit
and nine piston assy (7) arranged in the cylinder
bores. The cylinder (24) is supported by bearings (3)
(22) on both ends. Swash plate type Two-stage planetary
Each piston assy (7) is guided by a return plate (6) axial piston motor gear reduction unit
and retaining spring (4) so as to slide smoothly on
the cam plate (5).
The balance plate (21) is forced against the end of Mechanical brake
the cylinder by the force of the disc spring (18) and
the hydraulic force acting on the bushing (20). Relief valve
A mechanical brake is installed between the cylin-
der exterior and the housing (25).
A relief valve to cushion hydraulic shock and a Make-up valve
backup valve to prevent cavitation are built in to the
cover (32).
By-pass valve
2. The reduction gear system consists of two stage
planetary gears. The system decelerates high-
speed rotary motion of the swing motor and coverts
it to low-speed large-torque motion in order to rotate
the pinion shaft.
E485 T3-4-9
SWING DEVICE
OPERATION
Swing motor
The pressure oil fed by the pump via the control valve, In addition, the shoe bulb is similarly joined to univer-
etc. enters the motor through port A (or port B) installed sal joint. As a result, the shoe sliding power on the
on cover (32), and is discharged from port B (or port A). swash plate is converted into rotating power through
Also the oil leaking through the sliding section or piston assy (7) and cylinder assy (24) and transmitted
clearance returns to the tank through drain port Dr to the motor output shaft section.
installed on cover (32). In this way, every piston assy (7) receives the pres-
The pressure oil fed to port A goes through passage (b) sure oil within the stroke from top dead point to bottom
inside of cover (32) and to the passage on bushing (20) dead point on a grade, the oil pressure is converted to
section installed cover, then is fed to piston bore (f) on rotating power to rotate cylinder assy (24), resulting in
the cylinder through balance plate (21) passage (b) discharging oil in the stroke from bottom dead end and
which contains crescent shaped port switching supply top dead point.
and discharge by 180 degree of core rotation of motor, The discharge line function in reverse of the supply
and cylinder (24) passage (e). line, and the oil is discharged from port B.
The pressure oil exerts on piston assy (7), then the As described above, the hydraulic motor is operated,
piston assy is pushed against cam plate (5) through a and the output torque of hydraulic motor is determined
part of the shoe. Since the shoe sliding surface of cam by oil pressure, and speed of revolution by supply flow
plate (5) is inclined at a uniform angle, the pushing rate.
force of piston assy (7) on which pressure oil is exerted
is converted into sliding power for the shoe on the
swash plate.
15,16
33
32
17
35
28 39 38 37 36 SECTION A-A
15 16 17
18
14 19
13 20
21
12 22
11 23
10 24
9 25
8 26
7
6
5
3 2 1 27 R3574
T3-4-10 E485
SWING DEVICE
Parking brake
Separator plate (8) is fitted to the external section of

cylinder assy (24) with spline.
Friction plate (9) is fitted to housing (25). When the
primary pilot pressure of brake release port is Zero,
brake piston (11) locks the cylinder (24) (output shaft)
which is rotated by the force of the spring (13) pushing
separator plate and friction plate.
Conversely, when pressure of 3.27 to 4.9 MPa exerted
on the brake relief port, brake piston power exceeds
the force of spring and strokes to the contact with
cover end. Then space is generated between mating
parts, and the mechanical brake released.
Relief valve
1. Starting
With operation of the lever, the oil fed to port A at
first escapes and is discharged to port B without
obtaining regular revolution because the force of
inertia of the upper structure is larger. The hydraulic
oil from port A to passage (i) of relief valve, opens
poppet (44), and is discharged to port B.
2. Braking (Cushion)
By returning the lever to neutral position, the return 43 44 45 46 47 48 49
circuit of motor discharge oil close, and immedi-
ately after this operation, the motor is rotated by the
j Piston
force of inertia resulting in pumping function, and chamber “L”
the oil is sucked from port A and discharged to port
B side. Then, since the return circuit of the control
valve is closed, the pressure of port B is raised.
The raised pressure of port B opposes the spring
(45) force and opens poppet (44), and check valve
(36) through passage (g) (h), and flows into passage
(c). The movement stops while absorbing the force
of inertia in this process.
53 52 51 50
In the above-mentioned process of pressure in-
crease, the oil at port B enters the piston (L) Detail of relief valve (33)
chamber past the circumference orifice of poppet R3040
(44), through the small hole of piston (49) to move

till it hits the liner (48). In this period, the poppet (44) 43 - Seat
44 - Poppet
is already open, so that the cushion relief action 45 - Spring
operates first at a little lower pressure, and the 46 - Shim
pressure rises in a moment to set pressure. 47 - Seat
By these two operations, the shocks are absorbed 48 - Liner
49 - Piston
at starting and stopping of swing motor. 50 - Cap
51 - Back-up ring
52 - O-Ring
E485 T3-4-11
SWING DEVICE
Make-up valve
1. Operation in half lever position

(When cushion relief valve does not function.)
After accelerating slewing of the upper structure,
when the speed is being reduced by half-lever with
the function of control valve, the supply flow rate
from pump to port A is lowered. But if the upper
structure is slewed at a comparatively high speed,
the pressure in the (C) section is lowered to negative
pressure making lubrication necessary. However,
when the pressure of port B is equal to or lower than
the working pressure of cushion relief valve the all
oil of (C) section led through port B is discharged to
the control valve. As a result, the flow rate from the
control valve (Since the valve is in the half-lever
position, the flow rate from pump is limited.) does
not satisfy the specified oil quantity. To prevent
this, the make-up check valve (42) is installed to
supply necessary oil into the (C) section.
2. Braking
(When cushion relief valve is functioned)
When the lever is moved to neutral position rapidly
as described in item 1), the pump does not supply
oil to port A, but the upper structure is slewed by the
force of inertia. In this case, the cushion relief valve
on port B side functions, and the oil from relief valve
goes through the passage (i) (h) and opens make-
up check (36) valve on the port A side to flow into
passage (b) (c). But the oil quantity is insufficient
due to the leakage.
Therefore oil opens make-up check valve (36)
through the make-up port, and flows into passage
(b) (c) to prevent cavitation.
T3-4-12 E485
SWING DEVICE
Swing reduction unit
The swing reduction unit is used to reduce the rotating

speed which is transmitted by the hydraulic motor and RING GEAR
PLANETARY
(FIXED)
to convert it to the strong turning effort (torque). SHAFT
This swing speed reduction unit is equipped with
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear,
SPIDER
planetary pinion, planetary shaft, spider and ring gear,
as shown.
For the operation of the 1st stage planetary, the SUN
hydraulic motor rotates #1 sun gear (11). Sun gear (11) GEAR
is engaged with planetary pinion (12) and rotates, but
since ring gear (6) is fixed, planetary pinion (12)
revolves about sun gear (11) with the planetary shaft
and spider (10).
The role of spider is to hold the planetary pinion and PLANETARY

planetary shaft and transmits the power from the PINION
planetary pinion to the spider through the planetary
shaft. Planetary mechanism
R3041
The #1 spider (10) is linked with #2 sun gear (8) by the
involute spline, and transmits the power to the 2nd
stage planetary mechanism.
SWING MOTOR
For the operation of the 2nd stage planetary, the power
is transmitted to sun gear (8) → planetary pinion 12 11
(9) → spider (7) similarly to the 1st stage. 6
The #2 spider (7) is linked with pinion shaft (1) by the
involute spline, and pinion shaft (1) is engaged with the
10
swing gear fixed on the undercarriage (lower frame)
and rotates. 8
9
14
HOUSING
BEARING 1
Function of reduction unit

R3042
E485 T3-5-1
TRAVEL DEVICE
OUTLINE
Characteristics
Item Data
Reduction gear unit Epicycloidal, three-stage planetary type
Model 715C3K
Reduction gear ratio 1 : 62.4
Travel motor Two speed, axial piston swash plate type
Model MSF340VPEL6
max 271.5 cm3/rev

Displacement
min 165.3 cm3/rev
low speed 92 474 Nm

Max. gearbox output torque
high speed 56 295 Nm
Parking brake torque 1 120 Nm
Release pressure or parking brake 1.8 MPa
Relief valve set pressure cracking 36.8 MPa
Mass (with oil) 600 kg

T3-5-2 E485
TRAVEL DEVICE
Hydraulic motor Planetary gearbox
Two speed hydraulic motor (axial piston swash plate Planetary gearbox, 3 stages, rotating housing type.
type) containing: The track drive is suitable to be used as track drive for
crawled machines equipped with open loop hydraulic
- Integrated counterbalance valve;
circuit.
- Crossover relief valve wich contains a shock ab-
sorber to smoooth acceleration and stopping;
- Negative multidisc parking brake built-in directly
driven from the motor oil pressure (no additional
hose is required);
- Double speed function, allowing the motor to be set
to a fast or slow speed.
Ports
G1
Pi
G2
R3576
P1 SAE 1”
Main ports
P2 SAE 1”
Dr PF 3/4” Drain ports
Pi PF 1/4” 2 speed control port
G1 PF 1/4”
Gauge ports
G2 PF 1/4”
E485 T3-5-3
TRAVEL DEVICE
Hydraulic circuit
Motor
Gearbox
Pi R3577
T3-5-4 E485
TRAVEL DEVICE
Direction of rotation
When assembling the track drive on the machine and

connecting the hoses, follow instructions shown in
below sketch for proper direction of rotation.
P1
P2
R0754
Oil inlet port Oil outlet port Direction of rotation

P1 P2 Clockwise
P2 P1 Counterclockwise
E485 T3-5-5
TRAVEL DEVICE
CONSTRUCTION
Hydraulic motor
22
21
20
19
18
17
16
15
14
33
13
12
11
10
9
8
7 32
6 31
5 30
4 29
3 28
2
1
27
26
25
24
23
R3578
T3-5-6 E485
TRAVEL DEVICE
Hydraulic motor, base plate
58
57
56 59
55 60
34 54 61
35 53 62 63
36 64
65
52 66
51 67
50 68
49 69
37 70
74 71
38 75
39 48 72
76 73
40 47 77
41 43 78
42 44 79
45 80 82
46 81 83
84
85
86
87
88
115 89
114 90
91
120 92
119 93
118
117 95 94
116 96
113 97
112 98
111
110 100
109 101
108 102
107
106
103
104
105
R3579
E485 T3-5-7
TRAVEL DEVICE
1- Motor housing 41 - Spring (Q.ty 2) 81 - Relief valve assy

2- O-Ring 42 - Spring seat 82 - Free piston
3- Drain plug 43 - Plug (Q.ty 2) 83 - Back-up ring (Q.ty 4)
4- O-Ring (Q.ty 4) 44 - O-Ring (Q.ty 2) 84 - O-Ring
5- Motor seal ring 45 - Spring 85 - Back-up ring
6- Bearing 46 - Check valve 86 - Spring seat
7- Motor shaft assy 47 - Orifice (Q.ty 2) 87 - Spring
8- O-Ring (Q.ty 4) 48 - O-Ring (Q.ty 2) 88 - Spring seat
9- O-Ring 49 - Check valve (Q.ty 2) 89 - Back-up ring
10 - Drain plug 50 - Spring (Q.ty 2) 90 - Back-up ring
11 - Piston spring (Q.ty 2) 51 - O-Ring (Q.ty 2) 91 - O-Ring
12 - Piston (Q.ty 2) 52 - Plug (Q.ty 2) 92 - Plug valve
13 - Ball 53 - Relief valve assy 93 - Nut
14 - Swash plate 54 - Plug 94 - Screw
15 - Piston (Q.ty 9) 55 - O-Ring (Q.ty 2) 95 - Check valve (Q.ty 2)
16 - Retainer plate 56 - Spring seat 96 - Spring (Q.ty 2)
17 - Spherical bush 57 - Spring seat 97 - O-Ring (Q.ty 2)
18 - Spring (Q.ty 9) 58 - Spring 98 - Plug (Q.ty 2)
19 - Cylinder block 59 - Orifice (Q.ty 2) 100 - Screw
20 - Valve plate 60 - Plug (Q.ty 6) 101 - O-Ring (Q.ty 2)
21 - Bush 61 - O-Ring (Q.ty 6) 102 - Plug
22 - Bearing 62 - Plug 103 - Screw (Q.ty 4)
23 - Steel disc (Q.ty 2) 63 - Spool 2nd Speed 104 - Plug
24 - Steel disc 64 - Spool 2nd Speed 105 - O-Ring (Q.ty 2)
25 - Brake disc (Q.ty 4) 65 - Back-up ring 106 - Spring seat (Q.ty 2)
26 - Steel disc (Q.ty 3) 66 - O-Ring 107 - Spring (Q.ty 2)
27 - Steel disc (Q.ty 2) 67 - O-Ring 108 - Spring seat (Q.ty 2)
28 - Back-up ring 68 - Back-up ring 109 - Plug (Q.ty 2)
29 - O-Ring 69 - Filter 110 - O-Ring (Q.ty 2)
30 - O-Ring 70 - Circlip 111 - Spring
31 - Back-up ring 71 - Spring seat 112 - Check valve
32 - Brake piston 72 - O-Ring (Q.ty 2) 113 - Plunger
33 - O-Ring 73 - Plug 114 - Orifice (Q.ty 2)
34 - Plug 74 - Base plate 115 - O-Ring (Q.ty 2)
35 - O-Ring 75 - Screw (Q.ty 9) 116 - Plug (Q.ty 6)
36 - Screw 76 - Poppet seat 117 - O-Ring (Q.ty 6)
37 - Screw 77 - Back-up ring 118 - Orifice
38 - Plug 78 - O-Ring 119 - Spring (Q.ty 10)
39 - O-Ring 79 - O-Ring 120 - Pin (Q.ty 2)
40 - Spring seat 80 - Poppet
MOTOR DRAIN PRESSURE
Continuous running Less than 2 bar

Max. intermittent Less than 5 bar
Brake
The track drive is supplied with a safety negative disc the hydraulic motor. For this reason, there is no need
brake fitted into the hydraulic motor (parking brake). of brake external pilot.
Parking brake release is automatically operated when The brake technical data are shown on the track drive
high pressure oil is supplied to one of the two ports of installation drwing.
BRAKE TECHNICAL DATA

Min. pressure for release parking brake MPa 1.8
Static parking brake torque Nm 1120
T3-5-8 E485
TRAVEL DEVICE
Gearbox
1
2
3
4
5
6
15
16 7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
R3580
1- Screw M14x40 (Q.ty 16) 190 Nm 13 - Third reduction assembly

2- Oil breather plug M22 x 1.5 (Q.ty 2) 30 ÷ 40 Nm 14 - Bush (Q.ty 4)
3- Washer (Q.ty 2) 15 - Screw M24 x 65 (Q.ty 24) 950 Nm
4- Cover assembly 16 - Sprocket
5- O-Ring 17 - Gearbox housing
6- Pad 18 - Lifetime seal
7- Sun gear 19 - Discs retainer
8- First reduction assembly 20 - Hub
9- Sun gear 21 - O-Ring
10 - Second reduction assembly 22 - Hydraulic motor
11 - Sun gear 23 - Screw M18 x 60 (Q.ty 4) 295 Nm
12 - Screw M30 x 2 x 150 (Q.ty 4) 1480 Nm
E485 T3-6-1
SWIVEL JOINT
OUTLINE
General view
Drain port (F)
High pressure High pressure F

ports (B, D) ports (A, C)
Remote control Parts number

port (E)
4 - Ø18
Name
plate
Tap for
sling
VIEW A
A
R3581
Specifications
Working pressure 34.3 MPa

High pressure ports
Max. impact pressure 51.5 MPa
A,B,C,D
Remote control port Working pressure 4.9 MPa
E Rated flow 40 L/min
Drain port Working pressure 0.98 MPa
F Rated flow 12 L/min
Revolution 12 min-1
A,B,C,D 4 - PF1
Ports size E 3 - PF1/4
F 2 - PF3/4
Length (height) 373 mm
Mass 57.5 kg
T3-6-2 E485
SWIVEL JOINT
CONSTRUCTION
10 F
C
F E D A
B
2
E
VIEW Y
1
5
B
7 D F A
E 11 E
3
F C
9
4 8
Z VIEW Z
R3582
1 - Body 7- O-Ring
2 - Stem 8- Socket bolt; M8×20 (Q.ty 4)
3 - Thrust plate 9- Socket bolt; M8×40 (Q.ty 4)
4 - Cover 10 - Plug PF1/2
5 - Seal assy (Q.ty 6) 11 - Plug PF1/4
6 - Seal assy (Q.ty 2)
E485 T3-6-3
SWIVEL JOINT
OPERATION
Main portion of the swivel joint consists of body (1) and Body (1) and stem (2) rotate freely. Oil from body (1)
stem (2) which rotate freely, thrust plate (3) which or stem (2) flows into stem (2) or body (1) through
prevents disconnection of body and stem, cover (4) circumferential grooves between body (1) and stem
which closes one side of swivel body (1), slipper seal (2); oil flow is thus not obstructed by swiveling.
assy (5), which divide circuits, and O-Rings (6, 7), Lubricating oil groove to drain port is also provided to
which prevent external oil leakage. prevent seizure of body (1) or stem (2) by swiveling.
Body (1) and stem (2) are provided with four ports each With this construction, swivel joint assures circuit
for the main circuit and a port for the remote control connection between te undercarriage and the upper
circuit and a port for the drain circuit. In addition, the structure.
inner circumference of body (1) is arranged with a
groove for the oil path. Seal (5) is fitted above and
below the circumferential grooves.
T3-6-4 E485
SWIVEL JOINT
NOTES:
E485 T3-7-1
CYLINDERS
OUTLINE
General view
B
gth
l en
ed A
te nd gth
ex en
lly e dl
Fu nd
e xte
F ully
Part No. and Manufacturing No.

Stamp position
R0252
Specifications
Center distance
Cylinder bore / of pins
Use Stroke Cushion Dry weight
Rod Dia. Full extend B /
Full retract A
mm mm mm kg
Boom Ø 170 / Ø 115 1 590 3 790 / 2 200 With cushion 415

on rod side
Arm Ø 190 / Ø 130 1 970 4 600 / 2 630 With cushion 591

on both sides
Bucket Ø 170 / Ø 120 1 300 3 325 / 2 025 With cushion 416

on rod side
T3-7-2 E485
CYLINDERS
CONSTRUCTION
Boom cylinders
7
abc
1 4 5 9 13 10 8 1112
3
2 14 31
6
30
R3583
1 - Rod assy 8- Piston

2 - Tube assy 9- Ring cushion
3 - Seals rod 10 - Shim
4 - Head 11 - Screw; M15 96.6±18.2 Nm
5 - Back-up ring + O-Ring 12 - Ball steel
6 - Screw; M27 (Q.ty 8) 1140±206 Nm 13 - Seal cushion
7 - Seals piston 14 - Grease fitting
7a - Seal ring 30 - Wiper (Q.ty 2)
7b - Back-up ring 31 - Wiper (Q.ty 2)
7c - Slide ring
E485 T3-7-3
CYLINDERS
Arm cylinder
DETAIL OF "B"
31 32 29 30 B B
12 11 10 9 8 5 6 7 13 4 1 17 18 17 19 20 16 14 15 33 21 22
2, 3
A 2, 3
Ø2.6
24
25 23
26
27
DETAIL OF "A" 28
R3584
1- Tube assy 18 - Back-up Ring + O-Ring

2- Bushing (Q.ty 2) 19 - Back-up Ring + O-Ring
3- Seal dust (Q.ty 4) 20 - O-Ring
4- Piston rod 21 - Packing rod
5- Piston 22 - Seal dust
6- O-Ring 23 - Capscrew (Q.ty 20)
7- Back-up Ring + O-Ring; (Q.ty 2) 24 - Check valve
8- Seal 25 - Spring
9- Wear ring (Q.ty 3) 26 - Spacer
10 - Wear ring (Q.ty 2) 27 - Plug
11 - Nut 28 - O-Ring
12 - Setscrew 29 - Band
13 - Ring 30 - Band
14 - Cover 31 - Capscrew (Q.ty 2)
15 - Bushing 32 - Lockwasher (Q.ty 2)
16 - Clip 33 - Seal
17 - O-Ring (Q.ty 2)
T3-7-4 E485
CYLINDERS
Bucket cylinder
9
abc
15 4 5 2 8 10 11 13 14
1
3
7 30
30
R3585
1 - Rod assy 9b - Back-up ring (Q.ty 2)

2 - Tube assy 9c - Slide ring (Q.ty 2)
3 - Seals rod 10 - Piston
4 - Head 11 - Nut; M90 16800 Nm
5 - Back-up ring + O-Ring 13 - Screw
7 - Screw; M22 (Q.ty 12) 711 Nm 14 - Steel ball
8 - Ring cushion 15 - Grease fitting
9 - Seals piston 30 - Wiper (Q.ty 4)
9a - Seal ring
E485 T3-7-5
CYLINDERS
Hydraulic cylinder construction

(for boom, arm and bucket cylinders)
By construction the hydraulic cylinder consists mainly

of cylinder tube assy (2), piston rod assy (1) that takes
out the motion of pistons reciprocating in the cylinder
tube assy, and cylinder head (4) that serves as both a
lid and a guide. Cylinder tube assy (2) is equipped with
a pin mount that connects piston rod assy (1) with
other parts.
In addition to these main components, seal ring (9a)
and back-up ring (9b) are located between cylinder
tube assy (2) and piston rod assy (1); seals rod (3) are
located between piston rod assy (1) and cylinder head
(4); and an O-Ring and a back-up ring (5) are placed
between cylinder tube assy (2) and cylinder head (4).
OPERATION
If pressurized oil is fed alternatively to the oil inlet and
outlet provided in the cylinder, force acts on the piston
which in turn causes the piston rod (2) to extend and
retract.
Operation of cylinder with cushion

CUSHION RING (8) CHAMBER "A" PATH "B"
CUSHION ON ROD SIDE TANK
PISTON (10) ROD COVER
The cushion mechanism is provided to prevent the
generation of shock when the moving speed of piston ROD(2)
(10) is not reduced and strikes cylinder head (4). HEAD ROD
An oil in chamber "A" returns to the tank by passing SIDE SIDE
through paths "B" at a fixed flow rate in a intermediate
stroke state of pressing bottom side.
CILINDER HEAD (4)
CUSHION STROKE
R0256
Next, in a state of just before stroke end, cushion ring TANK

CLEARANCE "D"
(8) plunges into path "B".
At this time, an oil in chamber "A" passes clearance
"D" and mouth gap "C", an oil flow volume returning to
tank suddenly drops and the piston part movement
slows down. MOUTH GAP "C"
R0257
T3-7-6 E485
CYLINDERS
CUSHION ON HEAD SIDE CUSHION SEAL (6)
This construction is similar to the one of cushion on PATH "B" TANK CUSHION RING (16)
rod side. In a state of intermediate stroke pressing rod
side, an oil in chamber "A" returns to tank by passing
through path "B" at a fixed flow rate.
Next, in a state of just before stroke end, cushion ring
(16) plunges into path "B". At this time, an oil in
chamber "A" path clearance "D" and cushion seal (6)
are mouth gap "C", an oil flow volume returning to tank
suddenly drops and the piston part movement slows
CHAMBER "A" CLEARANCE "D"
down.
R0258
E485 T3-8-1
AIR CONDITIONER
CONSTRUCTION AND PIPING
Construction
1-9
1-1
6
4 1-8 1-2
2-9 2-10 1-3

2-1
1-4 1-6
2-2
2-11
1-5
2-5
2-6
2-7
2-8
R3586
1 - Air-conditioner assy 2-5 - S Hose

1-1 - Air-conditioner unit 2-6 - D Hose
1-2 - Plate 2-7 - L Tube
1-3 - Capscrew 2-8 - L Hose
1-4 - Hose (Q.ty 2) 2-9 - Capscrew
1-5 - Clip (Q.ty 2) 2-10 - Capscrew
1-6 - Sensor 2-11 - Capscrew (Q.ty 2)
1-8 - Clamp (Q.ty 2) 3- Compressor
1-9 - Cap 4- Panel
2 - Air dryer assy 5- Condenser
2-1 - Receiver dryer 6- Filter assy
2-2 - Bracket
T3-8-2 E485
AIR CONDITIONER
Piping
NOTE - 1. Apply oil for refrigerant R134a to the O-Rings at all air-conditioner hose fittings.
2. Refrigerant volume: 1010±100 g.
2
2
3
1 3
4 1
16 7 6
17 21
2
13
14
15 12
8
9
11 10
16
17
18 11
19
16 20
17
18
R3587
E485 T3-8-3
AIR CONDITIONER
1- Clip (Q.ty 5) 12 - Trasmission belt

2- Screw (Q.ty 5) 13 - Washer (Q.ty 2)
3- Washer (Q.ty 5) 14 - Screw (Q.ty 2)
4- Collar (Q.ty 4) 15 - Screw (Q.ty 2)
5- Hose 16 - Washer (Q.ty 8)
6- Hose 17 - Washer (Q.ty 8)
7- Bracket 18 - Screw (Q.ty 8)
8- Washer (Q.ty 4) 19 - Washer (Q.ty 2)
9- Washer (Q.ty 4) 20 - Screw (Q.ty 2)
10 - Screw 6x20 (Q.ty 2) 21 - Hydraulic connector (Q.ty 2)
11 - Collar
NOTE - Apply Three-Bond #1110B to ★ mark.
Heater circuit
AIR CONDITIONER UNIT

ENGINE
IN OUT
OUT IN
R0302
Air conditioner circuit
AIR CONDITIONER UNIT
L HOSE
S HOSE
D HOSE
COMPRESSOR
CONDENSER
RECEIVER DRYER
R1303
T3-8-4 E485
AIR CONDITIONER
MAIN COMPONENTS
Air-conditioner unit
38
69 37
60 7 26
60 19 5
36
63
61 20
9
63
1
61
25 21
61
30
14 61
59
35 61
60 4
29
61
18
28 17
10 31 61
4
23
22 33
24
65
34
65 23 61
32
65 11
61
22
61 16
12
15
65
64
22 8
2
58
61
23
65
22 63
57
19 61
27
1 61
3 5
63 40
6
13 6
55
53
R0305
E485 T3-8-5
AIR CONDITIONER
11 - Actuator (Q.ty 3) 26 - Rod 67

12 - Expansion valve 27 - Rod 120
13 - Thermistor 28 - Damper AM assy
14 - Clamp (Q.ty 2) 29 - Damper CM assy
15 - Rod holder (Q.ty 2) 30 - Damper VE assy
16 - Sensor holder (Q.ty 2) 31 - Damper FA assy
17 - Clamp A 32 - Damper DE assy
18 - Evaporator 33 - Damper FO assy
19 - Casing 34 - Heater core
10 - Casing 35 - Controller
11 - Casing 36 - Relay 24-4PE
12 - Insulator 37 - Clamp C
13 - Insulator 38 - Band CV-250
14 - Packing VE duct (Q.ty 2) 40 - Harness
15 - Packing DE duct 53 - Flange plate
16 - Packing FO duct 55 - Sems bolt
17 - AHC. bracket 57 - O-Ring; 1/2
18 - Clamp 58 - O-Ring; 5/8
19 - Lever MAL1 (Q.ty 2) 59 - Tapping screw (Q.ty 6)
20 - Lever AM 60 - Tapping screw (Q.ty 13)
21 - Lever CM 61 - Screw (Q.ty 31)
22 - Lever M01 (Q.ty 4) 63 - Tapping screw (Q.ty 9)
23 - Lever M02 (Q.ty 4) 64 - Capscrew (Q.ty 2)
24 - Cam 65 - Tapping screw (Q.ty 5)
25 - Rod AC 69 - Cap
T3-8-6 E485
AIR CONDITIONER
Intake unit
50 63
1 61
60
49
63 60
61
51 61
60 60
47
52
61
61
42 48
61
61
61
56
60
44 61
68
60
43
44
67
46
41
60
45
54
62
62 66
59
62
R0304
E485 T3-8-7
AIR CONDITIONER
41 - Resister TKS-B215A0 52 - Damper IN

42 - Casing top 54 - Inner air sensor
43 - Casing bottom 56 - Gasket
44 - Unit bracket (Q.ty 2) 59 - Tapping screw (Q.ty 6)
45 - Cooling hose 60 - Tapping screw (Q.ty 13)
46 - Blower motor 24V 61 - Screw (Q.ty 31)
47 - Casing R 62 - Sems bolt (Q.ty 3)
48 - Casing L 63 - Tapping screw (Q.ty 9)
49 - Inner air filter 66 - Drain hose (L = 300mm) (Q.ty 2)
50 - Lever MAL2 67 - Clip 14C (Q.ty 2)
51 - Lever IN 68 - Canoe clip (Q.ty 2)
Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
R0306
1 - Pressure switch
2 - Sight glass
3 - Desiccant
4 - Suction pipe
5 - Filter
6 - Receiver tank
T3-8-8 E485
AIR CONDITIONER
FUNCTION
Mechanism of cooling circuit
MECHANISM OF COOLING
In the cooling process, the refrigerant that flows
through the cooling circuit changes its phases from HFC-134a (R134a)
liquid to gas and vice versa during which process heat Chemical formula CH2FCF3
is transferred from the low temperature part (compart-
ment) to the high temperature part (outside of the Molecular weight 102.03
vehicle).
Boiling point –26.19 °C
Kind of Refrigerant Critical temperature 101.14 °C
Many kinds of refrigerants that change in that way are Critical pressure 4.065 MPa
available, but the following requirements are needed
for use in such applications: Critical density 511 kg/m3
• Latent heat of vaporization (heat of vaporization) is
Density of saturated 1206 kg/m3
large.
liquid (25 °C)
• It is easy to liquefy (condense). (It does not require
very high pressure for condensation.) Specific volume of saturated 0.0310 m3/kg
• It is easy to gasify (evaporate). (It evaporates vapor (25 °C)
sufficiently at not too low pressure, i.e. cools down
an object.) Latent heat of vaporization (0 °C) 197.5 kJ/kg
• It has small specific heat. (Since the refrigerant Flammability Non flammable
itself is cooled by the expansion valve, the loss
resulting from it must be held down to a minimum.) Ozone destruction coefficient 0
• It has a high critical temperature and a low solidifi-
cation point.
• It is stable chemically and does not corrode and
permeate into the circuit parts.
• It is free from toxicity, objectionable odor, flamma-
bility and explosiveness and excels in thermal
conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned
requirements, ones having characteristics that suit
the intended cooling unit are chosen and used. If a
refrigerant other that those designated is used, suffi-
cient refrigeration will not be performed or the equip-
ment in which the refrigerant is used may be broken.
Therefore, always use a designated refrigerant for the
cooling unit.
Table shows the principal characteristics of the PRESSURE
R134a refrigerant that is used in this machine. MPa
R134a
4
CHARACTERISTICS OF REFRIGERANT
3
In general, the fluid (general term of gas and liquid)
has the following qualities: LIQUID
1. As a gas under certain pressure is cooled down, it 2
begins to condensate at a certain temperature to GAS
take a liquid state. The temperature at which con-
1 TEMPERATURE
densation begins is unique to each substance
(°C )
(fluid) at a given pressure. The temperature deter-
mined by a given pressure is called saturation 0 0 15 18 35 50 100
temperature.
R0307
E485 T3-8-9
AIR CONDITIONER
2. Inversely to 1. above, the pressure at which a gas PRESSURE

condenses for a temperature is determined. This MPa
pressure is called saturation pressure. R134a
4
Figure beside illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in 3
the air-conditioner. At the temperature and the
LIQUID
pressure on the lower righthand side of the curve
2
in figure, the refrigerant take a gaseous state, while
at the temperature and the pressure on the upper GAS
lefthand side of the curve, the refrigerant takes a 1 TEMPERATURE
liquid state. (°C )
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the refrigerant 0 0 15 18 35 50 100
evaporates, it absorbs evaporation heat from the
R0307
air of the compartment. In order to cool the inside
of the compartment down to 25 °C, the refrigerant
must transform (evaporate) from a liquid to a
gaseous state at a lower temperature. It can be
seen from the figure 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 tem-
perature is used, air is mixed into the circuits,
thereby deteriorating the performance of the cool-
ing unit.) In the process in which gaseous refriger-
ant is brought back to a liquid state, the refrigerant
is cooled and condensed by the outer air exceed-
ing 35 °C.
Accordingly the refrigerant is capable of condens-
ing at a pressure exceeding 1 MPa, as seen from
the figure.
Cooling circuit
The figure illustrates the cooling circuit of the car air-

conditioner.
In this circuit diagram, the portion that cools the air of
INSIDE OF COMPARTMENT (CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
EVAPORATOR
heat off the surrounding area as evaporation heat as
it evaporates in the cooling circuit. Since the part at
which vaporization of the refrigerant takes place is the EXPANSION
BLOWER VALVE
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In
the meantime, liquid refrigerant (slightly wet vapor- INSIDE OF ENGINE ROOM
ized refrigerant) is fed into the evaporator, when S D

"cooling" effect is attained. For instance, in order to COMPRESSOR COOLING FAN
cool the air to 15 °C, the refrigerant can not absorb
evaporation heat from the air unless it evaporates at
a temperature lower that 15 °C. For that purpose, it
can be seen from the figure that the pressure of the
RECEIVER
refrigerant in the evaporator must be less than DRYER
0.51 MPa. CONDENSER
Furthermore, the cooling effect deteriorates unless

the feed rate of the refrigerant is controlled so that all R0308
of the refrigerant supplied to the evaporator vaporizes

and turns into dry vapor.
T3-8-10 E485
AIR CONDITIONER
Consequently, the cooling circuit is so constructed

that the evaporator can cool down an object (air in this
case) sufficiently (i.e. so as to decrease the pressure
in the evaporator) and that an adequate amount of
refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The com-
pressor 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.
Component parts
EVAPORATOR
The evaporator is an important heat exchanger that
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the low-
temperature, low-pressure liquid-state refrigerant. EVAPORATOR
Therefore, it is necessary that satisfactory heat trans-
fer between the object and the refrigerant take place
in the evaporator.
O-RING
To that end, the evaporator is equipped with fins on
EXPANSION
the air side in order to increase the heat transfer area VALVE
of the air side and thereby perform excellent thermal
transfer between the refrigerant and the air. SOCKET
BOLT
The humidity in the air condenses as the air cools M5x40
down and adheres to the outside of the evaporator as (2 PCS.)
water drops. The cooling effect deteriorates if the
water drops freeze. Therefore, how to discharge EVAPORATION
water is an important point. SENSOR
The amount of refrigerant supplied to the evaporator
is controlled by the expansion valve which is de-
scribed in the following. In order to attain proper R0309
control, it is necessary to reduce the pressure drop of
the refrigerant of the evaporator. Accordingly, reduc-
ing the pressure drop is one element that makes the
evaporator attain its full performances.
EXPANSION VALVE
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is too
high, unvaporized liquid refrigerant returns to the
compressor (liquid back). This not only deteriorates
the cooling effect, but also damages the compressor
valves.
E485 T3-8-11
AIR CONDITIONER
The expansion valve feeds the flowing high-pressure

high-temperature liquid refrigerant to the evaporator
as low-pressure low-temperature liquid refrigerant DIAPHRAGM
(damp vapor of low dryness). The expansion valve
controls the feed rate of the refrigerant at the same
time.
The figure beside shows how the block type expan- EVAPORATOR REFRIGERANT
sion valve is constructed. The temperature sensing SIDE OUTLET
part is provided in the shaft of the expansion valve to
directly detect the refrigerant temperature at the outlet
SHAFT
of the evaporator.
The diaphragm contains R134a in saturated state.
The pressure in the diaphragm changes according to
the temperature detected by the sensor. The change
in the pressure causes the force acting upon the REFRIGERANT
diaphragm to vary accordingly. INLET
The high-pressure high-temperature liquid refriger-
ant that is fed from the receiver side reduces the BALL
pressure abruptly as it passes through the valve VALVE
(throttling action). On that occasion, part of the refrig- SPRING
erant evaporates by the very heat of the refrigerant
R0310
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 equilib-
rium 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 refrig-
erant at the outlet of the evaporator to be sensed by
the thermowell). The feed rate is controlled automati-
cally so that under the pressure in the evaporator, the
refrigerant is properly overheated (3 ~ 8 degrees) and
goes out of the evaporator. This action is carried out
by sensing the refrigerant temperature at the outlet of
the evaporator as against the inlet pressure of the
evaporator and consequently controlling the feed rate
of the refrigerant.
This means that if the refrigerant pressure drop in the
evaporator is excessive, it is difficult to control the
overheating or the feed rate of the refrigerant. For this
reason, the smaller the pressure drop of the evapora-
tor, the better.
The expansion valve senses the pressure and the
temperature at the outlet of the evaporator and con-
trols the overheating of the refrigerant and the refrig-
erant supply to the evaporator more securely. The air-
conditioner of this machine adopts a block type ex-
pansion valve. R0311
T3-8-12 E485
AIR CONDITIONER
COMPRESSOR
The compressor performs the following three func- D HOSE
tions in the cooling circuit:
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 refrig-
erant to circulate in the cooling circuit. This enables
enables continuous cooling.
3. The compressive action, as combined with the
action of the condenser which is mentioned here-
under, transforms vaporized refrigerant back to a
liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes pos-
R0312
sible to cool down the refrigerant by the use of an
outer air of 35 °C and liquefy it. The compressive
action of the compressor works to turn low pres-
sure 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 refrig-
erant discharged by the compressor turns into
high-temperature high-pressure vapor and is deliv-
ered to the condenser.
CONDENSER
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by
the use of outer air and condenses the refrigerant.
The direction in which heat moves is from the refrig-
erant 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 pur-
pose, it is necessary to secure ventilation required for
the cooling of the refrigerant.
R0313
E485 T3-8-13
AIR CONDITIONER
RECEIVER DRYER
1. Receiver Tank
REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the com- INLET
pressor varies greatly which causes the proper
flow of refrigerant in the cooling circuit to vary. It is REFRIGERANT
the receiver tank that receives the variations. OUTLET
When the cooling circuit does not need much
refrigerant, the receiver tank stores extra refriger-
ant temporarily and supplies it when the cooling
circuit needs much refrigerant. The receiver tank
also stores an extra amount of refrigerant to be
used for filling balance and supplement small
amounts of leakage of the refrigerant through pen- R0314
etration into rubber hoses.
2. Dryer
If water is mixed in the cooling circuit, it deteriorates
the compressor valves and oil, corrodes the metal-
lic parts of the circuit or clogs the circuit as the water PRESSURE SWITCH
freezes in the expansion valve. It is desirable that
the amount of water mixed in the refrigerant should
be held below a concentration of 30ppm. The air-
conditioner uses a molecular sieve as desiccant
suited for the circuit, in order to absorb water
content that intrudes into the circuit when the dryer
is installed or when refrigerant is charged.
3. Sight Glass
This is a inspection window with which the refriger-
DESICCANT
ant level in the circuit is determined, the only means
of confirming the inside of the circuit visually.
4. Filter SUCTION PIPE
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 FILTER
pressure increases abnormally high (more than
3.14 MPa).
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the com-
pressor when the pressure of the circuit falls below
0.196 MPa.
RECEIVER TANK
R0315
T3-8-14 E485
AIR CONDITIONER
NOTES:
E485 T3-9-1
ATTACHMENT AUTOMATIC LUBRICATION SYSTEM
ATTACHMENT CENTRALISED LUBRICATION SYSTEM
General
The machine is equipped with a centralised lubrication in the figure below. The system of lubrication is called
system performing automatically, without intervention “progressive”, that means all lubrications points are
by the operator, the greasing of the front attachment at supplied successively and in a pre-established order
pre-established intervals. The grease under pressure by a quantity of grease. An overload relief valve (2)
is injected by the pump (1) to the main distributor (3), sets the maximum operating pressure of the system
then via the secondary distributors (4), (14) and (26) to at 280 bar.
all lubricating points of the front attachment; as shown
R3764
1 - Electric pump EP-1 4 - Secondary distributor (Boom)

2 - Overload relief valve 14 - Secondary distributor (Arm)
3 - Main distributor 26 - Secondary distributor (Bucket)
T3-9-2 E485
Greasing Points Lay-out
14/E 14/F 4/E 4/B 4/C 4/A
14/D 14/A 14 26/A 26/C
1,2 4/D 3 4 4/G 4/E 14/C 14/B
26/F 26 26/B 26/D 26/E
R3765
E485 T3-9-3
Technical Data
Electric pump EP-1

Motor Operating voltage: 24 V DC
Rpm: 15 rpm
Current consumption:
Idling at +20 °C: 0.4 A
Full load at +20 °C: 1.1 A
Container volume: 8 kg
Lubricant: Greases up to NLGI-Cl. 2
Pump units PE-120

Max. operating pressure: 280 bar
(Overload relief valve setting)
Permissible operating temperature: -35 °C to + 80 °C
Delivery rate of pump units: 0.12 cm3/stroke or rev.
Protection class: IP5K9K as per DIN 40050
Electric Schematic Diagram
3 2
BEKA-troniX1 Connector (AMP)
green 231
1 3
red 233
2 5
Red Green
3
3 2
Fuse 12
4
5 black 1 12A 10A 24V
6 orange 4 232
brown
1 Lubrication push button
7 2 E40
BEKA-troniX1 wiring Excavator wiring harness
R3766
T3-9-4 E485
OPERATION
Electric pump EP1

A DC motor (10) continually operates the eccentric container (1) through a screen (4), which reduces any
cam (5) and pressure ring (6). This eccentricity effects air bubbles, to the suction area in the pump housing
the suction and pressure strokes of the delivery piston (3). A scraper on the stirrer (2) enables a visual check
(7), whereby the integrated non-return valve (8) pre- of the lubricant volume still present in the transparent
vents the delivery media from being sucked back out supply container (1).
of the main line. The overload relief valve (9) is pre-set to 280 bar.
The stirrer (2) pushes the lubricant out of the supply
R3767
Pump unit intake Pump unit delivery
R3768 R3769
E485 T3-9-5
MAIN DISTRIBUTOR SXE-2
Outline
The progressive piston distributors type SXE-2 are The progressive distributor SXE-2 consists mainly of
distribution units with hydraulic sequence control, distributor panels. These consist of a basic unit and a
whose pistons are controlled by the lubricant supply so dosing unit. Basic units are divided into start units,
that the lubricant is forced in sequence through the middle units and end units.
individual outlets. If faults occur in the lubricant flow, The various delivery rates per piston stroke are
e.g. blockage of lubricant lines or lubricant points, this achieved by the different piston diameters of the
will block the distributor. This blocking is used to dosing units, which can be exchanged as required.
monitor the distributor.
If there is a blockage, in automatic pumps, the lubri-
cant escapes via the overload relief valve.
1 2
3
4 5
6
R3771 R3770
1 - Dosing unit 4 - Start unit

2 - End unit 5 - Middle unit outlet threaded joint
3 - Basic unit 6 - Inlet threaded joint
Technical Data
Output
Element denomination Piston Ø
Per outlet Per element
220 SXE-2 0.22 cm3 0.44 cm3 6 mm
620 SXE-2 0.62 cm3 1.24 cm3 10 mm
760 SXE-2 0.76 cm3 1.52 cm3 11 mm

T3-9-6 E485
Functional description
The progressive distributor is based on distributor
panels that are connected together by tie rods with
washers and nuts to form distributors.
The dosing units are screwed onto the basic units with
Allen screws. Individual units are sealed with O-Rings.
The four following figures show what happens inside of
the distributor.
FIGURE A
The lubricant flows through the distributor inlet to the
second dosing unit and piston (II).
III
3 6
II
2 5
I
1 4
Pressure chamber
R3772
FIGURE B
The piston (II) is pushed to the left and the lubricant is
pushed to outlet 2 from the left pressure chamber of
the delivery piston.
III
Subsequently, the dosing piston (III) is progressively
pushed and the lubricant delivered to outlet 3.
3 6
II
2 5
I
1 4
R3773
E485 T3-9-7
FIGURE C
After the piston is pushed (II), the lubricant is moved
to the left side of the delivery piston (I) and moved from
the right pressure chamber of the delivery piston (I) to
III
outlet 4.
Subsequently, the delivery pistons (II) and (III) are
pushed and the lubricant delivered to outlets 5 and 6.
3 6
II
2 5
I
1 4
R3774
FIGURE D
After the delivery piston is pushed (III), the lubricant is
moved to the right side of the delivery piston (I)
pushing the lubricant out of the left pressure chamber III
of the delivery piston (I) to outlet 1.
A new progressive piston distributor cycle then be-
gins. The described function repeats itself as long as
lubricant is supplied to the progressive distributor. 3 6
II
= Pressure ducts
2 5
= Already conveyed
= Subsequent delivery stroke I
1 4
R3775
T3-9-8 E485
SECONDARY DISTRIBUTOR MX-F
Outline
The progressive piston distributors are distributor of lubricating line or lubricating points, the distributors
devices with a hydraulic sequence control, the pistons will block up. This blockage is used for the monitoring
of which are regulated by the supplied lubricant in a of the distributors. In the case of manually operated
way that the lubricant inevitably and successively pumps a virtually insurmountable counter pressure
escapes at the individual outlets. In the case of occurs during the blockage.
malfunctions during the flow of lubricant, e.g. clogging
R3776 R3777
Technical Data
Output
Element denomination Piston Ø
Per outlet Per element
MX-F 25 25 mm3 50 mm3 3 mm
MX-F 45 45 mm3 90 mm3 4 mm
MX-F 75 75 mm3 150 mm3 5 mm
MX-F 105 105 mm3 210 mm3 6 mm

E485 T3-9-9
Functional description
The progressive distributors consist of the individual
components initial element IE (without piston), middle
element ME and end element EE, all of which are
assembled in distributor blocks by using tension rods
(hexagon socket screws) with lock washers. The
individual elements are sealed with O-rings.
These three following figures show what happens
inside of the distributor.
FIGURE A
The lubricant flows via the inlet of the distributor
through all distributor disks to the piston (I).
III
3 6
II
2 5
4 1
Pressure chamber
R3779
T3-9-10 E485
FIGURE B
The piston (I) is shifted to the left and the lubricant is
pressed from the left pressure chamber of the delivery
piston to the outlet 1.
After that, the proportioning pistons (II) and (III) are
progressively shifted and the lubricant is primed to the
outlets 2 and 3. III
3 6
II
2 5
4 1
R3780
FIGURE C
After the piston (III) has been shifted, the lubricant is
directed to the left side of the delivery piston (I) and
primed from the right pressure chamber of the delivery
piston to the outlet 4.
Subsequently, the delivery pistons (II) and (III) are
III
shifted and the lubricant is pressed to the outlets 5
and 6.
3 6
II
After the delivery piston (III) has been shifted, the
lubricant is once more directed to the right side of the
delivery piston (Figure A) and a new cycle of the
progressive piston distributor is initiated. The de- 2 5
scribed function is repeated as long as lubricant is fed
to the progressive distributor. I
4 1
R3778
E485 T3-9-11
CONTROLS
When moving the starter key into position "ON" are
going to be activated simultaneously:
- indicator light (2) on supplementary greasing button 1
(1) and indicator light (3) on the left side panel.
- green indicator light (4) and red indicator light (5) on
control panel (6) of the greasing pump.
After about 1.5 seconds, indicator lights (2), (3), (4), (5)
go OFF confirming the correct operation of the system
2
and the indicator lights. 3
NOTE - Should the engine be cut-off during the M0562
lubrication operation, the time is recorded and memo-

rised. After the next start of the engine, lubrication
starts from where it was interrupted.
When the automatic system starts a greasing cycle,

indicator light (2) and green indicator light (4) come ON
simultaneously and stay ON for the entire duration of
the greasing cycle. Once the operation is over, indica-
tor lights (2) e (4) go OFF and stay OFF until the
subsequent cycle occurs.
Supplementary greasing button

It is possible to perform manually, at any time, an
immediate greasing cycle by actuating button (1).
Subsequently, the controller of the system shall set 6
the next cycle, starting from the latter one. 7
NOTE - The same operation can be performed by

pressing button (7) located on the greasing pump. 5
4
M0563
T3-9-12 E485
BEKA-troniX1 signal indications

The pump functions are indicated via two control
LEDs, green (1) and red (2), in the control panel of the
pump's motor shell; the red LED (2) always indicating
a fault in the program sequence.
These functions of the control LEDs are also indicated
via signal lamps located on left panel of the cab.
1 2
R3781
Indication of operability
1) Operability
Read for operation 1.5 s
ON
Red LED
OFF
ON
Green LED
OFF
R3785
Sequence of lubrication
2) Lubrication active
ON
Red LED
OFF During the entire lubrication period
ON
Green LED
OFF
R3786
Speed fault on pump motor

3) Fault, speed
1 sec.
ON
Red LED
OFF
1 sec.
ON
Green LED
OFF
R3787
CPU/memory fault
4) Fault, CPU/memory
0.5 sec.
ON
Red LED
OFF
1 sec.
ON
Green LED
OFF
R3788
Permanent lubrication
5) Permanent lubrication
ON
Red LED
OFF 1 sec.
ON
Green LED
OFF 1 sec.
R3789
E485 T3-9-13
Number Revolution and Cycle Time setting (BEKA- Diagram of cycle sequence
troniX1)
The integrated electronic BEKA-troniX1 controller can
determine:
- The lubrication period via the number of revolutions Lubrication period
of the pump motor. Cycle time
- Cycle time, the time elapsed between two subse-
R3790
quent cycles.
(see figure A). (Figure A)
These functions can be set by means of notched
switches in the control panel of the pump (see figure
B). Control panel of the pump
Notched switch for setting the number of revolutions

(lubricating period).
How to reach the notched switches
For reaching the switches, remove the red frame on
the pump motor's protective housing by means of a flat
screwdriver; loosen the four Phillips screws, remove Red LED
the transparent protective lid.
Green LED
IMPORTANT - If the closing lid is improperly closed,

water will penetrate the controller and destroy it. The
warranty expires in that case.
Notched switch for setting the cycle time (time elapsed
between two subsequent cycles)
R3782
(Figure B)
How to set the number of revolutions
The number of revolutions of the pump motor (lubricat-
ing period) can be adjusted turning the switch by
means of a flat screwdriver.
Setting range: 10 to 160 revolutions - 16 notches at 10
revolutions each (see figure C).
(Figure C)
How to set the cycle time

The cycle time (time elapsed between two subsequent R3783
cycles) can be adjusted turning the switch by means
of a flat screwdriver.
Setting range: 0.5 to 8 hours - 16 notches at 0.5 hours
each (see figure D).
(Figure D)
Setting of permanent lubrication
To initiate a permanent lubrication must be set to a
higher value of the number of revolutions of the pump R3784
motor than cycle time.
Permanent lubrication is indicated by the red and the
green LED alternately blinking at 1 sec. intervals (see
figure E).
ON
Red LED
OFF
ON
Green LED
OFF
R3789
(Figure E)
T3-9-14 E485
MAINTENANCE
Installation of pump unit PE-120 in electric pump

EP-1
WARNING
Only install/remove when pump is off.
4
1. Install pump unit with piston (4) partially extended.
2. Insert at angle in top of housing bore (see figure A).
3. When piston head (4) rests on pressure ring - move (Figure A) R3791
unit into vertical position (see figure B).
4. Piston head must run in guide ring groove.
5 Tighten pump unit.
Removal occurs in reverse sequence.

When removing the pump unit, ensure that the piston
(4) is not left behind in the pump housing.
Grease filling
1. Insert a grease cartridge inside the greasing gun (3).
2. Get over the turret.
(Figure B) R3792
3. Loosen the fitting plug (4) and connect the greasing
gun to the fitting. Press down the rod (5) to release
the grease content of the cartridge into the tank.
NOTE - More cartridges could be necessary for filling

5
the tank (2).
2
If the greasing gun or the grease cartridge are not

available, the filling of the tank (2) can be performed
through the greasing nipple (6) using a greasing pump. 1
IMPORTANT - If the filling of the tank is performed

through the greasing nipple (6), be sure to use the
prescribed grease and free of contaminations from
3
external agents. Clean the zone around the greasing
nipple to avoid grease contaminations.
IMPORTANT - Never remove the grease tank cover.

This could demage the tank and the warranty could
become void.
6
M0580
E485 T3-9-15
TROUBLESHOOTING
N. FAULT CAUSE REMEDY
1 Leakage of Excessive pressure in the system Check the system

grease at the
overload relief Main distributor is blocked Replace main distributor element
valve units
System is blocked Replace secondary distributor

element units
Defective overload relief valve Replace overload relief valve
2 Excessive grease Wrong specification of distributor Correct output of distributor

at one or more
points of
lubrication
3 Excess grease at Number of pump revolutions too great Reduce number of pump revolutions
all lubrication
points Cycle time of pump too short Increase cycle time of pump
4 Pump will not Electric motor defective Replace the pump

operate (charing
arm not rotating Pump element piston no located Unscrew the pump element and fit
and warning lamp within cam shaft ring correctly in accordance with the
on electronic instructions
control unit
flashing) Electric cable to motor defective Replace the pump
5 No visual Pump is defective Refer to point 4 "Pump will not

indication of operate"
grease at
lubrication points Number of pump revolutions is Increase number of pump revolution
insufficient
Cycle time of pump too long Reduce the cycle time of pump
Main pipe to the distributor is leaking Replace pipe
6 No evidence of Feed pipe to secondary distributor Replace pipes or tighten or fittings

grease at some burst or damaged or leak in pipe
bearings
7 No evidence of Lubrication pipe is burst or there is Replace pipe or tighten pipe fitting
grease at just one leakage at pipe fitting
point in system
8 Warning lamp Pump motor defective Replace the pump

(red) Is flashing
Pump motor speed too low Replace the pump
Control unit defective Replace the pump

T3-9-16 E485
NOTES:
OPERATIONAL PERFORMANCE TEST
R0077
OPERATIONAL PERFORMANCE TEST E485
Section 4 OPERATIONAL PERFORMANCE TEST

Group 1 Introduction
Group 2 Standard Performances
Group 3 Test Procedures
Group 4 Mechatro Controller Adjustment
SECTION 4 E485
OPERATIONAL PERFORMANCE
TEST
CONTENTS
Group 1 - Introduction
How to Use the Maintenance Standard

and Cautions to Be Exercised ................. T4-1-1
Preparation for Performance Tests ........... T4-1-2
Group 2 - Standard Performances
Performance Inspection Standard

Table ....................................................... T4-2-1
Group 3 - Test Procedures
Measurement of Engine Speed ............... T4-3-1

Measurement of Hydraulic
Pressure ................................................. T4-3-2
Measuring Travel Performances ............... T4-3-7
Measuring Swing Performances ............ T4-3-11
Measuring Attachment Operating
Performances ........................................ T4-3-15
Measuring Performances of Swing
Bearing ................................................. T4-3-17
Group 4 - Mechatro Controller

Adjustment
Outline of electronic governor

control ..................................................... T4-4-1
Engine stop Control Installation ............... T4-4-1
Adjusting the engine speed ..................... T4-4-2
Mechatronic control related ..................... T4-4-2
E485 T4-1-1
INTRODUCTION
HOW TO USE THE MAINTENANCE

STANDARD AND CAUTIONS TO BE
EXERCISED
Application Cautions to be Exercised at Judgment
WHEN THE MACHINE IS NEW EVALUATION OF MEASURED DATA

Confirm that the performances are in accordance with Disagreement of measuring conditions, variations of
standard specifications as compared to the perform- data peculiar to a new machine, and measuring errors
ance standards. are to be evaluated. Determine generally at what
levels measured values are located, instead of deter-
AT SPECIFIC SELF INSPECTION mining whether or not values fall within or run out of
the reference values.
Use the data for the criterion, for the purpose of
correction, adjustment and replacement.
DETERMINING CORRECTION, ADJUSTMENT
OR REPLACEMENT
WHEN PERFORMANCES ARE DETERIORATED
Machine performances deteriorate with time as parts
Determine whether it is caused by a fault or end of
wear and some deteriorated performances may be
service life after long hours of operation, to be used for
restored to new levels. Therefore, determine correc-
safety and economical considerations.
tion, adjustment or replacement, depending upon the
operating hours, kind of work and circumstances in
WHEN MAIN COMPONENTS ARE REPLACED
which the machine is placed, and condition the ma-
For example, use data to restore performances of chine performances to its most desirable levels.
pumps and others.
Other Cautions to be Exercised
Terminology
PARTS LIABLE TO DEGRADE
STANDARD VALUES
Rubber products, such as, hydraulic hoses,
Values to be used to condition or assemble a new O-Rings, and oil seals deteriorate with time; replace
machine. Where special notes are not given, these them at regular intervals or at overhauls.
values represent standard specifications (machine
with standard attachments and standard shoes). PARTS REQUIRING REGULAR REPLACEMENT
REFERENCE VALUES FOR REMEDY Out of critical hoses that are necessary to secure
safety, we designate Very Important Parts (V.I.P) and
Values at which readjustment is required. In order to recommend that they should be replaced regularly.
ensure performance and safety it is strictly prohibited
to use the machine over the specified values. INSPECTION AND REPLACEMENT OF OILS
AND GREASES
SERVICE LIMIT
In performing maintenance, it is necessary for the
This is the limit value at which reconditioning is user to familiarize himself with how to handle the
impossible without replacement of parts. If the value machine safely, cautions to be exercised and inspec-
is expected to exceed the service limit before next tion/lubrication procedures. Refer to the operators
inspection and correction are performed, replace the manuals as well.
parts immediately. The operation over the specified
values causes increase of damage and requires the
down time of machine, and also causes safety prob-
lems.
T4-1-2 E485
INTRODUCTION
PREPARATION FOR PERFORMANCE

TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
The machine
1. Repair any defects and damage found, such as oil

or water leaks, loose bolts, cracks and so on,
before starting to test.
Test area
1. Select a hard and flat surface.

2. Secure enough space to allow the machine to run
straight more than 20 m, and to make a full swing
SM0131
with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
Precautions
1. Before starting to test, agree upon the signals to be

employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
SM3026
Make precise measurement
1. Accurately calibrate test instruments in advance

to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
E485 T4-2-1
STANDARD PERFORMANCES
PERFORMANCE INSPECTION STANDARD TABLE
NOTE - The mode is already "W" mode when power is thrown. Unless otherwise specified, measure it on "H/M"
mode.
Measuring Position Standard Adjusting Measuring

Inspection Item Unit
Position Size Port
Value Point Condition
Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 or less Class — Sampling
Std. Measuring condition
Hydraulic oil temperature Tank surface 50 ± 5 —

°C Atmospheric temp.
Water temperature Radiator surface 75 ± 15 — 50 °C ~ -10 °C
Low idle 1050 ± 25 Low throttle

Engine speed
H/M
Hi idle Multi display on 2000 ± 30 Full throttle
the gauge cluster Adjustment
W mode Hi screen (Injection 1850 ± 50 min-1
not required Perform all
pipe) measurement with
A mode Hi 2000 ± 30
the air conditioner
1050 ± 50 "OFF"
Auto-idle
Pilot primary pressure circuit G pump a4 4.9 ± 0.3 PR1 HI idle
P1 a1 Simultaneous
Main pump
31.4 ++ 00.5
valve pressure
ATT MR1 Operation of travel RH

Main relief
P2 a2 and LH and Boom up
P1 a1
Boost 34.3 +– 0.5
1.0
MR1 ATT boost SW. ON
P2 a2 Boom up
— — — — — — —
+0
H 36.3 – 5.4 OR3 Boom up
Boom a1
+0
R 34.8 – 3.4 OR4 Boom down
High pressure circuit
+0
H 36.3 – 5.4 OR1 Bucket digging
Bucket a1
Over load relief valve pressure
+0
R 34.3 – 3.4 OR2 Bucket dump
PF1/4 +0
MPa
H 34.8 – 3.4 OR7 Arm in
Arm a2
+0
R 36.3 – 5.4 OR8 Arm out
Main pump
LH OR5 Swing LH
Swing a2 25.0 ++ 4.9
1.0
RH OR6 Swing RH
Forward OT1
RH a1 34.3 + 1.0
Simultaneous
Travel
Reverse OT2
Operation of travel
Forward OT3 RH and LH
LH a2 34.3 + 1.0
Reverse OT4
— — — —
— —
— — — —
T4-2-2 E485
STANDARD PERFORMANCES
Standard Measuring
Inspection Item Unit
Value Condition
Sprocket revolution 1st speed 33.8~37.4

H/M mode min-1
(RH,LH) 2nd speed 20.4~22.6
Up 3.2~3.8
Boom
Down 2.6~3.2
In 4.2~5.0
Arm
Out 2.9~3.5
Operating time of Digging 3.1~3.7
Operating speed
cylinder Bucket s (At no load)

Dumping 2.4~3.0
— —
—
— —
— —
—
— —
Swing speed STD speed 7.7~9.4 s / 1 rev
Rubber —
1st speed
Iron 21.8~24.0
Travel speed s / 20 m
nd
Rubber —
2 speed
Iron 12.2~13.4
Amount of travel
deviation
2nd speed 0~240 mm / 20 m
Parking brake drift 1 / 5 Gradient 0 mm / 5 min

Performance of Swing Neutral position after 65~105 degree
brake 180° full speed swing
Performance
Swing parking brake drift 1 / 5 Gradient 0 mm

Tip of the bucket tooth 180
Boom cylinder 6
ATT amount of drift mm / 5 min (At no load)
Arm cylinder 6
— —
Amount of horizontal play at the bucket tooth 50~70 mm
CAUTION
8 4
Over load relief valves OR1~OR8 described in
advance correspond to the following operations.
5 6 1 2
1. Bucket digging 2. Bucket dump
3. Boom up 4. Boom down 7 3
5. Swing left 6. Swing right LH RH
7. Arm in 8. Arm out CONTROL LEVER
R316
E485 T4-3-1
TEST PROCEDURES
MEASUREMENT OF ENGINE SPEED
Warming up of engine
PICK UP
Start engine to raise the coolant temperature of en-

gine to 40 °C to 80 °C.
Engine water
temperature gauge The engine coolant tempera-
ture gauge is used to meas-
SPEED METER
ure. The range in white color
shows the temperature of
approx. 40 °C to 100 °C, so
confirm that the pointer indi-
cates the temperature within
the range of white color.
R0317
R0318
Measuring with diesel engine speed meter GAUGE CLUSTER
1. Install diesel engine speed meter pickup on and of

injection pipes on which the pickup can be easily
installed.
2. Check engine speed shown in Table in idling
speed.
6 LOW E/G
OIL PRESS
BUZZER STOP
Engine speed measured value through service SWITCH
diagnosis
1. Turn "ON" the starter switch with the buzzer stop

switch pressed.
2. A program No. and an actual engine revolution are
displayed as the No. 2 Item. SCREEN CHANGE SWITCH
3. The screen advances like No. 2, No.3....each time R0319
the "Screen change" switch on the gauge cluster is
pushed.
4. The screen returns like No. 25, No. 24....each time 2 No. 2
the buzzer stop switch is pressed. E/G SET 1850 No load set rpm
5. The display does not disappear unless the starter
MEAS 1851 Actual rpm
switch is turned to "OFF".
E/G PRS. LIVE LIVE/DEAD indication
MODE SW W W - H/M - A indication
Actual measurement of engine revolution by the

screen change switch
10 : 05 1850RPM
After the engine starts, the fol-
lowing items are displayed in
that order each time the screen
change switch is pressed. 256 Hr AFT
• Engine speed E/G OIL CH
• Hours after the engine oil was Press screen change switch
four times and display
• replaced changes to clock.
R0320 • Hours after the fuel filter, hy-
draulic oil filter and hydraulic Example of screen change
R0321
oil in turn.
T4-3-2 E485
TEST PROCEDURES
MEASUREMENT OF HYDRAULIC
PRESSURE
Preparing to measure hydraulic pressure
HYDRAULIC EQUIPMENT
6.9 MPa pressure gauge ................................. 1 unit
39.2~49 MPa Pressure gauge ......................... 2 unit
Pressure measuring equipment and
instrument for analysis .................................... 1 set
MEASURING CLEANLINESS OF HYDRAULIC OIL
WARNING
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the
measured value is higher than the reference value,
replace the return filter or change the hydraulic oil.
Place to install pressure gauge

a3
a2
MAIN CIRCUIT
Replace plugs PF1/4 of main pump gauge ports a1,
a2 with plugs for pressure measurement, and attach
pressure gauge 49 MPa.
PILOT CIRCUIT
Replace pilot gauge plug a3 with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa.
NOTE - In normal condition, pressure may be meas-

a1
ured by the below service diagnosis numbers. How-
ever, in faulty condition, the above pressure gauge
must be installed and pressure adjustment is re- R3590
quired.
Main circuit No. 14
Pilot secondary pressure No. 9~13
E485 T4-3-3
TEST PROCEDURES
Pressure adjustment position
MAIN CONTROL VALVE

Over load and relief valve position on main control
valve.
OR4 OR8
BOOM (R) ARM (R)
OPT1
OR2
BUCKET (R)
MAIN RELIEF
(ATT & TRAVEL)
View from the top of the machine

R3597
OR3
BOOM (H)
OR7
ARM (H)
OPT1
OR1
BUCKET (H)
View from the bottom of the machine

R3598
T4-3-4 E485
TEST PROCEDURES
PILOT RELIEF VALVE

The pilot relief valve PR1 is located on the gear pump A3
that is attached to the main pump.
a3
Dr4
LOCK
NUT
R3591
SWING OVER LOAD RELIEF VALVE

The swing motor is equipped with plugs GA, GB for
pressure measurement, but the measurement is car-
ried out using gauge ports a1 and a2, that are located GB
on the main pump.
GA
R3799
a3
a2
a1
R3590
E485 T4-3-5
TEST PROCEDURES
Procedure for adjusting relief valve
PILOT RELIEF VALVE

Adjust it with adjust screw (311).
: 24 mm Tightening torque: 29 Nm
: 6 mm
No. of turns of Pressure change

adjust screw MPa
LOCK NUT HEX24
1 turn Approx. 2.1
311
R0327
2-STAGE MAIN RELIEF VALVE (Common for travel

and ATT sections) HEX41 HEX30
Start from the boosting side, first. Loosen nut (1), 1 3
adjust the pressure with adjusting screw (2) and
tighten nut (1) after completion of the adjustment on
the boosting side.
Then, for low pressure setting loosen nut (3), adjust the
pressure on the standard side with adjusting screw (4)
and tighten nut (3) after completion of the adjustment.
2 4
: 22, 27 mm Adjust screw HEX27 HEX22
R3599

adjust screw MPa
Boosting side 1/4 turn Approx. 4.6
STD side 1/4 turn Approx. 4.6
OVER LOAD RELIEF VALVE (Boom, bucket, arm

sections)
Loosen lock nut (1) and adjust with adjust screw (2).
1
: 6 mm

adjust screw MPa
2
1 turn Approx. 20.4
R3891
T4-3-6 E485
TEST PROCEDURES
SWING OVER LOAD RELIEF VALVE 2 1

When the adjustment of pressure is required, loosen
plug (1) and adjust the pressure by adding or removing
shim from area (2).
Tightening torque: 78 Nm
: 4 mm
Thichness Pressure change R3621

of shim MPa
0.1 mm Approx. 0.4
TRAVEL OVER LOAD RELIEF VALVE

This valve was adjusted by valve maker. If adjustment
SHIM
is required, adjust with shim thickness.
R0331
E485 T4-3-7
TEST PROCEDURES
MEASURING TRAVEL PERFORMANCES
Travel speed
PURPOSES
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.
CONDITIONS
R0332
Hydraulic oil temperature: 45~55 °C
Crawler on the right and left sides are tensioned
evenly.
PREPARATION
Attach the reflection panel with a magnet to the travel
REFLECTION
motor cover. PANEL
Swing the swing frame through 90° as shown in
Figure and make the crawler on one side take off the
ground, using the attachment.
MEASUREMENT
Engine revolution: Hi idle
2-speed travel switch: 1-speed and 2-speed R0333
Measuring points: Right and left
Method, example 1:
Measure revolution with a stroboscope.
Method, example 2:
Measure the revolutions per minute visually.
Sprocket revolution Unit: min-1

Measurement Standard Reference value Service
item value for remedy limit
RH H/M1 20.9~23.1 15.9~17.9 14.4
&
LH H/M2 34.3~37.9 26.6~29.4 24.1
H/M1: Heavy Mode 1st speed

H/M2: Heavy Mode 2nd speed
T4-3-8 E485
TEST PROCEDURES
Deviation of travel
PURPOSE
Measure the amount of deviation at 20 m travel and
confirm the horizontal balance between the hydraulic
pump and the travel motor of the travel drive system.
CONDITION Approx. 30~40 cm

R0334
RH and LH crawler are tensioned evenly.
Plain, level and solid ground
PREPARATION
1. Straight course more than 30 m.
2. Travel position in which the bottom of the bucket is
lifted by about 30 cm.
A
MEASUREMENT
20 m
1. Measure the max. deviation distance of the circular
arc in the 20 m length, excluding the preliminary
R0335
run of 3~5 m.
2. Operate the travel lever at the same time.
Travel deviation Unit: mm/20 m

position value for remedy limit
A 240 or less 480 720
E485 T4-3-9
TEST PROCEDURES
Performances of parking brake
PURPOSE
Confirm that the parking brake holds a stopped con-
dition of the machine in a no-load travel position and
on a 1/5 gradient slope.
CONDITION 30 cm
A slope with 1/5 (Approx. 12°) gradient and a stopped
1/5 GRADIENT
condition in a no-load travel position (Approx. 12 deg)
R0336
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.
MEASUREMENT
Five minutes after the engine stops, measure the C ANGLE METER
GUIDE FRAME
movement distance (C) of the matching mark.
R0337
Parking brake Units: mm/5 min

C 0 1 2
T4-3-10 E485
TEST PROCEDURES
Drain rate of travel motor
PURPOSE
To measure the drain rate of the travel motor and to
confirm the performances of the travel motor.
CONDITIONS
PREPARATION
1. Place a stopper under the RH and LH travel sprock- FORWARD ø22 PIPE
ets. 90 ø10
2. Stop the engine and vent pressure from the hy-
draulic circuit. 40
3. Connect a hose with the drain port of the travel
motor and take drain in a container. RIB "A"
150
STOPPER
"B"
MEASUREMENT AT TRAVEL LOCK
ø80
ROTARY DIRECTION
WARNING
R0338
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.
Drain rate of travel motor Unit: L/30 s

Drain rate 6.5 13 19.5
R0339
E485 T4-3-11
TEST PROCEDURES
MEASURING SWING PERFORMANCES
Swing speed
PURPOSE
Measure the swing time and confirm the perform-
ances between the hydraulic pump and the swing
motor of the swing drive system.
CONDITIONS
Plain, level, and solid ground
PREPARATION
Bucket empty, arm cylinder fully retracted (Max.
reach), or arm cylinder fully extended (Min. reach)
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.
R0340
Swing speed Unit: s/rev

max.
7.8~9.5 9.9~12.1 12.9~
Swing reach
speed min.
reach 7.8~9.5 9.9~12.1 12.9~
R0341
T4-3-12 E485
TEST PROCEDURES
Performance of swing brake
PURPOSE
Confirm the braking torque performances by the
swing relief valve.
CONDITIONS
1.5 m
Engine revolution: Hi idle R0342
Bucket: Empty
PREPARATION
1. A height of 1.5 m at which the bottom of the bucket
matches the tip of the tooth on condition that the
arm cylinder is most retracted and the bucket is
used for digging.
2. Put a matching mark on the outer circumference of
the swing bearing of the upper frame side and of the
track frame side. Erect two poles (flags) at the front
and back of the extended line of the matching mark.
MEASUREMENT
Measuring the length of the arc over the
1. When operating in regular swing speed, by shifting outer circumference of outer race
lever to neutral position at pole position the swing
operation stops. Matching marks
2. Calculate the swing drift angle by the following on outer race B
equation, after the upper swing body stops, using
the amount "B" of deflection (m) of the matching
marks on the swing race and the length (m) of the
circumference of the swing race:
Amount "B" of deflection of

Swing drift matching marks (m) Matching marks on inner race
angle (°) = × 360°
Circumferential length of R0343
swing race (m)
Swing brake performance Unit: degree

Swing 180° 105° 110° 115
E485 T4-3-13
TEST PROCEDURES
Performance of swing parking brake
PURPOSE
To confirm the mechanical performances of the swing
parking brake that is fitted to the inside of the swing
motor.
CONDITIONS 1/5
On a slope with 1/5 (Approx. 12°) gradient.
Stop the machine at right angles with the slope at the
height of 1.5 m at which the bottom of the bucket R0344
matches the tip of the tooth on condition that the

bucket is empty, the arm cylinder is most retracted
and the bucket is operated for digging.
PREPARATION
Measuring the length of the arc over the
Put the angle meter on the shoe plate and make sure outer circumference of outer race
that the angle is more than 12°.
Put a matching mark on the outer race side and on the Matching marks
on outer race C
inner race side.
MEASUREMENT
When five minutes has passed after the engine stops,
measure the length of the movement (C) of the matching
marks.
Matching marks on inner race
R0345
Performance of swing
parking brake Unit: mm/5 min

C 0 1 2
T4-3-14 E485
TEST PROCEDURES
Drain rate of swing motor
PURPOSE
Measure the drain rate of the swing motor and confirm
the performances of the swing motor.
CONDITIONS
Hydraulic oil temperature: 45~55 °C R0346
PREPARATION
1. Stop the engine.
2. Release pressure from inside the hydraulic circuit.
3. Disconnect the swing motor drain hose from its end
returning to the hydraulic oil tank and take oil in a
container.
4. Put a plug to the tank side.
MEASUREMENT; AT SWING LOCK

1. Start the engine and put the side faces of bucket
against the inside of the right or left shoe plates.
2. Relieve the swing motor at full stroke of the swing
motion.
3. Receive in a container the amount of drain accu-
mulated in 30 seconds of relieving.
Drain rate of
swing motor Unit: L/30 s R0347

item value for remedy limit
Drain rate 9 18 27
E485 T4-3-15
TEST PROCEDURES
MEASURING ATTACHMENT OPERATING

PERFORMANCES
Operating time of cylinders
PURPOSE
2
Measure the operating time of the boom, arm and 1
bucket and confirm the performances between the 30 cm
hydraulic pump and the cylinder of the attachment
drive system. R0348
CONDITION
Operating time excluding the cushion stroke
PREPARATION
Plain ground with the bucket empty 3
MEASUREMENT 4
Boom up and down
R0349
With the boom operating lever at full stroke, measure
the required operating time of the bucket between the
ground surface and its highest position.
WARNING
When lowering the boom, allow the bucket onto a 8
soft ground or cushioning such as rubber tires;
never put the bucket against concrete or other solid
material.
7
30 cm
Arm in and out, bucket digging and dump R0350
In a position in which the tooth of the bucket rises to

a level of about 30 cm above ground, measure the full
stroke operating time required with the arm and
bucket operating levers at full stroke.
Cylinder Operating time Unit: s

1 3.2~3.8 4.1~4.9 5.3~
2 2.5~3.1 3.2~4.0 4.2~
3 3.3~3.9 4.2~5.0 5.4~
4 2.7~3.3 3.5~4.2 4.5~
7 4.3~5.1 5.5~6.5 7.1~
8 3.0~3.6 3.8~4.6 5.0~
T4-3-16 E485
TEST PROCEDURES
Oil tightness of cylinders
PURPOSE
Confirm that the cylinder oil tight by checking the
moving length of the cylinder rods.
CONDITION B
Plain, level and solid ground C
Immediately after cylinders are replaced, bleed off air
from the cylinders, before checking for oil tightness. A
CONDITIONS D
1.5 m
WARNING
R0351
Avoid the range of cushion stroke. Extend the
cylinder approx. 50 mm from stroke end.
PREPARATION
Keep the tip of the bucket at 1.5 m height, with the
bucket empty and the arm cylinder is most retracted.
MEASUREMENT
Measure the items five minutes after the engine is
turned off.
Oil tightness of cylinder Unit: mm/5 min

A 6 8 10
B 6 8 10
C — — —
D 180 230 300
E485 T4-3-17
TEST PROCEDURES
MEASURING PERFORMANCES OF SWING

BEARING
Axial play
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.
CONDITION
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making
abnormal sound during turning.
PREPARATION
LOCATION OF BEARING
1. Install a dial indicator to the magnetic base and fix ATTACHING CAPSCREWS
it to the lower frame.
2. Direct the upper swing body and the lower frame SWING BEARING
toward the travel direction, bring the probe of the A
dial indicator in contact with the bottom surface of
the outer race on the swing body side and set the DIAL INDICATOR
reading at zero.
LOWER FRAME
R0352
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) and in position II, 90~110°
using a dial indicator.
2. Take measurement three times on the right and the

left reapectively, and make the mean value a
measured value. 30 cm
POSITION I
R0353
Axial play of
swing bearing Unit: mm
A 0.8~1.8 2.3~3.3 3.6
1.5 m
POSITION II
R0354
T4-3-18 E485
TEST PROCEDURES
Tooth clearance
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 and swing the tip of the bucket to the
right and the left by man power.
But in this case, the gap of the attachment is
included. 10 mm
POSITION III
Right and left R0355
movement of
the tip of bucket Unit: mm
Bucket tiptoe 60 100 120
E485 T4-4-1
MECHATRO CONTROLLER ADJUSTMENT
OUTLINE OF ELECTRONIC GOVERNOR CONTROL

C-1 MECHATRO
ACCEL DIAL CONTROLLER
STARTER
SWITCH
C-3 ENGINE
GAUGE CONTROLLER
GOVERNOR
CLUSTER
ENGINE
PUMP
ENGINE
SPEED
BUZZER WORK MODE SENSOR
STOP SW. SELECT SW.
R0356
ENGINE STOP CONTROL INSTALLATION
STOP
°
37
IDLE
20°
)
12
(1
0
R4
R3622
T4-4-2 E485
ADJUSTING THE ENGINE SPEED
Since the engine speed is adjusted engine controller,

the adjustment of engine speed (conventional "A"
adjustment) is not necessary. But if the following parts
are replaced, perform the "B" adjustment.
1. Mechatro controller.
2. Hydraulic pump.
3. Injection pump of engine.
MECHATRONIC CONTROL RELATED

GAUGE CLUSTER
Variable displacement hydraulic pumps
The P1, P2 pump proportional valves are performing

mechatronic total power control.
Method of "B" adjustment MULTI

DISPLAY
1. Before adjustment, warm up engine and raise the

temperature of hydraulic oil to 50 °C (122 °F).
2. Start the engine.
3. Press the buzzer stop switch for five seconds.
STEP 4
4. MEMORY is indicated on the display, and engine
speed rise up to (High) automatically, then "B"
adjustment is completed.
FINISH SCREEN CHANGE SW.
5. 0rpm is appeared on the display, this is nornal
completion. R0361
Furthermore, the P1, P2 pump proportional valves are

also performing the flow control.
E485 T4-4-3
Work mode select switch

GAUGE CLUSTER
If the work mode select switch is pressed, a signal is

transmitted to the C-1 controller and changes the work
modes in the order of W➝HM➝A .
Buzzer stop switch
When the error is detected by self-diagnosis, the C-1

controller sends alarm by sounding buzzer. And press
buzzer stop switch to stop buzzer sounding. Also, MODE SELECT
SWITCH
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.
BUZZER STOP SWITCH
R0362
Engine emergency stop knob
When the engine does not stop after the starter switch
is turned off, pull the emergency stop knob located on
the lower right side of the seat fully, and the engine
stops.
R2197
T4-4-4 E485
NOTES:
TROUBLESHOOTING
R0077
TROUBLESHOOTING E485
Section 5 TROUBLESHOOTING
Group 1 Mechatro Control
Group 2 Hydraulic System
Group 3 Electrical System
Group 4 Engine
SECTION 5 E485
TROUBLESHOOTING
CONTENTS
Group 1 - Mechatro Control Group 4 - Engine
Outline .................................................. T5-1-1 Trouble Diagnosis .................................. T5-4-1

Trouble Diagnosis .................................. T5-1-2 Troubleshooting ..................................... T5-4-4
Outline (Mechatro Control) .................... T5-1-4 Engine diagnosis by means of
Check Point for Mechatro System Electronic Control Unit
(for Troubleshooting) .............................. T5-1-6 self diagnosis functions ........................ T5-4-11
Group 2 - Hydraulic System
Trouble Diagnosis ................................. T5-2-1

Hydraulic Pressure Measurement
by Service Diagnosis ............................ T5-2-4
Troubleshooting ..................................... T5-2-6
Group 3 - Electrical System
Trouble Diagnosis .................................. T5-3-1

Hydraulic Pressure Measurement
by Service Diagnosis ............................ T5-3-10
Troubleshooting ..................................... T5-3-12
Precautions for inspection
and maintenance ................................... T5-3-31
Fuse continuity test .............................. T5-3-33
Inspection and replacement
of maxi fusible links .............................. T5-3-34
Battery voltage check ........................... T5-3-35
Replacement of 12V
power outlet .......................................... T5-3-36
E485 T5-1-1
MECHATRO CONTROL
OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred.
This manual describes how to solve the specific
phenomenon systematically as early as possible.
Judgment of actual thing at site
GET TO THE SITE AS QUICKLY AS POSSIBLE

Verify model, serial number, situation of trouble and
R0131
field, and notify person of arrival time.
Attending the field to verify actual thing
VERIFY BACKGROUND
OF TROUBLE OCCURRED
1. Model name and serial number
2. Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not unrea-
sonable.
3. Operating time by hour-meter
4. History of trouble occurred and additional works.
5. Recurrence of past trouble, or problems on the
additional works.
HOW TO DIAGNOSE TROUBLE

R0132
1. Verify defective part
Verifying background of trouble occurred
2. Make the condition of trouble again
3. Where defective parts can not be verified, sur-
mise causes systematically.
4. Verify reasons for surmise
5. Report methods, procedure, and period for re-
pairing to user.
EXPLANATION OF THE CAUSE OF TROUBLE
1. Explain the cause of trouble to clients. For exam-

ple, oil leak through piston is caused by flaws on
the piston rod. And the method of using the R0133
machines should be explained so that the same
Confirm the symptoms of the trouble
kind of trouble does not reoccur.
2. Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those
surfaces.
R0134
Diagnosing fail by means troubleshooting

T5-1-2 E485
MECHATRO CONTROL
TROUBLE DIAGNOSIS
Electric
solenoid proportional valve

Arm variable recirculation
Actuator
Attachment power boost

Hi pressure sensor (P1)
Hi pressure sensor (P2)
Low pressure sensor
P2 Pump solenoid
P1 pump solenoid
proportional valve
proportional valve
Travel 1-2 speed
Safety lock lever

solenoid valve
solenoid valve
solenoid valve
solenoid valve
Travel straight
P2 bypass cut
P1 bypass cut
Swing P/B
S S S P P P P S S S S P P
Operating condition E E E S S S S V V V V S S
V V V V V V
22 23 1-10 1 2 3 4
A B C D P1 P2
Boom up inching operation { { { { { { {
Boom up full lever operation { { { { { { { { {
Boom down operation { { { { {
Arm out inching operation { { { { { {
Arm out full lever operation { { { { { { { {

Independent operation
Arm in inching operation { { { { { { { {
Arm in full lever operation { { { { { { { {
Heavy duty arm in full lever operation { { { { { { { { { { {
Bucket digging { { { { { {
Bucket dump { { { { {
Swing operation { { { { { {
Travel LH / RH operation (1st speed) { { { { { {
Travel LH / RH operation (2nd speed) { { { { { { {

{
{
{
Boom
E485
{
{
{
{
{
Arm
{
{
Bucket
{
Swing
{
{
Travel right
{
{
Travel left
{
{
P1 bypass cut valve
Control valve
{
P2 bypass cut valve
{
Travel straight valve
{
Boom conflux valve
{
Arm conflux valve
Hydraulic
{
{
{
Arm variable recirculation valve
{
{
Right travel motor
MECHATRO CONTROL
{
{
Left travel motor
Motor
{
Swing motor
{
{
{
Boom
{
{
{
{
{
Arm
Cylinder
{
{
Bucket
{
Boom lock valve

Other
{
{
{
Arm lock valve

T5-1-3
T5-1-4 E485
MECHATRO CONTROL
OUTLINE (MECHATRO CONTROL)
OPERATING Pilot secondary pressure Pressure sensor

ATT Lever position High pressure Low pressure
ATT TRAVEL
TRAVEL (Pump) (Pilot)
ATT
Bucket digging
Bucket dump
Control lever Approx 3.0 MPa Approx 3.0 MPa More than More than
at full stroke or more or more 4.5 V 4.5 V
Boom up
Boom down
Swing left
Swing right
Arm in
Arm out
Approx 0.6 MPa Approx 0.6 MPa
Lever at neutral Approx 0.5 V Approx 0.5 V
or less or less
TRAVEL
Forward
Reverse
Operating condition: Engine speed is High idling.

