E235sr 60413436

E235SR
Workshop Workshop manual

manual
Printed No. 604.13.436

English - Printed in Italy
E235SR
PROVEN PERFORMANCE
INTRODUCTION
E235SR
WORKSHOP MANUAL
ENGLISH
Print No. 604.13.436
Edition: 03/2005
English - Printed in Italy
Printed by Studio ti - 20205
0-1
SPICER OFF-HIGHWAY
AXLE DIVISION
21199
7
INTRODUCTION
TO THE READER
• This manual has been written for a skilled technician, - For any question or comment, or in case you
in order to give him the information necessary to notice a mistake in this manual content, please
repair this machine.
contact:
- Read this manual carefully for correct
information about repair procedures. NEW HOLLAND KOBELCO CONSTRUCTION
MACHINERY S.p.A.
Strada di Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCE MANUALS
• In addition to this Workshop Manual, refer also to

the following:
- Operation and maintenance instruction

manual
- Spare parts catalog
DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL
• The complete repair manual consists of two volumes: equipment, information on maintenance standards,
remove and install procedures, disassembly and
- E235SR Workshop Manual "Excavator" assembly procedures.
• The complete Workshop Manual for the excavator

• "Excavator" and "Engine" Workshop Manuals model E235SR consists of the following volumes
contain the technical information necessary for identified by print number as shown herebelow:
machine/engine service and repair, service
VOLUME MACHINE TYPE PRINT No.

Workshop Manual - "Excavator" E235SR 604.13.436
0-3
INTRODUCTION
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on

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

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

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

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

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

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

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

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

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

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

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

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

lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Very small (pinhole) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use card-
board or paper to locate pinhole leaks.
20. Tighten connections to the correct torque. Make

sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
0-7
SAFETY PRECAUTIONS
NOTE
0-8
E235SR
SECTION 1 OUTLINE
TABLE OF CONTENTS
1. GENERAL PRECAUTIONS FOR MAKING REPAIRS ............................................... 1
2. INTERNATIONAL UNIT CONVERSION SYSTEM .................................................... 4

SPICER OFF-HIGHWAY
AXLE DIVISION
21199
7

1. GENERAL PRECAUTIONS FOR MAKING REPAIRS

1.1 PREPARATION BEFORE 4) Confirm the position of first-aid box and fire
DISASSEMBLING extinguisher, and also where to make contact
(1) Knowledge of operating procedure for emergency measure and ambulance to
Read Operator’s Manual carefully to prepare for accidents and fire.
understand the operating procedure. 5) Choose a hard, flat and safe place, and put
(2) Cleaning machines attachment on the ground without fail.
Clean machines of soil, mud, and dust before 6) Use crane, etc. to remove parts of heavy
carrying into the repair shop. weight (20kg [44 lbs] or more).
Carrying a soiled machine into the repair 7) Use proper tools, and change or repair
shop, causes making less efficient work and defective tools.
damage of parts, and interferes with rust 8) Machine and attachment required to work in
prevention and dust protection while the lifting condition should be supported with
reassembling. supports or blocks securely.
(3) Inspecting machines
Confirm the disassembling section before 1.3 DISASSEMBLING AND
starting work, determine the disassembly ASSEMBLING HYDRAULIC
procedure taking the conditions in repair EQUIPMENT
shop into account, and request to procure (1) Removing hydraulic equipment assy
necessary parts in advance. 1) Before removing pipes, release the pressure
(4) Recording of hydraulic oil tank, or open the cover on the
Record the following items to keep contact return side to tank, and take out the filter.
and prevent malfunction from recurring. 2) Put the oil in the removed pipes in reservoir
1) Inspecting date, place taking care it is not spilled on the ground.
2) Model name, Applicable machine No., 3) Pipes with plugs or caps to prevent oil
Records on hour meter leaking, entry of dust, etc.
3) Trouble condition, place, cause 4) Clean the outside surface of equipment, etc.
4) Visible oil leakage, water leakage and before disassembling, and drain hydraulic oil
damage and gear oil before putting them on working
5) Clogging of filters, etc., oil level, oil quality, bench.
oil contamination and looseness which can be (2) Disassembling hydraulic equipment
inspected. 1) Since performance and function of hydraulic
6) Examine the problems on the basis of equipment after disassembly and assembly
operation rate with the last inspection date results in immunity from responsibility on
and records on hour meter. the manufacture’s side, disassembly,
(5) Arrangement and cleaning in repair shop assembly and conversion without permission
1) Tools required for repair work. are strictly prohibited.
2) Specify places to put the disassembled parts 2) If it is unavoidably necessary to disassemble
on in advance. and convert, it should be carried out by
3) Prepare oil pans for leaking oil, etc. experts or personnel authorized through
service training.
1.2 SAFETY WHEN 3) Make match mark on parts for reassembling.
DISASSEMBLING AND 4) Before disassembling, read Disassembling
ASSEMBLING Instruction supplied with equipment in
(1) Safety advance, and determine if the disassembly
1) Wear appropriate clothing, safety shoes, and assembly are permitted or not.
safety helmet, goggles, and clothes with long 5) For parts which are required to use jig and
sleeves. tools, don’t fail to use the specified jig and
2) Suspend warning tag ̌Don’t operate̍ from tools.
lever, and begin preliminaries before getting 6) For parts which can not be removed in the
down to work. specified produre, never force removal. First
check for the cause.
3) Before starting inspection and maintenance
which contain the danger of being caught in
machine, stop the engine.
1
7) The removed parts should be put in order and 3) For air bleed of hydraulic pump and swing
tagged so as to install on proper places motor, loosen drain plug on the upper part,
without confusion. start engine, and run in low idling, then
8) For common parts, pay attention to the bleed air until hydraulic oil is oozed out.
quantity and places. After completion of air bleed, tighten plug
(3) Inspecting parts securely.
1) Check that the disassembled parts are free 4) For air bleed of travel motor and hydraulic
from adherence, interference and cylinder, starts engine and operate it for 10
non-uniform working face. minutes or more at no-load and low speed.
2) Measure the wear of parts and clearance, and
record the measured values. For cylinder, don’t move it to the stroke
3) If an abnormality is detected, repair or end at beginning.
replace the parts.
5) Air in pilot circuit can be bled out by only
(4) Reassembling hydraulic equipment operating digging, swing and traveling
1) Before cleaning, turn the fun on or open doors motions thoroughly.
to ventilate air. 6) Check hydraulic oil level.
2) Before assembly, clean parts roughly first, Move attachments to hydraulic oil check
and then completely. position, and check hydraulic oil level of tank.
3) Remove with oil by compressed air, and apply Refill oil if the oil level is lower than the
hydraulic oil or gear oil, and then assemble minimum level.
them. Important Information
4) Replace the removed O ring, back-up rings
LEVEL GAUGE
and oil seal with new ones, and apply grease Oil level of hydraulic oil tank.
oil on them before assembling. If the indicator is within level
marks, the oil quantity is
5) Removes stain and water on the surface on
allowable.
which liquid sealant are applied, decrease
them, and apply liquid sealant on them. How to check oil level of hydraulic oil tank
6) Before assembling, remove rust preventives
on new parts.
7) Use special tools to fit bearings, bushing and
oil seal. 1.4 ELECTRICAL EQUIPMENT
8) Assemble parts matching to the marks. (1) The disassembly of electrical equipment is
9) After completion, check that there is no not allowed.
omission of parts. (2) Handle equipment with care so as not to drop
it or bump it.
(5) Installing hydraulic equipment (3) Connector should be removed by unlocking
1) Confirm hydraulic oil and lubrication oil. while holding the connector.
2) Air release is required in the following cases ; Never stress in tension to the caulked section
a. Change of hydraulic oil by pulling wire.
b. Replacement of parts on suction pipe (4) Check that connector is connected and locked
side completely.
c. Removing and attaching hydraulic pump (5) Switch starter key off before removing and
d. Removing and attaching swing motor connecting connector
e. Removing and attaching travel motor (6) Switch starter key off before touching
f. Removing and attaching hydraulic cylinder terminals of starter and alternator.
(7) Remove battery grounding terminal before
If hydraulic oil and lubricating oil are beginning work close to battery and battery
not filled and also air bleed is not relay with tools.
performed, the hydraulic equipment (8) Wash machine with care so as not to splash
may be damaged. water on electrical equipment and connector.
2

(9) When water has entered in the waterproofed ٨ Tighten it to the specified torque,
connector, the removing of water is not easy. and check that it is free from
So check the removed waterproofed connector distortion, over tension, interference,
with care to protect it from entry of water. If and oil leakage.
moisture adheres on it, dry it completely
before connecting. 1.6 WELD REPAIR
(1) The weld repair should be carried out by
Battery electrolyte is dangerous. authorized personnel in the specified
The battery electrolyte is dilute procedure after disconnecting the grounding
sulfuric acid, and causes scald and loss cable of battery. If the grounding cable is not
of eyesight by adhering on eyes, skin disconnected, the electrical equipment may
and clothes. When the electrolyte has be damaged.
adhered on them, take an emergency (2) Remove parts which may cause flame due to
measure immediately and see a doctor the entry of spark beforehand.
for medical advice. (3) Repair attachments which are damaged,
٤ When it has adhered on skin ; giving particular attention to the plated
Wash with soap and water. section of piston rod to protect it from sparks,
٤ When it has got in eyes ; and don't fail to cover the section with fire
Wash in water for 10 minutes or clothes.
more immediately.
٤ When it has spilled out in large 1.7 ENVIRONMENTAL ISSUES
quantity ; (1) Engine should be started and operated in the
Use sodium bicarbonate to place where air can be sufficiently ventilated.
neutralize, or wash away with (2) Industrial waste disposal
water. The following parts follows the regulation.
٤ When it was swallowed ; Waste oil, waste container
Drink milk or water. Battery
٤ When it has adhered on clothes ; (3) Precautions for handling hydraulic oil
Wash it immediately. Hydraulic oil may cause inflammation of
eyes.
Wear goggles to protect eyes on handling it.
1.5 HYDRAULIC PARTS ٤ When it has got in eyes ;
1) O ring Wash eyes with water until the
٨ Check that O ring is free from flaw stimulus is gone.
and has elasticity before fitting. ٤ When it was swallowed ;
٨ Even if the size of O ring is equal, Immediately see a doctor for
the usage differs, for example in medical advice.
dynamic and static sections, the ٤ When it has adhered on skin ;
rubber hardness also differs Wash with soap and water.
according to the pressure force, and (4) Others
also the quality differs depending on For spare parts, grease and oil, use
the materials to be seated. So, choose Distributor genuine ones.
proper O ring.
٨ Fit O ring so as to be free from
distortion and bend.

٨ Floating seal should be put in pairs.
2) Flexible hose (F hose)

٨ Even if the connector and length of
hose are the same, the parts differ

according to the withstanding
pressure. Use proper parts.
3
2. INTERNATIONAL UNIT CONVERSION SYSTEM

Introduction (4) Derived Units bearing Peculiar Designations
Although this manual uses the JIS unit system. Table 2-4
If you need SI unit, refer to following QUANTITIES DESIGNATION SIGN DERIVED UNIT
international system of units. Frequency Hertz Hz 1Hz=1s-1
Given hereinunder are an excerpt of the units Force Newton N 1N=1kgfym/s2
that are related to this manual : Pressure, Pascal Pa 1Pa=1N/m2
Stress
1. Etymology of SI Units Energy Joule J 1J=1Nym
French : Le Système International d’ Unitès Work,
English : International System of Units Quantity of
heat
2. Construction of SI Unit System
Power Watt W 1W=1J/s
Motive power,
Electric power
Basic units
Charge, Coulomb C 1C=1A࡮s
Table 2-1
Quantity of
electricity
Supplement- Derived units of
Potential Volt V 1V=1J/C
SI units ary units basic units
SI unit Table 2-2 Table 2-3 Voltage, (1W/A)
system Electromotive

Derived Derived units force

units bearing peculiar Quantity of Farad F 1F=1C/V
designations static
Table 2-4 electricity
Capacitance
Prefixes of SI Electric Ohm ǡ 1ǡ=1V/A
(n-th power of 10, where n is an integral) resistance
Table 2- 5
Celcius Celcius degree ͠
temperature or degree
(1) Basic Units Illuminance lux X 1 X=1 m/m2
Table 2-1
QUANTITIES DESIGNATION SIGN (5) Prefixes of SI
Length Meter m Table 2-5
Mass Kilogram kg PREFIX POWER
Time Second s DESIGNATION SIGN
Current Ampere A Giga- G 109
Thermodynamic Kelvin K Mega- M 106
temperature Kilo- k 103
Gram molecule Mol mol Hecto- h 102
Luminous intensity Candela cd Deca- da 10
Deci- d 10㧙1
(2) Supplementary Units Centi- c 10㧙2
Table 2-2 Milli- m 10㧙3
Micro- Ǵ 10㧙6
QUANTITIES DESIGNATION SIGN
Nano- n 10㧙9
Plane angle Radian rad Pico- p 10㧙12
Solid angle Steradian sr
(6) Unit Conversion Table
(3) Derived Units of Basic Units Table 2-6
Table 2-3 QUANTITIES JIS SI REMARKS
QUANTITIES DESIGNATION SIGN Mass kg kg
Area Square meter m2 Force kgf N 1kgf=9.807N
Volume Cubic meter m3 Torque kgfym Nym kgfym=9.807Nym
Velocity Meter per second m/s Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Acceleration Meter per second / second m/s2 Motive power PS kW 1PS=0.7355kW
Density Kilogram per cubic meter kg/m3 Revolution rpm min㧙1 r/min ̪1
̪1 Units that are allowed to use

4
E235SR
SECTION 2 SPECIFICATIONS
TABLE OF CONTENTS
1. NAME OF COMPONENTS ...................................................................................... 1
2. GENERAL DIMENSIONS ......................................................................................... 2
3. WEIGHT OF COMPONENTS ................................................................................... 3
4. TRANSPORTATION.................................................................................................. 4
5. SPECIFICATIONS AND PERFORMANCE ............................................................... 6
6. TYPE OF CRAWLER ................................................................................................. 7
7. TYPE OF BUCKET ................................................................................................... 8
8. COMBINATIONS OF ATTACHMENT ........................................................................ 9
9. ENGINE SPECIFICATION ....................................................................................... 10

1. NAME OF COMPONENTS
1
2. GENERAL DIMENSION
E235SR
3
2.1 5.65m (18’6") Boom+2.94m (9’8") Arm+0.8m (1.05cu yd) Bucket+600mm (23.6") Shoe
NOTE :
Dimensions marked do not
include the height of the shoe
E235SRLC E235SRNLC
3
2.2 5.65m (18’6") Boom+2.94m (9’8") Arm+0.8m (1.05cu yd) Bucket+600mm (23.6") or 800mm (31.5") Shoe
2
3. WEIGHT OF COMPONENTS
Unit : kg (lbs)
Shoe
Typical Market 600 (23.6") WidthሩNLC
Item Areas
Machine complete (STD) 23,900 (52,700)
1. Upper frame assy (including the following :) 11,500 (25,360)
1.1 Upper frame 2,370 (5,230)
1.2 Counterweight 5,900 (13,010)
Counterweight (Weighted) 7,300 (16,100)
1.3 Cab 200 (441)
1.4 Engine ೇ 480 (1,060)
1.5 Hydraulic oil tank ೇ 135 (298)
1.6 Fuel tank ೇ 130 (287)
1.7 Slewing motor (including reduction unit) 310 (684)
1.8 Control valve 165 (360)
1.9 Boom cylinder ೇ 195 (430)È2
1.10 Pin (for mounting boom) 45 (99)
1.11 Pump 170 (375)
1.12 Radiator 70 (154)
2. Lower frame assy (including the following :) 8,600 (19,000)
2.1 Lower frame 3,180 (7,010)
2.2 Slewing bearing 370 (816)
2.3 Travel motor (including reduction unit) 300 (662)È2
2.4 Upper roller 22 (48)È4
2.5 Lower roller 35 (77)È18
2.6 Front idler 106 (234)È2
2.7 Idler adjuster 150 (331)È2
2.8 Sprocket 54 (120)È2
2.9 Swivel joint 30 (66)
2.10 Track link with shoes assy 600mm (23.6in) shoes 1,490 (3,290)È2
800mm (31.5in) shoes ཌ
3. Attachment (including the following / STD :)
3
3,300 (7,280)
ᅐ 5.65m (18ft-6in) Boom 워 2.94m (9ft-8in) Arm 워 0.80m (1cuyyd)
Bucketᅑ
655 (1,440)
3.1 Bucket assy (STD)
990 (2,180)
3.2 STD Arm assy (including the following :)
610 (1,340)
3.2.1 STD Arm
3.2.2 Bucket cylinder ೇ 148 (326)
3.2.3 Idler link 21 (46)È2
3.2.4 Bucket link 90 (198)
3.2.5 Pin (2pcs. for mounting bucket cylinder / 97 (214)
2pcs. for mounting bucket)
3.3 Boom assy 1,700 (3,750)
3.3.1 Boom 1,400 (3,090)
3.3.2 Arm cylinder ೇ 250 (550)
3.3.3 Pin (Mounting armሩMounting arm cylinder) 40 (88)
4. Lubricant and water (including the following :) 490 (1,080)
4.1 Hydraulic oil 200 (441)
4.2 Engine oil 20 (44)
4.3 Fuel 250 (551)
4.4 Water 20 (44)
NOTE : Numerical values marked ೇ indicate the dry weight.
3
4. TRANSPORTATION
4.1 OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER
3
5.65m (18ft-6in) Boom+2.94m (9ft-8in) Arm+0.80m (1cu]yd) Bucket
Shoe Type 600mm (23.6in) 600mm (23.6in) NLC 800mm (31.5in) LC
Item
Width mm(ft-in) 2,990 (9’10") 2,990 (9’10") 3,390 (11’1")
Weight kg(lbs) 23,500 (51,820) 23,900 (52,700) 26,000 (57,300)
4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM
Type
5.65m (18ft-6in) Boom
Item
Length Height Width 5.85 1.56 0.68
L H W m(ft-in) (19 2 4 12 26.8 )
Weight kg (lbs) 2,280 (5,030)
(2) ARM AND BUCKET

Type 3
2.94m (9ft-8in) Arm+0.80m (1cu]yd) Bucket
Item
L H W m(ft-in) (17 3 2 11 3 10 )
Weight kg (lbs) 1,690(2,250)
4
(3) ARM
Type
2.94m (9ft-8in) Arm
Item
L H W m(ft-in) (12 9 2 7 18.9 )
Weight kg (lbs) 1,040 (2,290)
H
L
(4) BUCKET (IF EQUIPPED)
Type Hoe bucket

Length 1.37 1.26 0.87 1.37 1.26 1.08 1.37 1.26 1.16 1.37 1.26 1.33
Height Width
L H W m (ft-in) (4 6 4 2 2 10 ) (4 6 4 2 3 6 ) (4 6 4 2 3 10 ) (4 6 4 2 4 4 )
Weight kg
(lbs) 520 (1,150) 630 (1,390) 650 (1,430) 710 (1,560)
Bucket
capacity 0.51 (0.67) 0.70 (0.92) STD 0.80 (1) 0.93 (1.2)
3
m (cu]yd)
Type Hoe bucket Slope finishing bucket

Length 1.37 1.26 1.16 1.25 0.90 2.20
Height Width
L H W m (ft-in) (4 6 4 2 3 10 ) (4 1 2 11 7 3 )
Weight kg
(lbs) 750 (1,650) 890 (1,96)
Bucket HEAVY
capacity 0.80 (1) DIGGING 0.82 (0.63)
3
m (cu]yd)
l Hoe bucket l Slope finishing bucket

H
H
5
5. SPECIFICATIONS AND PERFORMANCE
5.1 SPEED AND CLIMBING CAPABILITY
Area & Shoe

Item 600 Width NLC
-1
Swing speed min {rpm} 11.0 {11.0}
km/h
Travel speed (1-speed/2-speed) (mile/h) 3.3 / 5.3 (2.0 / 3.3)
Gradeability %(degree) 70 (35)
5.2 ENGINE
MMC
Engine model
6D34 TLU2F
Water-cooled, 4-cycle direct injection
Type type engine with inter coler turbo
charger
Number of cylinders Bore Stroke 6 104mm 115mm

(4.09in 4.53in)
Total displacement 5,861cc (357.64cu]in)
Rated output / Rotation speed 110kW (150PS) / 2,000rpm
Maximum torque / Rotation speed 59kgf]m (428ft]lbs) / 1,600rpm
Starter 24V / 5.0kW
Alternator 24V / 35A
5.3 HYDRAULIC COMPONENTS

Variable displacement axial piston
Hydraulic pump + gear pump
Hydraulic motor (swing) Axial piston motor
Hydraulic motor (travel) 2-speed axial piston motor
Control valve 6-spool control valve

Cylinder
(Boom, Arm, Bucket) Double action cylinder
Oil cooler Air-cooled type
5.4 WEIGHT Unit : kg (lbs)
Fully equipped weight 23,900 (52,700)
Upper structure 11,500 (25,360)
Lower machinery 8,600 (19,000)

Attachment
5.65m (18 ft-6in) Boom+2.94m (9ft-8in) Arm 3,300 (7,280)
+0.80m3 (1cu yd) Japan-made Bucket
6
6. TYPE OF CRAWLER
Overall width of Ground pressure

Shape Shoe width mm (in) 2
crawler mm (ft-in) kgf /cm (psi)
Grouser shoe
NLC 2,990 (9´10• ) 0.48 (6.87)

600 (23.6)
LC 3,190 (10´6• ) 0.48 (6.89)
NLC 3,090 (10´2• ) 0.42 (5.96)

700 (27.6)
LC 3,290 (11´0• ) 0.42 (5.97)
NLC 3,190 (10´6• ) 0.37 (5.28)

800 (31.5)
LC 3,390 (11´1• ) 0.37 (5.29)
Flat shoe
600 (24)
NOTE :
Use grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate with
other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
7
7. TYPE OF BUCKET
Hoe bucket Heaped Outer width mm (ft-in) Availability

Struck Number of W or W/O Weight
capacity of face
3 3
m (cu㨯yd) With side Without side tooth side cutter shovel kg (lbs)
m (cu㨯yd) cutter cutter
0.39 870 770 520
0.51(0.67) 3 W YES
(0.51) (2´10˝ ) (2´6˝ ) (1,150)
0.52 1,080 980 630
0.70(0.92) 5 W YES
(0.68) (3´6˝ ) (3´3˝ ) (1,390)
STD 0.59 1,160 1,060 655
5 W YES
0.80(1) (0.77) (3´10˝ ) (3´6˝ ) (1,440)
Heavy Digging 0.59 1,150 1,060 700
5 W YES
0.80(1) (0.77) (3´9˝ ) (3´6˝ ) (1,540)
0.67 1,330 1,230 710
0.93(1.2) 5 W YES
(0.88) (4´4˝ ) (4´ ) (1,560)
8
8. COMBINATIONS OF ATTACHMENT
Bucket (Japan made) Available Arm

Heaped capacity Struck 2.94m (9ft-8in) Arm 3.3m (10ft-10in) 2.94m (9ft-8in) Arm
Type 3 3
m (cu yd) m (cu yd) (STD) Arm (Long) + Extension Arm
0.51 (0.67) 0.39 (0.51)
0.70 (0.92) 0.52 (0.68)
Hoe bucket STD 0.80 (1) 0.59 (0.77)
Digging 0.80 (1) 0.59 (0.77)
0.93 (1.2) 0.67 (0.88)
Breaker
(Reinforced arm)
Nibbler (Reinforced arm)
NOTE :
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
l Use the attachments recommended by Distributor. Reinforcement of arm allows to use it as

nibbler and breaker.
The trouble due to the use in the condition "Use not allowed" described in the above table is not
included in our responsibility
l When bucket marked by has been attached or nibbler has been attached on long arm, the
specified stability may not be obtained. So change counterweight to 7,500kg (16,500 lbs)
weight in as required.
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WRWKHDUPDQGEXFNHWPD\RFFXU
9
9. ENGINE SPECIFICATIONS
9.1 SPECIFICATIONS
Applicable machine E235SR, E235SRLC, E235SRNLC
Engine model MITSUBISHI 6D34-TLE2A, 6D34-TLU2F, 6D34-TLED

Diesel, 4-cycle water-cooled, in-line,
Type direct injection, with inter cooler turbo charger
Number of cylinder
Bore Stroke mm (in) 6 104 115 (4.09 4.53)
Total displacement cc (cu]in) 5,861 (358)
Compression ratio 18.2

1
Rated output PS (kW) at min 150 (110) at 2,000
Maximum 1
torque kgf m (lbf ft) at min 59 (428) at 1,500
1
High idling min 2,220
1
Low idling min 1,000 25
Injection valve 2
opening pressure kgf/cm (psi) 220 (3,130)
Thermostat action
Start/Full open ( F) 76.5 / 90 (170 / 194)
Firing order 1 5 3 6 2 4
Compression 2
pressure kgf/cm (psi) 26.5 (377)
Lubrication 2 1
oil pressure kgf/ cm (psi) at min 1.5 5 (21 71) at 850
Fuel injection timing 14 before top dead point
Valve clearance Open Close
Valve clearance Intake valve 0.4mm 19 before top 53 after bottom

(0.016• ) at cool dead point dead point
Exhaust valve 0.4mm 60 before bottom 16 after top
(0.016• ) at cool dead point dead point
Starter capacity V kW 24 5.0
Generator capacity
(Alternator) V A 24 35
∅600 (23.6• ) suction type 6 fans, V-belt drive,
Cooling fan drive method pulley ratio Crank / Fan= 1.0
Full level 18.0 (4.8)
Engine oil quantity (gal) Low level sensor actuation 15.5 (4.1)
Oil filter, etc. 4 (1.1)
Dry weight kg (lbs) 480 (1,060)
Fuel consumption
g / PS]h (g / kW]h) 162 (220)
ratio
(Limited by E/G
Allowable inclination lubrication) Front / Rear and Right / Left : 35
Dimension (L W H) mm (in) 1,183 684 898 (46.6 26.9 35.4)
Rotating direction Counterclockwise seeing from flywheel side
10
9.2 ENGINE CHARACTERISTIC CURVE (MITSUBISHI 6D34-T)
Condition to be measured : With fan, alternator and air cleaner
Without muffler
kgf m Nm
SHAFT TORQUE
60 600
50 500
SHAFT
40 400 TORQUE
30 300
kW PS
120
160
100 140
SHAFT OUTPUT
120
80
SHAFT 100
OUTPUT
60 80
60
40
40
g/PS h g/kW h
20 240
170 230
FUEL
CONSUMPTION
160 220
FUEL CONSUMPTION RATE RATE
210
150
1000 1200 1400 1600 1800 2000

1
ENGINE SPEED min {rpm}
Fuel consumption volume Fuel consumption volume
Fuel consumption rate Fuel consumption rate

= kW Load factor ( ) = PS Load factor ( )
0.835 1000 0.835 1000
220g / kW]h 162g / PS]h
= 110kW = 150PS
0.835 1000 0.835 1000
=29 ] /h =29 ] /h Standard load factor

(0.70 0.80)
Fuel consumption in regular operation
(load factor 0.70 0.80)
20.3 23.2 /h
11

7KLVSDJHLVOHIWEODQNIRUHGLWLQJFRQYHQLHQFH
E235SR
SECTION 3 ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
1. BOOM
1.1 Boom dimensional drawing .................................................................................................. 1
1.2 Boom maintenance standard ............................................................................................... 2
2. ARM
2.1 Arm dimensional drawing ..................................................................................................... 4
2.2 Arm maintenance standard .................................................................................................. 5
3. BUCKET
3.1 Bucket dimensional drawing................................................................................................. 7
3.2 Bucket dimensional table ..................................................................................................... 7
3.3 Detail dimensional drawing of lug section ............................................................................ 8
3.4 Detail dimensional drawing of boss section ......................................................................... 9
SPICER OFF-HIGHWAY
AXLE DIVISION
21199
7
1. BOOM
1.1 BOOM DIMENSIONAL DRAWING
SECTION B-B
Fig. 1-1 Boom dimensional drawing
Table 1-1
5.65M (18ft-6in) BOOM

Unit : mm (ft-in)
Code NAME DIMENSION
A Boom length 5,650(18 6 )
B Boom foot width 670(26.4 )
C Boom end inner width 347(13.7 )
D Boom end outer width 482(19 )
E Height of boom cylinder rod pin 990(39 )
F Height of arm cylinder (head side) pin 1,182(3 10 )
G Distance between pins of boss R2,555(8 5 )
H Distance between pins of bracket R2,750(9 03 )
I Arm cylinder (head side) inner width 126(4.96 )
J Outer width of bracket on the boom cylinder (rod side) 466(18.3 )
d1 Boom foot pin dia. ∅90(3.54 )
d2 Boom cylinder (rod side) pin dia. ∅85(3.35 )
d3 Pin dia. of boom end. ∅90(3.54 )
d4 Arm cylinder (head side) pin dia. ∅85(3.35 )
1
1.2 BOOM MAINTENANCE STANDARD
(1) Clearance of pin and bushing
on boom section
Fig. 1-2 Clearance of pin and bushing on boom section
Table 1-2 Unit : mm (in)

Standard value Clearance
Code Item Pin dia. Bushing ID Standard Repairable Service Remedy
Pin dia. tolerance tolerance value level limit
+0.201 +0.221
(+0.0079) (+0.0087)
A Boom foot +0.020 +0.100 +0.080
∅90 (+0.0008) (+0.0039) (+0.0031)
(3.5433) 0.020 +0.223 +0.243
Boom cylinder ( 0.0008) (+0.0088) (+0.0096)
B +0.106 +0.086 More than
(Head side)
(+0.0042) (+0.0034) 2.5 Replace
2.0 bushing
+0.222 +0.242 (0.1)
Boom cylinder (0.08) or pin
(+0.0087) (+0.0095)
C +0.020 +0.105 +0.085
(Rod side)
∅85 (+0.0008) (+0.0041) (+0.0033)
(3.34645) 0.020 +0.217 +0.237
Arm cylinder ( 0.0008) (+0.0085) (+0.0093)
D +0.097 +0.077
(Head side)
(+0.0038) (+0.0030)
2
2) Clearance in thrust direction on the boom
and cylinder installation section
4
L3 L3’ X3 웒
X4 L4
3
X1 L
SECTION C-C
2 2
SECTION A-A
SECTION D-D
X2 L2 L2 X2
SECTION B-B
Fig. 1-3 Clearance in thrust direction on the boom and cylinder installation section

Shim adjusting clearance Effective
Basic size length under
Sec- (Total of both sides) pin neck
Item Remedy
tion Sym Standard Repairable Service
Size No. Length
-bol value level limit
Boom 670(26.4) 0.6 (0.02) 849
A-A Boom foot L1 1 (33.43)
Upper frame 676(26.6) or less 2.0 2.5
Boom cylinder Boom cylinder 110(4.33) 0.6윟1.0 (0.08) (0.10) 230
B-B L2 2 (9.06)
(Head side) Upper frame 113(4.45) (0.02윟0.04) Shim
Boom cylinder Boom cylinder L3 105(4.13)0.6윟2.0 3.0 4.0 adjustment
734
C-C 3
(Rod side) Boom L3’ 466(18.3) (0.02윟0.08) (0.12) (0.16) (28.90)
Arm cylinder Boom cylinder 120(4.72) 0.6윟1.0 2.0 2.5 254

D-D L4 4 (10.00)
(Head side) Boom 126(4.96) (0.02윟0.04) (0.08) (0.10)
3
2. ARM
2.1 ARM DIMENSIONAL DRAWING
D1 D2 O
d5 d3
K L
N
VEIW
d1 d2
SECTION A-A
D4 d4
SECTION B-B
Fig. 2-1 Arm dimensional drawing
2.94m ARM
(9ft 8in) Table 2-1 Unit : mm (ft-in)
Code NAME DIMENSION No. NAME DIMENSION

2,940 342
C Arm length M Boss width
(9 8 ) (13.5 )
R834 126
D Distance between pins of boss and bracket N Bracket inner width
(32.8 ) (4.96 )
∅95 106
D1 I.D of boss O Bracket inner width
(3.74 ) (4.17 )
∅85 630
D2 I.D of boss P Idler link dimension
(3.35 ) (24.8 )
∅105 610
D4 I.D of boss Q Bucket link dimension
(4.13 ) (24 )
R2,175 Height between pins of boss and 23
E Distance between pins of boss and bracket R
(7 1.6 ) center (0.906 )
R420 ∅80
F Distance between pins of boss and boss d1 Pin dia.
(16.5 ) (3.15 )
616 ∅70
G Height between pins of boss and bracket d2 Pin dia.
(24.2 ) (2.76 )
298 ∅85
H Height between pins of boss and bracket d3 Pin dia.
(11.7 ) (3.35 )
325 ∅90
K Arm top end boss width d4 Pin dia.
(12.8 ) (3.54 )
320 ∅80
L Arm link section boss width d5 Pin dia.
(12.6 ) (3.15 )
4
2.2 ARM MAINTENANCE STANDARD
(1) Clearance of pin and bushing
Fig. 2-2 Clearance of pin and bushing on arm section

Standard value Clearance
Code Item Pin dia. Bushing i.d. Standard Repairable Service
Pin dia. tolerance value
Remedy
tolerance level limit
+0.203 +0.263
(+0.0080) (+0.0104)
A Arm point 0.020 +0.102 +0.122
∅80 ( 0.0008) (+0.0040) (+0.0048)
(3.1496) 0.060 +0.207 +0.267
Bucket link ( 0.0024) (+0.0081) (+0.0105)
B +0.108 +0.128
(Bucket connection)
(+0.0043) (+0.0050)
+0.213 +0.253
Idler link ∅70 (+0.0084) (+0.0100)
C
(Arm connection) (2.7559) +0.116 +0.116
(+0.0046) (+0.0046)
+0.000 +0.206 +0.246
Bucket link (+0.0000) (+0.0081) (+0.0097)
D (Idler link connection) 0.040 +0.107 +0.107
( 0.0016) (+0.0042) (+0.0042) 2.0 2.5 Replace
+0.279 (0.08) (0.1) bushing
or pin
Bucket cylinder ∅80 (+0.0110)
D’ (3.1496)
(Rod side) +0.219 +0.100
(+0.0086) (+0.0039)
+0.100 +0.259
Bucket cylinder (+0.0039) (+0.0102)
E (Head side) +0.070
(+0.0028)
+0.020
Arm cylinder ∅85 (+0.0008)
F 0.020
(Rod side) (3.3465) +0.202 +0.222
( 0.0008) (+0.0080) (+0.0087)
+0.102 +0.082
∅90 (+0.0040) (+0.0032)
G Arm foot (3.5433)
5
(2) Clearance of arm and cylinder installing
sections in thrust direction
X1 L1 X3 L3
X6 L6
X5 L5

SECTION C-C
SECTION A-A 6
SECTION F-F
; L2 ; / SECTION E-E
X4’ L4’
X7 L7
2
4
7
SECTION B-B
SECTION G-G
SECTION D-D, D’-D’
Fig. 2-3 Clearance of arm and cylinder installing sections in thrust direction
Shim adjusting clearance Effective length
Sec- Basic size
Item (Total of both sides) under pin neck Remedy
tion Repairable Service
No. Size Standard value
level limit
No. Length
Arm 325(12.79)
A-A Arm point L1 326(12.83) 0.6윟1.0 1
Bucket 2.0 482
Link side 325(12.79) (0.02윟0.04) (0.08) (18.98)
B-B Bucket link L2 327(12.87) 2
Bucket
Idler link Arm 320(12.60) 0.6 or less 1.0 2.5
C-C (Arm connection) L3 (0.10) 3
Link side — (0.02) (0.04)
Bucket link Rod side — 425
D-D (Idler link connection) Link side L4 320(12.60) 0.6윟1.0 2.0 (16.73) Shim
4
Bucket link Rod side 100(3.94) (0.02윟0.04) (0.08) adjustment
D’-D’ (Rod side) Bucket link side L4’ 106(4.17)
Bucket cylinder Head side 100(3.94) 233
E-E (Head side) L5 106(4.17) 5
Arm 0.6윟2.0 3.0 4.0 (9.17)
Arm cylinder Rod side 120(9.72) (0.02윟0.08) (0.12) (0.16) 254
F-F (Rod side) L6 126(4.96) 6
Arm (10.00)
Arm 342(13.46) 0.6 or less 1.0 2.5 483
G-G Arm foot L7 347(13.66) 7
Boom (0.02) (0.04) (0.10) (19.02)
6
3. BUCKET (IF EQUIPPED)
3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
G
d2 D
A
d1
Bushing OD
I I0 B
H C
F
Fig. 3-1 Hoe bucket dimensional drawing
Table 3-1
NAME No. NAME
Distance between pin and bracket Bucket outer width of front side
Distance between bucket pin and tooth end Pitch between teeth
Inner width of bucket top end Pitch between teeth
Inner width of lug Outer width of bushing
Inner width of bracket Pin dia.
Outer width of bucket bottom
3.2 BUCKET DIMENSIONAL TABLE

Table 3-2 Unit : mm (ft-in)
Type Hoe bucket
[STD] 0.51m
3
0.70m
3
0.93m
3
1.05m
3
Capacity 0.80m3
(1.05cu yd) (0.67cu yd) (0.92cu yd) (1.21cu yd) (1.37cu yd)
A R430(16.9• )
B R1,440(4´9• )
C 1,000(3´3• ) 711(28• ) 922(36.3• ) 1,173(3´10• ) 1,303(4´3• )
D 399(15.7• )
E 327(12.9• )
F 1,157(3´9.6• ) 868(34.2• ) 1,079(3´6.5• ) 1,330(4´4.4• ) 1,460(4´9.5• )
G 863(34• ) 572(22.5• ) 786(30.9• ) 1,036(3´5• ) 1,166(3´10• )
H 1,057(3´6• ) 766(30.2• ) 979(38.5• ) 1,230(4´04• ) 1,360(4´6• )
I 223(8.78• ) 300(11.8• ) 203(8.0• ) 266(10.5• ) 238(9.37• )
I0 223(8.78• ) 300(11.8• ) 203(8.0• ) 266(10.5• ) 240(9.45• )
d1 ∅95(3.74• )
d2 ∅80(3.15• )
7
3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION
(IF BUCKET IS EQUIPPED)
B
A
J
A A
BOSS
M
28 (1.10ಿ )
H
19
3-G
(0.748ಿ )
N
D
F
E
B BOSS
SECTION A웎A
SHIM t=1
(Five shims are installed at shipping)
DETAIL B
Fig. 3-2 Dimension of lug section

Lug plate thickness
Screw hole P.C.D

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

Pin hole dia.
Capacity
Boss width.
Boss width.
Type of
Screw dia.
of bucket
Hole dia.
bucket
m3 (cuyyd)
A B D 웦 F G H J M 웯
[STD]
0.80 (1.05)
0.51 (0.67)
Hoe 80 25 95 13 180 M16 25 170 36 140
bucket 0.70 (0.92) (3.15ಿ ) (0.984ಿ ) (3.74ಿ ) (0.512ಿ ) (7.09ಿ ) (0.984ಿ ) (6.69ಿ ) (1.42ಿ ) (5.51ಿ )
0.93 (1.21)
1.05 (1.37)
8
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION
(IF BUCKET IS EQUIPPED)
∅G H 5
(0.197 )
I
∅D
∅A
∅B
∅C
15
(0.591 )
DETAIL
E
Fig. 3-3 Dimension of boss section

Type Capacity
of of3bucket ∅A ∅B ∅C ∅D E F ∅G H I
bucket m (cu yd)
STD
114.3 84 105.5 111.5 27 42 17 13 3.0
0.80 (1.05)
(4.50 ) (3.31 ) (4.15 ) (4.39 ) (1.06 ) (1.65 ) (0.669 ) (0.512 ) (0.118 )
Hoe 0.51 (0.67)
bucket 0.70 (0.92)
23 38 2.5
0.93 (1.22)
(0.906 ) (1.50 ) (0.098 )
1.05 (1.37)
9

E235SR
SECTION 11 TOOLS
TABLE OF CONTENTS
1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ...................................... 1
2. SCREW SIZE ............................................................................................................ 2
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES ............................................. 3
4. PLUG ......................................................................................................................... 4
5. SPECIAL SPANNER FOR TUBE .............................................................................. 7
6. SPECIAL TOOLS ...................................................................................................... 8
7. APPLICATION OF SCREW LOCKING COMPOUND

AND SEALANT COMPOUND ............................................ 10
8. SUCTION STOPPER ............................................................................................... 11
9. COUNTER WEIGHT LIFTING JIG ........................................................................... 12
10. UPPER FRAME LIFTING JIG ............................................................................... 13
11. ENGINE MOUNTING PEDESTAL ......................................................................... 15
12. TRACK SPRING SET JIG ..................................................................................... 15

1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS
Tables 1-1 and 1-2 indicate tightening torques Insufficient tightening may lead to a loosening or
applicable to cases where no special note is given. loss of bolts. Always tighten bolts to proper
Overtightening of bolts may result in a twist-off torques.
and a fracture under load.
Table 1-1 Tightening torque for metric coarse threads (not plated) unit : kgf m (lbf ft)
Strength
grade 4.8T 7T 10.9T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
0.45 0.05 0.38 0.04 0.98 0.1 0.83 0.08 1.77 0.18 1.5 0.15
M6 P=1 (3.3 0.4 ) (2.7 0.3) (7.1 0.7) (6.0 0.6) (13 1) (11 1)
1.09 0.11 0.92 0.09 2.4 0.2 2.0 0.2 4.3 0.4 3.6 0.4
M8 P=1.25 (7.9 0.8) (6.7 0.7) (17 1) (14 1) (32 3) (26 3)
2.2 0.2 1.83 0.18 4.7 0.5 4.0 0.4 8.5 0.9 7.2 0.7
M10 P=1.5 (16 1) (13 1) (34 4) (29 3) (61 7) (52 5)
3.7 0.4 3.2 0.3 8.1 0.8 6.8 0.7 14.6 1.5 12.3 1.2
M12 (27 3) (23 2) (59 6) (49 5) (110 11) (89 9)
P=1.75
5.9 0.6 5.0 0.5 12.8 1.3 10.8 1.1 23 2 19.5 1.9
M14 P=2 (43 4) (36 4) (93 9) (78 8) (170 14) (140 14)
9.0 0.9 7.6 0.7 19.5 2.0 16.4 1.6 35 4 29 3
M16 P=2 (65 7) (55 5) (140 14) (120 12) (250 29) (210 22)
12.4 1.2 10.5 1.0 27 3 23 2 49 5 41 4
M18 P=2.5 (90 9) (76 7) (200 22) (170 14) (350 36) (300 29)
17.5 1.7 14.7 1.4 38 4 32 3 68 7 57 6
M20 P=2.5 (130 12) (110 10) (270 29) (230 22) (490 51) (410 43)
23 2 19.6 2.0 51 5 43 4 92 9 77 8
M22 P=2.5 (170 14) (140 14) (370 36) (310 29) (670 65) (560 58)
30 3 24 3 65 7 53 5 118 12 96 10
M24 P=3 (220 22) (170 22) (470 51) (380 36) (850 87) (690 72)
44 4 36 4 96 10 78 8 173 17 140 14
M27 P=3 (320 29) (260 29) (690 72) (560 58) (1300 120) (1000 100)
60 6 50 5 131 13 110 11 235 24 198 20
M30 P=3.5 (430 43) (360 36) (950 94) (800 80) (1700 170) (1400 140)
81 8 68 7 176 18 148 15 317 32 266 27
M33 P=3.5 (590 58) (490 51) (1300 130) (1100 110) (2300 230) (1900 200)
105 10 88 9 227 23 190 19 409 41 343 34
M36 P=4 (760 72) (640 65) (1600 170) (1400 140) (3000 300) (2500 250)
Table 1-2 Tightening torques for metric fine threads (not plated) unit : kgf m (lbf ft)
Strength
grade 4.8T 7T 10.9T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
1.15 0.11 0.97 0.1 2.5 0.2 2.1 0.2 4.5 0.4 3.8 0.4
M8 P=1 (8.3 0.8) (7.0 0.7) (18 1) (15 1) (33 3) (27 3)
2.3 0.2 1.91 0.19 4.9 0.5 4.2 0.4 8.9 0.9 7.5 0.7
M10 (17 1) (14 1) (35 4) (30 3) (64 7) (54 5)
P=1.25
4.0 0.4 3.4 0.3 8.7 0.9 7.3 0.7 15.7 1.6 13.2 1.3
M12 (29 3) (25 2) (63 7) (53 5) (110 12) (95 9)
P=1.25
9.4 0.9 7.9 0.8 20 2 17.2 1.7 37 4 31 3
M16 P=1.5 (68 7) (57 6) (140 14) (120 12) (270 29) (220 22)
19 1.9 15.8 1.6 41 4 34 3 74 7 62 6
M20 P=1.5 (140 14) (110 12) (300 29) (250 22) (540 51) (450 43)
32 3 27 3 70 7 58 6 126 12 105 10
M24 P=2 (230 22) (200 22) (510 51) (420 43) (910 87) (760 72)
65 6 54 5 142 14 118 12 255 26 212 21
M30 P=2 (470 43) (390 36) (1000 100) (850 87) (1800 190) (1500 150)
87 9 72 7 190 19 158 16 341 34 284 28
M33 P=2 (630 65) (520 51) (1400 140) (1100 120) (2500 250) (2100 200)
109 11 91 9 238 23 198 20 428 43 357 36
M36 P=3 (790 80) (660 65) (1700 1 170) (1400 140) (3100 310) (2600 260)
2. SCREW SIZE
(1) Capscrew 2) Socket bolt
d
d
Table 2-1 Table 2-2 Table 2-3

Nominal B mm Nominal B mm Nominal B mm
screw size screw size screw size
Tool Unified Tool Tool
(d) size (screw threads) size (d) size
M6 10 1/4-20UNC 11 (M3) 2.5
M8 13 5/16-18UNC 13 (M4) 3
M10 17 3/8-16UNC 14 (M5) 4
M12 19 7/16-14UNC 16 M6 5
(M14) (22) 1/2-13UNC 19 M8 6
M16 24 5/8-11UNC 24 M10 8
(M18) (27) 3/4-10UNC 29 M12 10
M20 30 7/8-9UNC 33 M14 12
(M22) 32 1-8UNC 38 M16 14
M24 36 1 1/8-7UN 43 (M18) 14
(M27) (41) 1 1/4-7UN 48 M20 17
M30 46 1 1/2-6UN 57 (M22) 17
M36 55 M24 19
M42 65 (M27) 19
M45 70 M30 22
M48 75 M36 27
M56 85 M42 32
(M60) 90 (M45) 32
M64 95 M48 36
(M68) 100 M52 36
M72 105
Table 2-4
M76 110 (3) Socket screw
Nominal B mm
M80 115 screw size
Tool
(d) size
d M2.5 1.27
M3 1.5
M4 2
M5 2.5
M6 3
M8 4
B
M10 5
M12 6
M16 8
M20 10
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES
Table 3 indicates standard tightening torques sleeves in FLARELESS JOINT may develop oil leaks
applicable to cases where no particular note is through pipe connections.
given. Always tighten nuts and sleeves to proper
Overtightening or understanding of nuts and torques.
Table 3-1
Working pressure Tube size Opposing Tightening torque
ODÈthickness
kgf / cm2 (psi) mm (in) flats (HEX) kgfym (lbfyft)
10È1.5 19 4.5¢0.5
(0.394È0.059) (33¢3.6)
15È2.0 27 15¢2.0
(0.591È0.079) (110¢14)
300 18È2.5 18¢2.0
32
(4270) (0.709È0.098) (130¢14)
22È3.0 36 22¢2.0
(0.866È0.118) (160¢14)
28È4.0 41 28¢3.0
(1.10È0.157) (200¢22)
300 35È5.0 45¢4.5
55
(4270) (1.38È0.197) (330¢33)
Table 3-2
SLEEVE NUT
B
d d
Opposing
Tube size Tube size
flats (HEX)
d d B
6 6 14
8 8 17
10 10 19
12 12 22
15 15 27
18 18 32
22 22 36
28 28 41
32 32 50
35 35 55
38 38 60
3
4. PLUG

(1) Plug for hydraulic pipe joint
Table 4-1
1) Cap nut (Joint plug)
Applicable Opposing flat
pipe Cap nut parts No. T screw
O. D : A H1 H
6 M12È1.5 14 14
8 M14È1.5 17 17
10 M16È1.5 17 19
12 M18È1.5 19 22
15 M22È1.5 24 27
18 M26È1.5 27 32
H1 T screw H 22 M30È1.5 32 36
28 M36È1.5 38 41
Table 4-2
2) Plug (Tube plug)
Applicable
pipe Plug parts No.
O. D : A
6
8
10
12
15
18
Flareless
joint body Nut 22
28
3) Nut Table 4-3

Applicable Opposing
pipe Nut parts No. d screw
O. D : A flat
D screw 6 M12È1.5 14
8 M14È1.5 17
10 M16È1.5 19
12 M18È1.5 22
15 M22È1.5 27
18 M26È1.5 32
22 M30È1.5 36
28 M36È1.5 41
32 M42È1.5 50
35 M45È1.5 55
38 M48È1.5 60
4
(2) Plug for hydraulic equipment
1) PF screw
B Table 4-4
O ring PF O ring parts Nominal
screw Plug parts No. B mm No. O ring
PF 1/4 19 1B P11
PF 3/8 22 1B P14
PF 1/2 27 1B P18
PF 3/4 36 1B P24
PF screw PF 1 41 1B P29
2) PT screw
Table 4-5
PT Plug parts No. B mm
B screw
PT screw
PT 1/8 5
PT 1/4 6
PT 3/8 8
PT 1/2 10
PT 3/4 14
PT 1 17
PT 1 1/4 22
PT 1 1/2 22
(3) Plug for (F) flare hose

Table 4-6
PF screw
PF Plug parts No. B mm
screw
PF 1/4 14
PF 3/8 17
PF 1/2 22
Opposing
flat B PF 3/4 27
PF 1 36
Table 4-7
PF Plug parts No. E mm F mm
screw
PF 1/4 14 19
PF PF 3/8 17 22
screw
PF 1/2 23 27
Opposing Opposing PF 3/4 27 36
flat F flat E PF 1 36 41
PF 1 1/4 40 50
5
(4) Plug for ORS joints
Male
O RING
Table 4-8
Applicable O ring parts Nominal
Opposing
Screw size A hose Plug parts No.
O.D flats(HEX) No. O ring
A
A 1-14UNS ∅21.7 27 1B A16
A
1 3/16-12UN ∅27.2 36 1B A18
1 7/16-12UN ∅34.0 41 1B A21
Female Table 4-9

Applicable
Opposing
Screw size A tube Plug parts No.
O.D flats(HEX)
A 1-14UNS ∅21.7 32
1 3/16-12UN ∅27.2 36
1 7/16-12UN ∅34.0 41
6
5. SPECIAL SPANNER FOR TUBE
Table 5-1
Applicable tube diameter HEX
Part No. Drawing of a special spanner mm (in)
mm (in) mm
70 (2.76)
8(0.315)
15 16
27 (0.630) 8 PART-No. 22(0.866)
(0.591)
HEX27 40(1.57)
12.7
0.3
0.1 ( 0.500 0.012
0.004 )
70 (2.76)
42(1.65)
18 19 22(0.866)
32 (0.748) PART-No.
(0.709)
22(0.866)
HEX32 12.7 0.3
0.1 ( 0.500 0.012
0.004 )
70 (2.76)
40(1.57)
22 19
PART-No. 22(0.866)
30 (0.748)
(0.866)
22(0.866)
HEX30 12.7 0.3
0.1 ( 0.500 0.012
0.004 )
48 (1.89) 70 (2.76)
11.5 (0.453)
22 23
36 PART-No. 22(0.866)
(0.866) (0.906)
HEX36 12.7 0.3

0.1 ( 0.500 0.012
0.004 )
60 (2.36) 109 (4.29)
14.5 (0.571)
28 29
41 PART-No. 22(0.866)
(1.10) (1.14)
HEX41
12.7 0.3
0.1 ( 0.500 0.012
0.004 )
80 (3.15) 109 (4.29)
28 31
PART-No. 35(1.38)
46 (1.22)
(1.10)
HEX46 19.05
0.5
0.1 ( 0.750 0.020
0.004 )
80 (3.15) 109 (4.29)
32 33 PART-No.
50 (1.30)
35(1.38)
(1.26)
HEX50
19.05 0.5
0.1 ( 0.750 0.020
0.004 )
7
6. SPECIAL
Table 6-1
No. Tools name Tools No. Shape Applicable
Allen wrench Pump

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

length
40(1.57˝ ) 웎 10(0.39˝ ) = 30(1.18˝ )
General tools
Spanner or
Pump
2 socket
install
Nominal B : 17
Cut
Swing
Spanner
3 motor
Nominal S : 36
A,B port
Commercial tool outer width (D) 웎 cut length = Required length

81(3.19˝ ) 웎 16(0.63˝ ) = 65(2.56˝ )
Additional M10È22 For

Plug threading slinging
4 for M10 eye bolt
PF3/4 the swing
O ring motor
PF3/4
M10 Eye bolt

For
slinging
5 Eye bolt the swing
M10È18 motor
M10 &
Flare hose
8
Table 6-2
No. Tools name Tools No. Shape Applicable
M8 Eye bolt
Plug
(Nominal
tube dia. 22 )
Reference nut Flare hose
6 Reference
Eye bolt
Nut M8 18
Additional
threading for
M8 Eye bolt
M8 Eye bolt
M8 18
Additional
Plug threading
Nominal
7 Flare hose
1-14UNS
Eye bolt
M8 Eye bolt
M8 18
Additional
threading
Plug
Nominal
8 Flare hose
1 3/16-12UN
Eye bolt
M8 Eye bolt
For slinging the
Eye bolt swing motor
9
M8 15 &
Flare hose
M8
M12 Eye nut
Plug For slinging the

10
PF1/2 Weld swivel joint
PF 1/2
9
7. APPLICATION OF SCREW LOCKING
8. COMPOUND AND SEALING COMPOUND
(1) For general use
Table 7-1
Manufacturer
Service Features
Loctite Three-Bond
#242 1360K Low strength

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

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

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

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

compound
& #222 #1344N Main pump
adhesive Loctite
#277 #1307N Pilot valve
(Manufacturer ; Three-Bond)
Loctite Parmatex 98D #1121 Hydraulic oil tank : Hose

Sumitomo
Chemical Cyano Bond P0 1 For swing bearing : Seal
Co., Ltd.
Showa-Shell Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease
petroleum bath
10
8. SUCTION STOPPER
8.1 COMPONENTS
No. NAME PARTS No. Q TY

SUCTION STOPPER ASSY
1 Rod
1 ROD 1
2 NUT 1
3 COVER 1
4 O RING 1
2 Nut
3 Cover
4 O ring
8.2 DIMENSION
50
(1.97 ) Fig. 8-1 Components of suction stopper
∅113 (4.45 )
2
M8 NUT
∅8(1.315 )
M8 ∅100 +0.5
0
(3.94 +0.0197
0 )
∅108
(4.25 )
ROD COVER
fig. 8-2 Dimension of suction stopper
11
9. COUNTER WEIGHT LIFTING JIG
For R.H. (YN60C01165P1)
Q’TY : A right-left pair

Material : POK400 (SS41)
Fig.9-1 Counter weight lifting jig
12
10. UPPER FRAME LIFTING JIG
(1) For R/H
Q’ty : 1set
Material : POK400(SS41)
Fig. 10-1 Upper frame lifting jig (R/H)
13
(2) For L/H
Q’ty : 1set
Material : POK400(SS41)
Fig. 10-2 Upper frame lifting jig (L/H)
14
11. ENGINE MOUNTING
350(13.8• ) Note) Hold the oil pan
250(9.84• ) 16 325(12.8• ) 16 section of engine.
(0.63• )
(0.63• ) (0.63• )
16
(3.35• )
85
16 245(9.65• ) 16
(0.63• ) 40 40 (0.63• )
(1.57• )
540(21.3•)
(1.57• )
(28• )
710
(3.35• )
85
16
(0.63• )
Material : Plywood or wooden plate

Fig. 11-1 Engine stand
12. TRACK SPRING SET

M30
Retainer nut
Retainer plate
Stand
Hydraulic jack
Base
Fig. 12-1 Track spring set jig
15