E485 T5-1-5
MECHATRO CONTROL
OPERATING Solenoid proportional valve

Lever position
ATT P1 Pump P2 P1 Arm variable
Pump Travel straight
TRAVEL P2 Bypass cut Bypass cut recirculation
ATT
Bucket digging
Bucket dump Control lever MIN MAX MAX MAX MIN

at full stroke 750 mA 706 mA 548 mA 706 mA 200 mA
Boom up
Boom down
Swing left
Swing right
Arm in
Arm out
MAX
Lever at neutral 200 mA 350 mA 200 mA 404 mA
350 mA
TRAVEL
Forward
Reverse
Operating condition: Engine speed is High idling.

T5-1-6 E485
MECHATRO CONTROL
CHECK POINTS FOR MECHATRO

SYSTEM (FOR TROUBLESHOOTING)
Attaching position of sensor SE-22 - Press sensor: pump P1
PUMP RELATION
SE-23 - Press sensor: pump P2
PSV-P2 - Pump
PSV-P1 - Pump
proportional solenoid
proportional solenoid
Pump assy
Pump high pressure sensor SE-22, SE-23 R3592
Pump proportional valve PSV-P1, PSV-P2
SOLENOID PROPORTIONAL VALVE BLOCK
Arm regeneration proportional

solenoid valve
SV-1 - Swing parking
brake SOL
SV-3 - Two-speed select SOL Not used
PSV-D - P1 by-pass cut

proportional SOL
PSV-C - Travel straight

proportional SOL
PSV-B - P2 by-pass cut

proportional SOL
SV-2 - Power boost SOL
SV-4 - Operating lever

lock SOL R3860 bis
Proportional block section

E485 T5-1-7
MECHATRO CONTROL
LOW PRESSURE SENSOR

FOR PILOT OPERATION
A Sensor block and Travel control valve
SE-11 - Press sensor: P2 OPT. (2-piece+N&B)
SE-10 - Press sensor: travel left
SE-9 - Press sensor: travel right
SE-20 - Press sensor: P1 OPT. (2-piece. 2-piece+N&B)

SE-11 - Press sensor: P2 OPT. (N&B)
R0136
SE-8 - Press sensor: arm out
SE-7 - Press sensor: arm in
SE-4 - Press sensor: boom down
SE-3 - Press sensor: boom up
SE-2 - Press sensor: bucket dump
SE-1 - Press sensor: bucket digging
R2231
Low pressure sensor SE-1~4, 7~11, 20
B Main control valve
SE-5: Pressure sensor: Swing
UPPER
HARNESS
R3593
Low pressure sensor SE-5

T5-1-8 E485
MECHATRO CONTROL
Components
SOLENOID PROPORTIONAL VALVE BLOCK
Atachment power boost

P2
P1
Safety lock lever

Travel 2-speed
Travel straight
P1 bypass cut
P2 bypass cut
Swing P/B
Tightening torque
7.0 Nm
P2 P1
T
(Directional valve) Emergency manual screw

Max. tightening torque 2.0 Nm and below Tightening torque
A8 A7 A6 A5 A4 A3 A2 A1 Slit width1.0 x depth 1.3 7.4 Nm
HYDRAULIC SYMBOL
P2 P1
P2
A8 A8 A7 A6 A5 A4 A3 A2 A1
2–Ø11
702 701 601 601 601 601 701 701
(–) SIDE (+) SIDE

LEAD WIRE LEAD WIRE
DIRECTIONAL VALVE
CONNECTOR
A8 A7 A6 A5 A4 A3 A2 A1
DETAIL OF DIRECTIONAL
R0140
VALVE CONNECTOR
601 - Solenoid proportional reducing valve (Q.ty 4)

701 - Solenoid directional valve (Q.ty 3)
702 - Solenoid directional valve
E485 T5-1-9
MECHATRO CONTROL
PROPORTIONAL VALVE (EXTERNAL OF VALVE BLOCK)
M8x16 Plate
Arm regeneration
Proportional valve
R3594
ACCUMULATOR
Accumulators
R3595
T5-1-10 E485
MECHATRO CONTROL
HIGH PRESSURE SENSOR
AMP MQS TYPE CONNECTOR 3 POLE (TYPE-B)

MATING CONNECTOR (FEMALE)
Terminal No. Connection

1 Common
2 Output (+)
3 Power supply (+)
22x25.4 HEX
PF3/8
O-Ring R0141
LOW PRESSURE SENSOR

Vout
PF1/4
Vcc GND
ELECTRIC CONNECTING DIAGRAM
(Ex. Construction of internal controller)

Vcc (CONTROLLER)
APT + 5 VDC
Vout A/D
GND
R0142
E485 T5-2-1
HYDRAULIC SYSTEM
TROUBLE DIAGNOSIS (HYDRAULIC SYSTEM)
Hydraulic
Pump Control valve

Component
Travel straight spool

Pilot relief valve
E/G revolution
Boom 2 spool
Bucket spool
Travel spool
Swing spool
Boom spool
Arm 2 spool
Pilot pump
Classification
Arm spool
P1 pump
P2 pump
Trouble
Group No.
Device No. 1 2
No operation is possible { { { { {
1 Machine moves unexpectedly when lever
{ { { { { { {
is at neutral
All actions { { { { {
Bucket digging and dump { { { { { {
Speed is low
Down { { { { { {
Boom
Attachment operation
2 Up { { { { { { {
Arm in conflux { { { { { { {
Arm out conflux { { { { { { {
All motions { { { { {
Bucket digging { { { { {
Power
lacks
3 Down { { { { { {
Boom
Up { { { { { {
Hydraulic systems
Arm in and out { { { { { { {

Bucket digging and dump { { { { {
impossible
operation
Down { { { { {
Fine
4 Boom
Up { { { { { {
Arm in and out { { { { { {
5 Travel 1, 2 speed change impossible { {
Travel operation
6 Travel speed is low { { { { { { {

7 Travel power is low { { { { { { {
Machine deviates in one direction
8 { { { { { { {
or zigzags
9 Machine does not stop still on a slope {
10 Swing motion does not work { { { {
11 Swing speed is low { { { { {
Swing operation
Swing power is low { { { { {

12
Swing drifts very large {
Fine operation impossible { { {
13 Swing parking brake is not held on a slope
Abnormal noise at swing {
T5-2-2 E485
HYDRAULIC SYSTEM
TROUBLE DIAGNOSIS (HYDRAULIC SYSTEM)
Hydraulic
Swing Travel
Control valve motor motor
Component
Pilot valve (1-2 speed select)

Counterbalance check valve
Counterbalance valve
Check valve for relief
P2 bypass cut valve
P1 bypass cut valve
Load check valve
Reduction parts
Parking brake
Parking brake
Bypass valve
Lock valve
Classification
Trouble
Group No.
Motor
Device No. 2 3 4
No operation is possible
1
Machine moves unexpectedly when lever
is at neutral
All actions
Bucket digging and dump { { {
Speed is low
Down { {
Boom
2 Up { { {
Arm in conflux { { {
Arm out conflux { {
All motions
Bucket digging { {
Power
lacks
3 Down { {
Boom
Up { {
Hydraulic systems
Arm in and out { { {

Bucket digging and dump { {
impossible
operation
Down { {
Fine
4 Boom
Up { {
Arm in and out { { {
5 Travel 1, 2 speed change impossible {
Travel operation
6 Travel speed is low { { { { {

7 Travel power is low { { { { {
Machine deviates in one direction
8 { { { { {
or zigzags
9 Machine does not stop still on a slope { { { {
10 Swing motion does not work { { {
11 Swing speed is low { { { { {
Swing operation
Swing power is low { { { { {

12
Swing drifts very large { { {
Fine operation impossible { { { {
13 Swing parking brake is not held on a slope { {
Abnormal noise at swing { { {
6
{
{
{
{
Boom cylinder
E485
{
{
{
Arm cylinder
Cylinder
{
{
Bucket cylinder
{
{
{
{
{
Swivel joint
Pilot valve (ATT)
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
9 10 11
Pilot valve (travel)
Other valve
{
{
{
{
{ {
{ {
Swing parking SOL valve
{
{
{
{
{
Power boost SOL valve
{
{
{
{
Travel 1-2 speed SOL valve
SV1 SV2 SV3
{
{
{
Lever lock SOL valve
{
SV4
A
{
B
P2 bypass cut proportional valve
{
{
C
Proportional valve block
Travel straight proportional valve
{
{
D
Hydraulic
{ { {
Main relief valve
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
Bucket digging
{ {
{ {
{ {
14
Bucket dump
{
{
{
Boom up
{
{
{
Boom down
{
{
{
HYDRAULIC SYSTEM
Main control valve
{
Arm in
Arm out
Relief valve
{ {
{ {
{
Left shockless
Travel
{ {
{ {
{ {
{ {
Right shockless
{
{
{
{
{
Left shockless
Swing
{ {
{
{
{
{
{
Right shockless
T5-2-3
T5-2-4 E485
HYDRAULIC SYSTEM
HYDRAULIC PRESSURE MEASUREMENT BY SERVICE DIAGNOSIS
Main circuit pressure Secondary pilot pressure

(Att. operation No. 1 ~ 8 Travel operation 1 ~ 4 )
E/G Hi, E/G Hi, E/G Hi, E/G Hi,

Full lever, at relief No load, at neutral Full lever, at relief No load, at neutral
No. 14 No. 9
PRESS. SENSOR Main pump P1,P2 PRESS. SENSOR 3 4
C–1 PUMP P1 B–1 BOOM RAISE
3.3 V 35 MPa 0.7 V 2.0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa
C–1 PUMP P2 B–2 BOOM LOWER
No. 15 No. 10
PRESS. SENSOR OPT PRESS. SENSOR 7 8
B–16 P1 OPT. B–3 ARM OUT
4.5 V 3.0 MPa 0.5 V 0 MPa 4.5 V 3.0 MPa 0.5 V 0 MPa
B–17 P2 OPT. B–4 ARM IN
No. 11
Conversion for pressure PRESS. SENSOR 1 2
1 MPa = 10.2 kgf/cm2 = 145 psi B–5 BUCKET DIG
4.5 V 3.0 MPa 0.5 V 0 MPa
B–6 BUCKET DUMP
4.5 V 3.0 MPa 0.5 V 0 MPa
No. 12
PRESS. SENSOR 6 5
B–7 SWING (R)
4.5 V 3.0 MPa 0.5 V 0 MPa
B–8 SWING (L)
0.0 V 0.0 MPa 0.0 V 0 MPa
No. 13
PRESS. SENSOR 1,2 3,4
B–9 TRAVEL (R)
4.5 V 3.0 MPa 0.5 V 0 MPa
B–10 TRAVEL (L)
R0166 4.5 V 3.0 MPa 0.5 V 0 MPa
LH control lever RH control lever

5 Swing left 1 Bucket digging
6 Swing right 2 Bucket dump
7 Arm in 3 Boom up
8 Arm out 4 Boom down
LH travel lever RH travel lever

3 Travel left reverse 1 Travel right reverse
4 Travel left forward 2 Travel right forward
E485 T5-2-5
HYDRAULIC SYSTEM
Solenoid primary pressure Solenoid proportional valve secondary pressure
Operation is not working In operation E/G Hi, E/G Hi,

•
No. 5 Full lever operation

• •
• No load, at neutral
SOL. VALVE Swing P/B No. 20
F–2 SWING-BRAKE Swing & arm digging PROPO-VALVE P1 bypass cut
COMP. ON OFF indication D–1 P1 BYPASS
MEAS. ON OFF indication
} 5.0 MPa COMP. 745 mA 3.0 MPa 300 mA 0.3 MPa
RELEASE SW OFF ON/OFF indication MEAS. 745 mA 3.0 MPa 300 mA 0.3 MPa
No. 6 No. 21
SOL. VALVE Travel 2-speed select PROPO-VALVE P2 bypass cut
F–3 1/2-TRAVEL D–2 P2 BYPASS
COMP. OFF ON indication COMP. 745 mA 3.0 MPa 300 mA 0.3 MPa
MEAS. OFF ON indication
} 5.0 MPa MEAS. 745 mA 3.0 MPa 300 mA 0.3 MPa
SWITCH OFF ON/OFF indication No. 22
No. 7 PROPO-VALVE Travel straight
SOL. VALVE Boost pressure select D–3 TRAVEL STRAIGHT
F–1 POWER BOOST COMP. 548 mA 1.9 MPa 350 mA 0.6 MPa
COMP. OFF ON indication MEAS. 548 mA 1.9 MPa 345 mA 0.6 MPa
} 5.0 MPa
No. 23
SWITCH OFF ON/OFF indication PROPO-VALVE Arm variable
D–6 A-RECIRCULAT recirculation
COMP. 400 mA 1.7 MPa 350 mA 0.6 MPa
MEAS. 400 mA 1.7 MPa 350 mA 0.6 MPa
No. 24
PROPO-VALVE P1 pump
E–1 P1 PUMP
NOTE - •
• •
• OPERATION: MEAS. 750 mA 3.1 MPa 350 mA 0.6 MPa
No. 20 OPTION Conflux relief POWER SHIFT 0 mA
No. 21 BUCKET DIGGING No. 25
No. 22 TRAVEL + ATT PROPO-VALVE P2 pump
No. 23 ARM IN operation full lever E–2 P2 PUMP
(at 647 mA arm in relief) COMP. 750 mA 3.1 MPa 350 mA 0.6 MPa
No. 24 during BUCKET DIGGING operation MEAS. 750 mA 3.1 MPa 350 mA 0.6 MPa
No. 25 during ARM IN operation POWER SHIFT 0 mA
T5-2-6 E485
HYDRAULIC SYSTEM
TROUBLESHOOTING
1- No operation is possible
24V is alive between 1 and 2 terminals of

NO
connector (SV-4) (CN-39F) of lever lock To electric troubleshooting.
solenoid.
YES
The primary pressure of pilot pump is NO Inspect or replace pilot pump

about 4.5 MPa. and pilot relief valve.
YES
The pilot valve P port inlet pressure is NO

Inspect or replace pilot line filter.
approx. 4.5 MPa.
YES
The secondary pressure of pilot valve for

NO
ATT; approx. 2.9 MPa. Travel; approx. Inspect or replace pilot valve.
2.3 MPa.
YES
The pressure of main relief valve is NO

Adjustable with relief valve. NO
Replace main relief valve.
P1-P2; approx. 31 MPa.
YES
Inspect or replace pump and

replace pump coupling.
NOTE ·· The
NG = No Good
number before the trouble indication is the Group No. on the pages T5-2-1, 2 and 3.
E485 T5-2-7
HYDRAULIC SYSTEM
1 - Machine moves unexpectedly when lever is at neutral
Positive control pressure of The secondary pilot pressure of the system

NO YES
P1, P2 are less than 0.98 MPa that is moving unexpectedly is generated when Inspect or replace pilot valve.
or lower. the lever is in neutral.
YES NO
The spool returning spring of the circuit that is YES Inspect or replace spool assy
moving unexpectedly is broken. and pilot cover.
NO
The spool of the system that is

operating unexpectedly moves NO The outer circumference YES
smoothly by hand. of spool is scratched. Replace spool assy.
(Remove pilot cover.) NG
NO
YES
Replace control valve.
(Diagnosis No. 20, No. 21)
Pilot pressure at ports 4pc2;

NO Inspect or replace the proportional valve
5pc2 (P1, P2 bypass cut valve)
is approx. 0.5 MPa. for bypass cut valve that is defective.
NG
YES
Inspect or replace propor-
tional valve block.
Return spring of bypass cut YES

Inspect or replace bypass cut
valve spool is broken. valve spool assy and pilot
cover.
NO
Bypass cut valve spool moves

NO Spool is scored on in- YES Replace bypass cut
smoothly by hand (together with
spection. valve spool assy.
P1 and P2 bypass cut valves).
NO NG
YES
When the lock valve, body seat and selector YES

Replace lock valve and cor-
ARM
Boom or arm? parts were inspected, faults such as scratch rect body seat or replace
BOOM
were discovered. body or replace selector.
Spool of the circuit that oper-

ates unexpectedly is scored YES
Replace spool assy.
on inspection (Both speed 1st
and 2nd).
NO
Inspect the cylinder of the cir-
Inspect or replace overload Inspect or replace control
cuit that operates unexpect-
relief valve. valve.
edly and replace if faulty.
(Inside leak)
T5-2-8 E485
HYDRAULIC SYSTEM
2 - All attachment (ATT) operations are slow
NO Inspect or replace pilot pump

Primary pilot pressure is 4.9 MPa. and pilot relief valve.
YES
(Diagnosis No. 14)
Main relief valve pressure is; P1, P2: approx. NO Inspect or replace main relief
31 MPa. valve.
YES Confirm in controller service NG
diagnosis. Replace control valve or
pump.
When operating, is the electrical current com-
mand value for the pump proportional valve
NO
normal? (W mode) To electric troubleshooting.
Bucket digging P1 & P2: 690 mA
P2 Arm in: 740 mA
YES
Is the action slow even if connector for travel NO

To electric troubleshooting.
straight proportional valve is disconnected.
YES
Pilot pressure at Pz1 port (travel straight) is NO Inspect or replace travel

under 0.7 MPa. straight proportional valve.
YES NG

tional valve block.
Return spring of travel straight spool is broken. Inspect or replace travel

NO
(Remove pilot cover) straight spool assy and pilot
cover.
YES
NO Outer circumference of travel YES Replace travel straight spool

Travel straight spool moves smoothly by hand. straight spool is scored. assy.
YES
NO NG
Replace pump proportional

valve.
NG
Replace pump or control

valve.
E485 T5-2-9
HYDRAULIC SYSTEM
2 - Only the bucket operation is slow
Is the operation normal if connector for P2 YES

bypass cut proportional valve (PSV-B) is dis- To electric troubleshooting.
connected?
NO
Secondary pilot pressure at 4pb2, 4pa2 ports NO

Inspect or replace pilot valve.
(bucket dump and digging ports) is approx.
3 MPa.
YES
(Diagnosis No. 24)
Command current values of pump proportional

valve during operation are as below: NO
Bucket dump P1; approx. 690 mA.
Bucket digging P1; approx. 750 mA.
YES
(Diagnosis No. 14)
Inspect overload relief valve
The relief pressure during bucket operation is NO
Relief pressures for both digging and
NO
on the faulty pressure side
31 MPa for both digging and dump. dump operations are abnormal. and replace valve if defective.
YES YES
Confirm the check valve before relief NG

valve for correct operation in control Replace control valve.
valve. Check the seat of it as well.
Return spring for bucket spool is broken. YES

Replace bucket spool assy.
(Remove pilot cover.)
NO
NO Outer circumference of bucket spool is YES

Bucket spool moves smoothly by hand. Replace bucket spool assy.
scored.
NG
NO
T5-2-10 E485
HYDRAULIC SYSTEM
2 - Only the boom up operation is slow
The secondary pilot pressure for 4pa3 and NO

5pb4 ports (boom up and boom conflux) is Inspect or replace pilot valve.
4.9 MPa (near control valve).
YES
Command current values of pump proportional

valve during operation are: NO YES If a heavy ATT is installed, the
Weight varies with ATT type, etc. boom up operating speed gets
P1: approx. 650 mA.
P2: approx. 650 mA. slow.
NO
YES
Inspect or replace overload

Relief pressure during boom up operation is NO
relief valve at port 4A3 (boom
31 MPa as standard.
head side).
YES
(Diagnosis No. 14)
Relief pressure indicated in service diagno- NO

sis is 31 MPa as standard.
YES
YES
Inspect or replace boom 1st
Return spring of boom 1st speed spool is bro-
speed spool assy and pilot
ken. (Remove pilot cover.)
cover.
NO
Boom 1st speed spool moves smoothly by NO Outer circumference of boom 1st speed YES Replace boom 1 st speed
hand. spool is scored. spool assy.
YES NO NG
YES Inspect or replace boom 1st

Return spring for boom 2nd speed spool is
speed spool assy and Pilot
broken. (Remove pilot cover.)
cover.
NO
Boom 2 nd
speed spool moves smoothly by NO YES Replace boom 2 nd speed
Outer circumference of boom 2nd speed
hand. spool is scored. spool assy.
YES NO NG

E485 T5-2-11
HYDRAULIC SYSTEM
2 - Only arm in operation is slow
(Service Diagnosis No. 23)
Control current readings for arm recirculation NO

proportional valve are about 400 mA when To electric troubleshooting.
H/M-mode arm in lever is turned to the full.
YES
Pilot pressure at arm in port 4pa4 is approx. NO Inspect or replace arm variable NG Inspect or replace
1.7 MPa. recirculation proportional valve. proportional valve block.
YES
Command current readings for pump propor-

tional valve during the operation. NO
P1: approx. 350 mA.
P2: approx. 750 mA.
YES
Secondary pilot pressure at 5pb5 and 5pc1 NO

ports (arm in, lock valve release) is over Inspect or replace pilot valve.
2.9 MPa.
YES
Relief pressure during arm in operation is NO

Inspect or replace overload
31 MPa. relief valve on the 5B5 port of
arm head side.
YES
Arm spool return spring is broken. (Remove NO Inspect or replace arm spool
pilot cover.) assy and spool cap.
YES
NO Outer circumference of arm spool is YES

Arm spool moves smoothly by hand. Replace arm spool assy.
scored.
YES
NO NG
YES Inspect or replace arm vari-

Arm variable recirculation spool return spring
able recirculation spool assy
is broken. (Remove pilot cover.)
and pilot cover.
NO
Arm variable recirculation spool moves NO Outer circumference of recirculation YES Replace arm recirculation
smoothly by hand. spool is scored. spool assy.
YES NO NG

T5-2-12 E485
HYDRAULIC SYSTEM
2 - Only arm out operation is slow
Secondary pilot pressure at port 5pa5, 4pb4 NO

Inspect or replace pilot valve.
(arm out) is over 3 MPa (near control valve).
YES
Command current values of pump proportional NO

valve during relief operation are; To electric troubleshooting.
P1, P2: approx. 600 mA
YES
(Diagnosis No. 14)
Relief pressure lies within standard level (be- NO Inspect or replace overload
low) in arm out operation. relief valve at port 5A5 (arm
31 MPa. rod side).
YES
(Service diagnosis No. 25)
Relief pressure on service diagnosis is approx. NO

31 MPa.
YES
st Inspect or replace arm 1 st

Arm 1 speed spool return spring is broken. YES
cover.
NO
NO Outer circumference of arm 1st speed YES Replace arm 1st speed spool
Arm 1st speed spool moves smoothly by hand.
spool is scored. assy.
YES NG
NO
YES
Inspect or replace arm 2 nd
Arm 2nd speed spool return spring is broken.
cover.
NO
NO Outer circumference of arm 2nd speed YES Replace arm 2nd speed spool
Arm 2nd speed spool moves smoothly by hand.
YES NG
NO

E485 T5-2-13
HYDRAULIC SYSTEM
3 - All attachment (ATT) operating power is poor
Each independent operating speed is within a NO Refer to "All attachment (ATT)

standard value. operations are slow".
YES
Relief pressure lies within standard level NO Adjust main relief pressure of control NG Replace the relief valve of
P1,P2: 31 MPa. valve. main control valve.
YES
NO NG Replace pilot pump and relief
Primary pilot pressure is approx. 4.5 MPa. Adjust pilot relief pressure.
valve.
YES
YES
Inspect or replace travel
Travel straight spool return spring is broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves smoothly by hand. NO Outer circumference of travel straight YES Replace travel straight spool
(Remove pilot cover.) spool is scored. assy.
YES NO NG
Inspect or replace control

valve or pump.
3 - Bucket digging power is poor
No-load independent operating speed is within NO Refer to "Only the bucket op-
a standard value. eration is slow."
YES
Relief pressure lies within standard level (be- NO NG

Replace overload relief valve
Adjust overload relief valve on bucket
low) when bucket digging lever is turned to the at port 4A2 (bucket head
digging side.
full. 31 MPa. side).
YES
Secondary pilot pressure at port 4pa2 (bucket NO

digging) is approx. 2.9 MPa. Inspect or replace pilot valve.
YES
YES Inspect or replace bucket
Bucket spool return spring is broken. spool assy and pilot cover.
NO
NO YES
Bucket spool moves smoothly by hand. (Re- Outer circumference of bucket spool is Replace bucket spool assy.
move pilot cover.) scored.
NG
YES NO
Replace control valve or

pump.
T5-2-14 E485
HYDRAULIC SYSTEM
3 - Boom up operating power is poor
NO Refer to "Only the boom up

Is the no load single operation speed normal.
operation is slow".
YES
Relief pressure lies within standard level at Adjust or replace overload re-
NO
boom up operation. lief valve at port 4A3 (boom
P1, P2; 31 MPa. head side).
YES
Secondary pilot pressure at port 4pa3, 5pb4 NO

(boom up, boom 2nd speed) is 3 MPa or more. Inspect or replace pilot valve.
(near control valve)
YES
st
Boom 1 speed spool return spring is broken. YES Inspect or replace boom spool
(Remove pilot cover). assy and pilot cover.
NO
Boom 1st speed spool moves smoothly by NO Outer circumference of boom 1st speed YES Replace boom 1st speed spool
hand. spool is scored. assy.
YES NO NG
Boom 2nd speed spool return spring is broken. YES

Inspect or replace boom 2nd
(Remove pilot cover). speed spool assy and pilot
cover.
NO
Boom 2nd speed spool moves smoothly by NO Outer circumference of boom 2nd speed YES Replace boom 2nd speed spool
YES NO NG

pump.
E485 T5-2-15
HYDRAULIC SYSTEM
3 - Arm in power is poor
No-load independent operating speed is within NO Refer to "Only arm in opera-

a standard value. tion is slow".
YES
Relief pressure during arm in for both P1 and P2 Adjust or replace overload re-
NO NG
pumps lies within standard levels. Adjust main relief on control valve. lief valve at port 5B5 (on arm
P1,P2: 31 MPa. head side).
YES
Control current readings for arm recirculation NO

proportional valve are about 400 mA when Refer to "Only arm in opera-
W-mode arm in lever is turned to the full. tion is slow".
YES
Control current of arm recirculation propor-

NO
tional valve during arm in relief normal. To electric troubleshooting.
(approx. 200 mA)
YES
Pilot pressure of port C (arm recirculation)

NO Inspect or replace arm variable recircula- NG Inspect or replace propor-
during arm in operation is approx. 0.7 MPa
tion proportional valve. tional valve block.
when lever is turned to the full.
YES
Pilot pressure of port 4pa4 (arm recirculation) NO

during arm in relief operation is approx. 3,0 MPa
when lever is turned to full).
YES
Secondary pilot pressure at port 5pb5, 5pc1

NO
and 4pa4 (arm in and lock valve release) are Inspect or replace pilot valve.
approx. 3 MPa.
YES
Arm 1 spool return spring is broken. (Remove YES Inspect or replace arm spool
pilot cover.) assy and pilot cover.
NO
NO Outer circumference of arm 1 spool is YES

Arm 1 spool moves smoothly by hand. Replace arm spool assy.
scored.
YES NG
NO
Inspect or replace arm 2 vari-

Arm 2 variable recirculation spool return spring YES
able recirculation spool assy
is broken. (Remove pilot cover.) and pilot cover.
NO
Arm 2 variable recirculation spool moves NO Outer circumference of arm 2 variable YES Replace arm 2 variable recir-
smoothly by hand. recirculation spool is scored. culation spool assy.
YES NO NG

pump.
T5-2-16 E485
HYDRAULIC SYSTEM
4 - Machine can not perform fine operation of bucket digging and dump
(Diagnosis No. 24)
Current value of P1 pump proportional Is the action okay if the propor- Replace pump propor-
NO YES
valve when lever is neutral is less than tional valve for P1 is ex- tional valve.
350 mA. (engine high idle) changed by the one for P2?
YES NO
Machine returns normal if connector of P1 bypass cut proportional valve YES

(PSV-D) is disconnected.
NO
Secondary pilot pressure at
No-load pressure of P1 pump is less Inspect or replace P1
NO port 4pc2 (P1 bypass cut YES NG Inspect or replace propor-
than 0.98 MPa when bucket digging bypass cut propor-
valve) is
YESapprox. 0.7 MPa tional valve block.
lever is at neutral. tional valve.
when lever is at neutral.
YES
NO
Inspect or replace P1 by-

P1 bypass cut spool return YES
pass cut spool assy and
spring is broken.
pilot cover.
NO
P1 bypass cut spool moves Outer circumference

NO YES Replace P1 bypass cut
smoothly by hand. (Remove of P1 bypass cut
spool assy.
pilot cover). spool is scored.
NG
YES NO

Secondary pressure of pilot valve is
NO Inspect or replace pilot
approx. 0.9 MPa when bucket close
valve.
lever is just shifted a little.
YES
Bucket spool return spring is broken.

YES Inspect or replace bucket
spool assy or pilot cover.
NO
Bucket spool moves smoothly by NO Outer circumference of bucket YES Replace bucket spool
hand. (Remove pilot cover.) spool is scored. assy.
NO NG

E485 T5-2-17
HYDRAULIC SYSTEM
4 - Machine can not perform fine operation of boom up and down
(Diagnosis No. 24)

Is the action okay if
Current value of P1 pump proportional valve when lever is neutral is less NO the proportional valve YES Replace pump propor-
than 350 mA. (engine high idle) for P1 is exchanged tional valve.
YES by the one for P2?
NO
To electrical troubleshooting.
Machine gets normal if connector PSV-D of P1 bypass cut proportional YES

valve is disconnected.
NO
No-load pressure of P1 pump is less Secondary pilot pressure at Inspect or replace

NO YES NG Inspect or replace propor-
than 0.98 MPa when boom lever is at port 4pc2 (P1 bypass cut proportional valve for
tional valve block.
neutral. valve) is approx. 0.7 MPa. P1 bypass cut valve.
YES
NO

Return spring of P1 bypass cut YES
pass cut spool assy and pilot
spool is broken.
cover.
NO
Outer circumference
P1 bypass cut spool moves NO YES Replace P1 bypass cut
of P1 bypass cut
smoothly by hand. spool assy.
spool is scored.
NG
YES NO

Secondary boom pilot pressure is
NO
approx. 0.9 MPa when lever is just Inspect or replace pilot valve.
shifted.
YES
Return spring of boom spool is broken. YES Inspect or replace boom spool
(Remove pilot cover) assy and pilot cover.
NO
NO Outer circumference of boom YES

Boom spool moves smoothly by hand. Replace boom spool assy.
spool is scored.
YES
NO NG
Does boom lock valve move smoothly NO

Inspect or replace lock valve.
by hand?
YES

T5-2-18 E485
HYDRAULIC SYSTEM
4 - Machine can not perform fine operation of arm in and out
(Diagnosis No. 25)

NO
Machine gets normal if connector PSV-B of P2 bypass cut proportional YES To electrical troubleshoot-
valve is disconnected? ing.
NO
Secondary pilot pressure at Inspect or replace

P2 pump unload pressure is less than NO NO NG Inspect or replace propor-
port 5pc2 (P2 bypass cut proportional valve for
0.98 MPa when arm lever is at neutral. tional valve block.
valve) is approx. 0.7 MPa. P2 bypass cut valve.
YES
YES
Return spring of P2 bypass cut YES
pass cut spool assy and
spool is broken.
pilot cover.
NO

smoothly by hand. of P2 bypass cut
spool assy.
(Remove pilot cover) spool is scored.
NG
YES NO

Secondary pressure is approx.
NO Inspect or replace pilot
0.9 MPa when arm lever is shifted a
valve.
little.
YES
YES
Return spring of arm spool is broken. Replace arm spool assy.
NO
NO Outer circumference of arm YES

Arm spool moves smoothly by hand. Replace arm spool assy.
spool is scored.
YES NO NG
Arm lock valve moves smoothly by NO Inspect or replace lock

hand. valve.
YES

E485 T5-2-19
HYDRAULIC SYSTEM
4 - There is a time-lag (delayed response) for each function
The primary pressure of pilot pump is NO Inspect or replace pilot

5 MPa. pump and pilot relief valve.
YES
The pilot valve P port inlet pressure is NO Inspect or replace lever

approx. 5 MPa. lock solenoid valve.
YES
The secondary pressure of pilot valve NO Inspect or replace pilot

is 3 MPa. valve.
YES
Is there clogged with dirt in orifice of Wash or replace slow re-

NO
slow return check valve of boom up, turn check valve and ori-
arm in, arm out pilot lines. fice.
YES
Is there a time-lag of boom down, arm

Time-lag from area indicates
out, bucket dump, or left swing. NO YES Inspect or replace spool
spool return spring damage.
(Operation of entering pilot pressure in assy and pilot cover.
the port top of the control valve)
NO
YES
Quickly changeover the control lever The spool for the time-lag Outer circumference
NG YES
for the time-lag several times to bleed moves smoothly manually. of the time-lag spool is Replace spool assy.
air. (Remove pilot cover.) scored.
NG
NO YES NO
Is there no change in the time-
Disconnect the pilot tube for the time- lag when the pilot tube for the NO Inspect or replace pilot
lag and bleed the air. time-lag is exchanged with
valve.
that for the no time-lag re-
sponse?
YES
Replace pilot valve.
5 - Travel 1st and 2nd speeds cannot be changed over
24V is alive between pins of connector NO

for travel 1-2 speed solenoid (SV-3). To electric troubleshooting
YES (Diagnosis No. 6)
Pilot pressure of travel 1-2 speed se- NO Inspect or replace travel 1-2 NG Inspect or replace propor-
lect solenoid (SV-3) is 2.3 MPa. speed select solenoid valve. tional valve block.
YES
Travel 1-2 speed select can not be Inspect travel motor (orifice in passage to
NO
done in heavy duty condition on a slope 1-2 speed select valve, clogging of foreign
or on a muddy fields. matter in shuttle valve, etc.) or replace it.
YES
Since the delivery rate of pump is small at

heavy duty working, the difference be-
tween 1st and 2nd speeds gets smaller.
This makes you feel somtimes that speed
is not changed. But this is normal.
T5-2-20 E485
HYDRAULIC SYSTEM
6 - Travel is low
Both the right and left travel idling

speeds are low. (W mode, Hi idle 1st- NO
speed, sprocket rotation; approx. Refer to "Travel deviates".
23rpm)
YES
Since the pump delievery

Machine is slow on slopes and in YES rate is decreased at high
muddy fields. (Is that on heavy duty). load, travel speed is de-
NO creased, but it is normal.
(Diagnosis No. 14)
Current readings of pump proportional

Secondary pressure for
valve lie within standard levels during NO NO Inspect or replace pilot
travel pilot valve is approx.
both travel speeds. valve for travel.
2.4 MPa
P1,P2; approx. 750 mA
YES
YES To electric troubleshooting.
Control current of travel straight pro-
portional valve is approx. 350 mA. NO
Is the machine slow even if connector To electric troubleshooting.
for traver straight proportional valve is
disconnected?
YES
Secondary pilot pressure at Inspect or replace

Is the pivot turn possible? NO YES NG Inspect or replace propor-
port Pz1 (travel straight valve) travel straight propor-
(in both directions) tional valve block.
is approx. 0.7 MPa. tional valve.
YES
NO
Return spring of travel straight YES

spool is broken. straight spool assy and
(Remove pilot cover.) pilot cover.
NO
Outer circumference
Travel straight spool moves NO YES Replace travel straight
of travel straight spool
is scored.
YES NG
NO
Return spring of travel spool is broken. YES Inspect or replace travel

(Remove pilot cover.) spool assy and pilot cover.
NO
NO Outer circumference of travel YES Replace travel spool

Travel spool moves smoothly.
YES
NO NG
Relief pressure during both travel NO Inspect or replace travel

speeds lies within standard value.
motor relief valve.
31 MPa
YES Inspect or replace travel

motor.
E485 T5-2-21
HYDRAULIC SYSTEM
7 - Travel power is poor
Both travel speeds are slow during idle

NO
traveling. (W mode, Hi idle 1st-speed, Refer to "Travel is slow".
sprocket revolution; approx. 23rpm)
YES
Command current for travel straight

proportional value is approx. 350 mA. NO To electric troubleshooting.
(Is it still weak even if the travel straight (Refer to Travel is slow.)
coupler is disconnected.)
YES
Since the delivery rate of
pump is small and travel
Power lack is felt on a slope or in muddy
YES speed is low in heavy duty
fields.
condition, power lack is felt
(Is that a heavy load.)
in some cases, but it is
NO normal.
Is the secondary pilot pressure for NO Inspect or replace travel

travel approx. 2.3 MPa. pilot valve.
YES
Pilot pressure at port Pz1 Inspect or replace

Is a pivot turn possible? NO NO NG Inspect or replace propor-
(travel straight valve) is travel straight propor-
(in both directions) tional valve block.
approx. 0.7 MPa. tional valve.
YES
YES
Return spring of travel straight Inspect or replace travel

YES
spool is broken. straight spool assy and
(Remove pilot cover.) pilot cover.
NO
Outer circumference
Travel straight spool moves NO YES Replace travel straight
of travel straight spool
is scored.
YES NG
NO

Return spring of travel spool is broken. YES
straight spool and pilot
cover.
NO
Travel spool moves smoothly by NO Outer circumference of travel YES Replace travel spool
YES NO NG
Relief pressure lie within standard NO Inspect or replace travel

value in both travel speeds.
motor relief valve.
31 MPa.

motor.
T5-2-22 E485
HYDRAULIC SYSTEM
8 - Machine deviates in one direction or zigzags
There is no speed difference between Since the delivery rate of

right and left rotations during travel pumps decreases at high
idling motion.
YES Machine deviates on a slope YES
load, the flow rate differs
(Is the idling speed within a standard and in muddy fields. between P1 and P2
value.) NO pumps. This is normal.
NO Relief pressure when travel is
31 MPa.
YES
(Diagnosis No. 14)
YES Is the P1, P2 pressure of service diag- NO
nosis normal during travel relief. 31 MPa
Machine travel deviates in opposite Current values of proportional

YES NO
direction if the delivery ports of pumps valves for both P1 and P2 To electric troubleshooting.
are exchanged. pumps are approx. 350 mA.
NO YES
Machine deviates in opposite

YES Replace pump propor-
direction if proportional valves
tional valve.
of pumps are exchanged.
NO
Machine deviates in opposite

YES
direction if regulators are ex- Replace regulator.
changed.
NO
Inspect or replace pump.
Secondary pressure of travel pilot NO Inspect or replace travel

valve is approx. 2.3 MPa. pilot valve.
YES
Machine travel motion deviates in op- (Diagnosis No. 14)
posite direction if the right and left pipes NO Relief pressure in each travel NO Inspect or replace travel
between control valve and motor are action is 31 MPa. motor relief valve.
exchanged.
YES
motor.

Return spring of travel straight spool is YES
straight spool assy and pi-
lot cover.
NO
Travel straight spool moves smoothly NO Outer circumference of travel YES Replace travel straight
by hand. straight spool is scored. spool assy.
YES NO NG

E485 T5-2-23
HYDRAULIC SYSTEM
8 - Machine does not travel straight when travel and ATT operation are combined
Control current for travel straight pro- NO Secondary pressure of travel NO Inspect or replace travel
portional valve is approx. 548 mA. pilot valve is 1.9 MPa. pilot valve.
YES YES
Diagnosis No. 22)
Secondary pilot pressure at port Pz1 NO Inspect or replace travel

(travel straight) is approx. 2.4 MPa. straight proportional valve.
YES NG

tional valve block.

Return spring of travel straight spool is YES
straight spool assy and pi-
lot cover.
NO
Travel straight spool moves smoothly NO Outer circumference of travel YES Inspect or replace travel
by hand. straight spool is scored. straight spool assy.
YES NO NG
9 - Machine drifts on a slope. (Machine can not be held on a slope.)

Machine can not be held on a slope YES
Inspect travel motor. motor counterbalance
when engine is OFF. valve.
NO
NG

motor relief valve.
NG

spool assy.
NG

reduction unit assy.
Diagnosis No. 13)
Secondary pilot pressure for travel is NO Inspect or replace control

0 MPa. valve.
YES
Return spring of travel straight spool is YES Inspect or replace travel

broken. (Remove pilot cover.) spool assy and pilot cover.
NO
Travel straight spool moves smoothly NO Outer circumference of travel YES Replace travel spool
by hand. spool is scored. assy.
YES NO NG

T5-2-24 E485
HYDRAULIC SYSTEM
10 - Swing operation does not work
Does the machine work if the connector YES

for swing parking brake release solenoid To electric troubleshooting.
valve is disconnected?
NO
(Diagnosis No. 5)
Secondary solenoid pressure is

0 MPa when the engine is at high NO Is the swing pilot pressure sen- YES Inspect or replace swing
speed, the lever is at neutral and the sor normal? parking solenoid.
swing parking solenoid is excited. NG
NO
YES Inspect or replace propor-
tional valve block.
Secondary pressure of swing pilot NO Dirt or something is clogged in YES

Inspect or replace orifice.
valve is 3 MPa or more for both ways. the orifice.
YES NO
Inspect or replace pilot
valve.
Return spring of swing spool is bro-

YES Inspect or replace swing
ken. (Remove the pilot cover to make
spool assy and pilot cover.
sure)
NO
NO Outer circumference of swing YES

Swing spool moves smoothly by hand. Replace swing spool assy.
spool is scored.
YES NG
NO
Swing relief pressure lies within stand- NO Inspect or replace swing

ard level. 25 MPa. motor relief.
YES NG
Machine can be held on a slope during NO

Inspect or replace swing
swing braked condition. reduction unit and swing
motor.
YES
Machine drifts largely when swing YES Inspect or replace swing

parking is released (arm in action) on motor.
a slope.
NO
motor.
E485 T5-2-25
HYDRAULIC SYSTEM
11 - Swing speed is slow
Current readings of pump proportional valve lie

within standard levels during both swing NO
speeds. To electric troubleshooting.
P1; approx. 350 mA. or less.
P2; approx. 750 mA.
YES
NO
Bypass valve works without any problem. Replace a shuttle valve.
YES
Secondary pilot pressure for swing Orifice in remote control pipe is Inspect or replace
NO YES NG Inspect or replace pilot
motion is over 3 MPa or more in both clogged with dirt. orifice. valve.
right and left.
NO
YES
To electric troubleshoot-
ing.
NO Inspect or replace swing mo-

Swing relief pressure lies; 25 MPa.
tor relief.
YES
NG
Machine drifts very much when swing parking YES Inspect or replace swing mo-
is released (arm in action) on a slope. tor.
NO
Return spring of swing spool is broken. (Re- YES Inspect or replace swing
move pilot cover.) spool assy and pilot cover.
NO
NO Outer circumference of swing spool is YES

Swing spool moves smoothly. Replace swing spool assy.
scored.
NO NG

T5-2-26 E485
HYDRAULIC SYSTEM
12 - Swing power is poor
Swing speed lies within standard level.

NO Refer to "Swing speed is
slow".
YES
Secondary pilot pressure of swing

NO Inspect ore replace pilot
motion is over 3 MPa in either direction
valve.
when lever is turned to the full.
YES

ard level; 25 MPa. motor relief.
YES NG
Machine drifts largely when swing

parking is released (arm in action) on
motor.
a slope.
NO
The pressure at the P (PG) port of

swing motor is over 4 MPa when swing NO Inspect or replace NG Inspect or replace propor-
lever is turned to the full or during arm Swing parking SOL valve. tional block.
in action.
YES

sure)
NO

spool is scored.
YES NG
NO

E485 T5-2-27
HYDRAULIC SYSTEM
12 - Swing motion drifts very large

ard level.
motor relief valve.
25 MPa.
YES
Swing braked condition can be held on NO Inspect or replace

a slope. shockless valve.
YES NG

reduction unit or swing
motor.
Machine drifts largely when swing YES Inspect or replace swing

parking is released (arm in action) on
motor.
a slope.
NO
Secondary pilot pressure in swing mo-

NO Dirt or something is stuck the YES
tion decreases within 0.2 second Inspect or replace orifice.
orifice.
when swing lever is brought to neutral.
YES NO Inspect ore replace pilot
valve.

sure)
NO

Swing spool moves smoothly. Replace swing spool assy.
spool is scored.
YES NG
NO

T5-2-28 E485
HYDRAULIC SYSTEM
13 - Machine can not perform fine swing operation
(Diagnosis No. 25)

NO
Machine gets normal if connector for P2 bypass cut proportional valve is YES
disconnected.
NO
Machine gets normal if connector for swing parking brake solenoid is YES
disconnected.
NO
Pilot pressure of port 5pc2 (P2

No-load pressure of P2 pump is Inspect or replace
NO bypass cut valve) is approx. YES NG Inspect or replace propor-
approx. 4.6 MPa or less when swing proportional valve for
0.7 MPaYESwhen swing lever is at tional valve block.
lever is at neutral. P2 bypass cut valve.
neutral.
YES
NO

Return spring for P2 bypass YES
pass cut spool and pilot
cut spool is broken.
cover.
NO

smoothly by hand. of P2 bypass cut
spool assy.
(Remove pilot cover.) spool is scored.
NG
YES NO

Secondary pressure when lever is
neutral during swing parking SOL. is Inspect or replace
NO NG Inspect or replace propor-
ON is 0 MPa. swing parking brake
tional valve block.
(Engine high idle) solenoid valve.
YES
Secondary pressure of pilot valve at NO

startup isNOapprox. 0.6 MPa. Inspect or replace pilot valve.
YES
Return spring for swing spool is bro- YES

Replace swing spool assy.
ken.
NO

spool is scored.
YES
NO NG

E485 T5-2-29
HYDRAULIC SYSTEM
13 - Swing parking brake is not held on a slope

Command voltage of swing parking brake so- YES

lenoid is OFF.
NO
Replace swing motor parking brake lin- NG Inspect or replace swing mo-
ing. tor and reduction unit.
13 - Abnormal noise is heard during swing motion
Abnormal noise occurs during swing relief YES Inspect or replace swing mo-
action. tor relief valve.
NO
Abnormal noise occurs when swing motion YES Inspect or replace swing mo-
stops. tor shockless valve.
NO
(Diagnosis No. 14)
Swing relief pressure lies within standard level NO Relief pressure on the P2 side of main NO Inspect or replace main con-
25 MPa. control valve is 31 MPa during arm in or trol valve and relief valve.
out action.
YES
YES
Inspect or replace swing mo-
tor relief valve.
NG

tor.

Return spring of swing spool is broken. spool assy and pilot cover.
NO
Swing spool moves smoothly by hand. (Re- NO Outer circumference of swing spool is YES
Replace swing spool assy.
move pilot cover) scored.
NO NG
YES
NO Inspect or replace swing mo-

Swing can be held on a slope. tor and reduction unit.
YES

tor pinion gear, swing bearing
race and swing bearing.
T5-2-30 E485
HYDRAULIC SYSTEM
NOTES:
E485 T5-3-1
ELECTRICAL SYSTEM
TROUBLE DIAGNOSIS (ELECTRICAL SYSTEM)

C-1 mechatro controller
Low pressure sensor and other signals
Component
Bucket digging pressure sensor (SE-1)
Bucket dump pressure sensor (SE-2)

Boom down pressure sensor (SE-4)
Travel right pressure sensor (SE-9)
Travel left pressure sensor (SE-10)

Boom up pressure sensor (SE-3)
Arm out pressure sensor (SE-8)

Arm in pressure sensor (SE-7)
Swing pressure sensor (SE-5)

Connector No. 1 (CN35F)
Trouble
Classification
1 4 7 10 13 16 19 25 28
Group No.
• • • • • • • • •
Pin No. 2 5 8 11 14 17 20 26 29
• • • • • • • • •
3 6 9 12 15 18 21 27 30
No motions operate
1 Machine moves unexpectedly when
lever is at neutral
{ { { {
All operation
Only bucket speed is slow
Speed is slow
{ { { {
Only boom up speed is slow

2 Motions are slow except
{ {
boom up or arm out
Only arm in motion is slow {
Only arm out motion is slow {
All operation
is poor
Power
Bucket digging
3
Boom up
Electrical system
Arm in
{ {
impossible
Bucket digging, dump

operation
Fine
4 Boom up, down { {

Arm in, out { { { {
Travel 1-2 speeds can
5
not be changed
Travel operation
6 Travel independent speed is low { { { { { { {

7 Travel power is poor
Att. travel combined and travel straight are impossible
8
Travel deviates, zigzags { { { { { { { { {
Machine drifts on a downhill and
9
does not stop still on a slope
10 Swing motion does not work {
Swing operation
11 Swing speed is slow {

12 Swing power is poor {
Swing parking brake
{ {
13 is not held on a slope
Swing fine operation impossible
T5-3-2 E485
ELECTRICAL SYSTEM

Pressure sensor and other signals
Component
P1 pump pressure sensor (SE-22)
P2 pump pressure sensor (SE-23)
Engine revolution sensor (SE-13)

P1 opt. pressure sensor (SE-20)
P2 opt. pressure sensor (SE-11)

Accell. potentiometer (SE-16)
Classification
Trouble
1 4 7 10 13 20
Group No.
• • • • • •
Pin No. 2 5 8 11 14 21
• • • • • •
3 6 9 12 15 22
No motions operate
lever is at neutral
All operation
Speed is slow

boom up or arm out
Only arm in motion is slow
Only arm out motion is slow
All operation
is poor
Power
Bucket digging
3
Boom up
Electrical system
Arm in
{ {
impossible

operation
Fine
4 Boom up, down { {

Arm in, out { {
5
not be changed
Travel operation
6 Travel independent speed is low {

8
Travel deviates, zigzags {
9
10 Swing motion does not work
Swing operation
11 Swing speed is slow

12 Swing power is poor
Swing parking brake
1
E485
{
Key switch ON/OFF
3
GLOW relay signal
4
5
{
{
Swing parking release SW (SW-4)
6
Alternator voltage
7
Load momentum alarm SW (SW-39)
8
Overheat signal to engine controller
9
Engine oil pressure low SW (SW-7)
3 (CN37F)
Air filter clogging SW (SW-8)
OPT pressure SW (SW-44)

Pressure sensor and other signals
Engine oil level switch (SW-23)
Engine coolant level SW (SW-24)
Hydraulic oil level SW (SW-25)
Fuel level sensor (SE-15)

ELECTRICAL SYSTEM
Wiper rise-up limit switch

10 11 12 13 14 15 16
T5-3-3
T5-3-4 E485
ELECTRICAL SYSTEM

Switch & relay
Component
ATT Power Boost switch (SW-21)
Quick coupler switch (SW-40)
No. 4 Connector detect signal
Safety lever switch (SW-11)

Wiper reverse limit switch
Heavy lift switch (SW-35)
Wiper inter-lock (SW-19)

Extra switch (SW-55/56)
Classification
Trouble
1 2 3 4 5 6 7 8
Group No.
Pin No.
No motions operate
lever is at neutral
All operation
Speed is slow

boom up or arm out
Only arm in motion is slow
Only arm out motion is slow
All operation
is poor
Power
Bucket digging
3
Boom up
Electrical system
Arm in
impossible

operation
Fine
4 Boom up, down

Arm in, out
5
not be changed
Travel operation
6 Travel independent speed is low

8
Travel deviates, zigzags
9
Swing operation

Swing parking brake
•
•
11
10
E485
Pressure drain switch (SW-50)
Wiper spark relay
Wiper forward relay
Wiper reverse relay
Washer motor relay
4 (CN38F)
Switch & relay
•
21
Engine stop relay (R-28) contr.

ELECTRICAL SYSTEM
Accell. 1 to engine controller

28
9 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27
T5-3-5
T5-3-6 E485
ELECTRICAL SYSTEM

Governor motor & proportional
Arm variable recirculation proportional valve A (PSV-A)

P1 bypass cut proportional valve D (PSV-D)
Travel straight proportional valve C (PSV-C)

P2 bypass cut proportional valve B (PSV-B)
Component
Power supply +24V
Battery back up
Classification
Trouble
1 3 4 6 8 10 12 14
Group No.
• • • • • •
Pin No. 2 5 7 9 11 13
No motions operate {
{ {
lever is at neutral
All operation {
Only bucket speed is slow {
Speed is slow
{ {

{
boom up or arm out
Only arm in motion is slow { {
Only arm out motion is slow { {
All operation
is poor
Power
Bucket digging
3
Boom up
Electrical system
Arm in
{
impossible

operation
Fine
4 Boom up, down {

Arm in, out { {
5
not be changed
Travel operation

8
9
Swing operation

Swing parking brake
Swing fine operation impossible {
•
E485
{
P1 pump proportional valve (PSV-P1)
{
{
P2 pump proportional valve (PSV-P2)
16 18 20
{
Travel 1-2 speed solenoid valve (SV-3)
{
Swing parking solenoid valve (SV-1)
5 (CN39F)
ATT power boost solenoid valve (SV-2)
Battery relay
•
Power supply grounding
26
15 17 19 21 22 23 24 25
1
Cluster gauge (TxD)
2
Cluster gauge (TxD)
•
4
3
Cluster gauge (RxD)
6 (CN40F)
9
•
16
15
•
•
3
2
1
•
•
7
6
5
Governor motor & proportional
ELECTRICAL SYSTEM
Hammer connect signal
P2 OPT pressure SW (SW-43)

7 (CN41F)
Orbcomm power
• •
16 18
10 11 12 13 14 15 17
•
•
•
Handy checker
22
21
20
19
T5-3-7
T5-3-8 E485
ELECTRICAL SYSTEM

Electrical equipments
E P
Arm variable recirculation proportional valve

Component
Travel straight proportional valve
P1 pump proportional valve
P2 pump proportional valve

Fuse box
Battery
E E P P P P P P
Classification
Trouble
1 4 S S S S S S
Group No.
Electrical V V V V V V
Reference
A B C D P1 P2
No motions operate { {
{ {
lever is at neutral
All operation { { {
Only bucket speed is slow {
Speed is slow
{ {

{
boom up or arm out
Only arm in motion is slow { {
Only arm out motion is slow { {
All operation { {
is poor
Power
Bucket digging
3
Boom up
Electrical system
Arm in
{
impossible

operation
Fine
4 Boom up, down {

Arm in, out { {
5
not be changed
Travel operation

8
9
Swing operation
11 Swing speed is slow {

12 Swing power is poor {
Swing parking brake
1
V
S
{
{
Swing parking brake SOL
E485
2
V
S
ATT power boost SOL
SV
3
V
S
{
Travel 2-speed SOL
4
V
S
{
Safety lock lever SOL
Swing parking brake SW-4

SW
S S
{
W W
Safety lock lever SW
4 11
{
{
{
{
{
{
3
E
S
Boom up pressure sensor
{
{
4
E
S
Boom down pressure sensor
{
{
{
{
{
{
{
{
8
E
S
Arm out pressure sensor
{
{
{
{
{
{
{
{
{
7
E
S
Arm in pressure sensor
{
{
1
E
S
Bucket digging pressure sensor
{
{
2
E
S
Bucket dump pressure sensor
{
{
{
{
{
{
{
{
{
5
E
S
Electrical equipments
Swing pressure sensor
{
9
E
S
Travel right pressure sensor

SE
{
Travel left pressure sensor
ELECTRICAL SYSTEM
Accel potentiometer
P1 pump pressure sensor

{
P2 pump pressure sensor

{
Engine revolution sensor
P2 side OPT pressure sensor

E E E E E E E
S S S S S S S
P1 side OPT pressure sensor

10 16 22 23 13 11 20
T5-3-9
T5-3-10 E485
ELECTRICAL SYSTEM
HYDRAULIC PRESSURE MEASUREMENT BY SERVICE DIAGNOSIS
Main circuit pressure Secondary pilot pressure

(Att. operation No. 1 ~ 8 Travel operation 1 ~ 4 )
E/G Hi, E/G Hi, E/G Hi, E/G Hi,

Full lever, at relief No load, at neutral Full lever, at relief No load, at neutral
No. 14 No. 9
PRESS. SENSOR Main pump P1,P2 PRESS. SENSOR 3 4
C–1 PUMP P1 B–1 BOOM RAISE
C–1 PUMP P2 B–2 BOOM LOWER
No. 15 No. 10
PRESS. SENSOR OPT PRESS. SENSOR 7 8
B–16 P1 OPT. B–3 ARM OUT
B–17 P2 OPT. B–4 ARM IN
No. 11
Conversion for pressure PRESS. SENSOR 1 2
1 MPa = 10.2 kgf/cm2 = 145 psi B–5 BUCKET DIG
4.5 V 3.0 MPa 0.5 V 0 MPa
B–6 BUCKET DUMP
4.5 V 3.0 MPa 0.5 V 0 MPa
No. 12
PRESS. SENSOR 6 5
B–7 SWING (R)
4.5 V 3.0 MPa 0.5 V 0 MPa
B–8 SWING (L)
0.0 V 0.0 MPa 0.0 V 0 MPa
No. 13
PRESS. SENSOR 1,2 3,4
B–9 TRAVEL (R)
4.5 V 3.0 MPa 0.5 V 0 MPa
B–10 TRAVEL (L)
R0166 4.5 V 3.0 MPa 0.5 V 0 MPa
LH control lever RH control lever

5 Swing left 1 Bucket digging
6 Swing right 2 Bucket dump
7 Arm in 3 Boom up
8 Arm out 4 Boom down
LH travel lever RH travel lever

3 Travel left reverse 1 Travel right reverse
4 Travel left forward 2 Travel right forward
E485 T5-3-11
ELECTRICAL SYSTEM
Solenoid primary pressure Solenoid proportional valve secondary pressure
Operation is not working In operation E/G Hi, E/G Hi,

•
No. 5 Full lever operation

• •
• No load, at neutral
SOL. VALVE Swing P/B No. 20
F–2 SWING-BRAKE Swing & arm digging PROPO-VALVE P1 bypass cut
COMP. ON OFF indication D–1 P1 BYPASS
MEAS. ON OFF indication
} 5.0 MPa COMP. 745 mA 3.0 MPa 300 mA 0.3 MPa
RELEASE SW OFF ON/OFF indication MEAS. 745 mA 3.0 MPa 300 mA 0.3 MPa
No. 6 No. 21
SOL. VALVE Travel 2-speed select PROPO-VALVE P2 bypass cut
F–3 1/2-TRAVEL D–2 P2 BYPASS
COMP. OFF ON indication COMP. 745 mA 3.0 MPa 300 mA 0.3 MPa
} 5.0 MPa MEAS. 745 mA 3.0 MPa 300 mA 0.3 MPa
SWITCH OFF ON/OFF indication No. 22
No. 7 PROPO-VALVE Travel straight
SOL. VALVE Boost pressure select D–3 TRAVEL STRAIGHT
F–1 POWER BOOST COMP. 548 mA 1.9 MPa 350 mA 0.6 MPa
COMP. OFF ON indication MEAS. 548 mA 1.9 MPa 345 mA 0.6 MPa
} 5.0 MPa
No. 23
SWITCH OFF ON/OFF indication PROPO-VALVE Arm variable
D–6 A-RECIRCULAT recirculation
MEAS. 400 mA 1.7 MPa 350 mA 0.6 MPa
No. 24
PROPO-VALVE P1 pump
E–1 P1 PUMP
•
NOTE - • •
• OPERATION: MEAS. 750 mA 3.1 MPa 350 mA 0.6 MPa
No. 20 OPTION conflux relief POWER SHIFT 0 mA
No. 21 BUCKET DIGGING No. 25
No. 22 TRAVEL + ATT PROPO-VALVE P2 pump
No. 23 ARM IN operation full lever E–2 P2 PUMP
(at 647 mA arm in relief) COMP. 750 mA 3.1 MPa 350 mA 0.6 MPa
No. 24 during BUCKET DIGGING operation MEAS. 750 mA 3.1 MPa 350 mA 0.6 MPa
No. 25 during ARM IN operation POWER SHIFT 0 mA
T5-3-12 E485
ELECTRICAL SYSTEM
TROUBLESHOOTING
1 - No motions operate
More than 1 sec. after lever stand is lowered.
24V is alive between terminals of connector for YES

To hydraulic troubleshooting.
lever lock solenoid (SV-4).
NO
24V is alive on cable 86A of connector for timer YES

Harness between lever lock solenoid
(SV-4) and timer relay (R-20) is discon- Inspect harness.
relay (R-20).
nected.
NO
24V is alive on cable 87B of connector for timer YES Cable E31 of connector for timer relay (R- YES
Replace timer relay (R-20).
relay (R-20). 20) is at grounding level.
NO NO
Harness between timer relay (R-20) and

Inspect harness.
ground is disconnected.
Harness between timer relay (R-20) and

24V is alive on cable 87C of connector for lever YES
lever lock switch (SW-11) is discon- Inspect harness.
lock switch (SW-11).
nected.
NO
Lever lock switch (SW-11) is faulty. Replace switch.

24V is alive on cable 15B of connector for lever YES
lock switch (SW-11).
Lever lock switch (SW-11) is attached
Adjust and/or replace.
NO improperly.
24V is alive on cable 15 of connector on fuse box YES Harness between lever lock switch
(SW-11) and fuse box (E-4) is discon- Inspect harness.
(E-4).
nected.
NO
YES Inspect the shorted point of

Fuse No.15 is blown. Harness shorted to frame.
harness.
NO
Inspect if there is no discon-

nection in fuse box (E-4).
NOTE ·· The
NG = No Good
number before the trouble indication is the Group No. on the pages T5-3-1 to T5-3-8.
E485 T5-3-13
ELECTRICAL SYSTEM
1 - Machine moves unexpectedly when lever is at neutral
The machine operates unexpectedly if the con-

nector for the P1 bypass cut proportional valve YES
and P2 bypass cut proportional valve is discon-
nected.
NO
(Service Diagnosis No. 9,10,11,12,13)
Are all low pressure sensor readings (boom,

NO
arm, bucket, swing, travel and OPT) 0.4 to 0.5V Replace faulty sensor.
at neutral?
NG
YES
Inspect electric wiring of faulty
sensor or pilot valve.
Is the electric wiring to P1 bypass cut propor-

NO
tional valve and P2 bypass cut proportional Correct electric wiring.
valve all right?
YES
Replace proportional valve.
NG
Replace mechatro controller.

T5-3-14 E485
ELECTRICAL SYSTEM
2 - All motions are slow

Actual engine revolution reading is 0 or a false YES

Adjust speed sensor gap.
value by service diagnosis.
NG
NO
Replace speed sensor.
(Diagnosis No. 2)
Service diagnosis at neutral indicates that a set

YES
engine revolution differs more than 50 rpm from Adjust engine.
an actual value.
NO
(Diagnosis No. 24,25)
Current values of pump proportional valves

NO Is the electric wiring to each sensor all NO
during travel idling are approx. 750 mA for both Correct electric wiring.
the right (P1) and the left (P2). right?
YES
YES
NG
(Diagnosis No. 22)

Motions are slow even if connector of travel

straight proportional valve is pulled out. (Is the YES
current value of travel straight proportional
valve approx. 350 mA?)
NO
(Diagnosis No. 9,10,11,12,13)

NO
at neutral?
NG
YES
Is the electric wiring to travel straight propor- NO

Correct electric wiring.
tional valve all right?
YES
NG

E485 T5-3-15
ELECTRICAL SYSTEM
2 - Only bucket motion is slow

Is the voltage level of low pressure sensor for

NO
bucket action normal? (0.4 to 0.5 V at neutral) Replace low pressure sensor.
(more than 4.5 V at full lever).
NG
YES
(Diagnosis No. 24)
Is the current value of pump proportional valve

during operation normal?
Dump:
P1: approx. 750 mA, NO Is the electric wiring to above-mentioned NO
P2: approx. 400 mA. sensor and proportional valve all right?
Digging:
P1: approx. 750 mA, YES
P2: approx. 400 mA. Replace P1 pump propor-
tional valve.
YES
NG
(Diagnosis No. 22)

Motions are slow even if connector of P2 YES
current value of travel straight proportional bypass cut proportional valve is pulled To hydraulic troubleshooting.
valve approx. 350 mA?) out.
NO
NO
(Diagnosis No. 9,10,12,13)
Are all low pressure sensor readings

NO
(boom, arm, bucket, swing, travel and Replace faulty sensor.
OPT) 0.4 to 0.5 V at neutral? NG
YES
Is the electric wiring to P2 bypass cut NO

proportional valve all right?
YES
NG

(Diagnosis No. 9,10,12,13)
Are all low pressure sensor readings (boom, arm,

NO
bucket, swing, travel and OPT) 0.4 to 0.5 V at Replace faulty sensor.
neutral?
NG
YES

tional valve all right? Correct electric wiring.
YES
NG

T5-3-16 E485
ELECTRICAL SYSTEM
2 - Only boom up speed motion is slow

(Service Diagnosis No.9)

boom up action normal? NO
Replace low pressure sensor.
(0.4 to 0.5 V at neutral) (more than 4.5 V at full
lever) NG
YES Check electric wiring.

(Diagnosis No.21)
Are the current values of P2 bypass cut propor- NO NO

Is the electric wiring to proportional valve
tional valve during boom up full lever operation Correct electric wiring.
all right?
normal or approx. 706 mA.
YES YES
NG

(Diagnosis No.24, No.25)
Are the command current value of pump pro- NO NO

Is the electric wiring to above-mentioned
portional valve during operation normal? Correct electric wiring.
sensor and proportional valve all right?
P1, P2: approx. 750 mA.
YES YES
valve.
NG

(Diagnosis No.14)
Is the relief pressure by service diagnosis YES

normal or approx. 35 MPa. To hydraulic troubleshooting.
NO
Replace high pressure sensor
for pump pressure.
NG
Check electric wiring.
2 - Machine motions are slow except boom up or arm out

(Service Diagnosis No.22)

NO
(Diagnosis No.9,10,11,12,13)
Are all low pressure sensor readings (boom, arm, NO

neutral? NG
YES Inspect electric wiring of faulty


tional valve all right? Correct electric wiring.
YES
NG

E485 T5-3-17
ELECTRICAL SYSTEM
2 - Only arm in motion is slow


arm in action normal? NO
(0.4 to 0.5V at neutral) (more than 4.5V at full
lever). NG

(Diagnosis No. 23)
Is the current value of arm variable NO NO

recirculation proportional valve during arm in Correct electric wiring.
all right?
full lever operation normal or approx. 538 mA?
YES
YES
NG
Are the command current value of pump pro-

NO Is the electric wiring to above-mentioned NO
P1: 400 mA or less
P2: approx. 750 mA.
YES
Replace P2 pump propor-
YES
tional valve.
NG
T5-3-18 E485
ELECTRICAL SYSTEM
2 - Only arm out motion is slow


arm out action normal? NO
(0.4 to 0.5V at neutral) (more than 4.5V at full
lever) NG

(Diagnosis No. 20)
Are the current values of P1 bypass cut propor- NO NO

tional valve during arm out full lever operation Correct electric wiring.
all right?
normal or approx. 745 mA?
YES YES
NG

P1, P2: approx. 750 mA.
YES YES
valve.
NG

(Diagnosis No. 14)

normal or approx. 35 MPa.
NO
for pump pressure.
NG

E485 T5-3-19
ELECTRICAL SYSTEM
3 - ATT all motion power is poor

NO
Is the speed in each single operation normal? Refer to "All motions are slow".
YES

normal or approx. 35 MPa.
NO
Is the relief pressure in actual pressure mea- NO

surement normal?
P1, P2: approx. 35 MPa.
YES
for pump pressure.
NG
3 - Bucket digging motion power is poor
Is the speed in empty bucket single operation NO Refer to "Only bucket motion
normal? is slow".
YES
3 - Boom up motion power is poor
Is the speed in no load single boom-up opera- NO Refer to "Only boom up speed
tion normal? motion is slow".
YES
(Diagnosis No. 21)
Are the current values of P2 bypass cut propor-

NO Is the electric wiring to proportional valve NO
tional valve during boom up relief operation Correct electric wiring.
all right?
normal or approx. 745 mA?
YES YES
NG
T5-3-20 E485
ELECTRICAL SYSTEM
3 - Arm in motion power is poor
Is the speed in no load single arm operation NO Refer to "Only arm in motion is
normal? slow".
YES
Are the current readings of arm variable

recirculation proportional valve normal by serv-
NO Is the electric wiring to proportional valve NO
ice diagnosis? Correct electric wiring.
all right?
Full lever: approx. 400 mA.
Relief: approx. 200 mA.
YES
YES Replace proportional valve.

NG

(Diagnosis No. 22)
Are the current readings of travel straight pro- NO Is the electric wiring to proportional valve NO
portional valve normal by service diagnosis? Correct electric wiring.
all right?
YES YES
NG

(Diagnosis No. 20)
Are the current readings of P1 bypass cut NO Is the electric wiring to proportional valve NO
proportional valve normal by service diagnosis? Correct electric wiring.
all right?
YES YES
NG
E485 T5-3-21
ELECTRICAL SYSTEM
4 - Fine operation of bucket digging and dump motions can not be performed
(Diagnosis No. 24)
Is the current reading of P1 pump proportional

NO Is the electric wiring for the proportional NO
valve normal or approx. 350 mA or less in high Correct electric wiring.
valve listed on the left normal?
idle neutral condition?
YES YES
tional valve.
NG
Is the action normal if connector of P1 bypass NO

cut proportional valve is pulled out?
YES
(Diagnosis No. 9,10,11,12,13)

NO
at neutral?
NG
YES
Is the electric wiring to P1 bypass cut propor- NO

YES
NG

T5-3-22 E485
ELECTRICAL SYSTEM
4 - Fine operation of boom up and down motions can not be performed

(Diagnosis No. 24)
Are the current readings of P1 pump propor-

tional valve normal or approx. 350 mA or less Correct electric wiring.
in high idle neutral condition?
YES YES
tional valve.
NG

YES
(Diagnosis No. 9,10,11,12,13)

NO
at neutral?
NG
YES

YES
NG

E485 T5-3-23
ELECTRICAL SYSTEM
4 - Fine operation of arm in and out motions can not be performed

(Diagnosis No. 25)
Is the current reading of P2 pump proportional

valve normal or approx. 350 mA or less in high Correct electric wiring.
idle neutral condition?
YES YES
tional valve.
NG

YES
(Diagnosis No. 9,10,11,12,13)

NO
neutral?
NG
YES

YES
NG
5 - Travel 1-2 speeds can not be changed
Are the voltage between the two pins connector YES

for travel 1-2 speed select solenoid 24V?
NO
(Diagnosis No.6)
Does actual readings change by turns
If travel 1-2 speed select switch is pushed in
YES each time the travel 1-2 speed select YES
service diagnosis, the display is turned "ON" Replace mechatro controller.
switch is turned ON and OFF in service
and if it is release, the display is turned "OFF".
diagnosis?
NO
NO
Replace travel 1-2 speed se-

lect SOL.
NG
Inspect harness between

mechatro controller and SOL.
Replace cluster gauge.

T5-3-24 E485
ELECTRICAL SYSTEM
6 - Travel independent speed is low

Are the current readings of pump proportional

valves during both travel actions normal? Correct electric wiring.
P1 and P2: approx. 750 mA. sensor and proportional valve all right?
YES
YES
valve.
NG

(Diagnosis No. 22)

YES
straight proportional valve is pulled out. (Is the
current value of travel straight proportional To hydraulic troubleshooting.
NO
(Diagnosis No. 9,10,11,12,13)
Are all low pressure sensor readings (boom, arm, NO

neutral?
NG
YES

YES
NG

E485 T5-3-25
ELECTRICAL SYSTEM
7 - Travel power is poor
NO Refer to "Travel independent

Is the speed normal in travel idling action?
speed is low".
YES
Travel power is poor even if connector of travel

YES
straight proportional valve is pulled out. (Is the To hydraulic troubleshooting.
NO
(Diagnosis No. 9,10,11,12,13)

NO
neutral? NG
YES

YES
NG

T5-3-26 E485
ELECTRICAL SYSTEM
8 - Machine does not travel straight. (Check ATT and travel actions at full lever stroke.)
For abnormal operations, re-

fer to troubleshooting corre-
All independent operations and the swing and NO
sponding to respective failed
travel independent operations are normal.
operation according to the ab-
YES normal phenomenon.
Are the current values for travel straight pro- YES

portional valve approx. 548 mA?
NO
Are the low pressure sensor voltage readings in

service diagnosis during these actions normal? NO
Neutral: 0.4~0.5 V Replace faulty sensor.
Full lever: more than 4.5 V NG


YES
NG

E485 T5-3-27
ELECTRICAL SYSTEM
8 - Travel deviates, zigzags

(Service Diagnosis No. 24, No. 25)
Is the current value of pump proportional

NO YES
Travel idling speed is within reference values. valve for service diagnosis at idling op- To hydraulic troubleshooting.
eration normal? P1, P2: Approx. 750 mA.
YES
NO
Is pump working pressure at engine NO Replace high-pressure sen-

idling 10 MPa or less? sor for pump.
NG
YES
Check wiring for possible

damage.
Is the voltage of travel pressure sensor at NO

full lever position 3.5V or higher? Replace low-pressure sensor.
NG
YES
Check wiring of failed sensor
or pilot valve for possible dam-
age.
All high loading pump delivery

rates becomes lower develop-
The travel speed on steep slope and muddy YES
ing the difference of flow on
ground is slow.
both right and left sides, but it
NO
is normal.
Is it OK after connector of travel straight propor- NO

To hydraulic troubleshooting
tional valve was disconnected?
YES
Are the current values of travel straight propor- NO Is wiring of travel straight proportional NO
tional valve in both operations approx. 350 mA? Correct wiring.
valve normal?
YES YES

NG
Replace mechatrocontroller.
T5-3-28 E485
ELECTRICAL SYSTEM
9 - Machine drifts on a slope at parking
10 - Swing motion does not work
Swing motion works if 2P connector of swing NO

parking SOL is disconnected.
YES
(Diagnosis No. 12)
In service diagnosis, the low pressure sensor

NO
voltage readings during swing motion are: Replace faulty sensor.
Neutral: 0.4~0.5V,
NG
Full lever: more than 4.5V.

E485 T5-3-29
ELECTRICAL SYSTEM
11 - Swing speed is slow

Are the voltage readings of low pressure sen-

NO
sor for swing action normal for both the right Replace low pressure sensor.
and left directions?
NG
Neutral: 0.4~0.5 V,
Full lever: more than 4.5 V. Inspect electric wiring of faulty
YES sensor or pilot valve.

portional valve during operation normal? NO Is the electric wiring to above-mentioned NO
P1: 400 mA or less, sensor and proportional valve all right?
P2: approx. 695 mA.
YES
YES Replace P2 pump propor-
tional valve.
NG
Is the swing speed slow even if the 2P connec-

YES
tor for swing parking solenoid is disconnected? To hydraulic troubleshooting.
(Use care to swing operation.)
NO
Refer to "Swing motion does
not work".
12 - Swing power is poor

NO
Is the swing speed normal? Refer to "Swing speed is slow".
YES
(Diagnosis No. 14)
Is the swing relief pressure by service diagno-

YES
sis normal or approx. 25 MPa? To hydraulic troubleshooting.
NO
NO
Are actual relief pressure readings normal? To hydraulic troubleshooting.
YES

for pump pressure.
NG

T5-3-30 E485
ELECTRICAL SYSTEM
13 - Swing parking brake is not held on a slope
Are the voltage between 2P connector for YES

swing parking brake solenoid 24V?
NO (Diagnosis No. 5)
Is the display of swing parking brake solenoid YES Is the swing parking solenoid status "ON" YES
"ON" in service diagnosis? Replace mechatro controller.
in service diagnosis?
NO
NO
Replace swing parking SOL.
NG
Inspect harness between

(Diagnosis No. 9,10,12) mechatro controller and SOL.
Are the low pressure sensors for swing, arm in,
arm out and boom up actions normal? YES
Neutral: 0.4~0.5 V.
Full lever: more than 4.5 V.
NO
Replace faulty sensor.
NG

13 - Fine operation of swing motion can not be performed
(Diagnosis No. 25)
Are the current readings of P2 pump propor- NO Is the electric wiring for the proportional NO
tional valve normal or approx. 350 mA or less Correct electric wiring.
in high idle neutral condition?
YES YES
Replace P2 proportional
valve.
NG
In the action normal if connector of P2 bypass NO

YES
(Diagnosis No. 9,10,11,12,13)

NO
neutral?
NG
YES

YES

NG

E485 T5-3-31
ELECTRICAL SYSTEM
PRECAUTIONS FOR INSPECTION AND

MAINTENANCE
1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
A
2. Wire harnesses identification.
The wire harnesses used on electrical system of the 511 511 511
machine are of three colours: red, white and brown.
20 to 30 mm
– The wire harnesses red coloured are used for
the main power supply distribution and for direct
connection to the positive not controlled by key B C
switch.
– The wire harnesses white coloured are used for 2.5 R 679
511
the all other functions for 24V, 5V powersupply 511
and signals.
– The wire harnesses brown coloured are used for D
ground connection.
Further on the machine twisted wires (with 1 inch 0.5 Br E10
pitch) of red and white coloured are used for connec-
tion with the proportional solenoid valve.
In addition shielded coloured cables with two on four
wires are used to connect mechatro controller to
gauge cluster, to engine revolution sensor, etc.
Each wire is identified by a numerical coding printed
on the whole lenght every 20 to 30 mm (A).
This coding is also shown on the wiring diagrams of
electrical system (B).
The ground wires brown coloured are identified by a
letter E print before the numerical code (e.g. E10,
E22) (D).
On the general electrical system diagram attached,
numbers and letters are shown before the digit
coding.
Numbers mean the wire section shown in mm2.
The following letters indicate the wire colours;
where W stands for white, R for Red and Br for
Brown. See detail (C).
C-1
3. Connector identification.
On the general electrical system diagram the con-
nectors are identified as shown on the figure.
Example = 14-3: First digit (1) means
C-1 Mechatro Controller, (2) means
C-2 Cluster gauge. 14-3
Second digit (4) means the number of connector
that also is print on a label of harness.
Third digit after dash (-3) means the number of pin
of the connector.
R1533
T5-3-32 E485
ELECTRICAL SYSTEM
– On the harness manufacturing drawing the following

references are shown:
a CN - 38F
– Connector designation number (a) (CN-38F)
d
that is used for the routing of wire from - to
connectors as shown in the table. 1 558 542A 130 120 87A 622A 559 8
– Connector identification number (b) (4) printed 9 13
on the harness label. 14 621 572 708 709 710 711 638 620 21
c
– Pin identification number (c) to locate the pin 22 799 78 595 91 28
position on the connector.
– Wire identification number (d) which is connect
to the pin on the connector.
b
4
R1534
4. Precautions for connecting and disconnecting ter- Right Wrong

minal connectors.
1) When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself.
Be sure to release the lock first before attempt-
ing to separate connectors, if a lock is provided. R1532
2) Water-resistant connectors keep water out so
that if water enters them, water will not easily
drain from them. When checking water-resi-
stant connectors, take extra care not to allow
water to enter the connectors. In case water
should enter the connectors, reconnect only
after the connectors are thoroughly dried.
3) Before connecting terminal connectors, check Right
that no terminals are bent or coming off. In Rust
addition, as most connectors are made of Wrong
brass, check that no terminals are rusting. (deformation)
4) When connecting terminal connectors provided
Wrong
with a lock, be sure to insert them together until (Separation)
the lock “clicks.”
R1535
E485 T5-3-33
ELECTRICAL SYSTEM
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse, NOTE - All the inside terminals of the fuses in the
and such fine cracks are very hard to detect by visual fuse box are connected to the power source,
inspection. while the outside terminals are connected to
Checking fuse continuity with a tester is far superior to the accessories.
sight inspection. Test all fuses using the same method.
(1) Turn the key switch ON
In doing so, the battery relay is activated by the
current from terminal M of the key switch, and
electric power is supplied to all circuit.
(2) Remove the fuse box cover and set the correct
voltage measurement range of the tester.
(Measurement range: 0 to 30 V)
(3) Connect the negative probe to the vehicle ground,

and touch the outside terminal of each fuse with the
positive probe of the tester.
When normal continuity of a fuse is intact, the
tester will indicate 20 to 25 volts.
Accessory (Outside)
R1536
Power Source (Inside)

Accessory (Outside)
T5-3-34 E485
ELECTRICAL SYSTEM
INSPECTION AND REPLACEMENT OF

FUSIBLE LINKS
Inspection
1. Remove the negative cable from the battery.
2. Loose the wing nut fixing the protection panel and

open it by rotating forward to gain the access.
3. Withdraw the front cover of the maxi fusible link box

and visually inspect the maxi fusible link inside. B L
Replacement
1. Make sure that the negative cable is removed from

the battery.
2. Loose the wing nut fixing the protection panel and R2124
open it by rotating forward to gain the access.
3. Withdraw the front cover of the maxi fusible link box.
4. Take out the maxi fusible link and replace it. Front cover
5. Reinstall the front cover to maxi fusible link box.
6. Reconnect the negative cable to the battery.

Fusible
Body
Bottom cover
R1538
E485 T5-3-35
ELECTRICAL SYSTEM
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle frame.
Normal Voltage: 24 V
NOTE - If voltage is abnormal, recharge or replace the

battery.
2. Start the engine. Check voltage between the battery

positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE - If voltage is abnormal, check the charging

system. R1539
T5-3-36 E485
ELECTRICAL SYSTEM
REPLACEMENT OF 12V POWER OUTLET
1. Gain the access to the rear of panel and disconnect

the connector from power outlet.
2. Open the guard.
Power outlet
R1540
3. Using the special plier (Fiat Auto code No.

1876044000) unlock the sleeve from the lock ring.
Panel
Power outlet
4. Withdraw the sleeve from the rear of the panel.
Guard
SM3041
5. Install the new power outlet inserting the sleeve

from the rear of the panel and pushing the lock ring
on the front of the panel.
SM3042
Special plier Fiat Auto Code No. 1876044000

6. Reconnect the connector to the power outlet.
E485 T5-4-1
ENGINE
TROUBLE DIAGNOSIS (ENGINE)

Inspection
Filters Fluid
Component
Poor quality fuel is used or heavy oil is used

Fuel system trouble (Air or water entered)
Viscosity of engine oil is not suited, engine oil

is leaking, or the engine oil level not proper
Fuel is of poor quality or leaking
Specific gravity of battery fluid
Fuel not filled up or leaking
Oil cooler element clogged
Group No.
Strainer filter clogged

System
Air cleaner clogged
Cooling water level

Breather hose bent
Fuel filter clogged
Oil filter clogged
V-belt slips
Trouble
Starting trouble
1 Starter does not run {
2 Starter runs but does not start { { { { { { { {
Idling unsmooth { { { {
Medium speed hunting {
{ { { {
Rotation trouble
High speed unsmooth
3 Does not reach max revolution { {
Max. revolution is too high
Revolution does not change if work modes are changed

Engine
Accel potentiometer does not work properly
Engine deficiency in output { { { { { { {

Drop in output
4
Over heat { { { { { {
5 Knocking occurs after engine warm-up { { { { { {
Exhaust gas is black { { {

6
Exhaust gas is white (In cold state, white smoke does not
{
disappear after idling)
Other trouble
7 Excessive oil consumption { {
8 Excessive fuel consumption { {
9 Engine does not stop when key is turned off
When starter key is turned OFF, power is not cut off but
10
engine stops
T5-4-2 E485
ENGINE
TROUBLE DIAGNOSIS (ENGINE)

Visual check
Electrical fittings
Gas / fluid
Component
Gas leaks from valve and gasket
Electronic governor controller
Connector and electric wiring

Mechatoronic controller
Engine oil is too much
Group No.
System
Blowby gas is much
Accel potentiometer
Battery fluid level
Starter motor
Battery relay
Safety relay
Glow plugs
Trouble
Starter key
Glow relay
Alternator
Fuse
Starting trouble
1 Starter does not run { { { { { { {
2 Starter runs but does not start { { { { {
Idling unsmooth { { {
Medium speed hunting { { {
{ { {
Rotation trouble
High speed unsmooth
3 Does not reach max revolution { { { {
Max. revolution is too high {
Revolution does not change if work modes are changed { { { {
{ { { { {
Engine
Accel potentiometer does not work properly
Engine deficiency in output { { { {

Drop in output
4
Over heat
5 Knocking occurs after engine warm-up { { { {
Exhaust gas is black { { {

6
Exhaust gas is white (In cold state, white smoke does
{ { { {
not disappear after idling)
Other trouble
7 Excessive oil consumption { {
8 Excessive fuel consumption { {
9 Engine does not stop when key is turned off { { { {

When starter key is turned OFF, power is not cut off but
10
engine stops
{ { {
Feed pump function
E485
Check injection timing
Fuel
{ {
Inspect nozzle
system
{
{ { {
{ {
{ {
Injection pump
Stop
{ { { {
Valve clearance
position
{ { { { { {
{ { { { { {
{ { { { { {
Valve spring is fatigued
system
Intake /
exhaust
{
{ { { { { { {
Air cleaner & muffler
{
{
{
Check if engine oil goes into combustion chamber
{
Check relief valve
Oil strainer clogged
system
Lubrication
Fuel is mixed
{
Check thermostat
{ {
Oil cooler element damaged
Cooling
{
{
Compression pressure low
{ {
{ {
{
{
{
{ {
{ {
Control rack movement unsmooth
Crank shaft oil seal no good
Piston liner worn
{ { {
Piston ring worn
ENGINE
{ { {
{ { {
Valve spring fatigued
{ { { {
{ { { {
Internal parts stuck
Main structure
Check fuel feed
{
{ { { { { {
{
{ {
Head gasket faulty
{ { { { { { { Flywheel gear damaged
{
{
Turbocharger damaged
T5-4-3
T5-4-4 E485
ENGINE
TROUBLESHOOTING
NOTE ·· The
NG = No Good
number before the trouble indication is the Group No. on the pages T5-4-1 to T5-4-3.
1 - Starter does not run
NO Check battery fluid level and

Check battery voltage. Charge or replace battery.
specific gravity.
OK
Check on + terminal on battery

+ side is 24V, but L side is no YES Replace fusible link 6
relay. Check on L terminal on
24V. E-27 (2).
battery relay.
OK
The voltage at outlet side of

NO
Check fuse box voltage. 10A fuse for key-switch is Replace fuse.
OK 24V.
OK
The voltage at inlet side of YES Check electric wiring and

keyswitch is no 24V. connectors.
Measure the voltage at L termi-

nal of battery relay instead of M NO Check electric wiring
terminal of keyswitch to check and connector.
the voltage of the M terminal.
Check or replace key
Check key switch voltage.
switch.
Check that ST terminal OUT
side is 24V with No. 63B wire NO Check electric wiring
on starter relay when Key SW. and connector.
is turned to start position.
OK
Check voltage of battery relay The voltage at L terminal of YES

coil. Replace battery relay.
battery relay is 24V.
OK
Check on starter motor bat- 24V is alive on terminal B of

tery terminal. starter motor.
OK
OK Replace starter motor.
Check on starter motor relay 24V is alive on terminal S of
side terminal S. starter motor.
OK
The voltage of No. 63B on

When starting engine, check YES
safety relay connector S ter-
on safety relay IN side.
minal side is 24V.
OK
Replace safety relay.
When starting engine, check The voltage of No. 65A on

on safety relay IN side termi- safety relay connector R ter-
YES
nal R. minal side is 24V.
Condition: Check keyswitch in START position.

Emergency stop knob (engine stop knob) is back in position.
E485 T5-4-5
ENGINE
2 - Starter turns but engine is hard to start
With electronic governor con- Refer to Group "Electronic

YES
troller error diagnosis switch Control System" of Engine
on, the diagnosis lamp shows section (W5-14), part 3 -
blinking codes. Self-Diagnostics.
OK
Check Engine oil of viscosity if NO
Check viscosity of Engine oil. it is suited to ambient tempera- Replace engine oil.
ture.
OK
Check starter power is strong WEAK Check battery fluid level and Charge or replace
or weak. specific gravity. battery.
STRONG
Check engine itself. Check compression pres-

sure and valve clearance.
Check that valve spring is
Check that air filter clogged not fatigued, that piston lin-
Check air intake system. lamp lights. er is not worn, that piston
OK ring is not worn, that head
OK
gasket is not faulty and that
Check that air cleaner flywheel gear is not dam-
clogged sensor. aged. Also check radiator
and thermostat.
Engine side Check strainer filter. Check feed pump per-

OK formance, injection pump,
Check fuel feed system.
Check fuel gauge and water injection nozzle and injec-
Machine separator. Check that poor tion timing.
side quality fuel is not used.
YES
Check electric system. Engine side 24V is alive on glow plug. Glow plug is faulty.
NO
24V is alive on wire No. 34B on Harness between glow

YES
glow relay terminal. relay and glow plugs is
faulty.
NO
Voltage of No. 67 wire on glow Harness between glow

NO
relay terminal is 24V. relay and battery relay is
faulty.
OK
Between the glow relay termi-

YES
nal of No. 11 wire and No. 799A Replace glow relay.
wire terminal there are 24V.
NO Harness between ECU

and glow relay is faulty.
Checking condition: Engine starter key is in START position.

T5-4-6 E485
ENGINE
3 - Engine revolution is faulty
With electronic governor trou- YES

Refer to Group "Electronic
ble diagnosis switch on, the Control System" of Engine
diagnosis lamp shows blink- section (W5-14), part 3 -
ing codes. Self-Diagnostics.
NO
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.
Idling revolution is "Accel potentiometer fail" is YES

Replace accel potentio.
too high. displayed on gauge cluster.
Hunting occurs at
Medium revolution
medium revolu- Check control rack.
is faulty.
tion.
Check that air is NG

Bleed air.
not mixed in fuel.
High idling is faulty. OK
Check air intake NG Check that air cleaner is

system. not clogged.
OK
Check fuel gauge, water

Check fuel feed NG separator and strainer fil-
system. ter. Check also that poor
OK quality fuel is not used.
Check injection nozzle,

injection pump and injec-
tion timing.
Engine does not

"Accel potentiometer fail" is YES Replace accel. potentio-
reach max. revo-
displayed on gauge cluster. meter.
lution.
NO
The voltage of accel 1 and NO Check accel. potentiome-

accel 2 is more than 4.2V. ter or mechatro controller.
YES
Replace electronic gover-

Max revolution is
nor controller.
too high.
Check injection pump.
Checking condition: Engine coolant temperature is more than 50 °C.

E485 T5-4-7
ENGINE
4 - Engine output is insufficient

NO
Check that Engine water OK Check the contents of
Overheat temp. alarm lamp is on and
working.
that buzzer sounds.
NG
Check Engine coolant

NG temperature switch,
Inspect electric system.
gauge cluster, electric wir-
OK ing and connectors.
Check coolant level.

Check that fan belt does
NG not slip.
Check cooling system.
Check engine thermostat.
OK Also check that oil cooler
of radiator is not clogged.
NG Check that poor quality

Check fuel system.
fuel is not used.
OK
NG
Check Engine oil system. Check Engine oil filter.
Check air intake NG Check that air filter clogged OK Check that air cleaner is
system. display of warning. not clogged.
OK
Check fuel feed NG Check that air is not mixed in

fuel. Bleed air.
system.
OK OK
Check water separator and Check feed pump per-

gauze filter. Check also that formance, injection pump,
poor quality fuel is not used. injection nozzle and injec-
tion timing.
NG
Check viscosity of Engine oil
Check Engine oil. if it is suited to ambient tem- Replace engine oil.
OK perature.
NG
Check inter cooler. Check that air does not leak.
OK
Check compression
pressure and valve clear-
Check that blowby gas is not ance. Check that valve
much, that gas does not leak spring is not fatigued.
Check engine it-
from gasket, and that engine Check that control rack
self.
oil goes into combustion moves smoothly. Check
chamber. that piston ring is not worn.
Check also that head gas-
ket is not faulty.
Checking condition: High idling

T5-4-8 E485
ENGINE
5 - Knocking occurs after engine warm-up

NO
Check fuel system. NG Check that poor quality fuel is Replace fuel.
not used.
OK
Check that engine oil does not NG Judge it if oil is there on

Check engine itself.
rise. exhaust port.
OK
Check that blowby gas is not Check compression

much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.
6 - Exhaust is abnormal
With electronic governor trou- Refer to Group "Electronic

YES
NO
Exhaust gas is black. Check that air cleaner is not NG

Replace air element.
clogged.
OK
Check engine oil viscosity.

Check that engine oil is not too
much.
OK Check injection nozzle,
injection timing, injection
Check that gas is not leaking pump and valve clear-
from head gasket. ance. Check that valve
spring is not fatigued and
that piston ring is not faulty.
Exhaust gas is white. Check that water is not mixed NG

Check water separator.
in fuel.
OK
Check that engine oil goes

Check compression
into combustion chamber.
pressure and injection
Blowby gas is much. A lot of
timing.
gas leaks from gasket.

E485 T5-4-9
ENGINE
7 - Excessive oil consumption
Check leakage by checking Retighten.

Check that engine oil is not NG
the ground under engine or an Replace packing and seal.
leaking.
oil pan.
(Check that engine oil is not OK
filled up too much.)
Check that breather hose is NG
Replace breather hose.
not bent or clogged.
OK
Check that poor quality fuel is NG

Advise to replace fuel.
not used.
OK
Check viscosity of engine oil.

NG Advise to replace engine
oil.
OK
Check that; CR shaft oil

Check that engine oil goes seal is not faulty, piston
into combustion chamber. liner is not worn, or piston
ring is not worn.
Checking condition: No engine oil leaks.
8 - Excessive fuel consumption
Check that poor quality fuel is NG

Advise to replace fuel.
Check fuel leakage.
not used.
OK
Blowby gas is much.

Check that gas does not leak Check nozzle function.
from gasket.
OK
Check injection timing.
Check compression
pressure.
Checking condition: Use proper fuel.

T5-4-10 E485
ENGINE
9 - Engine does not stop when starter key is turned off

NO
Wire No. 60 D wire from C-1 Check resistance be- Replace starter key if re-
Check that terminal M of NG NO
Mechatro controller, connec- tween terminals M and sistance across M and B is
starter key switch shows 0V.
tor No. 3 shows 0V. B of starter key. 0 Ω.
YES
Check harness between

starter key and C1
Mechatro controller.
10 - When starter key is turned OFF, power is not cut off but engine stops
Check that battery relay ter- Check harness be-

minal L measures 0V four NG OK
Wire No.73 measures 0V. tween C1 controller Check C1 controller.
seconds after key is turned and battery relay.
off.
OK
Check that battery relay oper- Does relay battery terminals YES
Replace battery relay.
ates. between + and - measure 0 Ω.
E485 T5-4-11
ENGINE
ENGINE DIAGNOSIS BY MEANS OF

ELECTRONIC CONTROL UNIT SELF-
DIAGNOSIS
Outline
The machine is equipped with a Diagnosis request The lighting of Diagnosis lamp is directly controlled by
switch (SW-46) and a Diagnosis lamp (L-13) located on the Engine Electronic Controller Unit (C-3) and, in case
the left side of the cab. of engine trouble, the Diagnosis lamp blinks with a
The Diagnosis request switch, when pushed and series of three repetitions of lighting. The lighting
maintained ON, operates to allow the reading of pattern defines a code.
Diagnosis Trouble Code by means of lighting of Diag- The reading of this code gives the information of failure
nosis lamp. that the Engine Electronic Controller has detected,
based on the input and output signals connected.
Diagnosis
request
switch
Diagnosis lamp
R2458
T5-4-12 E485
ENGINE
SELF-DIAGNOSIS FUNCTION
Diagnosis lamp lighting pattern
The below table shows the lamp diagnosis operations.
Diagnosis lamp condition
Engine in normal condition Engine in normal condition

without trouble with trouble
Key switch in ON position Diagnosis lamp switched On Diagnosis lamp switched On

(Engine stop) with fixed light. with fixed light.
(Diagnosis request switch not
actuated)

(Engine stop) with blink light at regular periods with blink light at no regular
(Diagnosis request switch showing the normal condition. periods showing the past and
pushed and maintained On) present trouble by means of
Diagnosis codes.
(Refer to Diagnosis trouble

(DTC 01) codes indication)
Key switch in ON position >> Diagnosis lamp switched Off. Diagnosis lamp switched On
START position >> ON position with fixed light, warning that an
(Engine running) engine trouble is detected. (*)
(Diagnosis request switch not (To know the Diagnosis trouble
actuated) code, the Diagnosis request
switch must be actuated and
maintain On)

(Engine running) with blink light at regular periods with blink light at no regular
(Diagnosis request switch showing the normal condition. periods showing the past and
pushed and maintained On) present trouble by means of
Diagnosis codes.
(Refer to Diagnosis trouble

(DTC 01) codes indication)
(*) When DTC15 and DTC25 occur, Diagnosis lamp does not turn light on.
E485 T5-4-13
ENGINE
Diagnosis code indicating pattern
When the diagnosis request switch is actuated on On, 1st digit lights for 0.3 sec. and goes out for 0.6 sec.
the diagnosis code is displayed after approximately The above actions are repeated three times for single
2.4 seconds. code.
The diagnosis code consists in two digits: the 10th digit Follow an example of schematic pattern of diagnosis
lights for 1.2 sec. and goes out for 0.6 sec, while the lamp lighting is shown for trouble code 23.
ON
Diagnosis code
(sec)
OFF
2.4 0.6 0.6 0.6 0.6 2.4
1.2 1.2 0.3 0.3 0.3
10th digit 1st digit
Repeat three times
R2459
Way of trouble codes memory clear
The diagnosis trouble codes past and present, and b. Localize the ground brown wire identified with print
memorized into the Engine Electronic Control Unit C-3 code E20 on which is installed a female terminal.
(ECU), can be clear by carrying out the following c. Connect together the terminals. After few seconds
operation: disconnect again the terminals and relocated them
where they were found.
a. Near the Electronic Control Unit C-3 (ECU) connec- d. The memory will be clear according to the sche-
tor, localize the white wire identified with print code matic pattern shown below.
328 on which is installed a male terminal.
Wires connected
Memory erased
Wires disconnected
more than more than more

1 sec 1 sec than
0.5 sec
R2460
T5-4-14 E485
ENGINE
Diagnosis code and backup
DTC Code Name DIAG Decision Criteria of Failure Backup Mode Rec.
01 Normal - - - -
11 Power error - V ≤ 0 mV or V ≥ 51200 mV V = Fixed at 28000 mV. Yes
enters continuously for 655
sec or more.
14 Boost sensor error O V ≤ 100 mV or V ≥ 4800 mV Fixed boost pressure Yes
enters continuously for 5 sec at 271.7 kPa
or more. {2038 mmHg}.
15 Water temperature sensor error O V ≤ 100 mV or V ≥ 4800 mV Water temperature fixed Yes
enters continuously for 5 sec at -40°C.
or more.
21 Accelerator sensor error O V ≤ 200 mV or V ≥ 4800 mV Accelerator aperture Yes
enters continuously for 655 fixed at 0%.
sec or more.
25 Fuel Delivery Resistor error O V ≤ 0 mV or V ≥ 4800 mV Fuel Delivery Resistor Yes
continuously for 10 sec No. 13
or more.
26 Atmospheric sensor error O V ≤ 1890 mV or V ≥ 5000 mV Atmospheric Pressure Yes
enters continuously for fixed at 101.3 kPa
3.8 sec or more. {760 mmHg}.
31 Governor servo error O [Target rack - Actual rack] Governo pull-down. No
≥ 2 mm lasts for 1 sec. (Engine stop)
32 Rack sensor error O V ≤ 500 mV or V ≥ 4500 mV Rack position fixed at No
enters continuously for 1 sec 3 mm.
or more. (Engine stop)
33 System error O ECU internal malfunction No
or ECU malfunction caused
by external factor (noise,
electrical wave etc.)
41 Rotation TDC sensor error O Absence of input. Yes
42 Rotation backup sensor error O Absence of input. Yes
For detailed operation of troubleshooting, refer to Group "Electronic Control System" of Engine Section (W5-14).
REPAIR INSTRUCTIONS
R0077
REPAIR INSTRUCTIONS E485
Section 1 GENERAL INFORMATION

Group 1 Precautions for Disassembly and Assembly
Group 2 Tightening Torque
Section 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Air Conditioner
Group 3 Counterweight
Group 4 Main Frame
Group 5 Pump Device
Group 6 Control Valve
Group 7 Swing Device
Group 8 Pilot Valve
Group 9 Solenoid Valve Unit
Section 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Swivel Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Tracks
Section 4 FRONT ATTACHMENT

Group 1 Front Attachment
Group 2 Cylinders
Section 5 ENGINE AND ACCESSORY

Group 1 General information
Group 2 Maintenance
Group 3 Engine I (Disassembly)
Group 4 Engine II (Inspection and Repair)
Group 5 Engine III (Assembly)
Group 6 Lubrication System
Group 7 Cooling System
Group 8 Fuel System
Group 9 Turbocharger
Group 10 Engine Electrical
Group 11 Troubleshooting
Group 12 Special Tools
Group 13 Repair standards
Group 14 Electronic Control System
SECTION 1 E485
GENERAL INFORMATION
CONTENTS
Group 1 - Precautions for Disassem- Group 2 - Tightening Torque

bly and Assembly
Torque Chart ........................................ W1-2-1
Precautions for Disassembly and Piping Joint .......................................... W1-2-4
Assembly ............................................. W1-1-1
E485 W1-1-1
PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY
PRECAUTIONS FOR DISASSEMBLY

AND ASSEMBLY
Preparations for Disassembly - Be sure to provide appropriate containers for drain-

ing fluids.
• Clean the Machine - Use matching marks for easier reassembling.
- Be sure to use the specified special tools, when
Thoroughly wash the machine before bringing it into instructed.
the shop. Bringing a dirty machine into the shop - If a part or component cannot be removed after
may cause machine components to be contami- removing its securing nuts and bolts, do not attempt
nated during disassembling/assembling, resulting to remove it forcibly. Find the cause(s), then take
in damage to machine components, as well as the appropriate measures to remove it.
decreased efficiency in service work. - Orderly arrange disassembled parts. Mark and tag
them as necessary.
- Store common parts, such as bolts and nuts with
• Inspect the Machine reference to where they are to be used and in a
manner that will prevent loss.
Be sure to thoroughly understand all disassem- - Inspect the contact or sliding surfaces of disassem-
bling/assembling procedures beforehand, to help bled parts for abnormal wear, sticking, or other
avoid incorrect disassembling of components as damage.
well as personal injury. - Measure and record the degree of wear and clear-
Check and record the items listed below to prevent ances.
problems from occurring in the future.
- The machine model, machine serial number, and

hour meter reading. • Precautions for Assembly
- Reason for disassembly (symptoms, failed parts,
and causes). - Be sure to clean all parts and inspect them for any
- Clogging of filters and oil, water or air leaks, if any. damage. If any damage is found, repair or replace
- Capacities and condition of lubricants. it.
- Loose or damaged parts. - Dirt or debris on the contact or sliding surfaces may
shorten the service life of the machine. Take care
not to contaminate any contact or sliding surfaces.
• Prepare and Clean Tools and Disassembly Area - Be sure to replace O-Rings, backup rings, and oil
seals with new ones once they are disassembled.
Prepare the necessary tools to be used and the area Apply a film of grease before installing.
for disassembling work. - Be sure that liquid-gasket-applied surfaces are
clean and dry.
- If an anti-corrosive agent has been used on a new
part, be sure to thoroughly clean the part to remove
Precautions for Disassembly and Assembly the agent.
- Utilize matching marks when assembling.
• Precautions for Disassembly - Be sure to use the designated tools to assemble
bearings, bushings and oil seals.
- To prevent dirt from entering, cap or plug the - Keep a record of the number of tools used for
removed pipes. disassembly/assembly. After assembling is com-
- Before disassembling, clean the exterior of the plete, count the number of tools, so as to make sure
components and place it on a work bench. that no tools are missing.
- Before disassembling, drain gear oil from the reduc-
tion gear.
W1-1-2 E485
Bleeding Air from Hydraulic System
When hydraulic oil is drained, the suction filter or the

suction lines are replaced, or the removal and instal-
lation of the pump, swing motor, travel motor or
cylinder is done, bleed air from the hydraulic system
in the following procedures:
• Bleeding Air from Hydraulic Pump
IMPORTANT - If the engine is started with air trapped

in the hydraulic pump housing, damage to the pump
may result. Be sure to bleed air before starting the
engine.
- Remove the air bleeding plug from the top of the

pump and fill the pump housing with hydraulic oil.
- After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the engine
and run at slow idle speed.
- Slightly loosen the plug to bleed air from the pump
housing until hydraulic oil oozes out.
- After bleeding all the air, securely tighten the plug.
• Bleeding Air from Travel Motor / Swing Motor
- With the drain plug / hose on travel motor / swing

motor removed, fill the motor case with hydraulic oil.
• Bleeding Air from Hydraulic Circuit
- After refilling hydraulic oil, start the engine. While

operating each cylinder, swing motor and travel
motor evenly, operate the machine under light loads
for 10 to 15 minutes. Slowly start each operation
(never fully stroke the cylinders during initial opera-
tion stage). As the pilot oil circuit has an air bleed
device, air trapped in the pilot oil circuit will be bled
while performing the above operation for approx. 5 SM1000
minutes.
- Reposition the front attachment to check hydraulic
oil level.
- Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
E485 W1-1-3
Floating Seal Precautions A
1. In general, replace the floating seal with a new one.

If the floating is to be reused, follow these proce-
dures:
1) Keep seal rings together as a matched set with

seal ring faces together. Insert a piece of card-
board to protect surfaces.
2) Check the seal ring face (A) for scuffing, scoring, B SM1001
corrosion, deformation or uneven wear.
3) Check O-Ring (B) for tears, breaks, deformation

or hardening.
2. If incorrectly assembled, oil leakage or damage will

occur. Be sure to do the following, to prevent
trouble.
1) Clean the floating seal and seal mounting bores

with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with com-
pressed air. RIGHT
2) Clean the floating seal and seal mounting bores,

as dust on them tends to enter the floating seal WRONG
when installing it.
3) Check that the O-Ring is not twisted, and that it

is installed correctly on the seal ring. SM1002
4) After installing the floating seal, check that seal

RIGHT WRONG
ring surface (C) is parallel with mating face (A) by
measuring the distances (a) and (b), as illus- A
trated. a a
If these distances differ, correct the O-Ring (B)
seating. C
b b
a=b a≠b
SM1003
W1-1-4 E485
Discharging R134a fluid from

the air conditioning system
For a correct discharge of the air conditioning system,

please call the nearest Dealer to comply with current
legislation involving the storage and disposal of
R134a refrigerant fluid.
E485 W1-1-5
Charging R134a fluid into

the air conditioning system
The change of refrigerant in the air conditioner requires

a "vacuum generation procedure" and a "gas charging
procedure".
- The "vacuum generation procedure" consists in

removing moisture from the air conditioner circuit.
In the event even a small quantity of moisture
remains in the system, it would freeze in the small
orifices of the expansion valve when in operation.
This causes a clogging of the circuit or the formation
of rust, with a series of operational troubles. Prior to
filling the circuit with refrigerant, apply the vacuum
and cause the boiling and vaporisation of the mois-
ture. In this manner, moisture is eliminated from the
system.
- The "gas charging procedure" consists in the filling

the circuit with refrigerant, after applying a vacuum.
The filling of the gas is not only depending upon the
cooling performance of the air conditioner, but it
influences also the useful working life of the circuit
components. An excessive overloading increases
considerably the pressure of the system and dam-
ages the cooling performance. On the contrary, a
too low charging, results in an insufficient circula-
tion of lubricant oil in the compressor, causing the
wear of the moving parts of the compressor.
WARNING
The gas filling operation involves the handling of
highly compressed gases; it is dangerous to handle
the gas without complying strictly with the relevant
procedures. The procedures and the protections
described in this manual for the filling of refrigerant
gas must be strictly adhered to.
Operation chart:
Vacuum making operation Gas charge operation
More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Lower than
-750 mmHg
Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.097 MPa
W1-1-6 E485
PROCEDURE FOR THE GENERATION

OF VACUUM D: Discharge
S: Suction
1. Close high pressure valve (3) and low pressure 2
valve (1) on manifold (2).
(Lo) 1 3 (Hi)
2. Connect the red charging pipe (5) and the blue one
(6) to compressor service valves (8) "D" and "S" as (Blue) 6 5 (Red)
described in the figure.
4 (Yellow)
Red hose: high pressure side (Hi) of the gauge
manifold ➝ high pressure side (D) of compressor. D
Blue hose: Low pressure side (Lo) of gauge mani-

fold ➝ low pressure side (S) of compressor. S
8 7
WARNING R0110
Never exchange by mistake the high pressure pipe

with the low pressure pipe when connecting them.
Install the pipe firmly until a click noise is heard.
Connect the quick release joint of the charging pipe
with the service valve of the compressor. If the
charging pipe is connected in the opposite direction,
mini-valve (9) of the compressor fails to open.
3. Connect the central valve of the manifold with

charging pipe (4) of the vacuum pump (7). Blue
S Red
IMPORTANT - Some types of manifold are not D

equipped with an open/close valve in the central part.
8 9 R0111
4. Open high pressure valve (3) and low pressure

valve (1) of manifold (2).
5. Start the vacuum pump and let it operate 30 minutes

to generate the vacuum.
6. At the end of the vacuum phase for the prescribed

time (vacuum value: lower than 1.33 kPa) close the
high pressure valve and the low pressure valve of
the manifold.
7. Cut-off the vacuum pump.
8. Close the high pressure valve and the low pressure

valve on the manifold and check, after five minutes,
that the pressure gauge dial does not return to 0.
NOTE - In the event the pressure gauge moves toward

0, this indicates the presence of a leakage. Tighten
again the connecting joints and apply the vacuum
again, verifying that there are no further leakages.
E485 W1-1-7
PROCEDURE FOR THE CHARGING OF THE GAS

1. After applying the vacuum repeatedly, exchange
charging pipe (4) of the manifold, from the vacuum
pump to the service bottle.
1
2. Open the valve (3) of service bottle (2). Close the
high (6) and low (5) pressure valves of the manifold.
Press central bleeding valve (1) of the side service
opening on the low pressure side of the manifold 4 3
using a screwdriver to bleed the air from the charg-
ing pipe using the pressure of the refrigerant. Pro-
ceed with this operation until a whistle is heard
coming from the bleeder.
2
R0112
3. Open high pressure valve (6) of the manifold and
charge the refrigerant to a pressure of 0.097 MPa.
Once the charge is completed, close high pressure
valve (6) of the manifold and service valve (3).
WARNING
5 6
Never start operating the compressor under any
circumstance. The starting of the compressor
causes the blowing of the service bottle.
D
4. Check that there are no leakages of gas in the cycle, 3
using a gas leakage tester. Retighten and eliminate
all points of leakage.
IMPORTANT - To check for gas leakages, always use

R0113
a tester for R134a. Do not use a type for obsolete
gases since they are insufficiently responsive.
5. Check that high pressure valve (6) and low

pressure valve (5) of the manifold and service
valve (3) of the bottle are closed.
6. Start the engine running it at 1500 ± 100 rpm and 5 6

open fully the door and windows of the cab.
7. Activate the air conditioner, setting it at maximum

ventilation speed and at lowest temperature.
D
8. During the charging of the gas, set the discharge
3
pressure of the compressor to 1.36 ~ 1.57 MPa.
R0114
W1-1-8 E485
9. Open low pressure valve (5) of the manifold and

8
service valve (3) of the bottle and fill with refriger-
ant until all air bubbles in sight window (8) of the
dryer (9) disappear.
Total quantity of gas to be charged: 1.05 ± 0.1 kg.
10. Once the refrigerant change operation is termi- 9

nated, close low pressure valve (5) of the manifold
and the service valve of bottle (3).
IMPORTANT - Do not open the high pressure valve of

the manifold under any circumstance no place the
R0115
service bottle upside down.
11. The level of refrigerant is correct only once the air

conditioner is activated and through the inspection
sight window, just a few air bubbles are seen and,
afterward, a white colour slightly milky is seen.
IMPORTANT - When the air conditioner operates with

an insufficient quantity of refrigerant, this has a nega-
tive effect on the compressor; on the contrary, when
the refrigerant is charged with an excessive quantity,
the cooling performance is lost. Also, the pressure of
the system increases abnormally.
12. Disassemble the manifold disconnecting the

charging pipes from the compressor, as indicated
here below:
a. Press the quick release coupling of the charg-
ing pipe on the low pressure side against the
service valve of the compressor so that the
refrigerant doers not escape leaking when loos-
ening the connection. As soon as the nut has
been removed, disconnect the charging pipe
from the service valve.
b. Wait for the pressure in the high pressure site to
decrease, indicated on the pressure gauge, to
a value of 0.98 MPa.
c. Disconnect the red charging pipe from the high
pressure side, in the same manner as de-
scribed for the low pressure.
E485 W1-2-1
TIGHTENING TORQUE
TORQUE CHART
WARNING
Use tools appropriate for the work to be done.
Makeshift tools and procedures can create safety
hazards. For loosening and tightening nuts and
bolts, use the correct tools. Avoid bodily injury
caused by slipping wrenches.
Bolt Types
Tighten nuts or bolts correctly to torque specifica-

tions. Two kinds of bolts, hexagon bolts T and
socket bolt, each made of different material, are SM1004
used. Make sure to employ the correct bolts and

tighten them to specification when assembling the
machine or components.
Hexagon T Bolt Socket Bolt
SM1005
Specified Tightening Torque Chart
Bolt Wrench Hexagon T Bolt,

Dia. Size Wrench Socket
Size bolt
(Nm)
M8 13 6 29.5
M10 17 8 64
M12 19 10 108
M14 22 12 175
M16 24 14 265
M18 27 14 390
M20 30 17 540
M22 32 17 740
M24 36 19 930
M27 41 19 1 370
M30 46 22 1 910
M33 50 24 2 550
M36 55 27 3 140
W1-2-2 E485
TIGHTENING TORQUE
IMPORTANT
1. Apply lubricant (i. e. white zinc B dissolved into
spindle oil) to nuts and bolts to stabilize their friction
coefficients.
2. Torque tolerance is ±10%.
3. Be sure to use bolts of correct length. Bolts that are
too long cannot be tightened, as the bolt tip comes
into contact with the bottom of the bolt hole. Bolts
that are too short cannot develop sufficient
tightening force.
4. The torques given in the chart are for general use
only.
Do not use these torques if a different torque is
given for a specific application.
5. Make sure that the nut and bolt threads are clean
before installing. Remove dirt or corrosion, if any.
Bolt Tightening Order
When tightening two or more bolts, tighten them

alternately, as shown, to ensure even tightening.
Equally tighten upper

and lower alternately Tighten diagonally Tighten from center and diagonally
1 12 9 4 1 6 7 14
1,4 6 3
2,3 4 5
2 13 8 5 2 3 10 11
SM1006
E485 W1-2-3
TIGHTENING TORQUE
Service Recommendations for Split Flange
IMPORTANT
1. Be sure to clean and inspect sealing surfaces.
Scratches / roughness cause leaks and seal wear. SM1007
Unevenness causes seal extrusion. If defects can-
not be polished out, replace the component.
WRONG
2. Be sure to use only specified O-Rings. Inspect O-
Rings for any damage. Take care not to file O-Ring
surfaces. When installing an O-Ring into a groove,
use grease to hold it in place.
3. Loosely assemble split flange halves. Make sure

that the split is centrally located and perpendicular
to the port. Hand-tighten the bolts to hold the parts
SM1008
in place. Take care not to pinch the O-Ring.
4. Tighten bolts alternately and diagonally, as shown,

to ensure even tightening.
5. Do not use air wrenches. Using an air wrench often

causes tightening of one bolt fully before tighten the
others, resulting in damage to O-Rings or uneven
tightening of bolts.
SM1009
Nut and Bolt Lockings
RIGHT WRONG
• Lock Plate
IMPORTANT - Do not reuse lock plates. Do not try to

bend the same point twice.
Bend along edge sharply Do not bend it round

• Cotter Pin
RIGHT RIGHT WRONG
IMPORTANT - Do not reuse cotter pins. Match the
holes in the bolt and nut while tightening, not while
loosening.
• Lock Wire
Bend along edge sharply
SM1010
IMPORTANT - Apply wire to bolts in the bolt-tightening
direction, not in the bolt-loosening direction.
RIGHT RIGHT WRONG
RIGHT WRONG
Loosen
Tighten
SM1011
W1-2-4 E485
TIGHTENING TORQUE
PIPING JOINT
Pipe Thread Connection / Union Joint Tightening 1 4 3 5 2

Torque Specifications
Union Joint
Metal sealing faces (4) and (5) of adaptor (1) and hose
(2) fit together to seal pressure oil. Union joints are
used to join small-diameter lines.
Joint Body
SM1012
IMPORTANT
1. Do not over-tighten union nut (3). Excessive force
will be applied to metal sealing surfaces (4) and (5),
possibly cracking adaptor (1). Be sure to tighten
union nut (3) to specifications.
37°
2. Scratches or other damage to sealing surfaces (4)

37°
or (5) will cause oil leakage at the joint. Take care
not to damage them when connecting /disconnect-
ing.
Male Union Joint Female Union Joint
SM1013
Wrench Size Tightening Torque

Type
Union Nut Joint Body (Nm)
37° Union Joint 19 17 29

22 19 39
27 22 78.5
36 30, 32 157
41 36 205
50 46 323.6
NOTE - Tightening torque for the non-union type 37° male joint is the same as the 37° female union joint.
E485 W1-2-5
TIGHTENING TORQUE
O-Ring Seal Joint
O-Ring (6) seats against the end face of adaptor (7) to

7 6 9
seal pressure oil.
IMPORTANT
1. Be sure to replace O-Ring (6) with a new one when
reconnecting.
2. Before tightening union nut (9), confirm that O-Ring

8 10 Joint body
(6) is seated correctly in O-Ring groove (8). Tighten-
ing union nut (9) with O-Ring (6) displaced will SM1014
damage O-Ring, resulting in oil leakage.
3. Take care not to damage O-Ring groove (8) or

sealing face (10). Damage to O-Ring (6) will cause
oil leakage.
4. If union nut (9) is found to be loose, causing oil

leakage, do not tighten it to stop the leak. Instead,
replace O-Ring (6) with a new one, then tighten
union nut (9) after confirming that O-Ring (6) is
securely seated in place.
Wrench Size Tightening Torque

Union Joint
Nut Body (Nm)
19 17 29.4
22 19 68.6
27 22 93
30 27 137.3
36 30 175
41 36 205
50 46 320
W1-2-6 E485
TIGHTENING TORQUE
Screwed-In Connection PT PF
30°
IMPORTANT - Many types of screwed-in connec-

tions are used for hose connections.
Be sure to confirm that the thread pitch and thread type
(tapered or straight) are the correct type before using
any screw-in connection. Male Tapered Thread Male Straight Thread
SM1015
Male Tapered Thread

Wrench Tightening Torque
Joint Body (Nm)
17, 19 34
22 49
27 93
36, 32 157
41 205
50 320
60 410
Seal Tape Application Internal Thread
Seal tape is used to seal clearances between male and

female threads, so as to prevent any leakage between
threads. Clearance External Thread
Be sure to apply just enough seal tape to fill up thread SM1016
clearances. Do not overwrap.
Leave one to two pitch threads uncovered

• Application Procedure
Confirm that the thread surface is clean, free of dirt

or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
Low-Pressure-Hose Clamp Tightening Torque SM1017
Low-pressure-hose clamp tightening torque differs

depending on the type of clamp. T-Bolt Type Worm Gear Type
See below for correct tightening torque of each type of
low-pressure-hose clamp.
T-Bolt Type Band Clamp:

4.4 Nm (0.45 kgf m)
Worm Gear Type Band Clamp:
5.9 a 6.9 Nm (0.6 a 0.7 kgf m)
SM1018 SM1019
E485 W1-2-7
TIGHTENING TORQUE
Connecting Hose WRONG RIGHT
WARNING
1. When replacing hoses, be sure to use only
genuine parts. Using hoses other than genuine
hoses may cause oil leakage, hose rupture or
separation of fitting, possibly resulting in a fire on
the machine. SM1020
2. Do not install hoses kinked. Application of high
oil pressure, vibration, or an impact to a kinked
hose may result in oil leakage, hose rupture or
separation of fitting. Utilize print marks on hoses WRONG RIGHT
when installing hoses to prevent hose from being
installed kinked. Rubbing Against Each Other
3. If hoses rub against each other, wear to the
hoses will result, leading to hose rupture.
Take necessary measures to protect hoses from
rubbing against each other.
Take care that hoses do not come into contact SM1021
with moving parts or sharp objects.
WRONG RIGHT
Clamp Clamp
Rubbing
SM1022
WRONG RIGHT
Rubbing
Clamp
SM1023
W1-2-8 E485
TIGHTENING TORQUE
NOTES:
SECTION 2 E485
UPPERSTRUCTURE
CONTENTS
Group 1 - Cab Group 7 - Swing Device

Removal and Installation of Cab ........... W2-1-1 Removal and Installation of
Swing Device ....................................... W2-7-1
Disassembly and Assembly
Group 2 - Air conditioner of Swing Motor ..................................... W2-7-4
Removal and Installation
of Swing Reduction Unit ..................... W2-7-20
of Air Conditioner ................................. W2-2-1
Maintenance Standard ....................... W2-7-30
Disassembly and Assembly of
Air Conditioner ..................................... W2-2-2 Special Tools ...................................... W2-7-33
Group 3 - Counterweight Group 8 - Pilot Valve
Removal and Installation of Removal and Installation of

Counterweight ...................................... W2-3-1 Right and Left Pilot Valve ..................... W2-8-1
Removal and Installation of
Travel Pilot Valve .................................. W2-8-3
Group 4 - Main Frame Disassembly Right and Left
Pilot Valve ............................................ W2-8-6
Removal and Installation of Assembly Right and Left
Main Frame .......................................... W2-4-1 Pilot Valve .......................................... W2-8-12
Disassembly Travel Pilot Valve ........... W2-8-16
Assembly Travel Pilot Valve ............... W2-8-19
Group 5 - Pump Device
Pump Device ....................................... W2-5-1
Disassembly and Assembly Group 9 - Solenoid Valve Unit
of Pump Device ................................... W2-5-2
Maintenance Standard ....................... W2-5-16 Solenoid Valve Unit .............................. W2-9-1
Disassembly and Assembly Disassembly and Assembly
of Regulator ....................................... W2-5-18 of Solenoid Valve ................................. W2-9-2
Group 6 - Control Valve

Control Valve ........................................ W2-6-1
Control Valve ........................................ W2-6-2
Special Tool ........................................ W2-6-22
E485 W2-1-1
CAB
REMOVAL AND INSTALLATION OF CAB
Removal of cab
1. Remove the operator's seat complete with longi-

tudinal travel slide, removing securing screws
(12) (Q.ty 4) complete with spring washers. Dis-
connect the seat heater switch cable.
: 6 mm
2. Remove securing screws (16) (Q.ty 4) complete

with washers and lift hooks (14) to remove panels
(17 and 19) to reach the conditioner unit.
3. Disconnect the connectors of loudspeakers (5)

from panels (17 and 19), from power outlet (15)
and pressure discharge button (18).
4. Disconnect connections (9 and 10) of the monitor,

ceiling light (7) and wiper interlock switch (8).
Disconnect connections of the engine controller.
5. Disconnect the ground wires from the cab struc-

ture loosening securing screw (6).
: 10 mm
6. Remove securing screws (4) (q.ty 3) complete

with washers to remove panel (2). Disconnect the
connectors from hourmeter (3).
7. Disconnect washer liquid hose (11).
8. Extract air duct (13) pushing it toward the rear side

of the cab until it is free from the mounting and
remove it.
9. Install tool no. 380001057 with two C profiles

arranged on the cab structure.
WARNING
Approximate mass of the cab: 270 kg
380001057
10. Remove screws (1) (Q.ty 8).

: 19 mm
11. Lift carefully the cab from the operator's compart-

ment.
R0001
W2-1-2 E485
CAB
5
6
4 8
9
10
3
2
11
1
4 13 12
16 16
Partial view from "A"
17
15
14
14
18
14
19
R0002
E485 W2-1-3
CAB
Installation of cab
WARNING
380001057
Approximate mass of the cab: 270 kg
1. Lift the cab structure using tool no. 380001057 and

place it in the operator's compartment.
2. Secure the cab to the operator's compartment

using screws (1) (Q.ty 8).
: 19 mm
: 100 ± 15 Nm R0001
3. Connect flex air duct (13) to the rigid duct, pushing

it forward.
4. Connect washer liquid hose (11).
5. Connect the connections to hourmeter device (3)

and secure panel (2) using securing screws (4)
(Q.ty 3).
6. Connect the grounding cable to the cab structure

using securing screw (6).
: 10 mm
: 28.5 ± 3 Nm
7. Connect connectors of the monitor (9 and 10),

ceiling light (7) and wiper interlock switch (8).
Connect connection of the engine controller (20).
8. Connect to panels (17 and 19) the connections of

loudspeakers (5), power socket (15) and pres-
sure discharge button (18).
9. Secure panels (17 and 19) acting on locking

hooks (14) and tightening securing screws (16)
(q.ty used 4) complete with washers.
10. Connect the cab heating switch cable and install

the operator's seat complete with longitudinal
travel slide using securing screws (12) (Q.ty 4)
complete with spring washers.
: 6 mm
: 29.5 Nm
W2-1-4 E485
CAB
NOTES:
E485 W2-2-1
AIR CONDITIONER
REMOVAL AND INSTALLATION OF

AIR CONDITIONER
Preliminary operations Installation of air conditioner
Prior to and during the removal and installation proc- 1. Place the air conditioning unit on the operator's
ess of the air conditioning unit, make sure that the compartment.
following conditions are complied with:
2. Arrange the unit securing the screws (Q.ty 6)
1. This air conditioning unit is filled with a type R314a
: 13 mm
refrigerant. Thus, make sure, prior to performing
: 10.8 Nm
removal and re-installation operations, that no re-
frigerant is present inside the air conditioning sys-
3. Install the air ducts, front protection panel, all the
tem. Implement the operations described in Proce-
connectors between the operator's seat and the air
dure: "Discharging R134a fluid from the air condi-
conditioning unit, the controller securing plate, the
tioning system" at page W1-1-4.
front bracket and the fluid pipes with the relevant
O-Rings.
2. Do not keep open the connections of the ducts on
the compressor and the portions of the refrigeration
4. Charge the conditioning system with refrigerant
system.
fluid as described in Procedure: "Charging R134a
fluid into the air conditioning system" at page
3. Prevent the lubricant from adhering to painted
W1-1-5.
surfaces and plastic made parts. In the event
lubricant is spilled, clean it at once.
4. The dryer is filled with material absorbing moisture in

the circuit. Consequently, the valves on the opening
of the ducts must be removed immediately before
connecting the ducts.
5. Prior to performing any operation, cut-off the engine

and disconnect all the electric power sources of the
systems relative to the air conditioner.
Removal of air conditioner
1. Remove the air ducts, the front protection panel, all

the connections between the operator's compart-
ment and the conditioning unit, the controller mount-
ing plate, the front bracket and the fluid pipes with
the relevant O-Rings.
2. Remove the screws (Q.ty 6) securing the condition-

ing unit to the operator's compartment.
: 13 mm
3. Lift and remove the air conditioning unit.

W2-2-2 E485
AIR CONDITIONER
DISASSEMBLY AND ASSEMBLY OF

AIR CONDITIONER
1. Disassembly the blower unit

a. Remove the connectors (1) connected to the
inner/outer air select motor actuator, the blower
motor and the blower controller. Also remove the 1
harness (2) from the blower casing.
b. Draw out the inner air filter (3) from the intake
casing. Remove the four cross-recessed screws
(4) from the top of the intake casing (5), using a 2
screwdriver. Then remove the intake casing. 1
1
1 R0003
c. Remove three cross-recessed screws (6) fasten-
ing the blower casing (7) with the unit casing.
Then separate the blower unit from the air-
conditioner unit (8).
3
2. Assembly blower unit
4
a. Assembly is the reverse order of disassembly.
3. Disassembly the blower motor

5
a. Disconnect the cooling hose (9) that is con-
nected between the blower motor (10) and the
blower casing (11).
b. Remove three cross-recessed screws (12) fixed 6
from the bottom of the blower unit casing. Then
draw out the blower motor.
8 7
IMPORTANT - Do not separate the fan from the blower R0004
motor.
4. Assembly the blower motor

a. Assembly is the reverse order of disassembly. 11
5. Disassembly the blower controller

a. Remove two cross-recessed screws (13) fixed
from the bottom of the blower unit casing and
draw out the blower controller (14).
10
14
IMPORTANT - Do not disassemble the blower control- 9
ler in any circumstances.
12
6. Assembly the blower controller 13 R0005

E485 W2-2-3
AIR CONDITIONER
7. Removing the heater core

a. After discharging the cooling water, disconnect
the heater hose from heater core (1). 1
b. Remove one cross-recessed screw (2) each for
the bracket (3 and 4) fixing the heater core to the 4
unit and for the pipe clamp. Then remove the
bracket and the pipe clamp and draw out the
heater core from the unit casing.
2
8. Assembly the heater core 3 2 R0006
9. Removing the upper and lower parts of the air-

conditioner unit casing
a. Draw out the connectors for the mode motor
actuator and the evaporation sensor.
5
b. Separate the rod (5) from the rod holder (6) that
is fixed to the lever (7) on the mode motor 11
6
actuator (8). 9
c. Remove three cross-recessed screws (9) fas- 7
tening the mode motor actuator that install the
bottom of the unit casing (10) to the back of the 9 10
unit casing (11). Then separate the mode motor
actuator. 9 8 R0007
d. Remove eleven cross-recessed screws (12)

that install the bottom of the unit casing (13) to
the top of the unit casing (14).
e. Draw out the top of the unit casing upwards,

using care so the evaporator sensor cord (15) is 14
not arrested by the casing.
NOTE - On that occasion, do the work with the heater

core off the unit casing.
10. Assembly upper and lower parts of the air condi-

15
tioner unit casing.
13
12
R0008
W2-2-4 E485
AIR CONDITIONER
11. Disassembly the evaporator and the expansion

valve
1
a. Remove the evaporator assy (1) from the bot-
tom of the casing, together with the casing
insulator and the expansion valve (2).
b. Remove the upper and lower casing insulators 5
from the evaporator assy and draw out the 2
evaporator sensor (3) with the sensor holder.
c. Remove the socket head cap screws M5x40 (4)
(Q.ty 2) from the evaporator. Then separate the 4
expansion valve from the evaporator.
: 4 mm
3
R0009
12. Assembly the evaporator and the expansion valve

a. Attach O-Rings to a new evaporator.
b. Then install the expansion valve to it with head
cap screws (M5x40) (Q.ty 2).
: 4 mm
: 7 Nm
IMPORTANT - When attaching O-Rings, use care so

the O-Rings are not caught.
13. Installing the evaporator sensor

a. Install the evaporation sensor (3) as shown in
figure.
IMPORTANT - When installing the casing, exercise

care so the sensor cord is not caught by the casing.
3
R0010
E485 W2-2-5
AIR CONDITIONER
14. Disassembly the motor actuator
a. Replacing the mode motor actuator (1).

Remove the connector fixed to the motor actu-
ator.
Remove the rod (3) linking the motor actuator
with the mode cam, from the rod holder (2). 2
Remove three cross-recessed screws (4) fixing
the motor actuator. Separate the motor actuator 3
from the unit, together with the rod holder and 4
the lever (5). Remove the rod holder and the 5
lever from the motor actuator.
4
4 1 R0011
b. Replacing the air mix motor actuator 8 6

Disconnect the connector connected with the 9
motor actuator. 10
Separate the rod (6) linking the motor actuator 7
(7) with the lever (8) from the rod holder (9).
Remove three cross-recessed screws fasten-
ing the motor actuator. Then remove the motor
actuator with the rod holder and the lever MAL1
(10) from the unit. Remove the rod holder and
the lever from the motor actuator.
R0012
c. Replacing the inner/outer air select motor actu-

ator (11).
Disconnect the connector connected with the
motor actuator. 12
Separate the motor actuator with lever (12) from
the unit.
Remove the lever from the motor actuator.
11 R0013
15. Assembly the motor actuator

W2-2-6 E485
AIR CONDITIONER
NOTES:
E485 W2-3-1
COUNTERWEIGHT

COUNTERWEIGHT
1
Removal of counterweight
WARNING
Approximate mass of counterweight: 10200 kg
1. Remove caps (1) from counterweight. Install eye-

bolts to the counterweight.
SM1135
Eye-bolts : M36
: 55 mm.
2. Attach wire rope (2) to eye-bolts using shackles.

Take out slack of wire rope by applying tension 2
slowly with a crane or hoist.
SM1136
3. Remove bolts (3).

Lift counterweight using a crane or hoist.
: 65 mm
SM1137
4. Lower the counterweight on proper stand.
SM1138
W2-3-2 E485
COUNTERWEIGHT
Installation of counterweight
WARNING
Approx. mass of counterweight: 10200 kg
1. Attach lifting tools to counterweight. 4

Lift counterweight (4) and install it onto the frame.
Install bolts (3) and washers to counterweight and 3
tighten temporarily.
: 65 mm SM1137
2. Remove wire rope.

Tighten the bolts with a power wrench (6) and torque
wrench (7).
: 65 mm
: 3920 Nm
6 7
SM1139
3. Remove the eye-bolts.

Install caps (1) to counterweight.
1
SM1135
E485 W2-4-1
MAIN FRAME
REMOVAL AND INSTALLATION OF MAIN FRAME
WARNING
Possible leakages of fluids under pressure could penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure before disconnecting hydraulic pipes or other pipes.
Hydraulic oil, at the end of a work shift, can be very hot and can cause, when spilling, potentially serious burns.
Prior to beginning any intervention, make sure that the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank. Press the valve located
on the hydraulic oil tank to release any residual pressure present in the tank itself.
Preparation Removal of main frame
1. Park the machine on a firm, level surface. 1. Remove the cab, performing the operations de-
scribed in the procedure at page W2-1-1.
2. Cut-off the engine. Press the valve located on the
hydraulic oil tank to release the residual pressure 2. Remove the counterweight performing the opera-
present inside the tank itself. tions described at page W2-2-1.
Please refer to the "Procedure: Releasing the
pressure from the Hydraulic System" at page W4-
2-12. 3. Remove the front equipment and the boom cylin-
der, performing the operations described in the
3. Remove hydraulic oil tank cap. Connect a vacuum procedure at pages W4-1-1 and W4-2-1.
pump to maintain negative pressure in the hydrau-
lic oil tank.
4. Remove the centre joint performing the operations
described in the procedure at page W3-3-1. Drain
NOTE - Be sure to run the vacuum pump continuously
the hydraulic oil from the relevant tank.
while working.
W2-4-2 E485
MAIN FRAME
WARNING
Approximate mass of main frame: 7500 kg
5. Attach wire ropes to the front and rear of main frame.

See wire ropes taut using a crane. Use chain blocks
for easy adjustment of wire rope lengths and to level Rear
the frame. SM1142
IMPORTANT - Make sure rear slings do not touch

engine.
Front
SM1143
SM1144
6. Put matching marks on swing bearing and main

frame. Remove bolts (14) from the swing bearing.
: 41 mm
14
SM1380
E485 W2-4-3
MAIN FRAME
7. Lift main frame slightly from undercarriage.

Level main frame by adjusting the chain blocks.
Remove main frame.
SM1146
W2-4-4 E485
MAIN FRAME
Installation of main frame
13
WARNING
Approximate mass of main frame: 7500 kg
1. Fasten hoist to front and rear of main frame.

Level main frame by adjusting chain blocks (13)
and lower main frame onto undercarriage.
Align the matching mark on the swing bearing with
that on the main frame.
SM1146
2. Install bolts (14) on the swing bearing and tighten

temporary.
Install main frame and tighten bolts to specification.
: 41 mm
Upperstructure side
: 1324 Nm
14
3. Install the centre joint performing the operations SM1380
described at page W3-3-1. Fill with hydraulic oil the

relevant tank.
4. Install the front equipment and boom cylinder per-

forming the operations described at pages W4-1-1
and W4-2-1.
5. Install the counterweight performing the opera-

tions described at page W2-2-1.
6. Install the cab performing the operations described

at page W2-1-1.
7. Fill the hydraulic oil tank with hydraulic oil to the

specified level.
Run the engine at slow idle. Check hose connec-
tions for any oil leakage.
SM1147
E485 W2-5-1
PUMP DEVICE
REMOVAL AND INSTALLATION OF PUMP DEVICE
WARNING
Preparation
1. Park the machine on a firm, level surface. 3. Remove hydraulic oil tank cap. Connect a vacuum
2. Cut-off the engine. Press the valve located on the lic oil tank.
hydraulic oil tank to release the residual pressure
present inside the tank itself.
while working.
Removal Installation
1. Remove all protection panels and doors to give 1. Lift the hydraulic pump device by means of hoist
access to the Hydraulic Pump Device. and ropes.
2. Disconnect all electrical connectors. WARNING

Hydraulic pump device mass: 260 kg
3. Remove all hoses and collector from hydraulic
pump device.
: 19, 22, 36 mm 2. Install the hydraulic pump device to the engine by
means of related bolts.
4. Fasten the hydraulic pump device by means of
hoist and lifting ropes. : 17 mm
: 65 Nm + Loctite 270
3. Install all hoses and collector to the hydraulic pump

WARNING
device.
Hydraulic pump device mass: 260 kg
: 19 mm
: 29.4 Nm
5. Remove the fixing bolts of hydraulic pump device : 22 mm
and draw it from engine. : 49 Nm
: 17 mm : 36 mm
: 118 Nm
4. Connect all electrical connectors.
5. Install all protection panels and doors.

W2-5-2 E485
PUMP DEVICE
DISASSEMBLY AND ASSEMBLY OF PUMP DEVICE
901 490 724

469 725 726
728 271
490
806
953 981
536 983
886
406 405 901 954 412
807
886 541 413
131
192 545
127 490 543
712
823 492
171 490 491 130
493 312
492
752 491
728
728 469 886
825
126 469 752
409
711 191 262
774 126 709
261 825
827 548 141
531 156 885 411
151 491
152 153 410
124
962 211
314
408 214
491 157 725
251 548 467
151
531 124
152
313
214 141
113 212 157 789
824 156 535
128 153
123 888
211
128
824 702
962 732
129 212
828
888 251 532
824 534
128 792
123
111
129
828
R3794
E485 W2-5-3
PUMP DEVICE
111 - Drive Shaft 490 - Plug NPTF 1/6, 8.8 Nm; (Q.ty 27)
113 - Driven Shaft 491 - Plug Re 1/8, 12 Nm (Q.ty 12)
123 - Roller Bearing (Q.ty 2) 492 - Restrictor NPTF 1/16, (Q.ty 4)
124 - Needle Bearing (Q.ty 2) 493 - Plug Re 1/4, 22 Nm (Q.ty 2)
126 - Spacer (Q.ty 2) 531 - Tilting Pin (Q.ty 2)
127 - Spacer 532 - Piston (Q.ty 2)
128 - Bearing Spacer (Q.ty 3) 534 - Stopper (Q.ty 2)
129 - Bearing Spacer (Q.ty 2) 535 - Stopper (Q.ty 2)
130 - Booster 536 - Cover (Q.ty 2)
131 - Booster Cover 541 - Seat (Q.ty 4)
141 - Cylinder Block (Q.ty 2) 543 - Stopper (Q.ty 4)
151 - Piston (Q.ty 18) 545 - Ball (Q.ty 4)
152 - Shoe (Q.ty 18) 548 - Pin (Q.ty 2)
153 - Set Plate (Q.ty 2) 702 - O-Ring (Q.ty 2)
156 - Spherical Bush (Q.ty 2) 709 - O-Ring
157 - Cylinder Spring (Q.ty 18) 711 - O-Ring (Q.ty 2)
171 - Front Casing 712 - O-Ring (Q.ty 2)
191 - Drive Gear 724 - O-Ring (Q.ty 13)
192 - Driven Gear 725 - O-Ring (Q.ty 6)
211 - Shoe Plate (Q.ty 2) 726 - O-Ring (Q.ty 2)
212 - Swash Plate (Q.ty 2) 728 - O-Ring (Q.ty 4)
214 - Tilting Bushing (Q.ty 2) 732 - O-Ring (Q.ty 2)
251 - Swash Plate Support (Q.ty 2) 752 - Seat Packing (Q.ty 2)
261 - Front Cover 774 - Oil Seal
262 - Cover 789 - Backup Ring (Q.ty 2)
271 - Pump Casing 792 - Backup Ring (Q.ty 2)
312 - Valve Cover 806 - Nut M20, 240 Nm; (Q.ty 2)
313 - Right Valve Plate 807 - Nut M20, 240 Nm; (Q.ty 2)
314 - Left Valve Plate 823 - Snap Ring
325 - Casing 824 - Snap Ring (Q.ty 3)
405 - Capscrew M8x30, 29 Nm; (Q.ty 8) 825 - Snap Ring (Q.ty 2)
406 - Capscrew M12x35, 98 Nm; (Q.ty 8) 827 - Snap Ring
408 - Capscrew M12x55, 98 Nm; (Q.ty 11) 828 - Snap Ring (Q.ty 2)
409 - Capscrew M10x16, 56 Nm; (Q.ty 2) 885 - Pin (Q.ty 2)
410 - Capscrew M22x60, 630 Nm; (Q.ty 9) 886 - Spring Pin (Q.ty 4)
411 - Capscrew M22x95, 630 Nm; (Q.ty 2) 888 - Pin (Q.ty 2)
412 - Capscrew M22x180, 630 Nm 901 - Eye Bolt (Q.ty 2)
413 - Capscrew M10x25, 56 Nm; (Q.ty 5) 953 - Setscrew (Q.ty 2)
414 - Capscrew M6x65, 12 Nm; (Q.ty 3) 954 - Setscrew (Q.ty 2)
467 - Plug G 1/4, 36 Nm; (Q.ty 2) 981 - Nameplate
469 - Plug G 3/4, 170 Nm; (Q.ty 4) 983 - Pin (Q.ty 2)
W2-5-4 E485
PUMP DEVICE
Disassembly
For disassembling and assembling the pump, read

this section thoroughly and then disassemble it in the
following sequence. The figures in parentheses after
part names show the items list in the Construction of
Pump figure.
In each step, mark each part of the pump so as not to
mix up it with others.
1. Select place suitable to disassembling.
NOTE -
a. Select clean place.
b. Spread rubber sheet, cloth or so on overhaul work-
bench top to prevent parts from being damaged.
c. Fix pump casing (271) by using thread 2-M10-L16 in
disassembling.
2. Remove dust, rust, etc, from pump surfaces with

cleaning oil or so on.
R3726
3. Remove outlet port plug (469, lower part of pump

casing) and let the oil out of pump casing.
NOTE - In order to be let the oil out of pump casing

easily, remove oil filling port plug (469, upper part of
pump casing).
4. Remove hexagon socket head cap screws (412,

413) and remove regulators.
NOTE -
a. Refer to regulator paragraph procedures for its
disassembling.
b. In order to avoid mixing up regulator of drive shaft
side with that of driven shaft side, mark each of
them.
R3727
E485 W2-5-5
PUMP DEVICE
5. Remove gear pump, booster cover (131), booster

(130), and cover (262).
R3728
6. Loosen hexagon socket head cap screws (410,

411, 412) which tighten valve cover (312).
NOTE - Remove regulators before starting this work.
7. Place pump horizontally on workbench and sepa-

rate pump casing (271) and valve cover (312).
WARNING
Crane valve cover (312) (about 60 kg).
IMPORTANT -
a. There are two spring pins for fixing position between
pump casing (271) and valve cover (312). Since
they have a tight fit, remove valve cover (312)
upright with respect to drive shaft (111) and driven
shaft (113), while lightly tapping the valve cover
(312) with a plastic hammer.
b. Take care not to damage fitting surfaces between
pump casing (271) and valve cover (312).
c. Take care not to drop valve plates (313, 314), check
valve subassemblies (541, 543, 545), O-Rings
(724, 725, 726) and seat packing (752) in removing
valve cover (312).
R3729
W2-5-6 E485
PUMP DEVICE
8. If necessary, remove needle bearings (124) from

valve cover (312).
NOTE -
a. Do not remove needle bearings as far as possible,
except when it is considered to be out of its life
span.
b. Do not loosen hexagon nut (807) of the valve cover.
If loosened, flow setting will be changed.
9. Pull cylinders out of pump casing (271) straightly

over drive shaft (111) and driven shaft (113). Pull
out also pistons (151), set plate (153), spherical
bush (156) and cylinder springs (157) simultane-
ously.
IMPORTANT - Take care not to damage sliding

surfaces of cylinder, spherical bush, shoes, swash
plate, etc.
R3730
10. Remove shoe plate (211) and swash plate (212)

from pump casing (271).
R3731
E485 W2-5-7
PUMP DEVICE
11. If necessary, remove stopper (L) (534), stopper

(S) (535), servo piston (532), tilting pin (531), and
servo cover (536) from pump casing (271).
NOTE -
a. In removing tilting pin, use a protector to prevent pin
head from being damaged.
b. Since adhesive (No.1305N of Threebond make) is
applied to fitting areas of tilting pin and servo piston,
take care not to damage servo piston.
c. Do not loosen hexagon nut (806) on servo cover
(536). If loosened, flow setting will be changed.
12. Remove snap ring (827) and front cover (261) from
front casing (171).
NOTE -
a. A groove is provided on the outer circumference of
front cover straight with respect to drive shaft (111)
by placing a minus type screwdriver in the groove.
b. Since oil seal (774) is fitted on front cover (261),
take care not to damage it in removing.
13. Loosen hexagon socket head cap screws (408) R3732

which tighten front casing (171).
14. Separate front casing (171) and pump casing

(271).
WARNING
Front casing mass: about 32 kg.
Take care of front casing not to fall.
NOTE -
a. There are two spring pins (886) for fixing position
R3733
between front casing (171) and pump casing (271).
Tapping lightly with a plastic hammer, remove front
casing (171) perpendicular to drive shaft (111)
because they are fitted firmly. When removing, take
care not to damage oil seal sliding surface of drive
shaft (111).
b. Take care not to damage fitting surfaces between
front casing (171) and pump casing (271).
W2-5-8 E485
PUMP DEVICE
15. Remove snap rings (823, 825), bearing spacers

(126, 127), drive gear (191), and driven gear (192).
R3734
16. Remove snap ring (828) and bearing spacer (129)

and take out drive shaft (111) and driven shaft
(113) tapping lightly ends of them.
R3735
17. If necessary, remove snap rings (824, 825), bear-

ing spacer (128), and roller bearing (123) from drive
shaft (111) and driven shaft (113).
IMPORTANT - Do not remove roller bearing as far as

possible, except when it is considered to be out of its
life span. Use a specified jig in removing because roller
bearing is shrinkage fitted to shaft.
18. Loosen hexagon socket head cap screws (405)

which tighten swash plate supports (251) and
pump casing (271).
NOTE - Adhesive (No.1305N of Threebond make) is

applied to hexagon socket head cap screws (405).
19. Remove swash plate supports (251) from pump

casing (271).
R3736
E485 W2-5-9
PUMP DEVICE
Assembly
Assembly in reverse order of disassembly procedures

but pay attention to the following items.
a. Do not fail to repair the parts damaged during
disassembling, and repair replacement parts in
advance.
b. Clean each part fully with cleaning oil and dry it with
compressed air.
c. Do not fail to apply clean working oil to sliding
surfaces, bearings, etc. before assembling them.
d. In principle, replace seal parts, such as O-rings, oil
seals, etc.
e. Apply grease to O-rings, seat packing, and check
valves in assembling them because they tend to
come off.
f. In case of parallel type pump, rotating directions of
drive shaft and driven shaft are different. Take care
not to mix up parts of the drive shaft side with those
of the driven shaft side.
g. For fitting bolts, plug, etc., prepare a torque wrench
or so on, and tighten them with specified torques in
this maintenance manual.
1. Select place suitable to assembling.
NOTE -
a. Select clean place.
b. Spread rubber sheet, cloth or so on overhaul work-
bench top to prevent parts from being damaged.
c. Fix pump casing (271) by using thread 2-M10-L16 in
assembling.
R3738
2. Fit swash plate supports (251) to pump casing

(271) and fix them with hexagon socket head cap
screws (405).
R3739
W2-5-10 E485
PUMP DEVICE
NOTE -
a. There are O-Rings (724) on the matching surface in
contact with pump casing (271). Fix them with
grease so they do not come off.
b. Positioning pin (888) is placed on the pump casing
(271) side. Adjust it so it enters the groove of swash
plate support (251) and fix it.
c. Fit swash plate support (251) so it enters straight,
while tapping it lightly.
d. Apply adhesive (No.1305N of Threebond make) to
hexagon socket head cap screws.
R3740
3. To pump casing (271), fit drive shaft (111) set and

driven shaft (113) set with roller bearing (123),
bearing spacer (128), and snap rings (824, 825).
Then fix them with snap rings (828).
NOTE -
a. Direct the sharp edge side of snap rings (824, 825)
to the outside.
b. Do not tap shafts with hammer or so on.
c. Assemble them into pump casing, tapping outer
race of bearing lightly with plastic hammer. Fit them
fully, using steel bar or so on.
R3741
d. Both side of snap rings (828) are burnished.
4. Fit drive gear (191), driven gear (192), and bearing

spacers (126, 127) to drive shaft (111) and driven
shaft (113). Then fix them with snap rings (823,
825).
R3742
E485 W2-5-11
PUMP DEVICE
NOTE -
a. Confirm the attaching direction of drive gear before
fitting.
b. Direct the sharp edge of snap rings (823, 825) to the
outside.
5. Fit front casing (171) to pump casing (271) and fix

them with hexagon socket head cap screws (408).
WARNING
Take care of front casing not to fall (about 32 kg).
NOTE -
a. There are two spring pins (886) for fixing position R3743
between front casing (171) and pump casing (271).
Always fit spring pins (886) to the pump casing (271)
side.
b. Fit front casing (171) to pump casing (271) perpen-
dicular to drive shaft (111), while tapping it lightly
because spring pin (886) has a tight fit. When fitting,
take care not to damage oil seal sliding surface of
drive shaft (111).
c. Take care not to damage fitting surfaces of front
casing (171) and pump casing (271).
d. Apply grease to seat packing (752) because it tends
to come off.
R3744
6. Fit front cover (261) to front casing (171) and fix

them with snap ring (827).
NOTE -
a. Apply grease lightly to oil seal in front cover.
b. Assembling oil seal, take full care not to damage it.
c. Direct the sharp edge of snap ring (827) to the
outside.
R3745
W2-5-12 E485
PUMP DEVICE
7. Place pump casing (271) horizontally. Fit servo

piston (532), tilting pin (531), stopper (L) (534), and
stopper (S) (535) to pump casing. Then fit servo
cover (536) to pump casing and fix them with
hexagon socket head cap screws (406).
NOTE -
a. Fix pump casing (271) by using thread 2-M10-L16 in
assembling.
b. In tightening servo piston (532) and tilting pin (531),
use a protector to prevent tilting pin head and
feedback pin from being damaged. In addition,
apply adhesive (No.1305N of Threebond make) to
their threaded sections.
8. Fit tilting bush (214) of swash plate (212) to tilting pin

(531) and fit swash plate to swash plate support
(251) correctly.
NOTE -
a. Take care not to mix up parts of drive shaft side with
those of driven shaft side.
b. Even after fitting, swash plate (212) comes off from
swash plate support (251), in some cases. They do
not come off easily if grease is applied to the sliding
surfaces.
c. Confirm that swash plate can be moved smoothly.
R3746
E485 W2-5-13
PUMP DEVICE
9. Assemble piston cylinder subassembly [cylinder

(141), piston subassembly (151, 152), set plate
(153), spherical bush (156), cylinder spring (157)].
Fit spline phases of spherical bush and cylinder
and insert piston cylinder subassembly into pump
casing with respect to drive shaft (111) and driven
shaft (113).
NOTE -
a. Take care not to mix up parts of drive shaft side with
those of driven shaft side.
b. Confirm that swash plate (212) is not off from swash
R3747
plate support (251) and from tilting pin (531), before
inserting them.
10. Fit valve plates (313, 314) to valve cover, entering

valve plate pin (885) into pin hole.
NOTE -
a. Take care not to mistake suction / delivery direc-
tions of valve plate.
b. Apply grease to matching surface in contact with
valve cover (312) because valve plates (313, 314)
tend to come off.
R3748
11. Insert check valve subassemblies (541, 543, 545)

and needle bearings to valve cover (312).
NOTE -
a. Insert check valve subassemblies into valve cover
in correct order.
b. Since check valve subassembly tends to come off,
apply grease to matching part of valve cover (312).
R3749
W2-5-14 E485
PUMP DEVICE
12. Fit O-Rings (724, 725, 726) and seat packing (752)
to the matching surface of pump casing (271) in
contact with valve cover (312).
NOTE - Since O-Rings and seat packing tend to come

off, apply grease to matching surface.
WARNING
Crane valve cover (312) (about 60 kg).
R3750
13. Fit valve cover (312) to pump casing (271) and

tighten them with hexagon socket head cap
screws (410, 411, 412).
NOTE -
a. Confirm that swash plate (212) is not off from swash
plate support (251) and tilting pin (531) before fitting.
b. Needle bearings (124) are located on the valve
cover (312) side; place the valve cover with care. In
order to protect needle bearing, cover drive shaft
(111) and driven shaft (113) with specified cover.
c. When fitting, take care as valve plates (313, 314),
check valve subassemblies (541, 543, 545), O-
Rings (724, 725, 726), and seat packing (752) may
come off in some cases.
d. There are two spring pins (886) for fixing position
between pump casing (271) and valve cover (312).
Since spring pin (886) has a tight fit, fit valve cover
(312) upright to drive shaft (111) and driven shaft
(113), while tapping it with a plastic hammer.
e. Take care not to damage fitting surfaces between
valve cover (312) and pump casing (271).
R3751
R3752
E485 W2-5-15
PUMP DEVICE
14. Fit booster (130), booster cover (131), cover (262)

and gear pump.
R3753
15. Putting feedback pin of tilting pin into feedback

lever of regulator, fit regulator and tighten hexagon
socket head cap screws (412, 413).
NOTE - Since the regulators on the drive shaft side and

the driven shaft side are set at different pressure and
flow values, take care not to mistake one for another.
R3754
W2-5-16 E485
PUMP DEVICE
MAINTENANCE STANDARD
Unit: mm
Standard Recommended
Part name and inspection item dimension value for Remedy
(mm) replacement (mm)
Clearance between piston and 0.038 0.078 Replace piston or cylinder.

cylinder bore (D-d)
D
R0719
Gap between piston and caulked 0 ~ 0.1 0.35 Replace piston shoe assy.
part of shoe (δ)
R0720
Thickness of shoe (t) 5.4 5 Replace piston shoe assy.
R0721
Free height of cylinder spring (L) 40.9 40.1 Replace cylinder spring.
L
R0722
Combined height of set plate and 13.5 12.5 Replace a set of spherical bushing
spherical bushing (H-h) or set plate.
H
h
R0723
Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section).

Surface roughness requiring correction. 3-Z
Swash plate (shoe plate face).
Cylinder (sliding section). Standard surface roughness
Less than 0.4 Z (lapping)
Roughness of each surface. (correction value).
E485 W2-5-17
PUMP DEVICE
NOTES:
W2-5-18 E485
PUMP DEVICE
DISASSEMBLY AND ASSEMBLY OF REGULATOR
732
627
626
625
624
623 D
B
612
622 621 611
733 F 874 728
897 645
732 613
631 875 646
898 652 644
A
651
836 G
655
654 C
E
653 438
814 656
643
755
722
438 630
629
924
763 801
801
925
628
756
413 412
418 79 496
496
D
496 H E
755
541 734 601
545
543 876
F
615
A I
543 G 755
B
545 C 858
541 724 496
436 755 875
755 730 725
641 614
708 887 466
733 724 755
858
642
753
727
467 801
R2070
E485 W2-5-19
PUMP DEVICE
079 - Solenoid proportional reducing valve 645 - Adjust stem

412 - Socket bolt M8x50 (Q.ty 2) 29 Nm 646 - Pilot spring
413 - Socket bolt M8x70 (Q.ty 2) 29 Nm 651 - Sleeve
418 - Socket bolt M5x12 (Q.ty 2) 6.9 Nm 652 - Spool
436 - Socket bolt M6x40 (Q.ty 4) 12 Nm 653 - Spring seat
438 - Socket bolt M6x20 (Q.ty 8) 12 Nm 654 - Return spring
466 - Vp plug PF 1/4 36 Nm 655 - Set spring
467 - Plug PF 3/8xM6 34 Nm 656 - Block cover
496 - Plug Seal coated (Q.ty 15) 8.8 Nm 708 - O-Ring
541 - Seat 722 - O-Ring (Q.ty 3)
542 - Seat 724 - O-Ring (Q.ty 9)
543 - Stopper (Q.ty 2) 725 - O-Ring
545 - Steel ball (Q.ty 2) 727 - O-Ring
601 - Casing 728 - O-Ring
611 - Feed back lever 730 - O-Ring
612 - Lever (1) 732 - O-Ring (Q.ty 2)
613 - Lever (2) 733 - O-Ring
614 - Fulcrum plug 734 - O-Ring
615 - Adjust plug 753 - O-Ring
621 - Compensating piston 755 - O-Ring (Q.ty 2)
622 - Piston case 756 - O-Ring
623 - Compensating rod 757 - O-Ring
624 - Spring seat 763 - O-Ring
625 - Outer spring 801 - Nut M8 16 Nm
626 - Inner spring 814 - Snap ring
627 - Adjust stem 836 - Snap ring
628 - Adjust screw 858 - Snap ring (Q.ty 2)
629 - Cover 874 - Pin
630 - Lock-nut M30x1.5 160 Nm 875 - Pin (Q.ty 2)
631 - Sleeve 887 - Pin
641 - Pilot cover 897 - Pin
642 - Rod 898 - Pin
643 - Pilot piston 924 - Set screw M8x20
644 - Spring seat 925 - Adjust screw
W2-5-20 E485
PUMP DEVICE
Disassembly
1. Proceed with disassembly operations in a clean

place.
Spread rubber sheet or cloth on work bench to
protect parts from damaging.
2. Clean the parts removing dust and rust, etc. on

regulator surface with wash oil.
IMPORTANT - Since the regulators at drive shaft side REGULATOR

and driven shaft side are set at different pressure and
flow values, mark each of them so as not to mix up one
with other.
3. Remove regulator by removing socket bolts (412,

413) and separate the regulator from the pump
body.
: 6 mm
4. Remove socket bolt (438) and separate the port

plate (656). R1202
: 6 mm
5. Remove socket bolts (438) and remove cover (629).

: 5 mm
IMPORTANT - The cover is equipped with adjust 624, 625, 626

screws (628, 925), adjust stem (627), lock nut (630),
627
hex nut (801) and set screw (924). Do not loosen those
screws and nut. If they are loosened, preadjusted set 801
pressure and flow valves change. 629 (628, 925)
630 924 R2071

E485 W2-5-21
PUMP DEVICE
6. After removing the cover (629) sub assy, take out

outer spring (625), inner spring (626) and spring seat M4 BOLT
645
(624) from the compensating part. Then take out
644, 646
adjust stem (645), pilot spring (646) and spring seat
(644) from the pilot part.
601
NOTE - Adjust stem (645) comes out easily if an M4

bolt is used.
R2072
7. Remove socket bolt (436) and pilot cover (641).

Once the pilot cover comes off, separate set spring
(655) from the pilot section.
: 5 mm
436
641, 655
R2073
8. Remove spring seat, return spring and sleeve.

Remove snap ring (814). Then remove spring seat
(653), return spring (654) and sleeve (651).
814 (653)
NOTE - Sleeve (651) is equipped with snap ring (836).
When removing snap ring (814), return spring (654)
654,
comes out: Use care so as not to lose it.
651 (836)
R2074
9. Remove snap ring (858) and take out fulcrum plug

(614) and adjust plug (615).
858
NOTE - Fulcrum plug (614) and adjust plug (615) come
off easily if a M6 bolt is used.
615
614
R2075
W2-5-22 E485
PUMP DEVICE
614
R2076
10. Remove lever 2 (613).

Do not draw out pin (875).
NOTE - The work is eased if tweezer is used.
613 (875)
R2077
11. Draw out pin (874) and remove feedback lever

(611).
874
NOTE - Push out pin (874) from above with a slender

steel rod so as not to interfere with lever (612).
611
R2078
611
R2079
E485 W2-5-23
PUMP DEVICE
12. Remove lever 1 (612).

Do not draw out pin (875). 612
•
• •
1 611
•
F 874
13. Draw out pilot piston (643) and spool (652). 897
875 613
875
14. Draw out piston casing (622), compensating pis-
ton (621) and compensating rod (623). This com- A
pletes disassembly of the regulator.
G
C
NOTE - Piston casing (622) comes out from the 643
opposite side of the piston casing if compensating rod
(623) is pushed out.
623
B
622 621
•
IMPORTANT - Since regulators of K5V DP series 733
• •
• 1
pump at drive shaft side and driven shaft side have 732
different pressure flow setting each other, mark each 631
of them so as not to mix up one with other. 898 652
A
651
836
655
654
653
814
R2080
Assembly
623
B
Assembly is the reverse order of disassembly. Do the 612
work paying attention to the following: 611
F 874
897
- Repair those parts that were damaged during disas- 875 613
sembly and prepare replacement parts beforehand. 875
- If foreign matter enters, it causes malfunction; A
clean parts thoroughly in cleaning oil, blow them
with jet air and assemble parts in a clean place. G
- Always tighten bolts and plugs to the specified

torque. R2081
- Do not fail to coat the moving parts with clean

hydraulic oil, before assembly.
- In principle, replace seals such as O-Ring.

W2-5-24 E485
PUMP DEVICE
1. Assemble compensating rod (623) into the compen-

sating hole of casing (601).
2. Put the pin pressed in lever 1 (612) into the groove

of the compensating rod. Then assemble the lever
to the pin that is pressed in the casing.
3. Assemble spool (652) and sleeve (651) into the

spool hole of the casing.
Spool (652) Feedback

NOTE - Make sure that the spool and the sleeve move
smoothly in the casing. lever (611)
Beware of the direction of the spool. R2082
4. Assemble feedback lever (611). Then put pin (874)

into the pin hole of the feedback lever.
NOTE - The work is eased if the pin is put in the Lever 1 Lever 2 (613) side
feedback lever a little, beforehand. (612) side (fulcrum plug and
Take care so as not to mistake the direction of the adjust plug sides)
feedback lever.
R2083
5. Assemble pilot piston (643) into the negative control

hole of the casing.
NOTE - Make sure that the pilot piston moves

smoothly.
613 (875)
6. Place pin (875) pressed in lever 2 (613) into the

groove of the pilot piston and assemble lever 2
(613).
R2084
7. Assemble fulcrum plug (614) so pin (875) pressed

in the fulcrum comes in the pin hole of lever 2 (613).
Then fit snap ring (858).
614
(875, 858)
R2085
E485 W2-5-25
PUMP DEVICE
18. Insert adjust plug (615) and fit a snap ring (858).
652
814
NOTE - Use care so as not to mistake the holes into
which the fulcrum and adjust plug are inserted. 653
At this point, operate the feedback lever and make
sure that the gap is not large and that the lever moves 654
smoothly.
R2086
19. Assemble return spring (654) and spring seat (653)

into the spool hole and fit snap ring (814).
10. Assemble set spring (655) into the spool hole.