E235SR
SECTION 12 STANDARD MAINTENANCE

TIME TABLE
TABLE OF CONTENTS
1. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE EXCAVATOR ... 1-1
01. Attachment ....................................................................................................................... 1-1
02. Cab & Guard .................................................................................................................... 1-2
03. Swing frame ..................................................................................................................... 1-3
04. Travel system .................................................................................................................... 1-5
06. Electric equipment ............................................................................................................ 1-6
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE ..... 2-1
STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR
1.
(1) Standard maintenance time table (2) Classification of working code
1) Units of working time : 6 minutes=0.1 hour
No. Group Remarks
2) Calculating method of standard maintenance
01 Attachment Indicates installing,
time : 02 Cab & Guard
removing, replacement
Maintenance time=Working time 03 Swing frame and overhaul.
04 Travel system
Number of workers
06 Electric Indicates the installing,
(Working time=Maintenance time¸ equipments removing and
Number of workers) replacement of single
3) When more than one operation is going on : items.
Add each standard service time. 09 E/G relation Indicates overhaul of the
single engine.
A pure time (readily started) is given except (Materials prepared by
covers easily removed by hand. Assy works manufacturer )
include the following works marked with
black dot •. (3) Conditions for standard service time of the
4)O/H : The removing and attaching time is not engine
included. 1) Tools designated by E/G maker are used
5) Abbreviations in the table. 2) Genuine parts are changed
A/C ; Air conditioner F hose ; Flexible hose 3) Correct working procedures are observed.
ASSY ; Assembly O/H ; Over haul • The time required for works specified
ATT ; Attachment SOL ; Solenoid in this Chapter shows the total time
BRG ; Bearing SW ; Switch for maintenance.
C/V ; Control valve V ; Valve
Cyl ; Cylinder
E/G ; Engine
Unit : Hour
Work to be E235SR(LC)
Group Location Unit Remark
done E235SRNLC
00 Bucket relation 2. Reference for bucket
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.6
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.2
06 Bucket (single) O/H 1 pc. Not include attaching and detaching. 2.4
07 • Tooth Replace 1 pc. 0.6
08 • Side cutter Replace 1 pc. 1.2
01 Attachment
09 • Bushing Replace 1 pc. 0.6

10 Arm relation 3. Reference for arm
11 Arm ASSY Detach/attach 1 pc. 1.2
• Bucket cylinder attaching and detaching
12 position and piping Preparation 1 pc. 0.4
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.1
17 • Boom top pin Detach/attach 1 pc. Include whirl stop pin. 0.1
18 • Arm sling and movement Detach/attach 1 pc. 0.2
30 Boom relation 4. Reference for boom
31 Boom ASSY Detach/attach 1 pc. 1.4
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.2
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.2
1㧙1
Unit : Hour
Group Location Unit Remark
done E235SRNLC
35 • Boom cylinder piping Detach/attach 2 pc. 0.2
36 • Arm & bucket piping Detach/attach 1 pc. 0.2
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.2
39 • Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.4
41 • Arm cylinder piping Detach/attach 1 pc. 0.2
01 Attachment
42 • Arm cylinder head pin Detach/attach 1 Include stopper pin. 0.1

43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.7
51 • Boom cylinder piping Detach/attach 2 0.3
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.2
53 • Boom cylinder slinging Detach/attach 2 0.2
60 Bucket cylinder O/H 1 3.6
61 • Pin bushing Replace 1 Include seal. 1.2
70 Arm cylinder O/H 1 3.6
71 • Pin bushing Replace 1 set Include seal. 1.2
80 Boom cylinder O/H 2 7.0
81 • Pin bushing Replace 1 set Include seal. 1.2
10 Cab relation 1. Reference for cab
11 Cab ASSY Detach/attach 1 pc. 1.2
12 • Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 • Rear cover mounting bolts Detach/attach 5 places 0.2
14 • Seat rear cover Detach/attach 1 pc. 0.2
15 • Air-con duct Detach/attach 2 0.2
16 • Coupler for gauge cluster (electric) Detach/attach 1 0.1
17 • Cab slinging Detach/attach 3 places 0.4
20 Guard relation 4. Reference for guard
21 Box (1-1) Detach/attach 1 pc. 0.2
22 Box (1-2) Detach/attach 1 pc. 0.2
23 Panel assy (2) Detach/attach 1 pc. 0.2
24 Panel assy (3) Detach/attach 1 pc. 0.2
25 Cover (4) Detach/attach 1 pc. 0.1
26 Cover assy (5) Detach/attach 1 pc. 0.1
Cab & Guard

30 Bonnet (9) Detach/attach 1 pc. 0.2
31 Bonnet assy (10) Detach/attach 1 pc. 0.3
02

36 Bracket (16) Detach/attach 1 pc. 0.2
37 Bracket assy (17) Detach/attach 1 pc 0.3
38 Cover assy (18) Detach/attach 1 pc 0.2
39 Bracket (19) Detach/attach 1 pc. 0.2
41 Bracket assy (21) Detach/attach 1 pc. 0.1
43 Bracket assy (45) Detach/attach 1 pc. 0.2
44 Cover (52) Detach/attach 1 pc 0.2
45 Cover (53) Detach/attach 1 pc 0.1
1㧙2
Unit : Hour
Group Location done Unit Remark
E235SRNLC
50 Cover relation 5. Reference for under cover
Cab & Guard

60 Counter weight relation 11. Reference for counter weight
02
61 Counter weight ASSY Detach/attach 1 pc. 0.6

62 • Counter weight lifting jig Detach/attach 1 set 0.1
63 • Counter weight temporary slinging Preparation 1 pc. 0.2
64 • Counter weight mounting bolt Detach/attach 1 pc. 0.2
65 • Counter weight slinging Detach/attach 1 pc. 0.1
00 Control relation
01 E/G control ASSY Detach/attach 1 pc. Include adjustment. 0.4
02 • Emergency stop knob (control) cable Replace 1 pc. 0.2
10 Intake relation 9. Reference for Air cleaner
11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 • Hose (3) Detach/attach 1 0.1
13 • Hose (4) Detach/attach 1 0.1
14 • Element Replace 1 0.1
20 Exhaust relation 10. Reference for muffler
21 Muffler ASSY Detach/attach 1 pc. 0.5
22 • U bolt Detach/attach 1 pc. 0.1
23 • Clamp ASSY Detach/attach 1 pc. 0.1
24 • Gasket Replace 1 pc. 0.1
30 Radiator relation 12. Reference for Radiator
31 Radiator ASSY Detach/attach 1 pc. 4.0
32 • Coolant (LLC) Replace 1 pc. 0.3
33 •• Concentration of coolant Measuring 1 pc. 0.2
Swing frame
34 •A/C condenser Detach/attach 1 pc. 0.3

35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.3
37 • Sub tank Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.3
39 • Water hose (radiator ψ E/G) Detach/attach 1 0.3
03
40 • Radiator mounting bolts removing Detach/attach 1 pc. 0.2

41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tank࡮suction stopper Attach/detach 1 pc. 0.2
43 •Hydraulic oil piping coupling Detach/attach 1 pc. 1.0
44 •Hydraulic oil piping Detach/attach 1 pc. 0.2
45 •Water hose (E/G ψ radiator) Detach/attach 1 0.2
46 •Radiator lifting or hoisting Detach/attach 1 pc. 0.2
47 • Radiator core Cleaning 1 pc. 1.0
48 • Inter cooler air leak Check 1 pc. 0.5
50 Fuel relation 6. Reference for fuel tank
51 Fuel tank ASSY Detach/attach 1 pc. 1.8
52 •Fuel Replace 1 pc. 0.3
53 •Hose (water separator side) Detach/attach 2 0.1
54 •Water separator Detach/attach 1 pc. 0.1
55 •Tube (tank side) Detach/attach 1 0.1
57 •Fuel tank installing bolts Detach/attach 1 pc. 0.3
58 • Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.4
Removing and installing battery 0.2
Note : The numbers in the parentheses like cover (1) match
the guard numbers on the UPPER STRUCTURE.
1㧙3
Unit : Hour
E235SRNLC
60 Hydraulic oil tank relation 7. Reference for hydraulic oil tank
61 Hydraulic oil tank ASSY Detach/attach 1 pc. After removing fuel tank ; 3.0
65 • Cover Detach/attach 1 pc. 0.2
66 • Hydraulic oil Replace 1 pc. 0.5
68 • Pilot drain hose Detach/attach 1 pc. 0.2
69 • Pump suction hose Detach/attach 1 0.5
70 • Mounting bolt Detach/attach 1 pc. 0.2
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.3
72 • Return filter Replace 1 0.2
73 • Suction filter Cleaning 1 0.2
80 Pump relation After removing counter weight
81 Pump ASSY Detach/attach 1 pc. 2.8
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 1.0
85 • Guard Detach/attach 2 pcs 0.4
86 • Pump slinging Detach/attach 1 pc. 0.5
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc. 0.1
89 Pump ASSY O/H 1 pc. 4.0
Other necessary works Detach/attach 1 set Counter weight 0.5
90 Swing motor unit relation
91 Swing motor ASSY Detach/attach 1 pc. 2.7
Swing frame

93 • Drain hose clamp Detach/attach 1 0.3
95 • Unit slinging Detach/attach 1 pc. 0.5
96 • Cleaning and sealant Cleaning 1 set 0.2
03
97 • Swing motor O/H 1 pc. 3.6

98 • Swing reduction gear O/H 1 pc. 4.2
100 Swivel joint relation 20. Reference for swivel joint
101 Swivel joint ASSY Detach/attach 1 2.6
102 • Piping (Top part only) Detach/attach 1 set 0.5
103 • Whirl stop bolt Detach/attach 1 0.2
104 • Cover Detach/attach 1 0.4
105 • Joint & elbow Detach/attach 1 set 0.4
106 • Mounting bolt Detach/attach 1 set 0.4
107 • Swivel joint slinging Detach/attach 1 0.4
108 • Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing guard 3.6
Other necessary works Detach/attach 1 set Lower piping 0.6
110 Multi control valve 15. Reference for multi C/V
111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.7
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.3
115 • Cleaning Cleaning 1 set 0.2
Other necessary works Detach/attach 1 set Guard 0.4
120 Main control valve 16. Reference for control valve
121 Main control valve ASSY Detach/attach 1 pc. 2.2
122 • Attach tag to port name of pipe Preparation 1 pc. 0.6
1㧙4
Unit : Hour
E235SRNLC
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY O/H 1 set 6.0
Other necessary works Detach/attach 1 set Guard 0.4
130 Valve relation
131 Solenoid valve ASSY Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
134 • Mounting bolt Detach/attach 1 0.3
140 Engine (E/G) mounting relation 13. Reference for engine
141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.8
142 • Harness connector & grounding & cable connection Detach/attach 1 pc. 0.3
143 • Fuel hose Detach/attach 1 pc. 0.1
Swing frame
144 • Others Detach/attach 1 set 0.5

146 • Engine slinging Detach/attach 1 set 0.2
148 Engine O/H 1 set Reference for engine
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
03
Detach/attach 1 set Removing and installing counter weight 0.6

Detach/attach 1 set Removing and installing pump 2.8
Removing and installing air 0.4
Detach/attach 1 set
cleaner
Detach/attach 1 set Removing and installing muffler 0.5
Detach/attach 1 set Removing and installing radiator 3.0
150 Upper frame 21. Reference for upper frame
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
153 • Upper frame slinging Detach/attach 1 pc. 0.4
155 • Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.2
Detach/attach 1 set Guard 0.4
Detach/attach 1 set Counter weight 0.5
Detach/attach 1 set Boom 1.4
00 Travel relation 2. Reference for crawler
One
01 Track link ASSY Detach/attach side Include adjustment of tension. 1.5
One
02 • Track link attaching and detaching position Preparation side 0.1
One
03 • Master pin Detach/attach side 0.5
One
04 • Track link extending and winding Detach/attach side 0.5
05 Shoe plate Replace 1 pc. 0.4
Travel system
10 Upper roller relation 3. Reference for upper roller

11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0
20 Lower roller relation 4. Reference for lower roller
21 Lower roller ASSY Detach/attach 1 0.2
04
22 Lower roller O/H 1 1.5

30 Front idler relation 5. Reference for front idler
One
31 Front idler ASSY Detach/attach side After removing track link 0.6
One
32 Front idler ASSY slinging Detach/attach side 0.3
One
33 Front idler ASSY Detaching side 0.3
One
34 Idler ASSY O/H side 1.0
One
35 Idler adjuster ASSY O/H side Replace spring 2.4
One
36 • Grease cylinder O/H side 0.6
1㧙5
Unit : Hour
E235SRNLC
40 Sprocket 6. Reference for sprocket
One
41 Sprocket Replace side After removing track link 0.6
50 Travel motor relation 7. Reference for travel motor
One
51 Travel motor ASSY Detach/attach side After removing track link 1.7
One
52 x Motor cover Detach/attach side 0.1
One
53 x Hydraulic piping Detach/attach side 0.9
Travel system
One
54 x Motor mounting bolt Detach/attach side 0.5
One
55 x Motor slinging Detach/attach side 0.1
One
56 Motor cleaning Cleaning side 0.1
One
57 Travel motor O/H side 3.6
One
58 Travel reduction gear O/H side 3.6
60 Swivel joint relation
04
Include bonnet assy removing and

61 Pipe on swivel joint travel side Detach/attach 1 pc. installing. 0.6
62 Swivel joint O/H 1 pc. Refer to Upper structure on page 1-4 3.6
8. Refer to YF34 Swing bearing
70 Swing bearing removing and installing.
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper flame 0.7
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.5
73 Swing bearing slinging Detach/attach 1 pc. 0.3
Controller
C-1 Controller (KPSS) Replace 1 0.2
C-2 Gauge cluster Replace 1 0.2
C-4 Air conditioner Amplifier Replace 1 0.2
C-5 Air conditioner switch (panel) Replace 1 0.2
C-6 Power window controller (OPT) Replace 1 0.2
Diode
D-1 Diode Replace 1 0.2
D-6 Diode Replace 1
06 Electric equipments
0.2
Electric equipments
Include C1 controller removing and
E-1 Fuse box Replace 1 installing. 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.2
E-4 Horn (low) Replace 1 0.2
E-5 Horn (high) Replace 1 0.2
E-6 Cigar lighter Replace 1 0.2
E-7 Tuner AM & FM(OPT) Replace 1 0.2
E-7 Tuner AM(OPT) Replace 1 0.2
E-8 Speaker left (OPT) Replace 1 0.2
E-9 Speaker right Replace 1 0.2
E-10 Receiver dryer Replace 1 Include gas sealing. 0.3
Include counter weight removing and
E-11 Air compressor Replace 1 installing. 0.5
E-25 Battery Replace 1 0.2
Light
L-1,L-9 Boom work light left Replace 1 Bulb 1pc. each 0.2
L-2 Work light right Replace 1 0.2
1㧙6
Unit : Hour
Group Location Work to be Unit Remark E235SR(LC)
done E235SRNLC
L-3 Room light Replace 1 0.2
L-4 CAB work light Replace 1 0.2
L-5 CAB work light (OPT) Replace 1 0.2
Motor
M-1 Starter motor Replace 1 installing. 1.0
M-2 Governor motor Replace 1 installing. 0.5
M-3 Wiper motor (Non rise up) Replace 1 0.2
M-4 Washer motor Replace 1 0.2
M-5 Cable assy (P/W motor OPT) Replace 1 0.5
M-6 Power window lock motor (OPT) Replace 1 0.2
M-7 Power window lock motor (OPT) Replace 1 0.2
M-8 Skylight wiper motor (OPT) Replace 1 0.2
Proportional valve
Include proportional valve removing and
PSV-A Arm re-circulation confulx proportional valve Replace 1 installing. 2.0
PSV-B P2 by-pass cut proportional valve Replace 1 installing. 2.0
PSV-C Travel straight proportional valve Replace 1 installing. 2.0
PSV-D P1 bypass cut proportional valve Replace 1 installing. 2.0
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.2
R-3 Glow relay Replace 1 0.2

R-4 Safety relay Replace 1 Include guard removing and installing 0.4
Include C1 controller removing and
R-5 Wiper motor relay Replace 1 installing 0.3
R-6 Washer motor relay Replace 1 0.3
R-7 Horn relay Replace 1 0.3
R-8 Work light relay Replace 1 0.3
R-29 Auto idle stop relay 2 Replace 1 0.3
R-30 Auto idle stop relay 1 Replace 1 0.3
Sensor
SE-1 Pressure sensor (low pressure ; bucket digging) Replace 1 0.2
SE-2 Pressure sensor (low pressure ; bucket dump) Replace 1 0.2
SE-3 Pressure sensor (low pressure ; boom up) Replace 1 0.2
SE-4 Pressure sensor (low pressure ; boom down) Replace 1 0.2
SE-5 Pressure sensor (low pressure ; swing) Replace 1 0.2
SE-7 Pressure sensor (low pressure ; arm in) Replace 1 0.2
SE-8 Pressure sensor (low pressure ; arm out) Replace 1 0.2
Include removing and installing guard on
SE-9 Pressure sensor (low pressure ; travel right) Replace 1 cab lower side. 0.4
Include removing and installing guard on
SE-10 Pressure sensor (low pressure ; travel left) Replace 1 cab lower side. 0.4
SE-13 Engine speed sensor Replace 1 Include guard removing and installing. 0.5
SE-14 Engine water temperature sensor Replace 1 0.2
SE-15 Fuel sensor Replace 1 Include guard removing and installing. 0.3
SE-16 Accel potentio Replace 1 0.2
SE-22 P1 pump pressure sensor Replace 1 0.2
SE-23 P2 pump pressure sensor Replace 1 0.2
Solenoid
SV-1 Swing parking SOL Replace 1 installing. 2.0
SV-2 ATT boost pressure SOL Replace 1 installing. 2.0
SV-3 2-speed travel SOL Replace 1 installing. 2.0
SV-4 Lever lock SOL Replace 1 installing. 2.0
1㧙7
Unit : Hour
Group Location done Unit Remark E235SRNLC
Switch
SW-1 Key switch Replace 1 0.2
SW-2 Switch Replace 1 0.2
SW-3 2-speed travel switch Replace 1 0.2

SW-4 Swing parking release switch Replace 1 0.2
SW-5 KPSS release switch Replace 1 0.2
SW-6 Engine water temperature switch Replace 1 0.2
SW-7 Engine oil pressure switch Replace 1 0.2
SW-8 Clogged air filter switch Replace 1 0.1
SW-10 Horn switch Replace 1 0.2
SW-11 Lever lock switch Replace 1 0.3
SW-12 Heater switch (OPT) Replace 1 0.2
SW-13 Air conditioner switch Replace 1 0.2
SW-16 Auto accel release switch Replace 1 0.2
SW-52 Auto idle stop select switch Replace 1 0.2
1㧙8
2. 㩷 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE
Introduction
This standard working time table provides time
required for maintenance (if the work is
carefully carried out) under the following
condition :
٤ Tools designated by us are used.
٤ Genuine parts are prepared.
٤ Correct working procedures are observed.
٤ The engine is mounted correctly to the
machine.
1. The working hours given in this table can not
be applied because of special machine
construction.
2. Special equipments not listed in this table
may be used for operation.
If such operations are performed, fill out reasons
in the Claim Application Sheet in detail and
submit it to us.
(Note 1) Unit of working time
The working time is given in 6
minutes=0.1 hour in the decimal system.
(Note 2) Applicable models :
6D34㧙T ............. E200(LC)
E210(LC)
E210NLC
E235SR(LC)
E235SRNLC
2㧙1
2.1 COOLING SYSTEM
Unit :
NAME OF WORK NAME OF TROUBLE Hour
Cooling fan 01㧙20

Attaching and detaching or replacing fan. Cooling fan is broken.
Cooling fan makes an abnormal sound. 0.6
Cooling fan parts are defective.
Replacing belts (2 pcs.) Fan belt is damaged.
Note : Where two or more belts are used, Fan belt squeaks.
0.3
increase 0.4hr. for each belt
increased.
Adjusting belts. 0.2
Idler pulley overhaul
㧙
Incl. :detaching and attaching it.
Detaching and attaching or replacing fan
0.7
coupling.
Thermostat 01㧙40
Inspecting or replacing thermostat. (1 pc.) Thermostat functions incorrectly.
Thermostat remains open.
0.6
Thermostat remains closed.
Thermostat system in general is out of order.
Inspecting or replacing thermostat. (RH one) Thermostat functions improperly.
㧙
Inspecting or replacing thermostat. (LH one) Thermostat functions improperly.
㧙
Water pump 01㧙50
Replacing water pump (that is mounted to Water pump squeaks.
this machine). Water leaks from water pump.
Incl. : (1) Detaching and attaching V-belt. Pump bearing is broken.
2.0
(2) Detaching and attaching idler Pump shaft is damaged.
pulley assy. Water pump parts are faulty.
Water pump in general are out of order.
Water pump overhaul, Water pump squeaks.
Excl. : detaching and attaching. Water leaks from water pump.
Pump bearings are damaged.
0.8
Pump shaft is damaged.
Water pump parts are faulty.
Water pump in general is out of order.
2㧙2
2.2 ELECTRICAL SYSTEM
Unit :
Alternator 02㧙05
Replacing alternator assy Alternator functions improperly.
Alternator makes an abnormal sound.
Alternator is burnt.
1.0
Alternator bearing parts are faulty.
Alternator pulley is broken.
Alternator mounting bracket is broken.
Overhaul of alternator Alternator functions improperly.
Incl. : Detaching and attaching . Alternator makes an abonormal sound.
Alternator burnt out.
㧙
Alternator bearing parts are faulty.
Alternator pulley are broken.
Overhaul of alternator. (single) Alternator functions improperly.
Alternator makes an unusual sound.
Alternator burnt out.
㧙
Alternator bearing parts are defective.
Alternator pulley is broken.
Starter motor 02㧙10
Replacing starter. Starter motor malfunctions.
Starter motor rusts from inside.
Pinion is broken.
Overrunning clutsh slips. 0.8
Overrunning clutch parts are defective.
Pinion engagement is no good.
Starter motor system in general is out of order
Overhaul of starter, Starter motor malfunctions.
Incl. : detaching and attaching starter Starter motor rusts from inside.
Pinion is broken.
Overrunning clutch slips. 㧙
Overrunning clutch parts are faulty.
Pinion meshing is no good.
Starter motor system in general is out of order.
Overhaul of starter Starter motor malfunctions.
Starter motor rusts from inside.
Pinion is broken.
Overrunning clutch slips. 㧙
Overrunning clutch parts are faulty.
Pinion meshing is no good.
Replacing starter switch assy. Magnetic switch contacts are no good.
Magnetic switch burnt out.
1.0
2㧙3
Unit :
Safety (starter) relay 02㧙12

Detaching/attaching or replacing starter relay. Relay malfunctions.
0.4
Relay system as a whole is out of order.
Voltage regulator 02㧙20
Replacing relay (safety relay) assy. Safety relay malfunctions.
0.5
Safety relay system as a whole is out of order.
Glow plug 02㧙33
Inspecting and replacing glow plugs. (all) Glow plug parts are faulty.
1.0
Glow plug system as a whole is out of order.
Intake air heater 02㧙34
Detaching/attaching or replacing intake air Intake heater parts are faulty.
heater assy. (one side) Intake heater system as a whole is out of order. 㧙
Replacing resistor. Resistor parts are faulty. 㧙

Detaching/attaching or replacing magnet valve. Magnet valve parts are faulty. 㧙
Switch (units) 02㧙35
Replacing starter switch Starter switch does not return well.
0.4
Starter switch is broken or developed other fault.
Replacing starter switch. (in switch box) Starter switch does not return well.
㧙
Starter switch is broken or developed other fault.
Replacing water temperature gauge unit. Water temperature gauge unit malfunctions. 0.3
Detaching/attaching or replacing fuel tank Fuel gauge unit malfunctions.
㧙
gauge unit.
Replacing oil bypass alarm. Oil leaks from oil bypass alarm.
Oil bypass alarm is broken or developed other 0.3
fault.
2㧙4
2.3 ENGINE
Unit :
Engine 03㧙00
Overhaul of engine assy. Refer to fault code table.
Incl. : (1) Detaching/attaching engine.
(2) Running-in of engine.
(3) Conditioning engine. (B)
Excl. : (1) Overhauling starter, dynamo
68.0
and injection pump.
(2) Grinding crankshaft.
(3) Boring and honing of cylinder
liners.
Semi overhaul of engine.

Incl. : (1) Semi overhaul of cylinder head.
(2) Replacing piston and piston ring. For each set of piston liners decreased 1.3hr.
28.0
(3) Replacing cylinder liners. Each time one line decreases 0.8hr.
(4) Adjusting engine. (A) Each time one piston decreases 0.5hr.
(5) Adjusting nozzle.
Adjusting engine. (A)
Incl. : (1) Adjusting valve clearance.
(2) Inspecting nozzle.
(3) Adjusting injection timing.
(4) Cleaning air cleaner element. 3.0
(5) Cleaning fuel filter element.
(6) Inspecting cooling water hose.
(7) Adjusting fan belt.
(8) Retightening all parts.
Adjusting engine (On-machine). (B)
(1) Retightening cylinder head.
(2) Cleaning air cleaner.
(3) Measuring compressive pressure.
(4) Inspecting cooling water hose.
(5) Inspecting fan belt for slackening
and adjusting it.
(6) Checking the max. and min
6.5
revolutions.
(7) Inspecting glow plug.
(8) Inspecting and adjusting nozzle.
(9) Adjusting injection timing.
(10) Cleaning oil and fuel filter
elements.
(11) Adjusting valve clearance.
(12) Retightening other parts.
2㧙5
Unit :
Measuring compressive pressure. 2.0

Adjusting injection timing. Climbing power of vehicle is deficient.
Max. speed of vehicle is deficient.
Accelerating power of vehicle is deficient.
0.8
Engine starting is faulty.
Engine output is deficient.
Engine fuel is no good.
Adjusting valve clearance. 1.0
Measuring black exhaust. 0.6
Cylinder head 03㧙10
Replacing cylinder head assy. (1 unit) Cylinder head cracked.
Incl. : (1) Adjusting engine (A). Cylinder head is distorted.
(2) Adjusting nozzle. Cylinder head is corroded.
Cylinder head is blowholed.
8.0
Area between cylinder head and valve is cracked.
Cylinder head system in general is out of order.
Overhauling cylinder head assy. (1 set.) Cylinder head is cracked.

Incl. : (1) Detaching/attaching cylinder head. Cylinder head is distorted.
(2) Replacing combustion chamber. Cylinder head is corroded.
(3) Correcting valve seat ring. Cylinder head is blowholed.
10.5
(4) Replacing valve guide. Area between cylinder head and valve is cracked.
(5) Lapping valve. Cylinder head system in general is out of order.
(6) Adjusting engine (A).
Replacing cylinder head assy. (one side.) Cylinder head is cracked.
Incl. : (1) Adjusting engine (A). Cylinder head is distorted.
(2) Adjusting nozzle. Cylinder head is corroded.
Cylinder head is blowholed. 㧙
Area between cylinder head and valve is cracked.
Overhauling cylinder head assy. (1 set.) Cylinder head is cracked.

Incl. : (1) Detaching/attaching cylinder head. Cylinder head is distorted.
(2) Correcting seat face. Cylinder head is corroded.
(3) Replacing valve guide. Cylinder head is blowholed.
㧙
(4) Replacing combustion chamber. Area between cylinder head and valve is cracked.
(5) Lapping valve. Cylinder head system in general is out of order.
(6) Adjusting engine (A).
Hydrostatic test of cylinder head. (1 set) Cylinder head is cracked.
(single) Cylinder head is blowholed.
1.5
2㧙6
Unit :
NAME OF WORK NAME OF TROUBLE
Hour
Replacing cylinder head gasket (1 pc.) Water leaks from cylinder head.
(On-machine) Oil leaks from cylinder head.
Incl. : Adjusting engine (A). Gas leaks from cylinder head. 6.5
Replacing cylinder head gasket. Water leaks from cylinder head gasket.
(one side) (On-machine) Oil leaks from cylinder head gasket. 㧙
Incl. : Adjusting engine (A). Gas leaks from cylinder head gasket.
Retightening cylinder head bolts.
(1 unit) (On-machine) 2.0
Incl. : Adjusting valve clearance.
Replacing pre-combustion chamber. (1 pc.) Pre-combustion chamber is broken.
Excl.: Detaching/attaching head. Water leaks from pre-combustion chamber
Incl. : (1) Detaching/attaching and gasket.
cleaning glow plug (1 pc.).
1.0
(2) Adjusting nozzle (1 pc.) for each
nozzle increased :
Medium size 0.4hr.
Large size 0.5hr.
Rocker cover 03㧙15
Replacing rocker cover packing. (1 pc.) Rocker cover packing is cracked.
Increase 0.1hr. as one direct injection Oil leaks from rocker cover packing. 0.6
increases.
Replacing rocker casing packing. (1 unit) Oil leaks from rocker casing packing.
Incl. : (1) Adjusting valve clearance.
㧙
(2) Detaching/attaching rocker
casing.
Cylinder block 03㧙20
Replacing cylinder block
Incl. : (1) Detaching and attaching engine.
(2) Conditioning engine (B) and
50.0
travel test.
Excl. : Replacing associated parts.
Replacing cylinder liners.

(all Q’y on present vehicle)
25.0
Incl. : (1) Conditioning engine (A).
Replacing side cover packing. (front side) Oil leaks from side cover gasket. 㧙
Replacing side cover packing. (left) Oil leaks from side cover gasket.
㧙
Replacing side cover packing. (right) Oil leaks from side cover gasket.
㧙
Increase 2.0hr. where injection pump is tilted.
Replacing side cover packing. (rear side) Oil leaks from side cover gasket. 㧙
Detaching/attaching or replacing rear plate. Rear plate is cracked. 㧙
2㧙7
Unit :
Cam shaft 03㧙31

Detaching/attaching or replacing cam shaft. Cam shaft is worn.
Incl. : (1) Detaching and attaching engine. Cam shaft is broken.
(2) Conditioning engine. Cam shaft bushing is worn. 18.0
(3) Travel test. Cam shaft bushing seized.
Cam shaft system in general is out of order.
Replacing cam shaft bushing. Cam shaft bushing worn.
Incl. : (1) Detaching/attaching engine. Cam shaft bushing seized. 19.0
(2) Conditioning engine.
Push rod 03㧙32
Detaching/attaching or replacing push rod. Push rod is broken.
(all) (On-machine) Push rod is bent. 2.5
Incl. : Adjusting valve clearance. Push rod system in general is out of order.
Detaching/attaching or replacing push rod. Push rod is broken.
(1㨪6,1㨪8) (On-machine) Push rod is bent. 㧙
Incl. : Adjusting valve clearance. Push rod system in general is out of order.
Rocker arm 03㧙33
Detaching/attaching or replacing valve rocker Rocker arm is worn.
assy. (all) Rocker arm is broken.
Incl. : Adjusting valve clearance. Bushing is worn. 2.5
Rocker arm system in general is out of order.
Rocker arm ball makes an unusual sound.
Detaching, attaching and disassembling Rocker arm is worn.
rocker arm and shaft. (1 unit) Rocker arm is broken.
Incl. : Adjusting valve clearance. Bushing is worn. 㧙
Detaching, attaching and disassembling Rocker arm is worn.
rocker assy. (one side) Rocker arm is broken.
Incl. : Adjusting valve clearance. Bushing is worn.
㧙
Detaching, attaching and disassembling valve Rocker arm is worn.

rocker and shaft. (one shaft) Rocker arm is broken.
㧙
Incl. : Adjusting valve clearance. Bushing is worn.
Replacing valve rocker adjusting screws. (all) Rocker arm system in general is out order.
Incl. : Adjusting valve clearance. 2.0
Replacing valve rocker adjusting screws. Rocker arm system in general is out of order.
(one side)
㧙
2㧙8
Unit :
Tappet 03㧙34
Replacing tappet. (all) Tappet is worn.
(1) Detaching and attaching engine Tappet is broken.
(6DS). Tappet system in general is out of order. 18.5
(2) Conditioning engine.
Increase 10.0hr for old type tappets (DC).
Valve 03㧙35
Replacing valves. (all) (On-machine) Inlet valve is broken.
(1) Detaching and attaching cylinder Exhaust valve is broken.
head. 10.0
(2) Correcting and lapping valve seat.
(3) Conditioning engine (A).
Lapping valve seat surface. (all) Valve seat is worn.
(1) Detaching and attaching cylinder Contact of valve seat with valve is no good.
㧙
head. Valve seat fell off.
Replacing valves. (6 or 8 pcs.) Inlet valve is broken.
(1) Detaching and attaching cylinder Exhaust valve is broken.
head. 㧙
Replacing valve guides. (all) Valve guide is worn.
(1) Detaching and attaching cylinder Valve is seized.
head. Engine oil goes into combustion chamber. 10.8
(2) Conditioning engine (A). Valve guide fell off.
Replacing valve guides. (one side) Valve guide is worn.
(1) Detaching and attaching cylinder Valve guide is sized.
head. Engine oil goes into combustion chamber. 㧙
(2) Conditioning engine (A). Valve guide fell off.
Replacing valve springs. (all) Valve spring is broken.
Incl. : Adjusting valve clearance. Valve spring is set parmanently.
Excl. : Detaching and attaching cylinder 3.4
head.
Replacing valve spring. (1 cylinder) Valve spring is broken.

(On-machine) Valve spring is set permanently.
Excl. : Detaching and attaching cylinder head
㧙
Add 0.3hr. for medium size and
0.6hr. for large size as one cylinder increases.
2㧙9
Unit :
Timing gear (chain) casing 03㧙40

Detaching/attaching or replacing timing gear Timing gear (chain) casing makes an unusual
casing. sound.
Timing gear (chain) casing parts are faulty.
4.5
Oil leaks from gasket.
Timing gear casing system in general is out of
order.
Replacing timing gear casing packing. Oil leaks from gasket. 4.5
Detaching, attaching and replacing timing Timing gear casing in general is out of order.
㧙
gear casing cover.
Replacing cam shaft gear and idle gear. Idle gear parts are defective.
Cam shaft gear is installed incorrectly. 5.3
Cam shaft gear parts are defective.
Replacing idle gear bushing Timing gear casing in general is out of order.
㧙
Note : Flywheel housing is dismantled.
Crank shaft 03㧙51
Detaching/attaching or replacing crank shaft.
Incl. : (1) Detaching/attaching engine. 24.0
(2) Adjusting idling.
Replacing crank shaft rear oil seal. Oil leaks from rear oil seal.
(On-machine)
7.0
Incl. : Detaching and attaching
transmission and flywheel.
Detaching/attaching or replacing crank pulley. Crank shaft pulley parts are faulty.
(On-machine) Crank shaft pulley nuts are loosened.
3.0
Incl. : Detaching and attaching radiator
shroud and fan.
Detaching/attaching or replacing crank pulley. Flywheel mounting bolts are broken.
Incl. : Detaching and attaching (incl. loosening) 6.5
transmission.
Detaching/attaching or replacing flywheel Flywheel ring gear is worn.
0.5
ring gear. (single body) Flywheel ring gear is broken.
Replacing flywheel pilot bearing. (single) Flywheel pilot bearing parts are faulty. 0.2
Replacing flywheel front oil seal. Oil leaks from front oil seal.
(On-machine)
5.0
Incl. : (1) Detaching and attaching fan and
front cover.
Replacing crank shaft gear. (On-machine) Crank shaft gear is worn.
Crank shaft gear is broken.
㧙
2㧙10
Unit :
Connecting rod 03㧙52

Correcting bend of connecting rod. Connecting rod is bent.
㧙
(1 pc. single)
Replacing connecting rod bearings. (all) Bearings are worn.
4.8
Bearings are seized.
Replacing connecting rod bearings. (1 set) Bearing is worn.
㧙
Add 0.4hr. as one rod increases. Bearing is seized.
Replacing connecting rod bushing. (set by set) Small end bushing is worn.
㧙
Small end bushing is seized.
Piston 03㧙53
Detaching/attaching or replacing pistons. (all) Piston is broken.
(On-machine) Piston is seized.
Incl. : (1) Conditioning engine (A). Oil consumption of engine is large. 17.0
(2) Adjust nozzle. Piston system in general is out of order.
Add 0.5hr. each time one piston decreases. Piston and piston pin make abnormal sound.
Detaching/attaching or replacing piston rings. Engine consumes much oil.
(all) (On-machine) Piston rings are worn off.
Incl. : (1) Detaching/attaching cylinder Piston rings is broken.
head oil pan. Engine oil goes into combustion chamber.
16.0
(2) Checking and correcting rod. Piston system in general is out of order.
(3) Scraping off carbon.
Intake manifold 03㧙60
Detaching/attaching or replacing inlet manifold. Intake manifold is broken.
(1 pc) Intake manifold is blowholed.
Incl. : Replacing gasket. Gas leaks from intake manifold gasket. 1.5
Intake manifold system in general is out of
order.
Detaching/attaching or replacing inlet manifold. Intake manifold is broken.
(one side) Intake manifold is blowholed.
Incl. : Replacing gasket. Gas leaks from intake manifold gasket. 㧙
Intake manifold system in general is out of
order.
Exhaust manifold 03㧙65
Detaching/attaching or replacing exhaust Exhaust manifold is broken.
manifold. Gas leaks from exhaust manifold gasket.
Incl. : Replacing gasket. Exhaust manifold system in general is out of 1.2
order.
Detaching/attaching or replacing exhaust Exhaust manifold is broken.

manifold. (one side) Gas leaks from exhaust manifold gasket.
㧙
Incl. : Replacing gasket. Exhaust manifold system in general is out of
order.
2㧙11
Unit :
Oil 03㧙70
Replacing engine oil. 0.5
Oil filter 03㧙71
Replacing oil filter assy. Oil leaks from oil filter.
Oil filter casing is damaged.
1.0
Oil filter head is scored.
Oil filter system in general is out of order.
Cleaning or replacing oil filter assy. (1 set)
0.5
Inspecting or replacing relief valve. Relief valve parts are faulty.

Excl. : Detaching and attaching oil filter 0.4
assy.
Turbocharger 03㧙62
Detaching/attaching or replacing
㧙
turbocharger assy.
Overhauling turbocharger. (single)
㧙
Incl. : Cleaning (1 pc.).
Detaching/attaching or replacing 2-stack oil Oil leaks from oil filter.
filter assy. Oil filter casing is damaged.
㧙
Oil filter head is damaged.
Oil filter system in general is out of order.
Oil pan 03㧙72
Detaching and attaching oil pan and Oil leaks from oil pan gasket.
replacing gasket. Oil pan parts are faulty. 2.5
Oil pan system in general is out of order.
Retightening oil pan attaching bolts. 0.5
Replacing oil level gauge guide or packing. Oil level gauge parts are defective. 㧙
Oil piping 03㧙74
Replacing oil piping. (between filter and Oil leaks from oil piping.
cooler) Oil piping system in general is out of order.
0.3
Replacing breather pipes. (2 pcs.) Oil piping system in general is out of order.
0.3
2㧙12
Unit :
Oil pump 03㧙75

Detaching/attaching or replacing oil pump. 1.0
Overhauling oil pump assy.
㧙
Incl. : Detaching/attaching oil pump.
Overhauling oil pump.
1.0
Excl. : Detaching and attaching oil pump.
Detaching/attaching or replacing oil strainer. Oil screen is installed incorrectly.
Oil screen is broken.
Oil screen is clogged. 3.3
Oil screen stay is broken.
Oil pump system in general is out of order.
Engine support 03㧙80
Replacing front cushion rubber. (one side) Front mount bracket rubber is broken.
0.7
Engine support in general is out of order.
Replacing rear cushion rubber. (one side) Rear mount bracket rubber is broken.
0.9
Engine support in general is out of order.
2.4 FUEL SYSTEM

Unit :
Engine control 05㧙10

Replacing decomp ression lever assy. Engine control system in general is out of order. 㧙
Detaching/attaching or replacing decomp Engine control system in general is out of order.
㧙
ression shaft.
Replacing return spring. Engine control system in general is out of order. 㧙
Fuel injection pump 05㧙30
Detaching and attaching or replacing Fuel injection pump malfunctions.
injection pump. Fuel injection pump develops leakage.
4.0
Incl. : (1) Adjusting injection timing. Fuel injection pump system in general is out
(2) Adjusting idling. of order.
Overhauling injection pump. (single) Fuel injection pump malfunctions. 㧙
Incl. : Disassembling fuel feed pump. Leakage occurs from fuel injection pump.
Excl. : Disassembling auto timer. Fuel injection system in general is out of order.
Injection pump test. 㧙

Overhauling auto timer assy. (single) 㧙
Replacing injection pump coupling. Pump coupling parts are faulty.
㧙
Incl. : Detaching/attaching injection pump
Detaching/attaching or replacing injection Fuel injection pump malfunctions.
㧙
pump.
Replacing delivery valve gaskets. (all) Oil leaks from fuel injection pump. 㧙
2㧙13
Unit :
Fuel injection pipe 05㧙35

Replacing injection pipe. (1 pc.) Injection pipe is cracked.
Add 0.2hr. each time 1 pipe increases. Injection pipe system in general is out of 0.5
order.
Nozzle holder 05㧙40
Detaching/attaching or replacing nozzle Nozzle malfunctions.
holders. (all) Nozzle holder system in general is out of order. 1.8
Incl. : Nozzle test.
Detaching/attaching or replacing nozzle Nozzle malfunctions.
holder. Nozzle holder system in general is out of order.
(1 pc.)
0.8
0.2hr. for medium and 0.3hr. for large size
each time 1 nozzle increases.
Detaching/attaching or replacing nozzles. (all) Nozzle malfunctions.
㧙
Incl. : Nozzle test. Nozzle holder system in general is out of order.
Replacing nozzle. (1 pc.) Nozzle malfunctions.
Add 0.3hr. and 0.4hr. for large size each time Nozzle holder system in general is out of order.
㧙
1 nozzle increases.
Detaching/attaching or replacing nozzle tube. Nozzle tube is damaged.
Excl. : Detaching and attaching head. Water leaks from nozzle tube.
㧙
Incl. : Detaching and attaching nozzle. Nozzle holder system in general is out of order.
Add 0.2hr. for an increase of 1 nozzle.
Fuel pump 05㧙45
Replacing fuel feed pump. Fuel pump makes an unusual sound.
Incl. : Venting air. Fuel leaks from fuel pump.
Oil leaks from fuel pump. 0.8
Fuel pump parts are faulty.
Fuel pump system in general is out of order.
Overhauling fuel feed pump. (single) Fuel pump makes an unusual sound.
Fuel leaks from fuel pump.
Oil leaks from fuel pump. 1.0
Fuel pump parts are faulty.
Fuel pump system in general is out of order.
Cleaning feed pump gauze filter. 0.4
Fuel filter 05㧙50
Replacing fuel filter assy. Fuel filter is broken.
Fuel filter is clogged. 0.6
Fuel filter system in general is out of order.
Replacing or cleaning fuel filter element. Fuel filter is broken.
Fuel filter is clogged. 0.5
Fuel filter system in general is out of order.
Fuel piping 05㧙55
Replacing engine fuel pipe. (1 pc.) Sections related to engine fuel pipe (incl. hose)
are damaged.
Leakage occurs on sections related to engine
0.5
fuel pipe (incl. hose).
General trouble with fuel pump related to
engine (incl. hose).
2㧙14
E235SR
SECTION 13 MAINTENANCE STANDARD

AND TEST PROCEDURE
TABLE OF CONTENTS
1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

EXERCISED ............................................................................................................. 1
2. PERFORMANCE INSPECTION STANDARD TABLE ................................................ 2
3. MEASUREMENT OF ENGINE SPEED ..................................................................... 4
4. MEASUREMENT OF HYDRAULIC PRESSURE ...................................................... 5
5. MEASURING TRAVEL PERFORMANCES ............................................................... 9
6. MEASURING SLEWING PERFORMANCES .......................................................... 11
7. MEASURING ATTACHMENT OPERATING PERFORMANCES ............................. 13
8. MEASURING PERFORMANCES OF SLEWING BEARING ................................... 14
9. MECHATRO CONTROLLER “A” & “B” ADJUSTMENT............................................. 15

1. HOW TO USE THE MAINTENANCE STANDARD
AND CAUTIONS TO BE EXERCISED
(1) Application (3) Cautions to be Exercised at Judgment
1) When the machine is new ; 1) Evaluation of measured data ;
Confirm that the performances are in Disagreement of measuring conditions,
accordance with standard specifications as variations of data peculiar to a new machine,
compared to the performance standards. and measuring errors are to be evaluated.
Determine generally at what levels measured
2) At specific self inspection ; (Rule by country) values are located, instead of determining
Use the data for the criterion, for the purpose whether or not values fall within or run out
of correction, adjustment and replacement. of the reference values.
3) When performances are deteriorated ; 2) Determining correction, adjustment or

Determine whether it is caused by a fault or replacement ;
end of service life after long hours of Machine performances deteriorate with time
operation, to be used for safety and as parts wear and some deteriorated
economical considerations. performances may be restored to new levels.
Therefore, determine correction, adjustment
4) When main components are replaced ; or replacement, depending upon the
For example, use data to restore operating hours, kind of work and
performances of pumps and others. circumstances in which the machine is
placed, and condition the machine
(2) Terminology performances to its most desirable levels.
1) Standard values ;
Values to be used to condition or assemble a (4) Other Cautions to be Exercised
new machine. Where special notes are not 1) Parts liable to degrade ;
given, these values represent standard Rubber products, such as, hydraulic hoses,
specifications (machine with standard O rings, and oil seals deteriorate with time ;
attachments and standard shoes). replace them at regular intervals or at
overhauls.
2) Reference values for remedy ;
Values at which readjustment is required. In 2) Parts requiring regular replacement ;
order to ensure performance and safety it is Out of critical hoses that are necessary to
strictly prohibited to use the machine over secure safety, we designate Very Important
the specified values. Parts (V.I.P) and recommend that they
should be replaced regularly.
3) Service limit ;
This is the limit value at which 3) Inspection and replacement of oils and greases ;
reconditioning is impossible without In performing maintenance, it is necessary
replacement of parts. If the value is expected for the user to familiarize himself with how to
to exceed the service limit before next handle the machine safely, cautions to be
inspection and correction are performed, exercised and inspection/lubrication
replace the parts immediately. The operation procedures. Refer to the operators manuals
over the specified values causes increase of as well.
damage and requires the down time of
machine, and also causes safety problems.
1
2. PERFORMANCE INSPECTION STANDARD TABLE
Table 1 (1/2)
Note ; The mode is already S mode when power is thrown. Unless otherwise specified, measure it on H
d
Measuring Position Standard Tolerance
Inspection Item Unit Adjusting Measuring
Position Size Port value Hi Lo Point condition
Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 +1 㧙1 Class ̆ Sampling

Measuring condition
50 +5 㧙5
Hydraulic oil temperature Tank surface (122) (41) (23) ͠ ̆ Ambient temp.
75 +15 㧙15 50͠㨪㧙10͠
Water temperature Radiator surface F)
(q ̆ (122q
F㨪14q F)
(167) (59) (5)
Standard
Lo idle 1000 +30 㧙30 LOW throttle

Engine speed
FULL throttle
Hi idle 2220 +30 㧙70
(HI idle)
Multi display on the
Adjustment
S mode gauge cluster screen 2100 +30 㧙30 rpm not required Perform all
FC mode (Injection pipe) 1800 +30 㧙30
measurement with
the air-conditioner
Decel 1050 +30 㧙30
̌OFF̍.
50 +3 㧙3
Pilot primary pressure circuit G pump a3 PR1 HI idle
(710) (43) (43)
valve pressure
Main pump
P1 a1 350 +5
ATT 0 MR1 Boom up
Main relief
(4980) (71)
P2 a2
P1 a1 385 +10 㧙5 ATT boost SW. ON
Boost MR1
P2 a2 (5470) (140) (71) Boom up
̆ ̆ ̆ ̆ ̆ ̆ ̆ ̆ ̆
405 㧙55
H (5760) 0
(780)
OR3 Boom up
Boom a1
385 㧙35
R (5470) 0 (500) OR4 Boom down
High pressure circuit
405 㧙55
H (5760) 0 (780) OR1 Bucket digging
Bucket a1 385 㧙35
R (5470) 0 (500) OR2 Bucket dump
PF1/4
Travel
OT1
Port relief valve pressure
Forward 350 +15

Main pump
RH a1 (4980) (210)
0
Reverse OT2 Simultaneous
Operation of travel
Forward
350 +15 OT3 RH and LH
LH a2 0
(4980) (210)
Reverse OT4
LH 285 +55 +10 kgf/cm2 OR5 Swing LH
Swing a2
(4050) (780) (140) (psi)
RH OR6 Swing RH
358 㧙35
H (5470) 0 (500) OR7 Arm in
Arm a2 405 㧙55
R (5760) 0 (780) OR8 Arm out
̆ ̆ ̆ ̆ ̆ ̆
̆ ̆
̆ ̆ ̆ ̆ ̆ ̆
̆ ̆ ̆ ̆ ̆ ̆
̆ ̆ ̆
̆ ̆ ̆ ̆ ̆ ̆
Performs proportional
P2 cut valve B 21 Indicated calculation from actual
Proportional Valve block
current reading on
Service diagnosis screen No.
Travel 6.9 current value display No. Values

straight valve
C 22 (100) +1.5 㧙0.5 (mA) which are calculated
by converting pressure
(20) (7) 350r5
Gauge cluster
D 20 values in the left figure to

Pressure circuit
Secondary pilot
C㧙2 Multi display
P1 cut valve current

values are shown.
Arm variable 25
recirculation
A 23 (300) 642 E/G Hi, Lever on neutral
position
25
P2 cut valve B 21 (300) 642 E/G Hi
Travel 28.6 The max. value is
straight valve
C 22 (410) +2 㧙1.5 700 displayed as the
25 (30) (20) full lever strokes
P1 cut valve D 20 (300) 642
differ with types of
Arm variable 4㨪25 operations.
recirculation
A 23 (60㨪360) 303㨪642
2
Table 1 (2/2)
Measuring Posision Stand- Tolerance Adjusting Measuring
Inspection Item ard Unit
Position Screen code value Hi Lo Point condition
Service diagnosis screen No.

pressure circuit
Indicated E/G High

No.24
6 +0.5 㧙0.5 Current value Lever on
&
Gauge cluster
P1 pump (85) (7) (7)
Multi display
(mA) neutral
No.25
proportional valve MIN 350 position
kgf/cm2
Secondary pilot
& (psi)
P2 pump
No.24 E/G High
proportional valve 30 +1.5 㧙1.5
& MAX 750
C㧙2
Lever on full
(427) (20) (20)
No.25 stroke
Inspection item Standard value Unit

1-speed 31.2㨪28.8
Sprocket revolution H mode
2-speed 47.5㨪43.5 rpm
(RH,LH)
S mode 2-speed 45.5㨪41.5
Raise 3.4㨪4.0
Boom
Lower 3.1㨪3.7
In 3.2㨪3.8
Arm
Out 2.6㨪3.2
Operating speed
Operating time of
Digging 3.1㨪3.7
cylinder Bucket sec
Dumping 2.0㨪2.6
(At no load)
̆ ̆ ̆
̆ ̆
̆ ̆ ̆
̆ ̆
Variable speed ̆
Swing speed sec/1 rev
STD speed 5.1㨪5.7
Rubber ̆
1-speed
Iron 20.2㨪22.2
Travel speed sec/20m
Rubber ̆
2-speed
Iron 13.3㨪14.7
Amount of travel
deviation 2-speed 0㨪240 mm / 20m
Parking brake drift 15 degree slope 0 mm / 5min
Performance of Neutral position after
Performance
Swing brake 180qfull speed swing 55㨪75 degree

Performance of
Swing parking brake 15 degree slope 0 mm (in)

Tip of the bucket tooth 95
ATT amount of Boom cylinder 7
mm/5min (At no load)
drift Arm cylinder 6
Dozer cylinder 0
Amount of horizontal play at the bucket tooth 30㨪50 mm (in)
The port relief valves No.OR1㨪OR8 on the control section are adjusted to the following operation
numbers in advance. ԟ ԛ
ԘBucket digging ԙBucket dumping ԚBoom raise
ԛBoom lower ԜSwing left ԝSwing right Ԝ ԝ Ԙ ԙ
ԞArm in ԟArm out
Ԟ Ԛ
LH RH
CONTROL LEVER
3

3. MEASUREMENT OF ENGINE SPEED

3.1 MEASUREMENT OF ENGINE SPEED
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4. MEASUREMENT OF HYDRAULIC PRESSURE
4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
2
70kgf/cm (1000psi) pressure gauge ......... 1 unit
2
400 500kgf/cm (5700 7100psi)
pressure gauge .................................................. 2 unit
Pressure measuring equipment and
instrument for analysis ................................... 1 set
(2) Measuring cleanliness of hydraulic oil

After releasing air in the hydraulic oil
tank, open the cover and sample oil in
the hydraulic tank, and measure with
the instrument for analysis. If the
measured value is higher than the
reference value, replace the return
filter or change the hydraulic oil.
Fig. 4 Gauge port on main pump
4.2 PLACE TO INSTALL PRESSURE GAUGE

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

Replace pilot gauge plug a3 with plug PF1/4
for pressure measurement, and attach
2
pressure gauge 70kgf/cm (1000psi).
5
4.3 PRESSURE ADJUSTMENT POSITION
(1) Main control valve
MR1
OR3 OR1 MAIN RELIEF VALVE
BOOM (H) BUCKET (H) (ATT & TRAVEL)
OPTION 2 ARM (H)

(PA02) OR7
View from the top of the machine
OPTION 2 OR8
(PB02) ARM (R)
BOOM (R) BUCKET (R)

OR4 OR2
View from the bottom of the machine
Fig.5 Relief valve position on main control valve
6
(2) Pilot relief valve
Pilot relief valve PR1 is built in main pump.
PR1 ADJUST
SCREW FOR
PILOT RELIEF
Fig.6 Pilot relif valve position

SWING LEFT SWING RIGHT
OVER LOAD OVER LOAD
(3) Swing over lode relief valve RELIEF RELIEF
OR5 OR6
The swing motor is equipped with plugs
PA,PB for pressure measurement, but the
measurement is carried out using gauge ports
a1 and a2 . (See Fig. 4)
Fig. 7 Swing over load relief position
4.4 PROCEDURE FOR ADJUSTING RELIEF

VALVE
(1) Pilot relief valve
Adjust it with adjust screw (311).
: 24mm Tightening torque :
3.0kgf m (22ft lbs)
: 6mm
311
Table 2
Pressure change LOCK NUT HEX24
No. of turns of adjust screw 2
kgf/cm (psi)
Fig. 8 Pilot relief valve
1 turn Approx. 21 (300)
7

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5. MEASURING TRAVEL PERFORMANCES

5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
45㨪55͠(113㨪131q
Hydraulic oil temperature ; 45㨪55͠ F)
Crawler on the right and left sides are Fig. 13 One side lifted position
tensioned evenly.
(3) Preparation
Attach the reflection panel with a magnet to REFLECTION
PANEL
the travel motor cover.
Swing the swing frame through 90qas shown
in Fig.13 and make the crawler on one side
take off the ground, using the attachment.
(4) Measurement YN-B74
Engine revolution ; Hi idle Fig. 14 Adhering position of reflection panel

2-speed travel switch ; 1-speed and 2-speed
Measuring points ; Right and left Sprocket revolution Table 6 Unit : rpm
Method, example 1 ; Measurement Standard Reference value Service
item value for remedy limit
Measure revolution with a stroboscope.
RH H1 31.2㨪28.8 24.3㨪22.5 20.1㨪
Method, example 2 ;
Measure the revolutions per minute & H2 47.5㨪43.5 37.1㨪33.9 30.5㨪
LH S2 45.5㨪41.5 35.5㨪32.4 29.1㨪
visually.