Place compensating piston (621) and piston cas-
ing (622) into the compensating hole and attach
pilot cover (641). Then fasten them together with
socket bolts (436).
: 5 mm,
622 (621)
R2087
NOTE - Confirm that pin (898) slides smoothly in Pf
sleeve (631) without binding.
11. Put spring seat (644), pilot spring (646) and adjust
stem (645) into the pilot hole. Then assemble
644, 645, 64
spring seat (624), inner spring (626) and outer
626
spring (625) into the compensating hole.
625
NOTE - Do not mistake the direction of the spring seat.
R2088
12. Attach cover (629) fitted with adjust screws (628),

(925), adjust stem (627), lock nut (630), nut (801)
and socket bolt (924). Then fasten them with
socket bolts (438).
: 5 mm,
624, 625, 626
627
801
629 (628, 925)
630 924 R2089

W2-5-26 E485
PUMP DEVICE
NOTES:
E485 W2-6-1
CONTROL VALVE
REMOVAL AND INSTALLATION OF CONTROL VALVE
WARNING
Preparation
1. Park the machine on a firm, level surface. Refer to “Bleed Pressure from Hydraulic Circuit” on
2. Cut-off the engine. Actuate the manual and pedal page W4-2-12.
pilot valves to release any residual pressure from 3. Remove hydraulic oil tank cap. Connect a vacuum
inside the hydraulic system. Press the valve lo- pump to maintain negative pressure in the hydrau-
cated on the hydraulic oil tank to release any lic oil tank.
residual pressure present inside the tank itself.
while working.
Removal of Control valve Installation of Control valve
NOTE - Refer to “Removal of Control valve” section

NOTE - Attach caps to hoses and pipes.
above for wrench sizes and tightening torques.
Attach labels or tags to hoses and pipes, to aid in
assembly. 1. Install control valve to frame and tighten the bolts.
2. Connect all hoses, pipes and connectors to the
1. Remove the panel protecting the control valve, control valve.
removing the securing screws. 3. Install the panel protecting the control valve using
: 19 mm the relevant securing screws.
: 108 Nm
IMPORTANT - After completing installation:
2. Disconnect all hoses, pipes and connectors from - Check hydraulic oil level. Add oil if necessary.
the control valve (5). - Run the engine. Check for any oil leakage.
: 19 mm
: 29.4 ± 2.94 Nm
: 22 mm
: 68.6 ± 6.8 Nm
: 36 mm
: 176.5 ± 17.6 Nm 5
: 30 mm
: 137.2 ± 13.7 Nm
: 27 mm
MACHINE
: 93.1 ± 93 Nm REAR SIDE
WARNING 3
Control valve assembly mass: 420 kg 3
1
3. Remove the control valve securing screws (2, 3)
and remove it with brackets (1, 7). 2
: 24 mm 7
: 384 Nm
R3630
W2-6-2 E485
CONTROL VALVE
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE
R3631
1 - Main Plunger 8- Main Relief Valve

2 - Center Bypass Valve 9- Priority Valve
3 - Holding Valve 10 - Check Valve [OPT SUM]
4 - Port Relief Valve 11 - Check Valve [BKT SUM]
5 - Cover Assembly [BM-1] 12 - Check Valve [BM BACK PRESSURE CHECK]
6 - Check Valve 13 - Port Relief Plug [OPT]
7 - Check Valve 14 - Plug
E485 W2-6-3
CONTROL VALVE
Preparation for disassembly
1. Since hydraulic components are finished to preci- 3. Attach a tag to each component so it is reassem-
sion with small clearance, it is necessary to disas- bled in a correct position.
semble and reassemble them in clean, less dusty
place. 4. Once disassembled, do not reuse O-Rings and
Use clean tools and cleaning oil and handle compo- backup rings. (Remove them with the tip of a steel
nents with sufficient care. wire shaped in a spatula. Take care so the groove
is not scored.)
2. If the control valve is removed from the machine,
clean ports thoroughly and put a plug in each port so 5. If parts are left, as they are halfway during disas-
as to prevent entry of dust and water. sembly or after disassembly, they may rust due to
When installing the control valve back to the ma- moisture and dust. When interrupting the work for
chine, do not remove plugs until the valve is unavoidable reason, use care so as to prevent parts
properly piped. from rusting or being exposed to dust.
3. Study the structural drawing before beginning work

and prepare necessary parts according to the pur- Replacing the main plungers
pose and the scope of the work. Some parts are not
available loosely but in assemblies. Therefore, Since the main plunger is selectively fitted to the
prepare parts beforehand according to the Parts housing, it is designated as 'not service part'. There-
Manual. fore, note that in principle the main plunger cannot be
replaced in the field. In case the plunger must be
replaced for some reason, inform us with the model
Cautions to be exercised in disassembly and the manufacturing number that are stamped on the
nameplate.
1. Since components are finished to high precision,
handle them with sufficient care. Use care so as not
to bump components against each other or drop
them.
2. Do not strike or twist components by force even if

they are tight, or the components develop burrs or
are broken. This makes the components impossi-
ble to be assembled and results in oil leakage and
deterioration in performances. Therefore, handle
components with full care.
W2-6-4 E485
CONTROL VALVE
Main Plunger
NOTE - Re-assembly in the reverse order to disas-

sembly. Attach an identification tag immediately after
disassembly. 3 2 1
1. Remove socket bolt (1) and cover (2) in that order.

: 10 mm
NOTE - Before reassembling the cover, make certain

that an O-Ring is placed on the mouth of the housing.
R3632
2. Draw out the plunger sub-assembly.
NOTE - Do not pull out the plunger all at once. Pull

slowly while confirming the fitness with the housing
hole.
R3633
3. Place the plunger between holders 380002085 and

loosen the plunger cap (3) by using a vise. 380002085
: 10 mm
NOTE - Put the plunger between the holders and clamp

them by a vise after degreasing the plunger and
holders as a special tool.
3
R3634
E485 W2-6-5
CONTROL VALVE
4. Remove the plunger cap (3), spring guide (4), spring

(5) and sleeve (6).
R3635
4
6
4
3 R3636
5. AM-1, AM-2, BM-1 plunger only.

Remove cap (7), spacer (8), spring (9), and check
(10).
a. Cap
BM-1
Width across flat: 10 mm
Tightening torque: 78.5 Nm
7
AM-2
AM-1
R3637
8
BM-1
9
10
AM-2 8
AM-1
9
10 R3638
W2-6-6 E485
CONTROL VALVE
Center Bypass Valve

sembly. Attach an identification tag immediately after 1 2 3
disassembly.
1. Remove cap (1) and pull out spool (3), and spring
(2).
a. Cap
R3639
3
R3640
E485 W2-6-7
CONTROL VALVE
Holding Valve
1 2
disassembly.
1. Loosen hexagon socket bolts (1) and remove cover

assembly (2).
a. Hexagon socket bolt
Z View
R3641
NOTE - When reassembly install cover (2) after
making sure that O-Ring is placed on the edge of the
cover hole.
R3642
2. Remove spring (3) and poppet (4).
R3643
W2-6-8 E485
CONTROL VALVE
3. Disassemble cover-assembly (2).
5 6 9 8 7
R3644
Remove cap (5) and the piston (6).

a. Cap
5
R3645
Remove cap (7) and then spring (8).

a. Cap
7
8
R3646
NOTE - Do not disassemble poppet. The poppet will be

unable to be taken out with sheet edge.
Poppet
Sleeve
R3647
E485 W2-6-9
CONTROL VALVE
Port Relief Valve
adjust screw
disassembly.
1. Loosen relief sleeve and remove relief valve.

a. Relief sleeve
1
5 4 3 2
sleeve
R3648
2. Loosen and remove relief sleeve (1) sub-assembly

and remove spring (2), (3), piston (4) and main
poppet (5).
a. Relief sleeve
Tightening torque: 98 Nm (by the sleeve)
NOTE - Do not disassemble adjusting screw. It's

impossible to re-adjust setting pressure exactly on the
machine.
4
5
R3649
W2-6-10 E485
CONTROL VALVE
Cover Assembly (BM-1) 1

2
disassembly.
1. Remove hexagon socket bolts (1) then remove

cover (2).
a. Hexagon socket bolts
NOTE - When reassembly install cover (2) after

3 R3650
making sure that O-Ring is placed on the edge of the
valve hole.
2. Remove plug (3).

a. Plug
R3651
E485 W2-6-11
CONTROL VALVE
Check Valves

1 1
disassembly.
2 2
4
1. Remove cap (1) and pull out spring (2), check (3)
and check (4). 3
3 [BM-1, -2. SW]
a. Cap [BKT. OPT. OTHER]
Tightening torque: 343 Nm [AM-2]
NOTE - When reassembly be careful for the back-up R3652

ring not to protrude.
4
(AM-2 only)
3
R3653
W2-6-12 E485
CONTROL VALVE
Main Relief Valve
DISASSEMBLY
4 3 2 1
1. Loosen nut (2) while holding adjusting screw (1).
a. Hexagon nut
b. Adjust screw
2. Loosen nut (3) while holding cap (4).

A 5
a. Hexagon nut
b. Cap R3654
3. Remove main relief valve from valve body.
4. Pull out main poppet sub-assembly (A) and remove

main poppet (7) spring (8) from sleeve (6).
a. Sleeve
6 7 8
A
R3655
8
7
R3656
E485 W2-6-13
CONTROL VALVE
5. Remove adjusting screw sub-assembly (B) then

remove spring (9) and pilot poppet (10).
NOTE - Do not disassembly pilot seat (C).

[Press fitting]
10 9 B
Pilot seat C 10
R3657
W2-6-14 E485
CONTROL VALVE
REASSEMBLY
1. Screw low pressure adjusting screw (1) until piston
(D) touches "Z" face, in this pisition, relief setting
Z face
pressure is high level.
Piston D
1
R3658
2. Install pilot poppet (10), spring (9) and adjusting

screw sub-assembly (B). Set adjunsting screw sub-
assembly (B) temporarily in the position that pilot
poppet (10) contacts to pilot seal (C). Then pressure Pilot poppet 10 9 Spring B
adjusting spring (9) begins to be effective.
Pilot seat C
R3659
3. Assembly main poppet sub-assembly (A), and

install the main relief valve which is set temporarily
in main body.
Tighten cap (4) with a torque wrench. 4
a. Cap A
R3660
E485 W2-6-15
CONTROL VALVE
RE-SETTING RELIEF PRESSURE

1. High pressure:
Set the prescribed pressure correctly adjusting 4 3 2 1
sleeve (5), while reading the pressure gauge.
Tighten lock nut (3) with torque wrench holding
sleeve (5).
a. Sleeve
b. Hexagon nut
Tightening torque: 98 Nm 5
NOTE - One quarter turn of sleeve (5) equals about R3661

4.5 MPa.
2. Low pressure:
Set the prescribed pressure correctly adjusting
screw (1), while reading the pressure gauge.
Tighten lock nut (2) with torque wrench holding
adjusting screw (1).
a. Adjust screw
b. Hexagon nut
NOTE - One quarter turn of adjusting screw (1) equals

about 4.5 MPa.
W2-6-16 E485
CONTROL VALVE
Priority Valve
1 2
disassembly.
1. Loosen hexagon socket bolts (1) and remove cover

assembly (2).
a. Hexagon socket bolt
3
NOTE - When reassembly install cover assembly (2)

4
after making sure that O-Ring and back-up ring is
placed on the edge of the valve hole.
6
R3662
2. Remove spring (3), spring guid (4), sleeve (5) and

poppet sub-assembly (6).
3
4
6
R3663
E485 W2-6-17
CONTROL VALVE
3. Place the poppet between holders 380002086 and

loosen the plunger cap (7) by using vise. 380002086
Remove cap (7), spring (8) and check (9).
a. Cap
6 Poppet
sub-assembly
NOTE - Put the poppet between the holders and clamp
them by a vise after degreasing the poppet and holders
as a special tool.
R3664
9
R3665
4. A cap (10) removed and a plate (11) is extracted by

10
the press.
Remove spring (12) and piston (13).
a. Cap
Width across flat: 5 mm 13
12
NOTE - It takes care that to not fly, when a plate (11)
with spring anti-power separates. 11
R3666
13
12
11 R3667
W2-6-18 E485
CONTROL VALVE
OPT Summation Check
NOTE - Re-assembly in the reverse order to disas- 1 2 3

disassembly.
1. Remove cap (1) and pull out spring (2), and check
(3).
a. Cap
R3668
2 R3669
E485 W2-6-19
CONTROL VALVE
Bucket Summation Check TAP: M6
NOTE - Re-assembly in the reverse order to disas- 5 4 3

disassembly.
2
1. Loosen hexagon socket bolts (1) and remove
flange (2).
a. Hexagon socket bolt 1
R3670
2. Remove sleeve (3) and pull out spring (4), and

check (5).
5
R3671
W2-6-20 E485
CONTROL VALVE
Boom Back Pressure Check

1 2 3
disassembly.
1. Remove cap (1) and pull out spring (2), and

poppet (3).
a. Cap
R3672
2
R3673
E485 W2-6-21
CONTROL VALVE
Port Relief Plug (OPT)

2
disassembly.
1
It is the relief valve attachment point at the time OPT
use.
R3674
1. Remove cap (1) and pull out plug (2).

a. Cap
2 R3675
2. The set-up relief valve (3) is attached.

a. Relief valve (relief seat)
R3676
W2-6-22 E485
CONTROL VALVE
SPECIAL TOOL
Holder
Division
R3677
Material: Brass
ØD L B H Remarks
380002085 36 90 50 25 Main plunger
380002086 25 30 35 20 Priority valve (Poppet assembly)

E485 W2-6-23
CONTROL VALVE
PART NAME INSPECTION ITEM CRITERION AND REMEDY
Casing 1. Look for scratches, rusting and 1. If any of the following parts are damaged,
corrosion. replace the casing:
· Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
· Part of sealing pocket through which
spool is inserted.
· Area of sealing part that is in contact
with O-Ring.
· Sealing and seating part of main or
overload relief valve.
· Defects of other parts that seem to
prevent normal function.
Spool 1. Look for scratches, galling, 1. If a defect detectable with your fingernail
rusting and corrosion. is found on the sliding part of the outer
circumference, replace the spool.
2. Inspect ends that are sealed 2. If the sliding part is damaged, replace
with an O-Ring. the spool.
3. Insert the spool in the casing 3. If the spool damages the O-Ring or does
bore, and move it while turning not move smoothly, repair or replace the
it. spool.
Poppet 1. Look for damage on the poppet 1. If sealing is incomplete, correct or

and the spring. replace the seal.
2. Insert the poppet in the casing, 2. If the poppet moves lightly without
and move it. catching, it is normal.
Spring and related 1. Look for rust, corrosion, 1. If damaged heavily, replace.
parts deformation, and breakage of
the spring, spring seat, plug
and cover.
Spool seal and related 1. Look for external oil leak. 1. Repair or replace.
parts 2. Look for rust, corrosion and 2. Repair or replace.
deformation of sealing plate.
Main relief valve 1. Look for rust and damage on 1. Replace.

Port relief valve outer surface.
2. Inspect the contact face of the 2. If damaged, replace.
valve seat.
3. Inspect the contact face of the 3. If damaged, replace.
poppet.
4. Look for spring abnormality. 4. Replace.
5. Inspect the O-Ring, backup 5. As a general rule, replace all parts with
ring, and seal. new ones.
Lock valve (selector 1. Spool, bushing and spring are 1. If damaged, replace.
portion) not damaged.
2. Spool seat shows even contact 2. If damaged, replace.
marks.
W2-6-24 E485
CONTROL VALVE
NOTES:
E485 W2-7-1
SWING DEVICE

SWING DEVICE
WARNING
Possible leakages of fluids under pressure could
penetrate the skin, causing serious injuries.
Prevent these dangers, discharging the pressure
before disconnecting hydraulic pipes or other
pipes.
Hydraulic oil, at the end of a work shift, can be very
hot and can cause, when spilling, potentially seri-
ous burns.
Prior to beginning any intervention, make sure that
the oil and components are cooled-off.
The hydraulic oil tank cap can be ejected, if the
pressure is not released from the tank. Press the
valve located on the hydraulic oil tank to release
any residual pressure present in the tank itself.
Preparation
1. Park the machine on a firm, level surface.
2. Cut-off the engine. Actuate the manual and pedal

pilot valves to release any residual pressure from
inside the hydraulic system. Press the valve locat-
ed on the hydraulic oil tank to release any residual
pressure present inside the tank itself.
3. Remove hydraulic oil tank cap. Connect a vacuum

lic oil tank.

while working.
W2-7-2 E485
SWING DEVICE
Removal
1. Remove hose (3) from the Tee in the makeup port 1 2

Mu.
: 36 mm
2. Remove the hoses (1 and 2) from the Tee in the

drain port DR.
: 27 mm
3
3. Remove the hose (7) from the elbow of the PG port.
: 19 mm
4. Remove the hoses (4 and 5) from the elbows of the

A, B port.
: 36 mm
5. Put in plugs into the opened ports on the swing 4

motor unit.
6. Remove the swing motor unit by loosing the screws 5

M20x65 (8) (Q.ty 16).
: 30 mm R0281
7. Remove the plastic cap (6) M12 at the top of the

swing motor and install the lifting eye bolt.
8. Sling and remove the swing unit.
WARNING
Swing unit mass: 297 kg
R2200
R2201
E485 W2-7-3
SWING DEVICE
Installation
1. Clean mating surfaces of swing motor unit and

upper frame. 8
Loctite
#515
2. Apply Loctite #515 on entire mounting surface of
swing motor unit.
3. Place the swing unit on the upper frame.
IMPORTANT – Use care so no dirt falls into the swing

grease bath.
WARNING
Swing unit mass: 297 kg
4. Remove the lifting eye bolts and inserts on the

holes, the plastic caps (6) M12, previsiously
removed.
5. Confirm the orientation and fix the swing unit to

the frame by tightening the screws M20x65 (8)
(Q.ty 16). R3680
: 30 mm
: 539 Nm
6. Before piping for draining, fill casing with hydraulic

oil from drain port of motor.
7. Install the hoses (4 and 5) on the elbows of port A

and B.
8. Install the hose (7) on the elbow of port PG.

: 19 mm
: 29.4 ± 2.9 Nm
9. Install the hoses (1 and 2) on the tee in the drain

port DR.
: 27 mm
: 78.5 ± 7 Nm
10. Install the hose (3) on the make up port Mu.

: 36 mm
: 175 ± 17.5 Nm
11. Before starting operation, check the gear oil level

of swing reduction unit.
Amount of charge: Approx. 15.3 L
IMPORTANT – At start the machine, run the motor

slowly at engine low idling for several minutes, check
oil leakage and abnormal sound from motor.
W2-7-4 E485
SWING DEVICE
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
17
41
42
SECTION A-A 15, 16
32 33
Relief valve on the
A Port port A side
b
g
Top dead point h Bottom dead point
i
B Port Relief valve on the

port B side
a Drain port
28 39 38 37 36 35
Makeup port
16 15
17 18
14 19
13 20
b
c 21
12
Mechanical brake
11 release port
10 d 22
9 e 23
8 f 24
7 25
6 26
3 2 1 27
R3037
E485 W2-7-5
SWING DEVICE
1- Innerring 21 - Balance plate

2- Oil seal 22 - Needle bearing
3- Tapered roller bearing 23 - Retaining ring
4- Retaining spring 24 - Cylinder
5- Cam plate 25 - Housing
6- Return plate 26 - Collar
7- Piston assy (Q.ty 9) 27 - Retaining ring
8- Separator plate (Q.ty 3) 28 - By-pass hyd. valve (Q.ty 2), 78 Nm
9- Friction plate (Q.ty 3) 32 - Cover
10 - O-Ring 33 - Relief valve (Q.ty 2), 78 Nm
11 - Brake piston 35 - Capscrew M16x60 (Q.ty 4), 284 Nm
12 - O-Ring (Q.ty 2) 36 - Check valve (Q.ty 2)
13 - Spring (Q.ty 19) 37 - Spring (Q.ty 2)
14 - Piston (Q.ty 2) 38 - Plug (Q.ty 2)
15 - Plug (Q.ty 3) 39 - Back-up ring (Q.ty 2)
16 - O-Ring (Q.ty 3) 40 - Plug
17 - Pin (Q.ty 3) 41 - Piston (Q.ty 2)
18 - Disc spring (Q.ty 4) 42 - Ring (Q.ty 2)
19 - Teflon ring (Q.ty 4)
20 - Bushing (Q.ty 4)
W2-7-6 E485
SWING DEVICE
Preliminary operations
1. Hydraulic components are precision products and

have small clearance. Therefore, assemble and
disassemble in a less dusty clean place. Use clean
tools and cleaning oil and handle components with
full care.
2. If a component is removed from the main body,

clean the area around the ports thoroughly and
plug them up so no dust and water do not enter.
When fitting them back to the body, do not remove
the plugs till piping is completed.
3. Study the structural drawing before the work be-

gins and prepare necessary parts according to
your purpose and the scope of work. Seals and
O-Rings once removed can not be used again.
4. The piston and the cylinder block are shop fitted

when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder block.
5. The separation of swing motor from reduction unit is

detailed in the "Disassembly and assembly of
swing reduction unit" paragraph.
Disassembly
32
NOTE - Choose a clean place, and lay with a rubber
sheet or a cloth on a work bench. Handle the valve
casing with care so parts do not have dents.
1. Fix the motor on a work bench so the drive shaft (1)

end comes down. On that occasion, put a match- 25
ing mark on the mating parts of casing (25) and
cover (32).
R3104
E485 W2-7-7
SWING DEVICE
2. Remove relief valve assembly (33), cap (38), spring

(37) and check (36) and bypass valve assembly 33 38
(28) from cover (32).
: 14 mm, 10 mm
37
36
32 28
R3105
3. Remove of cover assembly.

Loosen hexagon socket bolt (35) and place shaft of
motor assembly to downward and take cover (32) 35
out.
32
: 14 mm
25
R3106
4. Remove balance plate.

Remove retaining ring (23) with steel pointer and 23
remove inner race of needle-bearing (22) and bal-
ance plate (21) by bearing puller.
22
21
14
42
41
32
R3107
W2-7-8 E485
SWING DEVICE
Remove piston (14) and piston (41) and teflon ring

(42) from balance plate (21).
12
IMPORTANT - Work carefully to avoid damaging the
sliding face of balance plate.
Before removing, check and record location of balance
plate (21) to prevent misassembling.
32
R3108
5. Remove O-Ring (12) from cover (33).

20
6. Remove bushing (20) with teflon ring (19) and disc 19

spring (18).
18
32
R3109
7. Remove spring (13) from brake piston (11).

13
IMPORTANT - Check and record original position of

each spring (13) for correct assembling.
25
R3110
E485 W2-7-9
SWING DEVICE
8. Removal of brake piston. 12

When removing brake piston (11) from housing
(25), there is a sliding resistance against tighten-
11
ing of O-Rings (10) (12). Monkey wrench etc.
Use tap holes (M6) on brake piston (11) to take
them out as shown in the diagram.
Remove O-Rings (10) (12) from housing (25) and 10
piston (11).
Block
NOTE - Set a block outside diameter of housing (25). 25
R3111
9. Remove separation plate (8) and friction plate (9) 9

from housing (25).
25
R3112
10. Removal of cylinder assembly.

Holding end of cylinder assembly (24) with hand,
draw out cylinder assembly from housing (25).
24
IMPORTANT - Be careful to keep cylinder (24), as it
is slippery with oil.
Oil seal (2) and outer race of taper roller bearing (3) are
left inside of housing (25).
End surface A of cylinder (24) is sliding face. So,
protect the surface with a soft cloth against damage.
Make a matching mark on piston hole of cylinder (24)
and piston assembly (7) to fit piston into the same hole
when reassembling. 25
R3113
W2-7-10 E485
SWING DEVICE
11. Separate outer race of taper roller bearing (3) from

housing (25).
3
Remove oil seal (2) from housing (25) with driver
and hammer. 2
NOTE - Do not reuse oil seal (2) after removal.

25
R3114
12. Disassembly of the cylinder assembly.

a. Remove snap ring (27) with steel pointer and
remove inner ring (1) and inner race of taper
roller bearing (3). 27
Lift out cylinder (24) with 2 inner race of roller
bearing (3) by applying gear puller at the end of
spline in the cylinder. 1
3
Soft cloth etc.

24
R3115
b. Remove collar (26) from cylinder (24).

Separate cam plate (5), piston assembly (7), 26
return plate (6) from cylinder (24). 5
6
7
24
R3116
c. Get cam plate (5) slide on sliding face of piston

assembly (7) and remove it. 5
6
IMPORTANT - Work carefully to avoid damaging the
sliding face of the cam plate.
R3117
E485 W2-7-11
SWING DEVICE
d. Remove retaining spring (4) from cylinder (24).

4
This completes disassembly.
25
R3118
W2-7-12 E485
SWING DEVICE
Assembly
1. Preparation 7
Before reassembling, perform below procedure.
a. Check each part for damage caused by using or
disassembling. If damaged, remove scratches
by rubbing with "wet and dry" sandpaper of
appropriate coarseness. Clean each part with
clean washing oil and dry with an air jet.
Preparate replacement parts before hands.
R3119
b. Replace all seals.
21
c. Paper lap the sliding face of piston assembly (7),
balance plate (21), and cam plate (5) with sand-
paper #2000 on a true flat surface.
R3120
d. When assembling, lubricate the sliding parts with

specified clean hydraulic oil.
5
R3121
E485 W2-7-13
SWING DEVICE
2. Assembling of cylinder assembly.

4
a. Lubricate grease on round area (contacting area
with spring (4)) of cylinder (24) and assemble
spring (4).
Round area
24
R3122
b. Insert piston assembly (7) in hole of return plate

(6).
7
R3123
c. Assemble piston assembly (7) and return plate

(6) to cylinder (24). 6
7
NOTE - When assembling, check matching mark
between them. Before assembling.
Before assembling lubricate specified hydraulic oil
inside of each piston hole of cylinder (24).
24
R3124
d. Lubricate specified hydraulic oil on shoe sliding

face of piston assembly (7) and assemble cam 26
plate (5) and collar (26).
5
24
R3125
W2-7-14 E485
SWING DEVICE
e. Assemble inner race of taper roller bearing (3) to

cylinder (24). 380001872
IMPORTANT - End surface of cylinder (24) is sliding

face. So, protect the surface with a soft cloth against 3
damage. (Inner race)
24
R3126
f. Apply Loctite (515 or 518) to bearing mounting

area of inner race of cylinder (24) lightly. 380001872
Assemble inner ring (1) and retaining ring (27) to
cylinder (24).
1
IMPORTANT - Be careful not to attach a bond to the

27
roller of bearing (3).
Wipe off the bond which came out between a inner
ring (1) and bearing (3). Loctite
24
R3127
3. Assembly of oil seal.

Apply three bond (kk "1211") of white color on outer
surface of oil seal (2) and use the seal press
insertion jig (380001873) to press it into place.
380001873
IMPORTANT - Be cautions of assembling direction of
oil seal (2).
2
Taper roller bearing side

25
Output shaft side

R3301 R3128
E485 W2-7-15
SWING DEVICE
4. Assembly outer race of taper roller bearing.

Assemble outer race of taper roller bearing (3) into 3
the housing (25). (Outer race)
25
R3129
5. Assembly of cylinder assembly. The end of cylinder assy

Hold the end of cylinder assembly (24) with hands
and assemble cylinder assembly to housing (25).
24
IMPORTANT - Lubricate oil seal with grease.
Be careful to keep cylinder (24), as it is slippery with
oil.
Check that backing spring (4) is held in place by the
probe part of the return plate (6).
When assemble cylinder assembly, splined shaft of 380001874
the cylinder is protruded from the end of housing,
Top of housing
therefore put pad with length 30~40 mm under bottom
of housing.
Check that end surface of cylinder is about 15.5 mm
lower than top of housing.
25
30~40
(1.18~1.58 in)
Pad
R3130
6. Assembly separator plate and friction plate.

Assembly separator plate (8) and friction plate (9). 9
NOTE - Apply hydraulic oil to each side.
25
R3131
W2-7-16 E485
SWING DEVICE
7. Insert O-Rings.
Insert O-Rings (10) into housing (25). Insert O-Ring 12
(12) into piston (11).
NOTE - Lubricate O-Rings with grease. 11
10
25
R3132
8. Assembly of brake piston.

Lubricate specified hydraulic oil on outer sliding 380001875
face of piston (11) and assemble brake piston to
housing (25). 11
NOTE - It is too tight to assemble piston (11) because

O-Rings (10) (12) are fitted, therefore it is recom-
mended to push piston (11) horizontally by hands at
once.
25
R3133
9. Assembly of spring ((13), brake unit).

Assemble spring (13) to piston (11) of brake unit. 13
NOTE - Insert spring (13) into original position.
25
R3134
E485 W2-7-17
SWING DEVICE
10. Assembly of balance plate.

21
Assemble disc spring (18) and bushing (20) with
teflon ring (19) to bushing hole of cover (32).
Grease teflon ring (42) and piston (14) (41). 14
Assemble teflon ring (42) and piston (14) (41) to 42
balance plate (21).
Assemble balance plate (21) to cover (32). 41
20
IMPORTANT - Be cautions of assembling direction of 19
balance plate (21).
18
Port A, B side
V notch
32
R3135
Relief valve side R3254
11. Assembly of inner race of needle bearing.

Assemble inner race of needle bearing (22) and 23
retaining ring (23) to cover (32).
22
(Inner race)
32
R3136
12. Assembly O-Rings.

Assemble O-Ring (12) to cover (32). 12
NOTE - Lubricate O-Ring with grease.
32
R3137
W2-7-18 E485
SWING DEVICE
13. Assembly of cover.

Assemble cover (32) to housing (25) lightly, hold- 32
ing them up with hands.
IMPORTANT - Fit matching marks on housing (25)

and cover (32) made before disassembling.
At this stage, there is 4.5 mm distance between the
housing (25) and the cover (32).
25
R3138
14. Tighten cover (32) and housing (25) with hexago-

nal socket bolt (35).
35
: 14 mm,
32
IMPORTANT - The 4 bolts (35) should be tightened

equally, straight and slowly.
25
R3139
15. Assembly of valve assembly, check and bypass

valve assembly. 33 38
a. Assemble relief valve assembly (33) to cover

(32).
: 14 mm, 37
b. Assemble check valve (36), spring (37) and 36
plug (38) to cover (32).
: 14 mm,
c. Assemble bypass valve assembly (28) to cover
(32).
32 28
R3140
: 10 mm,
IMPORTANT - Assemble removed parts to original

state when reassembling.
E485 W2-7-19
SWING DEVICE
16. Check of assembly.

Load pilot pressure of 3.2~4.9 MPa to brake 32
release port after opening inlet and outlet port.
Check if output shaft is rotated smoothly around
torque of 30~40 Nm.
If not rotated, disassemble and check.
P port
NOTE - At this time, open the drain port. 25
IMPORTANT - Check the relief valves (33) setting to

the regulation pressure.
R3141
W2-7-20 E485
SWING DEVICE
DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
1 16 17 27 3 13 31 2 15 14 19 7 8 5 10 20 11
OIL FILLING PORT

PT 3/4
LEVEL PORT
PT 1/2
4 18
32 28 5 21 23 24 25 26
22 9 22 12 24
30 29
32
OIL FILLING PORT

PT 3/4
LEVEL PORT
PT 1/2
VIEW A
R3575
E485 W2-7-21
SWING DEVICE
1- Pinion shaft 17 - Oil seal

2- Housing 18 - Capscrew M10x30 (Q.ty 14)
3- Retainer 19 - Retaining ring
4- Sleeve 20 - Capscrew M14x150 (Q.ty 16)
5- Shaft (Q.ty 4) 21 - Spring pin (Q.ty 4)
6- Ring gear 22 - Thrust washer (Q.ty 8)
7- # 2 Spider 23 - Needle bearing (Q.ty 4)
8- # 2 Sun gear 24 - Trust washer (Q.ty 8)
9- # 2 Planetary pinion (Q.ty 4) 25 - Needle bearing (Q.ty 4)
10 - # 1 Spider assy 26 - Retaining ring (Q.ty 4)
11 - # 1 Sun gear 27 - Spacer
12 - # 1 Planetary pinion (Q.ty 4) 28 - Connector
13 - Bearing 29 - Hose
14 - Bearing 30 - Plug
15 - Spacer 31 - Plug
16 - O-Ring 32 - Set screw M20x30 (Q.ty 2)
W2-7-22 E485
SWING DEVICE
1. Before disassembly, clean thoroughly the swing

reduction unit outer, checking for no damage or
scratches.
20
2. Drain out the gear oil from reduction unit.
X
3. Remove the draining pipe.
4. In order to case the re-assembly, before disassem-

30
bly put a matching mark (X) on the parts to be
connected on the reduction casing.
190
Disassembly 350 R3142
1. Place the reduction unit assy on a stable work

bench as shown in figure, remove plug (30), drain 10
11
out oil put a matching mark on the matching surface
of the figure on the right side.
2. Loosen all socket bolt (20) (M14x150). Attach eye 6

bolts (M12×1.75) in the lifting bolt holes in the top
H
surface of the swing motor and lift the assy by
crane.
If it is hard to remove the swing motor assy from the
reduction unit, float it by inserting a flat-blade 2
screwdriver (H) in the groove of the flange.
R3143
: 12 mm
3. Remove #1 sun gear (11).
4. The spider assy (10) [consisting of thrust washer

(24), #1 pinion (12), needle bearing (23) and retain-
ing ring (26)] can be removed from the spline easily 6
if it is lifted up in that condition.
H
5. Attach eye bolts (M14) to the top surface of ring gear
(6) and lift the ring gear lightly by a wire sling. 2
Put a flat-blade screwdriver (H) into the matching
surface of ring gear (6) and housing (2) and remove
ring gear (6) by lightly tapping the outer circumfer-
R3144
ence of the ring gear with a plastic mallet.
7
8
6. Draw out #2 sun gear (8) and remove the #2 spider
assy (7).
R3145
E485 W2-7-23
SWING DEVICE
7. Turn over the housing so gear side of pinion shaft

faces up, as shown in figure on side.
1
250
380±10
R3146
8. Remove all socket bolts (18) (Q.ty 14).

: 6 mm
18 R3147
9. Remove retainer (3), with oil seal (17) and spacer

(27).
17
3
27
R3148
W2-7-24 E485
SWING DEVICE
10. Attach an M10 eye bolt to the end of the pinion and
lift it upright. M10
The pinion shaft assy (1, 4, 13, 14, 15) can be lifted 1
up easily.
4
16
13
15
14
19
R3149
11. Disassembly #1 spider assy in its components,

carring out the following operations: 10 12 26 25 24
a. Remove retaining ring (26) with a plier.

b. Remove thrust washer (24), #1 planetary pinion
(12) and needle bearing (25).
24
NOTE - The shaft attached to spider assy (10) is R3150
caulked. When replacing parts, replace the spider
assy as a whole.
The pinion can not be replaced as a piece. For
replacement, do it in a set of four.
12. Disassembling #2 spider assy:

5 22
a. Draw out spring pin (21).
b. Draw out shaft (5) from #2 spider assy (7) and
remove trust washer (22), #2 planetary pinion 23
assy (9), and needle bearing (23).
9
IMPORTANT - Pinion (9) can not be replaced as a

single part. Always replace four pinions as a set. 22
7 21
R3151
E485 W2-7-25
SWING DEVICE
13. Remove retaining ring (19), using pliers.
19
R3152
14. Erect three supporting metal bars (380001878) at

equal intervals in the grooves in the teeth of pinion
shaft (1), place sleeve (4) on them and draw down
the pinion shaft by press.
Pressing force: about 110-120 kN
WARNING 4
Bind the supporting metal bars (380001878) around 1
their outside with a steel wire when performing
press operation.
380001878
R3153
15. Draw out the pinion shaft (1) and remove O-Ring
(16) from sleeve (4).
3
16
14
4
15
13 1
17
R3154
W2-7-26 E485
SWING DEVICE
Assembly
1. Clean parts thoroughly in cleaning oil and dry them

with jet air.
2. Check that parts are not faulty.
3. Apply a thin film of grease over O-Ring (16) and the

O-Ring seat of pinion shaft (1).
4. Heat sleeve (4) to 100-120 °C, fit O-Ring (16) and fix 16
it into pinion shaft (1).
5. Coat the outer surface of the sleeve with a thin film 4

of grease.
1
6. Coat the outer circumference of pinion shaft (1)
with a thin film of gear oil to prevent seizure.
R3155
7. Heat bearings (13, 14) to 100-120 °C, fit the bearings

with spacer (5) into pinion shaft (1). Push them in,
using jig (380001876) and fix snap ring (14).
380001876
Pressing force: about 110-120 kN
19
14
15
13
R3156
E485 W2-7-27
SWING DEVICE
8. Assembly #1 Spider Assy carring out the following

operations: 10 12 26 25 24
a. Coat the bore surface of pinion (12) with grease.

Put pinion (12) on thrust washer (24) and assem-
ble needle bearing (25) into the bore surface.
b. Fit thrust washers (24) and pinion (12) and fit 24
retaining ring (26) by means of pliers (b). R3157
NOTE - Fix the retaining ring with the sharp edge on the
motor side (top side in the position as shown).
Motor Side
26 b
24
10
R3158
12
26
R3159
9. Assembling #2 spider assy: GEAR SIDE

a. Coat the bore surface of pinion (9) with grease. CAULK TWO
Put pinion (9) on thrust washer (22) and fit needle POINTS WITH
A PUNCH
bearing (23) to the bore surface.
b. Fit thrust washer (22) and pinion (9) as insert
shaft (5) into spider (7) and fix spring pin (21).
6~7 mm 6~7 mm
NOTE VIEW I
• Make sure that the oil hole ("A" in figure) in shaft (5)
faces the outside as shown in the figure. "A" 5 22
• Insert shaft (5) into spider (7) so spring pin hole (21)
is aligned.
23
22
7 21
R3160
W2-7-28 E485
SWING DEVICE
10. Place housing (2) on a workbench. Lift the pinion

assy and lower it slowly into the housing till it is set
in place.
1
NOTE - Take care on this step so that outer race of
bearing (13) is installed straight along the inner face of
housing (2). 13
IMPORTANT - Outer races of bearings (13, 14) can

normally be installed in the housing (2) easily as
enough clearance is provided between the two parts.
14
If they cannot be inserted easily, check to see whether
or not the outer race of bearings (13 and 14) are
2
positioned correctly and if there is any damage to
housing (2). Pressing them in with undue force may
damage these parts.
R3161
11. Apply grease on about one third (1/3) portion of

droove shape space on the lip section in contact
with the sleeve of the oil seal.
12. Fit the oil seal to retainer (3), making sure of its
direction and set it in place by using oil seal fitting
jig (380001877).
13. Apply sealing compound (Loctite #515) to the

retainer (3) with oil seal and the matching surface M10x30
of housing (2). Then fit it to sleeve (4).
18
2 3 R3162
IMPORTANT - Use care when assembling so as not

to score the oil seal by the gear teeth of pinion (1).
#2 Spider
14. Tighten socket bolt (18) (Q.ty 14).
: 6 mm
: 65 Nm
15. Place pinion shaft (1) on a stable workbench, with

its spline facing up.
R0423
16. Insert the #2 spider assy into the spline shaft of
pinion shaft (1).
8
17. Install #2 sun gear (8) with its spline facing up.
R3163
E485 W2-7-29
SWING DEVICE
18. Apply a thin film of sealing compound (Loctite

#515) to the matching surface of housing (2) and
ring gear (6) and assemble them, aligning the gear
teeth and according to the matching marks given. #2 SPIDER
ASSY
6
ALIGN
MATCHING
MARKS
R3164
19. Mesh the #1 spider assy with ring gear (6) and set
them in place. 12
#1 SPIDER ASSY
11
20. Mesh #1 sun gear (11) with #1 pinion (12) and set
them in place.
6
21. Fit drain pipe (28) and plug (30).
: 12 mm
22. Fill in 15.3 L of Extreme pressure gear oil in the
reduction casing. 2
R3165
23. Attach eye bolts (M12×1.75) in the tapped holes
of the swing motor and put a wire sling in them.
Coat the matching surface of ring gear (6) with
sealing compound (Loctite #515).
Insert the spline joint of the swing motor and match
the matching marks. 20
M14x150
Coat socket bolts (20) (Q.ty 16) with Three-Bond
1360K and fasten them.
: 12 mm
: 181 Nm MATCHING
MARKS 28
24. Fill in the swing motor with oil till the maximum
level. 30
190
350 R3166
W2-7-30 E485
SWING DEVICE
Swing motor maintenance
Check and Reference Value Measuring

Parts Name Correction
Measuring Point (Allowable limit) Instrument
Piston Assembly (7) Wear of shoe sliding Rmax 0.8 µm Surface Lap
surface gauge
Height od hollow of Min 0.4 mm Dial depth replace with new

shoe sliding surface gauge one
The amount of ball Max 0.4 mm Dial gauge replace with new
joint part movements one
of a piston and shoe
Piston diameter Hardly worn.

If damage or seizure is evident, replace with new one.
Cam plate (5) Surface Rmax 0.8 µm Surface Lap

gauge
Cylinder End surface Rmax 0.4 µm Surface Lap

Assembly (24) gauge
Piston hole Hardly worn.

If damage or seizure is evident, replace with new one.
Balance plate (21) Surface Rmax 0.8 µm Surface Lap

gauge
Parts Name Service standards
Tapered Roller A bearing in service for 3,000 hours should be replaced with new one even if it is good.
Bearing (3) Even a bearing in service for less than 3,000 hours should be replaced with a new one,
any minor defects in the rolling surfaces of the roller and needle are found at disassembly.
Needle bearing (22) Since a bearing may easily be damaged at disassembly, it is preferable to replace with a
new one at reassembly.
Oil Seal (2) If the lip is damaged, replace with a new one.
Even if there is no leakage and the lips are good, the oil seal should be replaced with a
new one every 3,000 hours.
Once removed, it should be replaced with a new one at reassembly.
O-Ring Damaged O-Ring should be replaced with new one.

(10) (12) (16) (31) (35) Even if there is no leakage and nothing wrong is evident, the O-Ring should be replaced
every 3,000 hours.
Once removed, it should be replaced with a new one at reassembly.
Backup Ring Once removed, it should be replaced with a new one at reassembly.
(30) (40)
E485 W2-7-31
SWING DEVICE
Swing reduction gear
INSPECTION AT DISASSEMBLY INSPECTION AFTER ASSEMBLY
1. Spacer and thrust washer 1. Function

Check to see that #1 sun gear (31) is not faulty when
a. Inspect that the parts are not seized or worn
turned by hand.
abnormally or unevenly.
b. Inspect and measure the parts to see that the 2. Checking for oil leakage and oil quality
wear does not exceed the allowable values. Check for oil leakage.
Check the oil level by level gauge and confirm that
2. Gears the oil is not dirty. If the oil is short, replenish engine
a. Inspect that the gear teeth do not show pitching oil SAE90 (API Service Grade GL-4).
and seizure.
b. Inspect by dye penetrant examination that the
bottom of the teeth does not show cracks.
3. Bearing
Turn the bearing and check that it does not generate
abnormal sound, catching and other faults.
4. O-Rings and oil seals

Do not reuse O-Rings and oil seals; always replace
them with new ones at reassembly.
W2-7-32 E485
SWING DEVICE
Swing reduction maintenance
A
(H)
D
APPLY LOCTITE Note
#515 Apply Three Bond #1360K
I (or equivalent) to each bolt
LUBE OIL
LEVEL C
APPLY LOCTITE #515
D
F
APPLY LOCTITE #515
APPLY LOCTITE
#515
G
R3168
Code Item Standard Value (mm) Serviceability Limit (mm) Remedy
Replace
A Wear in #1 planetary 0
Ø40-0.011 entire
shaft spider assy
No flaking
Replace four
0
B Wear in #2 planetary shaft Ø40-0.011 shafts as a
set
Replace
Condition of There should be no pitching exceeding 1.6 mm dia,
(Planetary
tooth flank abnormal wear or seizure
pinion
C Gears should be
Condition of replaced in a
There should be no cracks
tooth flank set of four)
±0.1
D Thickness of thrust washer 1.6 1.5 Replace
Wear in sleeve (Diameter of

E part coming in contact with 0
Ø200 -0.029 Ø199.5 Replace
oil seal)
Sleeve (the diameter of the

F Parts are not worn or scratch Replace
part in contact with oil seal)
Apply Three-Bond 1360K and
G Capscrew tightening torque M10 65.7 Nm
tighten to specified torque
Apply Three-Bond 1360K and
H Capscrew tightening torque M14 181 Nm
tighten to specified torque
Lube Extreme pressure engine oil

I 15.3 L (4.0 gal) Replenish or replace
SAE90 (API Service Grade GL-4)
E485 W2-7-33
SWING DEVICE
SPECIAL TOOLS
a) Special tools for swing motor assembly
Jig 380001872 Jig 380001874

(For assembling roller bearing (3) and inner race (1)) (For assembling cylinder assembly (24))
Jig 380001873
(For assembling oil seal (2))
Jig 380001875
(For assembling brake piston (11))
R3169 R3170
W2-7-34 E485
SWING DEVICE
b) Special tools for swing reduction unit
Tool Name Remarks
Material: SS41
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
75
65
1234567890123456789012345678901212345
Jig 380001876 1234567890123456789012345678901212345
1234567890123456789012345678901212345
(for press fitting bearing) 1234567890123456789012345678901212345
1234567890123456789012345678901212345
1234567890123456789012345678901212345
100±0.5
180±0.5
R3171
Material: SS41
201
12345678901234567890123456789012123456
12345678901234567890123456789012123456
12345678901234567890123456789012123456
Oil seal fitting jig 380001877 12345678901234567890123456789012123456
15
0
235 -0.5
R3172
3 pcs.
20
Metal bar 380001878
155
R3173
E485 W2-8-1
PILOT VALVE
REMOVAL AND INSTALLATION OF RIGHT AND LEFT PILOT VALVE
WARNING
Preparation 2. Cut-off the engine. Actuate the manual and pedal

1. Park the machine on a firm, level surface. inside the hydraulic system. Press the valve lo-
cated on the hydraulic oil tank to release any
Removal
5 1
1. Free and lift rubber cap (5) complete with plate (4) 6
unlocking its hooks using a screwdriver. 7
3
8
2. Remove side panels (2 and 3) removing securing 4

screws (1). 9
2
14 10
13 11
3. Remove the handgrip removing lock-nut (6) dis- 12
connecting the relevant electric connection.
: 22 mm
1
1
R.H. R0116
IMPORTANT - Attach an identification tag on each

hose to aid in reassembly.
6 1
5 7
4
8
4. Disconnect pipes (from 9 through 14) of body (8). 3
: 19, 22 mm
9
2 10
14
13 11
NOTE - Attach a cap on each of disconnectd hose 12
ends.
5. Remove body (8) removing securing screws (7)

1
complete with washers.
1
: 10 mm
L.H. R0117
W2-8-2 E485
PILOT VALVE
Installation
5 1
1. Install body (8) on the frame tightening securing 6
screws (7) complete with washers. 7
: 10 mm 3
8
: 11 Nm
4
2. Connect pipes (from 9 through 14) to body (8). 9
2
: 19 mm 14 10
: 29.4 Nm 13 11
: 22 mm 12
: 39.2 Nm
3. Tighten the handgrip on the pilot valve, tighten lock- 1

nut (6) and reconnect the electric connector. 1
: 22 mm R.H. R0116
4. Install side panels (2 and 3) tightening securing

screws (1).
6 1
5 7
5. Arrange rubber cap (5) complete with plate (4) 4
locking the hooks on side panels (2 and 3). 8
3
9
2 10
14
13 11
12
1
1
L.H. R0117
E485 W2-8-3
PILOT VALVE
REMOVAL AND INSTALLATION OF TRAVEL PILOT VALVE
WARNING
Preparation 2. Cut-off the engine. Actuate the manual and pedal

1. Park the machine on a firm, level surface. inside the hydraulic system. Press the valve lo-
Removal
1. Remove the floor mats in the cab.
2. Remove the pedal removing securing screws (1)

(Q.ty 4) then remove the levers, removing securing
screws (2) (Q.ty 4).
: 13, 17 mm
3. Disconnect electric joints (7) from body (8).
IMPORTANT - Attach an identification tag on each

hose to aid in reassembly. 1
2
4. Disconnect pipes (from 9 through 14) of body (8).

9
: 19, 22 mm
8 3
NOTE - Attach a cap on each of disconnected hose
ends. 4
7
5. Remove body (8) removing securing screws (7) 6 5

complete with washers. R0118
: 17 mm
W2-8-4 E485
PILOT VALVE
Installation
1. Install body (8) on the frame tightening securing

screws (9) complete with washers.
: 17 mm
: 64 Nm
2. Connect pipes (from 3 through 6) to body (8).

: 19 mm
: 29.4 Nm
: 22 mm
: 39.2 Nm
1
2
3. Connect joints (7) to body (8).
9
4. Install the levers tightening securing screws (2)
and the pedals tightening securing screws (1).
: 17 mm 3
: 34.8 ± 3.4 Nm 8
: 13 mm
7 4
: 29.5 Nm
6 5
R0118
E485 W2-8-5
PILOT VALVE
NOTES:
W2-8-6 E485
PILOT VALVE
DISASSEMBLY RIGHT AND LEFT PILOT VALVE
15
1 16
17
18
19
2
19
20
3 21
4
22
6 7 23
24
7
8
25
8
9
9
10 26
10 11
13
12 27
14 27
28
28
R0119
1 - Adjusting nut; M14 11 - Spring seat 2 (Q.ty 2) 21 - Spool (Q.ty 2)

2 - Boots 12 - Spring seat 1 (Q.ty 2) 22 - Casing
3 - Circular plate 13 - Spring seat 2 (Q.ty 2) 23 - O-Ring
4 - Joint; M14 14 - Spring seat 1 (Q.ty 2) 24 - Bushing
5 - Plate 15 - Spring (Q.ty 2) 25 - Spring pin
6 - Seal (Q.ty 4) 16 - Spring (Q.ty 2) 26 - Port plate
7 - Plug (Q.ty 4) 17 - Spring (Q.ty 2) 27 - Seal washer (Q.ty 2)
8 - O-Ring (Q.ty 4) 18 - Spring (Q.ty 2) 28 - Socket bolt; M8x35 (Q.ty 2)
9 - Push rod (Q.ty 4) 19 - Washer 2 (shim) (Q.ty 4)
10 - Spring (Q.ty 4) 20 - Spool (Q.ty 2)
E485 W2-8-7
PILOT VALVE
Disassembly right and left pilot valve
Be sure to thoroughly read "Precautions for Disas-

sembly and Assembly" on page W1-1-1 before start-
ing the disassembly work.
NOTE - Replace O-Ring every disassembly opera-

tions, as a rule.
1. Plug each port of pilot valve, and clean it.
2. Fix pilot valve with vise, and remove boots (2).
3. Remove adjusting nut (1) applying spanners to

circular plate (3).
: 22 mm, 32 mm
1
4. Remove circular plate (3).

: 32 mm 3
R0120
5. Turn joint (4) in counterclockwise with (380001055)

380001055
to remove.
: 24mm
4
WARNING
When the force of return springs (15 and 16) is high,
never loosen joint (4). If loosened, it might result in
jumping out of plate (5) plug (7) and push rod (9).
Remove joint (4) pressing plate (5) downward with
two fingers.
R0121
W2-8-8 E485
PILOT VALVE
6. Remove plate (5). 5
NOTE - When the force of return spring (15 and 16) is

high, press plate to let it come up slowly.
When the force of return springs (15 and 16) is low,
plug is left in casing (22) due to sliding resistance of
O-Ring (8).
R0122
22
R0123
7. Pull plug (7) out with a driver.
7 R0124
8. Remove push rod (9), plug (7), pressure reducing

valve assy (spool) and the return springs (15 and
16) from casing (22). 9
7
NOTE - Record combination of port holes on casing
and the pulled out parts. The stroke differs according
to direction. 15-16
22
R0125
E485 W2-8-9
PILOT VALVE
9. Turn upside down the assembly in order to posi-

tion upward the port plate (26), then fix it in a vise.
10. Remove the socket bolt (28).

: 6 mm 26
28
R0126
11. Remove port plate (26), O-Ring (23) from casing

(22). 25
26
12. Remove bushing (24) from casing (22).
24
23
22
R0127
13. Press springs (17 e 18) so that the movement of

the spring seats (12 and 14) is 7 mm (max), then
remove spools (20 and 21) through the larger hole
of the seat. 12-14
IMPORTANT - Under no circumstances press spring

seat (12) 7 mm or more, through passages 1 and 3. 20-21
Under no circumstances press spring seat (14)
9,4 mm or more, through passages 2 and 4. R0128
14. Remove spool (20 and 21), spring seats (12 and
12-14
14), springs (17 and 18) and washer (19).
10
11-13 17-18
R0129
W2-8-10 E485
PILOT VALVE
15. Remove spring (10), spring seat (11 and 13) from
push rod (9). 11-13 8
16. Pull out push rod (9) from plug (7).

10
17. Remove O-Ring (8) from plug (7).
7 9
R0130
18. Remove inside seal (6) from plug (7) with small
driver.
6 R0261
Cleaning parts
1. Clean parts with wash oil roughly and the parts of

pilot valve completely.
2. Dry parts by swabbing clean waste cloth.
3. Apply rust preventives on parts.

E485 W2-8-11
PILOT VALVE
NOTES:
W2-8-12 E485
PILOT VALVE
ASSEMBLY RIGHT AND LEFT PILOT VALVE
1
2
3
6 4
5 9
10
13
7
8
11
14 12
17
18
21 20
16 15
24
19 23
22
27
25
PORTS 2, 4 PORTS 1, 3 28
26
R0262
1 - Adjusting nut; M14 69 Nm 11 - Spring seat 2 (Q.ty 2) 21 - Spool (Q.ty 2)

2 - Boots 12 - Spring seat 1 (Q.ty 2) 22 - Casing
3 - Circular plate 13 - Spring seat 2 (Q.ty 2) 23 - O-Ring
4 - Joint; M14 47 Nm 14 - Spring seat 1 (Q.ty 2) 24 - Bushing
5 - Plate 15 - Spring (Q.ty 2) 25 - Spring pin
6 - Seal (Q.ty 4) 16 - Spring (Q.ty 2) 26 - Port plate
7 - Plug (Q.ty 4) 17 - Spring (Q.ty 2) 27 - Seal washer (Q.ty 2)
8 - O-Ring (Q.ty 4) 18 - Spring (Q.ty 2) 28 - Socket bolt; M8x35 (Q.ty 2) 21 Nm
9 - Push rod (Q.ty 4) 19 - Washer 2 (shim) (Q.ty 4)
10 - Spring (Q.ty 4) 20 - Spool (Q.ty 2)
E485 W2-8-13
PILOT VALVE
Assembly right and left pilot valve
1. Fit bushing (24) and O-Ring (23) to casing (22).
NOTE - Meet the position of spring pin (25).
2. Install port plate (26) on casing with socket bolt (28)

and seal washer (27). 26
28
: 6 mm
: 20.6 ± 1.5 Nm
27
NOTE - Replace seal washer (27) with new one.

R0263
3. Fit washer 2 (19), springs (17 and 18), spring seats

20-21
(12 and 14) to spool (20 and 21).
17-18 12-14
4. Push spring seat 1 (12) in the range of that the
movement is 7 mm or less, and install spool (20)
through the large hole of spring seat 1.
For spring seat 1 (14), push spring seat (14) in 9.4
mm or less and install spool (21)
19
R0264
5. Place spring (15) into ports 1,3 of casing (22), and

then install pressure reducing valve assy (29) in it.
Place spring (16) into ports 2,4 and install it. 29
NOTE - Install the removed respective assy into 15

respective holes.
22
R0265
W2-8-14 E485
PILOT VALVE
6. Fit O-Ring (8) and seal (6) into plug (7).

Apply hydraulic oil on surface of push rod. 8 7 6
7
6
9
HYDRAULIC OIL
R0266 R0267
7. Insert push rod (9) in plug (7) and install spring

seat 2 (11) to push rod (9) on port 1,3 side.
And install spring seat 2 (13) to push rod on port
2,4 side.
9 7 10 11
R0268
8. Fit plug (7) assy to casing (22).
9. When the force of spring (15 and 16) is low, it

stops at the position where it is pushed in by the
sliding resistance of O-Ring (8).
22 7 R0269
10. When the force of spring (15 and 16) is high,

attach plate (5) and press 4 push rods by hand at
the same time, and tighten joint (4) temporarily.
4
R0270
E485 W2-8-15
PILOT VALVE
11. Install joint (4) on casing (22) with special tool

(380001055) securely.
: 22 mm
: 47.1 ± 2.9 Nm
22 380001055
R0271
12. Install circular plate (3) to joint (4).
IMPORTANT - Screw it in until it comes in contact with

4 push rods (9) equally.
The exceeding of screw in may cause malfunction of
machine. 1
13. Screw adjusting nut (1), applying Loctite #277 to 3

the thread of joint, until it touches circular plate (3),
and tighten it applying spanner to stop circular
plate returning.
: 22 mm
R0272
: 68.6 ± 4.9 Nm
: 32 mm
14. Apply heat-resisting grease to joint (4) rotating

section and the top of push rod (9).
GREASE
15. Cover it with boots (2).
16. Spray rust preventives through each port and

attach plug respectively.
9
R0273
W2-8-16 E485
PILOT VALVE
DISASSEMBLY TRAVEL PILOT VALVE
▲ Z 33 2 36 33
13 12 28
36 B 14 42
19
37 25
26
1,3 30
20
34 25
15
22 21 42
20 20
39
32 17
33 36 33
44, 16 40
6 7 SECTION A-A
18 8
24 25, 42
A A
41
27
B
4 10, 11 35
9 31 5 29
4
38
24, 41
SECTION B-B
VIEW Z
R0274
1 - Orifice 24 - Plug; PF1/8 9.8 Nm

2 - Seat 15 Nm 25 - Plug; PF1/4 25 Nm
3 - Orifice 26 - Socket bolt; M10x60 59 Nm
4 - Spool 27 - Flange bolt 5 Nm
5 - Body 28 - Set screw; M8 15 Nm
6 - Stopper 29 - Washer
7 - Spring 30 - Washer
8 - Spring 31 - Rivet
9 - Name plate 32 - Pin
10 - Shim (0.2 mm) 33 - Ball
11 - Shim (0.1 mm) 34 - Ball
12 - Cam 35 - Ball
13 - Boots 36 - Ball
14 - Pin 37 - U packing
15 - Cover 38 - O-Ring
16 - Piston 39 - O-Ring
17 - Guide 40 - O-Ring
18 - Sleeve 41 - O-Ring
19 - Holder 42 - O-Ring
20 - Ring 44 - Piston assy
21 - Orifice
22 - Spring
E485 W2-8-17
PILOT VALVE
Disassembly travel pilot valve 9. Disassembling the damper.

a. Draw out piston assy (44) and guide (17) from
Be sure to thoroughly read "Precautions for Disassem-
cover (15).
bly and Assembly" on page W1-1-1 before starting the
disassembly work.
It is usual that disassembly and assembly are execut- NOTE - The damper is drawn out easily if it is pushed
ed at the maker's factory, but in unusual cases, do the from the ball (36) side.
work at a service shop where skilled technicians are
available.
b. Draw out four balls (36), holders (19) and orifices
Hydraulic parts are precision products of small clear-
(1), (3) from piston assy (44).
ance. Therefore, disassembly and assembly work
shall be performed in a clean place where there is little
dust in the following manner: NOTE - On that occasion, align the hole in the cover,
the piston assy and the guide as a set as each part is
- Never knock on precision parts in case they do not
shop fitted. Therefore, if parts for different locations
operate smoothly.
are assembled, functional faults may occur in some
- Replace seal parts such as O-Rings and U packings cases.
with new ones. Ring (20), orifice (21), spring (22) and ball (34) can not
be separated from the piston assy as they are assem-
1. Put a plug into each port (P,T,1,2,3,4,5,6) of the bled with ring (20) press fitted.
valve and clean the outside.
c. Separate four O-Rings (39) (Q.ty 4) from guide
2. Fix the valve after cleaning it in a vise.
(17).
3. Remove two boots (13). d. Remove four U packings (37) (Q.ty 4) from cover
(15), using a scriber.
4. Loosen 2×2 places of socket head set screws (28)
(Q.ty 4) and remove them from cam (12).
37
: 4 mm
15
5. Draw out two pins (14) from cover (15). On that

occasion, the pins may be drawn out with ease if the
pins are pushed out of the inside by the use of an
allen wrench.
: 4 mm 36
19
6. Remove two cams (12). 1, 3
7. Loosen socket bolts (26) and remove two of them 44, 16

with washers (30). 20
21
: 8 mm 34
22
8. Remove two dampers from the reducing valve.
20 20
39
17
R0275
W2-8-18 E485
PILOT VALVE
10. Disassembling the reducing valve section.

6
Reducing valve assy

a. Separate three socket plugs (24) from body
(5).
: 5 mm
b. Separate O-Ring (41) from socket plug (24).
c. Remove four reducing valve spool assemblies
from body (5).
7
d. Remove stopper (6) from the reducing valve
40
spool assy.
e. Remove four springs (7), parallel pins (32), 32
O-Rings (38), (40) from body (5).
38
24
5
41
R0276
11. Disassembling the reducing valve spool assy.

a. Fix spool (4) in a vise (Put a copper plate
27
against the mouthpiece) and loosen four socket
flange bolts (27). 18
: 3 mm
b. Draw out socket flange bolt (27), sleeve (18), 8
spring (8), shims (10), (11) and washer (29) 10, 11, 29
from spool (4), in that order.
NOTE - On that occasion, mate the disassembled

parts with mating parts as sets. 4
R0277
12. Disassembling the shuttle.
IMPORTANT - The shuttle is inseparable basically as

seat (2) is fixed with adhesive agent (Loctite #262). 33 33
36 36
a. Remove two socket plugs (25) from body (5). 2 2
: 6 mm
33 33
b. Remove two seats (2) from body (5).
: 5 mm
NOTE - On that occasion, the Loctite comes off.

Remove it including that adhered to the neighbouring 42 42
area of the screw. 25 25 R0278
c. Draw out two balls (36) from body (5) by

attracting the balls to a magnet.
NOTE - Balls (33), (35) are for circuit plugs and press
fitted to body (5). Therefore, they are not separable.
E485 W2-8-19
PILOT VALVE
ASSEMBLY TRAVEL PILOT VALVE
Assembly Travel Pilot Valve
IMPORTANT - Clean and degrease parts before

assembly. In particular, clean the body with a nylon
brush. Foreign matter intruded into the valve causes 33 33
functional faults to occur.
36 36
Before assembling prepare new seals (O-Rings and
U packings) and coat the surface with hydraulic oil or 2 2
a thin film of grease.
33 33
1. Assembling the shuttle.
a. Put two balls (36) into body (5).
b. Coat the screwed part of seat (2) with
Loctite#262 and fit two of them to body (5). 42 42
25 25
: 5 mm R0278
: 14.7 ± 0.98 Nm
c. Set O-Rings (42) to socket plugs (25) and fasten
two plugs to body (5).
: 6 mm 27
: 24.5 ± 1.9 Nm
18
2. Assembling the reducing valve spool assy.
a. Fix spool (4) in a vice. (Put copper plates against 8
the mouth.) Set washer (29), shims (10), (11),
spring (8) and sleeve (18), in that order, and 10, 11, 29
tighten them with four socket flange bolts (27).
: 3 mm
: 4.9 ± 0.98 Nm 4
R0277
IMPORTANT - On that occasion, pair parts with the

disassembled parts as sets, before performing as-
sembly work. Incorrect pairing may change the sec-
ondary pressure.
Reducing valve assy
6
3. Assembling the reducing valve.
a. Fit four O-Rings (38), (40), parallel pins (32) and
springs (7) to body (5).
b. Fit four reducing valve spool assemblies and
stoppers (6).
7
IMPORTANT - On that occasion, use care as stopper 40
(6) has a direction in which it should be installed. Place
it so the concave surface of it faces down (reducing 32
valve spool side).
38
24
c. Set O-Rings (41) to socket plugs (24). Fasten
three plugs to body (5).
5
41
: 5 mm
: 9.8 ± 0.98 Nm
R0276
W2-8-20 E485
PILOT VALVE
4. Assembling the damper.

37
a. Fit four U packings (37) to cover (15).
15
NOTE - On that occasion, place the cover so the lip of

the U packing faces down (damper chamber side).
b. Insert four piston assemblies (44) into cover (15).

36
NOTE - In that case, make sure that each piston is set 19
in the same hole where it was before disassembly. 1, 3
The performances of the piston are not affected at all
44, 16
if it is placed in any direction on the circumference.
20
21
c. Fit O-Ring (39) to guide (17). Install four guides 34
to cover (15). 22
20 20
NOTE - Fix the guide in the same hole where it was set 39
before disassembly. 17
R0275
d. Set orifices (1), (3) to piston assy (44) that is set

in the cover.
NOTE - The orifices absorbs rattles that are made

when cam (12) is in neutral: either orifice may be at the
top or at the bottom.
In case the cam rattles very much because the cam
and the pin are worn out after long hours of use, 13
increase the number of orifices.
However, if many orifices are set when there is no gap,
the reducing valve spool is actuated at neutral and
pressure is built up in the secondary pressure port. 28
When there is no gap on the cam at neutral, do not
increase the orifices. 12
26
30
e. Set four holders (19) and balls (36) to piston
assembly (44).
f. Install two dampers on the reducing valve and
14
fasten them with socket bolts (26) with washers
(30).
In that case, parallel pin (32) set in body (5) is
placed in the hole of cover (15) to position the
Damper
reducing valve and the damper in place.

: 8 mm
Reducing valve
: 58.8 ± 4.9 Nm
R0279
E485 W2-8-21
PILOT VALVE
g. Set cam (12) to cover (15) and insert pin (14). On

that occasion, check the gap of the cam and if
the gap is large, increase orifices (1), (3) accord-
ing to step 4.d above.
NOTE - Ball (36) and holder (19) can be drawn out

easily by magnet bar. If a magnet bar is not available,
place the valve on its side and give vibration to it.
h. When the gap adjustment of the cam has been

finished, apply grease to the moving parts of
cam (12), pin (14), cover (15) and ball (36).
i. Attach 2×2 pcs. set screws to cam (12) and
tighten them.
: 4 mm
: 14.7 ± 0.98 Nm
l. Fit two boots (13).

W2-8-22 E485
PILOT VALVE
Right and left pilot valve
Check items Standard Remarks
Push rod When the wear of top is 1 mm or-

more, replace it with new one.
Looseness of control section When looseness of 2 mm or more on In case of the looseness due to
circular plate (3) on control section and the loosening on tightening sec-
joint section (4) due to wear is pro- tion, adjust it.
duced, replace them with new ones.
Stability of operation When trouble such as noise, hunt-

ing, drop of primary pressure, etc.
has occurred in operation, and it
does not restore after taking correc-
tive action according to below Trou-
bleshooting, replace pilot valve assy
with new one.
E485 W2-9-1
SOLENOID VALVE UNIT
REMOVAL AND INSTALLATION OF SOLENOID VALVE UNIT
WARNING
Preparation
2. Cut-off the engine. Actuate the manual and pedal pump to maintain negative pressure in the hydrau-
pilot valves to release any residual pressure from lic oil tank.
inside the hydraulic system. Press the valve lo-
while working.
Removal
13 14 15 16 17 18 19
12
1. Remove all wiring harnesses from solenoid valves
connectors.
11
1
2. Disconnect pilot lines (1 to 10).
: 19, 22 mm
3. Remove bolts (11) to remove solenoid valve unit.

: 17 mm 2 3 5 6 7 8 9 10
R3849
1- Hose (delivery from pilot system filter)

2- Hose (to swing motor)
Installation 3- Hose (to centre joint)
5- Hose (by-pass cut-off valve P1 piloting)
6- Hose (travel straight valve piloting)
1. Install solenoid valve unit with bolts (11). 7- Hose (by-pass cut-off valve P2 piloting)
2. Connect pilot lines (1 to 10). 8- Hose (main pressure relief valve piloting)
3. Connect all wiring harnesses for solenoid valves to 9- Hose (to pilot system valves)
connectors. 10 - Hose (to hydraulic oil tank)
11 - Securing screws
12 - Swing parking brake solenoid valve
13 - ransmission 1st and 2nd speed solenoid valve
14 - Proportional solenoid valve (not used)
Wrench Size Tightening Torque Remark 15 - By-pass cut proportional solenoid valve P1
16 - Travel straight proportional solenoid valve
(mm) (Nm)
17 - By-pass cut proportional solenoid valve P2
18 - POWER BOOST solenoid valve
: 17 64 Bolt 19 - Pilot system cut-off solenoid valve
: 19 29.4 Hose
: 22 39.2 Hose
W2-9-2 E485
SOLENOID VALVE UNIT
DISASSEMBLY AND ASSEMBLY

OF SOLENOID VALVE
Disassembly Assembly
1. Remove solenoid valve (2) from main body (1) 1. Install O-Rings (from 3 to 6) on solenoid valve (2).
removing securing screws (7).
2. Install solenoid valve (2) on main body (1) tighten-
: 4 mm ing securing screws (7).
2. Remove from solenoid valve (2) the relevant : 4 mm

O-Rings (from 3 to 6).
: 7 Nm
SECTION A-A
2
3
1
4
A A
A8 A7 A6 A5 A4 A3 A2 A1
R0109
1- Central body 5 - O-Ring

2- Solenoid valve 6 - O-Ring
3- O-Ring 7 - Securing screws
4- O-Ring
SECTION 3 E485
UNDERCARRIAGE
CONTENTS
Group 1 - Swing Bearing Group 5 - Front Idler

Removal and Installation of Front Idler Disassembly ....................... W3-5-1
Swing Bearing ...................................... W3-1-1 Front Idler Assembly ............................ W3-5-4
Maintenance Standard ......................... W3-5-6
Group 2 - Travel Device

Removal and Installation of Group 6 - Upper and Lower Roller
Travel Device ....................................... W3-2-1
Upper Roller ......................................... W3-6-1
of Travel Device ................................... W3-2-4
Special Tools ...................................... W3-2-22
Lower Roller ......................................... W3-6-4
Upper Roller Disassembly .................... W3-6-7
Upper Roller Assembly ...................... W3-6-10
Group 3 - Swivel Joint
Lower Roller Disassembly .................. W3-6-13
Removal and Installation Lower Roller Assembly ...................... W3-6-15
of Swivel Joint ..................................... W3-3-1 Maintenance Standard ....................... W3-6-17
Swivel Joint
Disassembly and Assembly ................. W3-3-4
Maintenance Standard ......................... W3-3-9 Group 7 - Tracks
Removal and Installation of Tracks ....... W3-7-1
Group 4 - Track Adjuster Maintenance Standard ......................... W3-7-5

Track Adjuster (with Front Idler) ............ W3-4-1
Track Adjuster Disassembly ................. W3-4-2
Track Adjuster Assembly ..................... W3-4-6
Special Tools ........................................ W3-4-9
E485 W3-1-1
SWING BEARING

SWING BEARING
Before removing the swing bearing, the upperstructure

must be removed first. For removal and installation of
the upperstructure, refer to “Remove and Install Main
Frame” section. In this section, the procedure starts
on the premise that the upperstructure has already
been removed.
Removal
Mark
1. Put alignment marks on swing bearing (1) and track
frame (2).
1 2
SM1307
2. Remove screws (3) (Q.ty 36) and the relevant

washers (Q.ty 36).
: 41 mm
3. Remove grease in grease bath (4).
3 4 R0062
WARNING
Swing bearing mass: 710 kg
4. Attach lifting tools (380001026), hoist swing bearing

(5) and remove it.
5 SM1309
W3-1-2 E485
SWING BEARING
Installation
1. Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and stain.
WARNING
Swing bearing mass: 710 kg
2. Installing
Install swing bearing on lower frame meeting the
matchmarks and positioning the S mark on inner
race as shown in the figure.
R3686
3. Temporary fastening of inner race

Coat the threads of the capscrews (2) with
Loctite #262 and tighten all the capscrews (2)
temporarily.
: 41 mm
4. Regular tightening of inner race

Tighten the capscrews (2) at 180° degrees intervals
alternately to a specified torque.
: 41 mm
R3687
5. Filling grease
Fill grease bath (3) with 22 kg of grease NLGI-2
(containing molybdenum disulfide) or equivalent.
3
2
R0062
E485 W3-2-1
TRAVEL DEVICE
REMOVAL AND INSTALLATION OF TRAVEL DEVICE
WARNING
The hydraulic oil tank cap can be ejected, if the pressure is not released from the tank.
Press the valve located on the hydraulic oil tank to release any residual pressure present in the tank itself.
Preparation
2. Cut-off the engine. Actuate the manual and pedal pump to maintain negative pressure in the hydraulic
pilot valves to release any residual pressure from oil tank.
while working.
Removal 5 1
The procedure starts on the premise that the track
4
have already been removed. Refer to the proper
procedures in this section.
3
1. Removing cover (6).
Remove sems bolt (7) (M12x30) and also remove 2
covers (6).
: 19 mm
2. Preparation of oil pan.

7
3. Removing hydraulic pipe. 6
Remove all pipes connecting to travel motor. Then R0519
plug up all pipes and joint section to protect them
from entry of dust.
: 19 mm, 27 mm, 32 mm, 41 mm
R2144
W3-2-2 E485
TRAVEL DEVICE
4. Removing sprocket
Removing fourty eight (both side) capscrews (2)
M24x65 and washer (4).
: 36 mm
2, 4
R2145
5. Loosening travel motor attaching bolts (2).

Remove pipes. (Disconnect)
Apply match marks on travel motor and crawler
frame, and remove fourty eight (both side)
capscrews (3) M22x68.
: 32 mm
R2146
6. Slinging travel motor assy

Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.
WARNING
Mass of motor : About 600 kg (with sprocket)
R2147
E485 W3-2-3
TRAVEL DEVICE
Installation
Installing of the travel motor piping is performed in the

reverse order of removal.
1. Cleaning
Check that contact surface of travel motor and
crawler frame is free from burr and stain.
2. Tightening torque
Tighten capscrew and hydraulic pipes to the torque
specified in "Tightening Torque".
3. Before pipng for draining, fill casing with hydraulic

oil from drain port of motor.
At starts the machine, run the motor slowly at
engine low idling for several minutes, and check oil
leakage and abnormal sound from motor.
Tools Tightening
NAME SIZE HEX No. Torque (Nm) REMARKS
Sems bolt M12 19 7 83 Apply

M24 36 2 950±50 Loctite
Capscrew #270
M22 32 3 700±50
Flareless PF1/4 17 - 29.4
nut for PF1/2 22; 27 - 78.5
hose 1-7/16-12 un 36; 41 - 206
PF1/4 19 - 36.5
Connector PF1/2 27 - 108
PF1 41 - 255
W3-2-4 E485
TRAVEL DEVICE
DISASSEMBLY AND ASSEMBLY OF

TRAVEL DEVICE
In the case that it was necessary to undergo a (partial

or total) revision, it will be necessary to dismount the
gearmotor from the machine. As this is known as an
out of the ordinary maintenance procedure, it is impor-
tant that only personnel with specific skills and expe-
rience undertake it.
It is also important that this procedure is undertaken in
a workshop that is adequately tooled. As well as
normal workshop tools it will be necessary to use
special tools.
In the following pages all the procedures for disassem-
bling and reassembling the gearmotor are given, it is
important to strictly adhere to them.
Proceed with these operations using all the necessary
safety measures, like for example:
1. Cutting off all the hydraulic system connections on

the gearmotor to avoid the introduction of any
foreign parts in the circuit and the gear motor.
2. Making sure that the coupling surfaces are not

damaged.
3. Following the handling so as to be sure that there are

no risks for human safety and to guarantee the
reliability of the gear motor.
4. Making available a work area that is in line with work

and health safety in the workplace guidelines.
E485 W3-2-5
TRAVEL DEVICE
Reduction gear unit disassembly and assembly
1
2
3
4
5
6
15
16 7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
R3580
1- Screw M14x40 (Q.ty 16) 190 Nm 13 - Third reduction assembly

2- Oil breather plug M22x1.5 (Q.ty 2) 30÷40 Nm 14 - Bush (Q.ty 4)
3- Washer (Q.ty 2) 15 - Screw M24x65 (Q.ty 24) 950 Nm
4- Cover assembly 16 - Sprocket
5- O-Ring 17 - Gearbox housing
6- Pad 18 - Lifetime seal
7- Sun gear 19 - Discs retainer
8- First reduction assembly 20 - Hub
9- Sun gear 21 - O-Ring
10 - Second reduction assembly 22 - Hydraulic motor
11 - Sun gear 23 - Screw M18x60 (Q.ty 4) 295 Nm
12 - Screw M30x2x150 (Q.ty 4) 1480 Nm
W3-2-6 E485
TRAVEL DEVICE
DISASSEMBLY
1. Make sure that the oil is discharged.
2. Unscrew the four hexagonal head screws M18x60

(23) of the hydraulic motor by a hex head wrench.
23
R3800
3. By using an eyebolt M12 tightened on the motor

base plate, take out the hydraulic motor (22).
22
R3801
4. Remove the O-Ring seal (21) from the hydraulic

motor.
21
R3802
E485 W3-2-7
TRAVEL DEVICE
5. Unscrew the nos. 24 hexagonal head screws

M24x65 (15) of the sprocket (16) by a female hex
head wrench.
16
R3803
6. Take out the sprocket (16).
16
R3804
7. Turn the gearbox upside down, unscrew and re-

move the two plugs M22x1,5 (2) and the two 4
washers (3) from the end cover (4).
2
3
R3805
8. Unscrew and remove the 16 socket head screws

M14X40 (1), from the cover (4). 4
R3806
W3-2-8 E485
TRAVEL DEVICE
9. Remove the end cover (4) using the tool

380002067. 380002067
R3807
10. Remove the O-Ring (5) from its seat in the end
cover (4). 5
R3808
11. Screw a socket head screw M5x20 in the threaded

hole of the pad (6) in order to remove it from the
end cover (4).
R3809
12. Remove the 1st stage sun gear (7).
R3810
E485 W3-2-9
TRAVEL DEVICE
13. Remove the 1st reduction assembly (8).
R3811
14. Remove the 2nd stage sun gear (9).
R3812
15. Remove the 2nd reduction assembly (10).

10
R3813
16. Remove the 3rdt stage sun gear (11).

11
R3814
W3-2-10 E485
TRAVEL DEVICE
17. Unscrew the four socket head screws M30x2x150

(12), which fix the 3rd reduction assembly (13) to
the flanged hub (20).
12
13
R3815
18. Place the gearbox on two spacers. By using a

press and a metal stopper, remove the flanged hub 17
(20) from the gearbox housing (17), paying atten-
tion to the falling down of the main bearing's balls.
R3816
19. Remove the 3rd reduction assembly (13) from the

gearbox housing (17).
13
17
R3817
20. Using the tool 380002066, remove the bushes (14)

from the flanged hub (20).
380002066
20
14
R3818
E485 W3-2-11
TRAVEL DEVICE
21. By using a puller remove the inner ring of the

bearing and the spacer remaining on the flanged
hub (20).
20
R3819
22. Using the tool 380002066 remove the four planet

assemblies of the 3rd reduction (13).
380002066 13
R3820
23. View of the loose planet assembly of the 3rd

reduction (13).
IMPORTANT - In case of oil leakages, it might be

necessary to check and if needed replace the lifetime
seal (18), which means both the steel rings and the
O-Ring seals.
R3821
24. Remove both the half-seals (18) from the flanged

hub (20) and from the gearbox housing (17).
18
20
R3822
W3-2-12 E485
TRAVEL DEVICE
REPLACEMENTS
The pieces that are subject to general wear and tear
are the following.
- Gears
- Bearings
- All the seals
Replace the used or irregular parts respecting the
following steps.
1. Accurately remove dirt, and in particular properly
clean the seals, bearings and locking rings seating.
2. Lubricate the parts before connecting them.
3. In the case of damaged gears, for example a
planetary, do not proceed to replace the individual
gear but the entire reduction assembly.
4. When reconnecting a part always replace all the
seals involved.
5. Replace all the damaged parts with original spare
parts and doing so follow all the steps given in the
following paragraph.
ASSEMBLY
1. Makeready of the lifetime seal
Instructions to properly assemble the lifetime seal:
a. Carefully clean the seats (1 and 2) using, if
1 2
necessary, metal brushes or solvent (surfaces in
contact with or (3) must be perfectly clean and
dry).
6 6
b. Make sure that sealing surfaces (4) of metal rings
(5) are free from scratches, dinges or foreign
substances; metal ring surfaces must be per-
fectly clean and dry. 3 3
c. Carefully clean the lapped surface (4) of metal
5 5
rings (5) and remove dust or fingerprints. Then
lubrificate them with a thin oil film, taking care not
to oil the other components. 4 4
R0671
E485 W3-2-13
TRAVEL DEVICE
2. Assemble the half seal (18) on the tool 380002069.
18
380002069
R3823
3. Assemble the half seal (18) in the gearbox housing

(17).
18
17
R3824
4. Assemble, by using the same tool 380002069, the

half seal (18) on the flanged hub (20).
20
380002069
18
R3825
5. Clean carefully the metallic faces of the lifetime

seal (18), and Lube them metallic with a thin oil film.
18
R3826
W3-2-14 E485
TRAVEL DEVICE
NOTE - In case the bearing components are supplied

as a kit (main bearing assembled on the housing) do
not carry out the operations required by step 6 to
step 10. Complete assembling according to step 11.
6. Fit the lower ball row (d), into the gearbox housing d
(17) holding the inner raceway (c) with spacers (a-
b). c
17
7. Remove the spacer (a).
88.5
a
b
20
Ø 335.6
20 Ø 355.6
R0669
8. Insert the spacer (e).
9. Drop the upper ball row (f) and assemble the inner
raceway (g). g
a b
R0670
10. Place the flanged hub (20) inside the gearbox

housing (17). By using a press and a metallic
stopper, push the flanged hub (20) against the
shoulder on the gearbox housing (17) untill assem-
bling of the unit is complete. 20
17
R3827
E485 W3-2-15
TRAVEL DEVICE
11. In case the spare parts are supplied as a kit (i.e. Use the tool 380002068 part. 2 to center the
main bearing assembled on gearbox housing gearbox housing (17), and install the spacer
(17)), install the gearbox housing (17) on the 380002068 part. 1. Then press the spacer to install
flanged hub (20) according the drawing. Place the the gearbox housing (17) and bearing on the
flanged hub (20) on the support. flanged hub (20).
Tool for gearbox housing and main

bearing spare part assembly
380002068 part. 1
1
Gearbox housing and main
bearing spare part
Tube for packing and
assembling the main bearing
2 Tool for gearbox housing and main

bearing spare part assembly
380002068 part. 2
17
20
R3224
W3-2-16 E485
TRAVEL DEVICE
12. Place the four bushes (14) into their seats on the
flanged hub (20). By using a press, push the
bushes (14) against the shoulder inside their seats
into the flanged hub (20) until assembling is
complete.
14
20
R3828
13. Place the four planet assemblies of the 3rd reduc-

tion into their seats on the flanged hub (20), and
with a press, push them against the shoulder until
assembly is complete.
20
R3829
14. Place the 3rd reduction planet carrier on the flanged

hub (20).
R3830
E485 W3-2-17
TRAVEL DEVICE
15. Using a press, push the 3rd reduction planet carrier

(13) against the shoulder on the flanged hub (20)
until assembling is complete.
13
R3831
16. Apply LOCTITE type 243 on the four socket head

screws M30x2X150 (12), and insert them in the
thread holes.
12
R3832
17. Tighten the four socket head screws M30x2x150

(12), by a torque wrench, at 1480 Nm torque.
12
R3833
18. Insert the 3rd stage sun gear (11).
11
R3834
W3-2-18 E485
TRAVEL DEVICE
19. Assemble the 2nd reduction assembly (10).
10
R3835
20. Insert the 2nd stage sun gear (9).
R3836
21. Assemble the 1st reduction assembly (8).
8
R3837
22. Insert the 1st stage sun gear (7).
R3838
E485 W3-2-19
TRAVEL DEVICE
23. Assemble the O-Ring (5) into its seat in the cover
(4). 5
R3839
24. Place the pad (6) on the end cover (4) and by using
a press, push it against the shoulder untill assem-
bling is complete.
4
6 R3840
25. Use the tool 380002067 to place the end cover (4)
on the gearbox housing (17). 380002067
17
R3841
26. Apply LOCTITE type 243 on the 16 socket head

screws M14x40 (1), and tighten them by a torque
wrench at 190 Nm torque. 1
R3842
W3-2-20 E485
TRAVEL DEVICE
27. Place the sprocket (16) on the gearbox.
16
R3843
28. Apply LOCTITE type 270 on the thread of the nos.