5.2 DEVIATION OF TRAVEL
(1) Purpose
Measure the amount of deviation at 20m
(22 yard) travel and confirm the horizontal
balance between the hydraulic pump and the
travel motor of the travel drive system.
(2) Condition (Approx. 1ft)
45㨪55͠(113㨪131q
Hydraulic oil temperature ; 45㨪55͠ F) 30㨪40cm
RH and LH crawler are tensioned evenly. Fig. 15 Travel position
Plain, level and solid ground
Engine revolution ; Hi idle
(3) Preparation
1) Straight course more than 30m (33 yard)
2) Travel position in which the bottom of the A
bucket is lifted by about 30cm (1 ft). 20m (22 yard)
(4) Measurement
1) Measure the max. deviation distance of the Fig. 16 Measuring method
circular arc in the 20m (22 yard) length, Unit : mm / 20m
excluding the preliminary run of 3㨪5m Travel deviation Table 7 (in / 22yard)
(10㨪16 ft). Reference
Measuring value
Standard value Service limit
position
2) Operate the travel lever at the same time. for remedy
A 240 (9.45 ) or less 480 (18.9 ) 720 (28.3 )
9
5.3 PERFORMANCES OF PARKING BRAKE
(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a no-load (1ft)
travel position and on a 15 degree slope. 30cm
(2) Condition
A slope with 15 degree incline and a stopped (Approx. 15deg)
condition in a no-load travel position
(3) Preparation Fig. 17 Parking brake operating position
Place an angle meter on the shoe plate and
confirm that it makes an angle more than 15
degree.
Hang a perpendicular in parallel with the
guide frame rib on the track frame and put a
mark (matching mark) on the shoe plate.
(4) Measurement GUIDE FRAME C ANGLE METER
Five minutes after the engine stops, measure Fig. 18 Method of measurement
the movement distance of the matching
Parking brake Table 8 Unit : mm/5 min.
mark.
Measuring Reference
position Standard value value Service limit
for remedy

C 0 1 (0.04in) 2 (0.08in)

22 PIPE
5.4 DRAIN RATE OF TRAVEL MOTOR FORWARD (0.866˝ ) 90 10
(1) Purpose (3.54˝ ) (0.394˝ )
To measure the drain rate of the travel motor 40
(1.57˝ )
and to confirm the performances of the travel
motor. RIB "A" 150
STOPPER (5.91˝ )
(2) Conditions ˝ B˝
Hydraulic oil temperature ; 45㨪55͠
(113㨪131q F)
80
Engine revolution ; Hi idle (3.15˝ )
ROTARY DIRECTION
(3) Preparation
1) Place a stopper under the RH and LH travel Fig. 19 Location of stopper applied to travel sprocket
sprockets.
2) Stop the engine and vent pressure from the
hydraulic circuit.
3) Connect a hose with the drain port of the
travel motor and take drain in a container.
(4) Measurement ; at Travel Lock
Unless you observe the rotary force direction

at travel lock, rib̌ A ̍ may be broken by
stoppeřB̍in some cases. (See Fig. 19)

1) Start the engine and relieve pressure at the Fig. 20 Method of measuring
full stroke of the travel lever. the drain rate of travel motor
2) Measure the drain rate for 30 seconds of Drain rate of Table 9 Unit : /30sec
travel motor
relieving. Measuring Reference value
position Standard value for remedy Service limit
Drain rate 7 (1.8gal) 14 (3.7gal) 21 (5.5gal)
10
6. MEASURING SWING PERFORMANCES

6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature ;4 45㨪55͠(113㨪131q F) Fig. 21 Swing speed measuring position
Plain, level, and solid ground (at the max. reach)
Engine ;Hi idle
(3) Preparation
Bucket empty, arm cylinder fully retracted
(Max. reach), or arm cylinder fully extended
(Min. reach)
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make two turns after one turn of
preliminary run and calculate the time
required for one turn. Fig. 22 Swing speed measuring position
(at the min. reach)
6.2 PERFORMANCE OF SWING BRAKE Swing speed Table 10 Unit : sec / rev
(1) Purpose Measuring Reference value
Confirm the braking torque performances by position Standard value for remedy Service limit
the swing relief valve. max. reach 5.1㨪5.7 6.5㨪7.3 8.1㨪

(2) Conditions Swing speed
min. reach 5.1㨪5.7 6.5㨪7.3 8.1㨪
45㨪55͠(113㨪131q
Hydraulic oil temperature ;45㨪55qC F)
Engine ;Hi idle
(3) Preparation
1) A height of 1.5m (5ft) at which the bottom of
the bucket matches the tip of the tooth on
condition that the bucket is empty, the arm
cylinder is most retracted and the bucket is 1.5m (5ft)
used for digging.
2) Put a mark (matching mark) on the outer Fig. 23 Swing brake performance measuring position
circumference of the swing bearing of the
upper frame side and of the track frame side. Measuring the length of the arc over the
outer circumference of swing race
Erect two poles (flags ) at the front and back
of the extended line of the matching mark. Matching marks
(4) Measurement on swing race
B
1) When operating in regular swing speed, by
shifting lever to neutral position at pole
position the swing operation stops.
2) Calculate the swing drift angle by the
following equation, after the upper swing
body stops, using the amount of deflection
Matching marks on track frame
(m) of the matching marks on the swing race
and the length (m) of the circumference of the Fig. 24 Measuring position of swing brake performances
swing race :
Swing brake
Amount of deflection of performance Table 11 Unit : degree
Swing drift
matching marks [m (ft-in)] Measuring Reference value
angle(q)= 360q position Standard value for remedy Service limit
Circumferential length of
swing race [m (ft-in)] Swing 180q 75q 85q 90q
11
6.3 PERFORMANCE OF SWING PARKING BRAKE
(1) Purpose
To confirm the mechanical performances of
the swing parking brake that is fitted to the
inside of the swing motor.
(2) Conditions
On a slope with 15 degree incline.
15 degree
Stop the machine at right angles with the
slope at the height of 1.5m (5ft) at which the
bottom of the bucket matches the tip of the Fig. 25 Swing parking brake
tooth on condition that the bucket is empty, performance measuring position
the arm cylinder is most retracted and the
Measuring the length of the arc over the
bucket is operated for digging. outer circumference of swing race
(3) Preparation Matching marks
Put the angle meter on the shoe plate and on swing race C
make sure that the angle is more than 15
degree.
Put a matching mark over the outer
circumference of the swing bearing on the
upper frame side and on the track frame side.
(4) Measurement Matching marks on track frame
When five minutes has passed after the
Fig. 26 Measuring position
engine stops, measure the length of the of swing brake performances
movement of the matching marks.
Performance of swing
6.4 DRAIN RATE OF SWING MOTOR parking brake Table 12 Unit : mm/5 min
(1) Purpose Measuring Reference value
position Standard value Service limit
Measure the drain rate of the swing motor for remedy
and confirm the performances of the swing C 0 1 (0.04in) 2 (0.08in)

motor.
(2) Conditions
Hydraulic oil temperature;45㨪55q C
45㨪55͠(113㨪131q F)
Engine revolution ;Hi idle
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from
its end returning to the hydraulic oil tank
and take oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock
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. Fig. 27
3) Receive in a container the amount of drain Drain rate of
swing motor Table 13 Unit : /30sec
accumulated in 30 seconds of relieving.
Measuring Reference value
item Standard value for remedy Service limit
Drain rate 1.5 (0.40gal) 3.0 (0.79gal) 4.5 (1.2gal)
12
7. MEASURING ATTACHMENT OPERATING

7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm
ԙ Ԙ
and bucket and confirm the performances
(1ft)
between the hydraulic pump and the cylinder 30cm
of the attachment drive system.
(2) Condition Fig. 28 Measuring position for bucket digging
and dump
45㨪55͠(113㨪131q
Hydraulic oil temperature ;45㨪55qC F)
Engine ;Hi idle
Operating time excluding the cushion stroke
(3) Preparation
Plain ground with the bucket empty Ԛ
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke, ԛ
measure the required operating time of the
bucket between the ground surface and its Fig. 29 Measuring position for boom up
highest position. and down motions

ԟ
When lowering the boom, allow the
bucket onto a soft ground or cushioning
such as rubber tires ; never put the
bucket against concrete or other solid Ԟ
(1ft)
material. 30cm
Fig. 30 Measuring position for arm in
Measurement 2 ; Arm in and out, bucket and out motions
digging and dump
In a position in which the tooth of the bucket Cylinder Operating time Table 14 Unit :
rises to a level of about 30cm (1ft) above Measuring Reference Value
Standard Service limit
ground, measure the full stroke operating position for remedy
value
time required with the arm and bucket
Ԙ 3.1㨪3.7 4.0㨪4.7 5.1㨪
operating levers at full stroke.
ԙ 2.0㨪2.6 2.7㨪3.3 3.5㨪

Ԛ 3.4㨪4.0 4.4㨪5.1 5.6㨪
7.2 OIL TIGHTNESS OF CYLINDERS
ԛ 3.1㨪3.7 4.0㨪4.7 5.1㨪
(1) Purpose
Ԟ 3.2㨪3.8 4.1㨪4.9 5.3㨪
Confirm that the cylinder oil tight by
ԟ 2.6㨪3.2 3.3㨪4.1 4.4㨪
checking the moving length of the cylinder
rods. B
(2) Condition C
Hydraulic oil temperature ;45㨪55qC
45㨪55͠(113㨪131q F)
A
After cylinders are replaced, bleed off air CONDITIONS D
from the cylinders, before checking for oil 1.5m(5ft)
tightness.
(3) Preparation Fig. 31
Keep the tip of the bucket at 1.5m (5ft)
Oil tightness of
height, with the bucket empty and the arm cylinder Table 15 Unit : mm/5min
cylinder is most retracted. Measuring Reference Value
(4) Measurement
Measure the items five minutes after the A 7 (0.28in) 11 (0.43in) 14 (0.55in)
engine is turned off. B 6 (0.24in) 9 (0.35in) 12 (0.47in)
C ̆ ̆ ̆
D 95 (3.7in) 150 (5.9in) 200 (7.9in)
13
8. MEASURING PERFORMANCES OF SWING BEARING
LOCATION OF BEARING
(1) Purpose
ATTACHING CAPSCREWS
Measure the gap between the lower frame
and the bottom face of the swing bearing and
SWING BEARING
estimate the degree of wear of the swing
A
bearing.
DIAL INDICATOR
(2) Condition
Plain, level and solid ground LOWER FRAME
The swing bearing mounting bolts are not
loosened. Fig. 32 How to measure the axial play
The swing bearing is lubricated well, not of swing bearing
making abnormal sound during turning.
(3) Preparation
1) Install a dial indicator to the magnetic base 90 110
and fix it to the lower frame.
2) Direct the upper swing body and the lower (1ft)
frame toward the travel direction, bring the 30cm
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing Fig. 33 Measuring position
body side and set the reading at zero.
(4) Measurement 1 (Measuring position and

)
1) Measure the travel of the outer race in the
axial direction in position [The arm at 90
110 and the crawler front lifted about 1.5m (5ft)
30cm (1ft)] and in position , using a dial
indicator.
2) Take measurement three times on the right Fig. 34 Measuring position
and the left respectively, and make the mean
Axial play of
value a measured value. swing bearing Table 16 Unit : mm (in)
Measuring Reference value
0.8 1.8 2.3 3.3 3.6

A (0.03 0.07) (0.09 0.13) (0.14)
(5) Measurement 2 (Measuring position )

1) With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the
bucket about 10mm (0.4in) and swing the tip (0.4in)
10mm
of the bucket to the right and the left by man
power.
But in this case, the gap of the attachment is Fig. 35 Measuring position
included. Right and left
movement of
the tip of bucket Table 17 Unit : mm (in)
Measuring Standard Reference value
position value for remedy Service limit
Bucket
tiptoe 50 (1.97) 100 (3.94) 120 (4.72)
14
9. MECHATRO CONTROLLER "A" & "B" ADJUSTMENT
9.1 ENGINE CONTROL INPUT/OUTPUT
SWITCH PANEL C-1 MECHATRO CONTROLLER

GAUGE CLUSTER

MOTOR
GOVERNOR
ENGINE

PUMP
ACCEL DIAL
STARTER SWITCH
E/G SPEED SENSOR
Fig. 36 Engine control I/O
9.2 ENGINE CONTROL INSTALLATION

(1) Engine emergency stop knob
When the engine does not stop after the
starter switch is turned off, pull the
E/G
emergency stop knob located on the lower
EMERGENCY
right side of the seat fully, and the engine STOP KNOB
(18.1˝ )
stops.
Fig. 37 (1/2) Engine emergency stop knob position

Note : If emergency knob is pulled in halfway,
also fuel cut-off lever of governor is
pulled and engine does not start in some
case.
Even if engine is started, it is stalled
during operation, push the knob to
bottom position without fail.
15
(2) Engine control

Torque :
1.0kgfym
(7.2 lbfyft)
2 places
4 places
Torque : 4.7kgfym (34 lbfyft)
ENGINE CENTER
ENGINE CENTER 3 places
Apply Loctite #242
Torque : 2.0kgfym (14.5 lbfyft)
Torque :
1.8kgfym (13 lbfyft)
SECTION E㧙E
Torque :
Torque :
2.45kgfym (17.7 lbfyft)
SECTION A㧙A
Torque :
SECTION B㧙B 4.7kgfym (34 lbfyft)
SECTION C㧙C
Fig. 37 (2/2)
16

9.3 E/G CONTROL EQUIPMENT

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9.4 "A" & "B" ADJUTMENT OF MECHATRO
(1) When adjustment of mechatro control is
required; GROMMET

Case ̌A̍adjustment

Replace mechatro controller. ٤

Replace governor motor. ٤

CPU ROM DATA FAILURE
on display. ٤
CPU ROM DATA FAILURE and C㧙1 MECHATRO CONTROLLER

CPU MECHATRO SET ERROR ٤
are shown by turns. Fig. 41
(2) Preparation
1) Warm up engine.

2) Turn A/C switch OFF.
3) Turn starter switch OFF to stop engine.
4) Pull up the safety lock lever and pull up the
left control box upwards.
5) Pull operator seat forward fully and incline MULTI DISPLAY
seatback forward.

6) Remove plastic cover on the rear side, then
mechatro controller appears. (Remove 5
atta-ching bolts from plastic cover with driver Screen change
+). switch
Note : Check to be sure that the engine

emergency stop lever knob is fully

pressed down. If mechatro controller is
adjusted in the condition where the knob
is pulled out, the engine speed can not be Fig. 42
set properly.
(3) Adjustment Table 18 (1/2)
"A" AdjustmentProcedure Multi display Movement of governor motor
ԘRemove grommet on upper surface of
STOP
mechatro controller, and switch internal FULL
adjustment JP switch from RUN to
TEST .
.'8'4
In normal

RUN position
LEVER

During
TEST GOVERNOR
adjustment
MOTOR

ԙ Turn starter switch ON .
OK A
Turn the accel dial to a certain position.

Stop at the position set by accel dial.
18
Table 18 (2/2)
Procedure Multi display on Movement of governor motor
gauge cluster
Ԛ Keep the buzzer stop switch pressed and
A
when it is let free after 5 to 10 seconds, S
STEP 1 is displayed on the multi display.
Then let your hand free and wait till the
display changes to STEP 2.
Self-traveled to the engine stop

position (S).
ԛ After confirming the STEP2 display, move
S
to the engine room and adjust the rod assy
to its standard length 288 㨪 304mm(11.3 㨪
12.0in) so the clearance "A" between the
governor lever and the engine stop set bolt
becomes "0.1mm" (0.004in).
Then if the governor motor is replaced, Stop at the position (S)
insert the rod assy after the STEP 2 ާToolsި
٨ Spanner 13mm & 12mm
indication.
٨ Spanner 6mm
٨ Thickness gauge
Ԝ Press the buzzer stop switch once, and wait

A S
until the STEP 3 indication is provided.
Automatically run to the engine

available position(A).
ԝ When STEP 3 comes up, start the engine. A
On that occasion, the accel dial may be in
any position.
Stop at the position (A).

Ԟ If the buzzer stop switch is pressed one
time, STEP 4 comes up. The controller Hi A Lo
reads revolution from the A position of
governor motor to LOW IDLE and then to
HI IDLE. (The required time is approx 3
minutes.)
Move from position (A) to Lo
idling position, and self-travels
from Lo position to high idling
(Hi) position.
ԟ Wait till the indication on the multi Hi
display changes to "FINISH" after reading
is completed.
When the indication on the display
changes, the engine revolution returns (Approx.
automatically to an initial position of the 5 seconds) A
accel dial.
Hi
Note: If "FINISH" is not indicated, it means
that the adjustment has failed. Then turn
OFF the starter switch and readjust it.
19
"B" Adjustment
Ԡ When the screen "CPU FINISH 2220RPM"
is displayed after adjustment of engine,
the "CPU STEP 4 MEMORY" is displayed
automatically, the engine speed changes
into high idling and the pump is loaded,
and then "CPU FINISH 0 RPM" is
displayed after 1 minute in high idling
condition and adjustment is terminated.
Note :
1. The "B" adjustment is carried out by
mechatro controller after completion of "A"
adjustment automatically.
2. The temperature control of hydraulic oil is
necessary to adjust it to the correct output, so
special attention must be paid to the
hydraulic oil temperature.
(4) After completion of adjustment

1) Turn starter switch OFF to stop engine.
2) Return the inner adjust switch to RUN from TEST, attach the grommet, push the screen change
switch on the gauge cluster one time, and get an engine rpm indication.
3) Exchange the service connector for the auto accel release and turn the mode to HIGH IDLE after the
engine starts.
4) Make sure that if the work mode on the switch panel is changed, the mode display on the gauge
cluster changes and the engine rpm on the multi display changes.
5) Set accel dial to low idling position, and changes connector after engine stops, and starts engine
after switching to auto accel.
6) Set accel dial to high idling, and check engine speed when running in auto accel position.
7) Get "MONITOR SYSTEM OK" by pushing the screen change switch on the gauge cluster two times.
(5) Releasing auto accel (For checking the High Idling)

1) Location of auto accel releasing switch.
Auto accel releasing switch (SW-16)
Gauge cluster
Fig. 43
20
E235SR
SECTION 21 MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
1. SUMMARY OF MECHATRO CONTROL SYSTEM ................................................... 1

1.1 Mechatro Control System in General ................................................................................... 1
1.2 Boom Raise Conflux ............................................................................................................ 2
1.3 Swing Cut Valve Control ....................................................................................................... 2
1.4 Arm in Recirculation & Sequence Conflux ........................................................................... 3
1.5 Arm in Anti-cavitation Control .............................................................................................. 4
1.6 Arm Out Conflux .................................................................................................................. 4
1.7 Travel Straight....................................................................................................................... 5
1.8 Swing Priority Control .......................................................................................................... 6
1.9 Pressure Draining (Releasing) Control ................................................................................ 8
1.10 Pump Control ..................................................................................................................... 9
1.11 Standby flow Constant Control......................................................................................... 10
1.12 FC Mode Control .............................................................................................................. 11
2. MECHATRO CONTROLLER
2.1 Summary of Mechatro Controller ....................................................................................... 12
2.2 Self Diagnosis Display Function ......................................................................................... 12
2.3 Service Diagnosis .............................................................................................................. 14
2.4 Trouble History Diagnosis .................................................................................................. 15
2.5 How to Correct the E/G Oil Supply Cumulative Time ......................................................... 15
2.6 Mechatro Control Equipment ............................................................................................. 16
1. SUMMARY OF MECHATRO CONTROL SYSTEM
1.1 MECHATRO CONTROL SYSTEM IN GENERAL
System summary Features Purpose
P1, P2 pump is P1 pump is controlled by A) The power curve shall be an

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

3 z Make the changeover soft.
valve is controlled by proportional valve.
controlled by the
The bypass cut valve is controlled
proportional 4 z Make the changeover soft.
by proportional valve.
valve.
‫ ع‬: GOVERNOR MOTOR The arm variable recirculation z Control the arm speed as
The main spool is 5 valve is controlled by proportional
‫ غ‬: ENGINE SPEED SENSOR valve. you desire.
controlled
: HIGH PRESSURE SENSOR hydraulically. ATT boost is controlled by
(P1, P2 : 2pcs) 6
solenoid valve.
٧ : LOW PRESSURE SENSOR The open and close actions of the
(ATT : 7pcs, Travel : 2pcs) 7 swing P/B are controlled by
٠ : ACCEL DIAL POTENTIOMETER solenoid valve.
1
1.2 BOOM RAISE CONFLUX 1.3 SWING CUT VALVE CONTROL
(1) Boom raise conflux (1) Swing cut valve control

1) Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom 1) Start swing operation, and the swing pilot secondary pressure switches swing spool, and is input into
conflux spool, and inputs into low pressure sensor. low pressure sensor.
2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes 2) The output voltage of the low pressure sensor is put into the mechatro controller which processes the
the pilot signal and outputs the command corresponding to input voltage to P1,P2 pump and P2 bypass pilot signal. A command value is then put out to the P2 bypass cut proportional valve.
cut valve. 3) The P2 pump and the P2 bypass cut proportional valve put out secondary pilot pressure according to a
3) Each proportional valve puts out the secondary pressure for the pilot proportional valve according to command value of the mechatro controller.
command values from the mechatro controller, changes the delivery rates of the P1, P2 pump and This changes the delivery rate of the P2 pump and switches the P2 bypass cut valve.
switches the P2 bypass cut valve. 4) The pure hydraulic command switches the swing main spool. Then a mechatro command switches the
4) A pure hydraulic command switches the boom main spool and the boom conflux valve. A mechatro P2 pump and the P2 bypass cut valve.
command switches the P1, P2 pumps and the P2 bypass cut valve. This causes the oil delivered by the If the amount of change is controlled, the swing motion is controlled softly.
P1 pump to combine with that by the P2 pump at boom raise operation.
2
1.4
ARM IN RECIRCULATION & SEQUENCE CONFLUX (1) Recirculation cut control
1) If load increases and the load pressure of the pump rises above set pressure during arm in operation,
the output voltage of the high pressure sensor (SE-23) is put into the mechatro controller.
The mechatro controller processes pilot signals and puts out a command current that cuts off the
variable recirculation, to the variable recirculation proportional valve.
2) The variable recirculation proportional valve puts out secondary pilot pressure according to a command
current of the mechatro controller, brings back the variable recirculation valve to the recirculation cut
position and blocks the recirculation passage.
(2) Sequence conflux control

1) If load increases and the load pressure rises above set pressure during arm in operation, the mechatro
controller processes a pilot signal and puts out a command current to the travel straight proportional
valve and the P1 bypass cut proportional valve according to the secondary operating pilot pressure.
2) The travel straight proportional valve and the P1 bypass cut proportional valve put out the secondary
pilot pressure according to a command current of the mechatro controller and switches the travel straight
valve and the P1 bypass cut valve.
3) When the travel straight valve is changed over, the parallel passage on the P1 side connects with the
parallel passage on the P2 side.
When the P1 bypass cut valve is changed over, the oil delivered by the P1 pump is combined with that
by the P2 pump by arm operation.
(3) Recirculation control

1) Start arm in operation, and arm operation pilot secondary pressure switches arm spool, and is input into
low pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro
controller processes the pilot signal and puts out a command current according to the input voltage to
the P2 pump proportional valve, and the variable recirculation proportional valve.
3) Each proportional valve puts out secondary pilot pressure according to a command current from the
mechatro controller and switches the delivery rate of the P2 pump. At the same time it switches the
variable recirculation valve of the control valve.
4) The pure hydraulic command switches the arm main spool. Then a command from the mechatro
controller switches the P2 pump, and the variable recirculation valve. This causes the returned oil of the
arm cylinder rod side to be recirculated to the oil delivered by the P2 pump.
3
1.5 ARM IN ANTI- CAVITATION CONTROL 1.6 ARM OUT CONFLUX
(1) Arm in anticavitation control

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

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

ATT operation Boom Bucket Arm Swing
In travel right operation(P1) ٤ ٤ ̆ ̆
In travel left operation(P2) ̆ ̆ ٤ ٤
5
1.8 SWING PRIORITY CONTROL (1) Swing priority control at Arm in (The forced recirculation position)
1) If swing operation is performed during arm in (or arm in is performed during swing), the secondary pilot
pressure for arm and swing operation switches arm spool and swing spool. Respective pressure is
simultaneously put into each low-pressure sensor (SE-7, SE-5).
2) The output voltage of the low pressure sensor is put into the mechatro controller.
The mechatro controller processes pilot signals. The command currents according to the output voltage
are put out to the P1 pump proportional valve(PSV-P1), P2 pump proportional valve (PSV-P2), travel
straight proportional valve (PSV-C), P1 bypass cut proportional valve (PSV-D) and the arm variable
recirculation valve (PSV-A).
3) Each proportional valve outputs a secondary pilot pressure according to a command current from the
mechatro controller and switches the delivery rate of the P1&P2 pumps. At the same time, the pressure
moves travel straight spool to travel straight position (Inner conflux position) and P1 bypass cut spool to
stop oil flow, and switches the arm variable recirculation valve to the forced recirculation position.
4) If arm in and swing operations are performed simultaneously, the secondary pilot pressure moves
sub-spool of arm spool and consequently passage in arm cylinder head is restricted. The return oil from
rod side is recirculated while restricton because of the arm variable recirculation spool is shifted to forced
recirculation position. Consequently the operation pressure of arm cylinder is risen.
5) Delivery oil of P2 pump flows into swing and arm sections of P2 side, but it flows preferentially into swing
side because the operation pressure of arm cylinder is higher than swing side pressure.
6) On the other hand, as travel straight spool is shifted to travel straight position and P1 bypass cut spool is
cut, delivery oil of P1 pump flows into parallel circuit of P2 side and confluxes with swing circuit, and
swing priority is accelerated.
7) By this operation, delivery oil of P2 pump preferentially flows into swing side which pressure is lower than
arm.
However arm working speed keeps required speed because recirculation oil is used to arm cylinder, and
as P1 pump delivery oil confluxes with swing circuit, swing priority control is more available.
8) If arm in or swing operation are performed, command from mechatro controller to swing parking brake
solenoid valve (SV-1) is cut, and swing parking brake is released.
6
1.9 PRESSURE DRAINING (RELEASING) CONTROL (1) Pressure draining (releasing) control
1) Simultaneously the screen change switch and the buzzer stop switch of gauge cluster are kept pressed
for more than five seconds, the mechatro controller judges it as Pressure Releasing Control.
2) If the mechatro controller judges it pressure releasing control, the mechatro controller performs the
following regardless of input signals (From operation pilot valve, accel potentiometer, etc.):
a. Puts out a minimum tilting angle command to the pump proportional valve.
b. Puts out a command current for pressure releasing control revolution to the governor motor.
c. Puts out a command current for the pressure position switch to the travel straight proportional valve.
d. Puts out a standby command current to the P1 bypass cut valve and the P2 bypass cut proportional
valve.
3) A command current from the mechatro controller causes the following to occur:
a. The pump proportional valve puts out a secondary pilot pressure to the pump to minimize the tilting
angle of the pump.
b. The governor motor controls the engine revolution to a pressure releasing control revolution.
c. The travel straight proportional valve puts out a secondary pilot pressure to switch the travel straight
valve to the pressure releasing position.
d. The P1 bypass cut valve and the P2 bypass cut proportional valve put out a secondary pilot pressure
to hold the P1 bypass cut valve and the P2 bypass cut valve in their standby position.
4) The mechatro controller senses the output voltage of the high pressure sensor of the main pump, judges
it as pump pressure and displays “DRAINING HYD. PRESS” or “FAIL DRAIN HYD. PRESS” on the
gauge cluster.
5) Since the travel straight valve is in the pressure releasing position, the oil delivered by each pump is
unloaded to the tank passage.
If the operating levers are operated and the spools switched, the pressure remaining in the actuators may
be discharged.
7

(1)
Positive control

1.10 PUMP CONTROL (POSITIVE CONTROL & P Q CONTROL)
1) If any operation performed, the secondary pilot pressure switches the spools and is put into the low

pressure sensors.
2) The output voltage of the low pressure sensor is put into the mechatro controller which processes pilot
signals and puts out command current to the proportional valve of each pump according to the input
voltage.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
from the mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the
pump.
4) This causes the delivery rate according to a lever stroke to be supplied to the actuator, thus an operating
speed according to a lever stroke is achieved.
(2) P-Q control
1) The output voltage of the high pressure sensor attached to each pump piping is put into the mechatro
controller, which processes pilot signals and computes command current according to input voltage (load
pressure).
2) The lower of the command current computed by positive control and the command value (1) computed by
P-Q control is selected and put out to the proportional valve of each pump as a command current.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
of the mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the
hydraulic pressure.
4) This increases the load of the actuator, enabling the engine to keep running even if the pump is highly
loaded.

1.11 STANDBY FLOW CONSTANT CONTROL (1) Standby flow constant control
1) An engine rotation command put out of the accel potentiometer is put into the mechatro controller.
2) The mechatro controller processes pilot signals and puts out a command current to the proportional valve of

each pump so as to make the delivery rate of the pump constant when the engine speed is below an
intermediate rpm.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current of
the mechatro controller, changes the tilting angle of the pump till the engine speed arrives at an intermediate
rpm.
4) If the engine speed increases an intermediate rpm, command current from the mechatro controller become
constant, with the result that the delivery rate of each pump rises linearly as the engine speed increases.
5) The result is that the motion of the lever at the start of each operation becomes the same as that when a
standby flow is available. Also, if the engine revolution is increased, the operating feeling according to each
revolution is available.
9
1.12 FC MODE CONTROL (1) FC mode control
1) If the FC mode is selected by the work mode selector switch on the gauge cluster, FC mode signal is put
into the mechatro controller.
2) Upon receipt of the FC mode signal, the mechatro controller;
a. Judges it as FC mode.
b. Puts out a FC mode rpm command to the governor motor.
3) The governor motor controls the engine speed to a level that matches a command current from the
mechatro controller. During operation it puts out, to each proportional valve, a command current in the FC
mode according to the input voltage from the low pressure sensor.
10

2. MECHATRO CONTROLLER The functions displayed on the multidisplay are classified roughly into the following 7 types.
1. CPU error display Display the error of the mechatro controller, etc.
2.1 SUMMARY OF MECHATRO CONTROLLER 2. Self-diagnosis display Displays the failure of the I/O system of the mechatro controller such as
(OHFWURK\GUDXOLFFRQYHUVLRQLQIRUPDWLRQLVGLVSOD\HGRQWKHPXOWLGLVSOD\RIWKHJDXJHFOXVWHU+RZHYHUWKH the low and high pressure sensors, governor motor, proportional valve,
PHFKDWUR GLVSOD\ DQG WKH FXPXODWLYH HQJLQH RLO OXEULFDWLRQ WLPH PD\ EH FKDQJHG RYHU LI WKH VFUHHQ FKDQJH solenoid valve, etc. (30 items)
VZLWFKLVSUHVVHG 3. Service diagnosis display Displays the information output by the mechatro controller such as the
RIGHT HAND pressure sensor detection, proportional valve, solenoid valve, etc.
OPERATOR
CONTROL LEVER
(23 items)
4. Trouble history display Stores and displays the contents of the troubles detected through the
CIGARETTE LIGHTER mechatro self diagnosis.
5. Mechatro "A" adjustment display Displays it by procedure during the mechatro "A" adjustment.
PLUG 6. E/G oil supply cumulative (integrated) time Displays the E/G oil supply cumulative time and E/G speed (rpm) list.
(Opt.switch)
7. Warning displays When the machine is normal after self-diagnosis ( ) but the actual
operation fails, the occurence of any of the following items is indicated
AUTO ACCEL every time.

TRAVEL ALARM

ACCEL DIAL

STARTER SWITCH

CONFLUX / SINGLE
SELECT
FUSE BOX

MECHATRO
CONTROLLER SWING PARKING BRAKE RELEASE SWITCH Note 1. The buzzer sounds on display No. 2,3,5,6,7,10,32 and 33.
GAUGE CLUSTER Note 2. The buzzer does not stop by the buzzer stop switch, exept No.7 and 10.
KPSS WORK MODE RELEASE SWITCH
2.2 SELF DIAGNOSIS DISPLAY FUNCTION

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The work mode selector switch contains the following functions. GLVSOD\RIWKHJDXJHFOXVWHU5HJDUGLQJWKHFRQQHFWRUQXPEHUVDQGWKHSLQQXPEHUVUHIHUWRWKH&
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VXSSO\FXPXODWLYHWLPH
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INPUT
Buzzer stop switch contains the following functions SERIAL COMMUNICATION
3UHVVXUHVHQVRU
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SCREEN CHANGE MULTI DISPLAY LCD
SWITCH

(3) Self diagnosis Connector No.
No. Contents Display of monitor -Pin No. Wire No. Wire color

Indication item
Arm variable recirculation CN15㧙10 757 BrG
Connector No. 19 propo-valve fail CN15㧙11 758 YV
No. Contents Display of monitor -Pin No. Wire No. Wire color
Mechatro controller Pump P1 CN15㧙17 760 VR

1 20 pressure sensor fail CN15㧙18 759 BrG
fail
Pump P2 CN15㧙19 764 VW
2 ROM data fail CN14㧙25 600 R 21 pressure sensor fail CN15㧙20 763 GY
When the E/G Travel two-speed
speed is not in 22 solenoid valve fail CN15㧙21 702 LgB
3 Mechatro set error the range from
300rpm to 3000rpm
CN11㧙3 902 WV Swing parking
Boom raising 23 solenoid valve fail CN15㧙22 700 VR
4 CN11㧙2 502 LgY
pressure sensor fail CN11㧙1 952 BR
CN11㧙4 903 OB ATT boost pressure
Boom lowering 24 solenoid valve fail CN15㧙23 703 P
5 CN11㧙5 503 LO
pressure sensor fail
CN11㧙6 953 BrW CN15㧙1 851 G
CN11㧙9 904 OL Governor motor CN15㧙2 852 B
6 Arm in 25 current fail
CN11㧙8 504 PW CN15㧙15 853 R
pressure sensor fail CN11㧙7 954 BrY W
CN15㧙16 854
CN11㧙10 905 OW Governor motor
7 Arm out CN11㧙11 505 PL CN11㧙34 560 V
pressure sensor fail 26 starting point indexing
CN11㧙12 955 Gr fail
CN11㧙15 900 RB CN11㧙33 930 WR
Bucket digging
8
CN11㧙14 500 LgR 27 Accel potentio meter CN11㧙32 530 P
CN11㧙13 950 BrR fail CN11㧙31 970 BW
CN11㧙16 901 RL Gauge clusterψMechatro
9 Bucket dump CN11㧙17 501 LgW CN14㧙26 601 W
pressure sensor fail 28 controller communication CN14㧙27 602 B
CN11㧙18 951 BL failure
CN11㧙21 906 YB
10 Swing CN11㧙20 506 V 29 Battery relay fail CN15㧙24 805 WG
pressure sensor fail CN11㧙19 956 GrL
Travel right CN11㧙27 908 YL
12 CN11㧙26 508 VY Draining
pressure sensor fail 30 hyd. pressure ̆ ̆ ̆
CN11㧙25 958 BY
Travel left CN11㧙28 909 YR
13 CN11㧙29 509 Sb Fail drain
pressure sensor fail 31 hyd. pressure ̆ ̆ ̆
CN11㧙30 959 BG
Pump P1 CN12㧙3 941 YL
14 CN12㧙2 514 VY
pressure sensor fail CN12㧙1 964 BrB
Pump P2 CN12㧙4 915 YR
15 CN12㧙5 515 Sb
pressure sensor fail CN12㧙6 965 BrL
P1 bypass cut CN15㧙4 755 BP
16 propo-valve fail CN15㧙5 756 PW
P2 bypass cut CN15㧙6 751 BO

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

propo-valve fail CN15㧙9 754 GrB
12
2.3 SERVICE DIAGNOSIS No. DISPLAY REMARKS No. DISPLAY REMARKS
No.11 No.22
The result of the service diagnosis at the present time is displayed in 23 categories depending on the PRESS. SENSOR PROPO-VALVE
data output by the mechatro controller. B㧙5 BUCKET DIG Sensor voltage / D㧙3 S-TRAVEL Command current /
11 3.5V 23k Pressure converted value 22 COMP. 513mA 17k Pressure converted value
How to display B㧙6 BUCKET DUNP Sensor voltage / MEAS. 513mA 17k Feedback current /
1) Turn the starter key switch on, keeping the buzzer stop switch depressed. 3.5V 23k Pressure converted value Pressure converted value
2) The program version is displayed in the 1st item. No.12 No.23

PRESS. SENSOR PROPO-VALVE
B㧙7 SWING (R) Sensor voltage / D㧙6 A-RECIRCULAT Command current /
GAUGE CLUSTER B㧙8 SWING (L) Sensor voltage / MEAS. 538mA 18k Feedback current /
No.1 0V 0k Pressure converted value Pressure converted value
PROGRAM VERSION
No.13 No.24
VER 5.30 PRESS. SENSOR PROPO-VALVE
B㧙9 TRAVEL (R) Sensor voltage / E㧙1 P1 PUMP Command current /
Screen change switch Buzzer stop switch 13 3.5V 23k Pressure converted value 24 COMP. 750mA 30k Pressure converted value
Advances the screen Returns the screen B㧙10 TRAVEL (L) Sensor voltage / MEAS. 750mA 30k Feedback current /
3.5V 23k Pressure converted value POWER SHIFT 0mA Pressure converted value
3) By pressing the screen change switch, goes to No.2,No.3̖ in order.
No.14 No.25
4) By pressing the buzzer stop switch, returns from No.40, No.39̖ in order. PRESS. SENSOR PROPO-VALVE
5) Turn the starter switch off, and the display also goes off. C㧙1 PUMP P1 Sensor voltage / E㧙2 P2 PUMP Command current /
C㧙2 PUMP P2 Sensor voltage / MEAS. 750mA 30k Feedback current /
3.5V 23k Pressure converted value POWER SHIFT 0mA Pressure converted value
No.15 No.39
PRESS. SENSOR MECHATRO ADJT.
B㧙16 P1 OPT. Sensor voltage / CONT. SW TEST RUN/TEST indication
Service diagnosis display 15 3.5V 23k Pressure converted value 39 CONT. VOL 100% Inner trimmer
B㧙17 P2 OPT. Sensor voltage / PROG. SW OFF ON/OFF indication
No. DISPLAY REMARKS No. DISPLAY REMARKS 3.5V 23k Pressure converted value
No.1 No.6
PROGRAM VER SOL. VALVE No.20 No.40
VER 5.30 F㧙3 1/2-TRAVEL PROPO-VALVE RELEASE SW
1 Version indication 6 COMP. OFF ON/OFF indication
D㧙1 P1 BYPASS Command current / KPSS TEST
ON/OFF indication ON/OFF indication
MEAS. OFF
SWITCH OFF ON/OFF indication 20 COMP. 706mA 30k Pressure converted value 40 SWING BRAKE OFF ON/OFF indication
MEAS. 706mA 30k Feedback current /
Pressure converted value
No.2 No.7
E/G SET 2220 No load set rpm SOLENOID VALVE
MEAS 2220 Actual rpm F㧙1 POWER UP No.21
2 E/G PRS. LIVE LIVE/DEAD indication 7 COMP. OFF ON/OFF indication PROPO-VALVE
KPSS SW H H / S / FC indication MEAS. OFF ON/OFF indication D㧙2 P2 BYPASS Command current /
KEY SWITCH OFF ON/OFF indication 21 COMP. 706mA 30k Pressure converted value
MEAS. 706mA 30k Feedback current /
No.3 Pressure converted value
No.8
H㧙1 RELAY
ACCEL VOLT. 4.2V Potentio voltage I㧙2 BAT. RELAY
3 POS. 100% Voltage position 8 COMP. OFF ON/OFF indication
MOTOR STEP 256 No of motor steps MEAS. OFF ON/OFF indication
POS. 100% Step position KEY SWITCH OFF ON/OFF indication
No.4 No.9
GOVERNOR MOTOR PRESS. SENSOR
Note:
G㧙1 COIL A 0.9A A phase current B㧙1 BOOM RAISE Sensor voltage / Service diagnosis and trouble history can be displayed with the screen change switch and the buzzer stop
4 G㧙1 COIL B 1.0A B phase current 9 3.5V 23k Pressure converted value
G㧙2 LIMIT OFF ON/OFF indication B㧙2 BOOM LOWER Sensor voltage / switch. Note that the displays do not come out in some cases if the switches are pressed too quickly.
3.5V 23k Pressure converted value (This is not a fault.) Give one second or more before pressing next switch.
No.5 No.10
SOL. VALVE PRESS. SENSOR
F㧙2 SWING-BRAKE B㧙3 ARM OUT Sensor voltage /
5 COMP. OFF ON/OFF indication 10 3.5V 23k Pressure converted value
MEAS. OFF ON/OFF indication B㧙4 ARM IN Sensor voltage /
RELEASE SW OFF ON/OFF indication 3.5V 23k Pressure converted value
13
2.4 TROUBLE HISTORY DIAGNOSIS 4) To scroll the page, use the work mode selector 2.5 HOW TO CORRECT THE E/G OIL SUPPLY CUMULATIVE TIME
The error item detected by the self-diagnosis is switch and the buzzer stop switch. (1) LCD display
stored in the mechatro controller as a history and z Press the work mode selector switch, page up.

LCD display Operating procedure Buzzer sound
is displayed on the multidisplay. z Press the buzzer stop switch, page down.

Note :

(1) How to display All the error items are stored by hour meter, when
1) Turn the starter switch on. the hour meter is differed, press the work mode
O K 1515 RPM

2) Press the buzzer stop switch 5 times in selector switch and the buzzer stop switch, and
sequence for 10 seconds. displays all items and make sure that they are
Normal
(Example) right. 256Hr. have passed None
display after E/G oil was

CONTENTS DISPLAY

5) Turn the starter switch off, and the display is
No errors NO ERROR Supplementary explanation :
disappeared.
00025H If the screen change switch is pressed, the above three
Error detected in the B-1 BOOM RAISE (2) How to cancel the contents of the trouble screen may be changed over.
past D-1 P1 BYPASS CUT history
F-3 TRAVEL 1.2-SPEED 1) Display the trouble history mode.
2) Press the work mode selector switch and the
3) Transmits the error data (one or many) and buzzer stop switch for 10 seconds or more
hour meter to the gauge cluster. simultaneously.
z Hour meter and 3 error data are displayed 3) When the deletion is completed, the “NO
on the screen. ERROR” is displayed.
z If three error data or more exist, display the 4) Turn the starter switch off.
data three by three in order for every 5 (2) How to correct
seconds. Note : Proce-d
Operating procedure Display on multidisplay (Example)
All the stored items are erased. ure
(Normal)
It is impossible to erase data partially.
A Turn the starter switch “ON”. MONITOR
is displayed.
SYSTEM OK
E/G speed is displayed
B Press the gauge cluster screen change switch MONITOR Press once
once, and the E/G speed (rpm) is displayed. 2250RPM
(3) Contents of the trouble history SYSTEM OK
E/G speed is displayed
Symbol Display Symbol Display Press once more, and the engine oil supply 100Hr AFT
C Press once more
cumulative time screen is displayed. 2250RPM E/G OIL CH
A㧙1 ROM DATA FAILURE D㧙1 P1 BYPASS CUT
A Controller relation
A㧙2 MECHATRO SET ERROR Proportional valve D㧙2 P2 BYPASS CUT
D D㧙3 TRAVEL PRIORITY Press the screen change switch for 3 to 10
(Control valve) 100Hr AFT MONITOR
B㧙1 BOOM RAISING D㧙6 ARM VARIABLE D seconds and release the hand, it returns to 100Hr AFT
B㧙2 BOOM LOWERING RECIRCULATION
the correction mode. E/G OIL CH SYSTEM OK
E/G OIL CH
B㧙3 ARM OUT Portional valve E㧙1 PUMP P1 PORPO- VALV

E
B㧙4 ARM IN (Hydraulic pump) E㧙2 PUMP P2 PORPO- VALV
Low pressure Press the work mode selector switch, and the 100Hr AFT Cumulative time 101Hr AFT
B B㧙5 BUCKET DIGGING F㧙1 POWER UP E increases
sensor F Solenoid valve F㧙2 SWING PARKING cumulative time increases. (once 1Hr) E/G OIL CH E/G OIL CH
B㧙6 BUCKET DUMP
B㧙7 SWING RIGHT F㧙3 TRAVEL 1,2-SPEED
B㧙9 TRAVEL RIGHT G㧙1 STEP MOTOR F Press the buzzer stop switch, the cumulative 100Hr AFT The cumulative
time decreases
99Hr AFT
CURRENT-NG E/G OIL CH E/G OIL CH
B㧙10 TRAVEL LEFT G㧙2 STEP MOTOR S/PT. time decreases. (once 1Hr)
G E/G Accessory
ERROR
High pressure Press the gauge cluster screen change switch
C㧙1 PUMP P1 G㧙3 E/G REV. SENSOR (Normal)
C sensor
C㧙2 PUMP P1 H Potentio relation H㧙1 ACCELERATR once the correcting time is stored, and exits 99Hr AFT Complete the MONITOR
(Hydraulic pump) POTENTIO G E/G OIL CH correction SYSTEM OK
I㧙1 RECEIVE ERROR from the correction mode and OK symbol is
I
I㧙2 BAT. RELAY displayed to complete the correction.

MONITOR SYSTEM OK
Note :
Press the screen change switch once after the procedure D, and the condition is stored and the correction is
14
completed.
Connec- Pin Port In/out
tor No. No. name Specification put Signal level
Engine coolant high temp. LS
2.6 MECHATRO CONTROL EQUIPMENT 10 2 1 6 2 1 4 2 18 2 1 1 B8 High/Normal IN GND / OPEN Connec- Pin Port In/out
Engine oil pressure low LS tor No. No. name Specification put Signal level
16 2 B9 IN GND / OPEN
(1) C웎1 Mechatro controller Without/With
1 D7
Air filter clogged LS
1) Outside view 26 3 B10 IN GND / OPEN
Clogged/Normal 2 D7´
4 B11 Double single select SW. opt IN GND / OPEN
34 3 D8
5 B12 ATT boost pressure SW. IN GND / OPEN 4 D8´
27 22 18 16 28 22 6 B13 5 D9
CN11 CN12 CN13 CN14 7 B14 IN GND / OPEN 6 D9´
Fuel level thermistor
GROMMETFOR 13 2 18 2 1 11 12 2 1 8 B15 Low/Normal IN 670˖ /1140˖ 7 D10
ADJUST 9 B16 IN GND / OPEN 8 D10´
ROM REWRITE COUPLER CN16
10 B17 IN 24V / OPEN 9 D11
11 B18 E/G oil level SW. IN GND / OPEN 10 D11´
12 C1 Wiper motor (rise up) OUT +24V / OPEN 11 D12
26 14 16 9 13 Wiper motor (not rise 12 D12´

12 C2 OUT
CN15 CN16 CN17 ADJUSTMENT SWITCH up) 13 H1
CN14
14 C3 Wiper motor (rise up) OUT +24V / OPEN 14 H1´
22 15 B26 Heavy lift switch
15 C4 Washer motor relay Out/Stop OUT GND / OPEN
Connec- Pin Port In/out
tor No. No. name Specification put Signal level 16 C5 Front working light relay ON/OFF OUT GND / OPEN 16 C22
1 G 17 C6 IN GND / OPEN 1 C15 OUT GND / OPEN
2 A12 P1 pump pressure sensor IN 0.5윟4.5V 18 +5V 2 C16 OUT GND / OPEN
2) List of connectors
3 +5V 19 B19 3 C17 OUT GND / OPEN
Connec- Pin Port In/out 4 +5V 20 C7 4 C18 OUT GND / OPEN
tor No. No. name Specification put Signal level
5 A13 P2 pump pressure sensor IN 0.5윟4.5V 21 C8 5 C19
1 G 6 G 22 C9 6 C20 Travel alarm relay OUT GND / OPEN
2 A1 Boom raise pressure sensor IN 0.5윟4.5V 23 C10 7 C21 Power window controller OUT GND / OPEN
7 G
3 +5V 8 A14 Opt. 2 pressure sensor IN 0.5윟4.5V 24 G 8 B20 Auto decel releasing switch IN GND / OPEN
4 +5V 9 +5V 25 TXD1 IN/OUT 9 B21 OUT GND / OPEN
Boom lower pressure
5 A2 sensor IN 0.5윟4.5V 10 +5V 26 RXD1 Gauge cluster IN/OUT 10 B22 E/G coolant level switch IN GND / OPEN
6 G 11 A15 27 G 11 B23
7 G CN17
CN12 12 G 28 SHG Shield ground 12 B24 Hyd. fluid level switch IN GND / OPEN
8 A3 Arm in pressure senor IN 0.5윟4.5V 13 B25 IN GND / OPEN
13 A16 Alternator voltage IN 0윟36V 1 F1 OUT Swing flasher select switch
9 +5V Governor motor A phase
14 A17 Over load switch IN OPEN / GND 2 F1´ OUT 14 TXD2
10 +5V 15 B2 Key switch(ON) ON/OFF IN +24V / OPEN 3 SHG Shield ground 15 RXD2 Satellite system
11 A4 Arm out pressure sensor IN 0.5윟4.5V 16 G
16 B3 Key switch(GLOW) ON/OFF IN +24V / OPEN 4 D1 P1 bypass cut OUT 0윟800mA
12 G 17 B4 Travel 1.2 speed switch ON/OFF IN GND / OPEN 5 D1´ proportional valve D OUT 0윟800mA 17 SHG
13 G Swing parking release switch
6 D2 OUT 0윟800mA 18 +5V
Bucket digging pressure 18 B5 Release/Normal IN 17˖ / OPEN P2 bypass cut
14 A5 IN 0.5윟4.5V
sensor KPSS rerease switch 7 D2´ proportional valve B OUT 0윟800mA 19 A23 IN 0.5윟4.5V
15 +5V 19 B6 Release/Normal IN 윟12V / 12V윟
8 D3 Travel straight OUT 0윟800mA 20 A24 IN 0.5윟4.5V
16 +5V 20 E1 IN 3.0윟20Vp-p proportional valve C
Bucket extend pressure Engine revolution sensor 9 D3´ OUT 0윟800mA 21 A25
17 A6 IN 0.5윟4.5V 21 E1´ 22 G
sensor 10 D4 Arm variable recirculation OUT 0윟800mA
CN11
18 G 22 SHG Shield ground proportional valve A
11 D4´ OUT 0윟800mA 1 DL IN/OUT
19 G 1 G 2 TXD3
12 +24V IN/OUT
20 A7 Swing pressure sensor IN 0.5윟4.5V 2 A18 Opt. 1 Pressure sensor IN 0.5윟4.5V Power supply + 24V CN18 Handy checker
13 +24V 3 RXD3 IN/OUT
21 +5V 3 +5V CN15 4 G
14 +24V Battery back up
22 +5V 4 +5V
15 F2
23 A8 5 A19 Governor motor B phase
16 F2´
24 G 6 G
17 D5 P1 pump proportional OUT 0윟800mA
25 G 7 G
18 D5´ valve OUT 0윟800mA
26 A9 Travel right pressure sensor IN 0.5윟4.5V 8 A20 IN 0.5윟4.5V
CN13 19 D6 P2 pump proportional OUT 0윟800mA
27 +5V 9 +5V
20 D6´ valve OUT 0윟800mA
28 +5V 10 +5V Travel 1,2-speed selector valve
21 C11 2 speed/1 speed OUT +24V / OPEN
29 A10 Travel left pressure sensor IN 0.5윟4.5V 11 A21 IN 0.5윟4.5V
Swing parking selector valve
30 G 12 G 22 C12 ေ ,P /Release OUT +24V / OPEN
ATT boost pressure solenoid
31 G 13 G 23 C13 valve OUT +24V / OPEN
32 A11 Accel potentio IN 0윟5.0V 14 A22 24 C14 Battery relay Operation/Stop OUT +24V / OPEN
33 +5V 15 +5V 25 G
Accel motor starting point indexing Power supply (GND)
34 B1 IN GND / OPEN 16 B7 IN GND / OPEN 26 G 15
LS starting Point/Reguler
(2) Gauge cluster (symbol C-2) (3) Governor motor(Symbol M웎2)
1) General view NAME PLATE
Gauge and
Display lamp
Multi display LCD MATED SIDE

(Liquid crystal display) AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
Screen change VIEW ൩
switch etc.
2) Connector
MOTOR CONNECTOR
No. Item name No. Item name LIMIT SWITCH CONNECTOR
1 Fuel sensor 5 GND CONNECTION DIAGRAM
2 Engine coolant temp. sensor 6 Sourse (+24V) BROWN RED
LIMIT SWITCH MOTION RANGE
3 RXD (Serial communication) 7 GND (A) (B)
4 TXD (Serial communication) 8 (None)

ORANGE YELLOW
( (
3) Function LIMIT SWITCH CONNECTOR WIRE TABLE MOTOR CONNECTOR WIRE TABLE
ແ It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer. 6 No. Wire color Connection 1 2 No. Wire color Connection
ໂ It puts out coolant temperature signals, fuel level signals and panel switch signals to the mechatro 5 White COM 1 Brown A
웎
6 Red NO 2 Orange A
controller through the communication port.
5 7 Yellow NC 3 Red B
ໃ Screen Change SW: Scroll forward (See Page 10.), and displays of the E/G revolution and the cumulative 웎
7 4 Yellow B
hours after changing engine oil (See Page 13.).
ໄ Other functions 3 4
x MODE SW. : The display changes S, H, FC, S, in that order each time the switch is pressed.
After the key is turned OFF, the display begins with ‘S’.
x Adjusting the engine : Perform mechatronic "A" adjustment in a conventional way, using the
Buzzer Stop SW.
(See the Maintenance)
x Service diagnosis : This is displayed if the key is turned ON with the Buzzer Stop SW pressed.
x Trouble history : Turn ON the key and press the Buzzer Stop SW five times
continuously in ten seconds. (See Page 14.)
x Pressure release control : Press both the Screen Change SW and the Buzzer Stop SW. at the same
time and hold it for more than five seconds. (See Page 7.)
16
E235SR
SECTION 22 HYDRAULIC SYSTEM
TABLE OF CONTENTS
1. SUMMARY ................................................................................................................ 1
2. HYDRAULIC CIRCUITS AND COMPONENT

2.1 Std ........................................................................................................................................ 2
2.2 Boom & Arm Safety Spec. ................................................................................................... 8
2.3 N & B Spec. .......................................................................................................................... 9
2.4 Dozer Spec. ........................................................................................................................ 10
2.5 Extra Spec. ......................................................................................................................... 11
3. COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS ................................ 12
4. NEUTRAL CIRCUIT ................................................................................................ 12
5. TRAVEL CIRCUIT ................................................................................................... 14
6. BUCKET CIRCUIT .................................................................................................. 16
7. BOOM CIRCUIT ...................................................................................................... 18
8. SWING CIRCUIT ..................................................................................................... 22
9. ARM CIRCUIT ......................................................................................................... 24
10. COMBINED CIRCUIT ............................................................................................ 30
11. PRESSURE DRAINING CIRCUIT ......................................................................... 36
12. HYDRAULIC LINES .............................................................................................. 39

1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy
operability, safety, mass volume handling and low fuel consumption.
Table 1
Perfor-
mance Device Function Features
z Travel straight z Travel straight at combined operation.
z Travel 2 speed chang & Auto 1st (low) z 2 speed changeover of travel speed.
speed return
z Auto parking brake Automatic braking when parking.
Travel
z
z Motor overrun protection z Prevents overrunning of travel motor
on
z Travel pilot operation the slope.
z Prevents hunting by the built in travel
shockless mechanism.
z Reverse rotation protective function z Easy positioning to protect it from
(Swing shockless function) swinging back when stops swinging.
Easy operability and safety
Swing
z Swing priority circuit z Easy operation of stable swing speed,

(simultaneous operation of arm arm slanted leveling, swing press
in and swing motions) digging.
z Automatic swing parking brake z Protect it from swing drift on the slope.
z Hydraulic pilot control system z Delicate operability.
Attachment
z Pilot safety lock system z Cut out of pilot circuit by safety lock
lever
z Lock valve (boom / arm) z Prevention of natural fail
z Pressurized hydraulic oil tank z To prevent hydraulic oil from being

contaminated and to promote self
suction ability of pump.
z Suction strainer z Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from
Others
z z
malfunctioning.
z Return circuit z To prevent hydraulic oil from fouling
z Cooling hydraulic oil by oil cooler z To prevent hydraulic oil from being
deteriorated.
z Pressure drain (release) circuit z To release the main circuit pressure
for piping repair work.
z Variable displacement pump of electric z Pump delivery rate control by a current
Mass handling capability
flow control type command to the solenoid proportional

Pump
valve of the variable displacement

pump
z Boom raise conflux circuit z Speed up of boom raise operation.