24 hexagonal head screws M24x65 (15).
15
R3844
29. Tighten the nos. 24 hexagonal head screws

M24x65 (15), by a female hex head torque wrench
at 950 Nm torque.
R3845
30. Assemble the O-Ring seal (21) into its seat in the
hydraulic motor (22).
22
21
R3802
E485 W3-2-21
TRAVEL DEVICE
31. By using an eyebolt M12 UNI ISO 3266 tightened

on the motor base plate, assemble the hydraulic
motor (22).
22
R3846
32. Tighten the four hexagonal head screws M18x60

(23), by a male hex head torque wrench at 295 Nm 23
torque.
R3847
33. Fill the gearbox with the lubricant oil as shown in 4

the Operation and Maintenance Instruction
Manual. Tighten the plugs M22x1,5 (2) into the oil
draining-filling holes of the end cover (4) by a male
hex head torque wrench at 30 ÷ 40 Nm torque.
R3848
W3-2-22 E485
TRAVEL DEVICE
SPECIAL TOOLS
Tool Part Purpose Figure

Number
380002066 Percussion puller for planet

reduction and bush removing
380002066
380002067 End cover assembly and

disassembly
380002067
380002068 To install gearbox housing and

main bearing spare part (supplied
as a kit)
380002068
E485 W3-2-23
TRAVEL DEVICE

Number
380002069 Lifetime seal assembly tool
R3219
W3-2-24 E485
TRAVEL DEVICE
NOTES:
E485 W3-3-1
SWIVEL JOINT
REMOVAL AND INSTALLATION OF SWIVEL JOINT
WARNING
Preparation
pump to maintain negative pressure in the hydraulic
2. Cut-off the engine. Actuate the manual and pedal
oil tank.
while working.
Removal 2. Remove tubes (A, B ports, Ø35).

: 10 mm
NOTE - Attach labels or tags to hoses and adapters, : 83 Nm
to aid in assembly.
3. Remove tubes (C, D ports Ø35)
: 10 mm
• From the lower frame remove the following:
: 83.4 Nm
1. Remove tube (F port, PF3/4)
4. Remove the hoses (E port, PF1/4)
: 36 mm
: 118 Nm : 19 mm
: 29 Nm
Detail A
R3707
W3-3-2 E485
SWIVEL JOINT
• Disconnect the following hoses on the top part of

swivel joint.
5. Remove drain hose (F port, PF3/4).

: 36 mm
: 118 Nm
6. Remove hoses (A, C ports, PF1). B

E
: 36 mm, 41 mm D C
: 206 Nm
B A
7. Remove hoses (D, B ports, PF1).

: 36 mm, 41 mm A
: 206 Nm
8. Remove hose (E port, PF1/4) (2-speed change

over).
: 19 mm F
: 29 Nm C
D
B A
View A View B
R3708
9. Loosen the stop nut (7) M24 of swivel joint and

remove the screw (8) M24x190. 7 8
: 36 mm
: 157 Nm
R0040
10. Remove two adapters.

8 7
: 19 mm
: 36 Nm
R3722
E485 W3-3-3
SWIVEL JOINT
11. Remove clip (1).

1
: 6.8 Nm
12. Remove seal (2).
2
R0042
13. Attach eye bolt (5), lift it up temporarily, and

remove four screws (6) M16×25.
: 19 mm
: 108 Nm 5
WARNING
SWIVEL JOINT
Swivel joint mass: 58 kg
6
R3709
Installation
NOTE - Refer to “Removal” section above for wrench

sizes and tightening torque.
1. Proceed with the re-installation of the swivel joint

following the operation in reversed order with re-
spect to the removal.
WARNING
Swivel joint mass: 58 kg
W3-3-4 E485
SWIVEL JOINT
SWIVEL JOINT DISASSEMBLY AND ASSEMBLY
10 F
C
F E D A
B
2
E
VIEW Y
1
5
B
7 D F A
E 11 E
3
C
F
9
4 8
Z VIEW Z
R3582
1 - Body 7- O-Ring
2 - Stem 8- Socket bolt; M8×20 (Q.ty 4)
3 - Thrust plate 9- Socket bolt; M8×40 (Q.ty 4)
4 - Cover 10 - Plug PF1/2
5 - Seal assy (Q.ty 6) 11 - Plug PF1/4
6 - Seal assy (Q.ty 2)
E485 W3-3-5
SWIVEL JOINT
Disassembly
The part numbers used in this disassembly procedure

correspond to those of a construction drawing in the 1
figure on page W-3-3-4. 4
9
1. Mark cover (4) and body (1) with matching marks for
convenient reassembly.
2. Place a 'V' (A) block on a work bench, place a swivel

joint set on the side, fix it and loosen socket bolt (9)
by means of a pipe and wrench. Alternately, the
swivel joint may be fixed by holding stem (2) in a
vise.
: 6 mm A
R3710
3. Remove cover (4) from body (1) and draw out O-Ring
(7) from cover (4). 7
4
R3711
4. Loosen socket bolt (8) fastening thrust plate (3), in

the same manner as the removing of the above-
mentioned cover.
1
- When removing thrust plate (3) by fixing body (1),
support stem (2) so it may not fall down.
: 6 mm 3
R3712
W3-3-6 E485
SWIVEL JOINT
5. Erect the swivel joint on a work bench and place an

eye bolt in each of the two lifting bolt holes (M12) on
the top face of stem (2).
6. Put a wire sling in the eye bolts and lift stem (2) 2
upright slowly.
Stem mass: 19 kg.
R3713
7. Remove the back-up ring of the seals assemblies

E
(5 and 6) by means of a spatula (E).
NOTE - Make sure the body (1) is not scored from the
tip of the spatula (E).
R0050
8. Take off the slip ring (B) of the seals assemblies C

(5 and 6) by means of pin of screwdriver (A) and
remove them from the O-Ring grooves (D). The
figure on side shows the use of only one pin of
screwdriver, but by using two screwdriver pins,
these can be extracted with more sureness.
B
NOTE - Make sure the body (1) is not scored from the
screwdriver (A). Detail
5 and 6
1
A
6
R0049
E485 W3-3-7
SWIVEL JOINT
Assembly B
Prior to assembly, clean each parts (excluding the

O- Ring and slipper ring), and arrange in the sequence
of assembly.
1. Make sure that oil and grease remains have been

completely removed.
2. Apply grease on the groove where are seated the

O- Ring (6).
3. Slipper ring (B) is assembled, after first inserting the

backup ring, by slightly-distorting the shape as
shown in figure. Also after inserting all of the seals, R0051
be certain that these are installed in the seal groove
by use of the spatula.
4. Erect body (1) on a level work bench. Put an eye bolt

in two lifting bolt holes (M12) in the top face of stem Press in by your both hands
(2) and lift in upright with a wire sling.
5. Lightly coat the outer circumference of stem (2) and

the inner surface of body (1) with grease or vaseline
and slowly insert stem (2) into body (1).
NOTE - If stem (2) is pressed in too fast, the seal may

be damaged. Do it slowly. The clearance between
body (1) and stem (2) is about 0.1 mm. Push stem
straight along the shaft center.
1
WORK BENCH
R3714
W3-3-8 E485
SWIVEL JOINT
6. While holding stem (2) and body (1), match the hole
of thrust plate (3) and the stem (2) hole.
8 3 2
7. Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite 242 and tighten
to stem (2).
: 6 mm
: 30.4 Nm
R3715
8. After installing O-Ring (7) to cover (4) and aligning

the matching marks (A) of the cover (4) and body 1
(1), coat socket bolt (9) with Loctite 242 and tighten
it which will then complete assembly. A
: 6 mm 9
: 30.4 Nm
4
R3716
E485 W3-3-9
SWIVEL JOINT
Item Allowable Limit (basis of judgment) Remedy
Sliding surface
Scored or something hurt it. Replace
and sealed parts
1. Scored more than 0.1 mm. Replace

Sliding surface
exception sealed parts 2. Scored less than 0.1 mm. Repair
with oil stone
Body, Stem
1. Wear more than 0.5 mm deep. Normal wear
Sliding surface ring 2. Wear less than 0.5 mm deep.

Repair
a 0.5 mm.
3. Scored less than 0.5 mm and able

Repair
to repair.
1. Wear more than 0.5 mm. Replace
Cover Sliding surface ring 2. Wear less than 0.5 mm. Repair
3. Scored less than 0.5 mm and able

Repair
to repair.
1. Protruded excessively from seal

groove.
Replace (with
back-up ring)
R0055
2. Slipper ring narrower than 1.5 mm

of seal groove, or narrower than
back-up ring.
Slipper ring Replace (with

back-up ring)
1.5 mm (max)
R0056
3. Worn unevenly more than 0.5 mm.
0.5 mm (max) Replace (with

back-up ring)
R0057
W3-3-10 E485
SWIVEL JOINT
Inspection after assembly
After completion of assembly, inspection for oil leak-

age, pressure resistance, etc., using a device as 1
shown in the figure on right.
1. High pressure port (A,B,C,D port)

9
Install a directional valve (8) and pressure gauge (1)
to the stem side port and body side port respective-
ly, and while watching the pressure gauge (for high
pressure) installed on the body side and also by 2
regulating high pressure relief valve (7), gradually
increase the pressure. When the pressure has
reached 1.5 times the maximum working pressure,
close stop valve (3) and lock in the hydraulic oil in
3
the swivel.
At this time, keep stop valve (6) on the low pressure 8
relief valve side closed for, at least, 3 minutes and
check for any distortions, breakages or loosening.
During the first minute, check for oil leakages and,
in case of pressure drop, this shoul be the 10% of 7
the pressure trapped. This check should be per-
formed on each circuit.
2. Low pressure port

(Drain port, return port : E,F port.)
Similar to the high pressure port, install a directional
valve and pressure gauge on each port of the stem
side and body side. 4 6 5
Open stop valve (6) on the side of low pressure relief R0058
valve (5) and while watching the pressure gauge (for

low pressure) connected to the body side and also
1 - Pressure Gauge
by regulating low pressure relief valve (5), gradually 2 - Swivel Joint
increase the pressure and check for outside leak- 3 - Stop Valve
age with a color check at a pressure of 0.49 MPa. 4 - Hydraulic source
5 - Relief Valve for low pressure
6 - Stop Valve
7 - Relief Valve for high pressure
8 - Directional Valve
9 - Piping, etc.
E485 W3-4-1
TRACK ADJUSTER

TRACK ADJUSTER (WITH FRONT IDLER)
Before removing the track adjuster, the tracks must be

removed first. For removal and installation of the
tracks, refer to applicable removal/installation sec-
tions. In this section, the procedure starts on the
premise that the tracks have already been removed.
Removal
WARNING
Track adjuster assembly (with front idler)
mass: 634 kg
WARNING
Be sure cables are anchored and the anchor point
is strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.
SM1801
1. After swinging superstructure to 90° related to

machine longitudinal centerline for easier access to
track components, remove the front idler and track
adjuster assembly from track frame by prying it out,
using a pry bar shown in figure.
Installation
WARNING
Be sure cables are anchored and the anchor point
is strong enough to handle the expected load. Keep
exposed personnel clear of anchor point and cables
or chain.
1. As shown in figure, install the front idler and track

SM1802
adjuster into spring guide on track frame.
NOTE - Where front idler has to be separated from

track adjuster, loosen the cap screw (1) and with draw
the assemblies. Place the assemblies on dedicated
stands.
When the front idler is installed on the track ad-

juster, apply Loctite 242 on the thread of capscrews
(1) and tighten.
: 36 mm
: 1012-1190 Nm
WARNING
1
Front idler mass: 327 kg
Track adjuster mass: 307 kg
R1543
W3-4-2 E485
TRACK ADJUSTER
TRACK ADJUSTER DISASSEMBLY
11
2
4
10
1
9
6
8
X
10
R1559
1 - Grease cylinder 8- Wiper-Ring

2 - Yoke 9- Seal
3 - Nut 10 - Pin (Q.ty 2)
4 - Pin 11 - Cover plate
5 - Spring X- Grease nipple
6 - Piston
E485 W3-4-3
TRACK ADJUSTER
Disassembly
Be sure to thoroughly read "Precautions for Disas-

sembly and Assembly" on page W1-1-1 before start-
Be sure to use special tool (380001029) for

assembly / disassembly of the track adjuster. 380001029
WARNING
Prevent personal injury. The spring force of the
track adjuster is extremely large. Thoroughly in-
spect the special tool for any damage. Carefully
perform assembly work referring to the procedure
below. SM1160
WARNING
Approximate mass of the track spring holder as-
sembly: 225 kg
1. Place a jack on the bottom of the track spring holder Plate

assembly (380001029).
2. Loosen four holding down nuts of the jig and draw

out the plate.
: 46 mm
WARNING
Approximate mass of the track adjuster: 307 kg
Approximate mass of the piston (6): 25 kg SM1161
3. Draw out piston (6) from grease cylinder (1) of the

idler adjuster assy. 2 4 3 1 5 9 8 6
4. Removing seal (9), wiper-Ring (8) from grease

cylinder (1).
5. Set the idler adjuster assy on the stand of the jig,

with its yoke bracket side facing up.
11 10
R1566
W3-4-4 E485
TRACK ADJUSTER
6. Connect the track adjuster to a hoist using a lifting

strap.
Put the track adjuster in the track spring holder
assembly (380001029) (V).
Remove the lifting strap.
R0098
7. Fit retainer plate (1) of jig to yoke bracket (2) of track

adjuster, tighten holding-down nuts alternately, and
secure track adjuster assy. 4
: 46 mm
1
3
R0100
8. Remove spring pin (4), press spring (5) lifting it with 5

jack so that nut (3) can be turned freely, and remove
nut (3).
: 46 mm
: 105 mm
R0101
E485 W3-4-5
TRACK ADJUSTER
WARNING
Approximate mass of the yoke (2): 64 kg
Approximate mass of the spring (5): 154 kg
Approximate mass of the grease cylinder (1):
59 kg
2
19. Allow the hydraulic jack to retract slowly till the
spring is extended to its free length. Remove the 11
retainer plate of jig and take off the yoke (2) and
cover plate (11).
R0102
The free length of the spring: 816 mm
: 46 mm
10. Hook lifting eye nut (W) to screw M76 on grease

cylinder (1) top end and hoist it. Then, remove the
set of grease cylinder (1) and spring (5) using W
crane from the jig. 1
Remove spring (5), from grease cylinder (1).
R0103
W3-4-6 E485
TRACK ADJUSTER
TRACK ADJUSTER ASSEMBLY
3 4 5 1 9 8 6 10
X
2 11
R2190
1 - Grease cylinder 8- Wiper-Ring

2 - Yoke 9- Seal
3 - Nut 10 - Pin (Q.ty 2)
4 - Pin 11 - Cover plate
5 - Spring X- Grease nipple
6 - Piston
E485 W3-4-7
TRACK ADJUSTER
Assembly
2 4 3 1 5 9 8 6
WARNING
Approximate mass of the grease cylinder (1): 59
kg Approximate mass of the spring (5): 154 kg
Approximate mass of the yoke (2): 64 kg
1. Insert grease cylinder (1) into spring (5) and attach 11 10

lifting eye nut (W) to screw M76 at the tip of the R1566
grease cylinder. Lift the grease cylinder (1) by crane

and erect it in the center of the jig stand upright
(380001029).
W
R0104
2. Install yoke (2) and cover plate (11) on top of spring

(5). Center the rod of grease cylinder (1) and the 13
holes in yoke bracket (2). Attach the retainer plate 12
(12) and four holding-down nuts (13) of jig. Fasten
the nuts evenly all round and fix the idler adjuster
assy to the jig body (380001029).
: 46 mm
2
4
3. Extend the hydraulic jack, compress spring (5) to a 3
set length and screw in nut (3) to the screwed part 7
at the tip of grease cylinder (1). 11
1
Set length of the spring: 680 mm
5
4. Tighten nut (3) till the holes for locking spring pins R1567
(4) are aligned. Then fit spring pin (4).
: 46 mm
: 105 mm
W3-4-8 E485
TRACK ADJUSTER
5. Remove idler adjuster assy from jig (380001029).
WARNING
Approximate mass of the track adjuster: 307 kg
Approximate mass of the piston (6): 25 kg
R0106
6. Apply grease on the seal (9) and wiper-Ring (8) then

fit them to grease cylinder (1). 1 9 8
6
7. Fill up grease in cylinder (1), remove the grease
nipple from piston (6) in order to discharge the inside
air, and press in the piston by hand.
Direct grease nipple hole downward to make air
discharge easier.
8. Tighten grease nipple (X) to piston (6). X

R1568
: 19 mm
: 59 Nm
E485 W3-4-9
TRACK ADJUSTER
SPECIAL TOOLS

Number
380001029 Assembly/Disassembly
track adjuster
380001029
R3720
W3-4-10 E485
TRACK ADJUSTER
NOTES:
E485 W3-5-1
FRONT IDLER
FRONT IDLER DISASSEMBLY
3
6
2
1 4
4 2
R1544
1 - Front idler 5 - Pin

2 - Bushing 6 - Shaft
3 - Bracket 7 - O-Ring
4 - Floated seal with O-Ring 8 - Plug
W3-5-2 E485
FRONT IDLER
Disassembly
1. Remove plug (8) on the side of bracket (3) to drain

oil.
: 6 mm 1
2
3
4
WARNING
Approximate mass of the front idler assembly 6
with bracket: 327 kg 5
4 8
R3721
2. To remove pin (5) apply pin push bar to the top of pin,
and push out striking bar lightly by hammer. 5
Pin push bar
WARNING
Approximate mass of the bracket (3): 28 kgx2
Approximate mass of the shaft (6): 32 kg R0090
3. Put idler on repair stand. Apply push-out jig on shaft,

push out shaft (6) with bracket (3), then remove Push with press
bracket (3).
Push-out jig
6
3
1
R0091
E485 W3-5-3
FRONT IDLER
4. If removal of bracket (3) on the opposite side is Push with press

required, turn over front idler and proceed with the
procedure described in the previous step.
Push-out jig
6 3
R0092
5. With idler (1) mounted on the stand, tap bushing

Tap bushing 2
lightly by hammer, while placing the bushing draw- 1
ing rod against the end face of bushing (2) evenly all
round, till it comes out.
6. Take out floating seals (4) from idler (1), bracket (3).
If you intend to re-use floating seals (4), confirm that
there is no scoring and rusting on the contact
surface and store the floating seals in pairs by
placing card board between the sealing faces.
R0093
7. Separate O-Ring from shaft.
WARNING
Approximate mass of the front idler with bushing:
237 kg
W3-5-4 E485
FRONT IDLER
FRONT IDLER ASSEMBLY
1 6 2 3 4
8 7
R3717
1 - Front idler 5 - Pin

2 - Bushing 6 - Shaft
3 - Bracket 7 - O-Ring
4 - Floated seal with O-Ring 8 - Plug
E485 W3-5-5
FRONT IDLER
Assembly
Press
WARNING 6
Approximate mass of the front idler with the 7
bushing (1): 237 kg
4
Approximate mass of the shaft (6): 32 kg 3
Approximate mass of the bracket (3): 28 kgx2 5
1. Apply grease to O-Ring (7) and fit to O-Ring groove

R0095
on shaft (6).
2. Press fit the O-Ring (7) installed on the side of shaft

(6) into bracket (3), and drive pin (5).
3. Fit the half of floating seal and O-Ring (4) on each

side of bracket (3) and idler (1).
4. Install idler (1) on the shaft (6) with the floating seal 6
and O-Ring (4) fitted into shaft (6) with the toward 44
bracket (3).
1
5. Fit floating seal (4) on the other side of idler (1).
R0096
6. Fit the half of floating seal (4) on the other bracket

8 3
(3), press fit it in shaft (6), and drive pin (5) in with
hammer. 5
7. Fill in 740 cm³ of engine oil through the plug hole of 1

bracket (3), wind seal tape and tighten plug (8).
: 6 mm, 49-58 Nm
R0097
NOTE - After installing the idler assy to the idler
adjuster assy, make certain that no oil leaks from
floating seal and plug (8) and that idler (1) rotates
smoothly.
W3-5-6 E485
FRONT IDLER
Front Idler
C D
A
B
SM1189
Unit: mm
Standard Allowable Remedy
A 105 96
B 210 -
C 676 666 Buildup weld and finishing
D 726 -
E 25 -
IMPORTANT - Consult NEW HOLLAND KOBELCO for any inqueries concerning welding procedures.
Axle and Bushing

Unit: mm
Standard Allowable Limit Remedy
Axle Outside Dia 110 109.2

Replace
Bushing Inside Dia 110 111
E485 W3-6-1
UPPER AND LOWER ROLLER

UPPER ROLLER
Removal
WARNING
Do not loosen valve (1) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (1).
Never loosen grease fitting (2).
SM1228
IMPORTANT - When gravel or mud is packed between

sprockets and tracks, remove it before loosening.
1. Loosen valve (1) to drain grease.

: 19 mm
1
2
R0022
WARNING 3
Insert a piece of non-sliding rag between track
frame (5) and hydraulic jack to prevent that the
latter slides.
2. Lift track chains (3) with the hydraulic jack to a

height sufficient to remove upper roller (4).
4
SM1828
3. Insert a wooden block between tracks (3) and track

3
frame (5).
SM1827
W3-6-2 E485
4. Remove nuts (3) securing the support as well as

screw (2) M20x150 with related washer (4). 1 1 1
: 30 mm
WARNING
Approximate upper roller mass: 35 kg
R3718
5. Remove the upper roller complete with support (1)

extracting the shaft from the collar of the lower 3 4
frame.
4
2
R3719
Installation
1. Prior to the installation, check that the roller (1) turns

freely by hand and there are no leaks. S
2. Insert fully securing screws M20x150 (2) with

washer (4) fully in the collar toward the centre of the
machine.
WARNING
Approximate upper roller mass: 35 kg
3. Insert the roller until the collar contacts the support.

MACHINE
CENTRE
4. Position the support roller directing the mark of

bevel (S) on the shaft end, upward.
5. Apply Loctite 262 on the thread of the screw

M20x150 (2) and install washer (4) and nut (3). Then
tighten it to the specified torque listed here below.
: 30 mm
: 57±3 daNm 2-4 1 3-4 R3755
6. Remove the wooden blocks and the hydraulic jack.
SM1230
E485 W3-6-3
7. Supply grease to valve (1) to adjust tracks tension.
Track sag specifications (A): 390 to 440 mm

: 19 mm
: 59 Nm
NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.
1
2
R0022
SM1234
8. Add engine oil via plug (3) hole on cover (9). Tighten
plug (3). 9 11 10 4 3 1 5 6 7 8 2
Engine oil quantity: 367 cm3

: 6 mm
: 9.8 to 19.6 Nm
12
R2193
W3-6-4 E485

LOWER ROLLER
Removal
5
1. Remove the roller guard and loosen bolts (5).
: 32 mm
SM1236
2. Lift the one side of the track frame high enough to

remove the lower roller.
Insert wooden blocks under track frame (2).
2
SM1237
WARNING
Do not loosen valve (3) quickly or loosen it too
much as high-pressure grease in the adjusting
cylinder may spout out. Loosen carefully, keeping
body parts and face away from valve (3).
SM1228
3. Loosen valve (3) to drain grease enough to permit

the roller removal.
: 19 mm
3
4
R0019
E485 W3-6-5
WARNING
Lower roller mass: 97 kg
4. Securely hold the lower roller using a fork lift.

Remove lower roller (1).
1
SM1238
Installation
2 1
WARNING
Lower roller mass: 97 kg
1. Securely hold the lower roller using a fork lift.

Put lower rollers (1) on the tracks as illustration.
SM1239
2. Lower track frame (2) enough to allow bolts (4) with

2 4
washers to be installed into track frame (2).
SM1240
3. Align tapped holes in track frame (2).

Tighten bolts (4).
: 32 mm
: 700±50 Nm
4
SM1236
W3-6-6 E485
4. Supply grease to valve (3) throught nipple (4) to

adjust tracks tension.

: 19 mm
: 59 Nm
NOTE - Check track sag after thoroughly removing soil

stuck on the track area by washing.
3
4
R0019
SM1234
E485 W3-6-7
UPPER ROLLER DISASSEMBLY
10
R1546
1 - Upper roller 6- Bushing

2 - Shaft 7- Floating seal
3 - Collar 8- O-Ring
4 - Thrust washer 9- Screw 12x25 (Q.ty 5)
5 - Cover 10 - Plug
W3-6-8 E485
Disassembly
Be sure to thoroughly read "Precautions for Disassem- 9

11
bly and Assembly" on page W1-1-1 before starting the 4
disassembly work.
8
1. Remove plug (10) and drain out oil. 5
: 6 mm 10 1
2. Mount the end face inside upper roller (1) on stand

jig and separate snap ring (11), using snap ring
pliers.
Stand jig
3. Take off cover (5) upwards.
4. Separate O-Ring (8) from cover (5).
R1547
5. Loosen two screws (9) and draw out the thrust
washer (4) from roller (1).
: 19 mm
6. Put the extrusion jig against the end face of shaft (2)
and push shaft with collar (3) for floating seal (7), PUSH
using a press or hammer. WITH PRESS
Extrusion jig
Stand jig
R1548
E485 W3-6-9
7. Take out floating seal (7) from roller (1).

7
R1549
8. Remove from collar (3), floating seal (7) that is

located on the side from which shaft (2) was
disparted. 2
7
IMPORTANT - Collar (3) is press fitted into shaft (2) by
means of press.Therefore do not disassemble it. 3
R1550
9. Since the bushing is thin, machine it on a lathe or

scrape it off, exercise care so as not to damage the
bore of roller (1). If the bushing is not worn much, Extrusion jig
mount upper roller (1) on jig stand jig, insert jig
extrusion jig into the end face of bushing (6) and 6
push it out with a press.
1
Stand jig
R1551
W3-6-10 E485
UPPER ROLLER ASSEMBLY
5 8 4 6 10 1 6 7 7 3 2
9
R2194
1 - Upper roller 6- Bushing

2 - Shaft 7- Floating seal
3 - Collar 8- O-Ring
4 - Thrust washer 9- Socket bolt (Q.ty 5)
5 - Cover 10 - Plug
E485 W3-6-11
Assembly
PUSH
1. Assembly of the upper roller is done in the reverse WITH PRESS
order of disassembly.
Extrusion jig
2. Place upper roller (1) on the top end face of stand jig, 5
with its floating seal setting side facing down.
1
3. Confirm that the outer surface of bushing (5) is not
seized and coat the outer surface of the inserting
side of the bushing, with molybdenum disulfide Stand jig
grease.
4. Put extrusion jig into bushing (5) and press it in,

using the bore of the bushing and the bore of the
roller as guides.
R1553
IMPORTANT - If you fail in this operation by pressing

the bushing unevenly, the bushing is distorted and
gets unserviceable. In that case, do not re-use the
bushing as it may develop malfunctioning after as-
sembly.
IMPORTANT - For handling of floating seal (7), refer to

the section "Floating seal precautions" on page 2
W1-1-3.
7
5. Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 3
NOTE - Prior to placing floating seal (7) in, apply

engine oil lightly to seal surface.
R1554
R1555
W3-6-12 E485
6. Coat shaft (2) with a thin film of oil and insert it into PUSH
upper roller (1). WITH PRESS
R1556
7. Mount upper roller (1) on the stand jig and attach

thrust washer (4) to the end face of the shaft with 9
bolt (9). 8
: 19 mm 5
: 122 to 143 Nm 4
1
8. Fit O-Ring (8) to the groove of cover (5).
NOTE - Apply grease to O-Ring.
9. Install cover (5) to upper roller (1) and fix cover with Stand jig
the three screws (9).
: 19 mm
: 122 to 143 Nm
R1557
10. Fill in 367 cm3 of engine oil through the plug hole
(3). 3
11. Wind seal tape around plug (3).

: 6 mm
: 9.8 to 19.6 Nm
NOTE - After assembling the upper roller, confirm that

oil is not leaking from it and that it rotates smoothly by.
R2195
E485 W3-6-13
LOWER ROLLER DISASSEMBLY
10
7
9
6
2
4
1
4
6 5
5
9
10
8
3
5 5
R3724
1 - Roller 6- Seal (Q.ty 4)

2 - Shaft 7- Internal Bracket
3 - Plug 8- External Bracket
4 - Bushing (Q.ty 2) 9- O-Ring (Q.ty 2)
5 - Seal ring (Q.ty 4) 10 - Pin (Q.ty 2)
W3-6-14 E485
Disassembly
8 5 1 5
Be sure to thoroughly read “Precautions for Disas-
sembly and Assembly” on page W1-1-1 before start-
1. Remove plug (3) and pins (10) from collars (7 and 8),
and drain oil. 5 7
: 6 mm
: 20 mm
R3756
2. Press down axle (2) until O-Ring (9) comes out of

collar (8). 9 8
Remove collar (8) from axle (2).
3. Remove O-Ring (9) from axle (2).

Remove axle (2) from roller (1).
2
4. Remove floating seal (5) from roller (1) and collar (8).
5. Press out axle (2), and remove collar (7) and O-Ring
(9) from axle (2).
R3757
6. In case of replacing bushings (4), remove the

bushings using a press and the special tool.
Special Tool: (380002113).
380002113
R3758
E485 W3-6-15
LOWER ROLLER ASSEMBLY
8 1 2 4 565 7 9 10
R3723
1 - Roller 6- Seal (Q.ty 4)

2 - Shaft 7- Internal Bracket
3 - Plug 8- External Bracket
4 - Bushing (Q.ty 2) 9- O-Ring (Q.ty 2)
5 - Seal ring (Q.ty 4) 10 - Pin (Q.ty 2)
W3-6-16 E485
Assembly
2 10
1. Install bushings (4) (Q.ty 2) onto roller (1) using a
press. Take care not to dent the flange surface of
bushings. Apply a coat of grease to O-Ring (9) and
install onto axle (2).
2. Install collar (7) onto axle (2), aligning the pin holes.
Secure them using pin (10). Take care not to 7 9
damage O-Ring (9). R3759
3. Install floating seal (5) to roller (1) and to collar (7).

1 5
5 7
R3760
4. Insert axle (2) into roller (1). Install the other floating
seal (5) to roller (1) and to collar (8). Install O-Ring 8 5 2 1
(9) and the other collar (8). Secure them using pin
(10).
R3761
5. Add engine oil via plug hole (3) on collar. Apply

sealant (Loctite 503 or equivalent) to plug (3).
Tighten plug (3).
Engine oil quantity: 0.48 kg 3

: 6 mm
: 9.8 to 19.6 Nm
8 R3762
E485 W3-6-17
Upper Roller
A
B R1561
Unit: mm
A 95 -
B 210 - Replace
C 160 150.8
Lower Roller
C A C
B
SM1252
Unit: mm
A 218 -
B 280 - Buildup
weld and
C 31 - finishing
D 220 210
IMPORTANT - Consulting NEW HOLLAND KOBELCO for any inquiries concerning welding procedure.
W3-6-18 E485
Upper roller axle and Bushing

Unit: mm
Axle Outside Dia. 65 64.6

Replace
Bushing Inside Dia. 65 66
Lower roller axle and Bushing

Unit: mm
Axle Outside Dia. 90 89.2

Replace
Bushing Inside Dia. 90 91
E485 W3-7-1
TRACKS
REMOVAL AND INSTALLATION OF TRACKS
Removal
WARNING
Do not loosen valve (1) quickly on loosen too much
since high-pressure grease in the adjusting cylin-
der may spout out.
Loosen carefully, keeping body parts and face
away from valve (1).
SM1253
1. Move the tracks so that master pin (3) is positioned

over front idler (4). 5
Put a wooden block under track shoes (5), as
shown.
SM1254
2. To loosen the track tension, slowly turn valve (1)

counterclockwise one turn; grease will escape
from grease outlet.
: 19 mm
1
2
R0022
W3-7-2 E485
TRACKS
WARNING
The front idler may jump out of position due to
strong spring force when the tracks is discon-
nected. Especially, the strong spring force is al-
ways applied to the bolt part of the rod. If the rod
and/or the bolt are damaged, metal fragments may
fly off when the tracks is disconnected.
SM1256
3. Remove master pin (3) by using a special tool.
R0076
A: 380001008
D C 3 E
B: 380001907
C: 380002037
D: 380001020
E: 380001021
G: 380001019
3: MASTER PIN
G B A
SM1258
4. Slowly drive the machine in reverse until the whole

length of the removing track comes on the ground.
SM1259
5. Rotate the upperstructure 90 degrees toward the

removing track side, perpendicular to the tracks.
Operate the boom and arm so that the angle
between them is 90 to 110 degrees. Lower the
90° to 110°
boom with the bucket rolled-in to jack up the ma-
chine as illustrated.
SM1260
E485 W3-7-3
TRACKS
Installation
1. Jack up the machine and put the track under the

lower roller. Idler side Sprocket
Be sure to position the track in correct direction, as side
illustrated.
SM1261
2. Lift the track, and place it on sprocket (1).
SM1262
3. Slowly turn the sprocket in forward direction.
SM1263
4. Turn sprocket (1) until end of track (4) comes on

front idler (3). 3
Lower the machine and put a wooden block as
illustrated.
SM1264
W3-7-4 E485
TRACKS
IMPORTANT - Hole surfaces, link holes and

counterbore surfaces, bushing ends, shall be free
from dust and rust.
5. Install master pin (5), using a hammer and special

tool. 3
R0076
A: 380001008
B: 380001907
C: 380002037
D: 380001020
E: 380001021
G: 380001019 D C 5 E
5: MASTER PIN
IMPORTANT - Inject rust preventive protective (ex.

TECTYL165 G) between pin and bushing clearance.
G B A
SM1258
IMPORTANT - If any links have been removed from

the track, be sure to charge the grease into the
clearance between the pin and bushing when recon-
necting the links. Also, apply a coat of grease to the
ends of the bushing.
Grease Charging Method:
- Stand the bushing on a flat plate.
- Fill the bushing bore with the grease.
- Insert the pin into the bushing while pushing the
bushing onto the plate (so that the bushing end
stays on the plate).
- Wipe off excess grease.
6. Supply grease to the cylinder through the grease

fitting to adjust the track tension.
: 19 mm
SM1265
: 19 mm
: 59 Nm
IMPORTANT - Check track sag after thoroughly

removing soil stuck on the track area by washing.
SM1234
E485 W3-7-5
TRACKS
Link Pin and Track Bushing
• Measure the length of four links, as illustrated, with

the tension on the track.
• Do not measure the master-pin included part of the
track.
A
SM1266
Unit: mm
A 915 932 Replace
Master Pin
A
R0087
Unit: mm
A 264 - Replace
B 48.85 46 Replace
W3-7-6 E485
TRACKS
Master Bushing
B C
A
SM1267
Unit: mm
A 160 -
B 49.5 53 Replace
C 73.33 70
Grouser Shoe
C
B
SM1268
Unit: mm
A 254 -
B 18 - Replace
C 37 20
SECTION 4 E485
FRONT ATTACHMENT
CONTENTS
Group 1 - Front attachment Group 2 - Cylinders

Removal and Installation of Removal and Installation
Front Attachment ................................. W4-1-1 of Cylinders .......................................... W4-2-1
Maintenance Standard ......................... W4-1-6 Hydraulic Circuit Pressure
(Standard and BEH versions) Release Procedure ............................... W4-2-9
Bucket Teeth ........................................ W4-1-8 Disassembly Cylinders ...................... W4-2-12
Standard Dimensions for Arm and Assembly Cylinders ........................... W4-2-18
Bucket Connection ............................... W4-1-9 Maintenance Standard ....................... W4-2-26
Special Tools ...................................... W4-2-27
E485 W4-1-1
FRONT ATTACHMENT
REMOVAL AND INSTALLATION OF FRONT ATTACHMENT
WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries.
Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before
starting any intervention, make sure that oil and components have cooled off.
the hydraulic oil tank cap can be ejected if the residual pressure in the system is not released first.
Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Preparation
1. Park the machine on firm, level ground.

Position the front attachment as illustated and
lower the bucket to the ground.
SM1317
Removal
1. Disconnect lubrication pipes (12) from main dis-

tributor, lubrication pipe (13) from both boom
cylinder rod ends and (14) from cylinder bottom
side.
: 12 mm, 19 mm
12
WARNING
Boom cylinder mass: 415 kg
R3886
13
14
R3888 R3887
W4-1-2 E485
FRONT ATTACHMENT
2. Loosen lock nuts (1), remove bolt (2) and stoppers

(3) from both boom cylinder rod ends. 4
Carry out the same procedure for the other boom 4
cylinder.
2
: 30 mm
3 5
WARNING
Prevent personal injury. Metal fragments may fly off 1
when a hammer is used to remove pins. Be sure to
wear necessary protection, such as goggles,
hardhat, etc.
SM3502
3. Attach each boom cylinder to a crane.

Remove cylinder rod end pin (5) and thrust plate (4)
using a hammer and bar.
IMPORTANT - Avoid boom cylinder damage. A

grease fitting is located on the boom cylinder. Be sure
to position a wooden block so that the grease fitting
does not come in contact with the wooden block when
the boom cylinder is lowered.
4. Position a wooden block between the main frame

and the boom cylinder bottom, as illustrated. Slowly
lower the boom cylinder using the crane onto the
wooden block.
5. Press the valve located on the hydraulic oil tank to

bleed the residual pressure inside the tank itself.
Complete the bleeding of the residual pressure from
the hydraulic system, making reference to "Hydrau-
lic Circuit Pressure Release Procedure" at page
W4-2-9. Wooden Block
SM1320
6. Disconnect hoses (7) and (8) of arm cylinder and

bucket cylinder. 7 8
Close all openings with plugs to keep clean.
: 41 mm
: 12 mm
R3860
E485 W4-1-3
FRONT ATTACHMENT
7. Remove screws (10) and plate (9) securing pin (11)

of the boom foot of the main frame.
: 36 mm
11
10
9
R0059
WARNING
Approximate mass of the front equipment
standard version: 8400 kg
BEH version: 8000 kg
8. Sling the boom to a hoist. Lift slightly the boom

making sure that none of the slings is loose.
SM1323
9. Pull out the boom lower pivot pin (1) to the frame
using the appropriate puller (380001031).
380001031
R0060
10. Lift the front equipment. Move the machine away

from the front equipment and the hoist.
SM1325
W4-1-4 E485
FRONT ATTACHMENT
Installation
WARNING
Approximate mass of the front equipment
standard version: 8400 kg
BEH version: 8000 kg
1. Install the front attachment

Install dust seals to boom foot. 11
Align the boom foot boss with the main frame boss.
Insert a thrust plate to both right and left sides of the 10
boom foot boss to take out clearance between the
boom foot boss and the main frame boss the 9
R0059
remaining clearance should be less than 1 mm.
2. Install boom foot pin (11) using a hammer and bar.

Install bolt (10) (Q.ty 2) and lock plate (9). 7 8
: 36 mm
: 930 Nm
3. Remove the plugs of the hoses and pipes. Connect

hoses (7) and (8) of the arm and bucket cylinders to
the pipes.
: 41 mm
: 210 Nm R3860
: 12 mm
: 175 Nm
WARNING
4. Attach the boom cylinder to a crane. Lift the boom

cylinder and align the boom cylinder rod with the pin
hole on the boom.
NOTE - For easy alignment, start the engine and use

the boom control lever.
SM1326
E485 W4-1-5
FRONT ATTACHMENT
WARNING 4
Prevent personal injury. Metal fragments may fly off
4
when a hammer is used to insert pins. Be sure to
wear necessary protection, such as goggles, 2
hardhat, etc.
3 5
5. Install thrust plate (4). Drive pin (5) into the pin 1
hole.
6. Install thrust plate (4), stopper (3), tighten bolt (2)

SM3502
and lock nuts (1).
: 30 mm
: 185 Nm
7. Connect lubrication pipe (12) to main distributor;

connect lubrication pipes (13) and (14) to each
boom cylinder. Tighten the connection to specifi-
cation.
12
: 12 mm, 19 mm
: 29 Nm, 35 Nm
8. Disconnect lubrication pipes from the boom foot

R3886
boss. R3886
9. Remove plug (13) and install an adeguate grease

fitting into plug (13) removed hole.
Plug tapered thread: 3/8 GAS - UNI339
13 13
R3889
R3887
10. Fill grease via grease fitting.
Remove grease fitting and re-install the plug (13)
in the original position.
11. Connect lubrication pipes on the boom foot boss.
NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
Run the engine at idle. Check hose connections for
any oil leakage.
14
IMPORTANT - Bleed air from hydraulic circuit. R3888

W4-1-6 E485
FRONT ATTACHMENT
(standard and BEH versions)
F E
G
C
H
D J
A
I
K
B
SM1328
Clearance of pin and bushing on front attachment

Unit: mm
Parts Name Standard Allowable Limit Remedy
A Pin 120 119.0

Bushing 120 121.5
B Pin 110 109.0

Boss (Main Frame) 110 111.5
Bushing (Boom Cylinder) 110 111.5
C Pin 120 119.0

Bushing (Boom Cylinder) 120 121.5
Boss (Boom) 120 121.5 Replace
pin and/or
D Pin 120 119.0 bushing
Bushing 120 121.5
E Pin 110 109.0

Boss (Arm) 110 111.5
Bushing (Arm Cylinder) 110 111.5
F Pin 120 119.0

Boss (Boom) 120 121.5
Bushing (Arm Cylinder) 120 121.5
E485 W4-1-7
FRONT ATTACHMENT
Unit: mm
Parts Name Standard Allowable Limit Remedy
G Pin 110 109.0

Boss (Arm) 110 111.5
Bushing (Bucket Cylinder) 110 111.5
H Pin 110 109.0

Bushing 110 111.5
Bushing (Bucket Cylinder) 110 111.5 Replace
pin and/or
I Pin 100 99.0 bushing
Bushing 100 101.5
J Pin 110 109.0

Bushing 110 111.5
K Pin 110 109.0

Bushing 110 111.5
IMPORTANT - Be sure to install front attachment bushings using a press.

W4-1-8 E485
FRONT ATTACHMENT
BUCKET TEETH
REPLACEMENT
WARNING
Keep people not involved in the maintenance work
outside the working area.
Wear adequate personal clothes and glasses with
side shields as a protection against flying debris.
• Ensure the machine is parked on a level surface.
• Rest the bucket to the ground.

1
• Switch off the auto-idle, fully turn the engine speed
manual control anticlockwise, stop the engine,
remove the ignition key and move the safety lever
in the locked position (LOCK).
• Using a hammer and a drift, as shown, drive the lock

pin (1) from its seat and remove the tooth (2).
NOTE - Hit the lock pin (1) with the drift (2) on the pin
tapered portion to drive it out of its seat.
2 M0270
• Install a new insert of rubber (3) into the lock pin (1).
• Clean shank (4) surface and install a new tooth onto

the shank.
• Install the lock pin (1) into its seat and drive it in
using a drift and a hammer until it is fully seated.
M0269
E485 W4-1-9
FRONT ATTACHMENT
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION
d
e
f c
b
j
o p
k
i n
h m
g l
q
Section A Section B
SM1330
Unit: mm
E485 E485 BEH
a 527 527.5
b 54 (*) 53 (**) 53
c 750 ←
d 710 ←
e 550 584
f 1798 ←
g 643 ←
h 497 ←
i 110 ←
j 550 584
k 5 33
l 663 ←
m 471 ←
n 110 ←
o 0° ←
p 45° ←
q 663 ←
(*) Arm: 4.04 m
(**) Arm: 2.90 m and 3.45 m
W4-1-10 E485
FRONT ATTACHMENT
NOTES:
E485 W4-2-1
CYLINDERS
REMOVAL AND INSTALLATION OF CYLINDERS
WARNING
Possible leakages of fluids under pressure can penetrate the skin, resulting in serious injuries.
Prevent this dangers by releasing residual pressure prior to disconnecting hydraulic pipes or any other pipes.
Hydraulic oil, at the end of the work shift, can be very hot and cause, when spilling, possible serious burns. Before
starting any intervention, make sure that oil and components have cooled off.
the hydraulic oil tank cap can be ejected if the residual pressure in the system is not released first.
Press the valve located on the hydraulic oil tank to bleed the residual pressure trapped inside the tank.
Preparation
1. Park the machine on firm, level ground.

Position the front attachment as illustrated and
lower the bucket to the ground.

SM1317
Removal of Bucket Cylinder
1. Insert wooden block (15) between bucket cylinder

(1) and arm (8).
1
2. Completely release the residual pressure from the

hydraulic circuit by performing the “Hydraulic Circuit
Pressure Release Procedure”. Refer to page W4-2-
9.
15
IMPORTANT - Pin (6) end of the link will drop when pin 8
is removed, possibly resulting in personal injury. Be 15
sure to secure the link using a piece of wire before
removing pin (6). SM1331
3. Loosen nuts (4) and bolt (5), in that order.

16
Pull out pin (6). Then, remove thrust plates (16).
5
: 30 mm
6 SM3506
W4-2-2 E485
CYLINDERS
4. Use wire (14) to secure cylinder rod (13) as illus-

trated. 13 1
5. Disconnect hoses (9) (Q.ty 2) from bucket

cylinder (1).
Put plugs on cylinder pipes and hoses.
: 41 mm
6. Disconnect lubrication pipes from rod side and

bottom side of cylinder.
14
: 12 mm, 19 mm SM1333
17
WARNING
Bucket cylinder mass: 10
416 kg 12
7. Use a hoist to lift slightly bucket cylinder (1).

Loosen locking nuts (11) remove screw (12) and 11
pull-out pin (10) with the help of a mallet and a bar
so that the end of the cylinder is free. Recover
adjusting shims (17).
1
: 30 mm
8. Remove bucket cylinder (1). 9

R3890
E485 W4-2-3
CYLINDERS
Installation of Bucket Cylinder

17
WARNING 10
Bucket cylinder mass: 12
416 kg
1. Connect bucket cylinder (1) to a crane using a sling

belt. 11
Align the hole on the bucket cylinder tube with the
pin hole on the arm-tip bracket.
2. Install adjusting shims (17) and insert pin (10), 1

install screw (12) and tighten lock-nuts (11).
: 30 mm
9
: 185 Nm
9
R3890
3. Connect two hoses (9) to bucket cylinder (1).
: 41 mm
: 210 Nm
4. Align the bucket cylinder rod with bucket links (2),

(3).
Install thrust plates (16) and pin (6).

the arm control lever.
5. Install bolt (5), onto pin (6) and stopper (18); tighten
lock nuts (4).
: 30 mm
: 185 Nm
6. Connect lubrication pipes to rod side and bottom 2 5 18 16

side of cylinder.
: 12 mm, 19 mm
: 29 Nm, 35 Nm
IMPORTANT - If link (3) has been disconnected from

the arm, be sure to insert thrust plate (16) when
connecting it.
NOTE - Fill the hydraulic oil tank with hydraulic oil to 6 3 4

the specified level. SM3506

any oil leakage.
IMPORTANT - Bleed air from hydraulic circuit.

W4-2-4 E485
CYLINDERS
Removal of Arm Cylinder

1
1. Insert a wooden block between arm cylinder (1) and
boom (12).

W4-2-9.
12 SM1347
3. Loosen lock-nuts (10) and remove screw (11).

13
: 30 mm
11
9
2 1
4. Remove pin (9) and thrust plate (13).
10
R0064
5. Use wire to secure cylinder rod (2) as illustrated.
SM1337
6. Disconnect arm cylinder hoses (7), (16).

Put plugs on the pipe on arm cylinder (1) and hoses.
1
: 12 mm
8
7
7. Disconnect Iubricant supply pipe (8).
: 12 mm
16
R0065
E485 W4-2-5
CYLINDERS
WARNING 1
Arm cylinder mass:
591 kg
8. Use a crane to slightly hoist arm cylinder (1).
SM1335
9. Loosen lock nuts (4). Remove bolt (5) and pin (3).
Then remove thrust plate (15) from arm cylinder (1). 1 5 15
3
: 30 mm
R0066
W4-2-6 E485
CYLINDERS
Installation of Arm Cylinder
WARNING
Arm cylinder mass:
591 kg
1. Use a crane to install arm cylinder (1) to the boom

bracket.
2. Install adjusting shims (15), pin (3), install screw (5)

into pin (3) and tighten lock-nuts (4). 1 5 15 3
: 30 mm
: 185 Nm 8
7
3. Attach lubricant supply pipe (8) and arm cylinder
hoses (7) and (16).
: 12 mm 4
: 29 Nm
: 12 mm
16
: 175 Nm
R0067
4. Remove wire (6) from arm cylinder (1).

Slightly hoist arm cylinder (1) and align the arm
cylinder rod with arm.

the arm control lever. 6
2
5. Install adjusting shims (13), pin (9), install screw
(11) into pin (9) and tighten lock-nuts (10).
: 30 mm SM1337
: 185 Nm
NOTE - Fill hydraulic oil tank with hydraulic oil to the

13
specified level.
Run the engine at idle. Check hose connections for 11
9
any oil leakage.
2
1
IMPORTANT - Bleed air from hydraulic circuit.
10 R0064
E485 W4-2-7
CYLINDERS
Removal of Boom Cylinder
1. Park the machine on firm, level surface and lower

the bucket teeth and arm top to the ground with the
arm and bucket cylinders fully retracted as illu-
strated.
2. Disconnect lubricant supply pipes (1).

SM1317
: 19 mm
1
WARNING
Boom cylinder mass:
415 kg
3. Use a crane to hoist the boom cylinder.

3
4. Loosen lock nuts (2), remove bolt (3) and stopper
(4).
Using bar and hammer, tap pin (5) until the boom
cylinder is free. Remove thrust plate (6).
: 30 mm
4
5. Use a wire to secure the boom cylinder rod as 2
illustrated.
6 5
SM3511
Lower cylinder on proper stand.

W4-2-9.
7. Disconnect lubrication pipes (14), boom cylinder

hoses (11) (Q.ty 4). Put plugs on cylinder pipes.
: 12 mm, 41 mm
8. Remove securing screws (8) complete with wash-

ers, then remove pin (9) and recover adjusting SM1342
shims (10).
: 36 mm
WARNING
Boom cylinder mass: 11 11
415 kg
9
10
9. Hoist the boom cylinder with a crane.
Remove the other boom cylinder following the same
procedures. 10
14 10 8 10 14
R3892
W4-2-8 E485
CYLINDERS
Installation of Boom Cylinder
WARNING
Boom cylinder mass:
415 kg
1. Use a crane to install the boom cylinders to the main

frame.
2. Install adjusting shims (10) and pin (9), then tighten

securing screws (8) complete with washers. SM1342
: 36 mm
: 930 Nm
3. Install the other side boom cylinder.
4. Connect lubrication pipes (14), connect the boom 11 11

cylinder hoses (11) (Q.ty 4).
9
: 12 mm, 41 mm
: 29 Nm, 210 Nm 10
5. Hoist the boom cylinder, and align the rod side with
the boom. 10
14 10 8 10 14
the boom control lever.
R3892
WARNING
Prevent personal injury. Metal fragments may fly off
when a hammer is used to insert pins. Be sure to
wear necessary protection, such as goggles,
hardhat, etc. 3
6. Install pin (5) using a bar and hammer, then install

thrust plates (6).
7. Install bolt (4), stopper (3), and lock nuts (2).

Tighten lock nuts (2). 4
: 30 mm 2
6 5 6
: 185 Nm SM3511
8. Install lubricant supply pipes (1).

: 19 mm
: 35 Nm
1
9. Install other boom cylinder following the same
procedure.
NOTE - Fill the hydraulic oil tank with hydraulic oil to

the specified level.
any oil leakage.
IMPORTANT - Bleed air from hydraulic circuit. SM1346

E485 W4-2-9
CYLINDERS
HYDRAULIC CIRCUIT PRESSURE

RELEASE PROCEDURE
The procedure for the release of the pressure inside

the hydraulic system can be performed in two ways:
- pressure release with engine in running;

- pressure release with engine inoperative.
Pressure release with engine running
1. The switch, located behind the operator's seat,

provides the release of the pressure inside the PR
hydraulic system of the machine.
NOTE - The pressure bleeding operation must be

performed with engine in operation.
To release the pressure of the hydraulic system, press

switch (PR) to discharge the pressure upstream the
control valve and actuate, afterward, the control levers
to discharge the pressures downstream the control
R0074
valve.
To re-instate normal operating conditions for the hy-
draulic system, with engine inoperative, press switch
(PR) again to return it into inactive position.
NOTE - The function is subject to the self-diagnosis

automatic procedure. In the event the pressure dis-
2
charge operation does not occur in an optimised
manner, the monitor will display "PR"; in this case
repeat the operation from the beginning.
Pressure release with engine inoperative
In case the engine is inoperative and can not be re-

started, but the electrical system is available, proceed
as follows:
R1571
1. Set the key switch to ON position.
2. More the safety lever (2) to unlock position.
3. Move the pilot valves some times in order to

discharge any pressures, using the hydraulic accu-
mulator charge.
W4-2-10 E485
CYLINDERS
In case of hydraulic accumulator failure or unavailabil-

ity of electrical system, proceed as follows:
WARNING
• Be sure to slowly loosen the overload relief valves.
Quick loosening of the overload relief valves may
cause pressurized oil to spout, possibly resulting in
severe burns and/or oil penetration of skin.
• Make sure that nobody is standing under or near the
front equipment prior to starting the procedure for
5
pressure releasing.
4
Machine without anti-drop valves
1. Get over the upperstructure and remove the cover
in correspondence with the control valve. Identify
the overload relief valve (6) related to the circuit on
wich maintenance operations to be performed.
Make reference to the control valve lay-out on next 6
page.
2. Make a reference mark between the valve body,
lock-nut (4) and setting screw (5) of the related
overload relief valve (6).
3. Loosen lock-nut (4).
: 19 mm
4. Loosen slowly setting screw (5) to release the pres-
sure.
: 6 mm
R3861
5. Return setting screw (5) and lock-nut (4) to their
original position, making reference to the mark
previously made.
Machine with anti-drop valves

In case the machine is equipped with anti-drop valves 2
(1) that trap the residual pressure in the cylinder on 3
wich maintenance operations to be performed, to
release the pressure, proceed as follows:
WARNING
Make sure that nobody is standing under or near the
front equipment prior to starting the procedure for
pressure releasing.
1. Make a reference mark between the anti-drop valve

body (1), lock-nut (3) and setting screw (2).
2. Loosen lock-nut (3).
: 19 mm 1 R1573
3. Loosen slowly setting screw (2) to release pressure
and checking the cylinder movement.
: 6 mm
4. Return setting screw (2) and lock-nut (3) to their
original position, making reference to the mark
previously made.
E485 W4-2-11
CYLINDERS
2
4
View from the top of the machine
View from the bottom of the machine
R3862
1 - Boom cylinder (bottom side) 4 - Arm cylinder (rod side)

2 - Boom cylinder (rod side) 5 - Bucket cylinder (bottom side)
3 - Arm cylinder (bottom side) 6 - Bucket cylinder (rod side)
W4-2-12 E485
CYLINDERS
DISASSEMBLY CYLINDERS
Boom Cylinder
1b 1a 1 3a 3 5
1b
7 4a 4b
4
10 13 12 2b
2a
2
2b
6 8 11 9
R3863
1 - Rod assy 3a - Wiper ring 8- Cushion bushing

1a - Bushing 4 - Head 9- Seals piston
1b - Wiper (Q.ty 2) 4a - Bushing 10 - Piston
2 - Tube assy 4b - Snap ring 11 - Shim
2a - Bushing 5- Back-up + O-Ring 12 - Set screw
2b - Wiper (Q.ty 2) 6- Seal cushion 13 - Steel ball
3 - Seals rod 7- Screw M27 (Q.ty 8)
E485 W4-2-13
CYLINDERS
Disassembly of Boom Cylinders 5. Remove set screw (12) and steel ball (13).
Be sure to thoroughly read all the precautions for

disassembly/assembly work on page W1-1-1 before
NOTE - Cut away its mushroomed portion using a drill
starting the disassembly procedure.
first, as set screw was mushroomed with a punch and
hammer at two places after it had been screwed in.
The disassembly procedure below starts on the
premise that the hydraulic lines and the line securing
bands have been removed. : 8 mm
6. Loosen piston (10) using special tool (380000812).

WARNING
Remove piston (10), shim (11), cushion bushing (8)
and cushion seal (6).
Socket to loosen piston (10):

1. Lift and securely place the cylinder on a workbench
130 mm (380001232)
using a crane. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from the cylinder.
SM1366
7. Remove seals piston (9).

SM1364
2. Fully extend cylinder rod (1). Secure the rod end 8. Remove cylinder head (4) from cylinder rod (1).
using a crane. Remove socket bolts (7) from cylin-
der head (4).
9. Remove Back-up + O-Ring (5) from cylinder head
: 19 mm (4) then remove seals rod (3), wiper ring (3a),
bushing (4a) and snap ring (4b).
IMPORTANT - Be sure to pull cylinder rod (1) straight

so as not to damage the sliding surfaces.
3. Pull out cylinder head (4) from cylinder tube (2) by

tapping with a plastic hammer.
4. Secure cylinder rod (1) on special tool (380000812).

Put matching marks between cylinder rod (1) and
piston (10).
380000812
SM1365
W4-2-14 E485
CYLINDERS
Bucket Cylinder
1a 1 3a 3 4 5
1b
1b 6 4a 4b
8 12 11
2b
2
2a
7 9 10 2b
R3864
1 - Rod assy 3a - Wiper ring 8- Piston

1a - Bushing 4 - Head 9- Seals piston
1b - Wiper (Q.ty 2) 4a - Bushing 10 - Nut
2 - Tube assy 4b - Snap ring 11 - Set screw
2a - Bushing 5- Back-up + O-Ring 12 - Steel ball
2b - Wiper (Q.ty 2) 6- Screw M22 (Q.ty 12)
3 - Seals rod 7- Cushion bushing
E485 W4-2-15
CYLINDERS
Disassembly of Bucket Cylinders 5. Remove set screw (11) and steel ball (12).

premise that the hydraulic lines and the line securing
bands have been removed. : 8 mm
6. Loosen nut (10) using special tool (380000812).

WARNING
Remove piston (8) and cushion bushing (7).
Bucket cylinder mass: 416 kg
Socket to loosen nut (10):
130 mm (380001232)
1. Lift and securely place the cylinder on a workbench
using a crane. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from the cylinder.
SM1366
7. Remove seals piston (9).

SM1364
8. Remove cylinder head (4) from cylinder rod (1).

2. Fully extend cylinder rod (1). Secure the rod end
der head (4). 9. Remove Back-up + O-Ring (5) from cylinder head
(4) then remove seals rod (3), wiper ring (3a),
: 17 mm bushing (4a) and snap ring (4b).


tapping with a plastic hammer.
4. Secure cylinder rod (1) on special tool (380000812).

Put matching marks between cylinder rod (1) and
nut (10).
380000812
SM1365
W4-2-16 E485
CYLINDERS
Arm Cylinder
1b 3a 3b 3c 4 6 5 5
1a 1 4a 4b
7
1b
2b
10 12 13 14
2a 2
8 9 11 15 11 10 2b
R3865
1 - Rod assy 3c - Seal ring 9- Back-up + O-Ring

1a - Bushing 4 - Head 10 - Dust ring
1b - Wiper (Q.ty 2) 4a - Bushing 11 - Wear ring
2 - Tube assy 4b - Snap ring 12 - Piston seal
2a - Bushing 5- Back-up + O-Ring 13 - Nut
2b - Wiper (Q.ty 2) 6- O-Ring 14 - Set screw M8
3a - Wiper ring 7- Screw M18 (Q.ty 20) 15 - Piston
3b - Rod packing 8- Cushion bushing
E485 W4-2-17
CYLINDERS
Disassembly of Arm Cylinder 5. Remove set screw (14).

premise that the hydraulic lines and the line securing : 6 mm
bands have been removed.
6. Loosen nut (13) using special tool (380002070).
WARNING
Arm cylinder mass: 591 kg 380002070
1. Place the cylinder horizontally on a workbench

using a crane and secure it.
Drain hydraulic oil from the cylinder.
R3867
7. Remove piston (15) and cushion bushing (8) in that

order.
Strike the piston (15) lightly with plastic hammer to
remove it.
SM1364
2. Fully extend cylinder rod (1). Secure the rod end

der head (4).
: 14 mm

R3868

tapping with a plastic hammer and draw out rod assy
8. Remove dust rings (10), wear rings (11) and seal
from cylinder tube (2).
piston (12).
4. Fix rod assy (1) by holding its clevis section in a
9. Remove cylinder head (4) from cylinder rod (1).
vise. Fix the rod assy (1) rigidly as piston nut (13)
is tightened to a high torque.
10. Remove Back-up + O-Ring (5) from cylinder head
(4) then remove wiper ring (3a), rod packing (3b),
seal ring (3c), snap ring (4b) and bushing (4a).
13
R3866
W4-2-18 E485
CYLINDERS
ASSEMBLY CYLINDERS
Boom Cylinder
1 3a 3 4a 4b 5 2 8 6 11 9 12 13
7 4 10
R3869
1 - Rod assy 4b - Snap ring 10 - Piston

2 - Tube assy 5 - Back-up + O-Ring 11 - Shim
3 - Seals rod 6 - Seal cushion 12 - Set screw
3a - Wiper ring 7 - Screw M27 (Q.ty 8) 13 - Steel ball
4 - Head 8 - Cushion bushing
4a - Bushing 9 - Seals piston
E485 W4-2-19
CYLINDERS
Assembly of Boom Cylinder 7. Install shim (11) and piston (10) to cylinder rod (1).
Tighten piston (10) using special tool (380000812).
1. Install bushing (4a) to cylinder head (4) using a
press.
Special tools for bushing installation (4a):
Ø 115 mm (380001889) 380000812
IMPORTANT - Be sure that the rings are installed

correctly.
SM1365
2. Install seals rod (3), back-up ring + O-Ring (5) and Be sure to align the matching mark on the rod with
snap ring (4b) on the cylinder head (4). that on the piston.
Piston (10) Turning Special Tools:
130 mm (380001232)
3. Install wiper ring (3a) to cylinder head (4) using a
plastic hammer. : 18100 Nm
Special tool : (380001887)
8. Align the holes on cylinder rod (1) and piston (10).

4. Install seals (9) to piston (10). Insert steel ball (13) into the hole, and tighten set
Special tool for seals assembly: (380001822) screw (12) into the hole.
Mushroom the head of set screw (12) at two places
using a punch and hammer.
: 8 mm
: 96.6 ± 18.2 Nm
IMPORTANT - Be sure to align cylinder rod (1) with the

center of cylinder tube (2) when inserting, in order to
10 avoid damaging the rings.
SM1367
9. Secure cylinder tube (2) horizontally using a work
5. Install cylinder head (4) to cylinder rod (1). bench. Insert cylinder rod (1) into cylinder tube (2).
Special tool: (380001886)
10. Install cylinder head (4) to cylinder tube (2).

Tighten socket bolts (7).
IMPORTANT - Be sure that the cushion seal slit faces
toward the piston and that the cushion bearing oil
: 19 mm
groove faces the correct direction.
: 1140 ± 206 Nm
6. Install cushion seal (6) and cushion bushing (8) to

cylinder rod (1).
W4-2-20 E485
CYLINDERS
Bucket Cylinder
1 3a 3 4a 4b 5 2 7 9 10 11 12
6 4 8
R3870
1 - Rod assy 4a - Bushing 8 - Piston

2 - Tube assy 4b - Snap ring 9 - Seals piston
3 - Seals rod 5 - Back-up + O-Ring 10 - Nut
3a - Wiper ring 6 - Screw M22 (Q.ty 12) 11 - Set screw
4 - Head 7 - Cushion bushing 12 - Steel ball
E485 W4-2-21
CYLINDERS
Assembly of Bucket Cylinder 7. Tighten nut (10) using special tool (380000812).
1. Install bushing (4a) to cylinder head (4) using a

press.
380000812
Special tool for bushing installation (4a):
Ø 120 mm (380001813)
IMPORTANT - Be sure that the rings are installed

correctly. SM1365
Be sure to align the matching mark on the rod with

2. Install seals rod (3), back-up ring + O-Ring (5) and that on the nut.
snap ring (4b) on the cylinder head (4). Nut (10) Turning Special Tool:
130 mm (380001232)
: 16800 Nm
3. Install wiper ring (3a) to cylinder head (4) using a
plastic hammer.
Special tool: (380001891) 8. Align the holes on cylinder rod (1) and nut (10).
Insert steel ball (12) into the hole, and tighten set
screw (11) into the hole.
4. Install seals (9) to piston (8). Mushroom the head of set screw (11) at two places
Special tool for seals assembly: (380001822) using a punch and hammer.
: 8 mm
: 96.6 ± 18.2 Nm
IMPORTANT - Be sure to align cylinder rod (1) with the

center of cylinder tube (2) when inserting, in order to
avoid damaging the rings.
SM1367
9. Secure cylinder tube (2) horizontally using a work
bench. Insert cylinder rod (1) into cylinder tube (2).
5. Install cylinder head (4) to cylinder rod (1).

Special tool: (380001892) 10. Install cylinder head (4) to cylinder tube (2).
Tighten socket bolts (6).
6. Install cushion bushing (7), piston (8) and nut (10) to

: 17 mm
cylinder rod (1).
: 711 Nm
W4-2-22 E485
CYLINDERS
Arm Cylinder
A 7 A
14 13 10 11 12 11 10 15 9 8 2 5 6 4b 4 4a 3c 3b 3a
Section A-A
R3871
1 - Rod assy 4b - Snap ring 11 - Wear ring

2 - Tube assy 5- Back-up + O-Ring 12 - Piston seal
3a - Wiper ring 6- O-Ring 13 - Nut
3b - Rod packing 7- Screw M18 (Q.ty 20) 14 - Set screw M8
3c - Seal ring 8- Cushion bushing 15 - Piston
4 - Head 9- Back-up + O-Ring
4a - Bushing 10 - Dust ring
E485 W4-2-23
CYLINDERS
Assembly of arm cylinder

ASSEMBLING PISTON ASSY
1. Apply hydraulic oil (or vaseline if not available) and 380002071
install back-up ring + O-Ring (9).
2. To install piston seal (12), immerse it in hot hydrau-

lic oil heated to 150 ~ 180 °C for about five minutes.
Then put it swiftly into the groove in the outer 12
surface of the piston, using the special tool
(380002071). 9 R3872
3. Hold down piston seal (12), using the special tool

(380002072).
380002072
4. Attach wear ring (11), dust ring (10) when inserting
piston (15) into cylinder tube (2).
R3873
ASSEMBLING HEAD ASSY

(A)
1. Press bushing (4a) into head (4) using a metal ring 4a
A. Then fix snap ring (4b) into the groove B. Before
pressing in the bushing, coat the inner face of head (B)
(4) with hydraulic oil.
4
R3874
2. Apply grease to wiper seal (3a) and fit it into the head
(4) using the special tool (380002084).
380002084
3. Fit seal ring (3c) and rod packing (3b) in their 3a RUBBER
grooves in that order.
LIP
NOTE - Before setting packings, coat them with

METAL RING
hydraulic oil (or vaseline if not available). If you forget
the coating, the packings may be scored. R3875
Rod packing (3b) is harder than other packing and it
would be difficult to deform them in a heart shape. In
such a case, put a rod packing in the groove obliquely
by hand as deep as possible and push in the last part
with a push bar till it is set with a click.
Rod packing (3b) has direction in which it should be
4
fixed, therefore check its fitting directions.
If rod packing (3b) is set upside down, the lip may be
damaged. Check that it is positioned correctly.
3c
3b
R3876
W4-2-24 E485
CYLINDERS
INSERTING HEAD ASSY TO ROD ASSY

1. Fix the piston rod assy (1) into the work bench.
2. Attach O-Rings + back-up rings (5) onto head assy

5 6 4a 4
(4). Apply O-Rings with hydraulic oil. Put O-Ring (6)
into the groove by pulling it by hand.
3. Apply hydraulic oil to the outer of the rod assy (1),

to the inner diameter of seals (3a, 3b, 3c), and the 3c 3b 3a
bushing (4a). Hold the head assy (4) with care and
allow it to slide over rod assy (1).
NOTE - In some cases may be difficult to slide the

head assy (4) over the rod assy (1) for the resistance 13 (A) 1 R3877
of rod packing (3b) and seal ring (3c).
In such a case, force it in, using a suitable plate A and
piston nut (13).
4. If the plate A and the piston nut (13) have been used,
remove them, then push head (4) in further by about
300 mm.
During the operation, use care so not to allow the
head (4) to turn against rod assy (1).
ASSEMBLING PISTON ASSY TO ROD ASSY 9 8 1

1. Fit cushion bushing (8) and install the piston assy
(15) on rod assy (1).
NOTE - Exercise care as cushion bushing (8) has an

orientation in which it should be installed.
2. Apply hydraulic oil to the inside of the piston assy

and to the piston mounting part of rod assy (1) with
care so O-Ring (9) not scored. Then install the
piston assy.
15 R3878
3. Tighten the nut (13) using special tool (380002070)
: 1863 Nm
4. Screw setscrew (14) in.

1
: 6 mm
: 14.7 Nm
5. After tightening the setscrew caulk the two places

of the thread of the piston nut side to secure the
setscrew.
6. Fit wear ring (11), dust ring (10). Apply grease on 380002070
wear ring (11), dust ring (10) and wind and fit it
around the groove.
Shift it 90 degree in order that the slits are not on the
same axis. 13
R3879
E485 W4-2-25
CYLINDERS
OVERALL ASSEMBLY
1. Place a V-block on a rigid work bench. Place the
cylinder tube assy (2) on it and fix the assy by 2
passing a bar through the clevis pin hole of pin
bushing to lock the assy.
2. Insert the rod assy (1) into the cylinder tube assy
(2), while lifting and moving the rod assy with a
crane. Align the center of the rod assy with the
center of the cylinder tube assy and put it in straight
forward.
When inserting, make sure that wear ring (11), dust
ring (10) on the perimeter of the piston is not out on
the groove. 1 11 10 R3880
3. Turn up socket bolts (7). Apply a proper amount of

Loctite #242 to the tip of the screw threads of socket 7
bolt (7) to prevent it from loosening.
: 14 mm 1
: 353-382 Nm
R3881
W4-2-26 E485
CYLINDERS
Rod
SM1356
Unit: mm
Model Cylinders STANDARD (A) Remedy
Boom 130 ± 0.03 Replace or
E485 Arm 115 ± 0.03 plate with
Bucket 120 ± 0.03 chromium
E485 W4-2-27
CYLINDERS
SPECIAL TOOLS
Boom and Bucket Cylinders
Piston nut socket wrench:
380001232 for boom cylinders (130 mm)

380001232 for bucket cylinder (130 mm)
Use nut loosening/tightening workbench: 380000812 SM1366
Tools kit seals installation:
380001822 for boom cylinders

380001822 for bucket cylinder
SM1369
Wiper installation tool:

SM1370
Tool for the installation of the rod guide bushing:
380001889 for boom cylinders (Ø 115 mm)

380001813 for bucket cylinder (Ø 120 mm)
SM1371
Head installation tool:

SM1372
W4-2-28 E485
CYLINDERS
Arm Cylinder
380002070 Piston nut wrench
R3882
380002071 Piston seal installation tool
R3883
380002072 Piston seal retainer tool
R3884
380002084 Wiper ring installation tool
R3885
SECTION 5 E485
ENGINE AND ACCESSORY
CONTENTS
Group 1 - General Information Group 5 - Engine III (Assembly)

General servicing precautions ................ W5-1-1 Rocker arm shaft assembly ................... W5-5-1
Notes on the format of this section ........ W5-1-2 Cylinder head assembly ......................... W5-5-3
About angular tightening ......................... W5-1-5 Piston and connecting rod assembly ...... W5-5-6
Main data and specifications .................. W5-1-6 Assembly 1 ............................................ W5-5-9
External view ......................................... W5-1-7 Assembly 2 .......................................... W5-5-16
Standard bolt torque specifications ........ W5-1-8 Assembly 3 .......................................... W5-5-22
Tightening torques for main parts ......... W5-1-10 Timing gear train diagram ..................... W5-5-31
Model and identification
serial number .................................... W5-1-18
Group 6 - Lubrication System

Introduction ............................................ W5-6-1
Group 2 - Maintenance Oil Pump ................................................ W5-6-2
Lubricating system ................................. W5-2-1 Oil Filter ................................................. W5-6-6
Fuel system ........................................... W5-2-3 Oil Cooler ............................................... W5-6-7
Cooling system ...................................... W5-2-6
Valve clearance adjustment ................... W5-2-7
Fuel injection timing ............................... W5-2-9
Recommended lubricants ..................... W5-2-12 Group 7 - Cooling System
Cylinder compression pressure ............ W5-2-13 Introduction ............................................ W5-7-1
Engine repair kit ................................... W5-2-14 Water Pump ........................................... W5-7-2
Thermostat ............................................ W5-7-9
Group 3 - Engine I (Disassembly)

External view ......................................... W5-3-1 Group 8 - Fuel System
Disassembly 1 ....................................... W5-3-2 Introduction ............................................ W5-8-1
Disassembly 2 ....................................... W5-3-5 Injection Nozzle ..................................... W5-8-2
Disassembly 3 ....................................... W5-3-8
Cylinder head disassembly .................. W5-3-12
Rocker arm shaft ASM disassembly .... W5-3-14
Piston and connecting rod disassembly . W5-3-15 Group 9 - Turbocharger
Turbocharger servicing ........................... W5-9-1
Troubleshooting ...................................... W5-9-2
Construction ........................................... W5-9-4
Group 4 - Engine II (Inspection and Disassembly .......................................... W5-9-5
Repair) Cleaning ................................................. W5-9-8
Inspection and repair (1) Inspection ............................................ W5-9-10
(Cylinder head) .................................... W5-4-1 Reassembly ......................................... W5-9-12
Inspection and repair (2) Service standard .................................. W5-9-18
(Cylinder block) ................................. W5-4-11
SECTION 5 E485
Group 10 - Engine Electrical Group 12 - Special Tools

Starter ................................................. W5-10-1 Special tools list .................................. W5-12-1
Alternator ........................................... W5-10-13
Group 13 - Repair Standards

Group 11 - Troubleshooting Repair standards .................................. W5-13-1
Starting difficulties ............................... W5-11-1
1. Starter doesn't turn ...................... W5-11-1
2. Starter turns, but engine
doesn't turn .................................. W5-11-2 Group 14 - Electronic Control System
3. The engine turns and
System configuration ........................... W5-14-1
fuel reaches the injection pump,
RED IV governor .................................. W5-14-2
but it doesn't start ........................ W5-11-3
Component operation description ......... W5-14-5
4. The engine turns,
Control description ............................... W5-14-9
but doesn't start ........................... W5-11-3
Standard control function ................... W5-14-13
5. Fuel isn't supplied
Fail-safe functions (Safety devices) ... W5-14-16
to the injection pump .................... W5-11-4
External connection diagram of ECU .. W5-14-17
Unstable idling rpm .............................. W5-11-5
Troubleshooting .................................. W5-14-19
Lack of power ...................................... W5-11-7
Self-diagnostics ................................. W5-14-29
Excessive fuel consumption .............. W5-11-10
Explanation of terms and
Excessive oil consumption ................ W5-11-12
abbreviations .................................. W5-14-51
Overheating ....................................... W5-11-13
White smoke in exhaust ..................... W5-11-14
Black smoke in exhaust ..................... W5-11-15
Low oil pressure ................................. W5-11-16
Engine sounds ................................... W5-11-18
1. Knocking ................................... W5-11-18
2. Gas leak sounds ........................ W5-11-18
3. Continuous sounds .................... W5-11-19
4. Clanking sounds ........................ W5-11-20
Note - Before using this section to perform maintenance and repairs, be sure to read the paragraph "General
Repair Instructions" included in Group 1 (General Information).
E485 W5-1-1
GENERAL INFORMATION
GENERAL SERVICING PRECAUTIONS

1. Before performing any inspections or maintenance work, disconnect the battery’s ground cable to prevent any
damage from shorted wires.
2. Always use the proper tool for the job.
When a special tool is designated for a job, be sure to use only that special tool.
3. When replacement parts are required, consult the appropriate Parts Catalog.
4. Never reuse any cotter pins, gaskets, seals, o-ring, lock washers, or self-locking nuts removed in the course
of disassembly.
5. To facilitate reassembly, lay out engine parts in logical groups in the order in which they are removed.
Be especially careful to replace nuts and bolts in their proper locations, since characteristics such as length
and hardness may differ depending on the installation position.
6. Use identification labels or tags to mark valves, bearings, and pistons, to prevent confusing their proper order
and sequence.
7. Clean all parts before inspection and reassembly.

Be particularly sure to use compressed air to blow out oil ports and openings, to assure that they are free of
obstructions.
8. Be sure to apply oil or grease as appropriate to all rotating and sliding surfaces before reassembly.
9. Use sealants to prevent leaks where necessary.
10. Tighten all nuts and bolts to specified tightening torques.
11. After completing inspections and repairs, double check your work to confirm that the job has been done
properly.
W5-1-2 E485
GENERAL INFORMATION
NOTES ON THE FORMAT OF THIS SECTION

1. Use the Table of Contents at the beginning of the Section to find the general areas required.
2. Common technical data such as general maintenance, repair specifications, and tightening torques are listed
in the General Information group.
3. Each group is composed of “disassembly”, “inspection and repair”, “assembly” paragraphs. The only exception
is the treatment of the engine body itself, which is divided into three independent groups for ease of
explanation.
4. When similar maintenance procedures are applicable to multiple operations or parts, the manual will cross-
reference the page where the appropriate information can be found.
5. To provide brevity and conciseness, simple disassembly and repair operations are omitted, while more space
is devoted to explaining complex procedures such as adjustments and tightening torques.
6. The descriptions given in each chapter begin with an exploded diagram of the applicable parts, with numbers
indicated as shown below.
1 3
4
2 5
6 7 This number indicates the sequence of

the procedure.
10 8
13
Items enclosed in a frame are removed

14 and installed as a single unit, and the
order of disassembly and reassembly is
indicated in the illustration.
11
12 Parts listed beneath “Disassembly Steps”

or “Assembly Steps” are listed in the se-
quence in which they are removed or
Disassembly sequence
assembled.
1. Cylinder head cover 8. Cylinder head gasket
2. Head cover gasket 9. Water pump pulley
3. Camshaft upper bracket 10. Water pump
▲▲4. Camshaft ▲
▲11. Crankshaft pulley (with damper)
▲▲5. Rocker arm shaft assembly 12. Front cover
6. Thermostat housing ▲
▲13. Flywheel
(with thermostat unit) 14. Flywheel housing
▲▲7. Cylinder head
The triangle mark ▲ indicates a particu-

larly important part or operation, and is
accompanied by detailed instructions in
the text.
E485 W5-1-3
GENERAL INFORMATION
7. The following is a sample of the text in the Workshop Engine Section.
Measurement of cylinder Liner Projection

1. Place a straight edge 1 along the top edge of the 1
cylinder liner to be measured.
2. Using a feeler gauge 2 , measures the projection of
These tables indicate repair standards.
each cylinder liner.
Cylinder liner projection mm (in)
Standard
0.106 ~ 0.134 (0.0042 ~ 0.0053) Special tools are identified by name and/
The difference in cylinder liner projection between any or number.
two neighboring cylinders must not exceed 0.02 mm.
The illustration also indicates the proper
Cylinder Liner Removal
1.Attach a cylinder liner remover to the cylinder liner. procedure for using the special tool.
Cylinder liner remover : 1-85231-016-0
2. Confirm that the remover’s shaft anchor is hooked
firmly on the bottom of the cylinder liner.
3. Slowly rotate the remover’s shaft handle clockwise Symbols indicate the type of operation or
to remove the cylinder liner.
Note:
sequence to be performed. A detailed
Be careful not to damage the upper face of the cylinder
block when removing cylinder liners.
explanation of these symbols is given
below.
Cylinder Block Bore Measurement
1. At measuring point 1 , measure the cylinder block
bore in the four directions (W-W, X-X, Y-Y, Z-Z).
Measuring point 1 : 120 mm from upper face.
2. Calculate the average value of the four measure-
ments to determine the correct liner grade.
8. The following symbols appear throughout this Section, indicating the type of service operation or procedure
to be performed.
.... Removal .... Adjustment
.... Installation .... Cleaning
.... Disassembly .... Important operation; special care required
.... Assembly .... Tighten to specified torque
.... Alignment (marks) .... Special tool use required
.... Directional indication .... Use commercially available special tool
.... Inspection .... Lubrication with engine oil
.... Measurement .... Apply grease
.... Apply sealant

W5-1-4 E485
GENERAL INFORMATION
9. Measurements are indicated by “standard” or “limit”;

a “standard” value refers to the standard values at time of assembly.
A “limit” value is a maximum or minimum; measurements up to that value are usable.
Measurements falling beyond that value mean the part must be serviced, adjusted, or replaced.
10. Directional indications adopted within this manual are as follows;
Front: Toward the cooling fan when viewed from the flywheel side.
Right: Toward the fuel injection pump when viewed from the flywheel side.
Left: Toward the exhaust manifold when viewed from the flywheel side.
Rear: Toward the engine’s flywheel side.
11. “Cylinder numbers” and “Engine rotation direction”: Cylinder numbers are counted in sequence beginning form
the front side of the engine.
As a result, the first cylinder at the very front of the engine is cylinder No. 1, while the last cylinder toward the
rear is cylinder No. 6. The direction of engine rotation is clockwise when viewed from the cooling fan side.
Right
Flywheel
Front Rear
Left
Exhaust manifold
Cooling fan
12. “ASM” is an abbreviation for “assembly.”