Attachment
z Arm conflux circuit z Speed up of arm operation.

z ATT. boost (or heavy lift) circuit z Temporary power boost.
z Auto accel z Reduce fuel consumption and noise by

consumption
Micro computer
lowering engine speed when control

lever is in neutral position.
Low fuel
1
2.1A HYDRAULIC CIRCUITS AND COMPONENTS
STD. SPEC.
No. PART NAME MODEL No.
1 HYD. PUMP ASSY K3V1120P
2 CONTROL VALVE (MAIN) KMX15YC
3 SWING MOTOR UNIT MFC160
4 TRAVEL MOTOR UNIT MAG䋭170VP
5 BOOM CYL. (RH) 125䋭85䋭1320
6 BOOM CYL. (LH) 125䋭85䋭1320
7 ARM CYL. 135䋭95䋭1490
8 BUCKET CYL. 120䋭80䋭1080
9 SWIVEL JOINT
10 PILOT VALVE (ATT)
11 PILOT VALVE (TRAVEL)
13 INLINE FILTER DT03950A
14 SUCTION STRAINER Y䋭501400
15 SOLENOID VALVE ASSY 8KWE5G䋭30/G24WR䋭816
17 RETURN FILTER
18 AIR BREATHER AB020GA001A
19 CHECK VALVE (BOOST) LV10䋭25T
20 CHECK VALVE (BYPASS) LV10䋭50T
21 RESTRICTOR 07745䋭00000
22 RESTRICTOR 07579䋭00000
23 RESTRICTOR
24 CONTROL VALVE KADV28Y
2
STD. Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
RIGHT Tin Pm1 Pm2 Ps LEFT
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
MAIN CONTROL VALVE P2 P1 T T2 SWING LEFT
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
PL1 CMR2 BUCKET DUMP BOOM UP
PTb PBL BUCKET DIGGING
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN
TRAVEL PRIORITY CT2 BL

CP2
14 Drb LCs
PBs
SE1 SE2 SE3 SE4 SE7 SE8
HYD. TANK P P P P P P
PBr TRAVEL RIGHT PBs2
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
BUCKET LCc CONFLUENCE
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Bc Ԛ ԛ ԙ Ԙ Ԟ ԟ ԝ Ԝ
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PLc1 BOOM H CYLINDER
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
39.7MPA CAr CRa 37.7MPa
Ba
ARM R
CYLINDER
7
TRAVEL
39.7MPa X1 PILOT VALVE P T
ARM
CONFLUENCE R
6
PCb Pis
H
P1
SOL/V BLOCK P2 BY-PASS CUT ARM VARIABLE
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
LEVER LEFT TRAVEL FORWARD P SE9 P SE10
4 LOCK (P4) (TB) PBo2 LEFT TRAVEL REVERSE
TRAVEL P2 OPTION
STRAIGHT C TRAVEL PAo2 RIGHT TRAVEL FORWARD
1/2SPEED RIGHT TRAVEL REVERSE
P2
BY-PASS
3 CHANGEOVER 24 37.7MPa
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
RECIRCULATION 2 BOOSTING CONVERSION TABLE
A (P3)
MPa Kgf/cm psi MPa Kgf/cm psi

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
3
BREAKER SCHEMATIC HYD.LINES E235SR(LC), NLC
2.2 BOOM & ARM SAFETY ITEM NAME REMARKS
40 HOLDING VALVE (BOOM RH) KHCV20P082/405
41 HOLDING VALVE (BOOM LH) KHCV20P072/405
42 HOLDING VALVE (ARM) KHCV25P0
MAIN PUMP P2 P1
NOTE: This hydraulic circuit is used to add to following circuit.
REMARKS
M STD
HYD. TANK LCb

PBb LCa
ARM PBa
BOOM
400kgf/cm
2
PAb PAa
(5700psi) ARM CYLINDER
Bb Aa H
CRb CRa
B1 B
Ab Ba C
A
Dr 42
PL
400kgf/cm
2
(5700psi)
B1
39.4MPa BOOM CYLINDER(L.H)
C B
A
R
41
Dr
PL
PL
Dr
40
R
A
C B
BOOM CYLINDER(R.H)
B1
400kgf/cm
2
(5700psi)
4
2.3 N & B
N & B SCHEMATIC HYD. LINES E235SR(LC), NLC
ITEM NAME REMARKS
23 CONTROL VALVE (P2 OPT.)
51 SELECTOR VALVE
52 STOP VALVE
53 PILOT VALVE
NOTE:
1.MARK OF SELECTOR VALVE (ITEM 51)
N : NIBBLER
B : BREAKER
WHEN USING BREAKER, SET B SELECT VALVE(ITEM 51) TO RETURN TO HYDRAULIC TANK DIRECTLY HYDRAULIC OIL FROM
BREAKER.
2.SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR
BREAKER IS SERVISE.
P2 P1 T
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W:, W/O: )˴
CONFLUENCE/SINGLE FLOW MARK OF P1 P2 TRAVEL P1 BY-PASS P2 BY-PASS
PTb CHANGEOVER SWITCH SELECTOR VALVE (ITEM 51) PUMP PUMP STRAIGHT CUT CUT
CONFLUENCE FLOW OF NIBBLER CONFLUENCE "ON" N
SINGLE FLOW OF NIBBLER CONFLUENCE "OFF" N
M BREAKER CONFLUENCE "OFF" B
WHEN USING NIBBLER,ACCORDING TO SPECIFICATION OF NIBBLER INSTALLED,

MAIN PUMP CHOOSE CONFLUENCE OR SINGLE FLOW BY CONFLUENCE FLOW CHANGEOVER SWITCH.
3. ADJUST OVERLOAD RELIEF VALVE OF OPT. PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.
4. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO FOLLOWING CIRCUIT.
NOTE 1
52
B N NIBBLER
HYD. TANK
51 BREAKER
53
NIBBLER & BREAKER
PILOT VALVE
PCb
T
P
SOL/V BLOCK PCa
P1 T
B C1 C2 A
P
LEVER (P4) TB PBo2 SE-11
A1 LOCK
PAo2
Ao2
23 Bo2
(P3)
NOTE 4 250kgf/cm
2
(3600psi)
5
2.4 DOZER
63 64
HYDRAULIC COMPONENT SPEC. E235SR(LC), NLC

60 ITEM PART NAME MODEL NO.
60 HYD. PUMP ASSY SGP2A36F1H1-R

61 CONTROL VALVE KVS-65-1
M 62
D
H
C
B
E
A
F
62 SWIVEL JOINT
63 DOZER CYLINDER(LH) CA140200B28G
64 DOZER CYLINDER(RH) CA140200B28G
UP
DOWN
NOTE: 1. Thishydraulic circuit is used to add to following circuit.
REMARKS
STD.
HYD. TANK
2. Replace the pump assy & swivel joint to optional type.
61
DOZER
VALVE
A1 B1 280kgf/cm2(3700psi)
280kgf/cm2
(3700psi)
250kgf/cm2
(3600psi) P T
GAUGE
6
2.5 EXTRA
60
HYDRAULIC COMPONENT SPEC. E235SR(LC), NLC
ITEM PART NAME MODEL NO.
M P2 P1
60 GEAR PUMP SGP2A36F1H1-R383
71 PILOT VALVE 180AI-00000
72 CONTROL VALVE KVS-65-1
73 HYD VALVE ASSY
74 SOLENOID VALVE
TO EXTRA HYD.
72
EXTRA
VALVE
A1 B1
22.6MPa NOTE:This hydraulic circuit is used to add to following circuit.

PB1 PA1
20.6MPa
REMARKS
HYD. TANK STD.
P T
SE-24
P
GAUGE
A
73
B
T
74 71
A
PILOT VALVE
P T T
P
B A
SOL/V BLOCK
LEVER
4 LOCK
P T
7
4. NEUTRAL CIRCUIT
3. COLOR CODING STANDARD This section describes the following. The servo piston and the sleeve are linked 4.3 P-Q CONTROL
1) Safety lock lever and pilot circuit together by the feedback lever (611). A pin is 1) The voltage output by high pressure sensor
FOR HYDRAULIC CIRCUITS
2) Pump control provided at point "A" of the feedback lever. installed on the pump circuit inputs to
3) P-Q control Since the feedback lever turns on the mechatro controller and the mechatro
Blue ................... Feed, drain, tank circuit fulcrum, the servo piston and the sleeve (651) controller processes signal and selects lower
less than 2.5kgf/cm2 (36psi) 4.1 SAFETY LOCK LEVER AND PILOT CIRCUIT move in the opposite directions and stop priority one comparing it with operation
Green ................ Return, make up circuit, Purpose : where the spool-sleeve opening is closed. exponent value computed through the
Negative control circuit To protect attachment from unexpected positive control on the basis of voltage output
2.5㨪6kgf/cm2 (36㨪71psi) ELECTRIC by low pressure sensor, and outputs the
operation for safety. PROPORTIONAL
Purple ............... Secondary pilot pressure, Principle : REDUCING VALVE REGULATOR command value to the pump proportional
6㨪51kgf/cm2 (85㨪730psi) Cut pressure source of pilot valve for valve.
Red .................... Primary pilot pressure, operation. 2) With this, P-Q control is executed, enabling
35㨪51kgf/cm2 (500㨪730psi) Operation : machines to carry out the work without
Orange .............. Main pump drive pressure, After engine starts, push down the safety lock engine power down.
646
50㨪350kgf/cm2 (710㨪4980psi) lever (red), and the limit switch (SW-11) is
When power boosting turned on, and the pilot operation circuit is 652
385kgf/cm2 (5470psi) changed to standby condition by the action of
611
Blue tone .......... At valve operation SOL (SV-4) of solenoid valve block (15).
Red valve .......... At solenoid proportional valve ǩ MAIN
(reducing) is operating. 4.2 PUMP CONTROL PUMP
Red solenoid ..... In active and exciting Type :
Displaying the flow circuit and standby circuit 643
Variable displacement pump of electric flow
when operating. control type.
Regarding the electrical symbols in this manual, Principle : 651
C PORT 532 A POINT
refer to the electric circuit diagram. Controls the tilting angle of the pump
(delivery rate) by changing the command Regulator hydraulic diagram
current I to the solenoid proportional
reducing valve. 2) Flow reducing action
Operation : If the command current I of the mechatro
1) Flow increase function (for example; P1 controller decreases, the secondary pressure
pump): of the solenoid proportional valve decreases.
This is a positive control type that increases This causes the pilot spring (646) to move the
the command current I of the mechatro spool (652) to the left. If the spool is shifted,
controller. If each attachment, the swing and the discharge pressure P1 is flowed to the
travel is operated, the secondary pilot larger diameter chamber of the servo piston
operating pressure is put in each low by way of the spool.
pressure sensor. The output voltage of the The discharge pressure P1 is there at the
low pressure sensor is put into the mechatro smaller diameter of the servo piston at all
controller. The mechatro controller processes times, but because of the difference in the
pilot signals and put out a current command area causes the servo piston to move to the
according to the input voltage. If the right and to decrease the tilting angle. If the
secondary pressure of the solenoid servo piston moves to the right the same way
proportional valve increases, the spool (652) as above, the sleeve moves to the left by the
is pushed to the right via the pilot piston feedback lever, till the opening of the
(643) and stops where it balances the action spool-sleeve is closed.
of the pilot spring (646). Regarding the detail of the pump functions,
The larger diameter of the servo piston (532) refer to the Component system I-1.
opens to the tank port, moves to the left by
the discharge pressure P1 of the smaller
8 diameter of it and increases the tilting angle
(ǩ).
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
39.7MPA CAr CRa 37.7MPa Ba
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
NEUTRAL CIRCUIT : SAFETY LOCK LEVER ON 9

5. TRAVEL CIRCUIT
This section describes the following. pressure.
1) Travel forward pilot simultaneous operation Provided if the main circuit pressure exceeds
circuit 280kgf/cm2 (3980psi), the self pressure
2) 2 speed travel solenoid command circuit and pushes back the 2 speed select piston to select
auto 1st.-speed return function 1st speed.
3) Travel main circuit
4) Travel motor function 5.3 TRAVEL MAIN CIRCUIT
Operation :
5.1 TRAVEL FORWARD PILOT SIMULTANEOUS If the travel spool is changed by the travel
OPERATION CIRCUIT pilot action, the oil discharged from port A2,
Purpose : A1 of the main pump enters ports Ar, AL of
Light operating force and shockless operation the travel motor (4) by way of the VB, VA
Operation : port of C/V and the D, C ports of the swivel
1) If the travel lever with damping mechanism joint (9) and performs the following functions
is operated for travel right, left and forward in the travel motor.
motions, the secondary pilot proportional (Refer to the travel motor functions.)
pressure comes out of the 2, 4 ports of P/V
(11). The higher of the pressures is selected, 5.4 TRAVEL MOTOR FUNCTION
comes out of the 5, 6 ports and acts upon the Function :
low pressure sensors (SE-9), (SE-10). 1) Prevents overrunning of travel motor on
2) Pilot secondary pressure flows into PAr, PAl down hill slope.
ports of control valve (2), acts on travel spool, 2) Hydraulic motor cavitation protective check
and switches main circuit. valve.
3) The output voltage of the low pressure sensor 3) Shockless relief valve and anticavitation
is put into the mechatro controller. The valve when stopping it with the force of
mechatro controller processes signals and inertia.
puts out a flow increase current to the P1 4) High / Low 2 step change mechanism and
pump proportional valve (PSV-1) and the P2 auto 1st speed return at high load.
pump proportional valve (PSV-2). 5) Travel parking brake.
5.2 2 SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION
Purpose :
Change travel motor speed with switch.
Principle :
If the switch is turned, an electric signal is
issued. It excites the 2-speed travel solenoid
which in turn converts the primary pilot
pressure and the self pressure to a tilting
angle of the variable displacement motor.
Operation :
Press switches with rabbit and turtle marks
on travel lever grips, and the solenoid (SV-3)
of proportional valve block (15) is excited and
is switched, and solenoid command is output
by port 3 and sends to P port of travel motor
(4), opens oil passage to 2 speed piton, and
10
switches it to 2 speed tiling rotation with self
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 10
PAc
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
TRAVEL CIRCUIT : TRAVEL 2ND SPEED OPERATION 11

6. BUCKET CIRCUIT
This section describes the following. engine revolution back to the accel dial
1) Bucket digging pilot circuit setting according to the lever strokes.
2) ATT. boost pilot circuit
3) Auto accel operation 6.4 CONSTANT FLOW CONTROL FOR STANDBY
4) Constant flow control for standby Principle :
5) Bucket digging main circuit At pressures below the intermediate
revolution between the decel and the FC
6.1 BUCKET DIGGING PILOT CIRCUIT mode, a command current is put out so as to
Operation : make the delivery rate of the pump constant.
1) If bucket digging action is performed, the Operation:
secondary pilot pressure comes out of port 1 Even if the engine revolution of the accel
of the right pilot valve (10), enters port PBc of potentiometer is set in Lo rpm, the pump
C/V (2) and acts upon the low pressure sensor delivers a discharge rate equal to the
(SE-1). At the same time, the pressure intermediate revolution between the above
changes the bucket spool. decel and the FC mode. For this reason, the
2) The output voltage of the low pressure sensor actuator operates faster than the moving of
is put into the mechatro controller. The the operating lever when load is light.
controller processes signals and puts out a
command current for pump flow increase to 6.5 BUCKET DIGGING MAIN CIRCUIT
the solenoid proportional valve (PSV-1) on Operation :
the P1 pump. The relation between the low 1) With pilot operation, the pressure oil
pressure sensor and the pump flow increase switches bucket spool, and is fed into bucket
is the same as above; the explanation of it is cylinder H side through C/V (2) BC port. And
deleted hereafter. the return oil from cylinder R side flows into
tank circuit while being restricted by bucket
6.2 ATT. PRESSURE BOOST PILOT CIRCUIT spool through C/V (2) AC port.
1) By turning ATT. pressure boost SW. on, ATT. 2) When ATT. pressure boost SW. is ON, the
pressure boost SOL. (SV-2) on solenoid block power is produced instantly with a 10%
(15) is excited, and pilot primary pressure is increase in pressure from two-stage main
delivered through port 2 and is led to PL1 relief valve.
port of C/V (2). Consequently the pressure
from two-stage main relief valve rises 10%.
6.3 AUTO ACCEL OPERATION

Principle :
Start operating with signal output by low
pressure sensor.
Operation : <Lever in neutral position>
When the signal is not input to low pressure
sensor for 4 seconds or more after turning
accel dial to Max. position, become engine
speed to 1050rpm automatically.
<Lever in operation position>
If a pressure signal of 5.7kgf/cm2 (81psi) 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
12
enters the mechatro controller and brings the
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
BUCKET CIRCUIT : BUCKET DIGGING OPERATION AT ATT BOOSTING 13

7. BOOM CIRCUIT
This section describes the boom up conflux 3) Meanwhile, the oil delivered from the A2 port
operation. of the P2 pump enters the P2 port of C/V (2)
1) Boom up pilot circuit and is branched to the bypass circuit and the
2) Boom up 2 pumps conflux main circuit in C/V parallel circuit. If the P2 bypass cut valve is
changed over, the center bypass circuit is
7.1 BOOM UP PILOT CIRCUIT closed. The oil then passes through the
Operation : parallel circuit and via the restrictor on the
1) If the boom up action is performed, the circumference of the boom conflux spool,
secondary pilot pressure from the right pilot pushes the load check valve CCb open from
valve (10) comes out of port 3 and acts upon the boom conflux circuit, and combines the oil
the low pressure sensor (SE-3). At the same delivered by the P1 pump internally.
time, the pressure acts upon the PAb port 4) The return oil from boom cylinder R side
and the PB1 port of C/V (2). flows into tank circuit through boom spool
2) The voltage output by low pressure sensor is from C/V (2) Bb port.
processed by mechatro controller and outputs
command current to P2 bypass cut valve
(PSV-B) and solenoid valve outputs
proportional secondary pressure and the
pressure acts on C/V (2) PCa port.
3) Then, the secondary pressure fed into C/V (2)
PAb port switches boom conflux spool. And
the solenoid proportional secondary pressure
fed into PCa port switches P2 bypass cut
valve.
7.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
Purpose : Boom up speed up
Principle : Confluxing oil from 2 pumps
Operation :
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. However
since the boom spool is moved and bypass
circuit is closed, the oil opens load check
valve through parallel circuit and flows into
boom spool.
2) Then the oil passes through boom spool,
opens lock valve of boom lock valve, and is led
into H side of boom cylinder through C/V (2)
Ab port.
14
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
BOOM CIRCUIT : BOOM UP OPERATION, CONFLUX FUNCTION 15

This section describes boom lower operation. 7.5 FIXED RECIRCULATION FUNCTION OF
1) Boom down pilot circuit BOOM LOWER MAIN CIRCUIT
2) Prevention of natural fall by lock valve and Purpose :
actuation at down Prevention of cavitation during boom down
3) Fixed recirculation function of boom down motion.
main circuit Principle:
The oil returning from the boom cylinder
7.3 BOOM DOWN PILOT CIRCUIT head (H) is recirculated to the rod (R).
Operation : Operation :
1) Start boom down operation, and the pilot When the oil is supplied to the boom cylinder
secondary pressure is output through port 4 rod (R) side during boom lower operation, the
of pilot valve (10), and acts on low pressure boom moves faster than it should do in some
sensor (SE4), at the same time branches into cases by the self weight of the attachment.
two circuits, then acts C/V (2) PBb and PLC1 On that occasion, the circuit pressure on the
ports. rod (R) side is on the negative side. The oil
2) The voltage output by low pressure sensor supplied to the boom cylinder rod (R) flows
(SE-4) is input into mechatro controller. into the A1 port of the P1 pump and the P1
3) Then, the secondary pressure fed into C/V (2) port of C/V. The oil then passes through the
PBb port switches boom spool. And the boom spool and goes out of the Bb port. On
secondary pressure flowed into C/V (2) PLC1 that occasion, the oil returning from the head
port releases boom lock valve. (H) goes through the recirculation path in the
boom spool, pushes the check valve in the
7.4 PREVENTION OF NATURAL FALL BY LOCK spool open, is recirculated to the Bb port and
VALVE AND ACTUATION AT DOWN is supplied to the rod (R). When the (R)
Purpose : pressure is larger than the (H) pressure, the
Prevention of natural fall when the lever is check valve closes. Thereupon, the
neutral recirculation is stopped.
Principle :
The oil is prevented from returning to the
boom spool by the poppet seat of the boom
lock valve.
Operation :
During the boom lowering, the boom spool
shifts to change the selector valve of the lock
valve located at the end of the spool. Then the
poppet spring chamber CRb of the lock valve
connects with the drain line (Drc), with the
result that the lock valve poppet is moved to
an open state. When the boom spool is
neutral, the drain line on the lock valve
poppet spring chamber side is closed. Since
the poppet is closed, the oil returning to the
boom spool from the boom cylinder head (H)
is held. This prevents oil leaks from the boom
spool, thereby preventing the boom cylinder
from making a natural fall.
16
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
BOOM CIRCUIT : BOOM DOWN OPERATION 17

8. SWING CIRCUIT
This section describes the following operations. 3) The swing parking solenoid (SV-1) is excited
1) Swing left pilot circuit five seconds after the pressure of the swing
2) Swing auto parking brake low pressure sensors (SE-5) is reduced to
3) Swing main circuit zero.
4) Swing motor function In the case of arm digging operation, the
swing parking solenoid (SV-1) is excited the
8.1 SWING LEFT PILOT CIRCUIT moment the pressure of the arm digging low
Operation : pressure sensor (SE-7) is reduced to zero.
1) If the swing left action is performed, the This causes the mechanical brake to operate.
secondary pilot pressure goes out of port 5 of
left pilot valve (10) and acts upon the PBS 8.3 SWING MAIN CIRCUIT
port of C/V (2). At the same time, Operation :
high-pressure selection is carried out, and the The delivery oil through A2 port of P2 pump
pressure acts upon the low pressure sensor flows into P2 port of the C/V (2) and is
(SE-5). branched into the bypass circuit and parallel
2) The low pressure sensor output voltage circuit, but the bypass circuit is closed with
enters in the mechatro controller, and after the movement of the slewing spool, the
signal processing the mechatro controller pressure opens load check valve CP2, LCS
outputs the command current to P2 bypass through the parallel circuit, flows into A port
cut solenoid proportional valve (PSV-B), and of the slewing motor through BS port of the
the proportionl valve secondary pressure is C/V (2) and rotates the slewing motor
discharged from this the solenoid valve and counterclockwise. However, when starting
acts on PCa port of the C/V (2). slewing operation, the confluxed oil flows out
3) Then, the secondary pressure entered into in the tank circuit through P2 bypass cut
PBS port of the C/V (2) switches the slewing valve from the bleed off passage of the
spool. And the solenoid proportionl valve slewing spool. The P2 bypass cut valve closes
secondary pressure entered in PCa port in late and consequently the slewing hunting
switches the P2 bypass cut valve together due to the control of the slewing flow rate is
with the slewing conflux valve. prevented.
8.2 SWING AUTO PARKING BRAKE 8.4 SWING MOTOR FUNCTION

Purpose : 1) Anticavitation circuit when reducing swing
Swing lock and parking in neutral position speed.
Principle: 2) Shockless relief to protect it from reverse
Release mechanical brake only when required rotation.
to operate
Operation :
1) The swing parking function operates usually
when the key switch is ON, and swing
parking brake SOL. (SV-1) is energized, and
the mechanical brake is actuated.
2) The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing
and arm digging actions acts upon any of the
low pressure sensors (SE-5,7).
18
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
SWING CIRCUIT : SWING LEFT OPERATION 19

9. ARM CIRCUIT
This section describes the following operations. 9.2 ARM IN, LIGHT-DUTY VARIABLE NORMAL
1) Arm in, light-duty operating pilot circuit RECIRCULATION MAIN CIRCUIT
2) Arm in, light-duty variable normal Operation :
recirculation main circuit 1) The oil returning from the arm cylinder (R)
side opens the arm lock valve CRb and flows
9.1 ARM IN, LIGHT-DUTY OPERATING PILOT into the arm variable recirculation spool
CIRCUIT through the arm spool.
Purpose : 2) Since the passage to the tank is blocked by the
Speed-up and Anticavitation when the arm is arm variable recirculation spool, the oil
at light duty. returning from the arm cylinder (R) side
Principle : flows into the load check valve CAr.
The oil returning from the arm cylinder rod 3) Since the R side pressure of the cylinder is
(R) side is recirculated to the cylinder head higher than the H side pressure of it when
(H) in C/V. working load is light, the pressure pushes the
Operation : load check valve open and is recirculated to
1) If the arm in operation is performed, the the (H) side so as to speed up the light-duty
secondary pilot pressure gets out of port 7 of arm in operation.
the left pilot valve (10) and acts upon the low 4) If the FC mode is selected, the command
pressure sensor (SE-7). current to the arm variable recirculation
At the same time, the pressure is branched solenoid proportional valve decreases. This
off to two flows, acts upon the PAa port and reduces the secondary pressure of the
the PLC2 port, changes over the arm spool solenoid proportional valve. The result is that
and the arm lock valve selector. the arm variable recirculation valve is turned
2) The output voltage of the low pressure sensor to the normal recirculation, thereby causing
is put into the mechatro controller and the arm variable recirculation function to
processes pilot signals. It is then put out to prevent cavitation.
the P2 pump proportional valve (PSV-2) of
the arm variable recirculation proportional
valve (PSV-A).
3) The P2 pump proportional valve (PSV-2) acts
on the P2 pump in proportion to the
secondary pilot pressure. However, in the
case of the arm variable displacement
proportional valve, the secondary pressure of
the solenoid proportional valve operates in
reverse proportion to the secondary pilot
pressure. This causes the secondary pressure
of the solenoid proportional valve to be
reduced by the secondary pilot pressure in
light duty arm in operation. This change over
the machine mode from the forced
recirculation to the normal recirculation
mode.
20
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
ARM CIRCUIT : ARM IN (DIGGING) LIGHT LOAD OPERATION, RECIRCURATION FUNCTION 21

This section describes the following operations.
3) Arm in, heavy duty operating pilot circuit
(recirculation cut)
4) Arm in, heavy-duty sequence confluxed main
circuit
9.3 ARM IN, HEAVY DUTY OPERATING PILOT

CIRCUIT
Operation :
1) If the arm is at heavy duty [more than 160
kgf/cm2 (2280psi)] of the pump pressure
during arm in operation, the current of the
arm variable recirculation solenoid
proportional valve is reduced to a minimum,
and the arm variable recirculation function is
cut off.
2) The moment the arm variable recirculation
cut is performed, the travel straight
proportional valve and the P1 bypass cut
valve change to sequence conflux circuit.
9.4 SEQUENCE CONFLUX CIRCUIT AT

HEAVY-DUTY ARM IN
Purpose : Arm in speed up.
Principle : Confluxing oil from 2 pumps in C/V (2).
Operation :
1) The oil delivered by the P2 pump flows into
the travel left section from the P2 port of C/V
(2). The oil is then branched to the bypass
circuit and the parallel circuit. The pressure
then pushes the load check valve LCa via the
parallel circuit and flows into the arm spool.
2) Meanwhile, the oil delivered by the P1 pump
enters the P1 port of C/V (2) and then the
travel straight section, confluxed with the oil
from the load check valve CT2 of the P2
parallel line, and enters the arm spool.
3) Then, the confluxed oil is fed into arm
cylinder H side through C/V (2) Aa port from
arm spool.
4) In addition, the return oil from arm cylinder
(R) side flows into arm lock valve through Ba
port, but since the arm lock valve is open, it
flows into arm spool.
5) Then, the oil passes though orifices on arm
spool and returns into tank while restricting.
22
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
ARM CIRCUIT : ARM IN (DIGGING) OPERATION, CONFLUX FUNCTION 23

This section describes the following operations. 9.7 NATURAL DROP PROTECTION WITH ARM
5) Arm out pilot circuit LOCK VALVE
6) Arm out 2 pumps conflux main circuit Purpose :
7) Natural fall protection with arm lock valve To prevent the arm from falling naturally by
the weight of the arm & bucket.
9.5 ARM OUT PILOT CIRCUIT Principle :
Operation : Complete seat of the return circuit against
1) If arm out operation is performed, the the arm spool of the arm cylinder (R) side
secondary pilot pressure comes out of port 8 circuit.
of the left pilot valve (10) and acts upon the Operation :
low pressure sensor (SE-8). At the same time, 1) If the secondary pressure for arm operation
the pressure is branched to two circuits and disappears and the arm cylinder stops, the
acts upon the PBa, PA1 ports of C/V (2). pressure on the rod (R) side passes through
2) The output voltage of the low pressure sensor the selector of the lock valve from the Ba port
(SE-8) puts in the mechatro controller which of C/V (2), acts the back pressure on the lock
processes signals. The controller puts out a valve CRa and seats the lock valve.
current command to the P1 bypass cut 2) Since the oil flow from the lock valve to the
solenoid proportional valve (PSV-D). The arm spool is blocked completely, the arm is
secondary pressure comes out of the solenoid prevented from falling naturally due to oil
valve, acts upon the PCb port of C/V (2) and leaks through the arm spool.
switches the spool of P1 bypass cut valve.
3) Then, the pilot secondary pressure fed into
C/V (2) PBa port switches arm spool.
4) Secondary pressure entering into PA1 port of
C/V (2) switches arm conflux valve.
9.6 ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT

Purpose : Arm out operation speed up.
Principle :
The oil delivered by the P1 pump is combined
with that delivered by the P2 pump in C/V
(2).
Operation :
1) The action is the same as the arm in till the
oil delivered by the P2 pump enters the arm
spool. In the arm out action, the oil runs
freely through the arm lock valve CRa from
the arm spool and is supplied to the arm
cylinder (R) side from the Ba port of the
control valve (2).
2) The oil delivered by the P1 pump passes
through the arm conflux valve and check
valve CCa is combined with the oil of the arm
cylinder (R) side.
3) And, the return oil from arm cylinder (H) side
flows into Aa port, passes through arm spool,
and returns into tank circuit.
24
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
ARM CIRCUIT : ARM OUT (EXTEND) OPERATION, CONFLUX FUNCTION 25

10. COMBINED CIRCUIT
This section describes only the difference in 3) However, a part of flow is connected at the
combined operation. notched orifice of the travel straight spool.
1) Boom up/travel, pilot circuit When the attachment is operated during
2) Boom up/travel, main circuit running, a part of the pressure oil on the
attachment side flows in and changes the
10.1 BOOM UP/TRAVEL, PILOT CIRCUIT travel speed reducing the travelling shock.
Operation :
<Points which are differed from the independent
operation>
1) With signal processing of mechatro controller,
the controller outputs command current to
travel straight valve (PSV-C) and P2 bypass
cut valve (PSV-B) and this solenoid valve
outputs secondary pressure, then acts on C/V
(2) PTb and PCa ports.
2) Next, the PTb port pressure changes the
travel straight valve by one step. The
solenoid proportional secondary pressure
which flows into the PCa port of C/V (2)
changes over the P2 bypass cut valve.
10.2 BOOM UP/TRAVEL, MAIN CIRCUIT

Purpose :
Trevel straight operation is available even if
the attachment is operated during travel
operation.
Principle :
The travel motion and attachment operations
are performed by respective pump.
Operation :
1) The P1 pump and P2 pump delivery oil flows
into travel straight section through P1 and
P2 ports of the C/V (2). But the P2 pump
delivery oil is branched into P1 and P2
bypass circuits because of travel straight
spool is shifted. On the other hand, the P1
pump delivery oil is branched into P1 and P2
parallel circuits.
2) And, both travel operations are performed
bypass circuit, then is performed by the oil
delivered by P2 pump.
Since boom spool and other spool are
operated through parallel circuit, so oil
delivered by P1 pump is available.
26
Ps Pm2 Pm1
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
COMBINED OPERATION : BOOM UP / TRAVEL LH, RH FORWARD 1ST-SPEED TRAVEL 27

This section describes difference in combined 10.4 SWING/ARM IN, SWING PRIORITY MAIN
operation from single operation. CIRCUIT
3) Swing/Arm in, pilot circuit Purpose :
4) Swing/Arm in, swing priority main circuit Stabilization in the swing speed
Principle :
10.3 SWING/ARM IN, PILOT CIRCUIT The supplied oil to swing motor is used to
Operation : have the P1 pump flow rate confluxed to P2
1) When swing and arm in operations are pump flow rate.
concurrently carried out, with signal Operation ;
processing of mechstro controller, the Swing main circuit is actuated by P2 pump
controller outputs commands current to flow, but when the operation of swing and
travel straight valve(PSV-C) & P1 bypass cut arm in are operated simultaneously, the
valve(PSV-D) & P2 bypass cut valve (PSV-B) secondary pressure of travel straight valve
and this solenoid valve outputs secondary switches it's spool and the secondary pressure
pressure, then acts on C/V (2) PTb & PCb & of P1 cut proportional valve closes P1 cut
Pca ports. valve and oil of P1 pump confluxes
(These operations are the same as that of the consequently with P2 pump circuit. The oil
combined respective independent operation.) flows into swing and arm circuits in the same
2) The arm variable recirculation valve (PSV-A) time because both circuits are paralleled.
operates the same as usual, but the spool Return oil pressure rises and also arm
moves toward the forcible recirculation side cylinder head (H) pressure rises because of
according to the pilot pressure for the swing following two reason.
action. Arm variable recirculation spool returns to
3) The pilot secondary pressure for swing forced recirculation side according to swing
operation is output through PSS port and is pilot pressure. Return oil from arm cylinder
led to PiSC port of arm spool, consequently rod (R) side is restricted in arm variable
main passage flowing to arm cylinder head recirculation valve.
(H) side is throttled. And swing pilot pressure is led from "Pisc"
port to sub-spool in arm spool, the pressure of
arm cylinder head (H) rises higher by
restricting opening of arm spool circuit
according to swing pilot pressure, as a result
the oil P2 pump flows preferentially into
swing circuit.
This is so-called. swing priority control.
28
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E H CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
TRAVEL LEFT
16¥17 PAL
AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Bc B C A @ F G E D
Ac
PLc2
37.7MPa
Drd
PBb
LCb LCa
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
R
15 Ab
37.7MPa
ARM
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)
2 2
SWING MPa Kgf/cm psi MPa Kgf/cm psi
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
COMBINED OPERATION : SWING / ARM IN, SWING PRIORITY 29

11. PRESSURE DRAINING
(RELEASING) CIRCUIT
This section describes the following operations. 11.2 PRESSURE RELEASE MAIN CIRCUIT
1) Pressure drain (releasing) pilot circuit Operation:
2) Pressure drain (releasing) main circuit When the operating lever is shifted to neutral
during engine running, if the pressure is
11.1 PRESSURE RELEASE PILOT CIRCUIT drained (released) as mentioned left,
Purpose : "DRAINING HYD. PRESS" is displayed on
To release the main circuit pressure for the gauge cluster and intermittent buzzer
piping repair work. sound continuously. If the operating lever for
Mechatronics : the circuit required releasing pressure is
When press screen change switch of gauge operated four to five times, pressure draining
cluster and buzzer stop switch at the same may be completed. After draining pressure is
time for more than 5 seconds, mechatro completed, turn off the starter key, and
controller recognizes this is pressure release buzzer stops. If the pump pressure is
control and out puts the following command. determined to be more than 9.8kgf/cm2 (140
1) Puts out the minimum tilting command value psi) by the output value of the high-pressure
to the pump proportional valve (PSV-P1, sensor or the high-pressure sensors (SE-22,
PSV-P2). 23) are broken, "FAIL DRAIN HYD. PRESS"
2) Puts out a pressure release control revolution is displayed on the gauge cluster and the
command value to the governor motor. buzzer sounds continuously. In that case, also
(Electric system). the buzzer is not stopped unless the engine
3) Travel straight solenoid proportional valve key is turned to off. Repeat the pressure
(PSV-C) is input the command value to releasing procedure once again.
change the pressure release position. Operation:
4) Puts out a standby command value to the P1, If the travel straight valve is turned to the
P2 bypass cut proportional valves. (A pressure release position, the oil delivered by
command that does not put out the secondary each pump is unloaded to the tank passage. If
pressure of the P1, P2 bypass proportional the spools are switched by pilot operation, the
valves). remaining pressure from the actuators may
Hydraulics : be relieved to the tank circuit, i.e. the main
1) The pump proportional valve minimizes the circuit pressure may be released.
delivery rates of the P1, P2 pumps.
2) The secondary pilot pressure for the travel
straight valve pressure release position
selection comes out of the travel straight
proportional valve (PSV-C), flows into the
PTb port of C/V (2) and switches the travel
straight valve to its pressure release position.
30
Ps Pm2 Pm1 Tin
SE23 SE22
4
A2 P P A1 P1
R/G
P2
a2 a1 SWING
PSV2 PSV1
a5 a4 P2 P
R/G
P1
Av
4
TRAVEL TRAVEL
B D E E F F CA
a3
5.0MPa 9 3 28.5MPa Dr
1 GB
GA
B3 Dr2 A3
M B Mv A
B1 Dr1 245kPa
490kPa
13 2 20 19
34.3MPa SWING RIGHT
18 37.7MPa
CMR1
ARM IN
ARM OUT
17 TRAVEL LEFT PAL

AL 22 BOOM DOWN

CP2
14 Drb LCs
PBs
SWING Pss 1 2 3 4 5 6 7 8
CT1
PAr PAs
Br As 1 2 3 4 5 6 7 8
Ar Bs
Dra CP1 (T3)
BOOM
P
SE5
23
PBc
39.7MPa
PB1 21 ATT. 10
PAc
PILOT VALVE
Ac
PLc2
37.7MPa
PBb
LCb LCa
Drd
R
22
PBa BUCKET
Drc ARM
PAb PAa
Bb Pisc
Aa H
8 P T P T
CRb BOOM ARM
& BUCKET & SWING
15 Ab
37.7MPa
ARM R
CYLINDER
7
TRAVEL
ARM
CONFLUENCE R
6
PCb Pis
H
P1
RECIRCULATION PCa
5 11
P1 BY-PASS CUT
BY-PASS PA1 CCa H
CUT D BOOM 1 5 2 3 6 4
SAFETY R
CYLINDER
TRAVEL P2 OPTION
P2
BY-PASS
37.7MPa
AO2
CUT B BO2
ARM VARIABLE ATT
A (P3)

2 2
SWING
1 P/B
T
0.25 2.5 36.3 28.5 290 4130
P
0.49 5.0 71.1 34.3 350 4970
5.0 51 725 37.7 385 5470
- - - 39.7 405 5760
PRESSURE DRAIN(RELEASE)CIRCUIT 31
This page left blank for editional convenience.
32
12. HYDRAULIC LINES
12.1 HYD. LINES DWG. NO. LIST
DIVISION
DWG. NAME
Gr. ITEM
1 㧙1 PUMP CONTROL LINES
㧙2
2 SOL. VALVE CONTROL LINES
3 P-T BLOCK CONTROL LINES
4㧙1 ATT. REMOTE CONTROL LINES (ISO)
PILOT CONTROL LINES
㧙2 ATT. REMOTE CONTROL LINES (MULTI)

5㧙1 TERMINAL BLOCK CONTROL LINES
㧙2 MULTI (LEVER LESS) CONTROL LINES
㧙3 MULTI (WITH LEVER) CONTROL LINES
6 㧙1
㧙2 STD
㧙3 MAIN C/V CONTROL LINES BOOM / ARM SAFETY
㧙4 BOOM SAFETY
7 TRAVEL CONTROL LINES
8㧙1 HOLDING VALVE CONTROL BOOM / ARM SAFETY
㧙2 LINES BOOM SAFETY
11 PUMP HYD. LINES
12 UPPER HYD. LINES
13 SWIVEL (UPPER) HYD. LINES
14 RETURN HYD. LINES
MAIN HYD. LINES
15㧙1 LC
㧙2 LOWER HYD. LINES NLC
㧙3 STD
16㧙1 LC, NLC
TRAVEL MOTOR HYD. LINES
㧙2 STD
17 SWIVEL (LOWER) HYD. LINES
21 BOOM HYD. LINES
22 ARM HYD. LINES
23 㧙1
ATT. HYD. LINES
㧙2 BOOM STD
㧙3 BOOM WITH H/V
㧙4 CYLINDER HYD. LINES ARM STD
㧙5 ARM WITH H/D
㧙6 BUCKET
33
12.2 HYD. LINES PARTS LIST
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
PILOT CONTROL 21 HOSE ; PF1/4 L=340 1 P2 bypass cut secondary 21 SOCKET BOLT 8 M6È25
(1-1) PUMP CONTROL LINES 23 HOSE ; PF1/4 L=1600 1 Arm variable recirculation 22 WASHER 8 M6
(1-2) PUMP CONTROL LINES 24 BRACKET 1
1 HOSE ; PF1/4 L=400 1 ඌ P2 pump SOL. primary 25 BRACKET 1 (4-2) ATT. REMOTE CONTROL
2 HOSE ; PF1/4 L=2550 1 ඌ P1 pump SOL. primary 28 ELBOW 9 PF1/4 1 HOSE ; PF1/4 L=1450 1 Pilot primary
3 HOSE ; PF3/8 L=2300 1 ඌ Pilot pump delivery 29 ELBOW 2 PF3/8 2 HOSE ; PF1/4 L=1750 1 Pilot primary
4 HOSE ; PF3/8 L=1700 1 ඌ Pump drain 30 ELBOW 1 PF3/8 with mesh filter 3 HOSE ; PF3/8 L=1400 1 Drain
5 HOSE ∅25.4 1 ඌ Pilot pump suction 32 CONNECTOR 2 PF3/8 L=46 4 HOSE ; PF3/8 L=1750 1 Drain
6 TUBE 1 ඌ L=300 33 CONNECTOR 2 PF1/4 L=23 5 HOSE ; PF3/8 L=3000 1 Drain
8 CONNECTOR 1 ඌ PF3/8-∅25.4 34 GROMMET 1 6 HOSE ; RED L=1650 1 Bucket digging
9 ELBOW 1 ඌ PF3/8 35 CLIP 1 7 HOSE ; BLUE L=1650 2 N Bucket dump, S Arm in
10 ELBOW 1 ඌ PF1/4 with mesh filter 36 BUSHING 1 8 HOSE ; GREEN L=1950 1 Boom up
11 ELBOW 1 ඌ PF1/4 37 TUBE 2 L=300 9 HOSE ; GRAY L=1700 1 Boom down
12 ELBOW 2 ඌ PF3/8 38 TUBE 1 L=600 10 HOSE ; GRAY L=1600 1 Swing LH
13 TEE 1 ඌ PF3/8 39 CLIP 3 11 HOSE ; RED L=1600 1 Swing RH
14 TEE 1 ඌ PF1/4 12 RUBBER 2
15 INLINE FILTER 1 ඌ (3) P-T BLOCK CONTROL 13 HOSE ; GREEN L=1600 1 Arm out
16 CAPSCREW 2 ඌ M6È60 1 BLOCK 1 14 HOSE ; BLACK L=470 2
17 WASHER 2 ඌ M6 2 CAPSCREW 2 M8È40 16 CLIP 4
18 O RING 1 ඌ 1B P24 3 WASHER 2 M8 17 CONNECTOR 10 PF3/8
19 CLIP 2 ඌ 4 ELBOW 2 PF1/4 18 CONNECTOR 2 PF1/4 with mesh filter
20 CLIP 2 ඌ 5 ELBOW 3 PF3/8 19 BOOT 2
21 CONNECTOR 1 ඌ PF1/4 with mesh filter 6 ELBOW 1 PF1/4 20 PILOT VALVE 2
22 BRACKET 1 ඌ 7 ELBOW 2 PF3/8 21 SOCKET BOLT 8 M6È25
23 CAPSCREW 2 ඌ M12È20 9 CONNECTOR 1 PF1/4 L=23 22 WASHER 8 M6
24 WASHER 2 ඌ M12 17 PLUG 1 PF1/4
25 TUBE 1 웎 L=250 18 PLUG 1 PF3/8 (5-1) T. BLOCK CONTROL
26 CONNECTOR 1 웎 PF3/8 1 GROMMET 2
27 ELBOW 1 ඌ PF1/4-PF3/8 (4-1) ATT. REMOTE CONTROL 2 PRESSURE SENSOR 6
1 HOSE ; PF1/4 L=1450 1 Pilot primary 3 BRACKET 1
(2) SOL. VALVE CONTROL 2 HOSE ; PF1/4 L=1750 1 Pilot primary 4 BRACKET 1
1 SOLENOID VALVE ASSY 1 3 HOSE ; PF3/8 L=1400 1 Drain 5 CONNECTOR 1 PF3/8-PF1/4 L=23
3 CLIP 2 4 HOSE ; PF3/8 L=1750 1 Drain 6 GROMMET 1
4 CAPSCREW 2 M12È35 5 HOSE ; PF3/8 L=3000 1 Drain 7 ELBOW 15 PF3/8
5 CAPSCREW 2 M10È75 6 HOSE ; RED L=1700 1 Bucket digging 8 BLOCK 1
6 CAPSCREW 3 M10È20 7 HOSE ; BLUE L=1800 1 Bucket dump 9 RUBBER 1 L=305
8 CAPSCREW 1 M12È25 8 HOSE ; GREEN L=1650 2 O Boom up, TArm out 10 CAPSCREW 4 M8È20
9 WASHER 3 M12 10 HOSE ; GRAY L=1700 2 Q Swing LH,V Boom down 11 WASHER 6 M8
11 WASHER 5 M10 11 HOSE ; RED L=1600 1 Swing RH 12 GROMMET 1 PF1/4
12 HOSE ; PF3/8 L=1050 1 12 RUBBER 2 13 PLUG 2 PF1/4
13 HOSE ; PF3/8 L=500 1 14 HOSE 2 14 CLIP 5
14 HOSE ; PF1/4 L=1300 1 Swing P/B primary 15 HOSE ; BLUE L=1500 1 Arm in 15 CAPSCREW 2 M8È55
15 HOSE ; PF1/4 L=1000 1 Travel 2 speed primary 16 CLIP 4 16 CONNECTOR 1 PF3/8 L=23
16 HOSE ; PF3/8 L=2500 1 P/V pressure supply 17 CONNECTOR 10 PF3/8 17 ELBOW 1 PF1/4
18 HOSE ; PF1/4 L=1400 1 P1 bypass cut secondary 18 CONNECTOR 2 PF1/4 with mesh filter 18 CHECK VALVE 1
19 HOSE ; PF1/4 L=1200 1 ATT. boost command primary 19 BOOT 2 19 HOSE ; PF3/8 L=2600 1 Boom down
20 HOSE ; PF1/4 L=380 1 Travel straight 20 PILOT VALVE 2 20 HOSE ; PF3/8 L=2800 1 Bucket digging
34
21 HOSE ; PF3/8 L=3000 1 Swing LH 34 PLATE 웎 1 (6-3) MAIN C/V VALVE
22 HOSE ; PF3/8 L=4100 2 Boom up, Arm in 35 CAPSCREW 웎 1 M8È16 (6-4) MAIN C/V VALVE
23 HOSE ; PF3/8 L=3700 1 Swing RH 36 WASHER 웎 1 M8 1 PRESSURE SENSOR 1 ඌ
24 TUBE 1 L=750 2 CONNECTOR 6 ඌ PF1/4-PF3/8
25 HOSE ; PF3/8 L=2700 1 Arm out (6-1) MAIN C/V CONTROL 3 CONNECTOR 6 5 PF3/8
26 HOSE ; PF3/8 L=4000 1 Bucket dump 4 CONNECTOR 3 2 PF3/8 L=23
27 GUIDE 1 1 PRESSURE SENSOR 1 ඌ 5 CONNECTOR 1 ඌ PF1/4 L=38
28 RUBBER 1 L=200 2 CONNECTOR 6 ඌ PF1/4-PF3/8 6 CHECK VALVE 2 ඌ
29 RUBBER 2 L=85 3 CONNECTOR 5 ඌ PF3/8 7 CONNECTOR 2 ඌ PF3/8 L=46
30 CAPSCREW 2 M10È25 4 CONNECTOR 2 ඌ PF3/8 L=23 8 CONNECTOR 1 ඌ PF3/8 with orifice L=23
31 WASHER 2 M10 5 CONNECTOR 1 ඌ PF1/4 L=38 9 CONNECTOR 2 ඌ PF3/8 with orifice L=23
32 ELBOW 1 PF1/4-PF3/8 6 CHECK VALVE 2 ඌ 10 ELBOW 8 ඌ PF1/4
7 CONNECTOR 2 ඌ PF3/8 L=46 11 ELBOW 8 ඌ PF1/4-PF3/8
(5-2) MULTI CONTROL 8 CONNECTOR 1 ඌ PF3/8 with orifice L=23 12 ELBOW 7 ඌ PF3/8
(5-3) MULTI CONTROL 9 CONNECTOR 2 ඌ PF3/8 with orifice L=23 13 ELBOW 2 ඌ PF3/8
1 CONTROL VALVE 웎 1 10 ELBOW 8 6 PF1/4 14 TEE 2 ඌ PF1/4
2 PRESSURE SENSOR 6 ඌ 11 ELBOW 8 ඌ PF1/4-PF3/8 15 TEE 8 ඌ PF3/8
3 BRACKET 1 ඌ 12 ELBOW 5 ඌ PF3/8 16 TEE 1 웎 PF3/8
4 BRACKET 1 ඌ 13 ELBOW 2 ඌ PF3/8 18 TUBE 1 ඌ L=850
5 BRACKET 1 ඌ 14 TEE 2 1 PF1/4 19 HOSE ; PF1/4 L=1000 1 ඌ Drain
6 GROMMET 1 ඌ 15 TEE 6 ඌ PF3/8 20 HOSE ; PF1/4 L=400 1 ඌ Drain
7 ELBOW 4 ඌ PF1/4 16 ELBOW 웎 1 PF1/4 21 HOSE ; PF1/4 L=280 1 ඌ Drain
8 GROMMET 1 ඌ 18 TUBE 1 ඌ L=850 22 HOSE ; PF1/4 L=460 1 ඌ Arm confluence command
9 RUBBER 1 ඌ L=305 19 HOSE ; PF1/4 L=1000 1 ඌ Drain 23 HOSE ; PF1/4 L=500 1 ඌ Boom confluence command
10 CAPSCREW 12 ඌ M8È20 20 HOSE ; PF1/4 L=500 1 ඌ Drain 24 HOSE ; PF1/4 L=640 1 ඌ Swing priority command
11 WASHER 12 ඌ M8 21 HOSE ; PF1/4 L=280 1 ඌ Drain 25 HOSE ; PF1/4 L=700 1 ඌ Arm lock valve release command
12 GROMMET 1 ඌ 22 HOSE ; PF1/4 L=460 1 ඌ Arm confluence command 26 HOSE ; PF1/4 L=900 1 ඌ Swing LH priority command
13 PLUG 2 ඌ PF1/4 23 HOSE ; PF1/4 L=500 1 ඌ Boom confluence command 27 HOSE ; PF1/4 L=1000 1 ඌ Boom lock valve release command
14 CLIP 1 ඌ 24 HOSE ; PF1/4 L=640 1 웎 Swing LH priority command 28 CHECK VALVE 1 ඌ

15 CONNECTOR 2 ඌ PF1/4 L=38 25 HOSE ; PF1/4 L=700 1 ඌ Arm lock valve release command 29 HOSE ; PF1/4 L=950 1 ඌ Drain
16 CONNECTOR 6 ඌ PF1/4 L=17 26 HOSE ; PF1/4 L=900 1 ඌ Swing priority command 30 CONNECTOR 1 ඌ PF1/4
17 ELBOW 9 ඌ PF3/8-PF1/4 27 HOSE ; PF1/4 L=1000 1 ඌ Boom lock valve release command 31 ELBOW 1 ඌ PF1/4-PF3/8
18 ELBOW 7 ඌ PF3/8-PF1/4 28 CHECK VALVE 1 ඌ 32 ELBOW 2 ඌ PF3/8
19 HOSE ; PF3/8 L=2500 1 ඌ 29 HOSE ; PF1/4 L=950 1 ඌ Drain 34 TUBE 1 ඌ L=300
20 HOSE ; PF3/8 L=2700 2 ඌ 30 CONNECTOR 1 ඌ PF1/4 35 CLIP 1 ඌ
22 HOSE ; PF3/8 L=3600 1 ඌ 31 ELBOW 1 ඌ PF1/4-PF3/8 36 TEE 1 ඌ PF1/4
23 HOSE ; PF3/8 L=4000 2 ඌ 32 ELBOW 2 ඌ PF3/8 37 ELBOW 1 ඌ PF1/4
24 TUBE 1 ඌ L=750 35 TUBE 1 ඌ L=300
25 HOSE ; PF3/8 L=2900 1 ඌ 36 CLIP 1 ඌ (7) TRAVEL CONTROL
26 HOSE ; PF3/8 L=3900 1 ඌ 37 TEE 1 ඌ PF1/4 1 HOSE ; PF3/8 L=4000 2
27 GUIDE 1 ඌ 38 ELBOW 1 ඌ PF1/4 2 HOSE ; PF3/8 L=3200 2
28 RUBBER 1 ඌ L=200 39 PLUG 4 ඌ PF3/8 3 HOSE ; PF3/8 L=380 1
29 RUBBER 2 ඌ L=85 4 HOSE ; PF1/4 L=300 1
30 CAPSCREW 2 ඌ M10È35 5 PILOT VALVE 1
31 WASHER 2 ඌ M10 6 CONNECTOR 1 PF1/4 with mesh filter
32 CHECK VALVE 1 ඌ 7 CONNECTOR 1 PF3/8
33 CONTROL VALVE 1 웎 8 ELBOW 4 PF3/8
35
9 WASHER 4 M10 2 TUBE ; 27.2 1 Boom (R) 4 TUBE 2 1 3/16-12UN-PF1
10 SOCKET BOLT 4 M1030 3 TUBE ; 34 1 Arm (H) 5 O RING 8
11 PRESSURE SENSOR 2 4 TUBE ; 27.2 1 Arm (R)
5 TUBE ; 27.2 1 Bucket (H) (14) RETURN HYD. LINES
(8-1) BOOM/ARM SAFETY CONTROL 6 TUBE ; 27.2 1 Bucket (R) 1 TUBE 1
(8-2) BOOM SAFETY CONTROL 7 HOSE ; 1 3/16 L=1300 1 Boom (R) 2 TUBE 1
1 HOSE ; PF3/8 L=2600 1 㧙 8 CAPSCREW 1 M1270 3 ELBOW 1 PF1/2
2 HOSE ; PF3/8 L=1900 1 φ 9 HOSE ; 1 3/16 L=1400 1 Travel RH reverse 4 TUBE 1
3 HOSE ; PF3/8 L=1750 1 φ 10 SUPPORT 1 5 TUBE 1
4 HOSE ; PF3/8 L=2000 1 φ 11 CAPSCREW 2 M1255 6 HOSE ; PF3/4 L=1900 1
5 HOSE ; PF3/8 L=2100 1 φ 12 HOSE ; 1 3/16 L=1625 1 Travel LH forward 7 HOSE ; PF3/4 L=2500 1 Pump Dr
6 HOSE ; PF3/8 L=2700 1 㧙 13 PLATE 1 8 HOSE ; PF1/2 L=1000 1 Swing Dr
7 TUBE 2 φ L=350 14 O RING 2 9 HOSE ; PF1/2 L=2100 1 Swing Dr
8 CLIP 14 8 15 O RING 22 10 COUPLING 1 50.8
9 CONNECTOR 2 㧙 PF3/8 16 O RING 2 11 COUPLING 2 48.6
10 CONNECTOR 3 2 PF3/8 17 CONNECTOR 4 1 3/16-12UN-PF1 12 COUPLING 4 42.7
11 CONNECTOR 1 2 PF3/8 L=55 18 CONNECTOR 6 1 3/16-12UN-PF1 13 CHECK VALVE 1
12 CONNECTOR 1 φ PF3/8 L=28 19 CONNECTOR 1 1 3/16-12UN-PF1 14 CHECK VALVE 1
13 PLUG 1 φ PF3/8 20 CONNECTOR 2 1 3/16-12UN-PF1 15 SUPPORT 1
14 HOSE GUARD 1 㧙 L=450 21 CONNECTOR 1 1 7/16-12UN-PF1 16 SUPPORT 1
15 TUBE 2 φ L=400 22 ELBOW 1 PF3/4 17 SUPPORT 1
16 CLIP 4 φ 23 ELBOW 2 1 3/16-12UN-PF3/4 18 PLATE 1
17 HOSE GUARD 1 㧙 L=1000 24 CONNECTOR 1 PF3/4 L=60 19 SUPPORT 2
22 TUBE 2 φ L=400 25 CAPSCREW 4 M1275 20 ELBOW 1 PF3/4-PF1
26 NUT 1 M12 21 PLUG 1 PF1
(11) PUMP HYD. LINES 27 CLAMP 2 22 TUBE 1
1 TUBE 1 Suction 28 CLAMP 3 23 TEE 1 PF1/2-PF1/2-PF3/8
2 HOSE 1 Suction 29 WASHER 16 M12 24 TEE 1 PF3/4-PF1/2-PF3/4
3 HOSE ; L=800 1 P1 Delivery 30 CAPSCREW 8 M1225 25 CLAMP 2 42.7 P85
4 HOSE ; L=900 1 P2 Delivery 31 SUPPORT 1 26 SPACER 2 L=22.5
5 HALF CLAMP 4 32 SUPPORT 1 27 HOSE GUARD 1 L=1000
6 PRESSURE SENSOR 2 33 GROMMET 1 28 U BOLT 6 44
7 CLIP 2 34 GROMMET 1 29 CLIP 1
8 CLIP 4 35 HOSE ; 1 3/16 L=1325 1 Boom (H) 30 CLIP 1
9 O RING 1 1A G75 36 HOSE ; 1 3/16 L=1475 1 Travel LH reverse 31 O RING 1 1A G45
10 O RING 2 1B P26 37 HOSE ; 1 3/16 L=1600 1 Travel RH forward 32 TUBE 1 L=850
11 SOCKET BOLT 4 M1245 38 CLAMP 2 33 CAPSCREW 2 M1055
12 CAPSCREW 8 M1035 39 HOSE ; 1 3/16 L=1425 1 Swing (RH) 34 CAPSCREW 4 M10110
13 LOCK WASHER 4 M12 41 PLATE 4 35 CAPSCREW 5 M1225
14 LOCK WASHER 8 M10 42 HOSE ; 1 3/16 L=1375 1 Swing (LH) 36 CAPSCREW 5 M1230
15 ELBOW 1 PF3/4 43 BUSHING 2 37 CAPSCREW 4 M1235
16 GROMET 1 44 CLIP 2 38 WASHER 12 M8
17 GROMET 1 39 WASHER 8 M10
27 PLUG 2 PF1/4 (13) SWIVEL HYD. LINES 40 WASHER 18 M12
1 CONNECTOR 1 PF1/2 41 NUT 24 M8
(12) UPPER HYD. LINES 2 CONNECTOR 4 1 3/16-12UN-PF1 42 NUT 1 M10
1 TUBE ; 27.2 1 Boom (H) 3 TUBE 2 1 3/16-12UN-PF1 43 NUT 2 M12
36
44 CAPSCREW 1 M12È65 8 HOSE 4 L=300 (22) ARM HYD. LINES
45 CLAMP 1 50.8 9 CLIP 10 1 HOSE 1 L=1250
46 TUBE 1 L=1500 10 CLAMP 2 2 HOSE 1 L=1300
47 CLIP 1 11 CLAMP 2 3 HALF CLAMP 2
48 BUSHING 1 12 SPACER 4 4 CAPSCREW 4 M10È35
49 SUPPORT 1 13 CAPSCREW 4 M8È40 5 LOCK WASHER 4 M10
50 CLAMP 1 14 WASHER 4 M8 6 O RING 1 1B P26
51 CAPSCREW 1 M12È60 15 LOCK WASHER 4 M8
52 SUPPORT 1 (23) CYLINDER HYD. LINES
53 TUBE 1 L=1600 (16-1) TRAVEL MOTOR HYD. LINES (23-1) BOOM CYL.
54 CAPSCREW 1 M10È25 (16-2) TRAVEL MOTOR HYD. LINES
1 CONNECTOR 4 ඌ PF1-28 1 TUBE ೇ1 ඌ 27.2
(15-1) LOWER HYD. LINES (LC) 2 CONNECTOR 2 ඌ PF1/2-18 2 TUBE 1 ඌ 27.2
(15-2) LOWER HYD. LINES (NLC) 3 CONNECTOR 2 ඌ PF1/4 3 TUBE 1 ඌ 21.7
1 TUBE 1 ඌ 4 ELBOW 2 ඌ PF1/4 4 TUBE 1 ඌ 21.7
2 TUBE 1 ඌ 5 O RING 4 ඌ 1B P29 5 HOSE 2 ඌ
3 TUBE 1 ඌ 6 O RING 2 ඌ 1B P18 6 HOSE 2 ඌ
4 TUBE 1 ඌ 7 CLAMP 2 ඌ
5 TUBE 1 ඌ (17) SWIVEL HYD. LINES 8 CAPSCREW 2 ඌ M12È50
6 TUBE 1 ඌ 1 CONNECTOR 4 PF1-28 9 CAPSCREW 16 ඌ M10È30
7 TUBE ೇ1 ඌ 2 CONNECTOR 2 PF1/4 10 CONNECTOR 2 ඌ PF1/4
8 TUBE ೇ1 ඌ 3 CONNECTOR 2 PF1/2-18 11 GREASE NIPPLE 2 ඌ PT1/8
9 TUBE ೇ1 ඌ 4 O RING 4 1B P29 12 O RING 2 ඌ
10 TUBE ೇ1 ඌ 5 O RING 2 1B P18 13 O RING 2 ඌ
11 TUBE ೇ1 ඌ 14 O RING 4 ඌ 1B P26
12 TUBE ೇ1 ඌ (21) BOOM HYD. LINES 15 LOCK WASHER 2 ඌ M12
13 HOSE 2 ඌ 1 TUBE 2 16 PLUG 2 웎
14 HOSE 4 ඌ 2 TUBE 1
15 CLIP 10 ඌ 3 TUBE 1 (23-3) BOOM CYL.
16 CONNECTOR 4 ඌ 4 TUBE 1 1 TUBE 1 21.7
17 CONNECTOR 2 ඌ 5 TUBE 1 2 TUBE 1 21.7
18 CLAMP 2 ඌ 6 HOSE 1 3 TUBE 1 27.2
19 CLAMP 2 ඌ 7 HOSE 1 4 TUBE 1 27.2
20 SPACER 4 ඌ 8 HOSE 2 5 TUBE 1 15
21 CAPSCREW 4 ඌ M8È40 9 O RING 4 6 TUBE 1 15
22 WASHER 4 ඌ M8 10 O RING 6 7 TUBE 1 15
23 LOCK WASHER 4 ඌ M8 11 CLAMP 2 8 TUBE 1 15
12 CLAMP 2 9 TAPPED BLOCK 2
(15-3) LOWER HYD. LINES (STD) 13 CLAMP 4 10 HOSE 2 L=880
1 TUBE 1 14 CAPSCREW 6 M12È55 11 HOSE 2 L=880
2 TUBE 1 15 LOCK WASHER 8 M12 12 HOSE 1 L=1200
3 TUBE 1 16 CLIP 2 13 CONNECTOR 4
4 TUBE 1 17 CAPSCREW 2 M12È60 14 HOLDING VALVE 1
5 TUBE 1 15 HOLDING VALVE 1
6 TUBE 1 16 CLAMP 2 28-22
7 HOSE 2 17 CLAMP 2 15-15
Note : ೇmarked parts differ according to specifications.
37
18 ELBOW 2 6 HALF CLAMP 2
19 ELBOW 2 7 GREASE NIPPLE 1
20 CONNECTOR 1 8 SOCKET BOLT 8 M1240
21 CONNECTOR 2 9 CAPSCREW 1 M1255
22 CONNECTOR 2 10 O RING 2 1B P34
23 CONNECTOR 2 2-PF3/8 with mesh filter 11 O RING 1
24 O RING 4 1B P26 12 LOCK WASHER 4 M12
25 O RING 4 13 LOCK WASHER 1 M12
26 O RING 4
27 O RING 4 1B P14 (23-5) ARM CYL.
28 CAPSCREW 2 M1065 1 HOLDING VALVE 1
29 CAPSCREW 2 M835 2 TUBE 1 27.2
30 SOCKET BOLT 8 M1065 3 HOSE 1 1 3/16-12UN L=900
31 SOCKET BOLT 8 M1030 4 HOSE 1 L=920
32 WASHER 2 M10 7 HALF CLAMP 2
33 LOCK WASHER 2 M10 8 CLAMP 1
34 LOCK WASHER 2 M8 9 ELBOW 1 PF1-1 7/16-12UNS
35 LOCK WASHER 16 M10 10 ELBOW 1 PF3/8-PF3/8
36 GREASE NIPPLE 2 PT1/8 11 CONNECTOR 1 PF3/8 with mesh filter
37 CLIP 4 48 L=188 12 CONNECTOR 1 PT1/4-PF1/4
38 BLOCK 2 13 GREASE NIPPLE 1 PT1/8
39 SOCKET BOLT 8 M1045 14 O RING 1 1B P34
40 PLUG 2 15 O RING 1
42 TEE 1 16 O RING 1
43 CONNECTOR 1 17 CAPSCREW 1 M1255
44 OIL PRESSURE SW. 1 18 SOCKET BOLT 4 M1265
45 CLAMP 1 19 SOCKET BOLT 4 M1240
46 CLAMP 1 20 LOCK WASHER 1 M12
47 PLATE 1 21 LOCK WASHER 8 M12
48 BRACKET 1 22 PLUG 1
49 ELBOW 1 23 CLIP 21
50 CONNECTOR 1 29 HOSE 1 PF3/8 L=4300
51 CAPSCREW 2 M540 30 HOSE 1 PF3/8 L=4300
52 CAPSCREW 2 M825
53 CAPSCREW 2 M1265 (23-6) BUCKET CYL.
54 WASHER 2 M8 1 TUBE 1 27.2
55 WASHER 2 M12 2 CLAMP 1
56 LOCK WASHER 2 M5 3 CAPSCREW 1 M1055
57 O RING 1 4 SOCKET BOLT 4 M1035
5 O RING 1 1B P26
(23-4) ARM CYL. 6 O RING 1
1 TUBE 1 Arm cyl. rod 7 GREASE NIPPLE 1
2 HOSE 1 L=900 8 GREASE NIPPLE 1
3 HOSE 1 L=920 9 LOCK WASHER 1 M10
4 CLAMP 1 11 WASHER 1 M10
5 CONNECTOR 1
38
(1-1) Pump control lines
39
(2) SOL. valve control lines
40
(3) P-T block control lines
41
(4-1) ATT. remote control lines (ISO)
42
(5-1) Terminal block control lines
43
(6-1) Main C/V control lines
44
(6-1) Main C/V control lines
45
(6-3) Main C/V control lines with Boom/Arm safety
(6-4) Main C/V control lines with Boom safety
46
(6-3) Main C/V control lines with Boom/Arm safety
(6-4) Main C/V control lines with Boom safety
47
(7) Travel control lines
48
(8-1) Holding valve control lines with Boom/Arm safety
(8-2) Holding valve control lines with Boom safety
49
(11) Pump hyd. lines
50
(12) Upper hyd. lines
51
(12) Upper hyd. lines
52
(13) Swivel (upper) hyd. lines
53
(14) Return hyd. lines
54
(15-1) Lower hyd. lines (LC)
(15-2) Lower hyd. lines (NLC)
(17) Swivel hyd. lines
(16-1) Travel motor hyd. lines ;

(LC) (NLC)
55
(15-3) Lower hyd. lines (STD)
(16-2) Travel motor hyd. lines (STD)
56
(21) Boom hyd. lines
(22) Arm hyd. lines
57
(23) Cylinder hyd. lines (23-3) Boom cyl. (with H/V)
(23-1) Boom cyl. (STD)
58
(23-4) Arm cyl. (STD) (23-5) Arm cyl. (with H/V)
(23-6) Bucket cyl.
59
E235SR
SECTION 23 ELECTRIC SYSTEM
TABLE OF CONTENTS
1. ELECTRIC CIRCUIT DIAGRAM ................................................................................ 1
2. ELECTRICAL EQUIPMENT LIST .............................................................................. 7
3. HARNESS
3.1 Harness list ......................................................................................................................... 8
3.2 Harness Connection Drawing .............................................................................................. 9
3.3 Operators Controls ............................................................................................................. 11
3.4 Controller Assy ................................................................................................................... 13
3.5 Instrument Panel Assy ....................................................................................................... 21
3.6 Upper Electric Assy ............................................................................................................ 24
3.7 Upper Harness Assy .......................................................................................................... 26
3.8 Engine Harness Assy ......................................................................................................... 34
3.9 Floor Harness Assy ............................................................................................................ 36
3.10 Cab Harness Assy ........................................................................................................... 40
3.11 Cab Assy & Cab Install .................................................................................................... 45
3.12 Battery Install & Battery ................................................................................................... 47
3.13 Light Install ....................................................................................................................... 47
3.14 Boom Harness Assy ........................................................................................................ 50
3.15 Fuel Pump Assy ............................................................................................................... 51
3.16 Travel Alarm Assy ............................................................................................................. 52
1. ELECTRIC CIRCUIT DIAGRAM
2 WIPER/WASHER RELAY
7 CONTROLLER BACK UP
3 CIGARETTE LIGHTER
8 FUEL SUPPLY PUMP
DC-DC CONVERTER
930 WR (5V) 11-33
9 TUNER BACK UP
4 TUNER DC-DC
CONTROLLER
530 P
CONVERTER
SE-16:ACCEL POTENTIO 11-32
MACHATRO
ROOM LAMP
970 BW (GND)
MECHATRO
11-31 C-1:MECHATRO CONTROLLER
10 KEY SW.
PRESS.SENSOR(LOW)
900 BR (5V)
5 HORN
11-15
SE-1:BUCKET DIGGING 500 LgR 11-14
950 BrR (GND) 11-13
1A
1B
901 RL (5V) 11-16
RY
WG
WR
20A WV
WY
YG
RY
1.25
YB
RL
DL
E-1:FUSE BOX 501 LgW 11-17
SE-2:BUCKET DUMP
951 BL (GND)
11-18
20A
10A
10A
10A
10A
10A
20A
10A
902 WV (5V) 851 GREEN A
51 2W 11-3 15-1
502 LgY 852 BLACK
52 5R SE-3:BOOM RAISING 11-2 15-2
952 BR (GND) 853 RED B
11-1 15-15 M M-2:GOVERNOR MOTOR
50 1.25L 854 WHITE
903 OB (5V) 15-16
C-1:15-26 53 5Y 11-4 SHIELD
503 LO 15-3
MECHA SE-4:BOOM LOWERING 11-5
20A
10A
10A
20A
10A
20A
10A
20A
10A
20A
560 V B
TRO CONT- 953 BrW (GND) 11-6 11-34
ROLLER C-1 904 OL (5V) 11-9 ION L SE
SIT MA EA
1.25
1.25
1.25
1.25
1.25
WG
RW
WR
WB
WL
RG
RB
4 3 PO NOR REL
RL
504 PW
TERMINAL
W
R
SE-7:ARM IN 11-8
954 BrY (GND)
CAB WORK LIGHT 11
TRAVEL ALARM 12
GAUGE CLUSTER 13
WIPER,WASHER 14
SOLENOID 15
WORK LIGHT 16
RESISTOR 17
AIR CON. 18
AIR CON. 19
RESERVE 20
11-7 SW-4:SWING PARKING RELEASE SW.
905 OW (5V) 11-10 561 Lg
12-18 3
FUEL PUMP
505 PL 701 PB B
SE-8:ARM OUT 11-11 2 SV-1:SWING PARKING BRAKE SOL.
955 Gr (GND) 15-22 700 VR 1
11-12
906 YB (5V) 11-21
SE-5:SWING 506 V 11-20 702 LgB B
51A G 60A 60A 956 GrL (GND) 11-19 15-21 SV-3:TWO-SPEED SELECT SOL
EA B BATTERY BATTERY 908 YL (5V) 11-27 703 P B
51B R 60B 60B 60B 508 VY 15-23 SV-2:POWER BOOST SOL.
SE-9:TRAVEL RIGHT 11-26
EB W B 958 BY (GND) 751 BO
11-25 15-6
SHIELD 752 GrR PSV-B:P2 BY-PASS CUT
64 GW
909 YR (5V) 15-7 PROPORTIONAL SOL.
R-30: 805 WG 11-28
AUTO IDLE 509 Sb 11-29
ION ATING SE-10:TRAVEL LEFT 753 GB
POSIT
PREHE STOP RELAY 1 959 BG 11-30 15-8
TERMINAL
SW-1:KEY SW. D-10 R-1:BATTERY RELAY 754 GrB PSV-C:TRAVEL PRIORITY

㧿㨀㧭㧾㨀
60 GrL 70 YW
㧭㧯㧯
㧻
OPT
㧻㧲㧲
15-9 PROPORTIONAL SOL.

D-11
㧺
D-1
B 71 YL 910 RL (5V) 13-3 755 BP
10 1.25WV 510 GO 15-4
10 㧮 SE-11:OPT.1 13-2 756 PW PSV-D:P1 BY-PASS CUT PROPORTIONAL SOL.
960 BL (GND) 13-1 15-5
60B
㧭㧯㧯 R-3:GLOW RELAY

D-2 GLOW
㧹
67 20B 66 5W 912 RB (5V) 12-9 757 BrG
61 BrY 15-10 PSV-A:ARM VALUABLE RECIRCULATION
㧳1 512 LgR 12-8 758 YV PROPORTIONAL SOL.
62 GrB SE-20:OPT.2 15-11
㧳2 962 BO (GND) 12-7
㧿㨀 63 WY
M-1: B M E D-4
M
65 5L
STARTER MOTOR PRESS.˴SENSOR(HIGH) 914 YL (5V) 12-3
514 VY 12-2
SE-22:PUMP P1
R-2: S 964 BrB (GND) 12-1
E-2:ALTERNATOR
STARTER RELAY
69 WL S B 5B 915 YR (5V)
E B E 12-4
D-3 515 Sb 12-5
70 YW 65 L SE-23:PUMP P2
R R 965 BrL (GND) 12-6
P 68 W P OPT N
IO AL SE
651 WR SIT RM EA
L L 907 YG (5V) 12-10 PO NO REL
650 Sb
TERMINAL
507 VW 12-19 SW-5:K.P.S.S MODE RELEASE SW.
R-4:SAFETY RELAY SE-24:EXTRA PRESS 12-11
E-3:HOUR METER 957 Br (GND) E-14:RESISTOR
12-12 B
C-2:GAUGE CLUSTER 651 WR H㨯M B 17 WL 650 Sb 1
R-29:AUTO IDLE STOP RELAY 17
2 761 G
13 W 21-6 RY 3
13 1A 15-18 759 GrG
SE-14: ENG. WATER TEMP INDICATOR 4
537 YR 21-2 B 730 YR 15-24 760 VR 5 762 L
COOLANT THERMO SENSOR 15-17 PSV-P1:PUMP P1
553 BrB 6 B PROPORTIONAL SOL.
5 C-1:14-8 CHARGE 651 WR 7
FUEL METER 12-13 765 GB
B 536 BrR 21-1 KEY ON 8
SE-15:FUEL SENSOR 60 GrL 12-15
763 GY 9
GLOW 61 BrY 15-20 10
12-16 766 LB
15-19 764 VW 11 PSV-P2:PUMP P2
BACK LIGHT SW-3:TWO-SPEED SELECT SW.
B 559 PL 12-17 12 PROPORTIONAL SOL.
SW-34:POWER BOOST SW.
B 567 GR 14-5
B
SW-35:HEAVY LIFT SW. B 540 GO 16-15
H S FC 21-7 STD
534 B 12-20
NOTES
LCD SE-13:ENG,SPEED SENSOR 535 W 12-21 㧝.Wires used to be
2 2
SHIELD 12-22 㧝㧕̍AVSS̍or ̍AVX̍for 0.75চ and 1.25চ.
21-3 600 0.5R 2 2
14-25 㧞㧕̍AVS̍ for 2চ㧘5চ.
21-4 601 0.5W 14-26 㧟㧕̍AV̍ for others.
21-5 602 0.5B 2
SHIELD
14-27 㧞.Wires to be˴0.75চ unless otherwise specified.
14-28
1A RY
㧟.Grounding for which wire color is not shown to
1A 15-12
1B RY
be performed with component case.
DISPLAY BUZZER MODE WASHER 1B 15-13
SELECT SW. STOP EA B
㧠.Number in square shows line No.
LED 3 15-25
EB B 15-26
4 TO 2/3
WORKING WIPER 7 YG
7 15-14
LIGHT 1
Fig.1(1/3) Electric circuit diagram
C-1:MECHATRO CONTOLLER
FROM 1/3
SW-7:ENG.OIL PRESS.SW. 550 O 14-2

B 551 BrL
SW-8:AIR FILTER RESTRICTION SW. 14-3 14 RB
SW-6:ENG. WATER TEMP. SW. 552 GB 14-1 R-5:WIPER MOTOR RELAY

80 LY
330ǡ
1 RY 14 1.25RB 81 BrB B
E-1:FUSE BOX 1 14 M-3:WIPER MOTOR
M
2 WY
2
SE-15:FUEL SENSOR FUEL WARNING 553 BrB 14-8
5
SW-16:AUTO ACCEL RELEASE SW.

B 555 LB 17-8 SW-23:WIPER INTERLOCK SW.
SW-9:ENG.OIL LEVEL SW. B 543 BR 14-11 800 GB 180 OL

14-13
SW-17:ENG.COOLANT LEVEL SW.

B 568 BrY 17-10
SW-18:HYD.FLUID LEVEL SW.

B 569 GB 17-12
R-6:WINDOW WASHER MOTOR RELAY
14 RB 82 GO M
B M-4:WINDOW WASHER MOTOR
14
B 591 PB 2 WY
SW-52:AUTO IDLE STOP SELECT SW. 14-6 2
STD CONTACT AT RELEASE
14-15 801 GrL

B 563 PL 14-4
SW-22:DOUBLE SINGLE SELECT SW.
OPT
R-8:WORK LIGHT RELAY
16 1.25RW 16 1.25RW 85 1.25WB 85
B 583 VW 585 VR 16 L-1:BOOM WORKING LIGHT LEFT
SW-39:OVERLOAD SW. 12-14 16
SW-32:OVERLOAD INDICATE SW. 85 L-9:BOOM WORKING LIGHT RIGHT
STD STD
14-16 802 BrY WORKING LIGHT ON 85 B
L-2:WORKING LIGHT RIGHT
E-10:RECEIVER DRIER E-11:AIR COMMPRESSOR CLUTCH
85 C-4 92 BP 93 LW
R-20:TIMER RELAY
15 WB 87 WL E D 86 OW B
15
SW-11:LEVER LOCK SW.
SV-4:OPERATING LEVER LOCK SOL. 18 1.25WG
18 1.25B
A B 19 RL
TIMER 19
AIR
CONDITIONER
17-11 AMP. 24V 181 R
24V
TXD 608 G SW-13:AIR CONDITIONER SW.
RXD 609 W TXD
COOLING 184 B GND

UNIT
SW-43:JIB PRESS SW.

B 584 VY 13-16
R-26:EXTRA DISPRESS RELAY
OPT
WB 270 GL B
15
WY SV-11:
2
EXTRA DISPRESS SOL.
SW-44:EXTRA PRESS SW.
B 610 GrL 14-7 590 V
14-17
OPT
OPT EXTRA
TO 3/3
2
E-16:CONVERTER E-7:TUNER AM&FM SW-42:ENG.ROOM LIGHT SW. L-8:ENG.ROOM LIGHT
ANT.
YB B
OL 207 PB 88 LR 9
4 IGN 12V E-17:SOCKET 2(+)
6(-) 89 OB E-9:SPEAKER RIGHT
STD
YB MEM 208 PW FM/AM
9 24V B 1(+) 90 LW
B 5(-) E-8:SPEAKER LEFT
91 Br
207 PB 3 B L-3:ROOM LIGHT
7
208 PW 8 6 LOCALY PROCURED 9 YB
PARTS 9
STD
3 RL B
3 E-6:CIGARETTE LIGHTER
R-7:HORN RELAY
5 WG 5 83 WL B E-5:HORN HIGH
5
5 84 WB B
SW-10:HORN SW.(LEFT) B E-4:HORN LOW 11 R B
11 M
84 WB B M-9:FUEL PUMP
SW-20:HORN SW.(RIGHT) OPT
OPT
M-11:FUEL SUPPLY PUMP

15A
WR 1.25 B
8 M
STD
R-10:CAB WORK LIGHT RELAY 1
11 1.25R 11 179 1.25L L-4:CAB WORKING LIGHT(FRONT 1)
11
11 185 LY B
L-5:CAB WORKING LIGHT(FRONT 2)
SW-21:WORK LIGHT SW.
20
20 1.25WR 178 WY
EXAMPLE OF WIRE COLOR
B
L-10:CAB WORKING LIGHT(BACK)
R-11:CAB WORK LIGHT RELAY 2
W L
176 LO B
L-15:ROTARY LIGHT Stripe color (Blue)
SW-30:ROTARY LIGHT SW.
Ground color (White)

STD
WIRE COLOR CODING TABLE

Sign Color Sign Color Sign Color Sign Color
B Black W White Br Brown V Violet
G Green Y Yellow Lg Light Green
L Blue P Pink Gr Gray
R Red O Orange Sb Sky Blue
3
This page is left blank for editing convenience
4
2. ELECTRICAL EQUIPMENT
LIST
Group Code NAME Group Code NAME Group Code NAME
M㧙1 Starter motor ̆ Solenoid valve assy
C㧙1 Mechatro controller M㧙2 Governor motor SV㧙1 Swing parking brake SOL.
CONTROLLER
MOTOR
M㧙3 Wiper motor SV㧙2 Power boost SOL.
M㧙4 Washer motor SV㧙3 Two-speed select SOL.
SOLENOID
C㧙2 Gauge cluster M㧙9 Fuel pump (opt.) SV㧙4 Operating lever lock SOL.
M㧙11 Fuel supply pump SV㧙5 Breaker SOL.
C㧙4 Air conditioner amp. SV㧙6 Clockwise SOL.
C㧙5 Air conditioner panel ̆ Proportional sol. Assy SV㧙7 Counterclockwise SOL.
C㧙6 IT controller (ORBCOMM) PSV㧙A SV㧙9 Nibbler open SOL.
SOLENOID VALVE
Arm valiable recirculation proportional sol.
PROPORTIONAL
PSV㧙B P2 bypass cut proportional sol. SV㧙10 Nibbler close SOL.
D㧙1 Diode PSV㧙C Travel priority proportional sol. SV㧙11 Extra depressure SOL.
D㧙2 Diode PSV㧙D P1 bypass cut proportional sol.
D㧙3 Diode PSV㧙G SW㧙1 Key SW.
DIODE
D㧙4 Diode PSV㧙P1 P1 pump proportional sol. SW㧙2

D㧙5 Diode PSV㧙P2 P2 pump proportional sol. SW㧙3 Two-speed select SW.
D㧙6 Diode SW㧙4 Swing parking release SW.
D㧙10 Diode R㧙1 Battery relay SW㧙5 KPSS. Mode release SW.
D㧙11 Diode R㧙2 Starter relay SW㧙6 ENG. Water temp. SW.
R㧙3 Glow relay SW㧙7 ENG. Oil press. SW.
E㧙1 Fuse box R㧙4 Safety relay SW㧙8 Air filter restriction SW.
R㧙5 Wiper motor relay SW㧙9 ENG. Oil level SW.
E㧙2 Alternator R㧙6 Washer motor relay SW㧙10 Horn SW. (Left)
E㧙3 Hour meter R㧙7 Horn relay SW㧙11 Level lock SW.
RELAY
E㧙4 Horn low R㧙8 Work light relay SW㧙13 Air conditioner SW.
E㧙5 Horn high R㧙9 SW㧙16 Auto accel release SW.
E㧙6 Cigarette lighter R㧙10 Cab work light relay 1 SW㧙17 ENG. Coolant level SW.
ELEC EQUIPMENTS
E㧙7 Tuner AM&FM R㧙11 Cab work light relay 2 SW㧙18 Hyd. fluid level SW.
E㧙8 Speaker left R㧙19 Flasher relay (OPT.) SW㧙20 Horn SW. (Right)
E㧙9 Speaker right R㧙20 Timer relay SW㧙21 Work light SW.
E㧙10 Receiver drier R㧙26 Extra pressure release relay SW㧙22 Conflux single select SW. (OPT.)
E㧙11 Air compressor clutch R㧙28 Auto idle stop relay 1 SW㧙23 Wiper interlock SW.
SWITCH
E㧙13 R㧙29 Auto idle stop relay 2 SW㧙30 Rotary light SW.
E㧙14 Resistor SE㧙1 Press. sensor (low) : Bucket digging SW㧙32 Overload indicate SW.
SE㧙2 Press. sensor (low) : Bucket dump SW㧙34 Power boost SW.
E㧙16 DC-DC converter SE㧙3 Press. sensor (low) : Boom up SW㧙35 Heavy lift SW.
E㧙17 Socket (12V) SE㧙4 Press. sensor (low) : Boom down
E㧙22 Antenna (Cab side) SE㧙5 Press. sensor (low) : Swing
E㧙23 Antenna SE㧙6 SW㧙39 Overload SW.
E㧙24 GPS antenna SE㧙7 Press. sensor (low) : Arm in SW㧙41 Travel alarm SW. (OPT.)
E㧙25 Battery SE㧙8 Press. sensor (low) : Arm out SW㧙42 ENG. Room light SW.
L㧙1 Boom working light SE㧙9 Press. sensor (low) : Travel right SW㧙45 Handle assy. (breaker SW.)
SENSOR
L㧙2 Working light right deck SE㧙10 Press. sensor (low) : Travel lerft SW㧙46 Clockwise SW.
L㧙3 Room light SE㧙11 Press. sensor (low) : OPT.1 SW㧙47 Counterclockwise SW.
L㧙4 Cab work light (Front 1) SE㧙12 SW㧙48 Nibbler open SW.
L㧙5 Cab work light (Front 2) SE㧙13 ENG. Revolution sensor SW㧙49 Nibbler close SW.
LIGHT
L㧙6 Cab work light (Front 3) SE㧙14 Coolant thermo sensor SW㧙52 Auto idle stop select SW.
L㧙7 Cab work light (Front 4) SE㧙15 Fuel sensor SW㧙A Cab door SW.
L㧙8 ENG. Room light SE㧙16 Accel potentio SW㧙B Extra SW.
L㧙9 Boom working light right SE㧙20 Press. sensor (low) : OPT.2
L㧙10 Cab work light (Rear) SE㧙21
SE㧙22 Press. sensor (high) : P1 pump
L㧙15 Rotary light SE㧙24 Extra drain press
5
3. HARNESS
3.1 HARNESS LIST
DIVISION
POSITION ITEM NAME NAME ITEM
3.3 OPERATORS CONTROLS (STD) ̆̆
OPERATORS CONTROLS (DOZER) ̆̆
3.4 CONTROLLER ASSY Cab harness assy 3.4-4
Instrument panel harness 3.4-4-3
3.5 INSTRUMENT PANEL ASSY (STD) ̆̆
INSTRUMENT PANEL ASSY (N&B)
INSTRUMENT PANEL ASSY
UPPER 3.6 UPPER ELEC ASSY ̆̆

FRAME 3.7 UPPER HARNESS ASSY Upper harness 3.7-1
Cable ; Starter 3.7-2
Cable ; Ground 3.7-3
Cable ; Battery 3.7-4
Cable ; Battery relay 3.7-5
Cable ; Frame ground 3.7-15
Harness ; E/G room light 3.7-17
Harness ; overload SW. 3.7-19
3.8 E/G HARNESS ASSY Harness ; E/G sub harness 3.8-1
3.9 FLOOR HARNESS ASSY Cable ; Ground 3.9-2
Harness ; Under floor 3.9-7
3.10A CAB HARNESS ASSY Harness ; Inpane LH 3.10-1
3.10 Harness ; Inpane RH 3.10-2
Harness ; Cab front 3.10-3
3.11 CAB ASSY Harness ; Wiper motor 3.11-2-37
CAB
CAB INSTALL Harness ; Carl code 3.11-61
Harness ; Internal 3.11-64
Antenna 3.11-65
Harness ; Room lamp 3.11-189
3.12 BATTERY INSTALL ̆̆
BATTERY
BATTERY ̆̆
3.13 3.13.1 DECK ̆̆
LIGHT 3.13.2 CAB Harness ; Cab light 3.13.2-18
INSTALL 3.13.3 FLASHER ̆̆
3.13.4 BOOM ̆̆
BOOM 3.14 BOOM HARNESS ASSY Harness 3.14-5
FUEL 3.15 FUEL PUMP ASSY ̆̆
ALARM 3.16 ALARM ASSY ̆̆
6
3.2 HARNESS CONNECTION DRAWING
P-2 GND
MECHATRO CONTROLLER SWING PARKING SOL.
FUEL SENSOR ATT POWER BOOST SOL.
FUEL PUMP TRAVEL 1-2 SPEED SOL. P-29 GND 㩷
AIR FILTER SW. SAFETY LEVER LOCK SOL. ALTERNATOR
WASHER MOTOR E/G WATER COOLER SW. DIODE
E/G OIL LEVEL HYD. OIL LEVEL SW.
BATTERY RELAY(POWER) OVER LOAD SW.
HORN (Hi) E/G ROOM LIGHT
HORN (Lo) SWING FLASHER RH
DECK LIGHT (WORK LIGHT RH) SWING FLASHER LH
GOVERNOR MOTOR HYD. OIL TEMP. SW.
E/G SPEED SENSOR FUEL SUPPLY PUMP
GND 㩷
TRAVEL 1-2 SPEED SW.
EXTRA DISPRESS SOL.

P-1 GND
ROOM LIGHT INPANE RIGHT HARNESS
KPSS RELEASE SW. 䊶TRAVEL ALARM SW.(OPT.)
WIPER MOTOR 䊶ATT POWER BOOST SW.
AIR CONDITIONER 䊶AUTO ACCEL RELEASE SW.
SAFETY RELAY 䊶HORN SW.(OPT.)
AUTO IDLE STOP RELAY 1 䊶ACCEL POTENTIO
AUTO IDLE STOP RELAY 2 䊶AUTO IDLE STOP SW.
HORN RELAY 䊶KEY SW.
WORK LIGHT RELAY CAB WORK LIGHT
WASHER MOTOR RELAY BACK UP POWER (STD & OPT.)
RESISTOR CAB RIGHT FRONT HARNESS (OPT.)

SWING PARKING RELEASE SW. 䊶POWER WINDOW CONTROLLER
ROOM LIGHT 䊶POWER WINDOW SW.
SPEAKER LEFT 䊶WIPER MOTOR (RISE UP)
SPEAKER RIGHT ROTARY LIGHT
CAB RIGHT FRONT HARNESS (STD) DC-DC CONVERTER

䊶HOUR METER CAB WORKING LIGHT SW.
䊶CIGARETTE LIGHTER HEAVY LIFT SW.

䊶GAUGE CLUSTER
WIPER RELAY
INPANE LEFT HARNESS

䊶SINGLE CONFLUX SELECT SW. (OPT.) 䊶HORN SW.
䊶SWING FLASHERSW.(OPT.) 䊶ATT POWER BOOST SW. LH (OPT.)
䊶POWER PORT
Fig. 2 Harness connection drawing
7
3.3 OPERATORS CONTROLS 3.3-35 CONTROL BOX ASSY LH 3.3-36 CONTROL BOX ASSY RH
OPERATORS CONTROLS DOZER
ITEM PART NAME Q’TY REMARKS
6 GRIP ASSY 1
6-2 SWITCH 1 2 Speed change
35 CONTROL BOX ASSY 1 LH
35-21 LIMIT SWITCH 1 Safety lock
35-39 GRIP ASSY 1
35-39-2 HANDLE ASSY 1
36 CONTROL BOX ASSY 1 LH
36-12 GRIP ASSY 1
36-12-2 HANDLE ASSSY 1
3.3 OPERATORS CONTROLS
3.3-35-39-2
3.3-36-12-2 HANDLE ASSY RH
3.3-35-21 LIMIT SWITCH
3.3-6 GRIP ASSY
8 Fig.3 Operators controls

3.4 CONTROLLER ASSY
CONTROLLER ASSY
ITEM PART NAME Q’ REMARKS

TY
3 CONTROLLER 1
4 CAB HARNESS ASSY 㧙 Not shown
1
4-3A INPANE HARNESS 㧙
4-3B INPANE HARNESS 1
4-3A-2
4-3B-2 FUSE BOX 1
5 RESISTOR 1
6 SWITCH ASSY 1 S/P Release
7 SWITCH ASSY 1 KPSS Release
8 RELAY 8
17 FLASHER RELAY 㧙
20 STARTER SAFETY RE. 1 E/G Parts
23 TIMER 1
25 RELAY 1 Auto idle stop 1
NOTES
1. FIX THE JOINT CONNECTION AND DIODE ON THE INST-HARNESS.
2. REMOVE THE TAPE WHICH IS FIXING THE CONNECTOR AND CONNECT WITH EQUIPMENT.
Fig.4 Controller assy
9
3.4-4-3 INSTRUMENT PANEL HARNESS (1/2)
Fig.5 (1/2) Instrument panel harness

10
3.4-4-3 INSTRUMENT PANEL HARNESS (2/2)
Fig.5 (2/2) Instrument panel harness

11
12
3.5 INSTRUMENT PANEL ASSY
11 SPEAKER 2
21 SWITCH 1 Decel
26 CONVERTER 1 DC-DC
38 SOCKET 1 12V
40 SWITCH 1 Over load
41 SWITCH 1 Rotary light
46 HOUR METER 1
47 SWITCH 1 Heavy lift

2 GAUGE CLUSTER 1
59 COVER ASSY 1
59-4 CIGARETTE LIGHTER 1
61 RH PANEL ASSY 1
61-2 POTENTIO METER 1
61-3 KEY SWITCH 1
Fig. 6 Instrument panel assy

13
3.6 UPPER ELEC ASSY
UPPER ELEC ASSY

1 BATTERY RELAY 1
2 HORN 1 Hi
3 HORN 1 Lo
7 ROOM LIGHT 1
8 SWITCH 1
Fig. 7 (1/2) Upper elec assy

14
Fig.7 (2/2) Upper elec assy 15
3.7 UPPER HARNESS ASSY
UPPER HARNESS ASSY

1A UPPER HARNESS 1
2 CABLE 1 Starter
3 CABLE 1 Ground
4 CABLE 1 Battery
5 CABLE 1 Battery
relay
15 CABLE 1 Frame
ground
17 E/G ROOM LIGHT HARNESS 1
19 OVER LOAD SW. HARNESS 1
Fig.8 (1/3) Upper harness assy

16
17
18
3.7-1 UPPER HARNESS (1/2)
Fig.9 (1/2) Upper (main) harness

19
3.7-1 UPPER HARNESS (2/2)
Fig.9 (2/2) Upper (main) harness

20

3.7-2 STARTER CABLE 3.7-5 BATTERY RELAY CABLE

400

TERMINAL TERMINAL
60-8 BC818
CAP AV60B
YAZAKI 7034-1283 CAP
BTC-135-R (RED)
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3.7-3 BATTERY GROUND CABLE 3.7-15 FLAME GROUND CABLE

100
LA308 5B 5B
300
1PAM
YAZAKI 7123-3010
40 )LJ )ODPHJURXQGFDEOH
3.7-17 ENGINE ROOM LIGHT HARNESS
AV60B TERMINAL
60-8
TERMINAL
BC816 DOUBLE WOUND TAPING
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3.7-4 BATTERY CABLE

3.7-19 OVER LOAD SW. HARNESS

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3.8 ENGINE HARNESS ASSY

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3.8-1 ENGINE SUB HARNESS

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3.9 FLOOR HARNESS ASSY

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3.9-7 FLOOR HARNESS

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3.10 CAB HARNESS ASSY
CAB HARNESS ASSY

1 INSTRUMENT PANEL LH HARNESS 1
2 INSTRUMENT PANEL RH HARNESS 1
3 CAB FRONT HARNESS 1
8 INSTRUMENT PANEL RH HARNESS 㧙
9 CAB FRONT HARNESS 㧙
Fig.22 (1/2) Cab harness assy

27
Fig.22 (2/2) Cab harness assy
28
3.10-1 INSTRUMENT PANEL RH HARNESS
Fig.23 Instrument panel RH harness
29
3.10-2 CAB FRONT HARNESS
Fig.24 Cab front harness
30

3.11 CAB ASSY

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CAB INSTALL
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3.11-2-37 WIPER MOTOR HARNESS 3.11-61 CURL CODE HARNESS 3.11-64 M/W INTERNAL HARNESS 3.11-189 M/W ROOM LAMP HARNESS
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3.12 BATTERY AND BATTERY INSTALL 3.13 LIGHT INSTALL
SPECIFICATION VOLTAGE 12V 12V 3.13.1 DECK LIGHT INSTALL
AMP. HRS. (5HR. RATE) 92Ah 88Ah LIGHT INSTALL
WEIGHT Approx.30kg Approx.28kg
VOLUME OF ELECTROLYTE Approx.7 Approx.7
SPECIFIC GRAVITY OF 1 LIGHT 1
ELECTROLYTE 1.28r0.01(20͠) 1.28r0.01(20͠)
BATTERY INSTALL
1 PLATE 1
2 CAPSCREW 2
3 LOCK WASHER 2 M10
4 SEMS BOLT 2 M1230
5 BRACKET 1
6 RUBBER 1
Fig.33 Battery and battery install Fig.34 Deck light install
33
3.13.2 CAB LIGHT INSTALL
CAB LIGHT INSTALL
6 SWITCH 1
18 HARNESS 1 For 5 light
3.13.2-18 5 LIGHT HARNESS
Fig. 36 5 light harness

Fig. 35 Cab light instal
34
3.13.4 BOOM LIGHT INSTALL 3.14 BOOM HARNESS ASSY
BOOM LIGHT INSTALL BOOM HARNESS ASSY
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
1 LIGHT 2 1 HARNESS 㧙
5 HARNESS 1
Fig.39 Boom harness assy
3.14-1 BOOM HARNESS ; YN15E01013D1 KCMA & OCEANIA
Fig.38 Boom light install Fig.40 Boom harness
35
3.14-5 BOOM HARNESS
Fig.41 Boom harness
3.15 FUEL PUMP ASSY
FUEL PUMP ASSY

1 FUEL PUMP ASSY 1
1-1 FUEL PUMP 1
FUEL PUMP IS SAME AS BEFORE MODIFICATION.
Fig.42 Fuel pump assy

36
E235SR
SECTION 24 COMPONENTS SYSTEM
TABLE OF CONTENTS
I. HYDRAULIC COMPONENTS
1.1 Hydraulic Pump & Regulator .......................................................................................... H1-1
1.2 Pilot Valve (ATT) ............................................................................................................. H2-1
1.3 Pilot Valve (Travel) .......................................................................................................... H3-1
1.4 Control Valve .................................................................................................................. H4-1
1.5 Swing Motor Unit ............................................................................................................ H5-1
1.6 Travel Motor .................................................................................................................... H6-1
1.7 Swivel Joint .................................................................................................................... H7-1
1.8 Hydraulic Cylinder .......................................................................................................... H8-1
II. ELECTRIC EQUIPMENT

2.1. List of Electric Equipments ............................................................................................ E1-1
2.2. Specification of Electric Equipments ............................................................................. E1-3

1. HYDRAULIC PUMP REGULATOR

1.1 SUMMARY
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MAX. FLOW RATE
ADJUSTING SCREW MIN. FLOW RATE
'U
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(2) Hydraulic circuit diagram
A2 PH2 PH1A1 (DRIVEN)

(DRIVEN)
(KR3G-1E02-V) C (KR3G-1E02-V)
258 C 258
(KDRDE5K) (KDRDE5K)
C C
Regulator
Regulator
Main pump
Di
Do Dr1
$ Gear pump for pilot
$ # C Dr2
Fig. 1-2 Hydraulic circuit diagram of pump

(3) Specifications
Table 1-2
Item Main pump Gear pump for pilot
Pump model K3V112DP-114R㧙1E02 ZX10LSLZ2㧙06D
Max.displacement capacity cm3 /rev 1052 10
2,000 2,000
Rated revolution rpm
(CW as seen from shaft end) (CCW as seen from shaft end)
Working pressure kgf/cm2(psi) 350 (4980) 50 (710)
Max. flow /min(gal/min) 210 (55)2 20 (5.3)
Max. input horse power kW {PS} 107 {45} (Gear pump only : 3.6)
Max. input torque MIHyO
NDHyHV 52 (310) [Gear pump only : 1.5(11)]
Model KR3G㧙1E02
Regulator Control function Positive electric flow control 㧙
With solenoid proportional reducing
Others valve(KDRDE5K)
Relief set pressure kgf/cm2(psi) 350 (4,980) 50 (710)
H1㧙2
1.2 HYDRAULIC PUMP No. NAME Q'TY No. NAME Q'TY
1.2.1 CONSTRUCTION 111 DRIVE SHAFT 1 531 TILTING PIN 2
(1) Main pump 113 DRIVEN SHAFT 1 532 SERVO PISTON 2
122 ROLLER BEARING 1 534 STOPPER 2
789 123 ROLLER BEARING 1 535 STOPPER 2
954 806 406 793 703 531 214 732 953 412 124 NEEDLE BEARING 2 536 SERVO COVER 2
REGULATOR ASSY 536 534 532 548 901 535 807 126 SPACER 2 541 SEAT 4
410 127 SPACER 1 543 STOPPER 4
536 128 SPACER 2 545 BALL 4
406 129 SPACER 2 548 FEED BACK PIN 2
141 CYLINDER BLOCK 2 703 O RING : 1B G25 2
409,728 408 151 PISTON 18 709 O RING : 1B G85 2
157 152 SHOE 18 724 O RING : 1B P8 3
GEAR PUMP ASSY 153 RETAINER PLATE 2 725 O RING : 1B P11 2
156 SPHERICAL BUSHING 2 726 O RING : 1B P10 4
157 SPRING 18 728 O RING : 1B P24 2
171 FRONT CASING 1 732 O RING : 1B P18 2
191 DRIVE GEAR 1 735 O RING : 1B P12.5 4
806 192 DRIVEN GEAR 1 751 PACKING 1
954 211 SHOE PLATE 2 752 SEAT 1
212 SWASH PLATE 2 774 OIL SEAL 1
888 316 214 BUSHING 2 789 BACK UP RING 2
709 251 SWASH PLATE SUPPORT 2 793 BACK UP RING 2
406 261 COVER 1 806 NUT 2
271 CASING 1 807 NUT 2
312 VALVE CASING 1 823 SNAP RING 2
212 211 153 469 141 725 313 VALVE PLATE 1 824 SNAP RING 1
251 156 152 728 151 410 467 885 409 314 VALVE PLATE 1 825 SNAP RING 2
316 COVER 1 826 SNAP RING 2
828 123 724 129 826 271 491 314 124 406 SOCKET BOLT : M820 16 827 SNAP RING 1
408 SOCKET BOLT : M1265 10 828 SNAP RING 2
409 SOCKET BOLT : M1016 2 885 PIN 2
127 410 SOCKET BOLT : M1640 12 886 SPRING PIN 2
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P PORT

PORT (2,4)
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3. PILOT VALVE
(TRAVEL)
3.1 OUTLINE
(1) Outside view
VIEW FROM MACHINE FRONT SIDE
Tightening
Port torque Port 4-11
size MIHyO
HVyNDU name Function
Through
1 RH travel forward port
2 RH travel reverse port
7.5r0.5
PF3/8 3 LH travel forward port
(54r3.6)
4 LH travel reverse port
T Tank port
5 Travel pressure sensor
6 port
3.7r0.2
PF1/4 P Travel pressure sensor
(27r1.4) Fig. 3-1 Outside view of travel pilot valve
port
(2) Specification Pilot primary pressure port
(3) Performance characteristics
Item Specification
Type 07291-00000
Primary pressure 50kgf/cm2 (710psi)
Secondary pressure 5.5㨪24kgf/cm2 (78㨪340psi)
Rated flow 10 /min (2.6gal/min)
Weight Approx. 11kg (24 lbs)
Hydraulic simbol Control diagram
H3㧙1

3.2 CONSTRUCTION AND OPERATION

=

PORT 5

PORT 6

SECTION AA

T=TIGHTENING TORQUE : kgf m(ft lbs)

4-M10
T=4.3 0.4(31 29)
SECTION BB
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3.3 OPERATION
(1) Construction z If the cam operates during travel operation,
The valve consists of the following parts in the oil in the damper chamber is kept from
terms of hydraulic function : flowing back by the check valve. Thus the oil
flows to part E only from the orifice. Damper
A : Damper section
action operates by the resistance that is built
B : Reducing valve section
up as the oil passes through the orifice.
C : Shuttle section Let us explain the profile of the piston (See
(2) Operation Fig. 3-4.) The upper part of the piston has a
1) Damper section diameter of 12mm(0.472in), while the lower
z If the primary pressure is supplied by P, it is part of it has a diameter of 11mm(0.433in).
flowed to the damper chamber by way of This results in an areal difference, with the
circuits D and E . result that the piston is constantly subject to
The pressure is then filled up in the damper a vertical force. For this reason, the orifice
rises by the pressure caused by the areal
chamber via the orifice and the check valve.
difference between the operating part of the
In that case, the air present in the damper
cam and the piston on the opposite side i.e. the
chamber is pushed out to the T port from piston follows the cam. That is to say, constant
circuits F and G, in order to prevent the damper action operates wherever the cam is
damper characteristics from fluctuating by located. Since the larger diameter of the
air mixture. piston, the cover, the 11mm diameter part of
the piston and the guide are manufactured
with minimal clearance, only a little leakage
CAM
occurs. Consequently, the damper
performance is not affected at all.
F
PISTON G
COVER
E CHECK
VALVE
GUIDE
ORIFICE
DAMPER
SPRING FOR CHAMBER
T
SECONDARY
PRESSURE
D
I
SPOOL P P
H
SECONDARY PRESSURE PORT
BODY
Fig. 3-3
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ß
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ß
RETURN
SPRING
7 7
,
-
3 3
-
+
SECONDARY )LJ
PRESSURE PORT
+
3) Shuttle section
z If pressure is built up at port 1 or 3, the ball
is pressed against the seat by the pressure.
The pressure goes through from port 1 to port
5(or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4
as the ball is sealed metallically by the seat.
If pressure occurs at port 2 or 4, the ball is
pressed against the body by the pressure. The
result is that the pressure connects with port
5 from port 2(with port 6 from port 4).
Only a little leakage occurs at port 1 or 3 as
the ball is sealed metallically against the
body.
21465
PORT
PORT 1 PORT 2
SEAT BALL
BODY
PORT 3 PORT 4
PORT 6
Fig. 3-5 Shuttle section
H3㧙5

+
4. CONTROL
VALVE Table 4-1
Tightening
Port Port
torque Description
4.1 SPECIFICATIONS size name
kgfym (lbfyft)
P1 Pump P1 port
T P2 Pump P2 port
Ab Boom up port
Bb Boom down port
(1) Outside view and hydraulic ports P2 Ac Bucket dump port
Bc Bucket digging port
20㨪25 Ar Travel right port (forward)
P1 PF1
Note : Only one port in ( ) shows plug. In case of two (140㨪180) Br Travel right port (reverse)
T2 AL Travel left port (forward)
ports are written side by side, the port in ( ) shows BL Travel left port (reverse)
the port on backside. Aa Arm in port
Ba Arm out port
As Swing port (right)
2-M12-22 Bs Swing port (left)
FOR LIFTING T2 Tank port
15㨪18 (T3) Tank port
PF3/4
(110㨪130) (P4) Option port
(TB) Tank port
10㨪12
PF1/2 (P3) Option port
(72㨪87)
MAIN RELIEF VALVE
PAa Arm in pilot port
P2 P1 P1,(P2) T2(T) T2 T PBa Arm out pilot port
PAb Boom up pilot port
(CT2)
(CT1)
PBb Boom down pilot port
(CP2)
(CMR2) AL
BL PAc Bucket dump pilot port
(CMR1)
PTb
PL1 TRAVEL STRAIGHT TRAVEL LEFT PAL PBL PBc Bucket digging pilot port
PAr Travel right pilot port (forward)
Br (CP1) Ar PBr Travel right pilot port (reverse)
As LCs Bs
PBr PAr TRAVEL RIGHT SWING PBs1 PAL Travel left pilot port (forward)
Dra
PAs
PBL Travel left pilot port (reverse)
Drb PBs2 Pss (T3) 7㨪8
Bc (LCc) Ac Pisc PF3/8 PAs Swing right pilot port
(CCb) (51㨪58)
PBc BOOM PBs1 Swing (left) pilot port 1
PAc BUCKET CONFLUX PB1 PBs2 Swing (right) pilot port 2
Bb (LCb) (CRb) Aa (LCa) (CRa)
PA1 Arm conflux pilot port
PLc2
PLc1 PB1 Boom conflux pilot port
PBb PAb BOOM ARM (PBa)
Drc PAa PTb Travel straight pilot port
Drd
Ab PCa P2 bypass pilot port
(CCa) Ba PCb P1 bypass pilot port
ARM (CAr)
ARM PCb P1 CUT P2
CONFLUX RECIRCULATION Pis
CUT PCa Pis Arm recirculation pilot port
(X1) (PAo2) Option 2 pilot port (A)
PA1
(PBo2) Option 2 pilot port (B)
(P4) (P4) OPTION 2 PBo2
Pisc Swing priority pilot port
PAo2 Ao2 Bo2
PL1 ATT power boost pressure port
Pss Swing low pressure sensor port
Dra Drain port
3.5㨪3.9
(P3) PF1/4 Drb Drain port
(P3) (25㨪29)
Drc Drain port
Drd Drain port
PLc1 Boom lock valve release pilot port
(P3) PLc2 Arm lock valve release pilot port
5.0㨪6.6
㧹10 㨀 Tank port (32)
(36㨪48)
8.5㨪11.2 Ao2 Option 2 pilot port (A)
㧹12
(P4) (61㨪81) Bo2 Option 2 pilot port (B)
M12-26
PBo FOR LIFTING
ARM PCa P2 CUT

PA1
CONFLUX
(2) Specifications
Drd
BOOM PBb ARM (P4) Item
PBa
PLc2 Main control valve
BUCKET
PBc
(T3) (P3) Model KMX15YC
Option 2
TRAVEL control valve Model KADV28Y
PBr SWING
RIGHT PBs1
Max. flow /min (gal/min) 220(58)2
TRAVEL PTb Main relief valve kgf/cm2 (psi) 350 (4980)
PBL TRAVEL LEFT
STRAIGHT M12-26 set pressure At power boost 385 (5470)
FOR LIFTING
Boom H, Bucket H, Arm R 405 (5760)
↑ Over load relief valve
set pressure
Boom R, Bucket R, Arm H 385 (5470)
A
VIEW A OPT. H&R kgf/cm2 (psi) 385 (5470)
Fig. 4-1 Control valve outside

H4㧙1
4.2 CONSTRUCTION 154 164 101
T T2
273 273 974 154 164 102 974
P1,(P2) T2 T
P2 P1
PBL PAL
TRAVEL TRAVEL
STRAIGHT LEFT PAs PBs2
978 PTb
PBs
TRAVEL SWING Pss 973 973
RIGHT
977 PBr PAr
PB1
BOOM
BUCKET CONFLUX
PBc PAc
PBa PAa
ARM
973 973
BOOM
PBb PAb
PCa Pis 973
ARM 973
P1 CUT
RECIRCULATION
(ARM CONFLUX)
(P2 CUT) 162(4pc) PA1 PCb
PBo PAo
(P4) OPTION 2
162(4pc)
169 155
↑ (P3)
169 155
Σ SECTION A㧙A SECTION B㧙B
102
974 101 274, 275 203
274
162 562 334
T2 332 166 156
512 203
552 340
562 CT1 CT2 334
522 329
552 P1 PAL 332
512 327
(P4) 338
522 332
P2 601 328
161 327
262
T (P3) 332
974 212 161 262
212
PL1
512
SECTION H㧙H
AL
522 511
274 274, 275 CMR1 521
552 (CP2)
VIEW I 562 551
562 CMR2
164
552 163
BL
522 306 ; TRAVEL SPOOL
512
264
161 205
TRAVEL STRAIGHT
SPOOL ; 307 264
PTb 205 PBL
SECTION C㧙C
Fig. 4-2 (1/3) Construction of control valve
H4㧙2

203 PBs2
331 201 333 333 201 331
336 334
Pss
322 PAb PAa 332 PAr 202
336 PAs 333
321 338 331
322
331 328 336
321 327 322
261 332 321
604
262 331
211
331 261
163 Dra
261
162 302 ; ARM SPOOL
Aa 511 511 Ar As 511
164 CRb 521 523
556 521 551
(LCs)
CP1
524 LCb 551 556
(LCa) 164
514 164 164
Br Bs
551 514
(CRa) 556
164 Bb
Pisc 524 Drb 303㧧SWING SPOOL
521
511 164 TRAVEL SPOOL㧧306
BOOM SPOOL㧧301 264 PBr PBs1 264
PBb PBa 205 205
SECTION D㧙D
211
602 205 264 163 205 264 PCb Pis
SECTION F㧙F
204 204
334 332 334
PAb PAa 332 332
337 337
603 326
326 325
325 332
262 262
P1 BYPASS CUT SPOOL㧧309 CAr 311㧧ARM RECIRCULATION
PLc1 Drc 161 Ab
562 SPOOL
552
(PLc2) (Drd) 163
522
162 512
168
158 X1
164
Ba
551 (CCa)
521 310㧧P2 BYPASS CUT SPOOL
SECTION K-K 511
ARM CONFLUX SPOOL ; 308 603
162 262
262 332
326 332 325
337 326
325 337
332 332
334 334
204 PA1 PCa 204
SECTION G㧙G
Fig. 4-2 (2/3) Construction of control valve
H4㧙3
Table 4-3 Note
: ̪marked parts differ according to specifications.Apply
Loctite #262 to areas marked ‫ڏ‬.
201 PB1
Tightening Tightening
333 torque No. PARTS torque No. PARTS
331 PAc
207 kgfym (lbfyft) kgfym (lbfyft)
336
322 333 101 CASING A 1 309 BYPASS CUT SPOOL (P1) 1
321 331
102 CASING B 1 310 BYPASS CUT SPOOL (P2) 1
339
602 38㨪42
324 (270㨪300) 153 PLUG ; PF1 1 311 ARM RECIRCULATION SPOOL 1
331
261 323 21㨪26
154 PLUG ; PF3/4 3 312 ROD SPOOL 1
(152㨪190)
331 11㨪13
161 261 (80㨪94) 155 PLUG ; PF1/2 2 321 SPRING (ARM,BOOM,BUCKET,SWING OUTER) 4
161 7㨪8
511 (51㨪58) 156 PLUG ; PF3/8 2 322 SPRING (BOOM, ARM, BUCKET, SWING INNER) 4
Ac 521 3.5㨪4.0
(CCb) 551 (25㨪29) 157 PLUG ; PF1/4 䋭 323 SPRING (BOOM CONFLUX OUTER) 1
511 164 1.3㨪1.7
521 (9.4㨪12) 158 PLUG ; PF1/8 1 324 SPRING (BOOM CONFLUX INNER) 1
551 305 ; BOOM CONFLUX SPRING
(LCc) 551
SPOOL 161 O RING ; 1B G38 7 325 (ARM CONFLUX, CUT, ARM RECIRCULATION) 4
164 SPRING
164 165 162 O RING ; 1B G30 12 326 (CUT, ARM RECIRCULATION, ARM CONFLUX INNER) 4
Bc 153 SPRING
163 O RING ; 1B P15 4 327 (TRAVEL OUTER, TRAVEL STRAIGHT OUTER) 3
311㧧ROD SPOOL
161 164 164 O RING ; 1B P24 14 328 SPRING (TRAVEL INNER) 2
154
165 O RING ; 1B P29 1 329 SPRING (TRAVEL STRAIGHT INNER) 1
BUCKET SPOOL㧧304
(T3) 264
166 O RING ; 1B P14 2 331 SPRING SEAT 10
PBc 205
603 167 O RING ; 1B P11 䋭 332 SPRING SEAT 14
166 1.6㨪1.8 SPACER BOLT
264 205 168 O RING ; 1B P8 1 (12㨪13) ‫ ڏ‬333 (ARM,BOOM,BUCKET, SWING, BOOM CONFLUX) 5
156
1.6㨪1.8 SPACER BOLT (TRAVEL,ARM CONFLUX,CUT,
SECTION E㧙E 169 O RING ; 1B P18 2 (12㨪13) ‫ ڏ‬334 ARM RECIRCULATION,TRAVEL STRAIGHT) 7
201 SPRING COVER 3 336 STOPPER (ARM, BOOM, BUCKET, SWING) 4
STOPPER
202 SPRING COVER SW. SUB 1 337 (ARM CONFLUX,CUT, ARM RECIRCULATION) 4
203 SPRING COVER 3 338 STOPPER (TRAVEL) 2
204 SPRING COVER 4 339 STOPPER (BOOM CONFLUX) 1
PA02
205 SPOOL COVER 8 340 STOPPER (TRAVEL STRAIGHT) 1
207 SPRING COVER 1 511 LOAD CHECK VALVE (POPPET) (D=25) 8
LOCK VALVE SELECTOR
211 SUB ASSY 2 512 LOAD CHECK VALVE (POPPET) (D=20) 5
274 212 PLATE 2 514 LOAD CHECK VALVE (POPPET) (LOCK VALVE) 2
214
214 CONTROL VALVE FOR OPTION 2 1 521 SPRING (FOR 511) 7
275 261 O RING ; S50 5 522 SPRING (FOR 512) 5
A02 262 O RING ; S39 7 523 SPRING (FOR 511 LCS) 1