E485 W5-1-5
GENERAL INFORMATION
ABOUT ANGULAR TIGHTENING
At present, the method most commonly used to tighten bolts is to specify a torque value to which the bolts should
be tightened. This method, however, has the disadvantage of being characterized by considerable fluctuation in
axial force for a given torque, with the result that when attempting to maintain the minimum necessary axial force,
the bolt may be sheared at its upper limit value.
In order to produce less fluctuation in axial force, the ideal method would be to tighten the bolt while measuring
the amount of its stretch, but since this is impossible in practice, a substitute method was conceived, namely
considering the relationship of thread pitch to bolt stretch. The angular tightening method thus focuses on the
amount the bolt is turned - directly related to thread pitch - in order to allow tightening of the bolt up unto the region
of plasticity, thus reducing the variation in axial force.
TIGHTENING METHOD
1. Apply molybdenum disulfide grease to the threads and setting faces of the nuts and bolts.
2. Tighten all bolts to the designated tightening torque values.
3. Next, make a mark at a point corresponding to one edge of the bolt as shown in the accompanying illustration,
then tighten the bolt by turning it by the designated angle.
Afterwards, be sure to check the mark to confirm whether the bolt has been tightened to the specified angle.
If this confirmation is not performed, and if the bolt is subsequently retightened using the angular tightening
method, it may break.
Note:
1. Tighten bolts in their designated sequence.
2. When using the angular tightening method, do not retighten.
After tightening Before tightning

Tighten
A
A B C D
C D
B Designated
E E tightening angle
F F
Use a wrench to rotate the bolt until the line On the surface of the bolt and material to be
(A - B) on the bolt is aligned with the desig- tightened, draw a line extending through the
nated angle line on the material (line E - F). center of the bolt (A - B on the bolt, C - D on
the material), and a line on the material sur-
face which is aligned with the center of the
bolt at the designated tightening angle (line
E - F).
LOCATIONS OF USE OF ANGULAR TIGHTENING METHOD

1. Cylinder head bolts (M14 bolts only)
2. Lower crankcase bolts (M14 bolts only)
3. Connecting rods, bearing cap nuts
4. Flywheel bolts
5. Idle gear shaft bolt (A)
W5-1-6 E485
GENERAL INFORMATION
MAIN DATA AND SPECIFICATIONS
Engine Model
AA-6SD1T
Item
Engine type 4-cycle,water-cooled

vertical in-line overhead camshaft
Combustion chamber type Direct injection
Cylinder liner type Dry type
Number of cylinders; bore x stroke mm 6 - 120 x 145
Total exhaust displacement L (cid) 9.839 (601)
Compression ratio 16.8 : 1
Dimensions (L x W x H) mm * 1384 x 859 x 1189
Weight kg * 693
Ignition sequence 1-5-3-6-2-4
Fuel used Diesel (2-D)
Fuel-injection pump type In-line Bosch
Governor Variable speed, electrically controlled type (Red IV)
Injection nozzle type Multi-hole type
Injection starting pressure MPa (kg/cm2/psi) * 17.7 - 22.1 (180 - 225/2570 - 3,200)
Fuel injection timing (BTDC) * 7°
Compression pressure MPa (kg/cm2/psi) 2.84 (29/412)
(warm engine, 200 rpm)
Inlet valve Open (BTDC) 15°
Close (ABDC) 39°
Exhaust valve Open (BBDC) 40°
Close (ATDC) 14°
Valve clearance Inlet valve mm 0.4
(cold engine)
Exhaust valve mm 0.4
Lubricating system Forced circulation type
Engine oil capacity; Oil pan L (qts) * Max 30 (31.7), Min 25 (26.4)
Total system capacity L (qts) * Max 35 (37), Min 30 (31.7)
Lubricating engine oil API service type CD, or CF
Oil cooler Water-cooled, internally mounted
Cooling method Forced circulation, pressurized water-cooled type
Cooling system volume L (qts) About 19 (20) (engine only)
Cooling fan * Dia. 850 mm, 6-blade, sucker type
Alternator V-A * 24 - 50
Starter V-kW * 24 - 5.5
Specifications marked with an asterisk (*) will vary according to engine application.
EXTERNAL
EXTERNALVIEW
VIEW Note:
Note:
E485
Main oil filter Oil dipstick

MODEL Cylinder head cover Engine details
Engine details may
may
MODELAA-6SD1T
AA-6SD1T depending on
vary
vary depending on
Turbocharger specifications.
the
the specifications.
Exhaust manifold
Timing check hole cover
Starter motor
Water drain plug
Intake cover Oil filter cap Partial oil filter

Oil cooler
Fan pulley
Oil drain plug
Nozzle holder Fuel filter Fan guide
Coupling ASM
GENERAL INFORMATION
Flywheel
housing
Flywheel Crank pulley
Injection pump
Alternator
Oil pan
W5-1-7
W5-1-8 E485
GENERAL INFORMATION
STANDARD BOLT TORQUE SPECIFICATIONS
The tightening torque values given in the table below are applicable to all bolts unless otherwise specified.
Standard bolt
N·m (kgf·m/lb·ft)
Bolt
Identif.
Bolt
Diameter
x pitch
(mm)
M6 x 1.0 4 - 8 (0.4 - 0.8/3 - 6) 5 - 10 (0.5 - 1.0/4 - 7) –––––––
M8 x1.25 8 - 18 (0.8 - 1.8/6 - 13) 12 - 23 (1.2 - 2.3/9 - 17) 17 - 30 (1.7 - 3.11/2 - 22)
M10 x 1.25 21 - 34 (2.1 - 3.5/5 - 25) 28 - 46 (2.8 - 4.7/20 - 33) 37 - 62 (3.8 - 6.4/28 - 46)
* M10 x 1.5 20 - 33 (2.0 - 3.4/15 - 25) 28 - 45 (2.8 - 4.6/20 - 33) 36 - 60 (3.7 - 6.1/27- 44)
M12 x 1.25 49 - 74 (5.0 - 7.5/36 - 54) 61 - 91 (6.2 - 9.3/45 - 67) 76 -114 (7.7 - 11.6/56 - 84)
* M12 x 1.75 45 - 69 (4.6 - 7.0/33 - 51) 57 - 84 (5.8 - 8.6/42 - 62) 72-107 (7.3 - 10.9/53 - 79)
M14 x 1.5 77 - 115 (7.8 -11.7/56 - 85) 93 -139 (9.5 - 14.2/69 -103) 114 -171 (11.6 -17.4/84 -126)
* M14 x 2.0 72 - 107 (7.3 - 10.9/53 - 79) 88 - 131 (9.0 - 13.4/65 - 97) 107 - 160 (10.9 - 16.3/79 - 118)
M16 x 1.5 104 - 157 (10.6 - 16.0/77 -116) 135 - 204 (13.8 - 20.8/100 - 150) 160 - 240 (16.3 - 24.5/118 -177)
* M16 x 2.0 100 - 149 (10.2 -15.2/74 -110) 129 - 194 (13.2 -19.8/96 -143) 153 - 230 (15.6 - 23.4/113 -169)
M18 x 1.5 151 - 226 (15.4 - 23.0/110 -166) 195 - 293 (19.9 - 29.9/144 - 216) 230 - 345 (23.4 - 35.2/169 - 255)
* M18 x 2.5 151 - 226 (15.4 - 23.0/110 -166) 196 - 294 (20.0 - 30.0/145 - 217) 231 - 346 (23.6 - 35.5/171 - 255)
M20 x 1.5 206 - 310 (21.0 - 31.6/152 - 229) 270 - 405 (27.5 - 41.3/199 - 299) 317 - 476 (32.3 - 48.5/234 - 351)
* M20 x 2.5 190 - 286 (19.4 - 29.2/140 - 211) 249 - 375 (25.4 - 38.2/184 - 276) 293 - 440 (29.9 - 44.9/216 - 325)
M22 x 1.5 251 - 414 (25.6 - 42.2/185 - 305) 363 - 544 (37.0 - 55.5/268 - 401) 425 - 637 (43.3 - 64.9/313 - 469)
* M22 x 2.5 218 - 328 (22.2 - 23.4/161 - 242) 338 - 507 (34.5 - 51.7/250 - 374) 394 - 592 (40.2 - 60.4/291 - 437)
M24 x 2.0 359 - 540 (36.6 - 55.0/265 - 398) 431 - 711 (43.9 - 72.5/318 - 524) 554 - 831 (56.5 - 84.7/409 - 613)
* M24 x 3.0 338 - 507 (34.5 - 51.7/250 - 374) 406 - 608 (41.4 - 62.0/299 - 448) 521 - 782 (53.1 - 79.7/384 - 576)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting.
E485 W5-1-9
GENERAL INFORMATION
The tightening torque values given in the table below are applicable to all bolts unless otherwise specified.
Flanged head bolt

Bolt
Identif.
Bolt
Diameter
pitch
(mm)
M6 x 1.0 5 - 9 (0.5 - 0.9/4 - 7) 6 - 12 (0.6 - 1.2/4 - 9) –––––––
M8 x 1.25 11 - 20 (1.1 - 2.0/8 - 15) 15 - 28 (1.6 - 2.9/12 - 21) 18 - 34 (2.1 - 3.4/15 - 25)
M10 x 1.25 23 - 39 (2.4 - 3.9/17 - 28) 35 - 59 (3.6 - 6.1/26 - 44) 42 - 71 (4.3 - 7.2/31 - 52)
* M10 x 1.5 22 - 37 (2.3 - 3.8/17 - 28) 35 - 58 (3.5 - 5.8/25 - 42) 40 - 67 (4.1 - 6.8/30 - 49)
M12 x 1.25 55 - 82 (5.6 - 8.4/40 - 61) 77 - 117 (7.9 - 11.9/57 - 86) 85 - 128 (8.7 - 13.0/63 - 94)
* M12 x 1.75 51 - 77 (5.2 - 7.8/38 - 56) 71 - 107 (7.3 - 10.9/53 - 79) 80 - 119 (8.1 - 12.2/59 - 88)
M14 x 1.5 83 - 125 (8.5 - 12.7/62 - 92) 115 - 172 (11.7 - 17.6/85 - 127) 123 - 185 (12.6 - 18.9/91 - 137)
M14 x 2.0 77 - 116 (7.9 - 11.8/57 - 85) 108 - 162 (11.1 - 16.6/80 - 120) 116 - 173 (11.8 - 17.7/85 - 128)
M16 x 1.5 116 - 173 (11.8 - 17.7/85 - 128) 171 - 257 (17.4 - 26.2/126 - 190) 177 - 265 (18.0 - 17.1/130 - 196)
* M 16 x 2.0 109 - 164 (11.2 - 16.7/81 - 121) 163 - 244 (16.6 - 24.9/120 - 180) 169 - 253 (17.2 - 25.8/124 - 187)
A bolt with an asterisk (*) is used for female screws that are made of soft materials such as cast iron.
W5-1-10 E485
GENERAL INFORMATION
TIGHTENING TORQUES FOR MAIN PARTS
Cylinder head cover, cylinder head, camshaft bracket, rocker arm shaft
bracket
2.9~6.9(0.3~0.7/2.2~5.1)
114~171(11.6~17.4/84~126)
20~24(2.0~2.4/14~17)
Apply engine oil
14~24(1.4~2.4/10~17)
15~25(1.5~2.5/11~18)
M14 bolt
98.0(10)/72
142~152(14.5~15.5/105~112)
30°~60°
Apply molybdenum
disulfide grease
M10 bolt
31~45(3.2~4.6/23~33)
Apply engine oil
18~26(1.8~2.7/13~20)
E485 W5-1-11
GENERAL INFORMATION
Lower crankcase, connecting rod bearing caps, crank damper pulley,

flywheel, oil pan
1 74~83(7.5~8.5/54~61)
2 60
30°~60
1 2 Nut 37~41(3.8~4.2/27~30) Apply molybdenum
disulfide grease
1 Nut 60 °
2 Nut 120 °
1 Nut 60 °
Apply molybdenum disulfide grease

Tighten nuts 1 and 2 alternately
86~106(8.8~10.8/64~78)
Apply engine oil
16~26(1.6~2.6/12~19)
160~240(16.3~24.5/118~177)
Apply engine oil
M10 bolt
31~45(3.2~4.6/23~33)
Apply engine oil
M14 bolt
98.0(10)/72
142~152(14.5~15.5/105~112)
30°~60°
Apply molybdenum
disulfide grease
20~29(2.0~3.0/14~22) 69~88(7.0~9.0/51~65)
W5-1-12 E485
GENERAL INFORMATION
Front cover, flywheel housing, idler gear

14~24(1.4~2.4/10~17)
34~46(3.5~4.7/25~34) 20~29(2.0~3.0/14~22)
76~116(7.8~11.8/56~85)
68~83(6.9~8.5/50~61)
68~83(6.9~8.5/50~61)
Idler gear shaft A fixing

20~29(2.0~3.0/14~22)
32~36(3.3~3.7/24~27)
60°~90°
Apply molybdenum
disulfide grease
E485 W5-1-13
GENERAL INFORMATION
Intake manifold, exhaust manifold, turbocharger

25~30(2.5~3.1/18~22)
34~46(3.5~4.7/25~34)
36~46(3.7~4.7/27~34)
14~24(1.4~2.4/10~17)
W5-1-14 E485
GENERAL INFORMATION
Cooling system
14~24(1.4~2.4/10~17)
14~24(1.4~2.4/10~17)
M8 bolt
14~24(1.4~2.4/10~17)
M10 bolt
31~45(3.2~4.6/23~33)
(PULLEY FIX)
44~60(4.5~6.1/33~44)
(FAN FIX)
44~60(4.5~6.1/33~44)
E485 W5-1-15
GENERAL INFORMATION
Lubricating system
25~31(2.5~3.2/18~23)
20~29(2.0~3.0/14~22)
31~45(3.2~4.6/23~33)
18~26(1.8~2.7/13~20)
31~45(3.2~4.6/23~33)
Apply engine oil
20~29(2.0~3.0/14~22)
18~26(1.8~2.7/13~20)
W5-1-16 E485
GENERAL INFORMATION
Fuel system
28~31(2.9~3.2/21~23)
13~17(1.3~1.7/9.4~12)
20~24(2.0~2.4/14~17)
34~44(3.5~4.5/25~33)
31~45(3.2~4.6/23~33)
33~49(3.4~5.0/25~36)
33~49(3.4~5.0/25~36)
31~45(3.2~4.6/23~33)
E485 W5-1-17
GENERAL INFORMATION
Engine electrical, mounting bracket

67~75(6.8~7.6/49~55)
61~91(6.2~9.3/45~67)
93~139(9.5~14.2/69~103)
31~45(3.2~4.6/23~33)
125~150(12.7~15.3/92~111)
W5-1-18 E485
GENERAL INFORMATION
MODEL AND IDENTIFICATION SERIAL NUMBER

ENGINE MODEL AND SERIAL NUMBER
The engine model and serial number are stamped in the
middle of the lower left side of the cylinder block (crankcase).
Engine model and

Engine serial number location
E485 W5-2-1
MAINTENANCE
LUBRICATING SYSTEM
REPLACEMENT OF MAIN OIL FILTER ELEMENT (CARTRIDGE TYPE)
Removal Dipstick
Main oil filter
1. Remove the drain plug and drain the oil from the filter.
Place a receptacle beneath the drain port to contain the
drained oil. Removing the plug at the top of the main
filter will facilitate draining the oil.
Drain plug
Oil pan Partial oil filter
2. After draining the oil, replace the filter’s drain plug.

Hexagonal section Plug(width
Drain plug tightening torque N·m (kgf·m/lb·ft) (width across across flat
First Second Third flat: 24mm) : 17mm)
22 ~ 31 13 ~ 23
(2.2 ~ 3.2/16 ~ 23) Loosen (1.3 ~ 2.3/9 ~ 17)
(Main oil filter)
3. Place a wrench on the cartridge’s second hex lug and
rotate counter-clockwise to remove the cartridge.
Discard the removed cartridge.
Installation
1. Clean the cartridge mounting surface on the engine.
2. Lightly apply a film of clean engine oil to the gasket on
the new cartridge.
3. Screw the cartridge in lightly until the gasket surface
contacts the mounting surface on the engine.
4. Using a filter wrench, tighten the filter by turning one
revolution more.
5. After replenishing engine oil to the designated capac-
ity, start the engine and check for leaks around the
filter.
6. Stop the engine, wait for 10 - 20 minutes, then recheck
the engine oil level and replenish if necessary.
W5-2-2 E485
MAINTENANCE
REPLACEMENT OF PARTIAL FLOW OIL FILTER ELEMENT (CARTRIDGE TYPE)

Removal
Use an oil filter wrench to rotate the filter cartridge counter-
clockwise and remove. Be careful not to spill the oil con-
tained in the filter.
Installation
1. Apply a thin film of clean engine oil to the new cartridge
gasket.
2. Screw in the new filter element until its gasket contacts
the mounting surface, then use the filter wrench to
tighten the element by turning between 1 and 1 and
1/8 turns more.
E485 W5-2-3
MAINTENANCE
FUEL SYSTEM
REPLACEMENT OF FUEL FILTER ELEMENT (CARTRIDGE TYPE)
Removal
1. Remove the drain plug at the bottom of the filter, and
drain out any fuel inside the cartridge. Cartridge
Place a receptacle beneath the cartridge to prevent
soiling surrounding engine parts.
2. Using a filter wrench, rotate the cartridge counter- Set the filter
clockwise to loosen. wrench here
Discard the removed filter cartridge.
Filter wrench: commercially available Drain plug
Installation
1. Clean the cartridge installation surface on the engine.
2. Apply a thin film of clean engine oil to gasket surface of
the new filter cartridge.
3. To facilitate air bleeding, fill the filter with fuel.
4. Lightly screw in the filter cartridge until its gasket
contacts the installation surface on the engine.
5. Using a filter wrench, tighten the cartridge by an
additional 1/2 to 3/4 turn.
Note:
Be careful not to overtighten the cartridge, since it
could twist and cause a fuel leak.
Inspection of overflow valve

Inspect the overflow valve for clogging. Check for suction
leakage on the ball side.
Overflow valve opening pressure kPa (kgf/cm2/psi)
245 (2.5 / 36)

W5-2-4 E485
MAINTENANCE
INJECTION NOZZLE
Opening Pressure and Spray Condition Check
Nozzle tester
1. Use an injection nozzle tester to check the nozzle Nozzle holder
opening pressure.
If the opening pressure is above or below the specified
value, the injection nozzle must be replaced or ad-
justed.
Refer to “Adjustment of Injection Nozzle Opening Pres-
sure.”
Injection nozzle opening pressure MPa (kg/cm2/psi)
1st stage 17.7 (180/2570)

2nd stage 22.1 (225/3200)
WARNING:
Test fluid from the injection nozzle tester will spray out
of the injection nozzle under great pressure. It can 1 2 3
easliy puncture a person’s skin.
Keep your hands away from the injection nozzle at all
times.
2. Check the spray condition.

If the spray condition is bad, the injection nozzle must
be replaced or reconditioned.
(1) Correct
(2) Incorrect (Restrictions in orifice)
(3) Incorrect (Dripping)
Injection Nozzle Adjustment

Refer to “injection Nozzle” in this Section.
E485 W5-2-5
MAINTENANCE
FEED PUMP STRAINER

Cleaning the strainer
1. Remove the feed pump joint bolt (1).
2. Use a screwdriver to remove the strainer (2) from 2 1
inside the joint bolt.
3. Wash the strainer in clean diesel fuel.
WATER SEPARATOR
(WATER SEDIMENTER)
(If so equipped)
Inspect Float Level
Inspect the water sedimenter’s float level.
Water Plug
If the float is above the “water bleed level,” loosen the drain sedimentor
plug and allow the water to drain, then retighten the drain
plug securely. Warning level line
Drain plug tightening torque N·m (kgf·m/lb·ft)

Drain plug
2.9 ~ 3.9 (0.3 ~ 0.4 / 2.2 ~ 2.9) Float
AIR BLEEDING
Air bleeding
2
1. Loosen the fuel injection pump’s feed pump cap (1).
2. Loosen the fuel filter’s overflow valve (2).
3. Operate the feed pump’s handle up and down, and fill
the filter with fuel, then retighten the level loosened in
step 2.
4. Continue to operate the feed pump; the air bleeding is
completed when the handle becomes difficult to move
and the sound of air passing through the orifice can be 1
heard.
5. Operate the feed pump several times, and check to
confirm that no fuel leaks from the feed pump or fuel
filter.
6. Tighten the feed pump cap securely.
W5-2-6 E485
MAINTENANCE
COOLING SYSTEM
COOLING FAN DRIVE BELT
Inspection and Adjustment of Belt Tension
1. Check the cooling fan drive belt for cracking and other
damage.
2. Exert a force of 100 N (10kg/22lb) at a point midway 2 1
between the fan pulley and alternator pulley , and
measure the belt deflection.
3. Loosen the alternator mounting bolt and adjust plate
bolt, and adjust the tension by moving the alternator.
Following adjustment, be sure to retighten the loos-
ened bolts.
Fan belt deflection mm (in)
8.5 - 10.5 (0.30 - 0.41)
THERMOSTAT
Inspection Stirring rod
Visually inspect the thermostat; if excessive wear or dam-
age is detected, replace the thermostat. Measure the
amount of valve lift.
Valve lift at 90 °C (194 °F) mm (in)
10 (39) or more
Piece of wood
Valve opening temperature °C (°F)
76.5 (170)
E485 W5-2-7
MAINTENANCE
VALVE CLEARANCE ADJUSTMENT

Note:
Tightening of cylinder head bolts is performed by the
“angular tightening method”; as a result, no
retightening is necessary prior to valve clearance
adjustment.
Adjust the valve clearance when the engine is cold.
Checking for mounting bolt looseness

Before adjusting the valve clearance, check the rocker
arm bracket mounting bolts for looseness, and retighten
if necessary.
Rocker arm bracket mounting bolt tightening torque
14 - 24 (1.4 - 2.4 / 10 - 17)
Adjustment
1. Rotate the crankshaft clockwise to bring the TDC
mark on the flywheel in alignment with the timing
pointer on the flywheel housing. 1
At this time, if the S-mark on the drive-side flange of the
injection pump coupling is in alignment with the pointer,
the No. 1 cylinder’s piston is in the TDC position of the
compression stroke.
2
S mark
2. Adjust the valve clearance when either the No. 1

cylinder or No. 6 cylinder is in the TDC position as noted
below.
Valve clearance (intake and exhaust) mm (in)
0.4 (0.016) (cold engine)

W5-2-8 E485
MAINTENANCE
3. When the No. 1 cylinder is at the TDC position on the

compression stroke, adjust the valves indicated by No.1 cylinder T.D.C.
(compression stroke)
arrows in the illustration (valve indicated by a circle in
the table).
4. Loosen the locknut on the adjust screw affixed to the
rocker arm, and place a feeler gauge of the proper
thickness between the rocker arm and valve stem end.
5. Tighten the adjust screw until a slight amount of resist-
ance is felt in the movement of the feeler gauge.
6. Taking care not to allow the adjust screw to turn, tighten Front
the locknut.
Locknut tightening torque N·m (kgf·m/lb·ft)
15 - 25 (1.5 - 2.5 / 11 - 18)
7. Following adjustment with the No. 1 cylinder at the TDC

position, rotate the crankshaft one full turn.
8. Once again, align the flywheel’s TDC mark with the
pointer on the flywheel housing (the No. 6 cylinder will
be at compression TDC).
9. Adjust the clearance of the remaining valves noted by

the arrows in the illustration (indicated by in the No.6 cylinder T.D.C.
(compression stroke)
table).
Cylinder 1 2 3 4 5 6
No.
Valve In- Ex- In- Ex- In- Ex- In- Ex- In- Ex- In- Ex-
sequence take haust take haust take haust take haust take haust take haust
No.1 Front
cylinder
(compression
TDC)
No. 6
cylinder
(compression
TDC)
E485 W5-2-9
MAINTENANCE
FUEL INJECTING TIMING

INJECTION TIMING INSPECTION
Inspection
1. To set the injection for the proper timing, rotate the 2
crankshaft clockwise, aligning the engraved line (com-
pression BTDC) on the flywheel (1) with the flywheel
housing pointer (2).
Injection timing (B.T.D.C) deg
7°
2. Confirm that the line engraved on the pump body is

aligned with the line engraved on the timer side.
3. If the line engraved on the pump body is not aligned with
the line engraved on the timer side, align the timer mark
with the pump body mark, adjusting the coupling bolts.
After adjusting, tighten the coupling bolts to the speci-
fied torque.
ADJUSTING THE INJECTION TIMING

Adjustment
No.1 plunger
1. Remove the No. 1 injection pipe.
This is done to allow visual confirmation of the begin-
ning of the fuel injection at the No. 1 plunger.
2. Remove the No. 1 delivery valve holder (1), washer (2),

valve spring (3), and delivery valve (4).
Note: 1
When removing the delivery valve, be careful not to
allow dirt to enter the injection pipe.
2
4
W5-2-10 E485
MAINTENANCE
3. Install the delivery valve holder, and tighten to the

designated torque.
Do not install the delivery valve spring or delivery valve
at this time, since they are installed only after complet-
ing this procedure.
Delivery valve holder tightening torque N·m (kgf·m/lb·ft)
108 - 118 (11.0 - 12.0 / 80 - 87)
Note:
Over-tightening or under-tightening the delivery valve
holder may cause engine hunting or fuel leakage.
4. Keep the fuel control lever at the full open position.

No.1 plunger
5. Loosen the coupling plate's two joint bolts.

6. Rotate the automatic timer clockwise.
7. While operating the feed pump, confirm that fuel flows

No.1 delivery valve
out from the No. 1 delivery valve holder. holder
8. While confirming the outflow of fuel, slowly rotate the
automatic timer counterclockwise, and the fuel flow will
gradually decrease, and finally stop.
This position is the fuel injection beginning point. Feed
pump
9. Tighten the two coupling plate joint bolts to the desig-

nated torque.
Joint bolt tightening torque N·m (kgf·m/lb·ft)
103 - 113 (10.5 - 11.5 / 76 - 83)

E485 W5-2-11
MAINTENANCE
10. While operating the feed pump, slowly rotate the crank-
shaft clockwise, and at the point the fuel flow stops from 2
the No. 1 delivery valve holder, confirm that the pointer
(2) on the flywheel housing is aligned with the 7° mark
engraved on the flywheel (1).
11. Remove the No. 1 plunger delivery valve holder (1), and
insert the valve spring (3) and delivery valve (4). Install
the washer (2) and delivery valve holder, and tighten to 1
the designated torque.
Delivery valve holder tightening torque N·m (kgf·m/lb·ft) 2
108 - 118 (11.0 - 12.0 / 80 - 87)

3
12. Install the No. 1 plunger delivery valve, and screw on the
No.1 plunger
feed pump cap.
Note:
The feed pump may be damaged if the engine is started
when the feed pump cap is not screwed on.
W5-2-12 E485
MAINTENANCE
RECOMMEMDED LUBRICANTS
ENGINE TYPE TYPE OF LUBRICANT (API)
Diesel engine oil

With turbocharger
CF-4/SG (MIL-L-2104E)
ENGINE OIL VISCOSITY CHART
ENGINE OIL VISCOSITY GRADE-AMBIENT TEMPERATURE
Ambient
temperature (5ºF) (59ºF) (77ºF) (86ºF)
[Multi-grade]
E485 W5-2-13
MAINTENANCE
CYLINDER COMPRESSION PRESSURE

MEASURING THE COMPRESSION PRESSURE
Measurement
1. Start the engine and operate until warm.
(The radiator coolant must be about 80 °C at the time of
this measurement)
2. Remove all glow plugs.
3. Install the adapter and compression gauge in the No. 1
cylinder's glow-plug hole.
Compression gauge: (commercially available)
Gauge adapter: 380001976
4. Make sure that the fuel delivery lever is close (no fuel
being sent to the engine).
5. Use the starter to crank the engine, and read the value
from the compression gauge's indicator needle.
Perform each measurement at least twice.
Cylinder compression pressure (Sea level, 200 rpm)
MPa (kgf/cm2/psi)
Standard Limit
2.84 (29/410) 2.06 (21/300)
The measured compression pressure at each cylinder

indicates the approximate value. The variation in pressure
between cylinders must not exceed the limit value noted
below.
kPa (kgf/cm2/psi)
Limit variation of pressure

196 (2/28)
between cylinders
If the measured pressure exceeds the absolute limit value

or the limit for variation between cylinders, inspect all items
related to compression pressure.
6. Repeat steps 3 and 5 for the remaining cylinders. If the
measured value is less than the designated value,
consult the troubleshooting section of this manual, and
repair as required.
W5-2-14 E485
MAINTENANCE
ENGINE REPAIR KIT

THE PARTS SHOWN BELOW ARE INCLUDED IN THE ENGINE REPAIR KIT
17
1 27
24 26 17
29
11 18
7 30 11
2
28
11
4 11
3
9 11
17
5 14 9
23
21
12 19
20
22
15
10 16
13
1. Head cover nut seal 17. Leakoff pipe gasket

2. Head cover gasket 18. Injection nozzle gasket
3. Cylinder head gasket 19. Bearing case gasket
4. Valve guide seal 20. Water pump gasket
5. Thermostat housing gasket 21. Water pump gasket
7. Intake cover gasket 22. Oil level switch gasket
9. Exhaust manifold gasket 23. Thermostat housing gasket
10. Drain plug gasket 24. Intake pipe gasket
11. Fuel pipe gasket 26. Turbocharger gasket
12. Oil pan gasket 27. Turbocharger feed pipe gasket
13. Front oil seal 28. Turbocharger return pipe gasket
14. Rear oil seal 29. Turbocharger return pipe gasket
15. Oil relief valve gasket 30. Turbocharger return pipe gasket
16. Oil cooler gasket
E485 W5-3-1
ENGINE I (DISASSEMBLY)
EXTERNAL VIEW
(Left side view)
(Right side view)
Note:
Specification may vary according to the type of equipment on which the engine is installed.
W5-3-2 E485
DISASSEMBLY 1
2 5 6 20 23 22 21 27 12 13 10 9 11 8 18 7 3
25 26 24 19 17 14 16 15
1. Cooling fan 14. Oil pipe
2. Fan guide 15. Oil pipe
3. Alternator ▲16. Injection pump
4. Fan belt 17. Coupling ASM
5. Water pipe ▲18. Intake cover
6. Air duct 19. Starter motor
7. Intake pipe 20. Oil dipstick
8. Fuel pipes 21. Oil feed pipe
▲9. Injection pipe 22. Oil return pipe
10. Fuel leakoff pipe ▲23. Turbocharger
11. Fuel filter 24. Oil pipe
▲12. Glow plug and connectors ▲25. Oil cooler with oil filter
▲13. Nozzle holder 26. Partial oil filter
27. Exhaust manifold
E485 W5-3-3
IMPORTANT OPERATIONS
3
9. Fuel injection pipe
(1) Loosen the sleeve nut on the delivery valve side 2
of the fuel injection pipe.
Take care not to exert excessive force on the
injection pipe when doing this.
(2) Loosen the clip . 1
(3) Remove the fuel injection pipe .
Note:
In order to prevent dirt and other foreign materials from
entering the delivery valve, place a plastic cap over the
hole in the delivery valve holder.
12. Glow plugs and connectors

13. Nozzle holders
If the nozzle is to be reused, it must be installed in its
original position.
Note:
Use paper labels or tags to mark the cylinder numbers
of the nozzles.
Take care not to damage the nozzle tips.
16. Injection pump

(1) Remove the two coupling bolts and separate the
4 2
injection pump from the coupling.
1 3
(2) Remove the injection pump's four mounting bolts.
(3) Remove the injection pump.
18. Intake cover

A sealant has been applied to the intake cover at time
of assembly.
Screw holes (M8 x 1.25) are provided at both ends of the
intake cover; using bolts of the appropriate size (M8 x
1.25, shaft length 30 mm or more), screw in the bolts
evenly on both sides to press away the cover, and
remove.
W5-3-4 E485
23. Turbocharger
To prevent entry of foreign material, attach a cap to the
turbocharger's oil port after removal of the oil pipe.
25. Oil cooler (with oil filter)

(1) Remove the oil drain plug (1) and allow the oil to
drain from inside the filter.
(2) Loosen the water drain plug (2) and drain the
coolant.
(3) Remove the oil cooler mounting bolt.
(4) Use a plastic hammer to lightly strike the periphery
of the oil cooler case, and remove the oil cooler. 2
1
E485 W5-3-5
DISASSEMBLY 2
1 3
2
5
7
6
8
10
13
14
11
12
1. Cylinder head cover 8. Cylinder head gasket

2. Head cover gasket 9. Water pump pulley
3. Camshaft upper bracket 10. Water pump
▲ 4. Camshaft ▲11. Crankshaft pulley (with damper)
▲ 5. Rocker arm shaft assembly 12. Front cover
6. Thermostat housing ▲13. Flywheel
(with thermostat unit) 14. Flywheel housing
▲ 7. Cylinder head
W5-3-6 E485
4. Camshaft
(1) Fully loosen the rocker arm's adjust screw, and Feeler gauge
measure the gap at the end of the camshaft.
Camshaft axis gap mm (in)
Standard Limit
0.055 ~ 0.205 (0.0022 ~ 0.0081) 0.40 (0.016)
(2) Gradually loosen the camshaft bracket bolts in the

order shown.
3 4 6
Note: 5
8
The camshaft may be adversely affected if one bracket 7
bolt is fully loosened all at once. As a result, be sure to 2
1
loosen the bolts gradually in the numbered sequence.
Protect the bearing surface of the camshaft upper
bracket to prevent damage.
5. Rocker arm shaft assembly

3
Gradually loosen the rocker arm lower bracket bolts in 7
the sequence shown. 5
1 4
Note: 8
The rocker arm shaft may be adversely affected if one 6
bolt is fully loosened all at once. As a result, be sure to 2
loosen the bolts gradually in the numbered sequence.
7. Cylinder head
Loosen the cylinder head bolts evenly in the sequence Front
shown.
Note:
4 19 3
The lower surface of the head may be damaged if one 13
12 20 27
26 18
11
10
5 21 28 2
bolt is fully loosened at once. As a result, be sure to 29
17 9
loosen the bolts gradually in the numbered sequence. 6
7
14
15
22
23
25
16 8 1
24
11. Crankshaft pulley (with damper)

(1) Insert a steel bar or wedge into the flywheel ring
gear to prevent the crankshaft from turning.
(2) Loosen the crankshaft pulley's mounting bolts, and
remove the pulley.
E485 W5-3-7
13. Flywheel
Stop the crankshaft from turning, and loosen the bolts
gradually in the sequence shown.
6 1
3 4
8 7
5 2
W5-3-8 E485
DISASSEMBLY 3
26
28
30
23
29
25
27
26
22 24
21
20
17 18
19
15
16
▲15. Idler gear "A" ▲23. Piston and connecting rod
16. Idler gear shaft "A" (with upper bearing)
▲17. Idler gear "B" ▲24. Cylinder block lower crankcase
18. Idler gear shaft "B" ▲25. Crankshaft lower bearing
19. Oil pan ▲26. Thrust bearing
20. Oil pump 27. Crankshaft
21. Anti-drain valve ▲28. Crankshaft upper bearing
▲22. Connecting rod bearing cap 29. Oil jet
(with lower bearing) 30. Cylinder block
E485 W5-3-9
15. Idler gear "A"

17. Idler gear "B"
Before removing the idle gear, measure each gear's
backlash and end play.
Backlash measurement
(1) Attach a dial gauge to the idle gear to be measured.
Note:
When the gear to be measured is meshed with another
gear, fix that gear in position and prevent it from
moving.
(2) Move the gear to be measured to left and right, and read
the fluctuation of the needle on the dial gauge. If the
measured value exceeds the limit value, replace the
timing gear.
Backlash mm (in)
Standard Limit
0.1 (0.0039) or less 0.3 (0.012)
Measuring idler gear end play

(1) Insert a feeler gauge between the idle gear and the
thrust washer, and measure the gap.
(2) If the measured value exceeds the limit value, replace
the thrust washer or the gear.
Idle gear end play mm (in)
Standard Limit
0.04 ~ 0.19 (0.0016 ~ 0.0075) 0.3 (0.012)
W5-3-10 E485
22. Connecting rod bearing cap (with lower bearing)

23. Piston and connecting rod (with upper bearing)
(1) Before removing the piston and connecting rod,
remove any carbon deposits on the upper portion of
the cylinder liner.
(2) Set the piston at the BDC position, remove the
connecting rod cap, then rotate the crankshaft and
bring the piston to the TDC position.
Lightly tap the connecting rod's large end with the
handle of a hammer to drive the piston out with the
connecting rod attached.
Note:
When removing the piston, take care not to damage the
cylinder liner and oiling jet.
If the connecting rod bearings are to be reused, attach
a tag clearly indicating the position from which each is
removed.
24. Cylinder block lower crankcase

(1) As shown in the illustration, measure the end play
at the rear end of the crankshaft.
Perform this measurement before removing the
lower crankcase. If the measurement exceeds the
limit value, replace the thrust bearing.
Crankshaft end play mm (in)
Standard Limit
0.10 ~ 0.285 (0.0039 ~ 0.0112) 0.40 (0.016)
(2) Loosen the lower crankcase bolts in the following 1

sequence:
First stage: Loosen the M10 bolts on the
outer edge of the crankcase
Second stage: Gradually loosen the M14 bolts 1 5 9 13 12 8 4
-c 14 on the inside edge of the
crankcase in the numerical order 2 6 10 14 11 7 3
shown.
Third stage: Screw the removed M10 bolts in
the replacer holes (1) and tighten
1
evenly, pressing the lower
crankcase out and away to re-
move.
Note:
The cylinder block and lower crankcase are manufac-
tured as a single unit; as a result, if it is necessary to
replace either one, both must be replaced together.
E485 W5-3-11
25. Crankshaft lower bearing

26. Thrust bearing
28. Crankshaft upper bearing
If the bearings are to be reused, be sure to attach a tag
clearly indicating the position from which each one is
removed.
W5-3-12 E485
CYLINDER HEAD DISASSEMBLY
11
6
7
9 5
10
4
3
2
1. Thermostat housing 7. Valve spring upper seat

2. Idler gear cover 8. Valve spring
3. Idler gear gasket 9. Valve spring lower seat
4. Idler gear shaft "C" ▲10. Intake and exhaust valves
▲ 5. Idler gear "C" 11. Cylinder head
▲ 6. Split collar
E485 W5-3-13
5. Idler gear "C"

(1) Using a feeler gauge, measure the idler gear "C"
end play.
Idler gear "C" end play mm (in)
Standard Limit
0.047 ~ 0.218 (0.0019 ~ 0.0086) 0.40 (0.016)
(2) Remove the idler gear.
6. Split collar
(1) Lay the cylinder head on a flat surface.
(2) Use a spring compressor to remove the split collar.
Take care not to allow the valve to fall from the
head.
Spring compressor: 380001975
10. Intake and exhaust valves

Attach a tag to each valve noting the position from
which it was removed.
When installing new valves, be sure to install new valve
guides at the same time.
exh e
aus
t intak
W5-3-14 E485
ROCKER ARM SHAFT ASM DISASSEMBLY
4
3
5
3
4
3
2
6
1. Split pin 4. Rocker arm spring

▲2. Camshaft lower bracket 5. Rocker arm bracket
▲3. Rocker arm 6. Rocker arm shaft
2. Camshaft lower bracket
Be sure to store the removed upper (1) and lower (2)
1
brackets together (note alignment mark (3)). 3
3. Rocker arm
If the removed rocker arms are to be reused, be sure to
label with tags noting the cylinder number and whether
for intake or exhaust.
Note:
In the movable portion of the adjust screw, the "ball" is
peened to match the "pan", so do not subject it to Tag
excessive shock.
E485 W5-3-15
PISTON AND CONNECTING ROD DISASSEMBLY
▲1. Connecting rod bearing ▲ 4. Piston pin
▲ 2. Piston ring 5. Connecting rod
▲ 3. Snap ring 6. Piston
W5-3-16 E485
1. Connecting rod bearing
If the connecting rod bearings are to be reused, mark
each one with the cylinder number so that they are
reinstalled in the same position.
2. Piston ring
(1) Fix the connecting rod in a vice.
Take care not to damage the connecting rod.
(2) Use a piston pin replacer to remove the piston
rings.
Piston ring replacer: 380001716
Do not use other tools to remove the rings, since
they may stretch the rings, resulting in reduced ring
tension.
3. Snap ring
Use a pair of snap ring pliers to remove the piston pin
snap ring.
4. Piston pin
Remove the piston pin by lightly tapping with a hammer
and a brass bar.
If the piston pins are to be reused, label each one with
the cylinder number, and be sure to replace in the same
location.
E485 W5-4-1
ENGINE II (INSPECTION AND REPAIR)
INSPECTION AND REPAIR (1)

(Cylinder Head)
If excessive wear or damage is discovered during inspection, the appropriate parts must be adjusted, repaired, or
replaced.
CYLINDER HEAD
Warpage of lower face of cylinder head
1. Use a straight edge (ruler) and a feeler gauge to
measure the warpage of the four sides and the two
diagonals of the lower face of the cylinder head as
shown.
2. If the measured values are greater than the specified
limit, the cylinder head must be replaced.
Warpage of lower face of cylinder head mm (in)
Standard Limit
0.05 (0.002) or less 0.40 (0.016)
Note:
Lower face of cylinder head can not be reground
because 6SD1 model has overhead camshaft construc-
tion with the valve gear train. A
E F
C D
Cylinder head height
Cylinder head height (reference); H mm (in)

Standard Limit
173.0 ~ 173.025 (6.811 ~ 6.812) 172.775 (6.8022)
H
Note:
Do not regrind the lower face of the cylinder head.
Water jacket pressure test

1. Blow air in the water jacket to check for blockages.
2. In the hydraulic pressure test, apply the designated
pressure for 3 minutes and check all parts for water
leaks.
kPa(kgf/cm2/psi)
Test Pressure 490 (5/71)
W5-4-2 E485
VALVE GUIDES
Clearance between valve stem and valve guide
Measurement
1. With the valve stem inserted in the valve guide as point
about 10 mm from the upper end of the guide.
2. Move the valve head forward and back and read the dial 10mm(0.4in)
indicator, recording the maximum measurement. If the

measured value is less than the limit value, the valve
and valve guide must be replaced as a set.
Valve stem and valve guide clearance mm (in)
Standard Limit
0.040 ~ 0.077
Intake valve 0.15 (0.006)
(0.0016 ~ 0.0030)
0.065 ~ 0.102
Exhaust valve 0.20 (0.008)
(0.0026 ~ 0.0040)
Valve guide replacement
Removal
Use a hammer and valve remover to tap out the valve guide
from the head's lower side toward the upper side.
Valve guide remover: 380001977
Installation
1. Apply clean engine oil the outer periphery of the valve
guide.
2. Attach the installer to the valve guide.
3. Use a hammer to drive in the valve guide from the upper
face of the head until the installer's lower edge meets
the head surface.
Valve guide installer: 380001977
4. After installation, measure the distance (height) from

the cylinder head's upper surface to the upper edge of
the valve guide.
H
Height to valve guide upper edge; H mm (in)
22.0 (0.87)
Note:
Whenever the valve guide is removed, always replace
both valve and valve guide together with a new set.
E485 W5-4-3
VALVE AND VALVE SEAT INSERT

Valve stem diameter
Use a micrometer to measure the valve stem diameter in
three locations as shown.
If the measured value is less than the limit value, replace the
valve and valve guide as a single set.
Valve stem diameter mm (in)
Standard Limit
Intake valve 10 (0.39) 9.92 (0.391)
Exhaust valve 10 (0.39) 9.90 (0.390)
Valve thickness
Inspect the valve seat for damage or step wear, then
measure the thickness.
If the measured value is less than the limit value, both the
valve and valve guide must be replaced with a new set.
Valve thickness mm (in)
Standard Limit
Intake valve 2.50 (0.098) 2.00 (0.079)
Exhaust valve 2.35 (0.092) 1.85 (0.073)
The same values apply to valves which have been

reground.
Valve depression
2
1. Install the valve (1) in the cylinder head (2).
2. Using a depth gauge or two rulers, measure the amount
of depression from the lower face of the cylinder head
to the surface of the valve head. If the measured value
exceeds the limit, the valve seat insert must be re-
placed.
1
Valve depression mm (in)
Standard Limit
Intake valve 0.48 (0.019) 1.48 (0.058)
Exhaust valve 1.60 (0.063) 2.60 (0.10)
W5-4-4 E485
Valve contact width

1. Inspect the valve contact for roughness and uneven-
ness.
If necessary, smooth the surface of the valve contact.
2. Measure the contact surface width.
If the measured value exceeds the limit, the valve seat
insert must be replaced.
Valve contact width mm (in)
Standard Limit
Intake valve 2.7 (0.106) 3.5 (0.138)
Exhaust valve 2.4 (0.094) 3.2 (0.126)
Valve insert replacement

Screwdriver
Removal
1. Use an acetylene torch to heat the inner surface of the
valve seat insert on two opposing sides (700 ~ 800 °C).
2. Allow the insert to cool for 3 ~ 5 minutes (do not cool too
suddenly).
3. Use a screwdriver as shown to pry out the insert.
Take care not to scar the cylinder head.
4. Carefully remove any carbon deposits or other debris
from the insert installation holes.
Installation
1. Place the attachment (1) (with smaller outside diameter 3
than the valve seat insert) on top of the valve seat insert
(2) as shown. 1
Note:
Be sure the smooth surface of the attachment contacts 2
the valve seat insert.
2. Using a bench press (3), gradually apply pressure on the
attachment so as to drive the valve seat insert into the
head.
kN (kg)
Insertion
9.81 ~ 14.7 (1000 ~ 1500)
pressure
Note:
When pressing the valve seat insert, to not apply
excessive pressure since damage to the valve seat will
result.
E485 W5-4-5
Correction of the valve seat insert 150°

1. Remove carbon deposits from the surface of the valve 90°
seat insert. 30°
2. Using valve cutters (blade angles 15°, 45°, 60°, 75°), or
a valve seat grinder, trim the contact edge of the valve
seat to remove scratches and roughness.
This procedure can be used to return the contact
surface width to standard values. When performing this
repair, take care to remove only scratches and rough-
ness, and do not cut away sound parts of the valve seat.
Valve seat angle
Intake side 30°
Exhaust side 45°
Note:
Use an adjustable valve cutter.
Take care not to allow the valve cutter or seat grinder to
wobble inside the valve guide.
3. Apply cutting compound to the surface of the valve seat

insert.
4. Use a valve grinder to lap the valve.
5. Following lapping, inspect for proper valve contact.
W5-4-6 E485
VALVE SPRINGS
Valve spring free height
Use calipers to measure the valve spring free height. If the
measured value is less than the limit value, replace the
spring.
Inner and outer spring free length mm (in)
Intake side Exhaust side
Standard Limit Standard Limit
Inner 62.5 (2.46) 60.5 (2.38) 69.2 (2.72) 67.2 (2.65)
Outer 59.3 (2.33) 57.3 (2.26) 80.7 (3.18) 78.7 (3.10)
Valve spring inclination

Using a surface plate and square, measure the valve spring
inclination.
Inner and outer spring inclination mm (in)
Limit
Inner 3.0 (0.12)
Outer 3.5 (0.14)
Valve spring tension

Using a spring tester, measure the valve spring tension.
If the measured value is more than 10% under the standard
value, replace the spring.
Intake side Exhaust side
Compressed Standard Compressed Standard
length (mm) N (kg) length (mm) N (kg)
111.8 284.4
Inner 46.2 (11.4) 46.2 (29.0)
292.2 500.1
Outer 48.7 48.7
(29.8) (51.0)
Color Coding
Inner Green
Inner
Outer Green
Inner Yellow
Outer
Outer Yellow
1 2
E485 W5-4-7
ROCKER ARM SHAFT AND ROCKER ARM

Rocker arm shaft runout
1. Place the rocker arm shaft on a V-block.
2. Using a dial gauge, measure the rocker arm shaft runout
in the center of the shaft. If the runout is very slight, it
may be corrected with a bench press while cold.
If the measured value exceeds the limit value, the
rocker arm shaft must be replaced.
Rocker arm shaft deflection (1/2 of runout) mm (in)
Limit
0.3 (0.012)
Rocker arm shaft diameter

Use a micrometer to measure the shaft diameter at the
points where the rocker arms are attached.
If the measured value is less than the limit value, the rocker
arm shaft must be replaced.
Rocker arm shaft diameter mm (in)
Standard Limit
19.00 (0.748) 18.85 (0.742)
Rocker arm shaft and rocker arm clearance

1. Use inside calipers or an inside dial gauge to measure
the inside diameter of the rocker arm bushing.
2. Measure the outside diameter of the rocker arm shaft.
3. Use the two measurements to calculate the clearance.
If the measured value exceeds the limit, replace either
the rocker arm shaft or the rocker arm.
Rocker arm and rocker arm shaft clearance mm (in)
Standard Limit
0.01 ~ 0.05 (0.0004 ~ 0.0020) 0.2 (0.0079)
W5-4-8 E485
4. Inspect the rocker arm oil ports to confirm that no

clogging is present.
If clogged, clean out debris by blowing with compressed
air.
Also check for any friction or unevenness on the roller
surface.
Lower camshaft bracket

Inspect the oil ports on the bracket (rear side) for any
clogging, and clean if necessary.
E485 W5-4-9
CAMSHAFT
Inspection
Visually check journals, cams, and camshaft brackets for
excessive wear and other damage.
If any damage is evident, replace with a new part.
Journal diameter
1
Use a micrometer to measure the diameter of each journal
2 2
in both directions (1) and (2) as shown in the illustration.
If the measured value is less than the limit value, replace the 1
camshaft.
Journal diameter mm (in)
Standard Limit
39.915 ~ 39.940 (1.5726 ~ 1.5724) 39.89 (1.5704)
Camshaft and camshaft bracket clearance

Use a dial gauge to measure the inner diameter of the
bracket.
If the clearance between the camshaft bracket (inner
diameter) and the camshaft journal (outer diameter) ex-
ceeds the limit value, replace either the camshaft bracket,
or the camshaft, or both.
Camshaft bracket clearance mm (in)
Standard Limit
0.06 ~ 0.11 (0.0024 ~ 0.0043) 0.16 (0.0062)
Note:
When replacing one camshaft bracket, replace the
entire parts set.
Cam lobe height

Use a micrometer to measure the cam lobe height.
If the measured value is less than the limit, the camshaft
must be replaced. H
1
Cam height; H mm (in)
Standard Limit
2
5.92 (0.233) 5.56 (0.219)
Cam height ; H = 1 _ 2
W5-4-10 E485
Camshaft runout
Set a dial gauge on the No. 3 or No. 4 journal; rotate the shaft
gently on full turn, and read the gauge.
If the measured value exceeds the limit, the camshaft must
be replaced.
Camshaft Runout mm (in)
Standard Limit
0.05 (0.002) 0.10 (0.004)
Camshaft gear removal

1. Remove the camshaft gear bolt.
2. Using a gear puller, remove the camshaft gear.
Note:
When removing the gear, be careful not to damage the
gear teeth.
If the gear puller pressed directly against the teeth, the teeth
may be deformed; as a result, a brass plate should be
placed between the puller tip and the gear.
Inspection
Visually inspect the teeth of the camshaft gear; if any wear
or damage is found, replace the gear.
Camshaft gear installation

1. Insert the key in the camshaft key slot.
2. Apply clean engine oil to the threads of the gear bolt and
the gear setting surface.
3. Install the gear with the large bossing (arrow) mounted
toward the camshaft.
Camshaft gear tightening torque N·m (kgf·m/lb·ft)
114 ~ 171 (11.6 ~ 17.4 / 84 ~ 126)

E485 W5-4-11
INSPECTION AND REPAIR (2)

(Cylinder block)
Visually inspect the cylinder block for wear, cracks, water

leaks, and other abnormalities.
CYLINDER BLOCK, CYLINDER LINER

Warpage of upper face of cylinder block
1
1. Remove the block's dowel pins.
2. Remove the cylinder liner.
The procedure for removal is listed in the section
"cylinder liner replacement."
3. Use a ruler (1) and feeler gauge (2) as shown to measure
the four sides and diagnosis of the cylinder block's
upper face for warpage.
If the measured value exceeds the limit, replace the
cylinder block. 2
Cylinder block upper face warpage mm (in)
Standard Limit
0.05 (0.0020) or less 0.2 (0.0079)
Note: A
Do not attempt to use a surface grinder to regrind the E F

C D
upper face of the cylinder block.
B
4. If the height of the cylinder block is less than the
standard value, replace the cylinder block.
Cylinder block height (reference); H mm (in)
Standard
369.47 ~ 370.54 (14.546 ~ 14.588)
H
5. Refer to the section "Cylinder Block Bore Measure-

ment" for instructions on installation of the cylinder
liner.
6. Install the dowel pins.
Cylinder liner bore measurement

Use a cylinder gauge to measure the bore of the cylinder
liner at points and in order to measure the thrust
24 mm
direction ( - ) and axial ( - ) directions.

120 mm
Measuring point is 24 mm from the top face, while 1

measuring point is 120 mm from the top face.
If the maximum measured values exceed the limit, replace 2
the cylinder liner. 3 4
3
Cylinder liner bore mm (in) 2
Standard Limit
120 (4.724) 120.3 (4.736)
W5-4-12 E485
Measurement of cylinder liner projection

1. Place a straight edge along the top edge of the 1
cylinder liner to be measured.
2. Using a feeler gauge , measures the projection of
each cylinder liner.
Cylinder liner projection mm (in)
Standard
2
0.106 ~ 0.134 (0.0042 ~ 0.0053)
The difference in cylinder liner projection between any two

neighboring cylinders must not exceed 0.02 mm.
Cylinder liner removal

1. Attach a cylinder liner remover to the cylinder liner.
Cylinder liner remover: 380001973
2. Confirm that the remover's shaft anchor is hooked firmly
on the bottom of the cylinder liner.
3. Slowly rotate the remover's shaft handle clockwise to
remove the cylinder liner.
Note:
Be careful not to damage the upper face of the cylinder
block when removing cylinder liners.
Cylinder block bore measurement

1. At measuring point , measure the cylinder block bore
in the four directions (W-W, X-X, Y-Y, Z-Z).
Measuring point : 120 mm from upper face.
2. Calculate the average value of the four measurements
to determine the correct liner grade.
E485 W5-4-13
Selection of liner grade

The "liner grade" mentioned here refers to the combination
120 mm
of the cylinder block bore (before insertion of the liner), and
the outer diameter of the liner.
A liner which has an outside diameter that is too small
1
(loose) for the cylinder block will result in poor cooling
efficiency, leading to engine damage. Conversely, a liner
that is too big for the block will be impossible to install
properly.
In order to avoid such problems, it is important to measure
the cylinder block bore to allow selection of the proper liner
grade.
X
Z W
Y Y
W Z
X
Cylinder liner O.D. measurement

X
18
1. Measure the outside diameter of the cylinder liner for Y 1
Y
both directions (X-X and Y-Y) at each of the three
114
X
measuring points , , and .
X
Measuring points (distance from top face) mm (in) Y Y 2
210
18 (0.71) X
114 (4.49) X
Y Y 3
210 (8.27)
X
2. Calculate the average of the six measurements and use

that figure when selecting the liner grade.
Standard Liner Interference mm (in)
0.011 ~ 0.029 (0.00043 ~ 0.00114)
Combination of cylinder block bore diameter and liner

O.D. mm (in)
Grade Cylinder block bore Liner O.D.
123.001 ~ 123.010 123.021 ~ 123.030
1 (4.8426 ~ 4.8429) (4.8433 ~ 4.8437)
123.011 ~ 123.020 123.031 ~ 123.040
2 (4.8437 ~ 4.8441)
(4.8429 ~ 4.8433)
1230.21 ~ 123.030 123.041 ~ 123.050
3 (4.8433 ~ 4.8437) (4.8441 ~ 4.8445)
W5-4-14 E485
Cylinder liner installation

1. When using special tools
(1) Clean the outside of the liner and the inside walls 3
of the cylinder block with clean kerosene or diesel
fuel.
(2) Used compressed air to dry off all cleaned sur- 1
2
faces.
Note:
All engine oil and other foreign matter must be removed
from the liner and cylinder block bore before installa-
tion.
(3) Press in the liner from the top of the cylinder

block .
(4) Set the liner installer on top of the liner as
shown. 4
3
Cylinder liner installer: 380001970
(5) Position the body so that the centerline of the
installer is aligned with the centerline of the
bench press shaft .
Note:
Set the body so that the liner is perpendicular to the
bench press, taking care that no unevenness occurs
between the liner and bench press.
(6) Use the bench press to apply an initial force of 5 kN

(500 kg) on the liner, to press it into the cylinder
block.
(7) Next, apply 25 kN (2500 kg) of force to seat the liner
fully.
(8) After installation of the liner, measure the cylinder
liner projection.
Note:
The projection cannot be a negative value.
Refer to the paragraph "Measurement of Cylinder Liner
Projection".
2. Installation Using Dry Ice

Cooling the liner with dry ice will cause it to contact,
facilitating installation.
Note:
This method must be performed immediately after
cooling the liner.
WARNING:
Dry ice must be handled with great care, since careless
handling can result in severe frostbite.
E485 W5-4-15
Piston grade selection

"Piston grade" means that the proper piston for the combi-
nation of piston O.D. and cylinder liner bore measurements.
Selection of the proper piston grade is important to allow
optimum engine operation without damage to liner and
pistons.
Cylinder liner bore measurement

After installation of the cylinder liner, measure the liner bore X
Z W
to allow selection of the proper piston grade.
Y Y
1. Follow the instructions in the previous section on
W Z
Cylinder Liner Bore Measurement, and measure the X
liner bore.
Measuring point Q.........120 mm from upper face 216 mm120 mm
1
Measuring point R.........216 mm from upper face 2
2. Take measurements in the four radial directions (WW,
X-X, Y-Y, Z-Z) at each of the measuring points Q and
R.
3. Calculate the average value from the eight measure-
ments taken, and use that figure as the cylinder liner
bore.
Cylinder liner bore mm (in)
Standard Limit
120 (4.724) 120.3 (4.7362)
Note:
Selection of the proper piston grade is very important,
since using an improper piston size will result in
engine failure.
W5-4-16 E485
PISTON
Piston outside diameter measurement
Measure the piston O.D., and select from either grade AX
or CX so that the standard clearance is obtained between
liner and piston.
Measurement point .........98 mm (3.86 in.) from
piston face
Clearance between cylinder liner and piston mm (in)
0.131 ~ 0.175 (0.0052 ~ 0.0069) 1
Cylinder liner bore and piston O.D. for service parts

mm (in)
Grade Cylinder liner bore Piston O.D.
120.000 ~ 120.020 119.849 ~ 119.864
AX (4.7244 ~ 4.7252) (4.7185 ~ 4.7191)
120.021 ~ 120.040 119.865 ~ 119.890
CX
(4.7252 ~ 4.7260) (4.7191 ~ 4.17201)
Note:
The clearance between liner and piston is correct at
time of manufacture, but when a liner is removed from
the cylinder block and later reinstalled, the amount of
clearance may be reduced.
As a result, it is always necessary to measure the
clearance again after any reinstallation of a removed
liner.
Clearance between piston rings and piston ring

grooves
Use a feeler gauge to measure the clearance between the
piston ring and the piston ring groove at several points
around the piston.
If the clearance between the piston ring and the ring groove
exceeds the limit, the piston ring must be replaced.
Clearance between piston ring and piston ring groove
mm (in)
Standard Limit
No. 1
compression 0.105 ~ 0.140 0.20
ring (0.0041 ~ 0.0055) (0.0079)
No. 2
0.105 ~ 0.140 0.20
compression
(0.0041 ~ 0.0055) (0.0079)
ring
No. 3
0.085 ~ 0.120 0.20
compression
(0.0033 ~ 0.0047) (0.0079)
ring
0.020 ~ 0.060 0.15
Oil ring (0.0008 ~ 0.0024) (0.0059)
E485 W5-4-17
PISTON RING
Piston ring gap measurement
1. Holding the piston ring horizontally, insert it into the
cylinder liner to the liner's bore measuring point.
2. As shown in the illustration, use an inverted piston to
press the ring inside the liner until it reaches either
measuring point Q or measuring point R.
The liner diameter is narrowed at these two points.
Be sure that the inserted ring is kept perfectly horizontal
while being inserted.
Measuring point Q: 10 mm
Measuring point R: 160 mm
3. Using a feeler gauge, measure the gap where the ends
of the ring come together.
If the measured value exceeds the limit, replace the ring 1
2
for that piston.
Piston ring openng gap mm (in)
Standard Limit
No. 1
compression
ring
0.35 ~ 0.50 1.0
No. 2, 3 (0.0138 ~ 0.0197) (0.039)
compression
ring
0.25 ~ 0.45 0.8
Oil ring (0.0098 ~ 0.018) (0.031)
4. Visually inspect the piston ring grooves.

If any of the grooves are damaged or deformed, replace
the piston.
Ring tension
Measure piston ring tension with a piston ring tension
gauge.
Ring tension N (kgf)
Standard Limit
No. 1 24.1 ~ 31.8
compression (2.46 ~ 3.24) 14.7 (1.5)
No. 2 15.4 ~ 21.3

compression (1.57 ~ 2.17) 9.8 (1.0)
No. 3 17.7 ~ 24.5

(1.80 ~ 2.58) 11.8 (1.2)
compression
53.9 ~ 73.5
Oil ring 37.3 (3.8)
(5.5 ~ 7.5)
W5-4-18 E485
PISTON PIN
Piston pin diameter
Use a micrometer to measure the diameter of the piston pin
at each of the six locations shown in the illustration.
If the measured value is less than the limit, replace the pin.
Piston pin diameter mm (in)
Standard Limit
43.0 (1.693) 42.98 (1.692)
Clearance between piston pin and piston pin hole

Use an internal dial gauge to measure the diameter of the
piston pin hole, and use that figure to calculate the clear-
ance with the piston pin.
Clearance of piston pin and piston pin hole mm (in)
Standard Limit
0.004 ~ 0.017
0.05 (0.00197)
(0.00016 ~ 0.00067)
If an internal dial gauge is not available, use the following

procedure to check the piston pin clearance.
1. Use a piston heater to heat the piston to about 100 °C.
2. Strongly push the piston pin into the piston pin hole with
your thumbs. With proper pin clearance, the piston pin
should go into the hole without any, or with very little,
resistance.
E485 W5-4-19
CONNECTING RODS
Connecting rod twist and parallelism
Use a connecting rod aligner to measure the connecting
rod's twist distortion and parralelism between the rod's large
and small ends.
If the measured value exceeds the limit, replace the
connecting rod.
Connecting rod parallelism (per 100 mm length) mm (in)
Standard Limit
0.03 (0.0012)
Twist, parallelism or less 0.10 (0.0039)
Connecting rod small end bushing clearance

Use an inside dial gauge and micrometer to measure the
inside diameter of the connecting rod's small hole bushing
and the outside diameter of the piston pin.
If the measured clearance exceeds the limit value, the
piston pin, or the connecting rod's small hole bushing must
be replaced.
Connecting rod small end bushing clearance mm (in)
Standard Limit
0.012 ~ 0.027
0.10 (0.0039)
(0.00047 ~ 0.0011)
Connecting rod side face clearance

1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance between
the side face of the connecting rod's big end and the side
face of the crankpin's arm.
If the measured value exceeds the limit, the connecting
rod must be replaced.
Connecting rod large end side face clearance mm (in)
Standard Limit
0.17 ~ 0.28
0.35 (0.014)
(0.0067 ~ 0.0110)
W5-4-20 E485
CRANKSHAFT
The crankshaft of the model 6SD1T engine has been
treated by soft nitriding (tufftriding) in order to enhance
the crankshaft's strength.
As a result, crankshaft wear cannot be rectified by shaft
grinding and use of undersize bearings.
Further, no undersize bearings are made available for
the crankshaft.
If surface scorching or other damage to the crankshaft
exceeds the limit values, the crankshaft assembly
must be replaced.
Inspection of the crankshaft's tufftriding layer

The portion to be tested
1. Thoroughly clean the crankshaft. must be held horizontally Test liquid should
Be particularly careful to clean the inspection area by so as not to let the test not be applied to
solution flow. the area around the
using an organic solvent to clean away all oil. oil port.
2. Prepare a solution of 5 ~ 10 % ammonium cuprous The sliding surface
of the pin
chloride (dissolved in distilled water). or journal.
3. Using a dropper, place a drop of the solution on the test
area of the crankshaft. Approximately
Be sure to stabilize the test area and hold flat so the 10mm (0.4in)
solution does not run.
Note:
Do not allow the test solution to drip in or around the oil
ports.
Results
1. Wait 30 ~ 40 seconds after dripping the solution.
If no color change occurs after 30 ~ 40 seconds, the
crankshaft is usable.
If a color change occurs (test surface turns copper
color), the crankshaft must be replaced. (The test
solution is originally thin blue in color).
2. Following completion of the test, quickly wipe the test
solution from the surface of the crankshaft and clean
well with steam.
Note:
Since ammonium cuprous chloride is highly corrosive,
it must be cleaned from the test surface immediately
following completion of the test.
E485 W5-4-21
CRANKSHAFT AND BEARINGS

Basic measurement procedures:
When the
1. Main bearing inside diameter = A, B
A
2. Crankshaft journal diameter = B, and
3. Clearance between crankshaft journal and main
bearing = C,
the relationship between the three is
A-B=C
This section discusses the method used to measure
the "C" dimension.
C
The same description is also applicable to measuring
the clearance C' between the crankpin and the control
rod bearing.
These C and C' dimensions are decisive for determining
whether the crankshaft of the crank bearing must be
replaced.
Inspection of crankshaft and bearing

1. Visually inspect the crankshaft journal and pin for
excessive friction and damage.
2. Inspect the oil seal contact surfaces at the front and
back of the crankshaft for excessive wear and damage.
3. If any excessive wear or damage is discovered, the
crankshaft must be replaced or repaired.
4. Inspect the oil ports for clogging, and if necessary blow
out with compressed air.
Crankshaft runout
1. Set up a dial gauge on the No. 4 journal of the
crankshaft.
2. Slowly rotate the crankshaft one full turn clockwise, and
read the dial gauge.
If the measured value exceeds the limit, the crankshaft
must be replaced with a new one.
Crankshaft runout mm (in)
Standard Limit
0.08 (0.003) or less 0.15 (0.0059)
W5-4-22 E485
Bearing spread
Use calipers to measure the spread of the bearing arc.
If the measured value is less than the limit, the bearing must
be replaced.
Bearing arc spread mm (in)
Limit
Crank bearing 96 (3.779)
Control rod bearing 85 (3.346)
Outside diameter of crank journal and crank pin 1 3 4
1. Use a micrometer to measure the diameter of each

crank journal at each of the measuring points and 2 2
shown in the illustration.
2. At each measuring point, measure in both directions 1
- and - .
3. Use the same method to measure the diameter of the
crank pin. If the measured value is less than the limit,
the crankshaft must be replaced.
Crank journal outside diameter mm (in)
Standard
89.909 ~ 89.929 (3.5397 ~ 3.5405)
Crankpin outside diameter mm (in)
Standard
79.894 ~ 79.914 (3.1454 ~ 3.1462)
Crank journal and crankpin uneven wear mm (in)

Standard Limit
0.001 (0.00004) 0.05 (0.002)
E485 W5-4-23
Measuring the crank journal and bearing inside

diameter and clearance
Measure the crank bearing's inside diameter and its clear- um
ance with the crank journal. l y den
p b
Ap oly lfide
1. Clean the mounting surfaces of the cylinder block and m isu se
lower crankcase, and the bearing installation surfaces. d rea
2 g
2. Apply a thin coat of molybdenum disulfide grease to the
threads and the seating area of the mounting
bolts, and to the surfaces of the washers.
3. Install the lower crankcase (with bearings) to the cylin- 1
der block, and tighten the bolts as noted in the following:
Sequence 1 (M14 bolts)

Using the angular tightening method, evenly tighten the (M14 Bolt)
inner layer of crankcase bolts in the order shown ( to c
14 ).
Crankcase M14 bolts tightening torque N·m (kgf·m/lb·ft)

14 10 6 2 3 7 11
98 (10/72) 142 ~152 (14.5 ~ 15.5 / 105 ~ 112) 30° ~ 60°
13 9 5 1 4 8 12

(M10 Bolt)
Next, evenly tighten the outer layer of crankcase bolts in the
23 19 15 11 7 3 1 5 9 13 17 21
order shown to c 24 .
Crankcase M10 bolts tightening torque N·m (kgf·m/lb·ft)
31 ~ 45 (3.2 ~ 4.6 / 23 ~ 33)
24 20 16 12 8 4 2 6 10 14 18 22
4. Using a dial gauge, measure the inside diameter of the

crank journal bearing, and calculate its clearance with
the outer diameter of the crank journal.
If the clearance with the crank journal exceeds the limit
value, the bearing or the crankshaft must be replaced.
Crank journal and bearing clearance mm (in)
Standard Limit
0.045 ~ 0.110 (0.0018 ~ 0.0043) 0.16 (0.0063)
Note:
The cylinder block and the lower crankcase are manu-
factured as a single unit. As a result, if either part
requires replacement, both parts must be replaced as a
single set.
W5-4-24 E485
Using Plastigage to measure clearance between the

crank journal and bearing
1. Thoroughly clean the cylinder block, particularly the
bearing installation parts, lower crankcase and bear-
Plastigage
ings.
2. Install the bearings in their mounts.
3. Carefully set the crankshaft on the bearings.
4. Next, rotate the crankshaft about 30 times to stabilize
the bearings.
5. As shown in the illustration, set the plastigage across
the entire width of the bearing.
6. Install the crankcase with bearings.
7. Tighten the crankcase bolts using the designated order

and method. Refer to the paragraph Engine, "Crank 37 33 29 25 21 17 15 19 23 27 31 35
Journal and Bearing Clearance."
When installing the crankcase, take care to prevent the
Plastigage from slipping. 14 10 6 2 3 7 11
8. Remove the crankcase.
13 9 5 1 4 8 12
38 34 30 26 22 18 16 20 24 28 32 36
9. Measure the width of Plastigage affixed to the crank-

shaft or bearing, using the gauge printed on the
Plastigage
plastigage box.
If the measured value exceeds the limit, take the
following additional steps:
(1) Use a micrometer to measure the diameter of the
crank journal.
(2) Using an inside dial gauge, measure the bearing's
inner diameter. If the clearance calculated between
the journal and bearing exceeds the limit value, the
crankshaft or the bearing must be replaced.
Crankshaft and bearing clearance mm (in)
Standard Limit
0.045 ~ 0.110 (0.0018 ~ 0.0043) 0.16 (0.0063)
E485 W5-4-25
Connecting rod bearing clearance

1. Install the bearing on the large end of the connecting
rod.
2. Apply molybdenum disulfide grease to the bolt threads
and nut setting faces.
3. Use the following angular tightening method to tighten
the bearing cap nuts.
Bearing cap nut torque N·m (kgf·m/lb·ft)
Tightening
Order Tightening nut
torque and angle 1
2
Tighten nuts 37 ~ 41
1 and alternately (3.8 ~ 4.2 / 27 ~ 30)
2 Right side nut 60°
3 Left side nut 120°
4 Right side nut 60°
4. Using a dial gauge, measure the bearing's inside diam-

eter and calculate the clearance between the bearing
and crankpin.
If the clearance between the bearing and crankpin
exceeds the limit, replace the bearing or the crankshaft.
Crankpin and bearing clearance mm (in)
Standard Limit
0.04 ~ 0.106 (0.0016 ~ 0.0042) 0.16 (0.0063)
W5-4-26 E485
Using plastigage to measure the connecting rod bear-

ing clearance
1. Thoroughly clean the crankshaft, connecting rod, bear-
ing cap and bearing.
2. Assemble the bearing in the large end of the connecting
rod and the bearing cap.
Keep the crankshaft immobile so that is does not move
while assembling the bearing cap.
3. Stabilize the connecting rod so that is does not move.
4. Apply Plastigage to the crankpin. If the Plastigage is
stuck on with some engine oil, it will stick better and
make the job easier.
5. Install the bearing cap, and tighten the bolts in the
designated order, using the designated tightening
method and torque. (Apply the Plastigage flat, and
avoid the area of the crankpin"s oil port.)
Consult the paragraph "Engine II: Connecting Rod
Bearing Clearance."
Keep the connecting rod steady so that is does not
move during assembly and tightening of the bearing
cap.
6. Remove the bearing cap.
7. Measure the width of Plastigage affixed to the crankpin
or bearing, using the gauge printed on the Plastigage
box.
If the measured value exceeds the limit, perform the
following procedure:
(1) Use a micrometer to measure the diameter of the
crankpin.
(2) Using an inside dial gauge, measure the inside
diameter of the bearing. From these two figures
calculate the crankpin and bearing clearance, and
if it exceeds the limit, replace the crankshaft or
bearing.
Crankpin and bearing clearance mm (in)
Standard Limit
0.04 ~ 0.106 (0.0016 ~ 0.0042) 0.16 (0.0063)
E485 W5-4-27
Crank gear replacement
Removal
1. Using the crank gear puller, pull off the crank gear.
Crank gear remover: 380001966
2. Remove the key from the crankshaft.
Note:
When removing the crank gear, take care not to damage
the gear teeth with the gear puller.
Installation
1. Warm the crank gear with an oil heater (oil temperature
170 ~ 180 °C).
2. With the timing mark "0" facing the flywheel side (front),
align the gear's key groove with the crankshaft's knock
pin, and install so that there is no gap with the crank-
shaft's end.
Crank gear installer: 380001969
Oil pump drive gear replacement
Removal
See the section "Crank Gear Replacement."
Installation
1. Warm the drive gear with an oil heater (oil temperature
170 ~ 180 °C).
2. Install the gear facing the direction shown in the illustra-
tion, and allow no gap with the crankshaft's end.
Drive gear installer: 380001971
W5-4-28 E485
FRONT COVER OIL SEAL

Front cover oil seal replacement
Removal
Use the oil seal remover to remove the oil seal slinger.
Oil seal remover: 380001967
Oil seal
Remover
Slinger
Crankshaft
Installation
1. If there is some small scratch on the crankshaft after
removing the oil seal, apply threebond 1207C or equiva-
lent on the slinger as shown in the illustration.
1mm
3mm
2. Use the oil seal installer to install the oil seal with
slinger.
Tighten the center bolt until the installer comes into
contact with the guide.
Check that the oil seal is flush with front cover.
Oil seal installer: 380001968
Front cover
Oil seal
Oil seal
E485 W5-4-29
CRANKSHAFT REAR OIL SEAL

Crankshaft rear oil seal replacement
Removal
Use the oil seal remover to remove the oil seal slinger.
Oil seal remover: 380001967
Oil seal
Remover
Slinger
Installation Oil seal

Use the oil seal installer to install the oil seal with slinger.
Tighten the center bolt until the installer comes into
contact with the guide.
Check that oil seal is flush with flywheel housing.
Oil seal installer: 380001968
Oil seal
Installer
Flywheel housing
Crankshaft gear
Crankshaft
Oil seal
If there is some scratch on the crankshaft after removing the

oil seal, apply threebond 1207C or equivalent on the slinger
as shown in the illustration.
1mm
3mm
W5-4-30 E485
NOTES
E485 W5-5-1
ENGINE III (ASSEMBLY)
ROCKER ARM SHAFT ASSEMBLY
2
3
4
3
2
3
Assembly sequence
1. Rocker arm shaft ▲5. Camshaft lower bracket

2. Rocker arm spring 6. Camshaft upper bracket
▲3. Rocker arm 7. Cotter pin
4. Rocker arm bracket
W5-5-2 E485
3. Rocker arm
5. Camshaft lower bracket
(1) Apply engine oil to the rocker arm shaft, each
rocker arm, rocker arm bushing, and the lower
bracket’s shaft holes.
(2) Install all parts in accordance with the assembly

sequence. Alignment mark
1) When reusing parts
When reusing the rocker arms, replace them in the
original positions as noted on tags attached during
removal.
When reusing the camshaft bracket, confirm the
alignment mark positioning number, and return it
to its original position.
3 A21
↑ ↑
Set number: terminating number
00 ~ 99
Installation position number
(from front: 1, 2, 3, 4)
2) When using new parts

When installing new parts as the result of “Inspec- Alignment mark (Service part)
tion and Repair” performed under Group 4 (“Engine position number
II”):
Replace all four upper and lower brackets together
as a single set.
Never replace only one bracket.
Confirm position numbers when installing.
New parts (service parts) position numbers

3 11
↑ ↑
Set number: terminating numbers
00 ~ 99 No.4
Installation position number
(from front: 1, 2, 3, 4) No.3
3) Install the camshaft upper bracket and hand No.2

tighten.
No.1
(Front side)
E485 W5-5-3
CYLINDER HEAD ASSEMBLY
7
6
3
5
1
2
12
9
4
8
10
11
Assembly sequence
1. Cylinder head ▲7. Split collar

2. Valve spring lower seat 8. Idle gear shaft “C”
▲3. Valve stem seal 9. Idle gear “C”
▲4. Intake and exhaust valves 10. Idle gear gasket
5. Intake and exhaust valve springs 11. Idle gear cover
6. Valve spring upper seat 12. Thermostat housing
W5-5-4 E485
3. Valve stem seal
When inserting valve stem seals, apply oil to the
periphery of the valve guide and press in securely until
it strikes the upper surface of the seal guard.
Note 1:
Take care not to scar the seal lip.
Note 2:
After inserting the seal, confirm that the spring does not
fall out.
Special tool: 380001974
4. Intake and exhaust valves

(1) Before installing, apply clean engine oil to each
valve stem.
(2) Install the intake and exhaust valves.
(3) Turn over the cylinder head to install the valve
springs.
Take care when doing this so that the valves do not
fall out.
5. Intake and exhaust valve springs

The valve springs are installed so that the end with
narrow pitched coils (the side with color) are installed
pointing down.
Spring color coding

Inner
Intake side (1) Green
Outer
Inner
Exhaust side (2) Yellow
Outer
1 2
E485 W5-5-5
7. Split collar
(1) Use the spring compressor to compress the valve
springs in their mounted position.
Spring compressor: 380001975
(2) Install the split collar onto the valve stem.
(3) Use a rubber hammer to tap the edge of the split

collar to seat it properly.
W5-5-6 E485
PISTON AND CONNECTING ROD ASSEMBLY
Assembly sequence
▲1. Piston ▲5. Snap ring

▲2. Snap ring ▲6. Piston ring
▲3. Connecting rod ▲7. Connecting rod bearing
▲4. Piston pin
E485 W5-5-7
1. Piston
2. Snap ring
3. Connecting rod
Use a piston heater to heat the piston to about 100 °C.
(1) Using snap-ring pliers, install one snap ring in the
piston.
(2) Fix the connecting rod in a vice.
Hold the connecting rod in copper plates to prevent
damage to the connecting rod.
(3) Assemble the piston to the connecting rod.
Install the piston so that the front mark (1) on the
piston's head and the forged "ISUZU" mark on the
connecting rod (2) are pointing toward the engine's
front.
1
Front side
4. Piston pin
5. Snap ring
(1) Apply a liberal coat of clean engine oil to the piston
pin, connecting rod, and the piston's hole.
(2) Align the piston and the connecting rod's piston
hole, and press in the piston pin strongly.
(3) Use snap ring pliers to install the other snap ring in
the position.
Note:
1
Confirm that the snap ring is securely installed in the
ring groove.
(4) Remove the piston and connecting rod assembly
from the vise and check that the connecting rod
moves smoothly.
6. Piston rings
(1) Assemble the oil ring and expander ring.
Note: Oil ring gap
Assemble the two rings so that their gaps are located on
opposite sides (180° apart) from each other.
Gap
(2) Apply clean engine to the piston rings and piston
ring grooves.
Expander ring gap

W5-5-8 E485
(3) Use a piston ring replacer to install the piston rings

in the sequence shown.
(1) Oil ring
(2) 3rd compression ring R mark
(3) 2nd compression ring 4
(4) 1st compression ring
3
Note:
Install the 1st, 2nd and 3rd compression rings so that the 2
"1R", "2R" and "3R" marks are oriented toward the top
of the piston respectively. 1
Piston ring replacer: 380001716
(4) Confirm that each piston ring moves smoothly in its
groove.
7. Connecting rod bearing

While clean the rear surface of the connecting rod
bearing and the inner surface of the large end of the
connecting rod, and confirm that no foreign material is
on either surface.
Note:
Do not apply engine oil to the rear surface of the
connecting rod bearing and the inner surface of the
large end of the connecting rod.
E485 W5-5-9
ASSEMBLY 1
5
1
3
7
6
4
11
14 13
12
16
15
Assembly sequence
1. Cylinder block ▲9. Connecting rod bearing cap