2 264 O RING ; 1B G40 8 524 SPRING (FOR 514) 2
2.6㨪3.5 23㨪26
(19㨪25) 273 SOCKET BOLT ; M825 40 (166㨪190) 551 ROMH PLUG ; M27 8
10㨪12 13㨪15
(72㨪87) 274 SOCKET BOLT ; M1225 4 (94㨪110) 552 ROMH PLUG ; M22 5
212 B02 10㨪12 23㨪26
(72㨪87) 275 SOCKET BOLT ; M12100 4 (166㨪190) 556 PLUG (LOCK VALVE) 3
275 301 BOOM SPOOL ASSY 1 562 O RING ; 1B P20 5
7㨪8
302 ARM SPOOL ASSY 1 (51㨪58) 601 RELIEF VALVE (MAIN) 1
7㨪8
274 303 SWING SPOOL 1 (51㨪58) 602 RELIEF VALVE (OVER LOAD) 2
PB02
7㨪8
304 BUCKET SPOOL 1 (51㨪58) 603 RELIEF VALVE (OVER LOAD) 3
SECTION J㧙J 7㨪8
305 BOOM CONFLUX SPOOL 1 (51㨪58) 604 RELIEF VALVE (OVER LOAD) 1
14㨪18
Fig. 4-2 (3/3) Construction of control valve 306 TRAVEL SPOOL 2 (100㨪130) 973 SOCKET BOLT ; M14140 6
14㨪18
307 TRAVEL STRAIGHT SPOOL 1 (100㨪130) 974 SOCKET BOLT ; M14100 2
H4㧙4 308 ARM CONFLUX SPOOL 1

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(6) Lock valve selector sub assy (211) (7) Control valve for option 2 KADV28Y (214)
L101 P202
L541 P334 PA0 PA0
PLC1(PLC2) P337
L162
P323
L163 P324
P333
P271 P0 ’
L171 Drc(Drd) P337
L511 P261 P603 P161 0
P101 P512 TA’ TA

L512 A0
P301 P522
L161 P0
P561 P161
SECTION B㧙B
L201 P551
P0 ’ P0
P161
Fig. 4-6 B0
TB’ TB
Tightening Tightening P262

torque No. PARTS Q’TY torque No. PARTS Q’TY
kgfym (lbfyft) kgfym (lbfyft) PB0 P603 PB0
L101 CASING 1 7㨪8 (51㨪58) L201 PLUG ; M27 1 P204 SECTION A㧙A
L161 O RING ; 1B P22A 1 L511 SPOOL 1
L162 O RING ; AS568-017 3 L512 SPRING 1 Fig. 4-7
L163 O RING ; 1B P8 2 L541 BUSHING 1
1㨪1.4 (7.2㨪10) L171 SOCKET BOLT ; M645 4
Apply Loctite #262 to areas marked ‫ڏ‬.

torque No. PARTS Q’TY torque No. PARTS Q’TY
kgfym (lbfyft) kgfym (lbfyft)
P101 CASING 1 P333 STOPPER 1
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P161 O RING ; 1B G30 3 P334 SPACER BOLT 1
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P202 SPRING COVER 1 P337 SPRING SEAT 2
P204 SPOOL COVER 1 P512 POPPET 1
P261 O RING ; S50 1 P522 SPRING 1
P262 O RING ; 1B G40 1 32㨪36 (231㨪260) P551 ROMH PLUG ; M30 1
2.5㨪3.5 (18㨪25) P271 SOCKET BOLT ; M825 4 P561 O RING ; 1B P28 1
P301 SPOOL 1 7㨪8 (51㨪58) P603 RELIEF VALVE (OVER LOAD) 2
P323 SPRING (INNER) 1 P991 NAME PLATE 1
P324 SPRING (OUTER) 1 P992 RIVET 2
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(2) Functions for travel action
1) At independent travel
If travel operation (forward) is performed, the Meanwhile, the oil which has returned from
secondary pilot pressure from ports 2, and 4 the right and left travel P1 side passes
of the travel pilot valve acts upon ports PAr between the outer circumference of the right
and PAL of the control valve and moves the and left travel spool (306) and the casing and
right and left travel spools (306). returns to the hydraulic tank via the tank
The pressurized oil delivered by pump P1 port (T) of the low pressure circuit (D).
flows into the main passage (51) past the At reverse travel action (when the secondary
travel straight spool (307), passes between pilot pressure acts upon ports PBr and PBL
the outer circumference of the right travel of the control valve), the pressurized oil
spool (306) and the casing and is supplied to works the same way as in the forward travel
the right travel motor P2 by way of port Ar. action.
In the meantime, the pressurized oil
delivered by pump P2 passes between the
outer circumference of the left travel straight
spool (306) and the casing, runs to port AL
and is supplied to the left travel motor P1
side, the same way as the pressure oil by
pump P1.
RIGHT TRAVEL MOTOR
P1 P2
306
Br Ar
PILOT PORT
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51 52 51
Fig. 4-10 At right travel forward (when PAr is pressurized)
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2) Travel straight valve switching at Travel The pressure oil delivered by pump P2 flows,
When the actuator other than that for in most amount of oil, in the CψD direction
travelling and travelling are simultaneously and the main passage (54), becomes the oil
operated, the pilot secondary pressure of pressure for the right travel and the left
solenoid proportional valve (C) acts on PTb travel motions and realizes simultaneous
port of the control valve, moves travel operation of the actuator and travel action.
straight spool (307) upward to the position (travel straight function)
[II]. Furthermore, the secondary pressure of SOL
The result is that the pressurized oil (C) is pressurized and the pressure moves
delivered by pump P1 flows from A to B in travel straight spool (307) rightward to the
most amount of oil and becomes the pressure position (Υ).
for the actuators except one for travel action. Passages A to D are connected to T port, and
the pressure of all circuits are unloaded.
(Unloaded function)
Note : Pressure release operation can be
P2 P1
CMR2 CMR1 operated with hidden mode of gauge
cluster.
CA
T
PTb
DB
T Usual Position [Σ]

T C D A B
CA
T
DB
Travel straight Position [Τ] At travel straight
CA
T
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Pressure release Position [Υ] At unload
VIEW C㧙C
Fig. 4-11 Functions at travel straight spool
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2) Arm out conflux
In operation 1), the oil delivered by pump P1 Part of the delivered oil passes through the
flows into the bypass circuit (52) through the parallel circuit (53) and the restrictor (X1),
main passage (51), but since the bypass combines with the pressure oil of the bypass
circuit (52) and the low pressure circuit (D) circuit (52), pushes the conflux check poppet
are blocked by the bypass cut spool (309), it CCa (511) open, enters port Ba by way of the
does not run into the low pressure circuit (D). conflux circuit in the casing and finally
Meanwhile, since the arm conflux spool (308) combines with the pressure oil on the pump
has now been changed over, the pressure oil P2 side.
of the bypass circuit (52) goes between the
outer circumference of the arm conflux spool
(308) and the casing.
To port Ba through the conflux

P1 BYPASS CUT SPOOL passage in the casing
309 (52) 308
PCb D
PA1
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Fig. 4-19 At arm out operation (P1 bypass cut spool and arm conflux spool)
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Fig. 4-20 When arm is in (under light load)
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5.1 SPECIFICATIONS
SPECIFICATION
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(2) Specifications
Swing motor unit
Type MFC160㧙061
Displacement cm3 (in3) 151 (9.2 )
Hydraulic motor
Working pressure kgf/cm2 (psi) 291 (4140)

Max. flow /min (gal/min) 253 (67)
Braking torque kgfym (lbfyft) 69.9㨪90.9 (506㨪657)
Release pressure
(Stroke end) kgf/cm2 (psi) 31.6 (450)
Relief set pressure kgf/cm2 (psi) 290 (4120)
Weight kg (lb) 63 (139)
Part No. LQ32W00009F2
Speed reduction type Planetary 2-stage
Reduction unit
Reduction ratio 16.8

Lubicate oil Gear oil SAE90 (API class GL㧙4 grade)
Lubicate oil volume (gal) 15.3 (4)
Grease Extreme pressure multipurpose grease
Grease volume A small amount
Weight kg (lb) 234 (516)
Total weight kg (lb) 297 (655)
5.2 EXPLANATION OF CONSTRUCTION

1) The rotary group of the swing motor consists Swing unit
of a cylinder (24) which is integral with the
drive shaft and nine piston assy (7) arranged
in the cylinder bores. The cylinder (24) is Swash plate type Two-stage planetary
axial piston motor gear reduction unit
supported by bearings (3) (22) on both ends.
Each piston assy (7) is guided by a return
plate (6) and retaining spring (4) so as to Mechanical brake
slide smoothly on the cam plate (5).
The balance plate (21) is forced against the Relife valve
end of the cylinder by the force of the disc
spring (18) and the hydraulic force acting on Make-up valve
the bushing (20).
A mechanical brake is installed between the By-pass valve
cylinder exterior and the housing (25).
A relief valve to cushion hydraulic shock and
a backup valve to prevent cavitation are built
in to the cover (33).
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
H5㧙2
5.3 CONSTRUCTION
(1) Swing motor

SECTION A-A

A PORT SIDE
A PORT RELIEF VALVE
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K
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14 5
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15
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27
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1
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torque No. NAME Q’TY torque No. NAME Q’TY
1 PINION SHAFT 1 17 OIL SEAL 1
2 HOUSING 1 ̪6.7 (48.5) 18 SOCKET BOLT ; M10x30 14
3 RETAINER 1 19 RETAINING RING 1
4 SLEEVE 1 ̪18.5 (133) 20 SOCKET BOLT ; M14x150 16
5 SHAFT 4 21 SPRING PIN 4
6 RING GEAR 1 22 THRUST WASHER 8
7 #.2 SPIDER 1 23 NEEDLE BEARING 4
8 #.2 SUN GEAR 1 24 THRUST WASHER 8
9 #.2 PLANETRY PINION 4 25 NEEDLE BEARING 4
10 #.1 SPIDER ASSY 1 26 RETAINING RING 4
11 #.1 SUN GEAR 1 27 SPACER 1
12 #.1 PLANETRY PINION 4 31 SET SCREW ; M20x30 2
13 BEARING 1 33 CONNECTOR 1
14 BEARING 1 34 HOSE 1
15 SPACER 1 35 PLUG 1
16 O-RING 1
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MAKEUP PORT

D
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MECHANICAL BRAKE

RELEASE CHAMBER
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(3) Explanation of ultra shockless relief to piston chamber. Consequently, the
operation pressure of spring chamber P2 reaches equal
The high-pressure oil flowing in the front to the pressure P1 and moves poppet (109)
chamber of poppet (104) flows in the front leftward, resulting in the flowing oil from
chamber of poppet (109) through peripheral pinhole “m” to pin hole “l” again.
orifice of poppet (104) in the pressure-up In this way, the oil flow rate to piston
process. The poppet (109) equipped with chamber “n” is controlled by flow control
orifice “k” is pressed onto the end face of valve, controlling together the time taken to
piston (106) with shoulder due to the load of the position where the piston (106) contacts
spring (110). The pressure oil flowing in the to the liner (107).
front chamber of poppet (109) passes As the above-mentioned, with the movement
thorough orifice “k” and flows in piston of piston (106), the load of spring (103)
chamber “n” through pinholes “m” and “l”, increases from low load to higher load,
moving piston (106) leftward. Then, when the consequently, in the beginning, the cushion
difference (P1-P2) of the pressure P1 of front relief action operates at lower pressure, and
chamber of orifice “k” and the pressure P2 of rises to the specified pressure in a second.
spring chamber increases larger than the This smooth pressure rising enables the
value of spring fitting load (F) / poppet area reduction of shock produced when motor
(A), the poppet (109) moves rightward and starts and stops.
blocks up pin hole “l” with the shoulder of
groove, resulting in the cutoff of the oil flow

L 2 O
M P 2

Fig.5-5 Ultra shockless relief
H5㧙7
(4) Make-up valve
1) Operation in half lever position 2) Braking
(When cushion relief valve does not function.) (When cushion relief valve is functioned)
After accelerating slewing of the upper When the lever is moved to neutral position
structure, when the speed is being reduced by rapidly as described in item 1), the pump
half-lever with the function of control valve, does not supply oil to port A, but the upper
the supply flow rate from pump to port A is structure is slewed by the force of inertia. In
lowered. But if the upper structure is slewed this case, the cushion relief valve on port B
at a comparatively high speed, the pressure side functions, and the oil from relief valve
in the (C) section is lowered to negative goes through the passage (i) (h) and opens
pressure making lubrication necessary. make-up check (36) valve on the port A side
However, when the pressure of port B is to flow into passage (b) (c). But the oil
equal to or lower than the working pressure quantity is insufficient due to the leakage.
of cushion relief valve the all oil of (C) section Therefore oil opens make-up check valve (36)
led through port B is discharged to the through the make-up port, and flows into
control valve. As a result, the flow rate from passage (b) (c) to prevent cavitation.
the control valve (Since the valve is in the
RING GEAR (FIXED)㩷 PLANETARY SHAFT
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 (36) is installed to supply necessary oil SPIDER
into the (C) section.
SUN
(5) Swing reduction unit GEAR
The swing reduction unit is used to reduce
the rotating speed which is transmitted by
the hydraulic motor and to convert it to the
strong turning effort (torque).
This swing speed reduction unit is equipped
with planetary speed reducing mechanism. PLANETARY PINION
The planetary mechanism is made up of sun Fig. 5-6 Planetary mechanism
gear, planetary pinion, planetary shaft,
spider and ring gear, as shown in Fig. 5-6. SWING MOTOR
For the operation of the 1st stage planetary,
12
the hydraulic motor rotates #1 sun gear (11). 11
Sun gear (11) is engaged with planetary 6
pinion (12) and rotates, but since ring gear (6)
is fixed, planetary pinion (12) revolves about 10
sun gear (11) with the planetary shaft and
spider (10). 8
7
The role of spider is to hold the planetary
pinion and planetary shaft and transmits the
power from the planetary pinion to the spider
through the planetary shaft. 9
The #1 spider (10) is linked with #2 sun gear 14
(8) by the involute spline, and transmits the
power to the 2nd stage planetary mechanism.
For the operation of the 2nd stage planetary, HOUSING
the power is transmitted to sun gear (8)ψ
planetary pinion (9) ψ spider (7) similarly to BEARING
the 1st stage. 1
The #2 spider (7) is linked with pinion shaft
(1) by the involute spline, and pinion shaft(1)
is engaged with the swing gear fixed on the Fig. 5-7 Function of reduction unit
H5㧙8

6. TRAVEL MOTOR
6.1 SPECIFICATIONS
2XWVLGHYLHZ 3 SPROCKET INSTALLING FACE
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VIEW A

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6.2 CONSTRUCTION
18 18
30 18
30
29 29
19 20
$ 17 69 17
ൻ VIEW A SECTION C㧙C SECTION D㧙D
VALVE ASSY
22 23 27 27 21 24 26 23 25 52 17 64 57 58 42 37 38 40 39 48 61 73 72 75 76 74 85 86 87
96
52
17
60
90
51
8
69 91
12
62 92
9
27 88
7
41
10
50 89
11 31
36
6 93
32
16
31 95
13 2
44 83
43
68 94
14
59 97
15
98
56
63
34 5 4 3 67 30 33 35
55 54 1 45 46 70 47 49 53 71 99 77 78 79 80 81 82 84
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% 67 68 65 66 67
13
15
28
30
18
Fig. 6-2 Construction of travel motor VIEW B SECTION E㧙E
H6㧙2


No. NAME Q̉
TY No. NAME Q̉
TY No. NAME Q̉
TY
1 FLANGE 1 34 SPRING 2 67 PLUG 2

2 BASE PLATE 1 35 O RING 2 68 PLUG 1
3 (SPOOL) PLUNGER 1 36 SHAFT 1 69 PLUG 1
4 CHECK VALVE 2 37 CYLINDER BLOCK 1 70 FLOATING SEAL 2
5 SPRING 2 38 PISTON ASSY 9 71 ANGULAR BEARING 2
6 PLUG 2 39 PLATE 1 72 HOUSING (RING GEAR) 1
7 O RING 2 40 HOLDER 1 73 SHIM 1
8 SPRING SEAT 2 41 SNAP RING 1 74 HOLDER B 1
9 SPRING 2 42 SPRING SEAT 1 75 WASHER 8
10 SPRING SEAT 2 43 SPRING 1 76 SOCKET BOLT 8
11 CAP 2 44 COLLAR 1 77 THRUST PLATE 4
12 O RING 2 45 PIN 3 78 INNER RACE 4
13 SOCKET BOLT 8 46 PLATE (SWASH PLATE ) 1 79 NEEDLE BEARING 4
14 O RING 2 47 BALL 2 80 PLANETARY GEAR B 4
15 PLUG 2 48 PISTON ASSY 2 81 THRUST PLATE 4
16 ORIFICE 2 49 BALL BEARING 1 82 SOCKET BOLT 4
17 RELIFE VALVE ASSY 2 50 BALL BEARING 1 83 SUN GEAR B 1
18 PLUG 4 51 PIN 1 84 SNAP RING 1
19 SPOOL A㧦2-SPEED CHANGE OVER 1 52 SOCKET BOLT 10 85 HOLDER A 1
20 SPOOL C 1 53 OIL SEAL 1 86 THRUST PLATE 3
21 SPRING 1 54 DISK PLATE 3 87 INNER RACE 3
22 PLUG 1 55 FRICTION PLATE 2 88 NEEDLE BEARING 3
23 O RING 2 56 BRAKE PISTON 1 89 PLANETARY GEAR A 3
24 SPRING GUIDE 1 57 O RING 1 90 THRUST PLATE 3
25 PLUG 1 58 O RING 1 91 THRUST PLATE 1
26 WASHER 1 59 SPRING 8 92 CAPSCREW 3
27 PLUG 6 60 PIN 4 93 DRIVE GEAR 1
28 ORIFICE 1 61 SPRING 2 94 THRUST PLATE 1
29 ORIFICE 2 62 VALVE PLATE 1 95 COVER 1
30 ORIFICE 5 63 O RING 4 96 BOLT 16
31 PLUG 4 64 O RING 1 97 PLUG 3
32 O RING 4 65 NAME PLATE 1 98 O RING 3
33 CHECK VALVE 2 66 RIVET 2 99 PIN 4
H6㧙3

6.3 OPERATION
6.3.1 SUMMARY REDUCTION UNIT
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6.3.2 PISTON MOTOR
The construction drawing of piston motor is 3) With the reciprocating motion of piston (38),
shown in Fig. 6-5. shaft (36) linked with cylinder block (37) and
Nine pistons (38) are placed in the cylinder block each other rotates in the opposite direction to
(37), the end face of cylinder block is in contact arrow as shown in the figure.
with valve plate (62) in the two ports B and C 4) When the piston motor rotates clockwise, P1
(shaped somewhat like crescent). The hydraulic side turns to the low pressure side and P2
pump oil delivered flows into the piston through side turns to the high pressure side.
P1 or P2 port and flows out through P2 or P1 port
while having the piston motor rotated. And, the This way, the piston motor converts the
drain oil escaped through each sliding section and hydraulic fluid energy from the hydraulic
the space in the case returns in the hydraulic pump to the mechanical energy, and outputs
tank through Dr port of base plate (2). the turning effort at low speed and high
1) The high pressure oil through P1 port flows torque. And the torque and speed of the
into B port (shaped somewhat like crescent) piston motor is decided according to the
of valve plate, applies pressure to piston (38) pressure and flow rate. If the pressure and
and moves swash plate (46) from top dead flow rate are raised, the torque and speed of
point to bottom dead point rotating itself. piston motor are also raised.
2) The P2 port is moved to the low pressure side
and piston (38) discharges the oil through C
port (shaped somewhat like crescent) of valve
plate (62) into P2 port.
36
38
37
62
46
Fig. 6-5 Construction of piston motor
H6㧙5

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6.3.5 AUTO 2-SPEED CHANGE OVER 1) When switching the motor capacity to low
(1) 2-Speed change over mechanism capacity (High speed mode), (See Fig. 6-13.)
Fig. 6-13 shows the function when the motor With turning the speed control switch to high
capacity is low (at high speed). speed, the pilot pressure oil acts on Ps port
Swash plate (46) has three faces A to C. This and moves 2-speed control valves (19,20)
swash plate (46) is installed on flange holder rightward resisting to the spring (21) force
(1) with two steel balls (47) in the condition until the valves come into contact with plug
where the tilt rotation is possible. And (25). Therefore M1 and M2 ports of the motor
2-speed control piston (48) is in contact with are connected with oil passages A1 and A2
the face B of swash plate (46). led to the 2-speed control piston chamber F
And 2-speed control (select) valves (19,20) are and the motor drive pressure is led into the
installed on base plate(2). 2-speed control piston chamber F. The
2-speed control piston (48) is pushed up until
the face A of swash plate (46) is in contact
with flange holder (1) and the tilt angle of
swash plate becomes smaller, and
consequently the piston motor turns to high
speed.
PS (PILOT
PILOT PRESSURE OIL CHAMBER OIL PASSAGE A MOTOR LOAD PRESSURE CHAMBER
21
25
Dr1 Dr2
19,20
OIL PASSAGE B
A1
A2
PISTON CHAMBER F
48
FACE B
48
2-SPEED FACE C
CONTROL M1 M2
PISTON
PISTON THRUST (38)
THRUST
SPRING
THRUST (43)
46
47
FACE A
1 47
Fig. 6-13 High speed (low capacity)
H6㧙11
2) When switching the motor capacity to large
capacity (low speed mode), (See Fig. 6-14.)
With turning the speed control switch to low passages Dr1 and Dr2. And pressure oil in
speed, by returning the pilot pressure oil the 2-speed control piston chamber F is led
acting on Ps port into the tank, 2-speed into the motor case drain, and the face C is
control valves (19,20) is moved rightward by pushed by the thrust of piston (38) and spring
the spring (21) force until it comes into (43) until the face B of swash plate (46) comes
contact with plug (22). Therefore M1 and M2 in contact with flange holder (1),
ports of the motor close, and oil passages A1 consequently the tilt angle of swash plate (46)
and A2 led to the 2-speed control piston becomes larger and the piston motor speed
chamber F is led into motor case drain switches to low speed.
oil
PS (PILOT
21
22
Dr1 Dr2
OIL PASSAGE B
A1
A2
PISTON CHAMBER F
48
FACE B
48
FACE C
M1 M2
PISTON THRUST (38)
SPRING
THRUST (43)
46
47
FACE A
1 47
Fig. 6-14 When fixed to low speed (large capacity)
H6㧙12
(2) Auto 2-speed change over operation
This piston motor is available to select the auto 2-speed position which switches the
position where the motor capacity is fixed to motor capacity according to the load pressure
the low speed (large capacity) and the to the motor can be obtained.
position auto 2-speed position containing the 3) High speed (low capacity) position
motor capacity section function corresponding (See Fig. 6-15.)
to the load pressure of the motor. The motor high speed condition at auto 2-
1) Selection of low speed (large capacity) fixing speed position is shown in Fig. 6-15. Apply
position the specified pilot pressure on Ps port, and
The condition where the motor capacity is the pilot pressure oil flows through oil
fixed to the low speed (large capacity) is passage A and acts on the pilot hydraulic
shown in Fig. 6-14. Turn the speed control pressure chamber on the front face of the
switch to low speed, and the pilot pressure motor capacity control valve and pushes the
acting on Ps port returns into the tank and motor capacity control valve rightward. And
consequently the motor capacity control valve load pressure Pin to the motor flows through
housed in the motor is fixed to the low speed oil passage B, acts on the motor load pressure
(large capacity) position. chamber, and pushes the motor capacity
2) Selection of auto 2-speed position control valve leftward. When Pin is lower
The condition of auto 2-speed position where than the motor capacity control pressure P
the motor capacity is selected according to which is decided with a ratio of the pressure
the load pressure is shown in Fig. 6-15, 6-16. receiving areas of the pilot pressure and
Turn the speed control switch to high speed motor load pressure, the motor capacity
and the specified pressure acts on Ps port, control valve is maintained in the condition
and the pressure oil which is acted on Ps port shown in Fig. 6-15 and the motor is operated
acts on the front face of the motor capacity in high speed (low capacity) mode.
control valve housed in the motor, and the
PS (PILOT PRESSURE)
Dr1 OIL Dr2

PASSAGE B
Pin
M1 M2
Fig. 6-15 High speed (low capacity) in Auto 2-speed
H6㧙13
4) Low speed (large capacity) position
(See Fig. 6-16.)
The motor low speed condition at auto 2-
speed position is shown in Fig. 6-16. When
load pressure Pin to the motor is raised
higher than the auto 1st speed return
pressure, the motor capacity control valve
moves rightward, and is switched to the
motor low speed (large capacity) mode, that
is, the motor low speed operation.
PS (PILOT PRESSURE)
Dr1 Dr2
OIL
PASSAGE B
Pin
M1 M2
Fig. 6-16 Low speed (large capacity) in Auto 2-speed
H6㧙14
6.3.6 PARKING BRAKE
The construction of parking brake section is
shown in Fig. 6-17.
The parking brake is made up of disk plate (54)
linked with the cylinder block, friction plate (55)
and brake piston (56) located between disks and CYLINDER BLOCK
spring (59) which transmits the force to the brake
piston.
OIL 54
(1) Releasing parking brake (See Fig. 6-17.) PRESSURE
When the pressure oil is fed through P1 port

and the piston motor starts driving, the 55
MOTOR CASE
pressure oil is led into the cylinder chamber
E of the parking brake through oil passage D
as described in Article (2)-5 “Shuttle valve 59 CYLINDER
function for high pressure selection” of “6.3.3 56 CHAMBER E
Double counter balance valve”, the oil

pressure acts on brake piston (56) and moves Fig. 6-17 Parking brake release condition
leftward resisting the spring (59) force.
Consequently, the force pushing disk plate
(54) dies out, and disk plate (54) becomes free
and the parking brake is released.
(2) Operation of parking brake (See Fig. 6-18.)
When returning the control valve to the
neutral position, cutting the pressure oil to be
fed into P1 port and stopping the piston
motor, the oil passage D is connected to
motor case drain passage F as described in
Article (2)-5 “Shuttle valve function for high
pressure selection” of “6.3.3 Double counter
balance valve”, the pressure oil in cylinder
CYLINDER BLOCK
chamber E of the parking brake is led into
the motor case drain and the pressure drops.
Therefore, brake piston (56) is moved SPRING 54
FORCE
rightward by the spring (59) force, and disk
plate (54) is clamped by brake piston (56) and
MOTOR CASE 55
the motor case with the spring (59) force,
consequently the piston motor shaft is locked
and the parking brake actuates.
59 CYLINDER
56 CHAMBER E
Fig. 6-18 Parking brake operation condition
H6㧙15
6.3.7 REDUCTION UNIT SPROCKET MOUNTING
The reduction unit is constructed so that simple FIXED ON THE

1 76 83 85 72
FRAME OF
planetary gear reduction units which are made up MACHINE
of drive gear, sun gear, holder, planetary gear and
PISTON MOTOR
ring gear (tooth is cut inside of the housing.) are SHAFT 88
combined in two stage.
When the pressure oil flows into the piston motor, 87
the piston motor shaft rotates at high speed, and
the power is input to the reduction unit section. 89
In the reduction unit section, this high speed is 93
reduced in two stages by the simple planetary
82
gear reduction unit and has housing (72) with
ring gear rotated, and consequently the output in
low speed and high torque is obtained.
74 72 80 78 79
Fig. 6-19 Construction of reduction unit
(1) Operation of 1st stage reduction section (2) Operation of 2nd stage reduction section
The 1st stage reduction section is made up of The 2nd stage reduction unit is made up of
drive gear (93), planetary gear A (89), ring sun gear B (83), planetary gear B (80), ring
gear (72), holder (85), needle bearing(88) and gear (72), holder B (74), needle bearing (79)
inner race (87). and inner race (78).
Planetary gear A (89) is engaged with drive Planetary gear is engaged with sun gear B
gear (93). When drive gear (93) rotates (83). When sun gear B (83) rotates clockwise,
clockwise, planetary gear A (89) rotates planetary gear B (80) rotates
counterclockwise. On the other hand, it is counterclockwise.
also engaged with the ring gear, it kicks the Planetary gear B (80) is fixed on holder B (74)
tooth of the ring gear and attempts to revolve through the aid of needle bearing (79) in
around drive gear (93). rotation free condition, and holder B (74) is
This orbital motion in clockwise is connected to flange (1) with bolts (76) (82)
transmitted to holder A (85) and holderA (85) and the flange is not allowed to rotate
starts rotating clockwise because planetary because it is fixed on the frame of machine.
gear (89) is fixed on holder A( 85) through the Therefore, planetary gear B (80) is not
aid of needle bearing (88) in rotation free allowed to revolve differently to the 1st stage
condition. reduction section, but is allowed to rotate
And holder A (85) is engaged with the 2nd counterclockwise due to the installation
stage sun gear B (83) with spline, and the position. And planetary gear B (80) is
rotation of this holder A (85) is transmitted to engaged with the ring gear and this axial
the 2nd stage sun gear B (83). motion in counterclockwise of planetary gear
B (80) is transmitted to the ring gear and
rotates the ring gear counterclockwise.
With the operation as described above, the
housing cut on the inner bore of ring gear
(72) receives the power of planetary gear A
and B (89) (80) and rotates, and the power is
transmitted to the driven section of the
machine linked with housing (72) with ring
gear.
H6㧙16
7. SWIVEL JOINT
7.1 OUTSIDE VIEW
Y
VIEW Y
VIEW Z
Z
Fig. 7-1 Outside view of swivel joint
7.2 SPECIFICATIONS
Table 7-1
Item Spec.
2
Working pressure 350kgf/cm (4980psi)
High pressure ports
Max. impact pressure 525kgf/cm2(7470psi)
A,B,C,D
Rated flow 255 /min(67gal/min)
2
Low pressure ports Working pressure 5kgf/cm (71psi)
E Rated flow 50 /min(13gal/min)
Low pressure ports Working pressure 50kgf/cm2(710psi)
F Rated flow 30 /min(8gal/min)
Revolution 15rpm
A,B,C,D PF1
Ports size E PF1/2
F PF1/4
Length (height) 355mm(14̢)
Weight 27.4kg(60.4 lbs)
H7㧙1

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2. ELECTRICAL EQUIPMENT
2.1 ELECTRIC EQUIPMENT LIST
Group Code NAME Group Code NAME Group Code NAME

M㧙1 Starter motor ̆ Solenoid valve assy
C㧙1 Mechatro controller M㧙2 Governor motor SV㧙1 Swing parking brake SOL.
MOTOR
CONTROLLER
M㧙3 Wiper motor SV㧙2 Power boost SOL.

M㧙4 Washer motor SV㧙3 Two-speed select SOL.
SOLENOID
C㧙2 Gauge cluster M㧙9 Fuel pump (opt.) SV㧙4 Operating lever lock SOL.
M㧙11 Fuel supply pump SV㧙5 Breaker SOL.
C㧙4 Air conditioner amp. SV㧙6 Clockwise SOL.
C㧙5 Air conditioner panel ̆ Proportional sol. Assy SV㧙7 Counterclockwise SOL.
C㧙6 IT controller (ORBCOMM) PSV㧙A Arm valiable recirculation proportional sol. SV㧙9 Nibbler open SOL.
SOLENOID VALVE
PROPORTIONAL
PSV㧙B P2 bypass cut proportional sol. SV㧙10 Nibbler close SOL.
D㧙1 Diode PSV㧙C Travel priority proportional sol. SV㧙11 Extra depressure SOL.
D㧙2 Diode PSV㧙D P1 bypass cut proportional sol.
D㧙3 Diode PSV㧙G SW㧙1 Key SW.
DIODE
D㧙4 Diode PSV㧙P1 P1 pump proportional sol. SW㧙2

D㧙5 Diode PSV㧙P2 P2 pump proportional sol. SW㧙3 Two-speed select SW.
D㧙6 Diode SW㧙4 Swing parking release SW.
D㧙10 Diode R㧙1 Battery relay SW㧙5 KPSS. Mode release SW.
D㧙11 Diode R㧙2 Starter relay SW㧙6 ENG. Water temp. SW.
R㧙3 Glow relay SW㧙7 ENG. Oil press. SW.
E㧙1 Fuse box R㧙4 Safety relay SW㧙8 Air filter restriction SW.
R㧙5 Wiper motor relay SW㧙9 ENG. Oil level SW.
E㧙2 Alternator R㧙6 Washer motor relay SW㧙10 Horn SW. (Left)
E㧙3 Hour meter R㧙7 Horn relay SW㧙11 Level lock SW.
RELAY
E㧙4 Horn low R㧙8 Work light relay SW㧙13 Air conditioner SW.
E㧙5 Horn high R㧙9 SW㧙16 Auto accel release SW.
E㧙6 Cigarette lighter R㧙10 Cab work light relay 1 SW㧙17 ENG. Coolant level SW.
ELEC EQUIPMENTS
E㧙7 Tuner AM&FM R㧙11 Cab work light relay 2 SW㧙18 Hyd. fluid level SW.
E㧙8 Speaker left R㧙19 Flasher relay (OPT.) SW㧙20 Horn SW. (Right)
E㧙9 Speaker right R㧙20 Timer relay SW㧙21 Work light SW.
E㧙10 Receiver drier R㧙26 Extra pressure release relay SW㧙22 Conflux single select SW. (OPT.)
E㧙11 Air compressor clutch R㧙28 Auto idle stop relay 1 SW㧙23 Wiper interlock SW.
E㧙13 R㧙29 Auto idle stop relay 2 SWITCH SW㧙30 Rotary light SW.
E㧙14 Resistor SE㧙1 Press. sensor (low) : Bucket digging SW㧙32 Overload indicate SW.
SE㧙2 Press. sensor (low) : Bucket dump SW㧙34 Power boost SW.
E㧙16 DC-DC converter SE㧙3 Press. sensor (low) : Boom up SW㧙35 Heavy lift SW.
E㧙17 Socket (12V) SE㧙4 Press. sensor (low) : Boom down
E㧙22 Antenna (Cab side) SE㧙5 Press. sensor (low) : Swing
E㧙23 Antenna SE㧙6 SW㧙39 Overload SW.
E㧙24 GPS antenna SE㧙7 Press. sensor (low) : Arm in SW㧙41 Travel alarm SW. (OPT.)
E㧙25 Battery SE㧙8 Press. sensor (low) : Arm out SW㧙42 ENG. Room light SW.
L㧙1 Boom working light SE㧙9 Press. sensor (low) : Travel right SW㧙45 Handle assy. (breaker SW.)
SENSOR
L㧙2 Working light right deck SE㧙10 Press. sensor (low) : Travel lerft SW㧙46 Clockwise SW.
L㧙3 Room light SE㧙11 Press. sensor (low) : OPT.1 SW㧙47 Counterclockwise SW.
L㧙4 Cab work light (Front 1) SE㧙12 SW㧙48 Nibbler open SW.
L㧙5 Cab work light (Front 2) SE㧙13 ENG. Revolution sensor SW㧙49 Nibbler close SW.
LIGHT
L㧙6 Cab work light (Front 3) SE㧙14 Coolant thermo sensor SW㧙52 Auto idle stop select SW.
L㧙7 Cab work light (Front 4) SE㧙15 Fuel sensor SW㧙A Cab door SW.
L㧙8 ENG. Room light SE㧙16 Accel potentio SW㧙B Extra SW.
L㧙9 Boom working light right SE㧙20 Press. sensor (low) : OPT.2
L㧙10 Cab work light (Rear) SE㧙21
L㧙15 Rotary light SE㧙24 Extra drain press
E1㧙1

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2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS

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8VH
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For details, refer to
Mechatro System.
0HFKDWURFRQWUROOHU ∅

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&RQWUROOHU
*DXJHFOXVWHU
MATING CONNECTOR
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
(

File No. Specification Description
Name of part
Use
C㧙4 CONTROLLER
Rated voltage DC 20㨪30V
Controller
Air conditioner
controller
NIPPON AMP
C㧙5 Connector 2-174955-1
4-∅6
Air conditioner
switch panel ͠ and q
F are available
Air conditioner
operation
C㧙6
Controller GPS ANTENNA ORBCOMM ANTENNA (BNC)
IT controller
RS-232C
(D-sub 9pin)
TEST/
RESET
SW.
TEST
POWER INPUT CABLE LED
YAZAKI
HOUSING : 7122-2228
TERMINAL : 7114-2020
VINYL TUBE
E1㧙4
File No.
Name of part
Use Specification Description
D㧙1,2,3,5,6,10,11 Peak reverse voltage 400V
Mean output current 3A

Diode
Surge current 200A
Key switch relay
D㧙4 Rated current 2.5A
Diode
Starter relay
Glow relay
Fuse capacity and circuit name

E㧙1
No. Capacity Name of circuit
Ԙ 20A Mechatro controller
Fuse box
ԙ 10A Wiper / washer relay
Ԛ 10A Cigarette lighter
ԛ 10A Tuner
Fuse Ԝ 10A Horn
ԝ ̆ Spare
Ԟ 10A Controller back-up
ԟ 20A Power window back-up
Ԡ 10A Tuner (back-up), Room lamp
ԡ 20A Key switch
Ԣ 20A (Fuel pump) Cab work light
ԣ 10A Travel alarm
Ԥ 10A Gauge cluster
ԥ 20A Wiper, Washer
Ԧ 10A Solenoid valve, Lever lock
ԧ 20A Work light (front)
Ԩ 10A Resistor
ԩ 20A Air conditioner, Heater (option)
Ԫ 10A Air conditioner
ԫ 20A Power reserve (24V)
Function in ( ) are not equipped for oceania.
E1㧙5
File No.
Name of part
TERMINAL : B
E㧙2 System Three-phase A.C. M81.25 CONNECTOR
YAZAKI 7322-6223-40
TERMINAL : B
Rated voltage 24V M81.25
Alternator
Output 35A (900W)
Drive Pully and belt
PCD75
Increase of speed
ratio 2.13 (∅160 / ∅75)
Generator
TERMINAL : P
CONNECTOR
YAZAKI 7322-2215
E㧙3 Movement Quartz

Operating voltage GM TERMINAL : 2962447
hour 10㨪80VCD
Hour meter GM CONNECTOR : 2962448
Service meter
Bottom
E㧙4,5 Type H HIGH SOUND
L LOW SOUND
Rated voltage DC24V STAMP
Horn Operating voltage
range DC 22㨪28V
Sound level 113r5 dB / 2m

420r20 Hz high sound
Warning sound Basic frequency 350r20 Hz low sound
Insulation resistance More than 3Mǡ/DC500V
∅8.5
E1㧙6

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PLUG COMPLETE
&LJDUOLJKWHU KNOB
&LJDUOLJKWHU

CASE
SOCKET COMPLETE
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5DGLR$0 )0
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6SHDNHU
5DGLR
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$LUFRQGLWLRQHU
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$LUFRQGLWLRQHU
CONNECTOR YAZAKI 2PAM

( HOUSING 7122-2128
TERMINAL 7114-2020
5HVLVWRU
SILICON GLASS FURUKAWA DENKO
Braided wire Viewmex ER400 or equivalent
(NISSEI DENKI) heat resistant tube
.366UHOHDVH NS-GE 1.25sq ∅5 20mm (0.197 0.787 )
Hot soldering treatment

[melting point 240 (464 F)]
Sumi-tube K
55 +175
( 67 F +347 F)
20mm (0.787 )
∅4.7 0.3
(0.185 0.012 )
(
File No.
Name of part
Use Specification
Description
E㧙16
Input voltage DC 24V
Converter Output voltage DC 12V
Output current 2.5A Max
Ground Negative
DC24V→DC12V YV
WG YB
OL
Fix the wire B
with tape
HOUSING YAZAKI 7122-2262

TERMINAL YAZAKI 7114-2020
A
VIEW A
E㧙17
Power supply For 12V
Socket
Power socket
E1㧙9
File No.
Name of part
E㧙22 Electrostatic capacity 80r7pF

More than 100Mǡ
Insulation resistance (DC 500V megger
Antenna
Radio
ANTENNA JUMPER 30pF/m

OCE : PART NO. 2486R99
ANTENNA JUMPER 30pF/m

KCMA, KCME : PART NO.
E㧙23 Maker Orbcomm Japan

PVC CAP (BLACK)
Model 150-W347
Antenna HELICAL ELEMENT SUS
RUBBER CAP
For ORBCOMM
MOLD PLASTIC (BLACK)
M6 THREAD
E㧙24 Maker Orbcomm Japan

EBMGUB91R5VA
Model (KX-GNA04-G)
Antenna
For GPS
E1㧙10

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8VH
/
/LJKWKDORJHQ
%RRPZRUNOLJKW
CA104
OHIW ULJKW

M14 1.5
/ M12 1.25 25
/LJKW
'HFNZRUNOLJKW
CB104
CA104
/ BODY
LENS
Note) Equivalent to 2456Z322F1

/LJKW
5RRP'RPHOLJKW
BULB
SECTION A-A DOOR

SWITCH
/
/LJKWKDORJHQ
&DEZRUNOLJKW
237
DRAIN HOLE
BRACKET
(POWER SUPPLY) (EARTH)
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1DPHRISDUW
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/ A
/LJKW
(*URRPOLJKW
A
SECTION A-A
/
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5RWDU\OLJKW
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8VH
B-TERMINAL
0
0RWRU
L-TERMINAL
6WDUWHUPRWRU
SW-TERMINAL CONNECTOR
VEIW D
0
0RWRU
*RYHUQRUPRWRU
LMIT SWITCH
MOTION RANGE
Excitation sequence MOTOR

Brown Red CONNECTOR
(A) (B)
LIMIT SWITCH
Orange Yellow CONNECTOR
( A) ( B)
Limit switch connector Motor connector
1 2
6
5
7 3 4
HOUSING : 174359-2(AMP) HOUSING : 174259-2(AMP)

TERMINAL : 171661-1(AMP) TERMINAL : 171661-1(AMP)
(

File No.
Name of part Specification Description
Use
M㧙3 Maker DENSO
Model 5㧙159200㧙377
Motor
Torque 0.12kgfym (0.88 lbfyft)
Wiper Rated voltage 24V

More than 1Mǡ /
Insulation resistance 500V megger
Rotation 38r5rpm (at loaded)
Auto stop position
R (㧗1)
Y (S) HOLDER M201
(AVS 0.85)
(AVS 0.85)
L (㧗) B (㧙)
M201
(AVS 0.85) (AVS 0.5)
NUT M61
M61
TAPER 1/3
Circuit (at Motor OFF)
(+) (㧙)
M㧙4 Rated voltage DC 24V
Injection pressure More than 780cc / min

Motor (tank)
Tank capacity 1.5 (0.4gal)
Window washer Time rated Max. continuous 20sec
Injection nozzle ∅12 pcs.
PUMP
E1㧙15
File No.
Name of part
M㧙9 Rated voltage DC24V
Current Less than 1.5A

Motor (pump) HEX24
Operating fluid Light oil
Discharge rate
(open circuit) More than 200cc/min
OUT
ψ Z
Fuel pump (OPT.)
GROMMET M61
‫ڈ‬,㧗 BLACK / WATERPROOF

CONNECTOR (MALE)
VINYL TUBE (WHITE) YAZAKI 7322-9021
L=100 (3.94")
‫ڈ‬,㧙
VIEW Z
M㧙11 Flow rate More than 30 /min
Voltage 24V
Pump
Current Less than 14A
Fuse 15A
CA-104
Fuel supply pump
CB-104
GROUND
E1㧙16

1DPHRISDUW
8VH
5
5HOD\ TERMINAL
TERMINAL A
%DWWHU\UHOD\ F HOUSING :
SUMITOMO
7123-4220-30
F TERMINAL :
SUMITOMO
7116-3251
REAR HOLDER :
SUMITOMO
7157-6801-30
WATER
MODEL RESISTANCE :
NUMBER STAMPING L SUMITOMO
POSITION IN A TER- B 7157-3580-60
MINAL TERMINAL
FLOWING DIRECTION OF PRO-DUCTION
MAIN CURRENT
AVS1.25B
TERMINAL A TERMINAL B EARTH
TERMINAL
EARTH TERMINAL
TERMINAL
TERMINAL A1 LOCK SECTION
HOUSING AMP
174359-2
RETAINER AMP L TERMINAL
1-174360-1 or 7
TERMINAL AMP
TERMINAL B1 171661-1
WIRE SEAL AMP
VIEW 172888-2 or 172886-2
BLACK
CIRCUIT DIAGRAM
EARTH VIEW Z
5
ENGINE
5HOD\
STARTER MOTOR
6WDUWHUUHOD\ STARTER RELAY
B-TERMINAL
STARTER (5kW)
ALTERNATOR
B-CONNECTOR
TO STARTER SW
TO STARTER SW
TO TO HEATER RELAY
STARTER SW
TO BATTERY RELAY TO SAFETY RELAY
(

Name of part
Use
R㧙3 Rated voltage DC 24V
Exciting current 2.3A

Relay
Fuse 127a
Glow relay
FUSE ATTACHING BOLT CONTROL TERMINAL
FUSE
M61.0 COUPLER SIDE CONNECTOR
JISD5403 CB104
M61.0
CONTACT TERMINAL : M61.0

Operating alternator
revolution 1200r100rpm
Relay
Rated time 30SEC
Safety relay
6.5
(W㨯L)S E(B)
(Y)L
CONNECTION DIAGRAM
(W㨯G)R P(W㨯Y)
R㧙5,6,7,8,10,11,26 Maker MITSUBA
Rated voltage DC 24V

Relay More than 1Mǡ
Insulation resistance (500V megger)
Horn relay
Working light
Wiper motor
Washer motor
Cab work light
Travel alarm
Extra drain pressure
CIRCUIT
E1㧙18
File No.
Name of part
R㧙19 UPPER
Relay
Flasher relay
TERMINAL NUMBER
Consumption current 0.1A Max

Timer
CONNECTOR
YAZAKI No.7122-2262
Delayed-safety EQUIVALENT
lock action
Not used
E A
Not used Not used

D
UPPER
CIRCUIT DIAGRAM
R㧙28 Maker MITSUBA
Rated voltage DC24V

Relay More than 1Mǡ
Insulation resistance (500V megger)
Auto idle stop relay 1
CIRCUIT
E1㧙19

1DPHRISDUW
8VH
6(
3UHVVXUHVHQVRU
/RZSUHVVXUH GND Vcc
Vout
AMP
MQS TYPE CONNECTOR
3P (B TYPE)

O ring PF1/4
1B P11 Torque
3.7kgf m {27 lbf ft}
6( E/G RING GEAR
6SHHGVHQVRU
6SHHGVHQVRU M16 1.5 HEX 22

F(GND)-B
E(OUTPUT)-Y
HEX 19
LOAD CIRCUIT
CONNECTOR MITSUBISHI
CONNECTOR YAZAKI
6(
:DWHUWHPSVHQVRU
M16 1.5
(*FRRODQW TORQUE
2.5 kgf m
WHPSVHQVRU (18 lbf ft)
VIEW Z
(

1DPHRISDUW
8VH
FLOAT
6(
)XHOVHQGLQJXQLW
)XHOVHQVRU
A

FUEL LEVEL
WARNING LAMP POSITION
SENSOR SWITCH
FUEL METER
HOUSING : 174359-2
TERMINAL : 171661-1
24V3W FLU RETAINER : 1-174360-1
WIRE SEAL : 172888-2
DC
24V FLOAT AMP WATER PROOF
CONNECTOR
3MA-JM +
VIEW A
6:
NOTCH PART BRACKET
3RWHQWLRPHWHU
DIAL POTENTIO
$FFHOGLDO
3MA-JM +AMP

HOUSING : 174359-2
TERMINAL : 171661-1
RETAINER : 1-174360-1
WIRE SEAL : 172888-2
6(
3UHVVXUHVHQVRU
KLJKSUHVVXUH
3SXPS3SXPS
HEX 22
([WUDGUDLQSUHVV
O RING PF3/8
1B P14
AMP MQS CONNECTOR
TERMINAL NO. CONNECTION
3-POLE (TYPE B)
1 COM OPPOSITE CONNECTOR (FEMALE)
2 OUTPUT ( ) HOUSING : 2-967642-1
TERMINAL (GOLD PLATED) : 965906-5
3 POWER ( ) HARNESS SEAL : 967067-1
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8VH
69 5DWHGSUHVVXUH NJIFP SVL

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6ROHQRLGYDOYHDVV\
3URSRUWLRQDO 'LWKHU+]P$33
YDOYH
5HIHUWR+<'6<0%2/ &RLOUHVLVWDQFHr DW

6SHFLILFDWLRQV
RIFRQQHFWRU
369 $%&'
PORT P,T,4 PF3/8
6ROHQRLGYDOYHDVV\ PORT A,B,C,D,1,2,3 PF1/4
5HIHUWR+<'6<0%2/
Note :
Proportional valves are
equipped with orifices.
SECTION A-01-02-A
369 33 7\SH .'5'( .
5DWHGIHHGSUHVV NJIFP SVL

6ROHQRLG
$OORZDEOHEDFNSUHVV NJIFP SVL
3URSRUWLRQDOYDOYH AMP MARK 2P
&RQWUROSUHVVXUHUDQJH NJIFP SVL
IRUSXPSV33 HOUSING 174354-2 or equivalent
5DWHGYROWDJH '&9 TERMINAL 173706-1 or equivalent

HEX 10
O ring
Tightening torque
1B P20
0.5kgf m {3.6 lbf ft}
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1DPHRISDUW
8VH
AUTO RETURN
6: Connection table
6ZLWFK
AUTO RETURN
6WDUWHUVZLWFK
VIEW A

K250 STAMPED

TERMINAL
ARRANGEMENT
MARKS ON SWITCH PORTION
6:
6ZLWFK
7UDYHOVSHHG
6: INSULATION TAPE
R B W
6ZLWFK
6ZLQJSDUNLQJUHOHDVH VINYL TUBE

YAZAKI
RED(2)
7122-2237
7114-2020
WHITE(3) BLUE(1)
6:
CIRCUIT DIAGRAM
6ZLWFK
KEY WAY
.366UHOHDVH
SUMITOMO 6098-0252
TERMINAL 8230-4282
(

1DPHRISDUW
8VH
6:
6ZLWFK
(*ZDWHU
WHPSHUDWXUHVZLWFK
DATE OF MANUFACTURE
6:
(*RLOSUHVVXUH
VZLWFK
2LOSUHVVXUH
LQGLFDWLRQ

∅
6:
6ZLWFK
'XVWLQGLFDWRU
(

1DPHRISDUW
8VH
6:
6ZLWFK
(*RLOOHYHO

SWITCH
OFF LEVEL
GRIP MODEL : MH056347
CONNECTOR
CONNECTOR ON MATED SIDE
6:
6ZLWFK
CONNECTION TABLE
/RFNOHYHU
1
NO

2
COM YAZAKI HOUSING 7122-2228
NC TERMINAL 7114-2020

6:
6ZLWFK CONNECTOR (WITH LOCK) (R)

EQUIVALENT YAZAKI 7122-2228 RED
6:
TERMINAL CONNECTOR

Terminal L RW
Position RED /
WHITE
OFF
ON
(

Name of part
Use
All water level 3.4 (0.90gal)

SW㧙17 FULL 1.5 (0.40gal) OPEN-TO-ATOMOSPHERE SIDE
Sub tank
LOW level 0.43 (0.11gal)
E/G coolant water Remaining liquid level
temperature SW. Switch function 0.43r0.1 (0.11r0.023gal)
E/G coolant Contact type Normally closed

water level
YAZAKI PART No. 7121
LOW SIDE
RADIATOR-CONNECTED
AV0.5fB
HOUSING YAZAKI : 7122-2228

SW㧙18 Max. contact rating 10W TERMINAL YAZAKI : 7114-2020
Between terminals 100Mǡ
or more (100V)
Insulation resistance Between terminal-grounding
Switch 100Mǡ or more (500V)
CORRUGATE
Hydraulic oil level TUBE
switch AEX WIRE 0.85 (BLACK)
M271.5
Operating point
FLOAT OUTER
Liquid type Specific gravity ON (Amm) OFF (Bmm)
DIAMETER 23
Less than More than
OIL 0.88 10.5mm 2.0mm
When the level of remaining liquid is low, it is
turned off automatically by the function of float.
SW㧙21 Single-pole single-throw

Type (Alternate)
CONNECTOR (WITH LOCK) (R)
Operating voltage
Switch DC 24V EQUIVALENT YAZAKI 7122-2228 RED
range
More than 1Mǡ /
500V megger
Work light
TERMINAL CONNECTOR RED / WHITE

Terminal L RW (RW)
Position
OFF
ON
E1㧙26

Name of part
Use
SW㧙22 Rated voltage DC 24V

Single-pole single-throw CONNECTOR (WITH LOCK) (R)
Type (Alternate) EQUIVALENT YAZAKI 7122-2228 RED
Switch More than 1Mǡ /
Insulation resistance DC500V megger
Conflux/single select
(OPT.)
TERMINAL CONNECTOR
Terminal RED /
Position
R RW WHITE
(RW)
OFF
ON
SW㧙23 Maker's part No. DV-431

Single-pole single-throw 8.7‫غ‬
Contact components ON-(OFF) momently
Switch 14‫غ‬
More than 100Mǡ /
Insulation resistance DC500V megger BLACK CB104
Wiper interlock switch
RED CA104
Single-pole single-throw
SW㧙30 Type (Alternate)
Rated voltage DC 24V CONNECTOR (WITH LOCK) (R)
Switch More than 1Mǡ / EQUIVALENT YAZAKI 7122-2228 RED
Rotary light
TERMINAL CONNECTOR
Terminal R RW
Position RED /
WHITE
OFF (RW)
ON
Switch More than 1Mǡ / CONNECTOR (WITH LOCK) (R)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
Overload indicator
TERMINAL CONNECTOR
Terminal R RW
Position
RED /
OFF WHITE
(RW)
ON
E1㧙27

File No.
Use
Buried in right grip,

SW㧙34 Type Momentary
Buried in right grip
Rated 125V3A
ATT power boost SW More than 100Mǡ /
Insulation resistance DC500Vmegger
ATT power boost
SUMITOMO DENSO
HOUSING ITEM No. : 6090㧙1031 (2P MALE)
SUMITOMO DENSO
TERMINAL ITEM No. : 8230㧙4282
Rated voltage DC 24V CONNECTOR (WITH LOCK) (R)

Switch More than 1Mǡ / EQUIVALENT YAZAKI 7122-2228 RED
Heavy lift switch

TERMINAL CONNECTOR
Terminal L RW
Position RED / WHITE
(RW)
OFF
ON
E1㧙28

File No.
Use
SW㧙42
LA103 M3
CA-104 (R)
Switch TERMINAL YAZAKI : 7113-1020-02 RED
CAP YAZAKI : 7120-1010
Engine room
light switch
CB-104
TERMINAL YAZAKI : 7115-1050-02
CAP YAZAKI : 7120-1010
BLACK
(B)
SW㧙45,46,47,48,49 Voltage DC30V
Current 3A
Switch
Horn, Power boost
LEAD WIRE : AVFF 0.75ft

PROTECTION
TUBE
VIEW B
SW㧙 A Rated voltage DC 12V,24V

r0.008̢
(0.236̢ )
More than 5Mǡ 2-Ǿ6r0.2
Insulation resistance (500V megger) CASE
Switch SCREW
Max. stroke 7.1mm (0.28̢)
Cab door
(0.315̢)
Ǿ8
BUTTON SPRING TERMINAL
SW㧙B Type (Alternate)
Insulation resistance DC500V megger EQUIVALENT YAZAKI 7122-2228 RED
Extra & Breaker
switch
TERMINAL CONNECTOR
Terminal L RW
Position RED /
WHITE
OFF
(RW)
ON
E1㧙29
File No.
Name of part
More than 100Mǡ /

SW㧙10,20 Insulation resistance DC500Vmegger SUMITOMO DENSO
HOUSING P/N : 6090㧙1031
Switching mechanism Momentary
(2P MALE)
Switch SUMITOMO DENSO
TERMINAL P/N : 8230㧙4282
Horn switch (LH, RH)
M100.75
SW㧙41 Type momentary
CONNECTOR (WITH LOCK) (R)
Switch More than 1Mǡ / RED
Insulation resistance EQUIVALENT YAZAKI 7122-2228
DC500V megger
TERMINAL CONNECTOR
Terminal R RW
Travel alarm switch Position
RED /
OFF WHITE
ON
Insulation resistance 500V megger EQUIVALENT YAZAKI 7122-2228 RED
TERMINAL CONNECTOR
Terminal
Auto idle stop Position
R RW
RED /
OFF WHITE
ON
E1㧙30
E235SR
SECTION 25 AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
1. CONSTRUCTION AND PIPING

1.1 Construction ......................................................................................................................... 1
1.2 Piping ................................................................................................................................... 2
2. CONSTRUCTION OF MAIN COMPONENTS

2.1 Intake Unit ............................................................................................................................ 4
2.2 Air-Conditioner Unit .............................................................................................................. 5
2.3 Receiver Dryer ..................................................................................................................... 6
3. FUNCTION
3.1 Mechanism of Cooling Circuit .............................................................................................. 7
3.2 Cooling Circuit ...................................................................................................................... 8
3.3 Component Parts ................................................................................................................. 9
4. DISASSEMBLY AND ASSEMBLY

4.1Precautions to be Exercised in Operation ........................................................................... 13
4.2 Removal and Installation of Unit ........................................................................................ 14
5. CHARGING REFRIGERANT
5.1 Precautions to be Exercised in Operation .......................................................................... 18
5.2 Operating Procedure .......................................................................................................... 19
5.3 Charging Procedure ........................................................................................................... 20
6.ELECTRIC CIRCUIT
6.1 Wiring Diagram and Connectors ........................................................................................ 24
6.2 Inspecting Functional Parts ................................................................................................ 25
7. TROUBLESHOOTING ............................................................................................. 27
1. CONSTRUCTION AND PIPING
1.1 CONSTRUCTION
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Fig. 1 Air-conditioner group
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY

1 AIR-CONDITIONER ASSY 1 2 AIR DRYER ASSY 1 3 COMPRESSOR ASSY 1
1-1 AIR-CONDITIONER UNIT 1 2-1 RECEIVER DRYER 1 4 PANEL ASSY 1
1-3 SENSOR 1 2-2 BRACKET 1 5 FILTER ASSY 1
1-4 PLATE 1 2-3 L HOSE ASSY 1 6 CONDENSER 1
1-5 MACHINE SCREW 1 2-4 D HOSE ASSY 1
2-5 S HOSE ASSY 1
2-6 L HOSE ASSY 1
2-7 D TUBE ASSY 1
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2. CONSTRUCTION OF MAIN COMPONENTS
2.1 INTAKE UNIT
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3. FUNCTION
3.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that Table 1
flows through the cooling circuit changes its
phases from liquid to gas and vice versa Item HFC-134a (R134a)
during which process heat is transferred from Chemical formula CH2FCF3
the low temperature part (compartment) to Molecular weight 102.03
the high temperature part (outside of the
Boiling point -26.19͠ (-15.14q F)
vehicle).
1) Kind of Refrigerant Critical temperature 101.14͠ (214.05q F)
Many kinds of refrigerants that change in Critical pressure 4.065MPa (41.45kgf/cm2
that way are available, but the following *1)
requirements are needed for use in such
Critical density 511kg/m3 (31.9 lb/ft3)
applications:
$ Latent heat of vaporization (heat of Density of saturated 1206kg/m3 (75.3 lb/ft3)
vaporization) is large. liquid [25͠ (77.0q F)]
$ It is easy to liquefy (condense). (It dose not Specific volume of 0.0310m3/kg (0.496ft3/lb)
require very high pressure for condensation.) saturated vapor
$ It is easy to gasify (evaporate). (It evaporates [25͠ (77q F)]
sufficiently at not too low pressure, i.e. cools Latent heat of 197.5KJ/kg {47.19kcal/kg}
down an object.) vaporization
$ It has small specific heat. (Since the [0͠ (32q F )]
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held Flammability Nonflammable
down to a minimum.) Ozone destruction 0
$ It has a high critical temperature and a low coefficient
solidification point.
$ It is stable chemically and does not corrode *1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
and permeate into the circuit parts. (145psi)
$ It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
$ It has small specific volume.
$ It is easy to find out leakage.
Out of refrigerants meeting the
above-mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used, sufficient
refrigeration will not be performed or the
equipment in which the refrigerant is used
may be broken. Therefore, always use a PRESSURE
designated refrigerant for the cooling unit. MPa(kgf/cm2)
Table 1 shows the principal characteristics of R134a
the R134a refrigerant that is used in this 4 (40.8)
machine.
3 (30.6)
(2) Characteristics of Refrigerant (See Fig.6.) LIQUID
In general, the fluid (general term of gas and
liquid) has the following qualities: 2 (20.4)
1) As a gas under certain pressure is cooled
down, it begins to condensate at a certain
1 (10.2) GAS
temperature to take a liquid state. The
temperature at which condensation begins is (5.2)
TEMPERATURE

unique to each substance (fluid) at a given [͠ (qF)]
pressure. The temperature determined by a 0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
given pressure is called saturation
Fig. 6 Pressure-temperature characteristics of R134a
temperature.
7
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is
determined. This pressure is called
saturation pressure.
Fig.6 illustrates the relationships between
the saturation temperature and the
saturation pressure in the case of refrigerant
R134a used in the sir-conditioner. At the
temperature and the pressure on the lower
righthand side of the curve in Fig.6, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper
lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an
air-conditioner is operated in the midst of
summer. As the refrigerant evaporates, it
absorbs evaporation heat from the air of the
compartment. In order to cool the inside of
the compartment down to 25͠ (77q F), the
refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower
temperature. It can be seen from Fig.6 that
R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the
circuits, thereby deteriorating the
performance of the cooling unit.) In the
process in which gaseous refrigerant is
brought back to a liquid state, the refrigerant
is cooled and condensed by the outer air
exceeding 35͠ (95q F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding
10.2kgf/cm2 (145psi), as seen from Fig.6.
3.2 COOLING CIRCUIT
Fig.7 illustrates the cooling circuit of the car
air-conditioner.
In this circuit diagram, the portion that cools
the air of the compartment is the evaporator.
The object air is cooled off by utilizing the INSIDE OF COMPARTMENT
fact that the refrigerant takes heat off the
surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant
takes place is the evaporator, cooled air is EVAPORATOR EXPANSION
VALVE
constantly delivered to the circumference of BLOWER
the evaporator by the blower fan. In the
meantime, liquid refrigerant (slightly wet
vaporized refrigerant) is fed into the INSIDE OF ENGINE
evaporator, when “cooling” effect is attained. S D ROOM
For instance, in order to cool the air to 15͠
(59 qF), the refrigerant can not absorb COMPRESSOR COOLING FAN
evaporation heat from the air unless it
evaporates at a temperature lower that 15͠
(59qF). For that purpose, it can be seen from
Fig.6 that the pressure of the refrigerant in RECEIVER
the evaporator must be less than 5.2kgf/cm2 DRYER
(74psi).
Furthermore, the cooling effect deteriorates CONDENSER
unless the feed rate of the refrigerant is
controlled so that all of the refrigerant Fig. 7 Construction of cooling circuit
supplied to the evaporator vaporizes and
turns into dry vapor.
8
Consequently, the cooling circuit is so
constructed that the evaporator can cool
down an object (air in this case) sufficiently
(i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of
refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled
by the expansion valve, but the pressure in
the evaporator is held low by the throttling
action of the expansion valve and the suction
action of the compressor. The compressor acts
as a pump that allows the refrigerant to
circulate. The compressive action of the
compressor and the heat exchange (heat
radiation) action of the condenser transform
the refrigerant in a dry vapor state back to a
liquid state.