▲2. Oil jet (with lower bearing)
▲3. Crankshaft upper bearing ▲10. Front cover
▲4. Crankshaft ▲11. Oil pump
▲5. Thrust bearings ▲12. Oil pan
▲6. Crankshaft lower bearing ▲13. Idler gear shaft "B"
▲7. Cylinder block lower crankcase ▲14. Idler gear "B"
▲8. Piston and connecting rod ▲15. Idler gear shaft "A"
(with upper bearing) ▲16. Idler gear "A"
W5-5-10 E485
Note:
Before assembling, use compressed air to thoroughly
blow out the inside of the cylinder block, particular the
oil ports and water jacket.
2. Oil jet
Tighten the oil jets with the designated torque.
Note:
When installing the jets, take care not to damage the
nozzles, or to deform the nozzle angle by impact.
Oil jet tightening torque N·m (kgf·m/lb·ft)
16 ~ 25 (1.6 ~ 2.6 / 12 ~ 19)
3. Crankshaft upper bearing

Thoroughly clean the upper bearing.
When reusing bearings which were previously removed,
be sure to reinstall them in the same positions from
which they were removed, in accordance with the tags
affixed at the time of removal.
1~7
Be sure the bearing's locking lip fits securely in the slot

machined in the bearing mount.
Note: Slot
Oil port and groove
Locking lip
The upper bearings can be discriminated from lower
bearings since the upper bearings have oil ports and a
groove along their entire surface. In contrast, the lower
bearings have no oil port and only a partial groove. Be
sure to install the bearings in their correct locations.
4. Crankshaft
Before installing the crankshaft, apply a liberal coat of
clean engine oil to the journals and the inner surface of
the bearings.
Note:
bearings, or to the bearing mounts in the cylinder
block.
E485 W5-5-11
5. Thrust bearings (upper)

Before installing, apply a liberal coat of clean engine oil Upper side
to the thrust bearings. Groove
The oil groove of the thrust bearings must be facing the Groove toward inside
crankshaft's No. 7 contact surface. toward outside
5. Thrust bearings (lower)

6. Crankshaft lower bearing
7. Cylinder block lower crankcase
(1) Thoroughly clean the lower bearings, thrust bear-
ings, and lower crankcase.
(2) Apply clean engine oil to the lower bearings and the
1~ 7
contact surface of the thrust bearings.
lower bearings, or to the bearing mounts in the Lower side
lower crankcase.
(3) Install the bearings in the lower crankcase.
Be sure the bearing's alignment notch fits securely
in the slot machined in the bearing mount.
(4) Pack sealant into the crankcase groove as shown. Gasket
(5) Apply a light coat of molybdenum disulfide grease

to the threads and seating faces of the lower
crankcase's M14 bolts. um
(6) Install the crankcase (with bearings) to the cylinder p ly den
b
block, and tighten the bolts in the following se- Ap oly lfide
m isu se
quence. d rea
2 g
Note:
Take care not to drop the lower bearings and thrust
bearings.
1

Using the angular tightening method, evenly tighten the (M14 Bdt)
inner row of crankcase bolts in the sequence shown in the
illustration ( to c
14 ).
Crankcase M14 bolts tightening torque N·m (kgf·m/lb·ft) 14 10 6 2 3 7 11
98 (10/72) 142~152 (14.5~15.5/105~112) 30° ~ 60° 13 9 5 1 4 8 12

W5-5-12 E485

Evenly tighten the outer row of crankcase bolts in the 23 19 15 11 7 3 1 5 9 13 17 21
sequence shown in the illustration ( to c
24 ).
Crankcase M10 bolt tightening torque N·m (kgf·m/lb·ft)
31 ~ 45 (3.2 ~ 4.6 / 23 ~ 33)
Note:
24 20 16 12 8 4 2 6 10 14 18 22
The cylinder block and lower crankcase are manufac-
tured as a single unit. As a result, if either part requires
replacement, both parts must be replaced as a single
set.
See Engine II "Inspection and Repair" (2).
Note:
Crankcase bolts may be reused only two times.
8. Piston and connecting rod (with upper bearing)
9. Connecting rod cap (with lower bearing)
(1) Apply clean engine oil to the piston and piston
rings.
(2) Turn the piston rings so that their gaps are posi-
tioned in the positions shown in the illustration.
No. 1 compression ring 1
No. 2 compression ring
No. 3 compression ring 3
Oil ring
Note: 4
The piston ring gaps must not be positioned in the
2
direction of horizontal thrust, but in the direction of the
piston end, namely, in the position where they will not
be exposed to side pressure.
Also, the oil ring and expander ring gaps should be
positioned on opposite sides (180°) from each other.
(3) Apply molybdenum disulfide grease to the piston's
skirts as shown; this will facilitate smooth break-in
when the engine is first started after reassembly.
E485 W5-5-13
(4) Apply a coat of clean engine oil to the upper

bearing's contact surface and to the bore of the
cylinder liner.
(5) Install the piston so that the "front mark" (U) on the
head is oriented toward the front end of the engine.
Front side
(6) Using a ring compressor, compress the piston

rings. Front mark
Piston ring compressor: 380001972
(7) Use the handle of a hammer to push in the piston
until the connecting rod's large end makes contact
with the crankpin.
While pushing in the piston, turn the crankshaft as
necessary to bring the crankpin to the BDC posi-
tion.
Note:
Take special care to prevent the large end of the
connecting rod from contacting the oil jets.
Note:
The ring compressor must be set flush with the cylinder
block or the piston rings will be damaged.
(8) Orient the bearing cap's cylinder number and the

connecting rod's cylinder number marks as shown
in the illustration.
The engraved cylinder number marks must be
facing toward the injection pump side.
(9) Apply a coat of molybdenum disulfide grease to the
threads and seating area of the connecting rod
bearing cap bolts.
(10) Using the angular tightening method, tighten the

bearing cap nuts.
Bearing cap nut tightening data N·m (kgf·m/lb·ft)
Tightening
Sequence
torque and angle
Tighten and 37 ~ 41
1 alternately (3.8 ~ 4.2 / 27 ~ 30)
2 Nut 60° 1
2
3 Nut 120°
4 Nut 60°
Note:
After tightening the bearing cap nuts, confirm that the
oil jet is facing toward the oil channel hole for piston
cooling.
W5-5-14 E485
10. Front cover

(1) As shown in the illustration, apply sealant "Belco
Bond No. 4" to the front cover , and "Three Bond
No. 1207C" to the cylinder block and the ladder 2
frame .
3
1
(2) Install the front cover to the cylinder block and

ladder frame, then tighten the bolts and nuts
alternately to the proper torque.
Front cover bolts and nuts tightening torque
Bolts Nuts
14 ~ 24 (1.4 ~ 2.4/10 ~ 17) 34 ~ 46 (3.5 ~ 4.7/25 ~ 34)
Note:
Take care not to damage the oil seal.
11. Oil pump

Install the oil pump together with the anti-drain valve and
tighten the bolts to the designated torque.
Oil pump bolts tightening torque N·m (kgf·m/lb·ft)
31 ~ 45 (3.2 ~ 4.6 / 23 ~ 33)
12. Oil pan

(1) Apply a coat of sealant "Seal End No. 242" about
2 mm thick and 3 mm wide to the joining surfaces
of the cylinder block, flywheel housing, and front
cover.
Note:
Take care not to apply so much sealant that it drips
inside the engine.
(2) Install the oil pan with the sealant's silicon coating
facing the oil pan side, then tighten the bolts evenly
2
in the designated order.
Oil pan bolts tightening torque N·m (kgf·m/lb·ft)
14 ~ 24 (1.4 ~ 2.4/10 ~ 17)
1
E485 W5-5-15
13. Idler gear shaft "B"

Install the shaft so that its oil port is facing up.
Idler gear shaft "B" tightening torque N·m (kgf·m/lb·ft)
20 ~ 29 (2.0 ~ 3.0/14 ~ 22)
14. Idler gear "B"

(1) Apply clean engine oil to the inside surface and
thrust paragraph of the idler gear "B."
(2) Install and tighten the idler gear as shown in the
illustration.
Idler gear "B" bolt tightening torque N·m (kgf·m/lb·ft)
76 ~ 116 (7.8 ~ 11.8/56 ~ 85)
15. Idler gear shaft "A"

16. Idler gear "A" Idlegar
(1) Install the thrust plate and the shaft to the idler gear
"A."
(2) Apply clean engine oil to the inside and thrust areas Knok pin
Shaft
of the idle gear.
(3) Align the timing mark "O" on the crankshaft gear
with the timing mark "O" on the idle gear. Thrust plate
(4) Tighten the idler gear "A" to the specified torque.
Idler gear "A" tightening torque N·m (kgf·m/lb·ft)
32 ~ 36 (3.3 ~ 3.7 / 24 ~ 27) 60° ~ 90°

2
1 Up
(5) Tighten the idle gear shaft to the specified torque

from the flywheel side after installing the flywheel
housing.
Idler gear shaft "A" tightening torque N·m (kgf·m/lb·ft)
20 ~ 29 (2.0 ~ 3.0 / 14 ~ 22)

W5-5-16 E485
ASSEMBLY 2
30 28
27
29
26
24
25
23
21
22
19
18
20
10
Assembly sequence
▲18. Flywheel housing ▲25. Thermostat housing (with thermostat)

▲19. Flywheel ▲26. Rocker arm shaft assembly
▲20. Crankshaft pulley (with damper) ▲27. Camshaft
▲21. Water pump ▲28. Camshaft upper bracket
22. Water pump pulley ▲29. Cylinder head cover gasket
▲23. Cylinder head gasket ▲30. Cylinder head cover
▲24. Cylinder head
E485 W5-5-17
18. Flywheel housing
(1) Apply sealant "Belco Bond No. 4" to the flywheel 1
housing mounting surface , and to the areas
4
indicated by arrows in the illustration.
3 2
(2) Apply sealant "Three Bond No. 1207C" to the

joining surfaces of the cylinder block and ladder
frame.
(3) Install the flywheel housing to the cylinder block
and tighten the bolts evenly to the specified torque.
Flywheel housing tightening torque N·m (kgf·m/lb·ft)
68 ~ 83 (6.9 ~ 8.5 / 50 ~ 61)
19. Flywheel
(1) Apply molybdenum disulfide grease to the threads
and seating surfaces of the flywheel's installation
bolts and washers.
(2) Use the angular tightening method to tighten the 6 1
flywheel bolts in the sequence shown. 3 4
Flywheel tightening torque N·m (kgf·m/lb·ft) 8 7

5 2
74 ~ 83 (7.5 ~ 8.5 / 54 ~ 61) 60° 30° ~ 60°
Note:
The flywheel installation bolts may be reused only two
times.
W5-5-18 E485
20. Crankshaft pulley (with damper)

(1) Apply clean engine oil to the threads and seating
surfaces of the four pulley bolts, and to the wash-
ers.
(2) Install the pulley (with damper) to the crankshaft
and tighten.
The front end of the crankshaft has eight bolt holes;
installation can be performed in any desired posi-
tion.
Crankshaft pulley tightening torque N·m (kgf·m/lb·ft)
160 ~ 240 (16.3 ~ 24.5 / 118 ~ 177)
There is normally no need to remove the damper

from the pulley.
If the damper is removed, reused, or replaced, be
sure to tighten to specified torque.
Damper tightening torque N·m (kgf·m/lb·ft)
86 ~ 106 (8.8 ~ 10.8 / 64 ~ 78)
21. Water pump

(1) Install the water pump together with its gasket, and
tighten in place.
Water pump tightening torque N·m (kgf·m/lb·ft)
M8 bolts M10 bolts
14 ~ 24 (1.4 ~ 2.4/10 ~ 17) 31 ~ 45 (3.2 ~ 4.6/23 ~ 33)
(2) Apply molybdenum disulfide grease to the oring

and install on the water pump.
23. Cylinder head gasket

2
(1) Apply a coating of sealant "Parmatex No. 6" about
2 mm thick and 3 mm wide to the joint between the
cylinder block (1) and flywheel housing (2).
Note:
Do not block the cylinder's oil ports (3) with the sealant.
1
3
(2) Install the head gasket, aligning it with the cylinder

block's dowel pins.
"IS2161" Mount with
Note: part number facing up.
Install the gasket with the part number (at the No. 3
cylinder position) facing up.
E485 W5-5-19
24. Cylinder head

(1) Align the teeth of the idler gear "C" and idler gear
"B", and carefully install the cylinder head.
Note:
Be sure to securely align the three dowel holes in the
cylinder head with the dowel pins in the cylinder block.
Take care not to damage the gasket when setting the
cylinder head on top of the gasket.
(2) Apply molybdenum disulfide grease to the threads

and seating surfaces of the cylinder head bolts.
(3) Use the angular tightening method to tighten the
cylinder head bolts to in the sequence shown. 27
26 18 10 3 11 19
17 9 4 12 20
Cylinder head bolt tightening torque N·m (kgf·m/lb·ft) 25 2
28
24 16 8 1 5 13 21
22
M14 bolts 98 (10/72) 142 ~152 (14.5 ~ 15.5 23 15 7 6 14 29
~c 26 / 105 ~ 112) 30° ~ 60°

M10 bolts 31 ~ 45
c27 ~ c
29 (3.2 ~ 4.6 / 23 ~ 33)
Note:
The cylinder head bolts may be reused only two times.
After tightening the cylinder head bolts, plug the timing
gear hole with a rag, etc., in order to prevent entry of any
foreign matter.
25. Thermostat housing (with thermostat unit)

Install the thermostat housing, thermostat and water
outlet pipe assembly to the cylinder head.
Thermostat housing bolt tightening torque
14 ~ 24 (1.4 ~ 2.4 / 10 ~ 17)
26. Rocker arm shaft assembly

(1) Rotate the crankshaft clockwise, and align the
flywheel's TDC mark with the flywheel housing's
pointer. 1
2
W5-5-20 E485
(2) Apply clean engine oil to the roller paragraph of the

rocker arm. Rocker arm
(3) Install the rocker arm shaft assembly to the cylin-
der head.
Note:
Be careful during installation, since the rocker arm
must be stood on end and lowered to be installed.
27. Camshaft
(1) Apply clean engine oil liberally to the bearing
surfaces of the camshaft lower brackets.
(2) Apply molybdenum disulfide grease to the cam
profiles of the camshaft.
Apply molybdenum
disulfide grease
(3) Install the camshaft to the lower bracket, aligning

the V-groove on the camshaft with the alignment V-groove
surface of the bracket (intake manifold side).
Alignment
surface
28. Camshaft upper bracket

Install the brackets, align the stamped numbers, and Alignment mark
first tighten by hand from the camshaft gear side, finally
tightening to the designated torque.
Note:
Confirm that the V-groove and bracket alignment sur-
face are securely joined.
See the "Important Operations" entry in the paragraph
Engine III, "Rocker Arm Shaft Assembly."
Camshaft upper bracket nut tightening torque
20 ~ 24 (2.0 ~ 2.4 / 14 ~ 17)
Note:
The rocker arm's adjust screw must be fully loosened
(increase valve clearance) before installing the cam-
shaft.
E485 W5-5-21
Valve clearance adjustment

See the paragraph "Valve Clearance Adjustment" in group
2 (Maintenance).
29. Cylinder head cover gasket

30. Cylinder head
(1) Apply sealant "Three Bond No. 1208" to the head
6 2 4 8
cover gasket.
(2) Install the head cover, tightening the bolts in the
sequence shown.
Head cover bolt tightening torque N·m (kgf·m/lb·ft)
5 1 3 7
2.9 ~ 6.9 (0.3 ~ 0.7 / 2.2 ~ 5.1)
W5-5-22 E485
ASSEMBLY 3
26 27 21 8 5 7 6 1 16 15 17 18 19 10 20 22
25
24
23
3 2 4 9 11 14 12 13
Assembly sequence
▲1. Exhaust manifold ▲15. Nozzle holder

2. Partial oil filter ▲16. Glow plug
▲3. Oil cooler ▲17. Injection pipe
4. Oil pipe (partial oil filter) 18. Fuel filter
▲5. Turbocharger ▲19. Fuel pipes
▲6. Oil feed pipe 20. Intake pipe
▲7. Oil return pipe 21. Intake duct
8. Oil dipstick ▲22. Alternator
▲9. Starter motor ▲23. Water pump pulley and adapter
▲10. Intake cover ▲24. Fan belt
▲11. Coupling ASM 25. Cooling fan
▲12. Injection pump 26. Fan guide
▲13. Oil return pipe 27. Water pipe
▲14. Oil feed pipe
E485 W5-5-23
1. Exhaust manifold
(1) Install the exhaust manifold gasket on the stud
bolts.
(2) Install the exhaust manifold and tighten to the
designated torque.
Exhaust manifold bolt tightening torque N·m (kgf·m/lb·ft)
36 ~ 46 (3.7 ~ 4.7 / 27 ~ 34) Distance Washer Pan Nut

tube washer
3. Oil cooler (with oil filter)

(1) Apply sealant "Helmes Seal No. 123T" to the oil
cooler gasket, and stick the gasket to the cylinder
block.
(2) Install the oil cooler and tighten the bolts alternately
from inside to outside.
Oil cooler bolt tightening torque N·m (kgf·m/lb·ft)
18 ~ 26 (1.8 ~ 2.7 / 13 ~ 20)
5. Turbocharger
(1) Install the turbocharger gasket, with the upper
surface of the gasket facing up.
The illustration shows the upper surface of the
gasket.
(2) Install the turbocharger, taking care not to damage
the gasket.
Note:
Always use new nuts and washers when installing.
W5-5-24 E485
6. Oil pipe (turbo feed)

7. Oil pipe (turbo return)
(1) Before installing the oil pipe, fill the pipe through the
pipe mounting hole with about 100 ~ 130 cm3 of CD
grade engine oil.
(2) Turn the rotor shaft by hand to lubricate the bearing.
Note:
If steps (1) and (2) are not performed, the turbocharger
may seize upon engine startup.
(3) Install the oil feed pipe and oil return pipe and
tighten the turbocharger's mounting nut.
(4) Tighten the oil pipe.
Turbocharger nut tightening torque N·m (kgf·m/lb·ft)
34 ~ 46 (3.5 ~ 4.7 / 25 ~ 34)
Oil pipe bolt tightening torque N·m (kgf·m/lb·ft)

Turbocharger side Cylinder block side
25 ~ 31 20 ~ 29
Feed pipe
(2.5 ~ 3.2 / 18 ~ 23) (2.0 ~ 3.0 / 14 ~ 22)
31 ~ 45 20 ~ 29
Return pipe
(3.2 ~ 4.6 / 23 ~ 33) (2.0 ~ 3.0 / 14 ~ 22)
9. Starter
Install the starter and tighten to the designated torque.
Starter tightening torque N·m (kgf·m/lb·ft)
125 ~ 150 (12.7 ~ 15.3 / 92 ~ 111)
10. Intake cover

(1) Apply sealant "Three Bond No. 1207C" to the
intake cover.
(2) Install the intake cover and tighten the bolts gradu- 13 11 9 8 10 12 14
ally in two passes, using the tightening sequence 6 4 2 3 5
1 7
shown.
Intake cover bolt tightening torque N·m (kgf·m/lb·ft)
25 ~ 30 (2.5 ~ 3.1 / 18 ~ 22)

E485 W5-5-25
11. Coupling ASM

(1) Align the V-groove on the camshaft with the align-
ment surface of the cam bracket on the intake
manifold side (at compression TDC on the No. 1
cylinder). Confirm that the pointer on the flywheel
housing points to the TDC mark on the flywheel.
(2) If the injection pump drive gear has been removed
from the coupling, reinstall it to the gear, being sure
to align the key correctly.
Injection drive gear tightening torque N·m (kgf·m/lb·ft)
206 ~ 304 (21.0 ~ 31.0 / 152 ~ 224)
(3) As shown in the illustration, align the A mark with

the coupling pointer.
(4) Apply sealant "Three Bond No. 1208" to three
points around the o-ring, and insert the o-ring into
the coupling's groove.
(5) Install the coupling to the timing gear case and
S S
tighten to the designated torque.
(6) After installing the coupling, confirm that the cou- A A
pling's pointer is in alignment with the S mark. Before After

installing installing
Coupling bolt tightening torque N·m (kgf·m/lb·ft)
83 ~ 102 (8.5 ~ 10.4 / 61 ~ 75)
12. Injection pump

(1) Install the injection pump bracket, aligning it with
the positioning pins on the cylinder block.
Pump bracket bolt tightening torque N·m (kgf·m/lb·ft)
31 ~ 45 (3.2 ~ 4.6 / 23 ~ 33)
(2) Rotate the crankshaft clockwise and align the

timing pointer (2) with the engraved lines on the 2
flywheel (1), so that the No. 1 cylinder is set to
injecting timing.
Injection timing (BTDC)
7°
1
W5-5-26 E485
(3) Hand-tighten the injection pump on the bracket,

aligning the line engraved on the pump body with
the line on the timer, and tighten the coupling.
Coupling tightening torque N·m (kgf·m/lb·ft)
103 ~ 113 (10.5 ~ 11.5 / 76 ~ 83)
(4) Tighten the injection pump bolts in the sequence

shown.
4 2
Injection pump bolts tightening torque N·m (kgf·m/lb·ft) 1 3
31 ~ 45 (3.2 ~ 4.6 / 23 ~ 33)
13. Oil return pipe

Install the oil return pipe (2) and tighten to the desig-
nated torque.
Tightening torque N·m (kgf·m/lb·ft)
33 ~ 49 (3.4 ~ 5.0 / 25 ~ 36)
14. Oil feed pipe

Install the oil feed pipe (1) and tighten to the designated
torque.
1 2
24 ~ 31 (2.4 ~ 3.2 / 17 ~ 23)
15. Nozzle holder

(1) Install the dust cover and nozzle gasket to the
nozzle holder.
Note:
Take care not to damage the nozzle tip.
(2) Install the nozzle holder flange and nuts, and hand
tighten.
Dust cover
Note:
Nozzle gasket
Do not fully tighten until after installing the injection
pipe.
16. Glow plug

Install the glow plugs, and tighten to the designated
torque, then fasten the connectors.
Glow plug tightening torque N·m (kgf·m/lb·ft)
22 ~ 27 (2.25 ~ 2.75 / 16.3 ~ 19.9)

E485 W5-5-27
17. Injection pipe

(1) Install the injection pipe and hand tighten
(2) Tighten the nozzle holder flange nuts in alternate
order, finally tightening evenly to the designated
torque.
Flange nut tightening torque N·m (kgf·m/lb·ft)
20 ~ 24 (2.0 ~ 2.4 / 14 ~ 17)
(3) Tighten the injection pipe to designated torque.

Injection pipe tightening torque N·m (kgf·m/lb·ft)
Nozzle holder side 28 ~ 31 (2.9 ~ 3.2 / 21 ~ 23)
Injection pump side 34 ~ 44 (3.5 ~ 4.5 / 25 ~ 32)
(4) Install the injection pipe clip in the designated

position, and tighten.
Note:
If the pipe clip is installed in the incorrect position, the
pipe may be damaged and fuel pulsing sound may be
heard.
19. Fuel pipes

5
(1) Install fuel pipes , , and , together with
the return pipe .
Fuel pipe tightening torque N·m (kgf·m/lb·ft) 2
3
33 ~ 49 (3.4 ~ 5.0 / 25 ~ 36)
(2) Install the clips in their designated positions.

Note:
When tightening the fuel pipes, take care not to allow
the pipes to turn together with the nuts, since the pipes
may be deformed.
W5-5-28 E485
22. Alternator
2
Install the alternator bracket and alternator, and tighten
to the designated torque. 1
Alternator bracket tightening torque N·m (kgf·m/lb·ft)
31 ~ 45 (3.2 ~ 4.6 / 23 ~ 33)
Alternator bolt tightening torque N·m (kgf·m/lb·ft)
93 ~ 139 (9.5 ~ 14.2 / 69 ~ 103)
Tighten the alternator bolts first by hand; then adjust the fan
belt tension and finally tighten the bolts to the designated
torque.
23. Water pump pulley and adapter

Attach the pulley and adapter to the water pump and
44 ~ 60 (4.5 ~ 6.1 / 33 ~ 44)
24. Fan belt

Adjust the belt tension by moving the generator and
adjusting plate.
(1) Crank pulley 3 2
(2) Water pump pulley
(3) Alternator pulley
See group 2, Maintenance, "Cooling system".
Note: 1
When replacing a belt, replace both belts as a single set.

E485 W5-5-29
25. Cooling fan

Install the cooling fan to the water pump pulley adapter.
Tighten the bolt to the designed torque.
44 ~ 60 (4.5 ~ 6.1 / 33 ~ 44)
26. Fan guide

B
(1) Install the fan guide brackets.
Tighten the nuts and bolt to the designed torque.
Nut A 43 ~ 57 (4.4 ~ 5.8 / 32 ~ 42)
Bolt B 20 ~ 29 (2.0 ~ 3.0 / 14 ~ 22)
A
Tighten the bracket bolt to the designed torque.

Bolt C 20 ~ 29 (2.0 ~ 3.0 / 14 ~ 22)
(2) Install the stay (1) to the fan guide bracket.

Tighten the bolts to the designed torque.
1
44 ~ 60 (4.5 ~ 6.1 / 33 ~ 44)
1
W5-5-30 E485
(3) Install the fan guide and fan guard. A B

Tighten the bolts to the designed torque.
A A
Bolt A and B 44 ~ 60 (4.5 ~ 6.1 / 33 ~ 44)
(4) Adjust the fan tip clearance.

Tip clearance mm (in)
10 (0.39)
E485 W5-5-31
TIMING GEAR TRAIN DIAGRAM
Camshaft bracket assembly line V-groove
Camshaft gear
Idler gear C
Idler gear B
(Exhaust side) (Intake side)

Idler gear A
Injection pump drive gear
Crankshaft gear
Oil pump gear
With No. 1 cylinder at compression TDC

W5-5-32 E485
NOTES
E485 W5-6-1
LUBRICATION SYSTEM
INTRODUCTION
*1 Relief valve open pressure 1.08 MPa (11 kgf/cm2)

*2 Bypass valve open pressure 196 kPa (2 kgf/cm2)
*3 Relief valve open pressure 539 kPa (5.5 kgf/cm2)
Oil cooler assembly Oil filter assembly Oil pressure
pilot lamp
Bypass valve *2
Oil filter
pilot lamp
Oil Main
cooler oil Main oil gallery Sub-oil gallery
core filter
*3
Relief
valve
Anti- Connect - Main Idler Camshaft; Idler Partial

Turbo- Water Injection Oil
return ing rod bear- gear cam Coupling pump pump gear jets oil
valve bearings ings charger bearings; “A ” filter
“B ”
Oil pump assembly rocker arms
Oil Idler Piston

pump gear
“C ”
*1
Relief
valve
Oil pan
W5-6-2 E485
LUBRICATION SYSTEM
OIL PUMP
DISASSEMBLY
11
14
12
13
3
10
8 7
1. Oil strainer stay 8. Oil relief valve

2. Oil strainer 9. Oil pump body cover
3. Gasket 10. Driven gear
4. Oil pipe ▲11. Drive gear
5. Gasket 12. Key
6. Spring seat 13. Drive gear shaft
7. Spring 14. Oil pump body
11. Drive gear
Use a gear puller to remove the drive gear.
E485 W5-6-3
LUBRICATION SYSTEM
INSPECTION AND REPAIR

replaced.
Oil relief valve and spring

Visually inspect the relief valve and spring, and replace if
any damage is discovered.
Clearance between gear and pump cover inner wall

Use a feeler gauge to measure the clearance between the
gear and the cover's inner wall.
If the measured clearance exceeds the limit, replace either
the gear or the cover assembly.
Gear and cover inner-wall clearance mm (in)
Standard Limit
0.100 ~ 0.196 (0.0039 ~ 0.0077) 0.15 (0.0059)
Clearance between gear face and upper surface of cover

Use a feeler gauge and square to measure the clearance
between the gear face and the upper surface of the cover.
If the measured clearance exceeds the limit, the gear or the
gear assembly must be replaced.
Gear face and cover clearance mm (in)
Standard Limit
0.040 ~ 0.093 (0.0016 ~ 0.0037) 0.15 (0.0059)
W5-6-4 E485
LUBRICATION SYSTEM
ASSEMBLY
1
3
12
5
13
7 8
14
10
11
Assembly sequence
1. Rocker arm shaft 8. Spring

2. Drive gear shaft 9. Spring seat
3. Key 10. Gasket
▲4. Drive gear ▲11. Oil pipe
5. Driven gear 12. Gasket
▲6. Oil pump body cover ▲13. Oil strainer
7. Oil relief valve 14. Oil pump strainer stay
E485 W5-6-5
LUBRICATION SYSTEM
4. Drive gear
(1) Apply clean engine oil to the drive gear and the
drive gear shaft.
(2) Use a bench press to press the drive gear onto the
shaft. Bossing
Install the gear with its large bossing toward the
shaft.
Hold the shaft perpendicular and never apply pres-
sure at an angle.
6. Oil pump body cover

After installing the driven gear, tighten the oil pump body
cover at the designated torque.
Body cover bolt tightening torque N·m (kgf·m/lb·ft)
13 ~ 23 (1.3 ~ 2.3 / 9.4 ~ 16.6)
11. Oil pipe

Install the oil pipe on the pump body cover, and tighten
to the designated torque.
Oil pipe bolt tightening torque N·m (kgf·m/lb·ft)
14 ~ 24 (1.4 ~ 2.4 / 10 ~17)
13. Oil strainer

Install the oil strainer to the pump body cover and
Oil strainer bolt tightening torque N·m (kgf·m/lb·ft)
14 ~ 24 (1.4 ~ 2.4 / 10 ~ 17)

W5-6-6 E485
LUBRICATION SYSTEM
OIL FILTER
MAIN OIL FILTER
PARTIAL OIL FILTER
See Group 2 Maintenance, paragraph "Lubrication System"
E485 W5-6-7
LUBRICATION SYSTEM
OIL COOLER
DISASSEMBLY
4
3
4
3
10
8
7
1. Water guide 6. Plug

2. Oil cooler 7. Gasket
3. Gasket 8. Spring
4. Gasket 9. Bypass valve
5. Oil filter warning switch 10. Body case
W5-6-8 E485
LUBRICATION SYSTEM

replaced.
Oil cooler core

If necessary, use red dye to check for cracks in the core.
Bypass valve
1. Check for wear or damage to the bypass valve seat.
2. Inspect the valve spring for weakening.
Oil cooler element inspection

Fill the element with cleaning fluid and allow to stand for
about 10 hours.
Then drain about 1/3 of the cleaning fluid and apply
about 200 (2) kPa (kgf/cm2) of pressurized air to the oil
port, to force out the cleaning solution through
the element.
Repeat this procedure to clean out the element as
required.
Never use cleaning fluid in the vicinity of fire or flame;
when handling cleaning fluid, always wear goggles and
gas mask, and use only in a wellventilated room.
Straight Diluted with

solution diesel fuel
Haiarom 25
(Nisseki) c —
Suwazol 310
(Maruzen) c —
Haizol
(Showa shell) c —
Mobizol A
(Mobil Oil)
— c
E485 W5-6-9
LUBRICATION SYSTEM
ASSEMBLY
10
7
8
7
8
1
3
4
Assembly sequence
1. Body case ▲6. Oil filter warning switch

▲2. Bypass valve 7. Gasket
3. Spring 8. Gasket
4. Gasket ▲9. Oil cooler element
5. Plug 10. Water guide
W5-6-10 E485
LUBRICATION SYSTEM
2. Bypass valve
(1) Install the bypass valve and spring in the body
case.
(2) Apply clean engine to the gasket and install to-
gether with the plug, then tighten to the designated
torque.
Bypass valve plug tightening torque N·m (kgf·m/lb·ft)
29 ~ 39 (3.0 ~ 4.0 / 22 ~ 29)
6. Oil filter warning switch

(1) Install the valve and spring in the body case.
(2) Install the warning switch and tighten to the desig-
nated torque.
Warning switch tightening torque N·m (kgf·m/lb·ft)
39 (4/29)
9. Oil cooler element

(1) Apply sealant to the body case's o-ring groove.
(2) Install the o-ring and gasket to the element.
(3) Install the oil cooler element to the body case and
Oil cooler element tightening torque N·m (kgf·m/lb·ft)
15 ~ 25 (1.5 ~ 2.5 / 11 ~ 18)

E485 W5-7-1
COOLING SYSTEM
INTRODUCTION
Water outlet pipe
Thermostat
Cylinder head
Radiator
Oil cooler
Cylinder block
Water pump
W5-7-2 E485
COOLING SYSTEM
WATER PUMP
DISASSEMBLY
2
3
8 9
7
6
5
4
1. Gasket 6. Snap ring

▲2. Impeller ▲7. Water pump shaft (with ball bearing)
3. Impeller seal unit 8. Oil seal (impeller side)
▲4. Pulley center 9. Water pump body
5. Oil seal (pulley center side)
E485 W5-7-3
COOLING SYSTEM
2. Impeller
(1) Support the pulley center with a vice.
(2) Use an impeller remover to remove the impeller.
Impeller remover: 380001965
Note:
Do not remove the impeller by striking it, since it may
be damaged.
4. Pulley center
Use a pulley remover to remove the pulley center.
7. Water pump shaft (with ball bearing)

(1) Remove the snap ring on the pulley center side.
(2) Remove the water pump shaft by using a plastic
hammer to tap the shaft free from the water pump
body.
W5-7-4 E485
COOLING SYSTEM

replaced.
Impeller
1. Inspect the impeller for corrosion, excessive wear on
the seal unit fitting face, and other damage.
2. Measure the interference between the pump shaft and
impeller.
Interference mm (in)
0.025 ~ 0.060 (0.0010 ~ 0.0024)
Pulley center
Inspect the pulley center's oil seal fitting face for excessive
wear or damage.
Pump shaft (with ball bearing)

1. Inspect the pump shaft's oil seat fitting face for exces-
sive wear or damage.
2. Inspect the bearing for separation, wear and abnormal
noise.
(1) Check between the balls for scratches and separa-
tion in the race.
(2) Check for rattling between the balls and race.
(3) Rotate the bearings by hand and check for any
abnormal resistance. If any abnormalities are dis-
covered, replace the ball bearings.
E485 W5-7-5
COOLING SYSTEM
Ball bearing replacement
Removal
Place the water pump shaft (1) with the bearing attached,
between the base plates (2) of a bench press, and slowly
apply pressure to force the shaft from the bearing. 1
2
Installation
1. Apply clean engine oil to the inside surface (shaft side)
of the bearing's inner race.
2. Place the water pump shaft (1) between the base plates 5 1
(2) of a bench press.
4
Note: 3 2
To prevent damage to the water pump shaft, place soft
brass or copper sheets between the base plates and the
water pump shaft.
3. Place the small-diameter bearing (3) on the shaft, and

using a pipe with the same diameter as the shaft, slowly
press the bearing onto the shaft.
1
4. Install the spacer (4).
5. Insert the large-diameter bearings (5) and slowly press 5
3
onto the shaft. 4
Press on the final large-diameter bearing in the same 2
way.
Note:
1. When pressing the bearings, be sure to maintain the
pump shaft in a perpendicular position.
2. When pressing, do not hit the outer race with the
pressing pipe.
W5-7-6 E485
COOLING SYSTEM
ASSEMBLY
8
7
2 1
4
5
6
Assembly sequence
1. Water pump body ▲6. Pulley center

▲2. Oil seal (impeller side) ▲7. Seal unit
▲3. Water pump shaft (with ball bearings) ▲8. Water pump impeller
4. Snap ring 9. Gasket
▲5. Oil seal (pulley center side)
E485 W5-7-7
COOLING SYSTEM
2. Oil seal (impeller side)
(1) Apply molybdenum disulfide grease to the inner
periphery of the oil seal lip.
(2) Apply clean engine oil to the outer periphery of the
oil seal.
(3) Press the oil seal into place with the lip facing the
outside, and taking care not to deform the oil seal.
3. Water pump shaft (with bearings)

(1) Set the pump with the impeller mounting side
facing down, and set on top of the base plates of a
bench press.
(2) Apply engine oil to the outer periphery of the
bearing outer face.
(3) Use the bench press to slowly press in the pump
shaft (with bearings) from the pulley center side.
When pressing the pump shaft, take care not to damage
the oil seal.
5. Oil seal (pulley-center side) Oil seal

(1) Apply molybdenum disulfide grease to the inner
Pulley
periphery of the seal lip. center
(2) Press in the oil seal with the lip facing the inside and
taking care not to deform the seal.
Bearing
6. Pulley center
Use a bench press to press in the pulley center, taking
care not to damage the oil seal.
W5-7-8 E485
COOLING SYSTEM
7. Seal unit
(1) Apply sealant to the pump body contact surface of
the seal unit.
(2) Press in the seal unit fully until its collar strikes the
pump body.
Take care not to damage the seal unit.
8. Water pump impeller

Use a bench press to press in the impeller until the
designated clearance exists between it and the pump
body facing.
Pump body and impeller clearance mm (in)
0.5 (0.020)
Note:
1. The fan center and impeller have been installed on
the pump shaft with a press, and no attempt must be
made to remove or reinstall them separately.
Always replace the assembly as a single unit.
Removing and installing the fan center and impeller
alone may result in the failure of the water pump
during engine operation, leading to serious over-
heating.
Note:
2. The water pump assembly must be replaced any
time the fan center and impeller pressure can be
pulled off with a force of less than falls below 1,960
N (200 kgf).
Note:
3. Do not strike bearings with a hammer to install,
since damage may result.
E485 W5-7-9
COOLING SYSTEM
THERMOSTAT
replaced.
Operation test Stirring rod

1. Completely submerge the thermostat in water as
shown.
2. Heat the water while constantly stirring so that the
thermostat never come into contact with direct heat
from the bottom.
3. Check the temperature at which the thermostat valve
opens.
Piece of wood
Thermostat valve operation temperature °C (°F)
74.5 ~ 78.5 (166 ~ 173)
4. Check the temperature at which the valve is fully open.

Thermostat full-open temperature °C (°F)
90 (194)
Valve lift when fully open mm (in)
10 (0.39)
W5-7-10 E485
COOLING SYSTEM
NOTES
E485 W5-8-1
FUEL SYSTEM
INTRODUCTION
Overflow valve
Injection nozzle
(Opening valve 250 kPa)
Fuel filter
Overflow valve
(Opening pressure 130 kPa)
Injection pump
Fuel tank Water sedimenter

W5-8-2 E485
FUEL SYSTEM
INJECTION NOZZLE - 2 Stage Injection Type

DISASSEMBLY
14
15
9
7
13
5
4
12
3
11
10 2
1. Retaining nut 9. Collar

2. Nozzle & pin 10. Spring seat
3. Spacer & pin 11. First spring
4. Lift piece 12. Shim (First nozzle opening
5. Spring seat pressure adjustment)
6. Push rod 13. Nozzle holder body
7. Shim (Second nozzle opening 14. Eye bolt
pressure adjustment) 15. Gasket
8. Second spring
(1) Before disassembly remove carbon deposit from nozzle and nozzle holder using a wire brush and wash the
outside nozzle holder assembly.
Caution: Do not touch nozzle holes with the wire brush during cleaning it.
(2) Disassemble the nozzle holder assembly to numerical order.
E485 W5-8-3
FUEL SYSTEM
REASSEMBLY AND OPENING PRESSURE ADJUSTMENT
15
14
5
8
1
9
10
2
11
4 12
13
Reassembly sequence
1. Nozzle holder body 8. Shim (Second opening pressure

2. Shim (First opening pressure adjustment)
adjustment) 9. Spring seat
3. First spring 10. Lift piece
4. Spring seat 11. Spacer & pin
5. Collar 12. Nozzle & pin
6. Second spring 13. Retaining nut
7. Push rod 14. Gasket
15. Eye bolt
The nozzle holder is adjusted as the components are reassembled in the sequence above.
As adjustment of the 2 stage injection type nozzle holder is made in hundredths of a millimeter, clean the parts
thoroughly in light oil to completely remove any dirt or foreign matter.
W5-8-4 E485
FUEL SYSTEM
REASSEMBLY AND ADJUSTMENT PROCEDURE

1 Adjust the first nozzle opening pressure using the shim.
First nozzle opening pressure adjustment
2 Confirm the full needle valve lift in accordance with the

Full needle valve lift confirmation
closed method.
3 Confirm pre-lift in accordance with the closed method.

Pre-lift confirmation
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
4 Confirm the second nozzle opening pressure in accord-

Second nozzle opening pressure
ance with the closed method.
confirmation
5 Adjust the second nozzle opening pressure using the

shim.
adjustment
6 Confirm the condition of the fuel spray with the nozzle

Final inspection
and nozzle holder assembled.
E485 W5-8-5
FUEL SYSTEM
First nozzle opening pressure adjustment

1. Clamp the nozzle holder in a vise.
2. Install the shim, first spring and spring seat in the nozzle
Spring seat
holder.
(First spring)
First nozzle opening pressure

adjusting shim
3. Install the collar, second spring, shim, spring seat and Second nozzle opening pressure
push rod in the nozzle holder. adjusting shim Push rod
Second spring
Collar
Spring seat
4. Install the pins, lift piece and spacer in the nozzle (Spacer)
holder.
Lift piece
(Pin)
5. Install the pins in the spacer.

Nozzle
6. Install the nozzle on the spacer.
Pin
W5-8-6 E485
FUEL SYSTEM
7. Hand-tighten the adjustment retaining nut together with

the gasket to the nozzle holder.
Retaining nut Nozzle
Gasket
8. Tighten the adjustment retaining nut to the specified Torque wrench

torque.
Torque N·m (kg·m)
29 - 39 (3.0 - 4.0)
Retaining nut
9. Set the nozzle holder to the nozzle tester.

Nozzle tester
10. Operate the nozzle tester and measure the first nozzle Nozzle holder
opening pressure.
MPa (psi)
Nominal Adjustment
17.7 (2570) 18.1 - 18.9 (2630 - 2740)
11. If the first nozzle opening pressure is not as specified,

disassemble the nozzle holder and replace the shim
until the pressure is as specified.
CAUTION:
Use a micrometer to measure shim thickness.
First nozzle opening pressure adjusting shim.

Thickness
Ø 3.8
Ø 8.9
E485 W5-8-7
FUEL SYSTEM
Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining Plug
nut.
(Gasket)
2. Position the nozzle holder with the nozzle facing down Holder
and install the dial gauge holder on the nozzle holder.
3. Install the nut on the dial gauge holder.

Nut
Holder
4. Install the pin to the dial gauge.

Note: Dial gauge Pin
The lengths of the pins do not include the threaded
portions.
W5-8-8 E485
FUEL SYSTEM
5. Secure the dial gauge to the nozzle holder using the nut
so that the pin contacts the tip of the first spring seat.
CAUTION: Dial gauge
Secure the dial gauge so that a stroke of 2 mm can
be measured.
Do not over-tighten the nut as the dial gauge shaft Nut
may jam. (Confirm from the dial gauge that the shaft
moves smoothly.) Holder
Pin
Nozzle holder
First spring seat
6. Set the nozzle holder to the nozzle tester and put needle
Nozzle tester
to zero on the dial gauge. Nozzle holder
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.
8. Operate the nozzle tester and increase the in-line

pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm2) so that L
Needle Valve lift
the nozzle's needle valve moves through its full lift.

Record full lift 'L'. (Read dial gauge)
Note:
The above operation is used to determine whether the
nozzle seat is worn and whether the nozzle assembly is 0 First nozzle 34.3~44.1MPa
2
in good condition. opening pressure {350~450kgf/cm }
In line pressure
E485 W5-8-9
FUEL SYSTEM
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle 300
200
tester handle.
100 400
Note:
The in-line pressure will decrease and needle valve lift
(as indicated on the dial gauge) will also decrease a 0
kgf cm2 500
little.
Pressure gauge
Needle Valve lift

In line pressure
2. Read the needle valve lift 'l' from the dial gauge
L
indication (once the needle valve has descended when Measuring point
the second spring has stopped operating). Refer to the of prelift
Needle valve lift
pre-lift measuring point for 'l'.

Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure
+approx 1 MPa (10 kg/cm2).
Note: 0
First nozzle
This point can be found while the pressure is decreas- opening pressure
ing.
3. Confirm that pre-lift 'l' is as specified.
Pushrod Second spring
Pre-lift mm (in)
Spring seat Adjusting shim
0.06 (0.0024)
Spacer
Lift piece
Needle valve
4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit. Pin
Lift piece
Spacer
Capsule
Nozzle
assembly
W5-8-10 E485
FUEL SYSTEM
Second nozzle opening pressure confirmation

Nozzle tester
Nozzle holder
1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
kg/cm2) so that the nozzle's needle valve moves
through its full lift.
Full lift mm (in)
0.4 (0.0157)
2. Release the nozzle tester handle so that in-line pres-

sure decreases. L
Needle valve lift(mm)

Note:
The in-line pressure will decrease and needle valve lift
(as indicated on the dial gauge) will also decrease a +0.05
little.
0
Second nozzle 34.3-44.1MPa
opening pressure (350-450kg/cm2)
3. Then, read the pressure gauge indication (second When needle valve lift is
nozzle opening pressure) the instant that the dial gauge + 0.05mm
90
indicates the specified needle valve lift (usually pre-lift 10
l + 0.05 mm). 80
20
70
30
60
40
50
Full needle valve lift
Dial gauge
300
200
100 400
0 2 500
Pressure gauge
E485 W5-8-11
FUEL SYSTEM
Second nozzle opening pressure adjustment

If the second nozzle opening pressure is not as specified, adjusting shim
Push rod
disassemble the nozzle from the nozzle holder and replace
Second spring
the shim until the pressure is as specified.
Collar
MPa (psi)
Spring seat
Nominal Adjustment
22.1 (3200) 23.1 - 24.1 (3350 - 3500)
CAUTION:
Because the second opening pressure changes
when the first opening pressure changes, the sec-
ond opening pressure must be adjusted when the
first opening pressure changes.
Use a micrometer to measure shim thickness.
Second nozzle opening pressure adjusting shim.
Thickness
Ø 4.8
Ø 9.9
Final inspection
Dial gauge
1. Remove the dial gauge, nut and dial gauge holder.
Nut
Dial gauge
holder
2. Remove the adjustment retaining nut and gasket. Torque wrench

3. Install the original retaining nut, confirm that the pins are
inserted fully into the nozzle, and then handtighten the
retaining nut. Then, tighten the original retaining nut to
the specified torque.
Torque N·m (kg·m)
Retaining nut
59 - 79 (6.0 - 8.0)
W5-8-12 E485
FUEL SYSTEM
4. Set the nozzle holder to the nozzle tester and check first
Nozzle tester
nozzle opening pressure, spray condition, seat oil Nozzle holder
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.
E485 W5-9-1
TURBOCHARGER
TURBOCHARGER SERVICING
1. Refer to TROUBLESHOOTING in this Paragraph to determine whether or not turbocharger repair or overhaul
is required.
2. The following procedures should also be performed (either with the turbocharger on the equipment or removed
from the equipment but not disassembled) to determine whether or not turbocharger repair or overhaul is
required.
* Visual checks
* Clearance measurements
* End play measurements
3. The turbocharger compressor and turbine housing may be removed from the center housing and rotating
assembly for further visual inspection.
W5-9-2 E485
TURBOCHARGER
TROUBLESHOOTING
If the engine does not run well (insufficient output or irregular acceleration) -
1. Run the engine at idle.
2. Check for oil leakage from the turbocharger.
3. Listen for abnormal turbocharger noise.
4. Write down any abnormal conditions and their location.
5. Stop the engine.
6. Allow sufficient time for the turbocharger to cool.
7. Check the turbocharger air inlet hose and outlet hose. The bands attaching the hoses to the turbocharger must
be tight. There must be no oil leakage.
WARNING: The turbocharger generates very high temperatures during operation. It will remain danger-
ously hot for some time after the engine is stopped. Allow sufficient time for the turbocharger to cool
before touching it.
OIL LEAK
Leak point Cause Countermeasure
Turbine housing gas inlet and
outlet tightening area Bearing abrasion (Trouble in the oil
supply system) Check the turbocharger air inlet
Turbine and bearing housing
mating surfaces
Turbocharger oil inlet tightening Loose bolts Tighten bolts
area
O-ring damage Replace O-ring
Compressor housing case Oil leak from tightening area (Air Turbocharger OK
compressor oil leak)
ABNORMAL NOISE
Description Cause Countermeasure
Whistling sound High-speed turbocharger operation Normal sound of rotor rotation
Foreign particles in turbocharger
Grinding sound Bearing abrasion (Trouble in the oil Check the turbocharger air inlet
supply system)
Tighten bolts, screws, and/or hose
Hissing sound Loose air or gas pipe
bands as required
INSUFFICIENT OUTPUT OR IRREGULAR ACCELERATION

Problem Cause Countermeasure
Poor engine performance because Loose air and/or gas pipes running Tighten bolts, screws, and/or hose
of air and/or gas leakage to the turbocharger bands as required
E485 W5-9-3
TURBOCHARGER
Disconnect the air inlet hose at the turbocharger to perform the following inspection.
Checkpoint Problem Countermesure
Oil on air inlet inside and outside surfaces result-

Air inlet Turbocharger OK
ing from oil leakage
Loose or missing
Shaft end nuts or
Foreign particles in turbocharger
blades
Bearing abrasion (Trouble in the oil supply system) Replace turbocharger
Blade and housing interference
Compressor housing
Bearing abrasion (Trouble in the oil supply system)
Oil feed pipe Clogged Remove restrictions
W5-9-4 E485
TURBOCHARGER
CONSTRUCTION
2 3
1 4
7
8
5
6
Legend (5) Turbine wheel

(1) Compressor cover (6) Bearing housing
(2) Bearings (7) Oil deflector
(3) Turbine back plate (8) Compressor wheel
(4) Turbine housing (9) Nut
E485 W5-9-5
TURBOCHARGER
DISASSEMBLY
16
15
13 14
12
10
11
9
7
6
5
17
18
1
3
19
20
22
19 20
21
Legend (12) Gasket

(1) Coupling ASM (13) Oil deflector
(2) Turbine housing (14) Thrust ring
(3) Snap ring (15) Thrust bearing
(4) Compressor cover (16) Thrust ring
(5) Nut (17) Piston ring
(6) Compressor wheel (18) Turbine back plate
(7) Snap ring (19) Bearings
(8) Shaft & turbine wheel (20) Snap ring
(9) Insert (21) Gasket
(10) Thrust sleeve (22) Bearing housing
(11) Piston ring
W5-9-6 E485
TURBOCHARGER
1. Remove the coupling assembly (1).

Note:
When you reassemble the turbocharger the exact posi-
tioning of the compressor cover, bearing housing (3),
and turbine housing (2) are important. Before disas-
sembly, use a felt-tip pen or punch to mark these parts 3
1
so you can match them correctly at reassembly.
2
2. Remove the turbine housing (1).

1
3. Remove the snap ring (1).
4. Remove the compressor cover (1) by tapping around it

lightly with a plastic hammer or wooden mallet.
Note:
Do not bump the compressor wheel against the com-
pressor cover.
5. Fit bearing housing (3) to turbine housing (1) by clamp-

ing them in a vise.
2
Fix the boss of the shaft & turbine wheel with the 17 mm
3
box wrench. Remove the compressor wheel (2) and
1
mounting lock nut with a 14 mm box wrench.
E485 W5-9-7
TURBOCHARGER
6. Restrain the turbine wheel by hand, then turn the

compressor wheel (1) to lift it off the shaft.
1
7. Remove snap ring (1) with a pair of snap ring pliers (2).
WARNING:
If the ring ends slip off the ends of the pliers, the ring 2
may fly off. Use your hand to hold down the snap ring
while you pinch the ring ends with the snap ring pliers.
8. Use two screwdrivers to gently lift the insert (1) off the
1
bearing housing.
2
Remove the following parts after the insert is removed: 3
(1) Insert 4
(2) Piston ring
5
(3) Thrust sleeve 6
(4) Gasket 7
(5) Oil deflector 8
(6) Thrust ring
(7) Thrust bearing
(8) Thrust ring
9. Remove the following parts from the bearing housing (6).

1
Use snap ring pliers to remove the snap ring (5). 3 2
4
(1) Shaft & turbine wheel 6
5
(2) Piston ring
(3) Turbine back plate
(4) Bearing
(5) Snap ring
(7) Gasket 5
(8) Gasket 4
7
Note: 8
1. If you see the blades of the turbine wheel are bent or
damaged, replace it.
2. Do not attempt to straighten the bent blades. Re-
place the part.
3. Use snap ring pliers to remove the snap ring.
W5-9-8 E485
TURBOCHARGER
CLEANING
This paragraph will show you how to clean the turbocharger without using blasting equilpment, a common practice
at most maintenance factories and shops.
4
5
6
7
13
12
11
14
15
16
17
19
21
10
9
8
22
20
3
2
1
2
3
18
Legend (12) Thrust sleeve

(1) Bearing housing (13) Gasket
(2) Snap ring (14) Insert
(3) Bearings (15) Snap ring
(4) Thrust ring (16) Compressor wheel
(5) Thrust bearing (17) Nut
(6) Thrust ring (18) Gasket
(7) Oil deflector (19) Compressor cover
(8) Turbine back plate (20) Snap ring
(9) Piston ring (21) Turbine housing
(10) Shaft & turbine wheel (22) Coupling ASM
(11) Piston ring
Note:
1. Never blast the parts marked in the drawing above, the end surfaces of the compressor wheel (5), or the
shaft of the shaft & turbine wheel (13).
2. If you use a household detergent, choose one that is chemically neutral (non-corrosive).
E485 W5-9-9
TURBOCHARGER
1. Before cleaning, visually inspect all parts for signs of

wear or burning.
2. Soak the parts in a pan filled with solvent.
Wash each part separately to remove all oil, grease, and
carbon scale.
Note:
1. Do not soak in solvent the gaskets, bearing, and
thrust bearing.
2. Commercially available "Oil Clean", an alchol base
organic solvent, should be diluted with water (5-10
parts water to 1 part solvent).
3. Blow compressed air on the parts to clean them.
4. With a plastic scraper or wire brush, remove scale from

the parts.
Note:
If shot blasting is used to clean parts, the surfaces of the
compressor wheel, and the threads, rings and grooves
of the shaft & turbine wheel should be covered to protect
them.
5. Blow compressed air on the parts to clean them.
6. Apply clean engine oil to all sliding surfaces. Buff to

remove rust from screw threads, shaft, and ring
grooves.
Note:
Do not use a file to clean the surfaces.
W5-9-10 E485
TURBOCHARGER
INSPECTION
Bearing housing
Measure the inside diameter of the bearing bores in the
housing. If they exceed the service limit, replace the
housing.
Limit mm (in)
ø 20.506 (0.80732)
Bearing
1. Measure the outside diameter of the bearing. If it is less
than the service limit, replace the bearing.
Limit mm (in)
ø 20.382 (0.80244)
2. Measure the inside diameter of the bearing. If it exceeds

the service limit, replace the bearing.
Limit mm (in)
ø 12.042 (0.47409)
3. Measure the length of the bearing. If it is less than the

service limit, replace the bearing.
Limit mm (in)
11.94 (0.4701)
E485 W5-9-11
TURBOCHARGER
Shaft & turbine wheel

1. Measure the diameter of the shaft journals.
If it is less than the service limit, replace the shaft &
turbine wheel.
Limit mm (in)
ø 11.996 (0.4722)
2. Use a dial indicator and V-block to measure the runout

of the shaft. If it exceeds the service limit, replace the
shaft & turbine wheel.
Note:
1. Replace the shaft & turbine wheel if it is bent. Never
attempt to straighten a bent shaft.
2. Check the surfaces of the shaft journals. If they are
rough, hold the shaft on a lathe by tightening it in
the chucks at the center. Turn it at 300 to 600 rpm to
lightly polish the journals with #400 (or finer) sand-
paper and engine oil.
Insert
1
Place a new piston ring in the groove of the insert. End gap
2
Measure the end gaps of the ring. If the gap exceeds the
standard clearance, replace the insert.
Standard clearance mm (in)
0.05 - 0.25 (0.0020 - 0.0098)
Replacement parts
The following parts should be replaced at disassembly:
(1) Piston rings
(2) Gaskets
W5-9-12 E485
TURBOCHARGER
REASSEMBLY
2 3
1 4
7
8
5
6
Legend (5) Turbine wheel

(1) Compressor cover (6) Bearing housing
(2) Bearings (7) Oil deflector
(3) Turbine back plate (8) Compressor wheel
(4) Turbine housing (9) Nut
Note:
After installing an overhauled turbocharger on the engine, crank the engine with the starter to permit the
engine oil to flow to the turbocharger.
E485 W5-9-13
TURBOCHARGER
1. Reassemble the following parts. 6

(1) Bearing housing
(2) Snap ring 5
(3) Bearing 4
3
(4) Turbine back plate 2
(5) Piston ring 1
(6) Shaft & turbine wheel 2
3
Note:
1. Use snap ring pliers to attach snap ring (2). Insert
the snap ring (2) into the bearing housing (3). The 3
side with the round edge has to contact the bearing 2 2
(1). Upon inserting the snap ring, do not compress 1 1
it too much with the snap ring pliers.
2. After applying oil to the outer and inner surfaces of
the bearing (1), install it.
3. Apply a light coat of oil to the piston ring of the shaft
& turbine wheel.
Do not expand the ring more than necessary, and do
not twist its end gap.
4. Do push the shaft & turbine wheel unless it is
aligned properly.
Do not damage the blades of the shaft & turbine wheel.

Align the shaft properly before you insert it.
Excessive force can bend the shaft if it is not properly
aligned.
2. After the assembly above is completed, mount the

1
bearing housing (1) on the turbine housing (2).
Tighten temporaily with the coupling assembly (1).
3. install the thrust bearing (1) after applying engine oil to

its inside and outside surfaces. Wipe dust and oil from
the shaft and end surfaces of the thrust ring.
1
W5-9-14 E485
TURBOCHARGER
4. Apply engine oil to the O-ring (1) then install it.
5. Assemble the insert (2) sub-assembly parts in the

following order. 1
(1) Oil deflector 2
(2) Insert
(3) Piston ring
4
(4) Thrust sleeve
3
Note:
1. When you install the piston ring (3) to the thrust
sleeve (4), do not expand the ring more than neces-
sary and do not twist is end gaps.
2. Apply engine oil to the piston ring (3) fitted to the
thrust sleeve (4), then install the sleeve to the insert
(2). To avoid damage to the ring, fit the ring gently,
end gap first.
After completing the above assembly, mount the

subassembly to the bearing housing (2). Keep the end
surface of the thrust ring and both ends of the thrust sleeve
clean and free of dust and oil.
Apply Molkote to nut threads
In the drawing shown on the right shows, apply
1
Molykote, engine oil, or grease to the specified parts.
Remove all oil from parts of thick line.
2
Apply
grease to gasket
E485 W5-9-15
TURBOCHARGER
6. Using snap ring pliers, install snap ring (1) to the bearing
housing (2) with its tapered side facing up.
2
Note:
1. When you install the snap ring (2), position it in the
specified direction.
2. Use a hammer and screwdriver to tap lightly the
ends of the snap ring so it fits snugly in the groove 1 2
of the bearing hausing (1).
3. When tapping the snap ring in position, do not
damage the bearing housing with the screwdriver.
7. Set up a dial indicator on the shaft & turbine wheel (1).

Move the shaft & turbine wheel in the axial direction to
measure the clearance. If it is not within standard
clearance, disassemble the parts and check for the
cause. 1
0.39 - 1.00 (0.0154 - 0.0394)
8. Keep the ends of the thrust sleeve and both end

surfaces of the compressor wheel clean and free of dust
and oil.
9. Install the compressor wheel. Apply Molykote to the
threads of lock nut.
Tighten the nut to the specified torque
Tighten torque N·m (kgf·m/lb·ft)
20 (2.0 / 14)
Note:
(a) To tighten, set the turbocharger at a right angle with
the wrench at a right angle to the shaft. Be careful
not to bend the shaft.
(b) To tighten, hold down the commpressor wheel with
your fingers to prevent it from rotating with the
wrench.
W5-9-16 E485
TURBOCHARGER
10. Set up a dial indicator on the shaft and turbine wheel (2)
as shown. Move the compressor wheel (1) in the axial
direction to measure the play. If the play is not within
2
standard clearance, disassemble the parts and check
for the cause.
1
0.075 - 0.155 (0.00295 - 0.00610)
11. Remove the turbine housing from the bearing housing

(1). Install the compressor cover (2).
With feeler gauges, measure the clearance between
turbine back plate and turbine wheel. If the clearance is
not within standard clearance, disassemble the parts 1
and check for cause.
2
Note:
Measure the clearance with two feeler gauge from the
tips of the vanes as shown.
0.48 - 0.92 (0.0199 - 0.0362)
12. Install the compressor cover (2). Be sure that it is

correctly positioned with respect to the turbine housing.
2
Apply grease to O-ring (1) before you install it. 1
E485 W5-9-17
TURBOCHARGER
13. Install snap ring (1).
14. Be sure the turbine housing (1) is correctly positioned

with the compressor housing.
1
15. Appy Molykote to the threads of the coupling assembly

(1), then tighten it to the specified torque.
6 (0.6 / 4.3)
1
W5-9-18 E485
TURBOCHARGER
SERVICE STANDARD
Units: mm (in.)
Assembly Standard Service Limit
Part or Item Nominal Value (Clearance) Remarks
(Standard Clearance)
Inside diameter of ø 20.5 ø 20.506

bearing housing bores (0.807) (0.80732)
ø 20.382
Outside diameter
(0.80244)
ø 12.042
Bearing Inside diameter
(0.47409)
11.94
Lenght
(0.4701)
Diameter of ø 12.0 ø 11.996

Shaft & journals (0.47) (0.47228)
turbine
whell Runout of 0.015
shaft (0.00059)
With ring
0.05 - 0.25
End gap of piston ring fitted in the
(0.0020 - 0.0098)
insert
Clearance between
0.39 - 1.00
shaft & turbine wheel
(0.0154 - 0.0394)
and turbine housing
Axial play of shaft & 0.075 - 0.155

turbine wheel (0.00295 - 0.00610)
Clearance between turbine

0.48 - 0.92
back plate and turbine
(0.0189 - 0.0362)
wheel
E485 W5-10-1
ENGINE ELECTRICAL
STARTER
Rated voltage (V) 24
Rated output (kW) 5.5
Rating (s) 30
Direction of rotation
(Viewed from the pinion side) Clockwise
Clutch type Roller
Terminal voltage (No Load) (V) 24
Minimum current (No Load) (A) 120
Minimum operating speed
(No Load) (rpm) 4100
Pinion gear
Modules 3
Number of teeth 11
Outside diameter mm (in.) 40.5 (1.6)
Travel distance mm (in.) 0.82 (0.032)
Yoke outside diameter mm (in.) 100 (3.94)
Number of poles 4
Magnetic switch (at 20 °C [68 °F])

Series coil resistance (Ω) 0.76 - 0.84
Shunt coil resistance (Ω) 2.42 - 2.64
Brush length
Standard mm (in.) 20 (0.79)
Limit mm (in.) 13 (0.51)
Brush spring standard fitting load kg (lbs.) 3.3 (7.3)
Commutator
Outside diameter
Standard mm (in.) 43 (1.69)
Limit mm (in.) 42 (1.65)
Difference between the largest and

smallest diameters
Standard mm (in.) 0.02 (0.0008)
Limit mm (in.) 0.05 (0.0020)
Depth of undercut mica

Standard mm (in.) 0.5 - 0.8 (0.02 - 0.03)
Limit mm (in.) 0.2 (0.008)
W5-10-2 E485
ENGINE ELECTRICAL
SECTIONAL DRAWING
OUTPUT CHARACTERISTICS
Motor speed
Voltage
Torque
Ouput
(min-1) (N·m) (kW) (V)
Ouput
6000 120 6 24
Voltage
Torque
5000 100 5 20
4000 80 4 16
3000 60 3 12
2000 40 2 8
RPM
1000 20 1 4
0 0 0 0
0 200 400 600 800 1000 1200
Current (A)
E485 W5-10-3
ENGINE ELECTRICAL
CIRCUIT ARRANGEMENT
Brush
Field coil
Armature
Pinion
Idler gear
Ball bearing
Plunger
Main
contacts
Pinion clutch
Ring gear Clutch gear
Starter
switch
Battery
W5-10-4 E485
ENGINE ELECTRICAL
DISASSEMBLY
4
3 5
8
7
18
2
1
13
14
10
16
15
9
12
17
11
1. Hexagon nut ▲10. Starter housing

2. Connecting lead wire ▲11. Pinion clutch
3. Through bolts ▲12. Steel ball
▲4. End frame ▲13. Starter pinion
5. Starter seal ▲14. Idler gear
▲6. Yoke ▲15. Retainer
▲7. Brushes and brush holder ▲16. Clutch roller
▲8. Armature 17. Compression return spring
9. Screw ▲18. Magnetic switch body
E485 W5-10-5
ENGINE ELECTRICAL
4. End frame
6. Yoke
10. Starter housing
18. Magnetic switch body
Apply setting marks across the end frame, the yoke,
and the magnetic switch body.
This will ensure reassembly of the parts in their original
positions.
6. Yoke
Remove the yoke c from the magnetic switch d. 1
7. Brushes and brush holder

Use a long nose pliers to remove the brushes and pull
out the brush holder.
8. Armature
Remove the armature from the yoke.
Note:
If necessary, tap the yoke end with a plastic hammer to
remove the armature.
W5-10-6 E485
ENGINE ELECTRICAL
11. Pinion clutch

Remove the magnetic sub-switch from the starter
housing.
Note:
If the pinion is installed to the starter housing (exter-
nally attached to the magnetic sub-switch shaft, it must
be removed before the magnetic sub-switch.
12. Steel ball

Remove the steel ball from the pinion clutch.
13. Starter pinion

14. Idler gear
Remove the starter pinion and the idler gear from the
starter housing.
15. Retainer
16. Clutch roller
Remove the retainer and the clutch roller from the
starter housing.
E485 W5-10-7
ENGINE ELECTRICAL

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
ARMATURE
2
Armature short circuit test
1. Place the armature on a growler tester .
2. Hold a hacksaw blade against the armature core
while slowly rotating the armature.
1
If the armature is short circuited, the hacksaw blade will
vibrate and will be attracted to the armature core.
A short circuited armature must be replaced.
Armature winding ground test

Check for continuity across the commutator segments and
the core.
If there is continuity, the armature is internally grounded due
to insulation failure and must be replaced.
Armature winding continuity test

Check for continuity across the commutator segment.
If there is no continuity, the armature coil is open and must
be replaced.
Commutator run-out test

Use a dial indicator and a V-block to measure the commu-
tator runout.
If the measure value exceeds the limit, the commutator
must be replaced.
Commutator run-out mm (in.)
Standard Limit
0.02 (0.0008) 0.05 (0.002)
W5-10-8 E485
ENGINE ELECTRICAL
Commutator outside diameter measurement

Use a vernier caliper to measure the commutator outside
diameter.
If the measured value exceeds the limit, the armature must
be replaced.
Commutator outside diameter mm (in.)
Standard Limit
43.0 (1.7) 42.0 (1.65)
Segment mica depth measurement

Use a depth gauge to measure the segment mica depth.
If the measured value exceeds the limit, the segment mica
must be undercut.
Segment mica depth mm (in.)
Standard Limit
0.7 - 0.9 (0.028 - 0.035) 0.2 (0.008)
Bearing inspection
Visually inspect the bearing.
If the bearing is worn or damaged, it must be replaced.
YOKE
Field winding ground test
Use a circuit tester to check the field winding ground.
1. Touch one probe to the brush field winding end.
2. Touch the other probe to the bare surface of the yoke
body.
There should be no continuity.
If there is continuity, the field windings are grounded.
Repair or replace the field windings.
E485 W5-10-9
ENGINE ELECTRICAL
Field winding continuity test

Use a circuit tester to check the field winding continuity.
1. Touch one probe to the field winding lead wire.
2. Touch the other probe to the brush.
There should be continuity.
If there is no continuity, the field windings are open.
Repair or replace the field windings.
BRUSH AND BRUSH HOLDER

Brush length measurement
Measure the brush length to check for wear.
If the measured value exceeds the limit, the brush and/or
the yoke must be replaced.
Brush length (H) mm (in.)
Standard Limit
20.0 (0.79) 13.0 (0.51)
Brush spring inspection

Visually check te brush spring for weakness and rusting.
Replace the brush spring if it is weak or rusted.
Brush holder insulation test

Use a circuit tester to check the brush holder insulation.
1. Touch one probe to the field winding lead wire.
2. Touch the other probe to the brush.
There should be continuity.
If there is continuity, the brush holder must be repaired
or replaced.
PINION CLUTCH
Pinion inspection
Use your hand to turn the pinion in the direction of starter
motor rotation. The pinion should turn freely.
Try to turn the pinion in the opposite direction. The pinion
should lock.
W5-10-10 E485
ENGINE ELECTRICAL
REASSEMBLY
15
16 14
13
11
12
14
17
18
6
5
9
3
4
10
7
2
8
Reassembly sequence
1. Magnetic switch body 10. Screw

▲2. Compression return spring 11. Armature
▲3. Clutch roller ▲12. Brushes and brush holder
▲4. Retainer ▲13. Yoke
5. Idler gear 14. Starter seal
6. Starter pinion ▲15. End frame
7. Steel ball ▲16. Through bolt
8. Pinion clutch 17. Connecting lead wire
9. Starter housing 18. Hexagon nut
E485 W5-10-11
ENGINE ELECTRICAL
2. Compression return spring

Apply a coat of engine oil to the compression return
spring.
3. Clutch roller
4. Retainer
Apply a coat of engine oil to the clutch roller and the
retainer.
12. Brushes and brush holder

1) Install the negative brush (1) on the brush holder 3
side to the brush holder negative hole (2). 5
1
The brush holder negative hole is not insulated.
2) Install the positive brush (3) on the yoke side to the
brush holder positive hole (4).
The brush holder positive hole is separated from
the plate with the insulator (5).
3) Check that the positive brush lead wires are not
grounded. 4 2
4) Install the brush holder to the yoke.
Take care not to damage the brush holder or the
yoke.
Do not spill oil on the brush holder or the yoke.
W5-10-12 E485
ENGINE ELECTRICAL
13. Yoke
1) Install the yoke to the magnetic switch. Tab
The yoke must engage the notch on the magnetic
switch.
2) Securely set the rubber boot to the magnetic switch
C-terminal.
15. End frame

Install the end frame to the yoke.
The end frame tab engage the yoke lead wire grommet.
Tab Lead wire grommet
16. Through bolt

Tighten the through bolt to the specified torque.
Through bolt torque N·m (kgf·m/lb·ft)
9.8 ± 2.0 (1.0 ± 0.2 / 7.1 ± 1.4)

E485 W5-10-13
ENGINE ELECTRICAL
ALTERNATOR
GENERAL DESCRIPTION
5 6
4
7
8
1
9
10
Legend (6) Rotor

(1) Rear bracket (7) Bearing
(2) IC regulator (8) Pulley
(3) Bearing (9) Front bracket
(4) Rectifier (10) Field coil assembly
(5) Stator
The engine uses a brushless alternator. Terminal R is active only until the alternator begins to
Main alternator components are the rotor, the stator, generate electricity.
the rectifier, the front and rear brackets, the IC regula- Terminal L also serves as a voltage output terminal.
tor, the bearings, and the pulley. When the voltage across terminal L is equal to the
Moving parts include the rotor and the pulley. battery voltage, the indicator lamp (no charging) turns
The field coil is installed to the rear bracket. off.
6 main diodes (3 positive and 3 negative) in conjunc- Sealed bearings requiring no lubrication are used
tion with 2 sub-diodes provide 3-phase rectification. throughout the alternator.
The diodes are installed to the stator coil. The IC regulator is a solid-state device and is serviced
An additional 3 diodes (diode trio) are used to provide as a unit. It cannot be disassembled.
field current.
The alternator has 3 terminals.
a. Terminal B: DC power output
b. Terminal L: Exciting current input
c. Terminal R: Exciting current input
W5-10-14 E485
ENGINE ELECTRICAL
IDENTIFICATION MITSUBISHI IDENTIFICATION PLATE
The alternator identification plate is attached to the alterna-

tor rear bracket. The ISUZU part number, the manufactur- A
er's code number, and other important information are
stamped on the plate.
B
C D
Refer to the identification plate together with the "Main Data
and Specifications" Tables and accompanying charts in E
this Section when requesting service assistance from a
qualified electrical repair shop.
If you are unable to locate the data applicable to your engine,

please contact your machine supplier. A: Isuzu part number
B: Manufacturer's abbreviated name
C: System voltage output
D: Manufacturer's lot No.
E: Bar code

Rated voltage (V) 24
Rated output (A) 50
-1
Rated speed (min ) 5000
Rated output (Amp./Volt/min-1) 50/27/5000

No-load output at 0 Amp. (Volt/min-1) 24/900
Direction of rotation as viewed Clockwise

from pulley side
Ground polarity (-)
Pulley diameter mm (in.) 80 (3.15)
Coil resistance at 20 °C
Field coil (Ω) 4.5 - 5.2
E485 W5-10-15
ENGINE ELECTRICAL
CHARGING CIRCUIT
ADDITIONAL #
DIODES
DIODE TRIO INDICATOR LAMP
STATOR
-
COIL
- KEY
SWITCH
3 3
'
BATTERY
(24V)
&
FIELD
COIL
IC REGULATOR
&
ALTERNATOR
ALTERNATOR OUTPUT PERFORMANCE
70
Cold
Output current (A)
60
50 Hot 20 C
40
30
20
10
0 1 2 3 4 5 6 7
Alternator speed (x 1000min-1)

W5-10-16 E485
ENGINE ELECTRICAL
DISASSEMBLY
1
5
(1) IC regulator (4) Nut

(2) Terminal stud (5) Terminal B
(3) Rectifier assembly (6) Tube
E485 W5-10-17
ENGINE ELECTRICAL
1. Scratch setting marks between the front and rear

brackets and the alternator body (2 locations). This will B
ensure installation to its original position.
2. Remove the 4 through bolts.
3. Use the blade of a screwdriver to pry the front bracket
and the stator apart.
4. Carefully separate the front bracket, pulley, and rotor
from the stator and rear bracket.
A A
Note:
Do not push the screwdriver blade too deeply into 1
the stator. Coil damage will result.
A vise may be used to secure the rotor. Be sure to
clamp the vise at points A (see illustration below).
Do not clamp the vise at points B. Damage to the
rotor will result.
5. Remove the 2 screws (A) attaching the coil terminal

plate to the IC regulator.
6. Hold the coil assembly in your hand. Be careful not to A
damage the terminal plate.
7. Remove the 3 screws (B) and the coil assembly.
8. Remove the clame.
Note:
It is very important that Steps 5, 6 and 7 be performed
in that order. If Step 6 is performed before Step 5,
terminal damage will result. B
9. Remove the cap and nut from the rectifier terminal stud.
Note:
The tube will remain in the rear bracket. Take care not
to lose it.
10. Remove the rectifier retaining screw and the 2 IC
regulator retaining screws.
11. Remove the stator and rectifier assembly (as a single
unit) from the rear bracket.
12. Remove the IC regulator.
13. Unsolder the 4 stator coil leads from the rectifier
terminals.
14. Remove the stator from the rectifier.
Note:
High temperature solder with a melting point of 230 °C
connects the stator coil leads to the rectifier. Use a
180~280 Watt soldering iron to free the leads as quickly
as possible. Do not apply the soldering iron for more
than 5 seconds. Diode damage will result.
BEARING REMOVAL
Note:
Bearings are not normally removed. If they are re-
moved, they must be replaced with new ones.
Front bracket bearing
Remove the 4 retainer screws. Press out the bearing with a
suitable tool.
Rotor bearing
Use an ordinary bearing puller.
W5-10-18 E485
ENGINE ELECTRICAL

Startor
1. Check the stator for damage, loose connections, and
discolored windings.
1
2. Use a circuit tester to check for continuity between each
pair of stator coil leads (1). Replace the stator if there is
no continuity.
3. Use a circuit tester to check for continuity between each

of the stator coil leads (1) and the stator core (2).
Replace the stator if there is no continuity. 1
Rotor
2
1. Turn the rotor. Listen for bearing noise (a scraping
sound). Feel for rough rotation. Replace the rotor if
either of these conditions is present.
2. Check for grease leakage. If leakage is minimal, wipe
1
it away. If leakage is excessive, replace the rotor.
Note:
It is recommended that inspection be made with the
bearing fitted to the rotor shaft.
Coil assembly
Use an ohmmeter to measure the coil resistance between
both terminals (1) and the terminal plate (2). Replace the coil
assembly if the resistance is outside the specifications.
Coil resistance at 20 °C
4.5 - 5.2 Ohms

E485 W5-10-19
ENGINE ELECTRICAL
Rectifier 1
(1) Positive diode
(2) Diode terminals
(3) A part of negative diode
1. Use a circuit tester to test for continuity between each
diode terminal (2) and the positive heat sink.
Test in both directions.
If there is continuity and/or an open circuit in both
directions, the rectifier must be replaced.
2. Use a circuit tester to test for continuity between each 3
2
diode terminal (2) and the negative heat sink.
Test in both directions.
3. Check the diode trio for continuity in both directions.
Front bracket
Turn the bracket. Listen for bearing noise (a scraping
sound). Feel for rough rotation. Replace the bracket if either
of these conditions is present.
Check for grease leakage. If leakage is minimal, wipe it
away. If leakage is excessive, replace the bracket.
Regulator
The regulator cannot be checked in the absence of the other
components. Check regulator operation after alternator
reassembly.
W5-10-20 E485
ENGINE ELECTRICAL
REASSEMBLY
Follow the disassembly steps in the reverse order.
Note the following precautions.
No lubrication is required. Bearings are prelubricated.
Wipe away any grease leakage from the bearing area.
Use high-temperature solder (melting point of 230 °C).
Use a 180 - 280 Watt soldering iron to solder the leads
as quickly as possible. Do not apply the soldering iron
for more than 5 seconds. Diode damage will result.
Bracket, rotor, and stator reassembly is difficult be-
cause of the tight fit of the components. To make
reassembly easier, heat the area around the rear
bracket bearing box to approximately 55 °C.
Check that the rotor turns smoothy after alternator
reassembly.
Tightening torques
Pulley fixing nut: 147 N·m (15 kgm/108 lbft)
Through bolts: 5.1 N·m (0.52 kgm/3.8 lbft)
Bearing retainer screws: 3.6 N·m (0.37 kgm/2.7 lbft)
Coil retaining screws: 3.6 N·m (0.37 kgm/2.7 lbft)
Rectifier retaining screws: 3.6 N·m (0.37 kgm/2.7 lbft)
Regulator retaining screws: 3.4 N·m (0.35 kgm/
2.5 lbft)
Nuts for stud bolts: 8.8 N·m (0.9 kgm/6.5 lbft)
Bench testing
Perform bench tests on the reassembled alternator.
Voltage regulation
1. Make connections as shown in the illustration on the
AMMETER SWITCH 1
following page. Use an ammeter with a scale of 0 - 100 A
Amperes and voltmeter with a scale of 0 - 30 Volts.
LAMP (24V) SWITCH 2
2. Close switch 1 and open switch 2. The lamp should B
L
(3W MAX. )
light. R
V ALTERNATOR BATTERY
If the lamp does not light, check the voltage at terminal- (24V)
L.
LOAD
If the voltage is nearly equal to battery voltage (24 V), VOLTMETER
RESISTOR
check the alternator.
If the voltage is low, check for an open lamp and related
circuitry.
3. Slowly increase alternator speed.
The lamp should turn off as alternator speed ap-
proaches 1,300 min-1.
4. Check the voltage as alternator speed increases.
If the voltage fluctuates wildly during alternator speed
increase and rises above 30 Volts, the IC regulator is
probably defective.
If the voltage does not exceed battery voltage (24 V),
the alternator is defective (no generation of electricity).
Check alternator components again.
E485 W5-10-21
ENGINE ELECTRICAL
5. Increase alternator speed to approximately 5,000 min-1.