3.3 COMPONENT PARTS
(1) Evaporator (See Fig.8.)
The evaporator is an important heat
exchanger that absorbs the heat of the
compartment air (object) by the utilization of
the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that EVAPORATOR
satisfactory heat transfer between the object
and the refrigerant take place in the
evaporator.
To that end, the evaporator is equipped with O RING
fins on the air side in order to increase the EXPANSION
heat transfer area of the air side and thereby VALVE
perform excellent thermal transfer between
the refrigerant and the air. SOCKET
The humidity in the air condenses as the air BOLT
cools down and adheres to the outside of the M540
evaporator as water drops. The cooling effect EVAPORATION (2 PCS.)
deteriorates if the water drops freeze. SENSOR
Therefore, how to discharge water is an
important point.
The amount of refrigerant supplied to the Fig. 8 Evaporator
evaporator is controlled by the expansion
valve which is described in the following. In
order to attain proper control, it is necessary
to reduce the pressure drop of the refrigerant
of the evaporator. Accordingly, reducing the
pressure drop is one element that makes the
evaporator attain its full performances.
(2) Expansion Valve
In order for the evaporator to fulfill its
performances, a proper amount of
low-pressure low-temperature liquid
refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant
completes vaporization early in the
evaporator which results in deterioration of
the cooling effect. If the feed rate is too high,
unvaporized liquid refrigerant returns to the
compressor (liquid back). This not only
deteriorates the cooling effect, but also
damages the compressor valves.
9
The expansion valve feeds the flowing
high-pressure high-temperature liquid
refrigerant to the evaporator as low-pressure
low-temperature liquid refrigerant (damp DIAPHRAGM
vapor of low dryness). The expansion valve
controls the feed rate of the refrigerant at the
same time.
Fig.9 shows how the block type expansion REFRIGERANT
valve is constructed. The temperature EVAPORATOR OUTLET
sensing part is provided in the shaft of the SIDE
expansion valve to directly detect the
SHAFT
refrigerant temperature at the outlet of the
evaporator.
The diaphragm contains R134a in saturated
state. The pressure in the diaphragm changes
according to the temperature detected by the REFRIGERANT
INLET
sensor. The change in the pressure causes the
force acting upon the diaphragm to vary
BALL
accordingly.
VALVE
The high-pressure high-temperature liquid
SPRING
refrigerant that is fed from the receiver side
Fig. 9 Block type expansion valve
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
occasion, part of the refrigerant evaporates
by the very heat of the refrigerant and cooled
off. The result is that low-pressure
low-temperature damp refrigerant vapor is
fed to the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust
spring and the pressing force of the
diaphragm (the temperature of the

refrigerant at the outlet of the evaporator to

be sensed by the thermowell). The feed rate is

controlled automatically so that under the
pressure in the evaporator, the refrigerant is
properly overheated (3㨪8 degrees) and goes
out of the evaporator. This action is carried
out by sensing the refrigerant temperature at
the outlet of the evaporator as against the
inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure
drop in the evaporator is excessive, it is
difficult to control the overheating or the feed

rate of the refrigerant. For this reason, the

smaller the pressure drop of the evaporator,

the better.
The expansion valve senses the pressure and
the temperature at the outlet of the
evaporator and controls the overheating of
the refrigerant and the refrigerant supply to
the evaporator more securely. The Fig. 10 Expansion valve outside view
air-conditioner of this machine adopts a block
10

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(5) Receiver Dryer (See Fig.13)
1) Receiver Tank REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the INLET
compressor varies greatly which causes the REFRIGERANT
proper flow of refrigerant in the cooling OUTLET
circuit to vary. It is the receiver tank that
receives the variations. When the cooling
circuit does not need much refrigerant, the
receiver tank stores extra refrigerant
temporarily and supplies it when the cooling
circuit needs much refrigerant. The receiver
tank also stores an extra amount of PRESSURE SWITCH
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or DESICCANT
clogs the circuit as the water freezes in the
expansion valve. It is desirable that the
SUCTION PIPE
amount of water mixed in the refrigerant
should be held below a concentration of
30ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in
FILTER
order to absorb water content that intrudes
into the circuit when the dryer is installed or
when refrigerant is charged.
3) Sight Glass
This is a peep window with which the
refrigerant level in the circuit is determined,
the only means of confirming the inside of the RECEIVER TANK
circuit visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by
cutting off the power supply to the
compressor when high pressure increases Fig. 13 Receiver dryer
abnormally high [more than 32kgf/cm2
(460psi) ].
The pressure switch also detects the leakage
of refrigerant by cutting the power supply to
the compressor when the pressure of the
circuit falls below 2kgf/cm2 (28psi).
12
4. DISASSEMBLY AND ASSEMBLY
4.1 PRECAUTIONS TO BE EXERCISED IN
OPERATION
(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator Table 2 Unit : kgfycm (lbfyft)
oil SP20 for use with new refrigerant R134a.
Oils other than SP20 may not be used. Since Pipe Fastening Part Tightening Torque
SP20 tends to absorb moisture and may D hose and compressor
200㨪250 (14㨪18)
corrode paint and resin, the following points (M8 bolt)
must be noted: D hose and condenser 200㨪250 (14㨪18)
1) Keep open all pipe connections on a new L hose and condenser 120㨪150 (8.7㨪11)
compressor and the component parts of the L hose and receiver dryer
80㨪120 (5.8㨪8.7)
installed refrigeration circuit (M6 bolt)
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 120㨪150 (8.7㨪11)
of the compressor, just before connecting S hose and air-conditioner unit 300㨪350 (22㨪25)
pipes. If you have removed a pipe joint for Inlet of expansion valve 120㨪150 (8.7㨪11)
repair, put a cap to both ports immediately.) Outlet of expansion valve 200㨪250 (14㨪18)
2) Use care so SP20 does not adhere to the Pressure sensing part of
expansion valve 70㨪90 (5.1㨪6.5)
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off Table 3 Unit : kgfycm (lbfyft)
immediately.
Screw Size Tightening Torque
(2) The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore, N4, T4 machine screw, M4 8㨪12 (0.58㨪0.87)

remove the valve at the pipe port N5, T5 machine screw, M5 20㨪25 (1.4㨪1.8)

immediately before connecting pipes. M6 (mounting part of
L hose joint) 80㨪120 (5.8㨪8.7)
(3) Tightening Torque of
M6 (except mounting part
1) Pipe Joints (See Table 2.) 100㨪120 (7.2㨪8.7)
L hose joint)
When connecting pipe joints, coat the O ring M8 (mounting parts of S,D
200㨪250 (14㨪18)
with special oil (SP20) and fasten to the hosejoints)
tightening torque indicated in the table, M8 (mounting part of A/C unit) 100㨪120 (7.2㨪8.7)
using a double spanner. M8 (other than those 120㨪160 (8.7㨪12)
2) Screws and Bolts (See Table 3.) mentioned above)

(4) Amount of Oil for Compressor (See Table 4.) M10 400㨪550 (29㨪40)

The compressor SD7H (HD type) is filled with
135cc (8.2cuyin) of oil. If the oil volume is Table 4
small, seizure at high revolution and
Replaced parts Amount to be filled in
shortening of service life will occur. If the oil
volume is large, the cooling ability will be Evaporator 40cc (2.4cuyin)
deteriorated. Condenser 40cc (2.4cuyin)
Once the air-conditioner is operated, part of Compressor Drain out the volume of oil
the oil is dispersed in the refrigeration left in the compressor to be
circuit. Therefore, when replacing the parts replaced, from the new
compressor.
in Table 4, adjust the oil level to that of table.
(5) Before performing operation, stop the engine
and turn off all power supplies to the
equipment related to the air-conditioner.
(6) After the operation is over, confirm that all
faults have been repaired completely, by
operating the air-conditioner.
13
4.2 REMOVAL AND INSTALLATION OF THE UNIT
(1) Removing the blower unit INNER / OUTER
AIR MOTOR
1) Remove the connectors connected to the ACTUATOR
inner/outer air select motor actuator, the CONNECTOR
blower motor and the blower controller. Also
remove the harness from the blower casing.
HARNESS
EVAPORATOR
SENSOR BLOWER
CONNECTOR CONTROLLER BLOWER MOTOR
CONNECTOR CONNECTOR
Fig. 14
2) Draw out the inner air filter from the intake
casing. Remove four cross-recessed screws T5 INNER AIR FILTER INTAKE
14 (T1) from the top of the intake casing, CASING
MOUNTING
using a screwdriver. Then remove the intake SCREWS
casing. (4 PCS.)
INTAKE
CASING
3) Remove three cross-recessed screws T514 BLOWER
(T1) fastening the blower casing with the unit CASING
MOUNTING
casing. Then separate the blower unit from SCREWS
the air-conditioner unit. (3 PCS.)
UNIT BLOWER
(2) Replacing the blower motor CASING
1) Disconnect the cooling hose that is connected
between the blower motor and the blower Fig. 15
casing.
2) Remove three cross-recessed screws N516 BLOWER CASING

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

blower motor.
BLOWER
MOTOR
3) Assembly is the reverse order of disassembly. BLOWER
CONTROLLER
(3) Replacing the blower controller COOLING
1) Remove two cross-recessed screws T4 14 HOSE
(T1) fixed from the bottom of the blower unit
casing and draw out the blower controller. BLOWER MOTOR
BLOWER MOUNTING
2) Install a new blower controller in the reverse CONTROLLER SCREWS (3 PCS.)
MOUNTING
order of removal. SCREWS (2 PCS.)
Fig. 16
z Do not disassemble the blower
controller in any circumstances.
14
(4) Removing the heater core
1) After discharging the cooling water,
disconnect the heater hose from heater core.
HEATER CORE
2) Remove one cross-recessed screw N516 (T2)
each for the AHC bracket fixing the heater PIPE CLAMP
core to the unit and for the pipe clamp. Then
remove the AHC bracket and the pipe clamp PIPE CLAMP
and draw out the heater core from the unit MOUNTING
casing. SCREW
(1 PC.)
AHC BRACKET AHC MOUNTING
3) Assembly is the reverse order of disassembly. SCREW (1 PC.)
Fig. 17
(5) Removing the upper and lower parts of the
air-conditioner unit casing
1) Draw out the connectors for the mode motor
actuator and the evaporation sensor.
2) Separate the rod 120 from the rod holder that ROD 120
REAR OF
is fixed to the lever MAL1 on the mode motor UNIT CASING
ROD HOLDER
actuator.
MOUNTING SCREW
LEVER MAL1
3) Remove three cross-recessed screws N422
(T2) fastening the mode motor actuator that MOUNTING BOTTOM OF
SCREW UNIT CASING
install the bottom of the unit casing to the
back of the unit casing. Then separate the MOUNTING MODE MOTOR
mode motor actuator. SCREW ACTUATOR
4) Remove eleven cross-recessed screws N516 Fig. 18

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

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

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2) Replacing the air mix motor actuator
Disconnect the connector connected with the
motor actuator.
Separate the rod 67 linking the motor
LEVER AM ROD 67
actuator with the lever AM, from the rod
ROD HOLDER
holder.
LEVER MAL1
Remove three cross-recessed screws T414
AIR MIX MOTOR
(T1) fastening the motor actuator. Then ACTUATOR
remove the motor actuator with the rod
holder and the lever MAL1, from the unit.
Remove the rod holder and the lever MAL1
from the motor actuator and install them to a
new motor actuator. Assembly is the reverse
order of disassembly.
Fig. 23
3) Replacing the inner/outer air select motor
actuator
Disconnect the connector connected with the
motor actuator.
Separate the motor actuator with lever MAL2
from the unit. LEVER MAL2
Remove the lever MAL2 from the motor
actuator and install it to a new motor
actuator, in the reverse order of disassembly.
INNER / OUTER AIR

MOTOR ACTUATOR
Fig. 24
17

5. CHARGING REFRIGERANT

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5.2 OPERATING PROCEDURE
(1) Refrigerant charge into the air-conditioner 2) The “gas charging operation” consists of
consists mainly of “vacuum making filling refrigerant in the circuit after forming
operation”, and “gas charge operation”. vacuum. Filling gas not only depends upon
1) The “vacuum making operation” consists of the cooling performances of the
removing water in the air-conditioner circuit. air-conditioner, but also affects the service
If only a little water remains in the circuit, life of the component parts of the circuit.
the small holes of the expansion valve are Extreme overcharge will make the circuit
frozen during operation. This causes the pressure extremely high and causes the
circuit to clog up or rust, resulting in a cooling performance to deteriorate. On the
variety of malfunctions. Therefore, before contrary, undercharge causes poor circulation
filling refrigerant in the circuit, make of the lubricating oil of the compressor and
vacuum and allow the water in the circuit to causes seizure of the moving parts of the
boil and vaporize. Water in the circuit is thus compressor.
eliminated. The gas filling operation involves handling of
high pressure gas; filling gas according to
incorrect operation procedure is dangerous.
Fill refrigerant correctly following the
(2) Operation Chart operation procedures and cautions stated in
this manual.
Vacuum making operation Refrigerant filling operation
More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Less than
㧙750mmHg Gauge reading
wrong
Charge liquid gas to a gauge
Check and correct joints pressure of 1kgf/cm2 (14 psi)
(3) Tools
Table 5 unit : mm
No. Name of Part Q̉
TY Sketch Service No. Name of Part Q̉
TY Sketch Service
1 Gauge 1 4 Quick joint 1 Low
23.5 pressure
manifold side
5 T joint 1 For service
can valve
2 Charging 3 Red : high 6 Service can 2 For service

pressure can
hose side valve
Blue : low
pressure
side
Yellow :
vacuum
pump
side
3 Quick joint 1 High 7 Vacuum 1 For
pressure vacuum
27.5 side pump adapter pump
19
5.3 CHARGING PROCEDURE
5.3.1 VACUUM MAKING OPERATION
HIGH
(1) Connecting Gauge Manifold (See Fig.25.) PRESSURE GAUGE
LOW PRESSURE
1) Close the high pressure valve (HI) and the GAUGE GAUGE MANIFOLD
low pressure valve (LO) of the gauge (CLOSED) LOW HIGH PRESSURE
manifold. PRESSURE VALVE
VALVE (CLOSED)
2) Connect the charging hoses (red and blue) BLUE RED
with the service valves of the compressor.
HIGH
Red hose : High pressure side (HI) of the PRESSURE YELLOW
gauge manifold ψ high pressure SIDE
DIS
side (DIS) of compressor LOW
Blue hose : Low pressure side (LO) of gauge PRESSURE
manifold ψ low pressure side SIDE
SUC
(SUC) of compressor
VACUUM PUMP
COMPRESSOR
z Take care so as not to mistake the (STOP)
high pressure side for low pressure Fig. 25 Connecting gauge manifold
side and push it in till a click is
heard. BLUE
z Connect the end bent like ̌L̍ of the RED
charging hose with the service valve
of the compressor. If the charging CHARGING
hose is connected the opposite way, HOSE
the mini core valve of the compressor (MINI CORE VALVE)
does not open. (See Fig.26.)
Fig. 26 Connecting piping with compressor
3) Connect the middle valve of the gauge
manifold with the charging hose of the
vacuum pump.
Some kinds of gauge manifolds are not

equipped with an open/close valve in LOW PRESSURE VALVE (OPEN) (CLOSE)
the center. HIGH PRESSURE VALVE (OPEN) (CLOSE)
More than 30 min
(2) Vacuum Making (See Fig.27.)
1) Open the high pressure valve (HI) and the GAUGE MANIFOLD
low pressure valve (LO) of the gauge
manifold.
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes.
3) When vacuum making for a specified DIS
duration is over (degree of vacuum : less than
㧙750mmHg), close the high pressure valve
and the low pressure valve of the gauge
manifold. SUC
4) Then turn off the vacuum pump.
Fig. 27 Vacuum making operation
20
(3) Air-tightness Check
Close the high pressure valve and the low
pressure valve of the gauge manifold, leave it
as it is for more than five minutes and make
sure that the gauge indication does not
return toward O.

If the gauge indication swings toward
O, there is somewhere that is leaking.
Retighten pipe joints, make vacuum
again and make sure of no leakage.

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

SUC
(2) Checking for Gas Leakage
Check for gas leakage in the cycle, using a
gas leak detector (electric type). Retighten Fig. 29 Gas charging operation
and correct leaking points. (High pressure side)
Always use R134a for the leak tester.

(The presently used fron gas affects the
sensitivity adversely.)
21
(3) Charging from Low Pressure Side
(See Fig.30.)
1) Make sure that the high-pressure and
HIGH PRESSURE
low-pressure valves of the gauge manifold VALVE (CLOSE)
LOW PRESSURE
and the service can valve are closed. VALVE
(MUST BE CLOSED
2) Start the engine and run the revolution to POSITIVELY)
OPEN CLOSE
1500r100rpm and fully open the cab door WHEN AIR RED
BUBBLES IN THE
and the windows. SIGHT GLASS
DISAPPEAR
3) Turn on the air-conditioner switch, set the YELLOW
DIS BLUE
fan switch to Max and the temperature
control switch to cool Max.
SERVICE CAN
4) When charging gas, set the discharge VALVE (OPEN)
pressure of the compressor to 14㨪16kgf/cm2 SUC
(200㨪230psi).
5) Open the low pressure valve of the gauge COMPRESSOR SERVICE CAN
OPERATION (DO NOT TURN IT OVER)
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass Fig. 30 Gas charging operation
of the receiver go away. (See Fig.30.) (Low pressure side)
[Total amount of gas to be charged :
1000gr100g (2.2r0.22 lbs )]
SIGHT GLASS
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
z Do not open the high pressure valve

of the gauge manifold in any
circumstances.
z Never place the service can upside
down. (The compressor valve may be
scored because the refrigerant is
sucked in a liquid state.)
Fig. 31 Receiver dryer
22

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6. ELECTRIC CIRCUIT
6.1 WIRING DIAGRAM AND CONNECTORS
Fig. 32 Electric diagram
24
6.2INSPECTING FUNCTIONAL PARTS
3 1
(1)Relay (24㧙4PE)
1)Coil resistance : 320ǡ (across 1 and 2) 4 2
2)Operating voltage : DC20㨪30V
3)The coil of the relay has polarity : Care is As viewed from A
needed.
A
4) Turn on and off the power to the blower
motor by controlling the controller.
5) Check: Check conductance across 3 and 4 in
the following condition :
Apply 20㨪30V across terminals 1 and 2 :
through
No voltage applied across terminals 1 and 2 : Fig. 33 Relay
not through
(2) Inner air sensor (C44)

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

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

1) Operating voltage : DC20㨪30V
2) Operating temperature range :
㧙30͠(㧙22q F) to +75͠ (167q
F)
The motor is controlled by signals (pulses)
put out by the controller.
CONNECTOR
PIN NUMBER
Fig. 36 Motor actuator
25
(4) Pressure Switch (Attached to Receiver PRESSURE SWITCH
Dryer)
1) Contents of checking (specification)
Low pressure side OFF pressure :
2.0r0.2kgf/cm2 (28r3psi)
Low pressure side return pressure :
OFF pressure +0.3kgf/cm2 (4.3psi) or below
High pressure side OFF pressure :
32r2kgf/cm2 (455r28psi)
High pressure side return pressure :
OFF pressure㧙6r2kgf/cm2 (㧙85r28psi)
Fig. 37 Pressure switch
LOW PRESSURE RETURN HIGH PRESSURE RETURN

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

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

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

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

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

M/A failed or controller
M/A lever link.
is out of order.
z After cleaning lever link,
apply grease.
Replace.
27
‫ޣ‬Temperature does not rise.‫ޤ‬
HL.E is shown on the set temp. display of panel.
NO YES
HL. ̪ is shown on the set temp display the panel. Note) ̪ is any of the numbers 0㨪9
NO YES
Blowout temp. rises at blowout z Inner air sensor or harness

mode if temp. is set at is disconnected or shorted.
HOTMAX 32.0͠ (89.6q F). z Inner air sensor connector
is off or in poor contact.
Inspect and correct or replace parts.
NO YES Inspect and correct

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

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

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

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

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

or replace controller.
‫ޣ‬Blower motor speed does not change.‫ޤ‬
HL. ̪ is shown on the set temp. display of panel. Note) ̪ is any of the
numbers 0㨪9.
NO YES
Air flow rate is constant regardless of readings. z Inner air sensor and harness
are disconnected or shorted.
z Inner sensor connector is
disconnected or in poor contact.
Replace blower
amplifier or controller. Inspect and correct or replace parts.
29
‫ޣ‬Magnet clutch does not engage.‫ޤ‬
Snow mark ( ) lights if A/C switch is
NO YES
Snow mark flickers and E is Voltage acts upon clutch.

shown on panel display.
NO YES
To B On page 27. Terminal voltage present across Clutch faulty.

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

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

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

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

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

and replace parts.
Replace
30
‫ޣ‬Modes do not change.‫ޤ‬
Mode display on operating

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

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

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

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

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

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

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

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

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

Remove Clean Air is mixed. performances is faulty or position is leaks
clogging condenser Make vacuum are normal. cord is faulty. out of
or replace and refill Familiarize disconnected. Correct casing.
parts. refrigerant. the user with position.
how to use it.
32
E235SR
SECTION 31 DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ...................... 1

1.1 From Chapter of Disassembly & Assembly .......................................................................... 1
1.2 Indication of Tightening Torque ............................................................................................ 1
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY
1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY

This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .......................................................................................................... Code No.㧦32

PartΣ㧧Removing and Installing
PartΤ㧧Disassembling and Assembling
1) Cylinder
(2) UPPER SLEWING STRUCTURE ............................................................................... Code No.㧦33

1) Hydraulic pump 2) Control Valve 3) Pilot Valve (ATT)
4) Pilot Valve (Travel) 5) Slewing Motor 6) Swivel Joint
(3) TRAVEL SYSTEM ....................................................................................................... Code No.㧦34

1) Travel Motor
1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=10kgfym (72 lbfyft)
Tolerance is r10% unless specified.
z Refer Code No. YF11 TOOLS for standard tightening torque.
1
E235SR
SECTION 32 ATTACHMENT
TABLE OF CONTENTS
[Part I. Removing and Installing]

1. ATTACHMENT ASSY AND NAME .......................................................................... I-1
2. BUCKET .................................................................................................................. I-1
3. ARM ........................................................................................................................ I-4
4. BOOM ..................................................................................................................... I-7
[Part II. Disassembling and assembling equipment]

1. CYLINDER ............................................................................................................. II-1
1. ATTACHMENT ASSY AND NAME
(D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN
BOOM (A) BOOM FOOT PIN
ARM CYLINDER
(F) BOOM TOP PIN
(E) ARM CYLINDER ROD PIN
BOOM CYLINDER
BUCKET
(G) BUCKET CYLINDER

HEAD PIN
(J) BUCKET DRIVE PIN
(I) IDLER LINK PIN PIN
BUCKET CYLINDER ARM
IDLER LINK
BUCKET LINK
(H) BUCKET CYLINDER ROD PIN (K) BUCKET ATTACHING PIN (B) BOOM CYLINDER HEAD PIN
Fig. 1-1 Front attachment name and position
2. BUCKET

2.1 REMOVING BUCKET
(1) Put the machine in position to remove bucket.
Fig. 2-1 Position to remove bucket
(2) Removing pin (2) DRIVER

Expand slit of ring (1) with driver, and remove
it. Push out the pin (2) with driver (㧙). 1 2
SECTION AA SECTION BB & CC

Fig. 2-2 Removing pin (2)
Σ㧙1
(3) Removing bucket attaching pin (K).
Lift up bucket, position it so that bucket
attaching pin (K) is not loaded, adjust bucket K
link, and pull out bucket attaching pin (K).
Fig. 2-3 Removing bucket attaching pin

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

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

put your finger in the pin holes in
any circumstances, but align them
visually.
z Check that the seals are not scored
and replace a faulty one if necessary.
zWhen inserting the pin, coat the shaft
with grease.
Fig. 2-5 Attaching bucket
Σ㧙2
2.3 PROCEDURE FOR ADJUSTING CLEARANCE
Adjustment of clearance between bucket and
㧗1.0 㧗0.039″
arm 326㧙0.5 (12.84″㧙0.020″)
1) Shift O ring (3) toward the bucket boss, using 14㧧WASHER New bucket
a spatula. (a→b) 13㧧LOCK B
WASHER 3㧧O RING
11㧧CAPSCREW b
2) When adjusting clearance (B), bring the a
non-adjusting side of the bucket in contact
with the arm.
3) Measure clearance (B) and check that it is

within 1.0mm (0.04in).
6㧧BUSHING
4) Adjust clearance (B) where it is more than 7㧧PLATE

1.0mm (0.04in).
8㧧SHIM 9㧧PIN
5) An average of 5 shims (8) of 1mm (0.04in)
Install pin (9) until the top of pin
thickness are set in the plate (7) fixed by the
is even surface with bushing.
three capscrews M1650 (11). The clearance
can be decreased by 1mm (0.04in) if one shim Fig. 2-6 Adjusting clearance between
is removed. bucket and arm
: 24mm
6) After adjustment, tighten the socket bolts

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

sum of both clearance is within 1.0mm
(0.04in).
8) Refit O ring (3) to its original position.

z When shifting O ring (3) by means of
a spatula, use care so as not to score
O ring (3).
z Remove shims (8), push out bushing
(6) rightwards by means of three
socket bolts (11) and adjust
clearance (B) so it falls within the
standard value evenly all round.
z Check the clearance at 120 hours̉
intervals in normal operation.
Shorten these intervals in special
operation. Adjust the intervals as
necessary.
Σ㧙3
3. ARM
3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder to a maximum and bring the arm
down on the ground.
Fig. 3-1 Position to remove arm

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

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

required, skip to procedure (6).
Fig. 3-2 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H)
1) Loosen nut (9), remove capscrew M16140 After adjustment of shim,
(8), and push out pin (H). the total gap should be
within 0.6㨪1.0mm (0.02㨪
0.04in).
: 24mm
H 8
2) Retract cylinder rod.
㧴㧳
9
SECTION DD
Fig. 3-3 Detail of bucket cylinder rod pin (H)

(4) Removing cylinder head pin (G)
Loosen nut (3), remove capscrew M16140
After adjustment of shim, the total
(2), and push out pin (G). gap should be within 0.6㨪2.0mm
(0.02㨪0.08in).
SHIM
: 24mm
2
G
SECTION AA
Fig. 3-4 Detail of bucket cylinder head pin (G)
Σ㧙4
(5) Removing bucket cylinder
Sling tube of bucket cylinder with nylon sling,
and remove it.
Bucket cylinder weight : 149kg (328 lb)
Fig. 3-5 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Put a wooden block between the arm cylinder
and the boom.
㧱
(4), and push out arm cylinder rod pin (E).
: 24mm
Retract arm cylinder rod, and return pin (E) to

the original position (hole).
SHIM
After adjustment of shim, the
E total gap should be within 0.6
㨪2.0mm (0.02㨪0.08in).
BLOCK SECTION BB
Fig. 3-6 Detail of arm cylinder rod pin (E)
(7) Removing boom top pin (F)

Loosen remove capscrew M14 25 (5), and
pull out boom top pin (F). DUST SEAL
: 22mm 5
F
Put block between arm cylinder and boom.
Insert pin (F) into the original hole.
SHIM
After adjustment of shim, the total gap
should be within 0.5mm (0.02in).
SECTION AA
Fig. 3-7 Detail of boom top pin (F)
Σ㧙5
(8) Slinging arm assy
Sling arm with nylon sling and remove it.
Arm weight ; 600kg (1320 lbs)
Fig. 3-8 Slinging arm assy

3.2 ATTACHING ARM
Instal the arm in the reverse order of
removing, paying attention to the following :
1) When aligning the pin holes, do not put your
finger in the pin holes in any circumstances,
but align them visually.
2) Check that the dust seals is not scored and
replace a faulty one if necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Apply Locktite #242 to the pin-securing
capscrews and nuts and fasten them.
Pin lock nut handling procedure
5) When installing the arm and the cylinder,

inspect the clearance in the thrust direction
of the mounts and decide the thickness of
shims by referring to the Maintenance
Standard.
6) Tightening torque
Tightening torque
Classification Size
MIHyO ftylbs
M14 18.5r2.0 130r14
M-threads
M16 28.5r3.0 210r22
PF,PT
1/8̢ 1.7r0.2 12r1.4
threads
Σ㧙6
4. BOOM
4.1 PREPARATION FOR REMOVING AND
ATTACHING BOOM
When removing and attaching boom in the
position shown in Fig.4-1, to remove and
attach boom foot pin (A), removing and
attaching of cab and guard are required.
4.2 REMOVING BOOM A

(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc.
giving attention for arm cylinder rod not to be
extended.
BLOCK
Fig. 4-1 Position to remove boom

(2) Lifting up boom cylinder temporarily
Remove the right and left boom cylinders one
side by one side according to the following
procedure:
Lift up boom cylinder temporarily to prevent
it from dropping.
: : 24mm
STAND
Fig. 4-2 Lifting up boom cylinder temporarily
(3) Removing boom cylinder rod pin (C)

Loosen nut (5), remove capscrew M16X150 After adjustment of shim, the total gap
(3), boss (4) and push out pin (C). should be within 0.6㨪2.0mm (0.02㨪0.08in).
SHIM
:24mm
3
C 4
5
(4) Preparing for disconnecting cylinder pipes
Retract boom cylinder rod, and place one side SECTION AA
of cylinder on block. (See Fig.4-2.) Fig. 4-3 Detail of boom cylinder rod pin (C)
Σ㧙7
(5) Disconnecting piping of arm cylinder and
bucket cylinder
Release pressure in hydraulic tank, and
disconnect pipe at section AA.
: 36mm 18kgfym (130ftylbs)
41mm 21kgfym (150ftylbs)
After disconnection of pipe, plug every pipe.
Plug : 4-(4)
TO CLAMP
After connecting the

hoses to the body,
clamp them at a point
450mm (17.7in) from
the ARM (R) hose.
Fig. 4-4 Boom piping disconnection

SECTION AA
VIEW Σ
(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that
boom foot pin (A) is not loaded.
Weight of single boom : 1300kg (2870 lbs)
BOOM FOOT PIN A
Fig. 4-5 Boom assy temporary lift up procedure
(7) Removing boom foot pin (A) After adjustment of shim, the total gap
1) Remove pin (3) and washer (9) and pull out should be within 0.5mm (0.02in).
SHIM
pin (2).
2) Draw out pin (A).
DUST SEAL
2
A
9

Apply molybdenum added grease
in the inner surface of the bushing.
SECTION AA
Fig. 4-6 Details of boom foot pin (A) section
Σ㧙8
(8) Slinging boom assy
Sling and remove boom assy.
Weight of single boom : 1300kg (2870 lb)

Weight of arm cylinder : 250kg (551 lb)
Fig. 4-7 Boom assy slinging procedure
(9) Completion of removal of front attachments

When the removing and attaching of cylinder A
are not required, the work is finished.
(10) Removing arm cylinder

1) Disconnect hose at A section, and plug both
ends.
After adjustment of shim, the
total gap should be within 0.6㨪
ORS plug 4-(4) 1.0mm (0.02㨪0.04in).
SHIM
: 36mm,
Tightening torque ; 18kgfym(130 lbfyft)
D 2
2) Removing arm cylinder head pin (D)

(2) and pull out pin (D).
3
: 24mm
3) Remove arm cylinder.
Fig. 4-8 Removing arm cylinder
(11) Removing boom cylinder

1) Disconnect hose at B section. ORS plug both B
ends.
ORS plug 4-(4)
: 32mm,
Fig. 4-9 Removing boom cylinder
Σ㧙9
2) Removing boom cylinder foot pin (B) After adjustment of shim, the
total gap should be within 0.6
(See Fig. 4-10) 㨪1.0mm (0.02㨪0.04in).
Loosen capscrew M1630 (6), plate (7) and SHIM
pull out pin (B).
: 24mm
3) Remove boom cylinder. B
4) Remove another boom cylinder. B
6,7
SECTION
BB
Fig. 4-10 Removing boom cylinder head pin (B)
4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and
install the boom assembly.
Attach it in the reverse procedure of
㧭
removing, paying attention to the following
points.
z When aligning the pin holes, do not

put your finger in the pin holes in
any circumstances, but align them
B
visually.
z Check that the dust seals is not B
scored and replace a faulty one if B
necessary.
Fig. 4-11 Boom foot pin (A),
z When inserting the pin, coat the
boom cylinder head pin (B)
shaft with grease.
z M16 Tightening torque : 28.5kgfym
(210 lbfyft)
z Pin lock nut handling procedure
Σ㧙10
1. CYLINDER
1.1 PREPARATION BEFORE DISASSEMBLY (2) Work bench
Before assembly, secure a dustfree workshop and The work bench must have strength and
necessary equipment and facilities. rigidity capable of accommodating the total
length of the cylinder in its most retracted
1.1.1 WORK AREA condition and of withstanding the repulsive
The following working area is required for force of the tightening torques of the cylinder
disassembly: head and the piston nut. Since a vise is
(1) Ample space attached to the bench, the width of the work
For the disassembly of the hydraulic cylinder, bench must be sufficiently large.
the cylinder tube and the piston rod must be (3) Support stand
drawn out. For this reason, the first condition If the clevis part of the piston rod is fully
is that the working area is long enough for extended in a free condition, the bushing and
the work. In terms of width, it is also the seals may be damaged as the rod bushing
necessary to keep sufficient space so and the piston are twisted due to the weight
disassembly, cleaning and measuring of the rod. A stand is required to support the
equipment are placed and the work can be rod to prevent such.
performed. (4) Hydraulic source
(2) Suitable working environment A Hydraulic source is required for
The hydraulic cylinder is a disassembly and assembly of the cylinder
precision-machined product that uses seals head and piston nut and for oil leak tests
and packings made of rubber and plastic after completion of assembly.
materials. For this reason full care should be (5) Jet air source
exercised so the hydraulic cylinder is free It is used for drying after oil draining and
from dust, dirt, and in particular, such hard cleaning of the cylinder.
particles as sand, metal chips, and weld slag (6) Cleaning bath, cleaning oil and detergent
(spatter). If the hydraulic cylinder is (7) Oil pan and oil reservoir
assembled with hard particles adhered on An oil pan is necessary to contain oil drained
such components as the cylinder tube and the from the cylinder and oil spilt during work.
piston rod, the tube inner surface and the rod An oil reservoir is required to collect oil spilt
surface are scratched as the cylinder on the floor and waste oil.
operates, consequently disabling it in worst (8) Others
cases. Damage to the piston seals and the rod Oil extracting hoses, wooden skids, rag and
seals will result in oil leaks. For this reason, sawdust in which oil soaked are also
grinding and welding operation should not be necessary.
performed in the neighborhood of the working
area to keep it clean
1.1.2 APPARATUS
The following equipment are required for
disassembly:
(1) Hoist or crane
The hoist or crane must be capable of
carrying the cylinder in an assembled
condition. It must also be capable of marking
level and liner movement under load for
retracting and extending the piston rod and
the tube.
Τ㧙1㧙1
1.1.3 NECESSARY TOOLS
Tools and jigs vary with types of cylinder, but it is
necessary to prepare the tools in Table 1-1 as a
guideline.
Table 1-1 List of Tools and Jigs
Tool / Jig Remarks Tool / Jig Remarks

Hammer 1. Steel hammer Spatula Metallic one with smooth
2. Wooden or plastic mallet corners.
Screwdriver A few types of large and small sizes Special jig 1. For removing and press-fitting
Chisel Flat chisel bushing. (A)(B)(C)
Vise One having an operation wide 2. For press-fitting wiper ring.
enough to hold cylinder head O.D. (D)
and tube mounting pins (clevis) 3. For inserting and reforming
Wrench 1. Eye wrench seal ring. (E)(F)(G)(H)
2. Allen wrench See para. 1.9 for detail
3. Extension pipe for wrenches Rust remover
Measuring 1. Slide calipers
Gimlet A sharp-point tool may be used in instruments 2. Micrometer
place of a gimlet. 3. Cylinder gauge (Fig. 1-1)
4. V-block
z For the details of special tools and
jigs, refer to the back pages of this
manual.

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

PORT B
construction of boom cylinder. When V BLOCK
disassembling and servicing the
cylinder, confirm the construction of
cylinder referring to Parts Manual.
1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and place
the cylinder on it to prevent it from rotating. PORT A
Charge air into ports A and B alternately to AIR
actuate the piston rod till the hydraulic oil in the
cylinder is drained out. At this time, connect a
OIL PAN
suitable hose to each port so that the hydraulic oil
may not gush out. Fig. 1-2 Preparation
Τ㧙1㧙2
1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF BOOM CYLINDER)
T=Tightening torque ; kgfym (lbfyft)
)
)
(4.13˝ 㧙0.0197˝
(4.33˝ 㧙0.0197
27 26 12 T=27.2 (200) 24 25
0
0
B
105㧙0.5
110㧙0.5
0
0
PT 1/4
28
980 (38.6˝ )
30 T=3.2 (23) PS 1/8

29
30q
31 SLIT
28
M121.75 ONE HOLE
THROUGH
DETAIL 6 DETAIL B DETAIL C
VIEW Y
T=5470{558} T=56.9 {5.8}
9 8 7 6 3 4 5 10,11 1 2 14 13 15 16 17 18 19 20 21 22,23
CUSHION STROKE
Pay attention to the direction of the slit.
C
SLIT
Fig. 1-3 Construction of boom cylinder

(The figure shows the right cylinder.)
No. PARTS NAME Q’TY No. PARTS NAME Q’TY No. PARTS NAME Q’TY
1 CYLINDER TUBE 1 12 SOCKET BOLT; M1675 12 23 STEEL BALL 1
2 PISTON ROD 1 13 CUSHION BEARING 1 24 PIN BUSHING 1
3 ROD COVER 1 14 CUSHION SEAL 1 25 WIPER RING 2
4 BUSHING 1 15 PISTON 1 26 PIN BUSHING 1
5 SNAP RING 1 16 SEAL RING 1 27 WIPER RING 2
6 BUFFER RING 1 17 BACK-UP RING 2 28 BAND ASSY 1
7 U-RING 1 18 SLIDE RING 2 29 BAND 1
8 BACK-UP RING 1 19 SLIDE RING 2 30 CAPSCREW; M1043 2
9 WIPER RING 1 20 SHIM 1 31 WASHER 2
10 O RING 1 21 PISTON NUT 1
11 BACK-UP RING 1 22 SETSCREW; M12 1
Τ㧙1㧙3
1.3 DISASSEMBLY
z When disassembling and servicing

the cylinder, check the construction
and the availability of service parts
as well as necessary tools and jigs on
separate Parts Manual.
z The figures in parentheses after part
names correspond to those in
Fig.1-3.
z The explanations and quantities
below are for a boom cylinder. Apply
the same to other cylinder as well.
1.3.1 REMOVING CYLINDER HEAD AND PISTON

ROD
1) Hold the clevis section of the tube in a vise.
Use mouth pieces so as not to damage

the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
2) Pull out piston rod (2) about 200mm (8in).

Because the piston rod (2) is heavy, finish
extending it with air pressure after the
above-mentioned oil draining operation.
2
3) Loosen and remove socket bolts (12) of the Fig. 1-4

rod cover in sequence.
ALLEN WRENCH 12
: 14mm
Cover the extended piston rod (2) with rag

to prevent it from being accidentally Turn counterclockwise
damaged during operation.
4) Strike the corner of the rod cover flange by 3

means of a plastic mallet till rod cover (3) Cover here with rag.
2
comes off.
Fig. 1-5
Τ㧙1㧙4
z At this time, the weight of piston rod
KNOCK THIS EDGE
(2) is loaded on rod cover (3). WITH A PLASTIC
LIFT HERE.
Therefore, lift the top end of the MALLET.
piston rod with a crane to the extent
that only the rod weight may be
held.
1
5) Draw out the piston rod assy from cylinder

tube (1). 3
2
Fig. 1-6 Drawing out piston rod assy (2).
Since the piston rod assy is heavy in
this case, lift the tip of the piston rod
LIFT HERE. 1
(2) with a crane and draw it out.
However, when piston rod (2) has been
drawing out to approximately two PULL
STRAIGHT
thirds of its length, lift it in its center SIDEWAYS
to draw it completely. However, since O O
the plated surface of piston rod (2) is
lifted, do not use a wire rope which
OIL PAN
may score the surface, but use a strong
cloth, a belt or a rope. Fig. 1-7 Method of drawing out the piston rod
assy
6) Place the removed piston rod assy
on a wooden V-block that is set level.
PISTON ROD ASSY
z Cover a V-block with rag.
WOODEN V-BLOCK
(PLACE RAG.)
Fig. 1-8 Method of placing the piston rod

7) Remove slide ring (18) and (19) from piston. 15
TAKE IT OFF BY WIDENING
THE SLIT TOWARD
THE ARROW
19
18
Fig. 1-9 Remove slide ring (18) and (19)
Τ㧙1㧙5
1.3.2 REMOVING PISTON ASSY 3 WOODEN
1) Fix piston rod (2) by holding its clevis section 2 BLOCK
in a vise. Fix the piston rod (2) rigidly as 15
piston nut (21) is tightened to a high torque.
21
z Note that the tightening torque
differs with the type, the working
pressure and the mounting method
of the piston (15), though the rod
diameter remains the same.
z It is also necessary to place a
suitable supporting block near the
piston (15). In case a V-block is used,
WOODEN V-BLOCK
put rag or something over the rod to (PLACE RAG.)
prevent it from being scored
Fig. 1-10 How to loosen piston nut (21)
2) Scrape off the caulked part of setscrew (22) of
piston nut (21) by means of a hand drill and 22 DRILL
loosen setscrew (22) and remove ball (23).
: 6mm
21
23
Fig. 1-11 Removing setscrew (22) and ball (23)

3) Loosen and remove piston nut (21).
Since piston nut (21) is tightened to a

high torque, use a eye wrench most
suitable with the outside diameter of
piston nut (21) and also use a power
wrench equipped with hydraulic jack TURN
COUNTER
and hydraulic cylinder. CLOCKWISE. 15
EYE WRENCH
21
Fig. 1-12 How to loosen piston nut (21)
4) After removing shim (20), remove piston (15)
by tapping with plastic mallet, supporting
weight of piston (15) with crane.
2 15
Fig. 1-13 Removing piston (15)
Τ㧙1㧙6
5) After removing cushion bearing (13), remove
LIFT WITH A CRANE.
cushion seal (14) and remove rod cover (3) STRIKE WITH
from piston rod (2). If it is difficult to slide it, A PLASTIC MALLET.
PULL STRAIGHT.
strike the flange section of rod cover (3) with
plastic hammer and slide it. And then hang NOTE:
rod cover (3) with crane and pull it out DO NOT
DAMAGE
horizontally. PISTON ROD
SURFACE.
Take care so bushing (4) and the lip of
pistons (6), (7), (8), (9) may not be
damaged by screw the piston rod (2). 3 4 6 8,7 9 2
Fig. 1-14 Removing rod cover (3)
1.3.3 DISASSEMBLING PISTON ASSY

1) Remove seal ring (16) and buck-up ring (17). HAMMER
Cut the seal ring (16) by tapping it

SCREWDRIVER (OR CHISEL)
with a screwdriver or a chisel. Take
care not to strike it too hard, otherwise
the groove may be damaged. BACK-UP RING
17 SEAL RING
16
15 USE CARE NOT O RING

TO DAMAGE
THE GROOVE.
Fig. 1-15 Removing seal ring (16) and back-up

ring
(17)
Τ㧙1㧙7
1.3.4 DISASSEMBLING ROD COVER ASSY SPATULA
1) Remove O ring (10) and back-up ring (11).
Remove back-up ring (11) and O ring (10) in 10
that order. Remove back-up ring (11) and O
ring (10) by pulling and stretching them with
11
an spatula like earpick. (REMOVE THESE
FIRST.)
Fig. 1-16 Removing the outer circumferential

seal of rod cover (3)
2) Remove buffer ring (6), U-ring (7) and
back-up ring (8). Each seal is fixed in the GIMLET
groove on the bore and removing in flawless
is impossible. 8
Stab each seal with a gimlet and pull it out of 3 7
the groove.
6
Take care in this operation not to
damage the grooves.
Fig. 1-17 Removing the inner circumferential

seal of rod cover (3)
3) Remove wiper ring (9). When taking out HAMMER 3
wiper ring (9), fix rod cover (3) in a vise. SCREWDRIVER
WOOD PIECE
WOOD PIECE
VISE
Fig. 1-18 Removing wiper ring (9)

4) Remove snap ring (5) and bushing (4). PRESS HERE
CHUCK ASSY TOOL A
Remove snap ring (5) first, and remove
bushing (4). But the bushing (4) is press
fitted in rod cover (3), so push it out by press
with jig as shown in the figure.
BUSHING 4
See para 1.9.3.1) for removing.
BLOCK TOOL C
Fig. 1-19 Removing rod bushing (4)
Τ㧙1㧙8
1.3.5 REMOVING PIN BUSHING PUSH WITH A PRESS.
1) Apply driver to wiper rings (25)(27) of
JIG J
cylinder tube (1) and piston rod(2), and strike
it by hammer lightly.
2) Push out pin bushings (24)(26) press fitted in
cylinder tube(1) and piston rod (2) with press.