6. Note the ammeter reading.
If the reading is 5 Amperes or less, note the voltmeter
reading (be sure that alternator speed remains con-
stant). This is the regulated voltage.
If the reading is more than 5 Amperes, continue to
operate the ammeter at 5,000 min-1 until the reading falls
to 5 Amperes or less.
If the reading does not fall, replace the battery. If the
reading still does not fall, the alternator is defective and
must be repaired or replaced.
Current output
1. Operate the alternator at minimum speed.
2. Close switch 1. Check that the lamp lights.
3. Set the load resistor to its maximum resistance (mini-
mum current).
4. Close switch 2.
5. Increase the alternator speed to a constant 5,000 min-1.
6. Adjust the load resistor for maximum current output.
7. Allow the alternator to run for 15 minutes. Output should
increase as alternator temperature increases.
8. Once again, adjust the load resistor for maximum
current output.
The maximum current output must equal the specified
value. If it does not, the alternator must be rechecked.
Alternator output
50 Amp/27 Volt/5,000 min-1

W5-10-22 E485
ENGINE ELECTRICAL
TROUBLESHOOTING
Condition Possible Cause Correction

No output Bad terminal connection Repair
Open or shorted circuit Repair
Open field coil Replace
Defective diode Replace
Defective IC regulator Replace
Low output Loose terminal connection Tighten
Loose cooling fan belt Adjust belt tension
Shorted field coil Replace
Shorted stator coil Replace
Defective regulator Replace
Defective battery Replace
Poor terminal contact Repair
Overcharging Defective regulator Replace
Defective battery Replace
Unstable current Poor terminal contact Repair
Loose cooling fan belt Adjust belt tension
Short field coil Replace
Abnormal noise Intermittent contact in wiring Replace
Poor terminal contact Repair
Defective regulator Replace
Improper alternator installation Correct
Defective bearing Replace
Contact between the rotor core and Replace the rotor core and/or stator core
stator core
E485 W5-11-1
TROUBLESHOOTING
TROUBLESHOOTING
Note:
This group has been prepared to provide quick guidance for responding to common engine problems. Each
troubleshooting column is explained in the following topical order, from left to right:
(1) Inspection items (2) Possible Causes (3) Remedie
STARTING DIFFICULTIES
1. Starter doesn't turn
Inspection Item Possible Causes Remedies
NG* Loose electrodes or corrosion,

Battery Clean or tighten terminals
resulting in poor contact
NG
Dead or weakended battery Recharge or replace
NG Loose or damaged fan belt,

with resulting inability to Adjust or replace
recharge battery
OK
NG Faulty starter switch or starter

Starter switch Replace
relay
OK
NG
Starter Faulty magnetic switch Repair or replace
NG
Faulty motor Repair or replace
* NG = No good
W5-11-2 E485
TROUBLESHOOTING
2. Starter turns, but engine doesn't turn

NG
Battery Loose electrodes, or corrosion Clean or tighten terminals
NG Excessive battery depletion, or

Recharge or replace
dead battery
NG Loose or damaged fan belt,

with resulting inability to Adjust or replace
recharge battery
OK
NG Broken pinion gear, or slipping

Starter Replace
clutch
NG
Faulty magnetic switch Repair or replace
NG Brush wear, or weak spring,

Replace
resulting in insufficient output
OK
NG Seized piston, crankshaft

Engine bearing, or scorching of Repair or replace
related parts
E485 W5-11-3
TROUBLESHOOTING
3. The engine turns and fuel reaches the injection pump, but it doesn't start
NG Excessively low injection

Nozzle starting pressure, or improper Adjust or replace
spray condition
OK
NG
Injection pump Back leak
Loose in fuel injection
electrodes, nozzle
or corrosion. Clean or tighten
Replace terminals
delivery valve
NG Defective operation of control

Loose electrodes, or corrosion.
rack Cleanororreplace
Repair tightencontrol
terminals
rack
NG
Seizure
Loose or abrasion
electrodes, orof plunger
corrosion. Clean or plunger
Replace tighten terminals
assembly
4. The engine turns, but doesn't start
NG Faulty stop-mechanism,
Engine stop mechanism Defective electromagnetic fuel-
improper control system
cut valve
adjustment
NG Replace stop-mechanism,
Loose electrodes, or corrosion. Clean or Replace
tighten terminals
readjust control system
W5-11-4 E485
TROUBLESHOOTING
5. Fuel isn't supplied to the injection pump

NG
Fuel No fuel in tank Fill fuel tank
OK
NG Piping clogged, ruptured, joint

Fuel system piping Repair, replace, or tighten
loose
OK
NG
Fuel filter Overflow valve isn't closed Repair or replace
NG
Element clogged Replace element or cartridge
OK
NG
Fuel system Air in fuel line Bleed air from system
E485 W5-11-5
TROUBLESHOOTING
UNSTABLE IDLING RPM

NG
Idling device Idle adjustment faulty Readjust
OK
NG
Low-speed circuit Faulty low-speed control circuit Repair or replace
OK
NG Improper adjustment of speed

Speed control device Readjust
control device
OK
NG Repair or replace appropriate

Fuel system Fuel system leak
parts
NG
Air in fuel system Bleed air
NG
Water in fuel system Drain fuel and replace
OK
NG
Fuel filter Element clogged Replace cartridge
Continued on next page

W5-11-6 E485
TROUBLESHOOTING
Continued from previous page
OK
NG Faulty operation of governor

Injection pump Repair or replace
lever
NG
Broken plunger spring Replace
NG
Plunger worn Replace plunger assembly
NG
Camshaft worn Replace camshaft
OK
NG
Battery
Valve clearance Improper adjustment Readjust
OK
NG Gasket leak, liner wear, ring

Cylinder compression pressure scorched or broken, poor valve Replace appropriate parts
contact
E485 W5-11-7
TROUBLESHOOTING
LACK OF POWER
NG
Air cleaner Element clogged Clean or replace element
OK
NG
Fuel Water in fuel Drain fuel and replace
OK
NG
Fuel filter Element clogged Replace cartridge
OK
NG
Feed pump Faulty feed pump Repair or replace
OK
NG
Nozzle Nozzle sticking Replace

starting pressure, or improper Readjust or replace
spray condition
OK
NG
Fuel pipe Broken or clogged Replace

W5-11-8 E485
TROUBLESHOOTING
OK
NG
Injection pump Faulty delivery valve Replace
NG
Faulty timer Repair or replace
NG
Faulty operation of control lever Readjust or replace
NG Readjust injection timing,

Faulty injection timing
Repair or replace timer
NG
Weak governor spring Replace
NG
Plunger wear Replace plunger assembly
NG
Camshaft worn Replace
NG
Faulty roller tappet Replace
Continued to next page

E485 W5-11-9
TROUBLESHOOTING
OK
NG Exhaust leak from exhaust

Turbocharger Repair or replace appropriate
Replace
Faulty delivery
system, valve
or air leak from air
parts
intake system
NG
Faulty turbocharger assembly Replace
OK

Cylinder compression pressure sticking or damaged; or poor Replace appropriate parts
valve contact
OK
NG
OK
NG
Valve spring Valve tension too low or broken Replace
OK
NG
Exhaust system Exhaust pipe clogged Clean
OK
NG
Full load adjust screw seal No seal or improper adjustment Readjust and replace seal
OK
NG
Intercooler Clogged Clean
W5-11-10 E485
TROUBLESHOOTING
EXCESSIVE FUEL CONSUMPTION


Fuel system Fuel leak
parts
OK
NG
Air cleaner Element clogged Clean or replace element
OK
NG
Idle speed Improper adjustment Readjust
OK

Nozzle starting pressure, or improper Readjust or replace nozzle
spray condition
OK
NG
Fuel injection timing Improper timing adjustment Readjust timing
OK
NG Faulty delivery valve, resulting

Injection pump Replace delivery valve
in back leak
OK
NG
Turbocharger Turbocharger air intake leak Repair

E485 W5-11-11
TROUBLESHOOTING
OK
NG
Turbocharger Faulty turbocharger Replace
OK
NG
OK

Cylinder compression pressure sticking or damaged; or Replace appropriate parts
improper valve contact
OK
NG Valve tension too low or

Valve spring Replace
broken
W5-11-12 E485
TROUBLESHOOTING
EXCESSIVE OIL CONSUMPTION

NG Wrong oil grade, or too much

Engine oil Replace or adjust amount
added
OK
NG
Oil seal and gasket Oil leal from oil seal or gasket Replace
OK
NG
Air breather Air breather clogged Clean
OK
NG Faulty valve seal, wear

Intake/exhaust valve seal between valve stem and valve Replace appropriate parts
guide
OK
NG Ring wear, damage, or

Piston rings Replace rings, or reinstall
improper installation
OK
NG
Cylinder liner Liner damaged or worn Replace
E485 W5-11-13
TROUBLESHOOTING
OVERHEATING
NG
Radiator coolant Insufficient coolant Replenish
OK
NG Belt too loose, or slipping due

Fan belt Adjust or replace
to damage
OK
NG
Radiator Faulty cap, or core clogged Replace cap, clean out radiator
OK
NG
Water pump Faulty water pump Repair or replace
OK
Sealing cap between head and NG Water leakage due to faulty Replace sealing cap
cylinder block sealing cap
OK
NG
Thermostat Faulty thermostat Replace
OK
NG Foreign object leading to

Cooling system Clean out system
clogging
OK
NG
Fuel injection timing Improper injection timing Readjust injection timing
W5-11-14 E485
TROUBLESHOOTING
WHITE SMOKE IN EXHAUST

NG
Fuel Water in fuel Drain fuel and replace
OK
NG
Fuel injection timing Retarded timing Adjust injection timing
OK

Cylinder compression pressure adhesion or breakage, Replace appropriate parts
improper valve contact
OK
NG
Turbocharger Faulty turbocharger Replace
OK
NG Faulte valve seals, wear

Air/exhaust valves, valve seals between valve stems and Replace appropriate parts
guides
OK
NG Ring wear, breakage or

Piston rings Replace or reinstall
improper installation
OK
NG
Cylinder liner Liner damaged or worn Replace
E485 W5-11-15
TROUBLESHOOTING
BLACK SMOKE IN EXHAUST

NG
Air cleaner Element clogged Clean or replace
OK

Nozzle starting pressure, or improper Readjust or replace nozzle
spray condition
OK
NG
Fuel injection timing Improper injection timing Readjust injection timing
OK
NG Faulty delivery valve, resulting

Injection pump Replace delivery valve
in back leak
NG
Excessive fuel injection Readjust injection volume
W5-11-16 E485
TROUBLESHOOTING
LOW OIL PRESSURE

NG
Engine oil Inappropriate oil viscosity Replace oil
OK
Oil gauge, oil pressure unit, or NG Faulty oil guage, oil pressure Repair or replace appropriate
oil indicator lamp unit, oil indicator lamp parts
OK
NG
Oil filter Element clogged Replace cartridge
OK
NG Stuck relief valve or weak

Relief valve and bypass pipe Replace appropriate parts
bypass valve spring
OK
NG
Oil pump Strainer clogged Clean strainer
NG
Pump parts worn Replace appropriate parts
OK
NG
Rocker arm shaft Bushings worn Replace
Continued to next page

E485 W5-11-17
TROUBLESHOOTING
OK
NG
Camshaft Camshaft and bearings worn Replace appropriate parts
OK
NG
Camshaft and bearings Camshaft and bearings worn Replace appropriate parts
W5-11-18 E485
TROUBLESHOOTING
ENGINE SOUNDS
1. Knocking

Before beginning inspections and repairs, be sure the engine is fully warmed up
NG
Fuel Improper fuel Replace fuel
OK
NG Improper fuel injection timing

Fuel injection timing Readjust timing
adjustment
OK
NG Improper adjustment of
Nozzle injection starting pressure, or Readjust or replace
improper spray condition
OK
NG Gasket leak or piston ring

Cylinder compression pressure Replace appropriate parts
damage
2. Gas leak sounds
NG Loose joint connections, Retighten joints or replace

Exhaust pipe
broken pipe pipe
OK
NG
Nozzle and glow plugs Improper installation Replace seals or reinstall
OK
E485 W5-11-19
TROUBLESHOOTING
OK
NG Loose installation of manifold

Exhaust manifold Retighten
or glow plugs
OK
NG
Head gasket Faulty Replace
3. Continuous sounds
NG Readjust belt tension, or

Fan belt Loose or damaged
replace
OK
NG
Cooling fan Loose fan installation Tighten
OK
NG
Water pump bearing Wear or damage Replace
OK

Alternator Faulty alternator
parts
OK
NG
Valve clearance Improper valve clearance Readjust
W5-11-20 E485
TROUBLESHOOTING
4. Clanking sounds
NG
Valve clearance Improper valve clearance Readjust
OK
NG
Rocker arm Damaged Replace
OK
NG
Flywheel Loose mounting bolts Retighten
OK
NG Worn or broken crankshaft or

Crankshaft and thrust bearing Replace appropriate parts
thrust bearing
OK
Crankshaft and connecting rod NG

Worn or damaged bearings Replace appropriate parts
bearings
OK
Connecting rod bushings and NG Worn or damaged bushings or Replace appropriate parts
piston pins pins
OK
NG Worn or damaged pistons and

Pistons and liners liners, or foreign matter inside Replace appropriate parts
cylinder
E485 W5-12-1
SPECIAL TOOLS
SPECIAL TOOLS LIST
Item No. Illustration Part Number Part Name Page
W5-3-13
1 380001975 Valve spring compressor
W5-5-5
2 380001977 Valve guide remover W5-4-2
3 380001973 Cylinder liner remover W5-4-12
4 380001970 Cylinder liner installer W5-4-14
5 380001969 Crankshaft gear installer W5-4-27
W5-4-28
6 380001967 Oil seal remover
W5-4-29
W5-4-28
7 380001968 Oil seal installer
W5-4-29
8 380001976 Compression gauge adapter W5-2-13

W5-12-2 E485
SPECIAL TOOLS
Item No. Illustration Part Number Part Name Page
W5-3-16
9 380001716 Piston ring replacer
W5-5-8
10 380001971 Drive gear installer W5-4-27
11 380001966 Crank gear remover W5-4-27
12 380001974 Valve stem seal installer W5-5-4
13 380001972 Piston ring compressor W5-5-13
14 380001965 Water pump impeller remover W5-7-3

E485 W5-13-1
REPAIR STANDARDS
REPAIR STANDARDS
General Rules
1. These tables provide standards relating the repair of the following diesel engine;
Model AA-6SD1T (turbocharged)
2. These Repair Standards are based on inspection items, together with dimensions, assembly standards, limit
values, and repair procedures.
(1) Nominal dimensions are the standard production values.
(2) Assembly standards considered to be the values used as objectives during the assembly procedures
which follow repairs; as a result, they may be somewhat at variance with the assembly dimensions of a
new engine.
(3) Limit values refer to the measured values resulting from wear, etc., beyond which a part must not be used.
If a measured value falls beyond the limit value, the part involved must be repaired or replaced.
(4) "Repair Procedures" indicates normal repair methods.
(5) Unless otherwise stated, the unit of numerical values in tables should be taken to refer to millimeters (mm).
3. Explanation of Terms Used in Tables

(1) The dimension of "wear" refers to the difference between the dimensions of a part which is not worn (or
the "nominal dimension" of a part without wear) and the dimension of the part suffering from the most wear
(the dimension of the worn part).
(2) Uneven wear means the difference between the maximum and minimum wear values.
4. When repairs are requested on the overall engine, first perform bench tests to determine what parts require
repairs, then perform the minimum disassembly and repairs required to correct the problems.
When repairs on a specific engine part are requested, repairs to be made in reference to the relevant items in
accordance with the repair standards listed in this Section.
Major Name Nominal Assembly
Inspection Item Dimension Standard Value Limit Repair Procedure Comments
Category of Part
W5-13-2
Water temperature
70 - 80 °C,
Cylinder compression pressure 2.84 (29) 2.06 (21) engine speed
(kgf/cm2) or more or less 220 rpm
Time for engine
Disassemble and (varies depending
disassembly
repair engine on altitude)
and repair
Fuel consumption l/h 100% 140% New engine perform-
ance is assumed
Lubricating oil consumption cm3/h 100% 200% 100%
Wear on liner bore

Measured at A-A
24,120
(Ref)
Upper step wear must Cylinder & liner
Dia. 120 Dia 120.3 be repaired, or replace interference
A A with standard dimen-
sion liner 0.011 - 0.029
REPAIR STANDARDS
Liner projection
Engine Body
Difference in liner
Cylinder Block
Some projection must projection between
0.106 - 0.134
be present neighboring cylinders
not to exceed 0.02
0.2 Not repairable; must

Cylinder block upper face warpage 0.05 or less
or more be replaced
Pressure test: 3 minutes Leaks require repair or

2 490 (5) replacement
kPa (kgf/cm )
E485
E485
Category of Part Inspection Item Dimension Standard Value Limit Repair Procedure Comments
Valve seat depression: B

(both inlet and exhaust)
1.48
Inlet side 0.48
or more
(Insert) Valve seat angle: α
A
Replace insert Inlet side 30°
(Cylinder Exhaust side 45°
head) (Valve)
B
2.60
45 Exhaust side 1.60
Lower surface
or more
of cylinder head
3.5
Inlet side 2.7
or more Repair with valve seat After repair, be sure
Contact width with valve seat: A
3.2 cutter to lap contact surfaces
Exhaust side 2.4
or more
Warpage and flatness of cylinder Cannot be repaired:
0.2
head lower face (mounting 0.05 or less must replace cylinder
or more
surface) head
Warpage of manifold mounting 0.4
Engine Body
Cylinder Head
0.05 or less Repair
surface or more
REPAIR STANDARDS
Water-pressure test, 3 minutes Leaks require repair or

kPa (kgf/cm2) 490 (5)
replacement
Clean bolt mounting Tighten M14 bolts to

surface and 98.0 N·m (10 kgf·m)
threads, and apply then to 147 N·m
molybdenum (15 kgf·m).
Cylinder head bolts tightening M10 bolts
disulfide grease. Next, use angular
torque (angular tightening method) 31 - 45
Never tighten again method to additionally
N·m (kgf-m) (3.2 - 4.6)
after using angular tighten to 30° - 60°
tightening method. rotation.
Reuse bolts max. 2
times
W5-13-3
Category of Part
W5-13-4
Clearance with cylinder: Clearance with

grade position from upper face major axis
98 mm 0.131 - 0.175
Piston pin and piston pin hole 0.05 Replace piston or
Pistons
clearance 0.004 - 0.017 piston pin
or more
Dia. 42.98
Pin wear Dia. 43 Replace piston pin
or less
No. 1
0.35 - 0.50
compression ring
1.0 Replace rings when
Gauge inner
or more performing engine
Piston Ring Gap No. 2, 3 standard diameter
0.35 - 0.50 disassembly and
compression ring 120
repair
0.8
Oil ring 0.25 - 0.45
or more
No. 1 24.1 - 31.8 14,7
compression ring (2.46 - 3.24) or less (1.5)
No. 2 Measure with ring
15.4 - 21.3 9.8 (1.0)
compression ring Replace compressed to
(1.57 - 2.17) or below
standard ring gap.
Main Operating Parts

Tension N (kgf)
REPAIR STANDARDS
No. 3 17.7 - 24.5 11.8 (1.2)

compression ring (1.80 - 2.50) or below
53.9 - 73.5 37.3 (3.8) Measure with
Oil ring Replace
Cylinder Head
(5.5 - 7.5) or below expander attached.
No. 1 0.20 When assembling
0.105 - 0.14 compression rings on
compression ring or more
No. 2 0.20 piston, be sure ring’s
Clearance 0.105 - 0.14 marked surface is up.
between piston compression ring or more Replace rings or Backwards installation
ring and ring No. 3 0.20 piston will result in excessive
groove 0.085 - 0.120
compression ring or more oil consumption.
0.15 No top/bottom to oil
Oil ring 0.02 - 0.06
or more ring.
Ring gap orientation At 120° intervals
E485
Inspection Item
E485
Category of Part Dimension Standard Value Limit Repair Procedure Comments
Uneven wear on journal Dia. 90 0.05 Replace

0.001
and pins Dia. 80 or more
Journal wear Dia. 90 Dia. 89.909 Replace
or less Do not attempt to grind:
Dia. 79.894 always replace with new
Pin wear Dia. 80 or less Replace
parts
Journal and pin finish
Ellipse and
precision (taper and
taper 0.007
allipse)
Use those with projection
Journal and bearing 96 Load 9807 [1000] N[kgf]
and proper arc; take care
spread or less Projection 0.03 - 0.07
with back side fit
Clearance between 0.16
0.045 - 0.11 Replace bearing
journal and bearing or more
Journal bearing Undersize bearings cannot
undersize be used
0.4 Measure at crankshaft’s
Crankshaft and play 0.15 - 0.33 Replace thrust bearings
or more No. 4 bearing thrust surface
Crankshaft
0.15
Crankshaft runout 0.08 or less Replace
or more

REPAIR STANDARDS
Perform lapping on gears

Ring gear with burrs; in cases of
severe damage, replace
Crankshaft balance (Ref. value)
36 or less Check dynamic balance
(g-cm) At ends of journal
M14 bolts
Lower crankshaft bolts 98 (10) Apply molybdenum disul-
tightening torque fide grease to threads and
147 (15) 0.15 Do not catch foreign matter
(angular tightening
or more seating areas of bolts in bolts
method) 30 - 60°
M10 bolts before tightening
N·m (kgf-m)
38 (3.9)
Check for oil seal collapse
Crankshaft rear oil seal In case of oil leak, replace (liberally apply oil when
wear oil seal installing)
W5-13-5
Category of Part
W5-13-6
Use those with projection

Connecting rod bearing 85 Load 9807 (1000) N (kgf)
and proper arc; take care
runout or less Projection 0.03 - 0.07 mm
work back side fit
Clearance between
0.16 Replace bearing or Take special care with
connecting rod 0.04 - 0.106
or more crankshaft crankpin precision
bearing and crankpin
Contact between con-
Replace parts with poor
necting rod bearing
contact or abrasions
and crankpin
Clearance between Sufficient gap to allow
0.10
smallend bushing and 0.12 - 0.027 Replace bushing or pin smooth rotation when
or more
piston pin holding big end
Connecting rod bearing Crank must not be ground
Dia. 80
undersize (no undersizes available)
Connecting rod and 0.35
0.17 - 0.28 Replace connecting rod
crankpin end play or more
Center distance
between big end and 223.5 Reference value
Connecting Rods
small end (mm)

REPAIR STANDARDS
Big end to small end hole 0.1

0.03 or less or more Repair or replace
twist (per 100 mm)
Big end to small end hole 0.1
parallelism 0.03 or less Repair or replace
or more
(per 100 mm)
Piston weight difference
20 or less Repair or replace
after assembly g
39 (4.0) After tightening to 39 N·m
Bearing cap bolt alternately (4.0 kgf·m), use angular
tightening torque (One side) Apply molybdenum disul-
fide grease to bolts before tightening to tighten
(angular tightening (Other side) alternately first side 90°,
method) 60° tightening
other side 120° - 150°, first
N·m (kgf-m) 120°
60°
side 30°- 90°
E485
E485
Journal uneven wear Replace camshaft
0.16 Replace camshaft or

Clearance between journal and bearing 0.06 - 0.11
or more bearing
Dia. 39.89
Journal wear Dia. 40 Dia. 39.915 - 39.940 Replace camshaft
or less
Cam height:
A-B
A 5.56 Minor step wear on

5.92 Replace camshaft
or less cams can be repaired
Camshaft
B

Measure with dial
0.10 gauge at No. 3 or
Camshaft runout 0.05 Replace camshaft
or more No. 4 journal, runout
during one rotation
0.4
Camshaft play (front-back direction) 0.055 - 0.205
or more
REPAIR STANDARDS
W5-13-7
Inspection Item Standard Limit Repair Procedure Comments
Category of Part Dimension
Value
W5-13-8
Inlet valve stem wear Dia. 10 Dia. 9.92 Replace valve and Measure valve stem
Exhaust valve stem wear Dia. 10 Dia. 9.90 valve guide together at three posotion
Clearance between inlet valve
stem and valve guide 0.040 - 0.077 0.15 or more
Replace valve and
Clearance between exhaust valve valve guide together
0.065 - 0.102 0.20 or more
stem and guide
Interference between valve guide Apply oil to valve
0.024
and cylinder head guide and press in
Inlet 2.50 2.00 or less Replace valve and
Valve
thickness 2.35 1.85 or less valve guide together
Exhaust
Height of valve H
guide above 22 Reference value

cylinder head
Valve stem oil seal lip Dia. 9.5 Dia. 9.8 or more Replace oil seal Don’t damage lip
Inner [11.4] Inner [10.2 orless]
Tension N
Valves
Inlet
(When compressed Outer [29.8] Outer [26.8 or less]
Valve System
to installed length)
Inner [29.0] Inner [26.1 or less]
REPAIR STANDARDS
Inner 46.2 mm
Outer 48.7 mm Exhaust
Outer [51.0] Outer [45.9 or less]
Inlet
Free height mm Replace oil seal
Exhaust
Valve spring
Inclination mm Inner 3.0 or more
Outer 3.5 or more

E485
E485
Valve clearance (inlet & exhaust)

0.4 Adjust
(cold)
Clearance between rocker arm Replace bushing or

shaft and bushing 0.01 - 0.05 0.2 or more
shaft
Valves
Valve System
Dia. 18.85
Rocker arm shaft wear Dia. 19 Replace
or less
Special order item

Air cleaner element condition
from manufacturer
Air cleaner
Intake System
REPAIR STANDARDS
W5-13-9
Category of Part
W5-13-10
Lubricating oil pressure
Oil
kPa (kg/cm2)
pressure
Clearance between pump body Replace bushing,
0.10 - 0.196 0.15
inner wall and gear teeth mm gear or body
Pumping rate l/min

2486 rpm, SAE #30,
pumping pressure 780 (8) 90.0
( kPa (kgf/cm2) )
oil temp. 80 °C
End gap between pump cover and Replace gear or

0.040 - 0.093 0.15
gear cover
Clearance between drive shaft and

0.032 - 0.070 0.15
pump body
Clearance between drive shaft and

0.045 - 0.078 0.15 Replace bushing
Oil pump and Relief valve

bushing
Lubricating System
REPAIR STANDARDS
Dia 15.9
Diameter of drive shaft Dia. 16 Replace shaft
or less
Initial operating Oil gallery 539 (5.5)

pressure of relief Reference value
valve kPa (kgf/cm2) Oil pump 1080 (11.0)
Replace cartridge
Clogging and damage to oil filter Repalce every 500 hours of
operation
Oil filter
Initial operating pressure of main oil
filter relief valve kPa (kgf/cm2) 196 (2.0)
E485
Inspection Item
E485
Water pump ball bearing chatter #6305 (2)

0.008 - 0.010 0.2 Replace
(radial direction) #6205 (1)
Pumping rate l/m
pumping speed 2000 rpm, 265

water temp 30 °C
Total head 8.6 m or more
( )
Repair or replace if
Clearance between pump impeller
0.5 impeller and pump
and pump body mm
body are touching
Press with finger
Fan belt (Reference)

About 7 - 9 Adjust
deflection mm 10 Kg/each
Water pump
Cooling System
Initial thermostat operating Replace thermostat if
74.5 - 78.5 °C
operation is incorrect
REPAIR STANDARDS
temperature (at sea level)
Temperature at which
Termostat full-open temperature
90 °C thermostat lift reaches
(at sea level)
13 mm or more
Maximum
Press-in
Fan center and bearing shaft 2 disassemblies.
load
interference 0.07 - 0.11 From 3rd time,
600 kg
replace shaft
or less
assembly
Bearing shaft and impeller

0.020 - 0.060
interference
Pulley and fan center clearance 0.14 or less

W5-13-11
Category of Part
W5-13-12
Clogged, cracked, loose fuel pipes,

injection pipes, nozzle holders; Repair or replace
defective seals
Fuel filter element clogging or
Piping, etc.
Replace Cartridge type
damage
Pumping performance
with hand primer pump, speed Pumped up
60 - 100 times/minutes within 120 times
Repair or replace
1 m head, pipe internal 25 stroke or more
( diameter x lenght (8 mm x 2 m)
) or less
Pumping capacity (cc)

pump speed 1000 rpm.
15 seconds duration, 530 or more 400 or less Repair or replace
( Inlet head : 1m )
Outlet : 0.3 m
Fuel feed pump

Bubbles from
pushrod less
Fuel System
Air tighteness than rice-grain Other leaks require or
196 kpa (2.0 kgf/cm2) size, not to replacement
REPAIR STANDARDS
exceed 30 cc/min
Inspect for damage to
valve’s piston and seat;
replace in case of severe
vertical craks on piston
or impact scars on seat
with loss of finish gloss.
Immerse delivery valve in
Delivery valve wear clean diesel fuel, then
lightly press lower part of
Delivery valve
Injection pump
valve seat with finger and
release; replace assembly
if valve does not return to
original state when finger
is released
E485
Standard
E485
Inspection Item Dimension Limit Repair Procedure Comments

Category of Part Value
Technology Needle valve seat: 7.84 Mpa Repair or replace parts
(80 kgf/cm2) with leaks from seat area
Needle valve shaft seat: seconds

Impress fuel pressure of 29.4 Mpa
(300 kgf/cm2) (nozzle starting pressure) 5.0 Fuel used: diesel fuel,
Replace clay (Redwood);
and measure time required for pressure to or more
( drop from 24.5 Mpa (250 kgf/cm2) to ) 37 - 40 seconds 120 °C
19.6 Mpa (200 kgf/cm2).
Fuel system
Injection Nozzle
Fuel spray and injection Visually inspect, no telatively
Impress fuel pressure of Adjust needls large drops
valve opening pressure to No drops scattered to one side Replace faulty parts
( 1st stage: 17.7 Mpa (180 kg/cm2/2570 psi) ) No unevenness of spray from
2nd stage: 22.1 Mpa (225 kg/cm2/3200 psi) jets
If warning indicator lights
when engine is operating at
Warning lamp indication normal speeds, check and
Charge/
indication
repair electrical system.
Check for looseness, cuts or damaged
Repair
insulation to wiring
Wiring Discharge
REPAIR STANDARDS
Electrical
Rate output current 27 V (5000 rpm) 50A
Performance
Alternator 24V, 50A

W5-13-13
Category of Part
W5-13-14
Loose mount Repair
Brush height 20 13 or less Replace
Series coil 0.76 - 0.84

resistance value (Ω) (20 °C) If coil resistance value
Magnetic
is severely abnormal,
switch Shunt coil replace switch
2.42 - 2.62
resistance value (Ω) (20 °C)
O.D Dia. 43 Dia. 42 Replace armature
Starter 24V, 5.5 kW

Commutator
Undercut dept 0.5 - 0.8 0.2 Repair
Smooth pinion
Electrical
Unloaded
Performance characteristics 4100 rpm operation without
(24V, 120A or less) noise
Replace if cut wiring

Control register, glow plug
or shorts are found
Preheater
REPAIR STANDARDS
Battery terminals
Special order from
Plates, separator plates, container,
original manufacturer;
etc.
Battery
manufacturer’s specs
Electrolyte turbidity
E485
Inspection Item
E485
Electrolyte specific gravity

(at recharging, 20 °C)
Capacity (20 hours) Special order from

original manufacturer
Battery
Electrical
Electrode voltage
Electrolye surface height
Engine run-in operation 30 minutes or more
Cylinder compression pressure

MPa (kgf/cm2) 2.6 (21)
2.84 (29) Inspect Warm engine
(water temp. 70 - 85 °C, or less
about 220 rpm)
Difference in compression
between cylinders
196 Warm engine
kPa (kgf/cm2) Inspect
(2 or more)
(water temp. 70 - 85 °C,
about 220 rpm)
Final Inspection
REPAIR STANDARDS
Lubricating oil pressure 196 or less

539 (5.5) Adjust
kPa (kgf/cm2) (2.0)
Output check 85% or more

When new engine
Fuel consumption check 110% or less output is 100%
W5-13-15
W5-13-16 E485
REPAIR STANDARDS
NOTES
E485 W5-14-1
ELECTRONIC CONTROL SYSTEM
SYSTEM CONFIGURATION
System outline Features:

This system functions as an all-speed governor that • Characteristic programs of high output, normal
control the engine revolution during changes in the output and low output are loaded to the control unit,
load and, the output is minutely regulated to protect the so that an optimum output can be selected accord-
engine by means of various additional functions. ing to the work conditions, thereby contributing to
reducing the fuel consumption and improving the
workability.
• The self-diagnostic functions enhance the service-
ability.
To cluster gauge
Glow plugs
Engine Hydraulic system
Water
temp.
sensor N sensor
RED IV
Each hydraulic cylinder
Injection pump
Rotation sensor
(Back up)
Q-adj.
Engine revolution signal
Hydraulic control signal
Boost pressure signal
resistance
Engine control signal
Water temperature signal
Target rack position signal

Actual rack position signal
TDC Rotation signal
Rotation signal
+24V
Each sensor signal
Glow
relay Accelerometer
dial
Electronic governor
To starter control unit
relay Mechatro
controller
Eng. Diagnosis
emerg. lamp
stop
relay
Start signal
Diagnosis switch
Key on signal R3500

W5-14-2 E485
RED IV GOVERNOR
Governor configuration diagram

The type RED IV electronic control governor is set up control governor are broadly classified into a housing,
to work as an all-speed governor, high/low speed actuator and a cover, with their control circuits (servo
governor, by means of the program contained in the circuit, drive circuit, sensor circuit) incorporated in the
control unit. actuator.
The component parts of the type RED IV electronic This minimizes noise interference.
Housing
Rack sensor (link)
Rack
Stop lever
Cover
Eye joint
(oil return)
Actuator
R2431
E485 W5-14-3
Pulse Gear
Housing
Actuator
Cover
R2432
Rack sensor (link) Rack sensor (coil)
Coil
Rack
Linear DC motor
R2433
W5-14-4 E485
Governor cross-section
Governor ACT
drive circuit
Rack sensor
Control rack
TDC Rotation
sensor
Governor ACT Pulse Gear

(Linear DC motor)
Camshaft
Injection pump side
R2434
E485 W5-14-5
COMPONENT OPERATION DESCRIPTION

Rack sensor
1. Actuator
• The linear DC motor moves the coil assembly up
and down in response to the drive signal output by
the servo-circuit in the governor.
Coil assembly
Control rack
Linear DC motor
R2463
• The link mounted on the coil assembly transmits

Connector
the up and down movement of the coil assembly
to a connector mounted on the end of the control
rack. The control rack is then moved left or right
to adjust the fuel injection quantity. Thus, when
the coil assembly moves up, the control rack is Control rack
moved in the fuel increase direction; when the coil
assembly moves down, the control rack is moved
in the fuel decrease direction, with the link con- Link
verting vertical movement to horizontal move-
ment.
R2464
• A copper plate is mounted on top of the connector Control rack Copper plate Rack sensor
on the end of the control rack and forms a part of
the rack sensor. This rack sensor detects the
actual control rack position and feeds back this Link
information to the control unit.
The control unit is constantly comparing the
target rack position with the actual rack position
and moving the control rack to make the differ-
Coil assembly
ence between the two as close to zero as possi-
ble. Accordingly, rack sensor operation is ex-
tremely important to controlling rack accuracy
and response.
R2465
W5-14-6 E485
2. Linear DC motor
• The principal of operation of the liner DC motor is Current "I"
the same as that of a rotary type motor. Force "F" Force "F"
operates when current "I" flows in magnetic field
"B". If, as shown on side, the thumb represents
magnetic force "F", the index finger magnetic Magnetic field "B"
field "B", and the middle finger current "I", and
current "I" flows in the magnetic field "B", in the
direction of the middle finger, then "F" flows in the
direction of the thumb. This is called "Fleming's N S
Left Hand Rule". The magnitude of the force
generated is proportional to the strength of the R2466
magnetic field intersecting the coil, the strength
of the current flowing in the coil and the length of
the coil.
• The figure shows a top cross-sectional view fo the Cover Pole

linear DC motor. The magnetic field is flowing
from the outside to the center. If the current flows Magnet
in direction "A", the force acting on the coil
pushes the coil assembly up in accordance with
"Fleming's Left Hand Rule". N
Conversely, if the current flows in dierction "B",
the force acting on the coil pushes the coil
ON assembly down.
Coil assembly
Top cross-sectional view R2467
• An electromagnetic switching system is used to

drive the linear DC motor.
On figure on side, a schematic diagram shows
the principle of operation of the drive circuit that
includes a switch circuit, controlled at 1 kHz and Up Down
moves the coil assembly up and down.
In details the drive circuit of Governor is carry out
Coil
with transistors and electronic circuit. assembly
R2468
E485 W5-14-7
• When the coil assembly is in a balanced status,

the ratio of the up and down signals is 1:1. When
the coil assembly moves up or down, however,
duty control changes the ratio of the up and down
signals. By changing this duty ratio, it is possible 1 msec
to change the speed at which te coil assembly
ON
moves.
Up signal
This electromagnetic switching system reduces 50% 50%
OFF
coil heating, greatly improving response. Balanced
status
ON
Down signal 50% 50%
NOTE - Duty control is the changing of the ratio of the OFF
ON signal and OFF signal during 1 pulse signal cycle.
1 ms
ON
ON period Up signal
Duty ratio: x 100% 75% 75%
ON period + OFF period OFF
Rising
ON
Down signal 25% 25%
OFF
R2469
3. Rack sensor
• When the copper plate is positioned in relation to Magnetic field
the coil as shown on side, and eddy current which Magnetic generated by Eddy Copper
flux eddy current current plate
negates the magnetic field is generated at the
copper plate. It is therefore possible to vary both
the strength of the magnetic field and the back-
electromotive force generated at the coil by
changing the position of the copper plate.
Another coil and copper plate are provided for
temperature compensation to correct any varia-
tion of inductance due to temperature fluctua-
tions. The control rack position is detected from
the ratio of the inductances of the two coils (the
back-electromotive force ratio) and improves
detection accuracy by eliminating errors caused
by temperature fluctuations.
NOTE - Inductance is expressed as the resistance

corresponding to variations in current.
Large
Small
Coil Inductance
R2470
W5-14-8 E485
4. Speed sensor
Sensing gear
• As shown on side, when the sensing gear
mounted on the camshaft rotates, the magnetic Pole Magnetic field
field generated by the speed sensor is varied by
the sensing gear cogs. These magnetic field
To control unit
fluctuations generate a tiny voltage in the coil and
fluctuations of this voltage are detected as the
speed signal. Detected signal
Coil Magnet
R2471
5. Stop lever
Stopper bolt
• The figure shows the relation between the stopper
bolt and the oval hole during normal engine Control rack
operation. (The stopper bolt does not contact the
edge of the oval hole.)
Therefore, the control rack can move independ- Normal
ently of the stopper bolt. side
Oval hole
R2472
• The figure on side shows stop lever operation to Control rack

stop the engine with the control rack in the full
position Stop lever Oval hole
When the sthop lever is moved to the stop side,
the stopper bolt contacts the edge of the oval hole
Stopper bolt
and the link moves. Because of this, the control
rack is pulled in the non-injection direction and the
engine stops.
Thus, the stop lever can stop the engine regard-
Stop
less of the control rack position. side
Link
R2473
E485 W5-14-9
CONTROL DESCRIPTION
Outline
Input Part Operation Part Drive Part
CPU (Central Processing Unit)

From sensors and switches
Conversion circuit
Rsoll
Operation circuit
Control circuit
Servo circuit Drive circuit
Rist
Rack sensor Actuator
ROM
R soll: Target rack position signal

R ist: Actual rack position signal
R2435
The control of the type RED IV electronic control control such that the actual position signal will
governor is basically divided into an input part, opera- match the target value.
tion part and a drive part. By executing this series of processing continuous-
• Signals detected by the sensors and switches are ly, the system performs an optimum fuel injection
applied to the control unit via the input part. After so control in response to the request of the engine.
converted that the signals can be computed, they
are supplied to the operation part as information Knowledge
signals.
ROM: Abbreviation of Read Only Memory, which
• The drive part converts the actuator control signal
means a memory element.
(target rack position signal) to an actuator drive
It holds fixed data and programs stored, and this
signal to drive the actuator. It also feeds back the
information is not lost even after the power is cut off.
actual position of the control rack (actual rack
position signal) from the rack sensor and exerts
W5-14-10 E485
Governor control system

The type RED IV electronic governor has a servo circuit, signals from the CPU through its servo circuit and
drive circuit and a sensor circuit built in. It receives PWM processes them to drive the linear DC motor.
Inside RED IV
CPU PWM signal (Pulse) Digital Analog

Servo circuit Drive circuit
Target rack position
communicated by way
of duty ratio.
Vist (Analog)
VsoI I
V1
V2
a% b%
Duty ratio Linear DC motor
Signals cannot be viewed directly.
Rack sensor
Vist (Analog) for Machine

side self-diagnostics
Vist Sensor
monitor circuit Rack sensor
Vist signal (Analog)
V1
V2
a mm b mm
Rack position
R2436
PWM: Pulse Width Modulation Servo circuit: Servo means to have an object to
Duty ratio: Ratio of an ON signal within the time follow another. This circuit compares
of 1 cycle of a pulse signal the target value to an actual value
Vist: Actual rack position voltage and corrects for the difference.
Digital: To represent data digitally. Drive circuit: Circuit that delivers a signal to drive
Analog: To represent data by a continuous the linear DC motor.
physical quantity. Sensor circuit: Circuit that processes signals from
CPU: Central Processing Unit the rack sensor.
E485 W5-14-11
RED IV system configuration diagram
ECU RED IV governor ACT circuit
Actual rack
Rack sensor position Sensor Rack
input circuit circuit sensor coil
Servo Switching
CPU
circuit circuit
Rack position
Target output request Input D/A Drive
circuit Limp Home signal circuit circuit
Rotation pulse
ROM
Rotation Linear
sensor motor
(TDC and Backup) R2437
RED IV governor side block diagram
Actual rack Vist

Rack sensor
value output
circuit
buffer
To ECU
Governor Waveform Target rack PWM Soll

M ACT drive shaping value
circuit circuit D/A conversion
PID control circuit
PWM soll for Limp Home
Limp Home signal
Pull-Down signal
R2438
Outline of Type RED IV Governor Control

The ECU delivers a target rack position computed The pull-down signal applied from the ECU side has a
from a map, etc., to the injection pump as a PWM higher priority order over the target rack value and the
signal (PWM Soll above). It performs PID operation of Limp Home signal. Therefore, when the pull-down
this target value and actual value obtained by the rack signal is active, it causes the pull-down control
sensor circuit on the hardware, and shapes the opera- (rack = 3 mm) to be exerted on the rack, regardless of
tion results (mainly separation of UP side and DOWN the target value. Normally, the pull-down signal is
side duties) in waveform to drive the DC motor through employed in response to non-injection requests during
the drive circuit. the control. Under the Limp Home control, when the
The actual rack value is delivered to the ECU via the Limp Home signal is turned active, PWM Soll directly
output buffer (Vist above). This signal is used to works as a governor support UP side DUTY signal.
decide whether or not the governor is correctly follow-
ing the target value.
W5-14-12 E485
Governor ACT drive circuit

The governor actuator has a linear DC motor incorpo- Meanwhile, when the DOWN signal turns active,
rated. When the UP side signal turns active, transis- transistors T2 and T3 come on, enabling the rack to
tors T1 and T4 in the diagram below come on, allowing move toward the fuel-decreasing side. The drive pe-
the rack to move toward the fuel-increasing side. riod is approximately 1 kHz.
VB
T1 T2
UP-side signal
M
DOWN-side signal
T3 T4
Controll.C.
GND
R2439
E485 W5-14-13
STANDARD CONTROL FUNCTION
Control Function Outline
1 Control of engine • Controls the number of revolutions based on the target number of revolutions.
revolution
• Controls the number of revolutions by directly applying potentiometer signals
to the engine controller.
• Controls the number of revolutions through the direct communication from
the Mechatro controller to the engine controller.
2 Idling revolution control • Controls the number of idling revolutions according to the temperature of
with compensation engine cooling water.
for water temperature
• Controls the startup injection volume of fuel according to the temperature of
engine cooling water.
3 Idling revolution control • Increases the number of idling revolutions according to the supply voltage.
with compensation for
battery voltage
4 Glow control • Controls the energizing time of glow pursuant to the temperature of engine
cooling water.
5 Altitude-compensation • Prevents the emission of dark smokes at high altitudes by reducing the fuel
control injection volume according to the atmospheric pressure.
6 Communication control • Transfers diverse data to the mechatro controller and receives requests from
the mechatro controller through communication.
7 Failure control • Outputs trouble codes of sensor malfunctions, wire breakage, governor
errors, etc. and executes backup operation.
W5-14-14 E485
Idling revolution control

• Battery voltage compensation
Controls the number of idling revolutions according to the battery voltage.
Characteristics of idle revolution adjusted by Battery Voltage compensation

1200
Number of Idling Revolutions (min-1)
1100
1000
900
800
18 20 22 24 26
Battery Voltage (V)
R3501
• Water temperature compensation

Controls the number of idling revolutions according to the temperature of engine cooling water.
Characteristics of idle revolution adjusted by Water temperature compensation
1200
Number of Idling Revolutions (min-1)
1100
1000
900
800
-30 0 20 30
Cooling Water Temperature (°C)
R3502
Of the numbers of idling revolutions resulting from battery voltage and water temperature compensations, the larger
one will have the priority.
E485 W5-14-15
Glow control time-chart
ST
ON
IG SW
ACC
OFF
ON
Glow lamp
OFF
ON
Glow relay
OFF
By pre-glow By after-glow
energizing map energizing map
R2442
Operation conditions for glow plugs:

When any of the conditions listed below is satisfied, the glow plugs are operated:
• When the pre-glow map operates.
• When the after-glow map operates.
• When the key switch is turned on.
Relationship between the change of cooling water temperature and preheating times
Pre glow After glow

Time of after glow (sec)
Time of pre glow (sec)
Cooling Water Temp (°C) Cooling Water Temp (°C)

R2456 R2457
W5-14-16 E485
FAIL-SAFE FUNCTIONS (SAFETY DEVICES)
Control rack pull-down function

In case an overrun or major failure occurs, this function
pulls the control rack instantaneously in the non-
injection direction to protect the engine.
This function also works when the starter key is turned
off, causing the engine to come to a halt. This
eliminates the need to add a device dedicated to
stopping the engine.
Overrun protection function

When the engine has reached the allowable number of
revolutions “N1,” the pull-down function works to re-
Fuel Injection
Volume
duce the fuel injection volume, and as the engine
reaches the reset number of revolutions “N2,” the
normal control is restored. This function provides
protection for the engine. 0 N2 N1
Revolutions
N1: Allowable number of engine revolutions
N2: Reset number of revolutions R2443
Limp Home
Target number of revolutions
When the Limp Home mode is activated, the rack
position is regulated by the revolution feedback control
Rack position
interlocked to the accelerator, which is based on the

deviation of the actual number of revolutions N from
the target number of revolutions, so that the engine
revolution will be controlled to the target number of
revolutions. In an emergency, this function allows to N
pull up to a safe place. Revolutions R2444
NOTE - Should not be Engine long run at limp home

condition.
Rack control at starting

At low temperature
Rack control at starting is the control of the fuel
injection quantity increase at starting. At low tempera-
At normal temperature
Rack position
tures, the fuel injection quantity is increased to ensure

easier starting, while at normal temperatures, the
supply of excess fuel is prevented.
Pump speed
R2461
Rack position compensation

(compensation resistor)
Rack position
To obtain optimum engine matching, the full rack

position can be adjusted through the use of a resistor
located outside the control unit.
NOTE - This resistance (Q adjusting resistance) is

determined through bench tests during the engine
manufacturing process and cannot be changed indis- Pump speed R2462
criminately.
E485 W5-14-17
EXTERNAL CONNECTION DIAGRAM OF ECU
Terminal Layout Diagram of ECU:
RED4 1
22 Limp Home request
Backup sensor 5 RED4 2
17 34 VB output
52 RED4 GND
44 Rack position request
45 +5V output
{
From Accel. 1 (SIG) 53 RED4 SIG GND
73
Mechatro Accel. 2 (SIG) 74
Controller SIG GND 83 54 Shild GND
RED4 3
9 PULL DOWN
VB 33 VB output
51 RED4 GND
Power 92.93 35 Rack position request
36 Rack sensor +5V
43
Rack sensor SIG
KEY SW 4
TDC sensor
15
SIG
75 VB
Engine water
GND
temperature 27 1 Glow relay
Output Side
91 Diag. lamp
Input Side
SIG
37 10.11
Fuel Delivery resistance GND
46
42.32
GND
99.100
Ignition switch VB 60.61
Start switch VB 65
76 Overheat signal (To Mechatro Controller)

Diag. selector SW 71
Memory Clear 82
TXD
89 Scan Tool (Tech 2)
VCC (+5V)
Atmospheric 63
pressure SIG
Limp Home 50 Boost sensor
67 sensor GND
84
R3503
W5-14-18 E485
Connector Pin Assignment and Connections of ECU
ECU Connector Pin Assignment
1 2 3 4 5 6 7 8 9 10 11 33 34 35 36 37 38 39 40 58 59 60 61 62 63 64 65 66 67 89 90 91 92 93
12 13 14 15 16 17 18 19 20 21 22 23 24 41 42 43 44 45 46 47 48 49 50 68 69 70 71 72 73 74 75 76 77 78 79 94 95 96 97 98 99 100
25 26 27 28 29 30 31 32 51 52 53 54 55 56 57 80 81 82 83 84 85 86 87 88 101 102 103 104
32-pin connector 25-pin connector 31-pin connector 16-pin connector
1 Glow relay output 27 TW SENSOR (GND) 53 RED4 SIG GND 79 -

2 - 28 - 54 RED4 SHILD GND 80 -
3 - 29 - 55 - 81 -
4 TDC SENSOR (SIG) 30 - 56 - 82 Memory clear SW input
5 BACKUP SENSOR (SIG) 31 - 57 - 83 SIG. GND
6 - 32 GND (M/V) 58 - 84 Boost sensor GND
7 - 33 RED4 + VB OUT 59 - 85 -
8 - 34 RED4 + VB OUT 60 IG SW input 86 -
9 PULL DOWN SIG 35 PWM SOLL 61 IG SW input 87 -
10 + VB (MV/VB) 36 RED4 + 5V 62 - 88 -
11 + VB (RED POWER) 37 Q-adj. resistance (SIG) input 63 Boost sensor (+ 5V) 89 TECH2, DDS (TXD)
12 - 38 - 64 - 90 -
13 - 39 - 65 Start SW input 91 Diag. lamp output
14 - 40 - 66 - 92 ECU POWER
15 TDC SENSOR (GND) 41 - 67 Limp Home 93 ECU POWER
16 - 42 GND (M/V) 68 - 94 -
17 BACKUP SENSOR (GND) 43 RED4 V-IST 69 - 95 -
18 - 44 RED4 PWM SOLL 70 - 96 -
19 - 45 RED4 + 5V 71 Diag. selector SW 97 -
20 - 46 Q-adj. resistance (GND) input 72 - 98 -
21 - 47 - 73 ACCEL 1 SIG 99 ECU GND
22 RED4 LIMP HOME (SIG) 48 - 74 ACCEL 2 SIG 100 ECU GND
23 - 49 - 75 TW (SIG) 101 -
24 - 50 Boost sensor SIG 76 Overheat signal output 102 -
25 - 51 RED4 GND 77 - 103 -
26 - 52 RED4 GND 78 - 104 -
R3504
E485 W5-14-19
TROUBLESHOOTING
Troubleshooting Procedures
Make preparations for diagnostics pursuant to instructions of the workshop manual.
Have the serviceperson describe the situation in which the failure occurred.
➜
Analyze the situation using the Detailed Failure Report, etc.
(Check whether Diag. Code lights come on or not.)
➜
Identify the cause of the failure by following the troubleshooting procedures.
➜
Repair.
➜
Verify the repair.

➜
Ask the serviceperson to verify the repair.

W5-14-20 E485
Detailed Failure Report
Customer Name Machine Model ENG No.
Chassis No. Date of Delivery Mon.__ Yr.___
Date of Occurrence Day__ Mon.__ Yr.___ Place

Operation Time System Standard/Custom
Startup failure • No initial explosion takes place. • Initial explosion does take place, but no complete
explosion follows. • Hard to start up • Others ( )
• Cranking (• Possible • Not possible)
Idling failure • First idling not effective • Idling unstable
• Idling revolution too high • Idling revolution too low
Symptom or Phenomenon
• Huntin
Drivability • Hesitation • Knocking • Backfire • Afterfire
failure • Insufficient output • Acceleration failure • Low revolution
• Others ( )
Engine stall • Immediately after startup • During idling
• When load is applied At relief While traveling • At a stop
• When load is removed. • When accelerator is released. • Others ( )
Restarted
Exhaust gases
Exhaust smokes Dark smoke (Always, At load application, At acceleration), White smoke (At startup, Immediately after startup, Always)
Abnormal noise Yes No Degraded fuel economy Yes No
When failure started • Since new car • Recently (Approx. since mon.__ yr.__) • Formerly (___ times) • For the first time
Frequency of occurrence • Always • Under certain conditions • Sometimes
Climate • Irrelevant • Spring • Summer • Fall • Winter
Weather Fair Cloudy Rain Snow (Others )

Humidity Temperature
Operating conditions • Traveling • Loading or excavating • Others ( )

Conditions
Type of fuel • Diesel • Kerosene • Heavy oil • Others ( )

Fueling station • Manufacturer ( ) • Place ( )
Fueling method
Diag. code when ( )→( ) hr ( )→( ) hr

failure occurred ( )→( ) hr ( )→( ) hr
Other situation
E485 W5-14-21
1. Engine Starting Failure
Step Action Value Yes No

1 The starter does not rotate. Verify the repair. Go to Step 2
• If the starter does not rotate, check the
battery terminals, voltage, starer in itself,
and other parts, and repair, as needed.
2 See if the fuel-cut lever is in the fuel-cut Verify the repair. Go to Step 3.
position.
• If the lever is set in the fuel cut position,
check the solenoid valve, cable and other
parts, and repair, as needed.
3 See if the fuel has run out or is blocked, Verify the repair. Go to Step 4.
and if the fuel filter is clogged.
• If any abnormality is found, clean the
tubing, change the filter, and take other
actions, as needed.
4 See if the fuel system contains air bubbles. Verify the repair. Go to Step 5.
• If bubbles are found, repair the tubing,
bleed it again, and verify.
5 Is the air cleaner clogged? Verify the repair. Go to Step 6.
• If yes, change the element.
6 Is the fuel in use the right one? Verify the repair. Go to Step 7.
• If it is out of the standard, change the fuel.
7 Is the static timing normal. Verify the repair. Go to Step 8.
• If not, set it to the right timing.
8 Preheating is working (at low temperature). Verify the repair. Go to Step 9.
• If it is not working, check the wirings,
and repair or change the glow plugs and
controller.
9 Are the nozzles normal? Verify the repair. Go to Step 10.
• If atomization of the nozzles is abnormal,
adjust it or change the nozzles.
10 Is the compression normal? Go to step 11. Go to step 12.
• Measure the compression and see if the
normal pressure is generated.
11 Disassemble the engine, check for seizure Verify the repair. Go to Step 13.
of the main bearings, etc., and repair,
as needed.
12 Check the pistons, liners, rings, etc., and Verify the repair. Go to Step 13.
change them, as needed.
13 Change the injection pump. Verify the repair. Go to Self-Diagnos-
tics of Electronic
Control System.
W5-14-22 E485
2. Engine Hunting

1 Does the oil in use have the right viscosity? Verify the repair. Go to Step 2.
• Change for oil with right viscosity,
if necessary.
4 See if the fuel is blocked, and if the gauze Verify the repair. Go to Step 5.
filter and fuel filter are clogged.
tubing and change the filters.
5 Is the static timing normal? Verify the repair. Go to Step 6.
6 Normal state is recovered when the Rotation In case of TDC Go to Step 9.
sensor (TDC or Backup) are removed. sensor
In case Go to Step 7.
of rotation backup
sensor, change
the rotation backup
sensor.
8 Is the compression normal? Verify the repair. Go to step 9.
9 Change the injection pump. Verify the repair. Go to step 10.
10 Go to Self-Diagnostics of Electronic - -
Control System.
E485 W5-14-23
3. Insufficient Engine Output

1 See if the fuel is blocked and if the gauze Verify the repair. Go to Step 2.
3 See if the air cleaner is clogged. Verify the repair. Go to Step 4.
7 Preheating is working (at low temperature). Verify the repair. Go to Step 8.
• If it is not working, check the wirings,
and repair or change the glow plugs and
controller.
8 Check the intake pipes. Verify the repair. Go to step 9.
• Boost sensor hose.
• Leakage between the turbocharger,
intercooler and intake manifold.
• Looseness, damage, and/or gaps.
If any abnormality is found, repair as need.
10 Disassemble the engine, check for seizure Verify the repair. Go to Step 11.
of the main bearings, etc., and repair them,
as needed.
11 Check the pistons, liners, rings, etc., Verify the repair. Go to Step 12.
and change them, as needed.
Control System.
W5-14-24 E485
4. Hesitation

3 Normal state is recovered when the Rotation In case of TDC Go to Step 4.
sensor (TDC or Backup). sensor
In case
of rotation backup
sensor, change
the backup
sensor.
4 Change the injection pump. Verify the repair. Go to Step 5.
Control System.
E485 W5-14-25
5. Engine Stall

Control System.
W5-14-26 E485
6. The Engine Would Not Stop

1 See if the engine stops when the governor Go to Step 2. Remove the fuel line.
connector of the injection pump is Change the injection
disconnected. pump.
2 The trouble is recovered when the ignition Change the Go to Step 3.
switch is changed. ignition switch.
Control System.
E485 W5-14-27
7. Heavy Dark Smokes from Engine

1 Is the air cleaner clogged? Verify the repair. Go to Step 2.
4 Is the boost sensor normal? Verify the repair. Go to Step 5.
Refer to "DTC14 Boost sensor Error" Table.
5 Is the atmospheric pressure sensor normal? Verify the repair. Go to Step 6.
Refer to "DTC26 Atmospheric Pressure
Sensor Error" Table.
7 Is the turbocharger normal? Verify the repair. Go to Step 8.
• Check for looseness of the bearings,
distortion or breakage of the impeller, etc.,
and change the turbocharger, if necessary.
8 Measure the compression and see if the Verify the repair. Go to step 9.
10 Check for wear of the pistons, liners, Verify the repair. Go to step 11.
rings, etc., and change them, as needed.
Control System.
W5-14-28 E485
8. Heavy White Smokes from Engine

5 Check for wear of the pistons, liners, Verify the repair. Go to step 6.
rings, etc., and change them, as needed.
6 Change the injection pump. Verify the repair. Go to Step 7.
Control System.
E485 W5-14-29
SELF-DIAGNOSTICS
Introduction
About troubles related to the electronic control system:
• The relevant trouble codes can be viewed on the lamp on the cab of the machine. These trouble codes are called
DTC (DIAGNOSIS TROUBLE CODE). Take appropriate actions in line with the troubleshooting procedures
corresponding to these DTCs.
1. Self-Diagnostic Flow
Make preparations for diagnostics pursuant to instructions of the workshop manual.
Have the serviceperson describe the situation in which the failure occurred.
➜
Check the DTC (Diagnosis Trouble Code) No.
➜
Identify the cause of the failure by following the troubleshooting procedures.

➜
Repair.
➜
Verify the repair.

➜
Ask the serviceperson to verify the repair.

W5-14-30 E485
2. Table of Self-Diagnostic Functions
DTC Code Name DIAG Decision Criteria of Failure Backup Mode Rec.
01 Normal - - - -
11 Power error - V ≤ 0 mV or V ≥ 51200 mV V = Fixed at 28000 mV. Yes
enters continuously for 655
sec or more.
14 Boost sensor error O V ≤ 100 mV or V ≥ 4800 mV Boost pressure Yes
enters continuously for 5 sec fixed at 271.7 kPa
or more. {2038 mmHg}.
15 Water temperature sensor error O V ≤ 100 mV or V ≥ 4800 mV Water temperature fixed Yes
enters continuously for 5 sec at -40°C.
or more.
21 Accelerator sensor error O V ≤ 200 mV or V ≥ 4800 mV Accelerator aperture Yes
enters continuously for 655 fixed at 0%.
sec or more.
25 Fuel Delivery Resistor error O V ≤ 0 mV or V ≥ 4800 mV Fuel Delivery Resistor Yes
continuously for 10 sec No. 13
or more.
26 Atmospheric sensor error O V ≤ 1890 mV or V ≥ 5000 mV Atmospheric Pressure Yes
enters continuously for fixed at 101.3 kPa
3.8 sec or more. {760 mmHg}.
31 Governor servo error O [Target rack - Actual rack] Governo pull-down. No
≥ 2 mm lasts for 1 sec. (Engine stop) (1)
32 Rack sensor error O V ≤ 500 mV or V ≥ 4500 mV Rack position fixed No
enters continuously for 1 sec at 3 mm.
or more. (Engine stop) (1)
33 System error O ECU internal malfunction No
or ECU malfunction caused
by external factor (noise,
electrical wave etc.)
41 Rotation TDC sensor error O Absence of input. Yes
42 Rotation backup sensor error O Absence of input. Yes
DTC Description
When electrical abnormality occurs, the lamp of electrical abnormality occurance lights on the control panel.
Follow instructions on the Excavator troubleshooting paragraph T-5, Group "Engine" (T5-4) for checking of the
DTC's.
NOTE - (1) Back-up running: LIMP HOME OPERATION PROCEDURE

When governor servo-system error (DTC No. 31) or rack sensor error (DTC No. 32) is diagnosed, engine
will automatically be stopped.
Before restarting the engine, make sure that No. 31 or No. 32 is diagnosed by self-diagnosis, and then
the engine will be started again by limp home following procedure:
1. Do not turn the starter key to OFF.
2. Wait for at last 10 second.
3. Turn the starter key to "Start" for about 10 second.
CAUTION - • The engine will emit excessive black smoke when in limp home control.
• Should not be engine long run at limp home condition.
E485 W5-14-31
Diagnosis Lamp indicating pattern
OPERATION CONDITIONS ENGINE FAULT STATUS
Diagnosis Without
Key switch Engine request switch fault Fault Tense
1 ON Not running OFF Diagnosis Diagnosis

Lamp on Lamp on Present
(fixed) (fixed) and
2 ON Not running ON Diagnosis Lamp Diagnosis Past
Lamp shows Lamp flashes Fault
DTC 01 with DTC
3 ON Running OFF Diagnosis Diagnosis

Lamp off Lamp on
(fixed) (*)
Present
4 ON Running ON Diagnosis Diagnosis Fault
Lamp shows Lamp flashes
DTC 01 with DTC
(*) When DTC 15 and DTC 25 occur, Diagnosis Lamp does not turn light on.
3. Remedial Actions
Basic Concept of Troubleshooting The troubleshooting scheme described below has

been configured on the basis of the concept outlined
Fundamentally, troubles of electronically-controlled
above.
parts are considered to derive from any of the following
causes: About Recoverability:
Recoverability refers to the characteristic as to
1. Malfunction of individual parts; whether the system automatically goes back to the
2. Lack of continuity; or normal mode from the backup mode, after a malfunc-
3. Malfunction of ECU tion has been repaired.
Recoverability possessed:
Therefore, the basic troubleshooting procedure re-
The system automatically recuperates the normal
sides in the following actions:
mode following the repair of a trouble.
1. Malfunction of individual parts Recoverability not possessed:
Measurement of unit resistance and voltage measure- The system recuperates the normal mode only after it
ment. is briefly powered off and on again, following the repair
of a trouble.
2. Check of continuity
* Backup mode - Operation mode established with the
Resistance measurement and voltage measurement
aim of ensuring the safety of the operator, machine,
on the ECU terminal side, if the individual parts check
engine, etc., in case a malfunction occurs.
does not find any problem.
3. Check of ECU
Replacement of ECU, if no problem is detected in the
resistance measurement and voltage measurement
on the ECU terminal side.
W5-14-32 E485
Power Error (DTC11)

Principal phenomena of trouble:
Overvoltage: V ≥ 51200 mV
Undervoltage: V ≤ 0 mV
Conditions of backup mode:

Operates with V = 28000 mV.
Recoverability: Yes
DTC11 Power Error
1 Check the battery voltage. 18 V ≤ V ≤ 28 V Go to Step 2. Go to Step 5.
2 Check the ECU voltage. 18 V ≤ V ≤ 28 V Go to Step 4. Go to Step 3.

(Across ECU terminals 92-42)
3 Correct the connector coupling. Go to Step 6. Go to Step 4.

Verify the normal state.
4 Change the ECU. Go to Step 6. -

5 Change the battery. Go to Step 6. Go to Step 4.

6 End. - -
E485 W5-14-33
Boost Sensor Error (DTC14)

Principal phenomena of failure:
Heavy dark smokes from engine.
Insufficient engine output.
DTC setting condition:

V ≤ 100 mV or V ≥ 4800 mV lasts for 5 seconds or more.

Boost pressure fixed at 271.7kPa (2038 mmHg).
Recoverability: Yes.
DTC14 Boost Sensor Error
1 Check the boost sensor hose for damage, Go to Step 2. Go to Step 5.

clogging and holes.
2 Check the voltage value of the boost 0.1 ≤ V ≤ 4.8 Go to Step 3. Go to Step 8.
sensor.
3 Is the connector plugged in? Go to Step 4. Go to Step 6.
4 Does the wiring have continunity? Go to Step 9. Go to Step 7.
5 Repair the boost hose. Go to Step 10. Go to Step 9.


7 Repair or change the harness. Go to Step 10. Go to Step 9.

8 Change the boost sensor. Go to Step 10. Go to Step 9.

9 Change the ECU. Go to Step 10. Go to Step 8.

10 End. - -
Boost Sensor Wiring Diagram
ECU 63 Vcc (+5V) Boost

sensor
50 SIG (V out)
84 GND
Measurement of boost sensor output voltage:
ECU terminal Across 50 - 84 Output Voltage

Across 63 - 84 Vcc Voltage (5V) R3505
W5-14-34 E485
Water Temperature Sensor Error (DTC15)

Principal phenomena of failure:
No signal arrives at the ECU from the water temperature sensor.
Or, the signal is out of the standard.


Operates with water temperature set at -40 °C.
DTC15 Water Temperature Sensor Error
1 Check the resistance value of the water Refer to Go to Step 2. Go to Step 7.

temperature sensor. Resistance table
3 Does the wiring have continuity? Go to Step 6. Go to Step 5.



7 Change the water temperature sensor. Go to Step 8. Go to Step 6.

8 End. - -
E485 W5-14-35
Water Temperature Sensor Wiring Diagram
ECU 75
R
27
R2449
Measurement of water temperature sensor resistance

value:
Measure the resistance across ECU terminals 75 and
27 or that of the connector terminals.
Water Temperature Resistance Value

-10 °C 20.26 ± 0.6 kΩ
20 °C 6.004 ± 0.101 kΩ
80 °C 0.8949 ± 0.029 kΩ
100
Sensor Resistance Value (kΩ)
10
0.1
-40 -20 0 20 40 60 80 100 120
Engine Water Temperature (°C)
31 29
23 15.5
11
2.5 M16 × P1.5
19 5 C1.5
φ13.5
φ 5.6
R2447
W5-14-36 E485
Accelerator Sensor Error (DTC21)

Principal phenomenon of failure:
Signals from the accelerator sensor, which is installed on the machine side, exceed the standard value.


Accelerator aperture fixed at 0%.
DTC21 Accelerator Sensor Error
1 Check the output voltage of the 0.2 < V < 4.8 Go to Step 2. Go to Step 7.
accelerator sensor.
2 Check for variation in the output voltage Go to Step 3. Go to Step 7.

of the accelerator sensor.


7 Change the accelerator sensor. Go to Step 9. Go to Step 8.


9 End.
E485 W5-14-37
Accelerator Sensor Wiring Diagram
74 ACCELL 2 SIG.
ECU
73 ACCELL 1 SIG. From

mechatro
controller
83 SIG. GND
R2448
Measurement of accelerator sensor output voltage
Accelerator Across 73-83 Across 74-83

0% 0.5 V 0.5 V
100% (*) 4.2 V 4.2 V
(*) These valves are applicable only when Heavy Mode is selected.
When Work Mode is selected the output voltages with Engine Dial Accelerometer on 100%, the output voltages
will be 3.70 V.
W5-14-38 E485
Fuel Delivery Resistor Error (DTC25)

Dark smokes or white smokes.
Engine noise, rough idle

V < 0 mV or V > 4800 mV enters continuously for 10 seconds or more.
Condition of backup mode:

Fuel delivery resistor number fixed at No.13.
DTC25 Fuel Delivery resistor Error

1 Check the voltage value of the Go to Step 2. Go to Step 6.
Fuel delivery resistor.
6 Change the Fuel delivery resistor. Go to Step 8. Go to Step 7.
8 End. - -
E485 W5-14-39
Atmospheric Pressure Sensor Error (DTC26)

Heavy dark smokes from engine. (The area where altitude is high)
Exhaust gas temperature may become high.

V < 1890 mV or V > 5000 mV enters continuously for 3.8 seconds or more.

Atmospheric Pressure fixed at 101.3 kPa {760 mmHg}.
DTC26 Atmospheric Pressure Sensor Error

1 Change the ECU. Go to Step 2. -
2 End. - -
Atmospheric Pressure Sensor Wiring Diagram

The internal organs of the atmospheric pressure sen-
sor are carried out to ECU.
W5-14-40 E485
Governor Servo Error (DTC31)

Governor pull down = Engine stopped.

The actual rack position is deviated from the target rack position by ± 2 mm or more.

None.
Recoverability: None.
DTC31 Governor Servo Error

1 Check the output voltage of the rack Refer to Go to Step 2. Go to Step 8.
sensor. DTC32.
7 Change the injection pump. Go to Step 8. Go to Step 6.
8 End. - -
E485 W5-14-41
Governor Servo Wiring Diagram
Injection pump
ECU GND
51 2
SIG
35 3
R2450
Governor servo system terminals:
580
460
100
1 2 3 4 63 19
5 6 7 8
9 10
111213
15 14
R2451
Continuity check of governor servo system
ECU terminal Across 35-51

Connector terminal Across 2-3
W5-14-42 E485
Rack Sensor Error (DTC32)

The sensor is designed to detect the rack position of the injection pump and failures of the rack operation.
For some reason, it turns unable to make these detections.
Sensor: Differential transformer type displacement sensor (Sensor and amplifier built in the injection pump).

An ECU input voltage ≤ 500 mV enters continuously for 1 sec or more.
An ECU input voltage ≥ 4500 mV enters continuously for 1 sec or more.

Rack position fixed at 3 mm (Engine stop).
DTC32 Rack Sensor Error

1 Check the output voltage of the rack 0.5 < V < 4.5 Go to Step 2. Go to Step 7.
sensor.
8 End.
E485 W5-14-43
Rack Sensor Wiring Diagram
Injection pump
ECU 51 GND
2
36 5V
43 SIG
4
R2452
Rack sensor terminals:
580
460
100
1 2 3 4 63 19
5 6 7 8
9 10
111213
15 14
R2451
Continuity check of rack sensor

W5-14-44 E485
Governor Harness Connectors
580
460
100
1 2 3 4 63 19
5 6 7 8
9 10
111213
15 14
R2451
Terminal Terminal Terminal

Symbol Signal Symbol Signal Symbol Signal
1 - VB 6 - SIG GND 11 - POWER GND
2 - POWER GND 7 - BACK UP SENSOR 12 - SIG GND
3 - PWM 8 - PULL DOWN 13 - VCC
4 - RACK IST 9 - VB 14 - LIMP HOME
5 - VCC 10 - PWM 15 - Not used
E485 W5-14-45
RED IV Harness Specifications and ECU Specifications

(1) RED IV Harness Specifications:
Wire ECU Pin Wire Dia.

No. Signal Color No. (Nominal
Conductor dia.)
Wire Type Connector
1 VB output Red 33 0.75 AEX Automotive Low-Voltage Wire

2 RED4 GND White 51 ↑ ↑
3 Rack position request Blue 35 ↑ ↑
4 Rack sensor SIG Green 43 ↑ ↑
1
5 Rack sensor +5V Yellow 36 ↑ ↑
6 TDC sensor GND Brown 15 ↑ ↑
7 TDC sensor SIG Orange 4 ↑ ↑
8 Pull-Down Black 9 ↑ ↑
9 VB output Red 34 ↑ ↑
10 Rack position request Blue 44 ↑ ↑
11 RED4 GND White 52 ↑ ↑ 2
12 RED4 SIG GND Brown 53 ↑ ↑
13 +5V output Yellow 45 ↑ ↑
14 Limp Home request Violet 22 ↑ ↑
Black 3
15 Not used - - -
Yellow
(2) Connectors (Governor Side)
1 2 3
1 2 3 4 9 Space 10 15 Space 14
5 6 7 8 11 12 13
Yazaky SWP Yazaky SWP Yazaky SWP
7323-7484-40 7323-7464-40 7323-7434-40
R2453
(As viewed from the engaging surface of the governor connector)

W5-14-46 E485
System Error (DTC33)

Engine stalls
Engine is difficult to start

When the power supply turns on, the ECU performs a system check. If this check is not successfully
completed, a malfunction is indicated.
DTC33 System Error
1 Recheck the DTC. Go to Step 2. Go to Step 3.

Is the DTC detected ?
2 Change the ECU. Go to Step 3.

3 End.
E485 W5-14-47
Rotation TDC Sensor Error (DTC41)

The sensor built in the injection pump is designed to load the rotation waveforms through the camshaft. For
some reason, those waveforms do not arrive at the ECU.

Absence of input.

The ECU reads the waveforms of the sensor, which is built in the injection pump, to compute the engine
revolution. In case this sensor goes wrong, the revolution computation is switched to that with wave forms
deriving from rotation back-up sensor, which is installed on the flywheel housing.
Recoverabily: Yes.
DTC41 TDC Sensor Error
1 Check the resistance value of the TDC 0.2 - 2.2 kΩ Go to Step 2. Go to Step 7.
sensor.




8 End. - -
W5-14-48 E485
Rotation TDC Sensor Wiring Diagram
15 Injection
ECU
7 Pump Side
6
4
R2454
Continuity check of TDC sensor:

Check of TDC sensor resistance value:
Connector terminal Across 6-7 2.2-0.2kΩ
580
460
100
1 2 3 4 63 19
5 6 7 8
9 10
111213
15 14
R2451
E485 W5-14-49
Rotation Backup Sensor Error (DTC42)

The sensor installed on the flywheel is designed to read rotation waveforms from the flywheel. For some
reason, those waveforms do not arrive at the ECU.

Absence of input.
The ECU computes the engine revolution by reading waveforms of the sensor which is built in the injection
pump. In case this sensor goes wrong, the revolution computation is switched to that with waveforms deriving
from the rotation TDC sensor, which is installed on the governor.

DTC42 Rotation Backup Sensor Error

1 Check the resistance value of the rotation 125 ±17Ω Go to Step 2. Go to Step 6.
backup sensor.
6 Change the rotation backup sensor. Go to Step 7. Go to Step 5.
7 End. - -
W5-14-50 E485
Rotation Backup Sensor Wiring Diagram
5
ECU Rotation sensor
SIGN on flywheel
housing side
GND
17
R2455
Continuity check of rotation backup sensor:

Connector terminal
Check of rotation backup sensor resistance value
Connector terminal –
125.5 ± 17 Ω 20 °C
E485 W5-14-51
EXPLANATION OF TERMS AND ABBREVIATIONS
Abbreviation Explanation
ACC ACCESSORY Accessory

ACT ACTUATOR Actuator
CPU CENTRAL PROCESSING UNIT Central processing unit
DTC DIAGNOSIS TROUBLE CODE Self-diagnostics trouble code
ECU ENGINE CONTROL UNIT Control unit
GND GROUND Ground
IG IGNITION Ignition
M/V MAGNETIC VALVE Magnetic valve
PID PROPORTIONAL, INTEGRAL, DIFFERENTIAL Proportional, Integral, Differential control
PWM PULSE WIDTH MODULATION Pulse width modulation
PWR POWER Power
R soll RACK soll Target rack position
R ist RACK ist Actual rack position
SHILD SHIELD Shield
SIG SIGNAL Signal
SW SWITCH Switch
TDC TOP DEAD CENTER Top dead center
TW TEMPERATURE WATER Water temperature
VB BATTERY VOLTAGE Battery voltage
Vist VOLT ist Actual voltage
Vsoll VOLT soll Target voltage
W5-14-52 E485
NOTES
E485. Schematic Wiring diagram reading key
1 - Fuse box (E-4) 84 - Two speed select solenoid valve (SV-3)

2 - Fuse link 6 (60 A) (E-27) 85 - Power boost solenoid valve (SV-2)
3 - Fuse link 5 (E-28) 86 - P2 By-pass cut proportional solenoid valve (PSV-B)
4 - Preheating relay (R-6) 87 - Travel straight proportional solenoid valve (PSV-C)
5 - Mechatro Controller (C-1) 88 - P1 By-pass cut proportional solenoid valve (PSV-D)
7 - Battery (E-1) 89 - Arm variable recirculation proportional solenoid
8 - Battery relay (R-1) valve PSV-A)
9 - Key switch (SW-1) 90 - Attachment unload proportional solenoid valve
10 - Starter motor assembly (M-1) (PSV-E) (only for E385)
12 - Engine emergency stop relay (R-28) 91 - Travel unload proportional solenoid valve (PSV-F)
13 - Engine oil level switch (SW-23) (only for E385)
16 - Safety relay (R-4) 92 - Pump P1 proportional solenoid valve (PSV-P1)
17 - Alternator assembly (E-2) 93 - Pump P2 proportional solenoid valve (PSV-P2)
18 - Glow Plug (engine) (E-12) 98 - Coolant thermo sensor (SE-14)
22 - Fleet link (Opt) 99 - Engine coolant temperature indicator
23 - Antenna 100 - Cluster gauge (C-2)
24 - Speakers 101 - Fuel sensor (SE-15)
25 - Socket 12 V D.C. 180 W (E-23) 102 - Fuel meter
26 - Converter 24 V/12 V (E-22) 107 - Prevent spark relay
27 - Hour meter (E-3) 108 - Wiper motor relay
28 - Diode 16 109 - Wiper motor relay
29 - Diode 17 110 - Wiper motor relay
30 - Fuse link box A (E-25) 111 - Wiper relay assembly (R-7)
34 - Diode 2 112 - Wiper motor (M-3)
37 - Antenna GSM 113 - Washer motor (M-4)
38 - Antenna GPS 114 - Wiper interlock switch (SW-19)
40 - Accelerator potentiometer (SE-16) 115 - Quick coupler operation switch (SW-40) (Opt)
41 - Bucket digging sensor (SE-1) 116 - Quick coupler operation solenoid valve (SV-14) (Opt)
42 - Bucket dump sensor (SE-2) 117 - 9P Connector (CN-6M)
43 - Boom raising sensor (SE-3) 118 - Working light switch (SW-20)
44 - Boom lowering sensor (SE-4) 119 - Frame working light (L-2)
45 - Arm in sensor (SE-7) 120 - Boom working light right (L-6)
46 - Arm out sensor (SE-8) 121 - Boom working light left (L-1)
47 - Swing sensor (SE-5) 122 - Cab working light switch (SW-26) (Opt)
48 - Travel right sensor (SE-9) 123 - Cab back working light right (L-9) (Opt)
49 - Travel left sensor (SE-10) 124 - Cab front working light right (L-7) (Opt)
50 - Pump P1 sensor (SE-22) 125 - Cab front working light left (L-8) (Opt)
51 - Pump P2 sensor (SE-23) 126 - Room light (L-5)
52 - P1 Opt sensor valve (SE-20) 127 - Room light switch
53 - P2 Opt sensor valve (SE-11) 128 - Cigarette lighter (E-14)
54 - Power boost switch (SW-21) 129 - Auto grease controller (C-6)
55 - Engine revolution sensor (SE-13) 130 - Auto grease switch (SW-57)
56 - Radio (E-7) 131 - Horn relay (R-5)
57 - Load momentum alarm switch (SW-39) 132 - Horn
58 - Load alarm select switch (SW-12) 133 - Horn switch (SW-10)
59 - Engine coolant temperature sensor 134 - Seat heater (E-26)
60 - Engine oil pressure switch (SW-7) 135 - Air conditioning AMP (C-4)
61 - Air filter restriction switch (SW-8) 136 - Receiver drier (E-10)
63 - Engine coolant level switch (SW-24) 137 - Air compressor clutch (E-11)
64 - Hydraulic level switch (SW-25) 138 - Air conditioning switch (SW-13)
65 - Pressure switch for OPT 1 (SW-44) 139 - Engine room light switch (SW-16)
66 - Pressure switch for OPT 2 (SW-43) 140 - Engine room light (L-12)
67 - Hydraulic pressure release switch (SW-50) 141 - Fuel supply pump (M-11)
68 - Heavy lift switch (SW-35) 142 - No. 4 Connector detect signal
70 - Rotary Bucket (Extra) Right relay (R-26) 143 - Hammer connect signal
71 - Rotary Bucket (Extra) solenoid valve (B) (SV-15) 144 - Diode 20
72 - Rotary Bucket (Extra) Left relay (R-27) 145 - Automatic grease connector
73 - Timer (R-20) 146 - Automatic grease diagnosis lamp (L-57)
74 - Rotary Bucket (Extra) Right switch (SW-55) 147 - Engine diagnosis lamp (L-13)
75 - Diode 18 148 - Engine diagnosis request switch (SW-46)
76 - Diode 19 149 - Engine controller (C-3)
77 - Rotary Bucket (Extra) Left switch (SW-56) 150 - Engine controller memory reset connector (SW-45)
78 - Operating lever lock solenoid valve (SV-4) 151 - Q.ADJ Resistor (E-18)
79 - Rotary Bucket (Extra) solenoid valve (A) (SV-16) 152 - Engine controller check connection
80 - Lever lock switch (SW-11) 153 - Engine revolution sensor for back-up (SE-30)
82 - Swing parking release switch (SW-4) 154 - Electronic governor
83 - Swing parking brake solenoid valve (SV-1) 155 - Boost sensor
E485. Hydraulic circuit reading key
1 - Hydraulic pump assy

2 - Main control valve
3 - Swing motor unit (RH)
4 - Swing motor unit (LH)
5 - Boom cylinder (LH)
6 - Boom cylinder (RH)
7 - Arm cylinder
8 - Bucket cylinder
9 - Swivel joint
10 - Pilot valve (ATT)
11 - Pilot valve (TRAVEL)
12 - Travel motor
13 - Pilot filter
14 - Suction strainer
15 - By-pass check valve
16 - Boost check valve
17 - Return filter
18 - By-pass valve
19 - Air breather
20 - Solenoid valve assy
21 - Restrictor
22 - Restrictor
23 - Arm Regeneration proportional valve
24 - Restrictor
25 - Restrictor
28 - By-pass cut valve P1
29 - By-pass cut valve P2
30 - Hydraulic accumulator
31 - Check valve
1 12
PSV-P1 PSV-P2
3 4
26
21
19
18 22
14 15 16
17 8
13 24
5
6
31
25
10
29 28
7
23
11
30
20
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A.

Product Support
Strada di Settimo, 323 - S. MAURO T.SE ( TO ) ITALY
Reproduction of text or illustrations,

in whole or in part, is strictly prohibited
Print No. 604.13.472 - English - III - 2005

Printed by Satiz - Turin (Italy)
Coordinamento Editoriale Satiz - Torino

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Copyright © New Holland

NEW HOLLAND KOBELCO CONSTRUCTION MACHINERY S.p.A. - Product Support

• Please refer to the materials listed below in addition

- Operation and Maintenance Instruction

WORKSHOP MANUAL COMPOSITION

Consecutive page number for each group

Group number (if exist)

This is the safety alert symbol.

SI Units (International System of Units) are used in this manual.

Example: 24.5 MPa (250 kgf/cm2)

Section 3 COMPONENT OPERATION

OPERATIONAL PERFORMANCE TEST

Section 1 GENERAL INFORMATION

Section 4 FRONT ATTACHMENT

Section 5 ENGINE AND ACCESSORY

Section 2 SAFETY PRECAUTIONS

Section 3 SAFETY PLATES

GENERALITIES Such paths should be opportunely defined by compe-

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

DANGER: Indicates an imminent hazardous situation

NOTE: Indicates an additional explanation for informa-

• This Manual also contains this symbol accompany-

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

- Avoid wearing loose clothing, jewellery, or other

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impair-

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

- In the walk-around inspection, be sure to cover all

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always face

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and off

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work require-

- The seat should be adjusted whenever machine

- The operator should be able to fully press the

FASTEN SEAT BELT

• Should the machine overturn, the operator may

- Prior to operating the machine, thoroughly

- After a significant accident, replace the seat belts

MOVE AND OPERATE

• Bystanders can be run over.

- Pay the utmost attention not to run over bystand-

- Be sure and aware of the location of bystanders

- If fitted, keep the travel alarm and horn sounding

- When operating, swinging, or moving the machine S0031

in a congested area use a signal man.

- Co-ordinate hand signals before starting the

OPERATE ONLY FROM

• Inappropriate engine starting procedures may cause

KEEP RIDERS OFF THE MACHINE

• Riders on the machine are subject to injuries such as