2

24,(26) BASE

Fig. 1-20 Drawing out pin bushing (24)(26)

1.4 CLEANING
1) After disassembly the cylinder, wash all parts
with commercial detergent.
Never use benzene(gasoline, thinner,

etc.) because it may be damage the
rubber, etc.
2) Don’t use the used oil seal, O ring, back-up

ring, etc. even if they are not damaged after
inspection.
3) After cleaning, dry all parts by compressed
air, and put them on the working bench
taking care not to damage them.
1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
٤ Cylinder tube assy
٤ Piston assy
٤ Rod cover assy
1.5.1 ASSEMBLING PIN BUSHING

PUSH WITH A PRESS
1) Press fit pin bushings (24)(26) in cylinder 2
tube (1) and piston rod (2) respectively with 24,
press.
2) Press fit wiper rings (25)(27) in the upper and
lower sides of cylinder tube (1) and piston rod
(2) respectively with press.
z Before press fitting, apply grease on

wiper ring and boss hole.
z Before press fitting the pin bushing, OIL HOLE LOCATION
adjust the position of oil hole.
Fig. 1-21 Press fitting of pin bushing (24)(26)
Τ㧙1㧙9
PRESS HERE
1.5.2 ASSEMBLING PISTON ASSY METAL (G)
1) The fitting of seal ring (16) requires special PRESS JIG (E)
tool as shown in Fig. 1-22. Seal ring (16) is
pushed in by press, etc. with pushing in tool SLIDE JIG (F)
as shown in the figure.
(The O-ring of seal ring (16) and back-up ring
15
(17) on one side should be installed
beforehand.)
16 O RING
Heat them, and they may be soften.
But never heat them over 100 ͠
17
(212.0qF) or more.
2) Fit back-up ring (17) on the other side. After Fig. 1-22 How to fit sael ring (16)
fitting, correct it immediately to prevent from PRESS HERE
expansion of seal ring (16) with correcting jig 16 17
(H) as shown in Fig. 1-23.
CORRECTIONAL JIG (H)
z For piston, stop it once tentatively
(for 3 to 5 seconds), and then push it
in fully.
z After fitting, wind tape around seal
ring (16) 2 or 3 times, and remove it
immediately before piston (5) is
inserted in cylinder tube (1).
z Fit slide rings (18)(19) at the same
time when piston (15) is inserted in Fig. 1-23 Installing seal ring (16)
cylinder tube (1). PRESS HERE. (STRAIGHT DOWN)
PRESS FITTING JIG (A)
1.5.3 ASSEMBLING ROD COVER ASSY 4
1) Press fit bushing (4) in rod cover (3) with
bushing press-fitting jig (A). Then, fit snap
GROOVE FOR
ring (5) in the groove. Apply hydraulic oil on
FIXING SNAP RING (5)
internal surface of rod cover (3).
PRESS BUSHING TILL

The snap ring (5) can not be fitted
BUSHING COMES IN
when the bushing (4) is not press-fitted 3 CONTACT WITH
fully to the stop end. THIS FACE.
2) Apply grease to wiper ring (9), and fit wiper PRESS HERE. (STRAIGHT DOWN)
ring (9), directing the lip side toward the
groove of retainer tool (D). And set retainer
RETAINER TOOL (D)
tool (D) on rod cover (3) and press fit wiper
ring (9) with press.
U-RING GROOVE
Fig. 1-24 Press fitting of bushing (4)
Τ㧙1㧙10
3) Fit buffer ring (6), back-up ring (8) and PUT IN GROOVE FROM THIS SIDE.
U-ring (7) in their grooves in that order.
Before setting packings, coat them with
hydraulic oil (or vaseline if not available). If
you forget the coating, the packings may be
scored. When attaching seals, deform them in
a heart shape as illustrated.
Fig. 1-25 Inserting a seal into the inner

circumference of rod cover.
z U-ring (7) is harder than other
PUSH BAR
packing and it would be difficult to (WOOD OR PLASTIC)
deform them in a heart shape. In such
10
a case, put a U-ring in the groove
obliquely by hand as deep as possible 11
and push in the last part with a push 3
bar till it is set with a click.
z Buffer ring (6) should be fitted taking
care of the fitting direction. The
reverse fitting may cause deformation,
damage, etc. of the piston due to high
pressure generated between the buffer
ring and U-ring.
z If U-ring (7) is set upside down, the
lip may be damaged. Check that it is 6
positioned correctly.
z Attach back-up ring (11) on the open 7
air side of O ring (10). (See Fig. 8
Open air side
1-26.) 9
Fig. 1-26 How to fit U-ring (7)

1.5.4 INSERTING ROD COVER ASSY TO
PISTON ROD
1) Fix piston rod assy on working bench. INSERT GUIDE JIG ( I ) 3
2) Install rod cover (3) on piston rod (2) with
PUSH
inserting guide jig (I) as shown in Fig. 1-27,
paying attention for the lip section of U-ring
not to be caught on the stepped section.
2
z For the rod the outer diameter of
piston installing section is small,
insert spacer on the faucet section of Fig. 1-27 Inserting rod cover (3)
rod first, and attach inserting guide
jig.
z Apply hydraulic oil on the inserting
guide jig and outer surface of piston
rod lightly to make the insertion
Τ㧙1㧙11
1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD
PISTON
13
1) Install cushion on the extraction side,
14
cushion bearing (13) and cushion seal (14) by
the following procedure.
1. Put cushion seal (14) on it, directing the slit
machined side toward the piston side.
2. Fit cushion bearing (13) on it directing the
flattening side as shown in Fig. 1-28.
FLAT SECTION
2) When cushion is installed on the retraction
side, fit cushion bearing and cushion seal by Direct slit toward
the following procedure. piston side
1. Fit cushion bearing before fitting piston nut. Fig. 1-28 Cushion mechanism on extension side
The nut attached obstructs the fitting of
cushion bearing. Direct slit toward
2. Put cushion seal on it, directing the slit thread side
machined side toward the piston side. THREADED PART
3. Fit cushion bearing on it directing the
flattening side as shown in Fig. 1-29.
4. Put stopper in the groove. Push cushion PISTON ROD
bearing to stopper fully, and drive snap
ring. Use plastic mallet in order not to
damage the rod, cushion bearing.
Cautions
SNAP RING STOPPER
z Cushion seal and cushion bearing CUSHION SEAL CUSHION
(Divide into
(Slit 1 place) BEARING
should be fitted taking care of the 2 portions)
fitting direction. If they are fitted in Fig. 1-29 Cushion mechanism on retraction side
reverse directions, the cushion might
not make into play.
After installing cushion, be sure that
the cushion bearing moves up and
down, and right and left.
Τ㧙1㧙12
3) Insert shim (20), turn in piston nut (21) till it
gets tight.
Always tighten the piston nut (21) of each 21
piston to specified torque (Refer to II-1-16.)
EYE WRENCH
z Always correct the threads of the

tapped hole in piston nut (21) before
TURN CLOCKWISE.
fixing piston nut, using a tap.
z The lack of tightening torque may Fig. 1-30 Tightening piston nut (21)
cause internal leakage and damage of
screw. The tightening to higher torque 22 ANTI-LOOSENING CAULKING
may cause bulge of cushion bearing on 20 2
the extension side and permanent set 23
in fatigue on the working face of piston.
z Before tightening the piston, clean,
degrease (with thinner, etc.) and dry
the attaching parts.
4) Put steel ball (23) into hole and tighten V-BLOCK

21
setscrew (22). Fig. 1-31 Attaching setscrew (22)
:6mm
22 18 19
After tightening the setscrew to a specified 2
torque of 5.8kgfym (4.2 lbfyft), caulk the two
places of the thread of the piston nut side to
secure the setscrew.
5) Attach two slide rings (18) and (19). Take off

vinyl tape wound around the perimeter of
piston (15), apply high-quality grease (or V-BLOCK
vaseline) to slide ring (18), (19) and attach the 21
slide rings in a manner that they may be coiled Fig. 1-32 Attaching slide ring (18)
around the groove. Set the slide rings about 180
degrees apart with each other so that the slits
may not point to the same direction.
1.5.6 OVERALL ASSEMBLY 1

1) Place a V-block on a rigid work bench (A
wooden V-block is preferable.). Place the
LIFT
cylinder tube assy (1) on it and fix the assy by
passing a wooden bar through the clevis pin
hole to lock the assy.
2) Insert the piston rod assy into the cylinder tube
assy, while lifting and moving the piston rod STRAIGHT FIX IT WITH A BAR
assy with a crane. In this operation, apply (A WOODEN ONE
PREFERABLE)
hydraulic oil (or vaseline) to the inner surface of OR IN A VISE.
the tube mouth and the circumference of the
piston. Align the center of the piston rod assy
with the center of the cylinder tube assy and
put it in straight forward. When inserting,
make sure that slide rings (18),(19) on the Fig. 1-33 Inserting piston rod assy
perimeter of the piston is not out on the groove.
Τ㧙1㧙13
3) Turn up socket bolt (12). Match the bolt holes 12
of the rod cover flange to the threaded holes
in the cylinder assy, and screw in socket bolts PLACE RAG.
(12) one by one. Tighten the bolts to a
specified torque, taking care so the bolts may
not be tightened unevenly.
:14mm,
Tightening torque : 27.2kgfym(197
lbfyft)
Refer to Τ-1-16 ALLEN WRENCH
TURN
Take care so as not to damage the rod CLOCKWISE.
surface by accidentally slip a wrench. Fig. 1-34 Tightening socket bolts (12)
Covering the rod surface with rag is
recommended to prevent damage to it.
For the tightening torques, refer to DIRECTIONAL VALVE
̌(Τ-1-16)̍. PUMP
1.6 INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load, operate H R
the piston rod 5 to 6 strokes by the
directional valve and make certain that it
operates without fault.
HYDRAULIC CYLINDER
z Do not raise the hydraulic pressure Fig. 1-35 External leak test
above the maximum pressure of
385kg/cm2 (5480psi) for the cylinder MEASURE THE
of the machine. INTERNAL LEAK.
z Grease coated on the O rings and the
seals of the rod cover may ooze out.
Wipe it off and retest the cylinder in
such a case.
(2) Leak test (See Fig. 1-35 and Fig. 1-36.) FROM DIRECTIONAL VALVE
1) Apply a test pressure to the retracting and Fig. 1-36 Internal leak test
extending sides of the cylinder for three
CYLINDER ASSY
minutes independently, and check that the
rod section and the welds have external leaks
and permanent deformation. For an internal
leak test, connect the cylinder with a test
unit .
PLUG PLUG
2) After completing the test, apply a plug to Fig. 1-37 How to store the cylinder
each port and store it (Fig. 1-37).
For storage, place the cylinder on

wooden V-blocks and bring the cylinder
to the most retracted condition.
Τ㧙1㧙14
1.7 MAINTENANCE STANDARDS
1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see
that excessive wear, crack and other faults that
are detrimental to use are not present.
(1) Inspection Item

Table 1-2
Part Name Inspecting Section Inspection Item Remedy
Piston rod 1. Neck of rod pin Presence of crack Replace.
2. Weld on rod hub Presence of crack Replace.
3. Stepped part to which Presence of crack Replace.
piston is attached
4. Threads Presence of seizure Recondition or replace
5. Bend Measure degree of bend Refer to Table 1-3.
(See Fig. 1-38.)
6. Plated surface Check that:
1) Plating is not worn off 1) Replace or replate
to base metal
2) Rust is not present on 2) Replace or replate
plating.
3) Scratches are not 3) Recondition, replate or
present. replace.
7. Rod Wear of O. D. Recondition, replate or replace.
8. Bushing at mounting Wear of I. D. Replace.
part
Cylinder 1. Weld on bottom Presence of crack Replace.
tube 2. Weld on head Presence of crack Replace.
3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of faults Replace if oil leak is seen.
5. Bushing at mounting Wear on inner surface Replace.
part
Rod cover 1. Bushing 1) Wear on inner surface 1) See para. 1.7.2.
2) Flaw on inner surface 2) Replace if flaw is deeper than
coating.
(2) Repair method

Check all seals and parts to see that they do z Always regrind after replating. The
not show excessive damage and wear. For thickness of the plating must be
co-rrection of faults on the piston rod, observe maximum 0.1mm (0.004in).
the following procedure: z In case plating is removed to the
1) Correct very fine longitudinal scratches with base metal during reconditioning
an oilstone. Replace the piston rod if the with an oilstone, do not fail to
scratch is so deep as may be caught by your replate the surface.
nail.
2) In case of a smooth indention, recondition by
removing the sharp area around the
inden-tion with an oilstone. If the flaw or the
in-dention is excessive, replace or replate the
faulty part.
Τ㧙1㧙15
1.7.2 LIMIT OF SERVICEABILITY 1.7.3 TIGHTENING TORQUE
Serviceability limits represent the limits of wear
on the sliding surfaces of the cylinder tube and B A
the rod that have no such faults as may degrade
the sealing effect.
(1) Clearance between piston rod and rod
bushing
Replace the bushing if the clearance between Fig. 1-39
the piston rod and the rod bushing exceeds
0.25mm (0.01in). Table 1-4 Unit : kgfym (lbfyft)
(2) Bend of piston rod A B
Cylinder
The allowable bend of the rod is maximum Piston nut Socket bolt
1mm / 1m (0.04˝ /3´3˝ ). For measurement, 550 27.2
support both ends of the parallel section of Boom
(4040) (197)
the piston rod with V-blocks, set a dial
indicator in the center between the two V- 1050 37.4
Arm
block turn the piston rod, and read the (7580) (271)
difference between the maximum and
minimum oscillations on the dial indicator. 743 27.2
Bucket
(5470) (197)
Dial indicator
1.7.4 VOLUME OF OIL LEAKAGE

The oil leak rates as mentioned in 1.6 (2) of Ins-
pection after Assembly are as shown in Table 1-5.
Middle of rod

Table 1-5
Fig. 1-38 Measuring Method
Cylinder Volume of Internal Oil Leakage
Table 1-3 shows an example of measurement.
Boom 1.0cc (0.06 cuyin) or below / 3min
Arm 1.0cc (0.06 cuyin) or below / 3min

Table 1-3 Example of Measurement
Oscillation of the dial Bucket 1.0cc (0.06 cuyin) or below / 3min

Distance
between indicator in the middle
Remedy
V-blocks of the rod.
m (in) mm (in)
1 (3´3˝ ) 1 (0.04˝ ) Replace
Even if the bend is within the above

limit, the cylinder may not operate
smoothly because of localized bend.
Beware of it during function test after
assembly. Replace the rod if the
cylinder makes a squeaking noise or
dose not operate smoothly.
Τ㧙1㧙16
1.8 TROUBLESHOOTING Table 1-6
Trouble Faulty Part Cause Remedy
1. Oil leakage through 1. Back-up 1. Foreign matter is 1. Remove foreign matter.
sliding surface of piston ring included in the bore of
rod oil ring is formed on back-up ring
piston rod, and the ring 2. Lips on outer and inner 2. Replace back-up ring.
grows up to oil drops, diameter surfaces of
and they drip. back-up ring are scored.
3. Other back-up ring are 3. Replace back-up ring.
faulty.
2. U-ring 1. Foreign matter is caught 1. Remove foreign matter.
Buffer ring in the bore of ring.
2. Flaw is present on the 2. Replace ring.
bore of ring.
OIL LEAKS FROM HERE. 3. Other rings are faulty. 3. Replace ring.
3. Wiper ring 1. Foreign matter is include 1. Remove foreign matter.
in the bore of wiper ring.
2. Lip on the bore of wiper 2. Replace wiper ring.
ring is scored.
3. Another wiper ring is 3. Replace wiper ring.
faulty.
4. Piston rod 1. Flaw is present on the 1. Smooth out the sliding
sliding surface of piston surface with an oilstone.
rod. If leakage occurs even if
the sliding surface is
finished below 1.6S, rod
packings may be scored.
Disassemble and inspect
it and replace rod
packings as required.
If leakage will not stop by
that treatment, replace
piston rod.
2. Hard chromium plating 2. Replate.
has peeled off
2. Oil leaks from the 1. O ring 1. O ring is damaged. 1. Replace O ring.
circumference of rod 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
cover.
3. Cylinder 1. Swelling of cylinder tube. 1. Replace cylinder tube.

tube
OIL LEAKS FROM HERE.
3. Oil leaks from welds. 1. Cylinder 1. Welds of cylinder are 1. Replace cylinder tube.
tube fractured.
WELDS
4. Cylinder falls by it-self. 1. Seal ring 1. Foreign matter is caught 1. Remove foreign matter.
[When the rod is loaded on the sliding surface of
with a static load equal seal ring.
to the maximum 2. Flaw is present on the 2. Replace seal ring..
working pressure sliding surface of seal
multiplied by the area ring.
of the cylinder bore, the 2. Slide ring 1. Sliding surface of slide 1. Replace slide ring.
maximum movement of rings is scored.
the piston is more 3. Piston rod 1. Elongation. 2. Replace Piston rod.
than 0.5mm (0.02̢) in Piston rod and piston are
ten minutes.] elongated.(Loose nut)
Τ㧙1㧙17
1.9 JIGS LIST
1.9.1 SPECIAL JIG LIST (POSSIBLE TO SUPPLY)
When assembling, the following jigs are required.
Table 1-7
APPLICATION SHAPE PAGE

A D
For removing and press

EDGE OF CHUCK C 1㧙8, 1㧙10
fitting bushing
For press fitting wiper

1㧙10
ring
E H
F
For correcting seal ring G

1㧙10
INSERTING JIG CORRECTING JIG
For inserting rod cover 1㧙11
For above jigs, contact our representative.

(The Jig No. List provided by cylinder maker is
shown in the following page.)
Τ㧙1㧙18
Special Jig No. List
1) For jigs for rod cover, select jig corresponding
to respective rod diameter.
2) For jigs for piston, select jig corresponding to
the cylinder bore.
Table 1-8
Application rod diameter (mm) Kit No. of maker
65 3006J-56001
Jig for rod cover removing & installing
70 3007J-06001
75 3007J-56001
80 3008J-06001
85 3008J-56001
90 3009J-06001
95 3009J-56001
100 3010J-06001
102 3010J-56001
110 3011J-06001
115 3011J-56001
120 3012J-06001
Application cylinder bore (mm) Kit No. of maker
95 3009J-51001
100 3010J-01001
Jig for seal ring inserting & correcting
105 3010J-51001
110 3011J-01001
115 3011J-51001
120 3012J-01001
125 3012J-51001
130 3013J-01001
135 3013J-51001
140 3014J-01001
145 3014J-51001
150 3015J-01001
160 3016J-01001
170 3017J-01001
Τ㧙1㧙19
1.9.2 OTHER SPECIAL JIGS
(PREPARED BY SERVICE SHOP)
1) Bushing extraction jig (Symbol J) MATERIAL : Mild steel
80 (3.15̢) Table 9 Unit : mm (inch)

50 15 15 (0.59̢)
d D Cylinder Used
12-S
(1.97̢) (0.59̢)
5 (0.197̢)
C2 (0.079̢) R2 (0.079̢) R0.2 (0.0079̢) 80 (3.15) 89 (3.50) Bucket
10q 12-S
(-0.0197̢
-1 (-0.0394̢
)
)
-3 (-0.118̢
(-0.158̢
)
)
85 (3.35) 94 (3.70) Arm

25-S
(-0.0079̢
(-0.0158̢
)
)
∅d -0.2
-0.4
85 (3.35) 99 (3.90) Boom (Rod side)
∅D -4
∅D -0.5
90 (3.54) 104 (4.10) Boom (Bottom side)

Fig. 40 Bushing extraction jig
2) Wrench for piston nut

Table 10 Unit : mm (inch)
B Cylinder Used
110 (4.33) Arm
95 (3.74) Boom
90 (3.54) Bucket
B
Fig. 41 Wrench for piston nut
Τ㧙1㧙20
1.9.3 SPECIAL JIG HANDLING PROCEDURE
(1) How to extract bushing from rod cover.
1) Attaching chuck assy tool
Insert tool in rod cover slowly until the edge
EDGE
top end of chuck assy reaches to the end of
bushing.
z Special attention must be paid so

that the inner surface of rod cover is
not damaged by the edge of tool.
z Attach too on the position 5mm
(0.2 in) from the bushing end face so
that the edge does not protrude from
the end face.
4 5 (0.197̢
)
A
CHUCK
2) Tightening chuck assy tool temporarily

LEVER
1. Fit allen wrench to the head of adjuster bolt
on the top end of tool, and insert lever in the
round hole on the rear end of tool.
2. Fix it with allen wrench and lever to the

position where the tool does not drop even if
the rod cover is raised, inclining it forward
and rearward.
ALLEN
z Move rod cover onto the working WRENCH
bench holding tool attached.
z Be careful not to drop it on foots, etc.
Τ㧙1㧙21
3) Attaching tools for retainer
Put retainer on the press bench directing the
wiper ring fitting section of rod cover upward, D
then put retainer too (D) on the rod cover.
FLANGE
z Fit retainer tool as shown in the
right figure directing large diameter
section (flange section) upward.
z Clean the surface of press bench,
and take care for the tool bottom face
not to be damaged by foreign matter
like dust, chip, etc.
4) Cutting into of the edge of chuck PRESS HERE

Press the upper section of retainer tool
gradually so that the edge of chuck tool (D)
cuts into the bushing surface.
z Set the pressing force to 2㨪3 tons

(4410㨪6615 lbs).
After completion of pressing, tighten adjuster

bolt again by hand.
z Don’t fail to press it with retainer

tool (D).
CHUCKING JIG
Τ㧙1㧙22
5) Setting of tools for block
Prepare block (C), and put rod cover (3) on it
aligning them.
Select corresponding block (C) in shape,
dimensions, etc. from the table shown below.
D
15 (0.591̢)
d 10q
15 (0.591 )
10q h
Unit : mm (in)
Class
(Nominal size)
d D h
∅55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15) C
65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)
90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)
6) Taking out bushing
1. Move block (C) and rod cover (3) with tool
under the press.
2. Press the upper part of retainer tool (D) D
slowly until bushing (4) is take out from rod
cover (3) (until there is a sound that the
chuck tool(A) drops on the working bench)
z The force of 3 tons (6615 lbs) is

necessary to press it out.
The stroke of press ram is about 32㨪52mm

(1.26in㨪2.04in). (But it varies according to
the difference of dimension of cylinder head.)
z Don’t fail to press it with retainer

tool (D).
When the block and rod cover assy are not

aligned, interrupt the work and align the
block and rod cover assy.
Τ㧙1㧙23
7) Taking out rod cover 3
1. Take out block (C) with rod cover (3) near
side, remove retainer tool from rod cover (3),
and then move rod cover (3) to other place.
2. Take out the chuck tool with bushing from
block (C).
z Never work under the press because

it is very dangerous.
8) Taking out bushing

1. Put chuck tool (A) with bushing (4) sideways,
and loosen adjuster bolt with allen wrench
and lever.
2. Put the chuck tool (A) vertically and turn the
adjuster by hand until the wedge is raised
ADJUSTER BOLT
about 5mm (0.2 in).
3. Remove the wedge from the edge of chuck.
z Clean the surface of working bench,

and be careful for the tool not to be
damaged by foreign matters like
dust, chips, etc.
4
Τ㧙1㧙24
9) Tightening of adjuster bolt
Tighten the chuck tool (A) the bushing (4) is
removed to the extent that there is no gap ADJUSTER BOLT
between the chuck and the wedge upper face,
WEDGE
turning the adjuster bolt by hand.
z This special tool differs according to

the corresponding piston rod diameter.
z The chuck edge is an important
portion. Take care of handling and
storage.
CHUCK EDGE
Τ㧙1㧙25
(2) Rod cover bushing press-fitting procedure
1) Setting rod cover
1. Put rod cover (3) on the press-working bench
directing the tube connection upward.
4
2) Temporary setting of head bushing
1. Set bushing (4) on the inner surface of rod
cover (3) temporarily.
z Make sure that the inner and outer

surfaces of bushing are free from
foreign matter. 3
3) Setting chuck assy tool (A)

Insert the chuck assy tool (A) in
temporary-set bushing (4) directing the flange 4
downward, and set it on rod cover (3).
z Be sure that the adjuster bolt is

tightened to the extent that there is
no gap between adjuster of chuck
assy and wedge.
ADJUSTER BOLT
WEDGE
Τ㧙1㧙26
4) Attaching retainer tool
Put retainer tool (D) on the wedge stepped
section of chuck assy tool (A) slowly directing
the flange upward.
z Align chuck assy(A) and the wedge.
STEP OF WEDGE
5) Preparation for press-fitting

Move the rod cover on which chuck tool (A)
and retainer tools are attached under the PRESS RAM
press.
z Adjust it so that the press ram is

centered to the tool.
RETAINER (D)
CHUCK (A)
BUSHING (4)
PRESS FITTING
PART
Τ㧙1㧙27
6) Press-fitting of bushing
Push the head of retainer (D) with press, and
press fit bushing (4) to the specified position
of rod cover (3) slowly.
z The pressing force should be held 5

tons (11025 lbs) or less, keeping the
required force for the press-fitting.
z Raise the pressure gradually
adjusting the force by means of
pressure adjusting valve of press
unit.
z Be sure that the end face of bushing
is located on the interior of the
groove for snap ring. When it is
located on near place, press fit and
adjust the location again.
LIFTING THREAD
D RETAINER JIG
ADJUSTER BOLT
WEDGE
A CHUCK TOOL ASSY
CHUCK
BLOCK TOOL C
Bushing extraction and press fitting jig (For reference only)
Τ㧙1㧙28
E235SR
SECTION 33 UPPER SLEWING BODY
TABLE OF CONTENTS
[Part I. Removing and Installing Assy]

1. CAB .......................................................................................................................... I-1
2. OPERATOR SEAT .................................................................................................... I-2
3. BATTERY.................................................................................................................. I-4
4. GUARD ..................................................................................................................... I-5
5. UNDER COVER ..................................................................................................... I-10
6. FUEL TANK ............................................................................................................ I-11
7. HYDRAULIC TANK ................................................................................................. I-12
8. HYDRAULIC PUMP ................................................................................................ I-15
9. AIR CLEANER........................................................................................................ I-19
10. MUFFLER............................................................................................................. I-20
11. COUNTERWEIGHT.............................................................................................. I-21
12. RADIATOR & OIL COOLER ................................................................................. I-22
13. ENGINE ................................................................................................................ I-26
14. INSTRUMENT PANEL .......................................................................................... I-28
15. MULTI SELECTOR VALVE ................................................................................... I-29
16. CONTROL VALVE ................................................................................................ I-31
17. PILOT VALVE (FOR ATT) ..................................................................................... I-33
18. PILOT VALVE (FOR TRAVEL) .............................................................................. I-34
19. SWING UNIT ........................................................................................................ I-35
20. SWIVEL JOINT ..................................................................................................... I-37
21. UPPER FRAME .................................................................................................... I-39
[Part II. Disassembling and assembling]

1. PUMP ...................................................................................................................... II-1
2. CONTROL VALVE ................................................................................................... II-2
3. PILOT VALVE (FOR ATT) ........................................................................................ II-3
4. PILOT VALVE (FOR TRAVEL) ................................................................................. II-4
5. SWING MOTOR UNIT ............................................................................................. II-5
6. SWIVEL JOINT........................................................................................................ II-6
1. CAB Rotate 90 degrees to remove.
GROMMET BOLT (25-9)

COVER
1.1 REMOVAL
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1.2 INSTALLATION
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2. OPERATOR SEAT
2.1 REMOVAL
(1) Remove seat. (Include upper rail.)
1) Remove four M8 capscrews (15) in the upper
rail.
: 6mm
2) Remove seat
[Approx.15kg (33 lbs) with upper rail]
(2) Remove slide on lower rail of seat.

1) Remove four capscrews (15)M8.
M816 SEAT
2) Remove support (4).
15
4) Remove lower rail (3).
: 6mm
(3) Remove seat stand (1)

2) Remove seat stand (1).
: 8mm
4 UPPER RAIL
Weight of seat stand ; 17kg (37 lbs)

2.2 INSTALLATION
Install it in reverse procedure of removing 8
LOWER RAIL M825
according to the tightening torque table. 3
Allen Tightening torque

Tightening position wrench kgfym (ftylbs)
HEX
Capscrew (9) 8 4.7 (34) M830
M830 13
Capscrew (8),(15) 6 2.4 (17) M816 13
15
Reference : Movement on rail PLATE
Upper rail 㨯㨯㨯㨯㨯㨯㨯Fixed on lower surface of seat 9 (STOPPER)
M1025 1
(Forward 80, backward 80)
Lower rail 㨯㨯㨯㨯㨯㨯㨯Fixed on seat stand.
Height adjustment lever (L.H)
Seat raise 23mm (0.91inch)
Seat lower 37mm (1.5inch)
Floor plate
Fig. 2-1 Dismounting and mounting seat
Σ㧙2
3. BATTERY
RIGHT COVER
3.1 REMOVE
ASSY
(1) Open right cover assy.
1) Open it with starter key.
2) Open cover.
3) Fix it with stay.
4) Remove rubber (A6). (See Fig.3-3)
5) Remove cover assy (32). (See Fig.4-8)
6) Remove two M12 sems bolts (A4) and remove
bracket (A15).
: 19mm
(2) Remove battery cable

1) Remove M8 nut (C8). Then disconnect cable
(C3) across earth and battery (ï). (Always Fig. 3-1 Preparation for removing battery
remove (ï) terminal first and install it at last.)
2) Cable (C4) (between battery (+) and (ï))
3) Cable (C5) (between batter (+) and battery relay)
: 13mm BATTERY RELAY
Follow the battery removal order.

Start removing battery from grounding C3 C4
side, and finish attaching to grounding C8
side. If this order is missed, C5
short-circuits may occur.
(3) Remove battery (B1)

1) Remove two attaching bolts (A2) M10.
: 17mm Fig. 3-2 Remove battery cable
2) Remove plate (A1).
3) Remove battery (B1). A6
#
3.2 INSTALL
(1) Install the battery in the reverse procedure of
removing.
A1 B1
Battery attaching bolt (A2)
: 17mm,
A4
Tightening torque : 1.1kgfym (8.0 lbfyft)
(2) Installing grounding cable

A5
Install grounding cable last. Especially care
must be taken that the grounding face is free
from painting, rust, etc.
: 13mm
Fig. 3-3 Removing battery
Σ㧙3
4. GUARD
4.1 PREPARATION FOR REMOVAL 11 2,3
(1) Remove guard in the following procedure. 1-1 18
1-2
When removing the components remove only
32
the guards that are required for removal. The
B1
order of removal of the engine : (B1)ψ(B8)ψ 52
(9) and (10) 14,25,53,54
9
66
(2) All the locked cover, open them using starter
key. 17
7
6 10
B8
Fig. 4-1 Arrangement of guard assy

(The figures represent the item numbers)
4.2 REMOVE GUARD
(1) Remove cover assy (11)
1) Unlock cover assy (11) and lift it up 11
36
2) Remove the clips and the rod.
3) Remove gas-spring stay.
4) Remove two sems bolts (36) M1230.
5) Remove cover assy (11).
: 19mm
Weight : 20kg (44 lb)
Fig. 4-2 Removing cover assy (11)

(2) Remove panel assy (2),(3)
1) Remove two sems bolts (37) M1025 and 37
open the panel assembly.
2
: 17mm
36 3
2) Remove two nuts (70) M12.
3) Remove panel assy (2).
: 19mm
4) Remove four sems bolts (36) and remove the
panel assy (3).
36
: 19mm 36
70
Fig. 4-3 Removing panel assy (2), (3)
Σ㧙4
(3) Remove bonnet assy (10)
1) Remove snap pin (27) and gas spring (41).
2) Remove four sems bolts (36) M1230.
3) Lift up bonnet assy (10) with nylon sling.
: 19mm
35
9
80
(4) Remove bonnet assy (9)

2) Remove capscrew (80) M1230. 10
36
: 19mm
3) Remove bonnet sssy (9).
41
27 28 36
Fig. 4-4 Removing bonnet assy (9), (10)

(5) Remove cover (B1)
1) Remove four capscrews (B9) M10 25 and
cover (B1).
: 17mm B9
(6) Remove cover assy (B14)

1) Unlock it with the key.
2) Remove two sems bolts (B8) M1230.
3) Remove cover assy (B14).
: 19mm
B14 B8 B1
Fig. 4-5 Removing cover (B1), (B14)

(7) Remove cover (66)
1) Remove two sems bolts (36) M1230. 66
2) Remove cover (66).
36
: 19mm
Fig. 4-6 Removing cover (8)
Σ㧙5
(8) Remove cover (1-2)
1) Unlock cover (1-2) and remove snap pin (1-5) 1-2
and stay (1-3). 1-6
2) Remove two sems bolts (1-6) M1225. 1-3
: 19mm
3) Remove cover (1-2).
36
Weight : 9.3kg (20 lb)
1-1
36
Fig. 4-7 Removing cover assy (1-2)
(9) Remove cover assy (32), (52) and box assy (1-1)
1) Remove three machine screws (48).
: 5mm 48
3) Remove five sems bolts (36) M1230.
4) Remove cover assy (52). 32
: 19mm
52
36
(10) Remove box (1-1)
1) Remove five sems bolts (36) M1230.
: 19mm
2) Remove box (1-1). Fig. 4-8 Removing cover assy (32), (52)
(11) Remove stay (90) 90

1) Remove six capscrews (78) M1255.
: 19mm
(12) Remove bracket (21)

: 19mm
2) Remove bracket (21).
78
72
71
21
36
Fig. 4-9 Removing stay (90) and bracket (21)
Σ㧙6
1) Remove four sems bolts (35) M1225.
: 19mm
2) Remove cover assy (75). 19
(14) Remove cover assy (13) 35

1) Remove three sems bolts (35) M1225. 36
: 19mm
2) Remove cover assy (13). 35 18

35 13
35 75
1) Remove six sems bolts(35) M1235.
: 19mm 35
2) Remove cover assy (18) . Fig. 4-10 Removing cover assy (13),(18),(19),(75)
(16) Remove bracket (19)

1) Remove three sems bolts (36) M1230.
: 19mm
2) Remove brackets (19).

64 35 14
(17) Remove cover assy (14), (25), (53) and (54)
56
located under the boom. 54
1) Remove all attaching bolts.
: 19mm 53
2) Remove covers (14), (25), (53) and (54), in

that order.
35
35
25
Fig. 4-11 Removing cover assy (14), (25), (53),
(18) Remove guard assy (47) (54)
64
1) Remove two capscrews (64) M1225.
: 19mm
47
2) Remove guard assy (47).

: 19mm
36
15
Fig. 4-12 Removing cover assy (15)

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5.1 REMOVAL
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6. FUEL TANK
6.1 PREPARATION FOR REMOVAL
(1) Draining fuel.
1) Unlock cap (A2) with a starter key and open it.
(See Fig.6-2.)
2) Loosen cock (B9) under the tank. 1 7 6
(See Fig.6-2.)
3) Draining fuel 7
Capacity of tank : 290 (77gal)
6
(2) Open bonnet (10) and guard (B8) and remove
8
covers (66), (15) and guard assy (47). 7
7
(Refer to Fig.4-4, 4-5, 4-6, 4-12.) 6
(3) Remove the connector for level sensor (B4). 5
3
(See Fig. 6-2)
(4) Remove cab assy (Refer to 1. CAB.). 2,10
15,16
(5) Remove guard tube and hose (10,11,16) and 4,11
(2,4,15) Fig. 6-1 Removing fuel hose (2), (4), (15)
1) Loosen clips (6), (7) at water separator (1)
and at the tank return positions. Then draw
A2
out the hose.
2) Put in plugs that match the hose bore.
B21
A1
6.2 REMOVAL
(1) Remove bracket (B19) and stay (B20) that B22
connect the tank with the upper frame.
1) Remove two sems bolts (B21) M1230. B21
B19
2) Remove bracket (B19). B20
: 19mm

3) Remove four sems bolts (B22) M1225 and B22
separate stay (B20).
B4
: 19mm
B1 B13
B8B9
(2) Remove fuel tank assy (A1)
B3
1) Remove four capscrews (B1) M16 45 and B6 B18 B17
three shims (B3).
: 24mm
Fig. 6-2 Removing fuel tank
2) Hook the wire to the lifting eye on the fuel
tank assy and remove the fuel tank.
Weight : 130kg (287 lb) (2) Tightening torque
Tightening torque
6.3 INSTALLATION No. NAME kgfym (lbfyft)
(1) Installing is done in the reverse order of B1 CAPSCREW 22 (160)
removing.
B6 MACHINE SCREW 0.2 (1.4)
Tank attaching bolt (B1) M1645
: 24mm, Apply Loctite #262 B8,B13 COCK, ELBOW 3.7 (27)
Tightening torque : 22.0kgfym B21,B22 SEMS BOLT 8.1 (59)
(160 lbfyft)
Σ㧙10
7. HYDRAULIC TANK
11 2,3
(1) Remove cover assy (11), panel assy (2), (3)
and other guards necessary to remove the
hydraulic oil tank. (Refer to 4. GUARDS.)

Fig. 7-1 Remove guard

(2) Bleeding internal air of tank (A9)
Push
Press the rubber cap by your finger tip to
bleed off the inside air.

Keep pressing until the hissing stops.

Fig. 7-2 Bleeding internal air of tank
[After modification]
(3) Remove cover (A7). [Before modification]
1) Remove six capscrews (A13) M1025.
A13 A13
: 17mm
A13

2) Remove cover (A7). A8
3) Remove suction strainer (A2).
A7
A8

(4) Remove cover (A8).
1) Remove six capscrews (A13) M1025. B
: 17mm
A2 C
2) Remove cover (A8). A9 A4-1

A17
3) Remove filter element (A4-1). D

z Remove element (A17) in case of E
earlier machine than modification. F

(5) Turn the handlie of element assy. (B), and
disassemble the removed filter element (A17).
Disassemble parts : (B), (C), (D), (E), (F)

z This work is not required in case of
earlier machine than modification. Fig. 7-3 Remove cover (A7), (A8)
Σ㧙11

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7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.

Installing is done in the reverse order of
removing.
(4) Install four attaching capscrews (B1) M16

40 with Loctite #262. (See Fig. 7-4)
: 24mm
Tightening torque : 22kgfym (160
lbfyft)

If there is any clearance (gap) between
the tank mount and the frame, adjust
shim (B3) thickness and fasten them
together.
(5) Connection of suction hose (2)

Apply PERMATEX on pipe side of hose
connection and insert it.
Put the hose with clip (8).
Tightening torque : 0.55kgfym (4.0 lbfyft)
Place grommet (16) with clip (7).
(6) Assembling return element

Assemble filter element by the use of element O RING
kit (A17). (See Fig. 7-3, 7-7)
1. Two elements (D) are used as one

set.
2. Replace O ring (C) and packing (F) C
with new ones respectively.
[This work is not required in case of
earlier machine than modification.]
D
(7) Install return element (A17).
[For filter return element before modification,
install element (A4-1).]
(8) Installing suction strainer (A2) A2
F
(9) Tighten capscrews (A13) M1025 that attach
ELEMENT KIT (A17)
tank covers (A7), (A8).
[After modification]
: 17mm
Tightening torque : 4.7kgfym (34 lbfyft)
A4-1
Replace O ring fitted on the back side RETURN ELEMENT
[Before modification]
of tank cover (A8) with new one. SUCTION STRAINER

Fig. 7-7 Element & filter

(After modification)
Σ㧙13
8. PUMP A13
8.1 PREPARATION FOR REMOVAL A7

(1) Remove counterweight.

(2) Release pressure in hydraulic oil tank.
(Refer to 7. Hydraulic Tank.) SUCTION
STOPPER
(3) Remove six capscrews (A13) M10.
: 17mm
SUCTION
(4) Remove cover (A7) STRAINER

(5) Take out suction strainer.

(6) Install suction stopper.
For suction stopper, see item “Tools”.

(7) Remove guard (16), (68).
1) Remove two sems bolts (35) M1225. Fig. 8-1 Suction stopper installing
: 19mm 35
68
3) Remove guard (16), (68).

16
BRACKET ASSY
8.2 REMOVAL 36
(1) Loosen half clamp (5) on hoses (3), (4) and Fig. 8-2 Removing guard (16), (68)
capscrews (12) M1035 and disconnect two
hoses (A1), (A2) on the delivery side. 3
: 17mm 4

(2) Remove suction tube (1)
1) Loosen clip (A19), and remove suction hose 12
(A5) for pilot pump. (Refer to Fig. 8-4)
5

2) Remove four capscrews (11) M1245. B1
: 19mm

3) Remove tube (1) of suction hose (2) from
pump. 2

DRAIN HOSE
11
4) Remove drain hose (Dr1). 1
: 30, 36mm
Fig. 8-3 Removing hose (3), (4), (7) and
suction tube (1)
Σ㧙14
(3) Removing other hoses
1) Disconnect hoses of the following ports.
(See Fig. 8-4.)
Port Tool Remarks

Dr2 19,22 Pilot pump drain
PSV1 19,19 Primary pressure for power HYDRAULIC
shift PUMP
A3 22,22 Pilot pump delivery
2) Attach tags to hoses to identify.

3) Put a plug in the hoses and the pump.
A19
A5
A19
Fig. 8-4 Pump port
(4) Remove main pump

1) Give a little tension to the wire sling, 6
utilizing the eye bolt (M10) located in the top 0
of the hydraulic pump. Place a wire sling on
the hydraulic pump and loosen 11 capscrews
(6) M1030 and one capscrews (3) M1025.
: 17mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the
tension of the wire rope.
On that occasion, the assy is drawn out with
the insert NA (1-2) remaining on the flywheel
side. 3
3) Remove element (1-1) from the tip of the
spline shaft.
4) Remove four socket bolts (2) M1650 that 171 (with pump)
fasten insert R (1-3) and remove insert R
(1-3). 2
: 14mm
5) Remove hub (1-4)
If you loosen two set screws M1625 (4), hub
comes off from the spline shaft of the pump. 4
: 14mm
6) Remove 4 socket bolts (2) M16 25 that 1-4
fasten the insert NA (1-2) with the engine
1-3
side flywheel, as necessary. Then remove 2
insert R (1-3) and spring pin (5) from hub 1-2
(1-4). 5 1-1
: 14mm 5
1
7) Casing (171) is an accessory to the pump. For
disassembly, refer to Disassembly and Fig. 8-5 Removing pump
Assembly of Pump.
Σ㧙15
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(9) Install suction tube (1) with four capscrews
(11) M1245. (See Fig. 8-3.)
: 19mm,
Tightening torque : 10kgfym (72 lbfyft)
(10) Install the hydraulic piping by referring to
“Hydraulic System”.
(11) Installing the hose

Tool
Tightening position
Cap nut Dr2 19,22

Cap nut PSV1 19,19
Cap nut A3 22,22
(12) Remove suction stopper PF3/4 OIL FILL PORT & AIR BLEED PORT
Bleed air by loosening the oil filling port F. F
(13) Install suction strainer
When the pump is replaced, replenish

more than 1 (0.26gal) of hydraulic oil
from the oil filling port.
(14) Bleed air in pump

Bleed air by loosening the oil filling port F.
EYE BOLT (M10)

(15) Check hydraulic oil level.
Fig. 8-7 Bleed air in pump
(16) Start engine and check it for oil leakage and
noise.
35
68
(17) Attach drain down pipe under engine muffler.
(18) Install guards (16), (68)
Tool Tightening torque

Tightening position kgfym (lbfyft)
16
Sems bolt (35), (36) 19 8.1 (59)
36
Fig. 8-8 Installing guard (16),(68)
Σ㧙17
9. AIR CLEANER

(1) Opening bonnet assy (9), (10)
9
(2) Opening cover assy (B8)
(3) Unplug terminals on indicator lines (1-5)

9.2 REMOVAL
(1) Pulling out hose (2). 10
B8
1) Loosen clips (5) on both sides of hose (2).
Fig. 9-1 Preparation for removal
2) Pulling out hose (2)
: Flat-blade screw driver
(2) Remove air cleaner assy (1) 1-6

1
1) Remove four sems bolts (8) M1025 1-2
: 17mm
2) Remove air cleaner assy (1) from guard
bracket. 1-1
5

GUARD BRACKET
9.3 INSTALLATION
(1) Installing is the reverse order of removing 1-5
with attention paid to the following items:
1) The insertion depth of air hose (2) shall be 2 5
30mm (1.2in).
2) The insertion depth at both ends of air hoses

(2), (3), (4) shall be 40mm (1.6in), provided 5 5 8
that the depth on the turbo side shall be 4
25mm (1.0in).
7
6 3
3) Tightening torque :
Tightening Torque
No. NAME kgfym (lbfyft)
1-5
INDICATOR 0.4 (2.9)
8 SEMS BOLT 4.0 (29) Apply Loctite #262

Fig. 9-2 Removing air cleaner
(2) Replacing parts
FILTER ELEMENT (1-2) O RING (1-6)
Σ㧙18

10. MUFFLER

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10.3 INSTALLATION
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11. COUNTERWEIGHT


(1) Removing bonnet assy.
Remove bonnet on engine.
(See GUARD Fig. 4-4.) B1
(2) Remove cover (4), (5) (See GUARD Fig. 4-5.)
(3) Preparing slinging jig

Remove plug (B5) and attach weigh slinging
jig (Refer to the Tool.) to the counterweight. B8
: 75mm Fig. 11-1 Lifting up counterweight

11.2 REMOVAL
(1) Lifting up counter weight temporarily
$
Hook wire rope to slinging jig, and lift it and
stretch wire rope to the degree where it is
providing no slack temporarily.
Weight of counterweight ;
Approx. 5900kg (13,000 lb) A1
Wire more than ∅16 (0.63̢) ;
1.5m (5ft)2 pcs.
(2) Removing counterweight

B7
1) Remove four capscrews (B6) M36300. B6
: 55mm
2) Remove shim (B3), (B4).

3) Remove counterweight (A1).
B4
B3
Fig. 11-2 Removing counterweight
11.3 INSTALLATION
(1) Install counterweight in the reverse
procedure of removing.
(2) Install shim (B3), (B4) as it was. (select)
(3) Slinging counterweight

Check that the attaching bolts can be
B3,B4
screwed in by hand.
(4) Apply Loctite #262 on capscrews (B6), and

tighten them with washers (B7).
B6
: 55mm
Tightening torque : 300kgfym (2,200 lbfyft)
(5) Remove slinging tools, and attach plugs (B5).

Fig. 11-3 Fastening the counterweight
attaching bolts
Σ㧙20

12. RADIATOR & OIL COOLER

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12.2 REMOVAL
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% %
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hose : 40mm
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$T 12.3kgf m
(89 lbf ft)
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12.3 INSTALLATION Insertion depth : 30mm (1.2 in)

Place clips as shown
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13. ENGINE
13.1 PREPARATION FOR REMOVING
(1) Remove battery ground (See 3. BATTERY) (8) Remove harness connector
1) Remove E/G ground cable
(2) Remove bonnet and cover (See 4. GUARD) 2) Starter cable ֣ Starter B terminal
3) Remove the connector that connects the
(3) Remove air cleaner hose upper harness with the engine.
(See 9. AIR CLEANER) 4) Upper harness 㧙CN-206㧙E/G sub harness
See 㧙CN-165㧙
Govenor motor
(4) Remove counterweight ELECTRIC 㧙CN-166㧙
(See 11. COUNTERWEIGHT) SYSTEM 㧙CN-155㧙E/G oil level SW.
㧙CN-170㧙 Pump proportional
(5) Remove radiator hose 㧙CN-171㧙 valve
(See 12. RADIATOR) 㧙CN-167㧙E/G speed sensor
㧙CN-168㧙 P1, P2 pressure
(6) Remove fuel hose and heater hose, and if 㧙CN-169㧙 sensor
necessary air-con hose.
Prepare a stand, which withstands the
(7) If necessary, remove pump, muffler and weight of the engine assy and can place
radiator. the removed engine firmly.
(Refer to Tools on Page 15.)
OIL PRESSURE SWITCH
SPEED SENSOR
FUEL FILTER
BYPASS VALVE OIL FILTER GASKET ELEMENT
ELEMENT
STARTER ASSY
THERMOSTAT
KIT
HEATER RELAY
THERMO SENSOR
ALTERNATOR
THERMO SWITCH
ASSY
OIL LEVEL SENSOR
Fig. 13-1 Outside view of engine
Σ㧙25
13.2 REMOVAL
7 7 LJ KW
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Locktite #262
T=6.6kgf m (48ft lbs)
Three Bond
#1110B
T=2.5kgf m
(18ft lbs)
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T=2.3kgf m (170ft lbs)
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14. INSTRUMENT PANEL
Remove terminal (㧙) from battery.
12 12
14.2 REMOVAL
(1) Remove RH, LH instrument panel
1) Remove eight sems bolts (12) M516.
12 12
: cross recessed screw driver
2) Lift instrument panel.
3) Remove two connectors and antenna cable on

rear side of left instrument panel
Ԙ 8P for air-con panel Fig. 14-1 Around instrument panel
ԙ 9P for tuner
LH instrument panel RH instrument panel
CAP
12 M516 12
4) Remove four connectors on rear side of right
12
panel 12
Ԙ 6P for key switch
ԙ 3P for accel dial
Ԛ 2p for auto accel release SW. BRACKET
ANTENNA CABLE
TUNER
(2) Remove control box Fig. 14-2 Removing instrument panel

1) Remove four sems bolts (19) M8 on right and
left sides.
2) Separate control box from support. PILOT VALVE
: 13mm
PILOT
VALVE 19
Remove hose referring to Item Σ-32. M825
37
M616
SUPPORT
14.3 INSTALLATION SEAT STAND

Install it in reverse procedure of removing Fig. 14-3 Removing control box
according to the tightening torque table.
Tightening Tightening torque
Tool
position kgfym (lbfyft)
Sems bolt (19) 13 2.4 (17)
cross recessed
Sems bolt (12) screw driver 0.27 (2.0)
Σ㧙27
Functions Ports Ports on front sides (on machine) Ports Functions
UPPER SIDEφ ψLOWER SIDE
Boom up (H) conflux Ab

$E
(Plug)
Bb Boom down (R)
%E
Bucket dump (R) Ac Bc Bucket digging (H)

$& %&
Drain Dra 'UD
Travel right forward Ar Br Travel right reverse
$U %U
Attach boost pressure PL1 3/
Ports on rear sides (on machine)

LOWER SIDEφ ψUPPER SIDE
Option 2 valve B02

% $
Arm (R) out Ba

%D
3LVF Aa Arm in (H)

$D
PBs2 Swing left LH2
Pss Swing pressure
3%V PAs sensor
Swing left Bs %V $V
3$V
As Swing
3VV
Swing (RH)
Travel left forward BL $/
AL
%/
Travel left forward
Ports on lower sides (on machine)

REAR SIDEφ ψFRONT SIDE
37E
Travel left reverse PBL PTb Travel straight
3%/
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3$
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3%
Option valve PB02
Σ㧙28

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17. PILOT VALVE (FOR ATT)
PANEL ASSY
The removing procedure for right and left is the
same, so the preparation for left side is described
here. 25
(1) Put attachment on ground, stop engine and
3
release pressure in tank. 20

(2) Remove panel assy referring to Section 14.
Instrument Panel.
4
(3) Remove one sems bolt (12) M516 and one
sems bolt (20) M512. 12

Fig. 17-1 Removing instrument panel
(4) Remove cover (4) on outer surface.
BOOTS

(5) Remove sems bolt (25) and securing cover
and control box on inner surface. A21

(6) Remove cover (3) on inside surface.
PILOT VALVE

(7) Remove harness connector for horn.
PF3/8
VALVE SIDE Opposing
PF1/4
Opposing
(8) Attach tag to hoses for identification. Flats 22 Flats 19

17.2 REMOVAL
MARK “F”
(1) Remove hoses from your side to far side in
order. 2(
2(
: 19mm,22mm P PORT CONNECTOR
HOSE SIDE (WITH FILTER)
(2) Shift boots. 1㨪4,5㨪6,T PORT CONNECTOR

Fig. 17-2 Pilot valve connector
(3) Remove four socket bolts (A21) M6.
: 5mm FRONT OF THE MACHINE
(4) Remove pilot valve. T ԟ ARM(R) ԛ ԙ

Ԝ (GREEN) T BOOM(R) BUCKET
(R)
SWING(L.H) ԝ (BLUE)
(5) Plug hose ends. Plug PF1/4 (GRAY) SWING
(R.H)
17.3 INSTALLATION (RED)
Install it in the reverse order of removal and
Ԙ
tighten it to the specified torque. P
P BUCKET(H)
: 5mm T=1.1kgfym (8.0 lbfyft) Ԟ ARM(H) (RED)
: 19mm T=3.0kgfym (22 lbfyft) (BLUE) Ԛ BOOM(H)
(GREEN)
: 22mm T=5.0kgfym (36 lbfyft)
LEFT SIDE RIGHT SIDE
Fig. 17-3 Pilot valve port position (from upper side)
Σ㧙30
18. PILOT VALVE (FOR TRAVEL)
(1) Release pressure in hydraulic oil tank

(2) Remove under cover (5) (See 5. UNDER COVER)
TRAVEL
2 SPEED
(3) Remove floor mat SWITCH

18.2 REMOVAL
3
(1) Separate the pressure sensor (B11) at the
connector.

CA103 7
(2) Remove pressure two sensor (B2).
: 19mm

(3) Disconnect lead cable CA103 for travel 1,2 13
speed at two places from main harness. B10 25
B11
(4) Attach tag, and disconnect connectors and 26
hoses (B1), (B2), (B3), (B4)㧚 B5 B3
: 19mm (P port) B11 24
: 22mm (T port, 1㨪4 port)

CONNECTOR B4 B2
(5) Plug hose ends
Plug PF1/4, PF3/8
B1
(6) Remove four sems bolts (7) M1020. B2

B1
(7) Remove right and left levers (3).

(8) Remove four socket bolts (10) M1030.
: 8mm

(9) Remove four sems bolts (25) M1030 and
remove plate (26).
: 17mm Opposing
PF3/8 flats 22

PF3/8
(10) Remove pilot valve lifting it upward.

(11) Stop up holes with plugs PF1/4, 3/8. VALVE HOSE
SIDE SIDE

VALVE SIDE T port connector
18.3 INSTALLATION PF3/8
Install it in the reverse order of removal and Opposing
Opposing flats 19 MARK “F”
tighten it to the specified torque. flats 22 PF1/4
PF1/4
Hose PF3/8
: 22mm T=5.0kgfym (36 lbfyft) HOSE SIDE
: 8mm T=7.2kgfym (52 lbfyft) 1윟4 port connector P port connector
Pressure sensor Fig. 18-1 Installing and removing pilot V
Σ㧙31

19. SWING UNIT

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(2) Removing the swing unit
1) Remove twelve capscrews (B1) M2065.
: 30mm
2) Remove two plastic caps (B2) M12 at the top

of the swing motor and install eye bolts.
: Flat-blade screw driver
3) Hook sling to eye bolts attached on swing

motor unit.
Weight of swing unit ; Approx. 310kg
(680 lb)
19.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing unit and
upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting

surface of swing unit.
19.4 INSTALLATION
Install the swing unit in the reverse order of Apply Loctite #515 equivalent.
Coat all the mounting surface
disassembly, confirming the direction of the swing
of the swing motor with Loctite
unit.. #515 or equivalent.
(1) Tighten capscrews (B1).
: 30mm
Tightening torque : 55.0kgfym (400 lbfyft)
Apply Loctite #262
(2) Fill inside from motor drain port to casing Swing motor assy mount
with hydraulic oil before piping for drain

19.5 PREPARATION FOR DRIVE Apply Loctite #262 or equivalent.
(1) Before starting operation, check that gear oil Tightening torque 55kgfym (400 lbfyft) 1
#90 (API grade GL-4) level of swing reduction
is sufficient.
Amount of charge : 15.3 (4gal)
(2) When starting operation, operate motor in

low idling and at low speed for several
minutes, and check it for possible oil leakage
and noise.
Fig. 19-3 Installing swing motor
Σ㧙33

20. SWIVEL JOINT

20.1 PREPARATION FOR REMOVE
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SWIVEL JOINT

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21. UPPER FRAME
(1) Remove attachment
(Refer to 1. section : ATTACHMENT)

(2) Remove cab (Refer to 1. CAB.) WIRE ROPE
∅162.5m
(3) Remove guard (Refer to 4. GUARD) (0.630") (8ft 2in)

(4) Remove counterweight CHAIN BLOCK
(Refer to 11. COUNTERWEIGHT)
LIFTING JIG FOR
UPPER FRAME
(5) Remove swivel joint
(Refer to 20. SWIVEL JOINT)

21.2 REMOVAL
(1) Lifting up upper frame temporarily
Install two upper swing body lifting jigs and
two bolts M36120 in the holes into which
the counterweight is placed. Mount two chain Fig. 21-1 Temporarily lift upper frame
blocks to the boom foot and lift the upper
frame at four points.
Wire rope ; ∅16 (0.630")2.5m(8ft 2in), 2pcs. MATCH
MARK
∅16 (0.630")1.5m(4ft 11in), 2pcs.
Chain block ; For 1,000kg (2,200 lb) 2pcs.

(2) Marking match marks on swing bearing
Mark match marks on upper frame and
swing bearing.

(3) Removing upper frame attaching bolts
Remove thirty one capscrews M20115 and Fig. 21-2 Matching mark on swing bearing
two reamer bolts used to install swing and upper frame
bearing and upper frame.
: 30mm

(4) Slinging upper frame
Sling according to Fig.21-1, and remove
upper frame and put it on a stand.
Weight : Approx. 10ton (22,000 lb)

Fig. 21-3 Removing upper frame attaching bolts
Σ㧙36
21.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
(2) Cleaning mating surfaces of upper frame and Apply Loctite #515 to the race surface over the whole
circumference (hatched) on the inside of capscrew.
swing bearing.
(3) Apply Loctite #515 to the inside of the

capscrews on the contact surface. Apply Loctite #262 or
equivalent.
(4) Slinging upper frame T=50kgfym (361 lbfyft)
Match marks and install it with two reamer

bolts (11) temporarily. 10
Fig. 21-4 Bearing mount
Confirm the reamer bolt positions
referring to Fig. 21-5.
: 30mm, Tightening torque :

50kgfym (361 lbfyft)
Apply Loctite #262
(5) Install swing bearing

Install thirty one capscrews (10) M20115.
: 30mm Tightening torque :
50kgfym (361 lbfyft)
Apply Loctite #262
BEARING
OUTER
(S) ZONE
POSITION
Fig. 21-5 Reamer bolt position (̪)

Apply Loctite on section specified
by slanted lines
Σ㧙37


1. HYDRAULIC PUMP࡮REGULATOR

Table 1-1
901
1.1 HYDRAULIC PUMP TIGHTENING
TORQUE No. NAME Q̉
TY
1.1.1 STRUCTURAL EXPLODED VIEW 271 kgfym (lbfyft)
(1) Main pump
111 DRIVE SHAFT 1
806 490 113 DRIVEN SHAFT 1
981 122 ROLLER BEARING 1
954 536 983
123 ROLLER BEARING 1
406 04 124 NEEDLE BEARING 2
887 901 541
888 126 SPACER 2
545
543 127 SPACER 1
192 128 SPACER 2
406 726 412
127 735
824 724 312 129 SPACER 2
141 CYLINDER BLOCK 2
171
728 151 PISTON 18
709
751 886 152 SHOE 18
469
491 409 153 RETAINER PLATE 2
825 156 SPHERICAL BUSHING 2
126 316
191 157 SPRING 18
774 126 171 FRONT CASING 1
261 825 548 141 191 DRIVE GEAR 1
410
709 156 885 192 DRIVEN GEAR 1
827 531
151 211 SHOE PLATE 2
152 153 725
124 726 467 TIGHTENING 212 SWASH PLATE 2
211
314 TORQUE No. NAME Q̉
TY 214 BUSHING 2
214 752 kgfym (lbfyft) 251 SWASH PLATE SUPPORT 2
251 157
408 548 725 O RING : 1B P11 2 261 FRONT COVER 1
726 O RING : 1B P10 4 271 CASE 1
151 124
531 152 728 O RING : 1B P24 2 312 VALVE COVER 1
313 732 O RING : 1B P18 2 313 VALVE PLATE 1
113 214 141 735 O RING : 1B P12.5 4
212 157 314 VALVE PLATE 1
826
156 751 PACKING 1 316 COVER 1
129
123 153 752 SEAT PACKING 1 3.0 (22) 406 SOCKET BOLT : M820 16
828 774 OIL SEAL 1 10.0 (72) 408 SOCKET BOLT : M1265 10
129 211
789 BACK UP RING 2 5.8 (42) 409 SOCKET BOLT : M1016 2
826 953
212 793 BACK UP RING 2 24 (170) 410 SOCKET BOLT : M1640 12
807
251 789 13.0 (94) 806 NUT : M16 2 24 (170) 412 SOCKET BOLT : M1695 1
13.0 (94) 807 NUT : M16 2 3.7 (27) 467 PLUG : PF1/4 2
823 SNAP RING 2 17 (120) 469 PLUG : PF3/4 2
111 824 SNAP RING 1 0.9 (6.5) 490 PLUG : NPTF1/16 10
703
535 825 SNAP RING 2 1.0 (7.2) 491 PLUG : PF1/8 9
732
823 826 SNAP RING 2 34 (250) 531 TILTING PIN: M24 2
128 532 827 SNAP RING 1 34 (250) 532 SERVO PISTON㧦M24 2
122 534
793 828 SNAP RING 2 534 STOPPER 2
828
128 885 PIN㧦∅8 2 535 STOPPER 2
823 886 SPRING PIN㧦∅6 2 536 SERVO COVER 2
887 SPRING PIN㧦∅8 2 541 SEAT 2
888 PIN㧦∅12 2 543 STOPPER 2
901 EYE BOLT 2 545 BALL 2
953 SET SCREW 2 548 FEED BACK PIN 2
954 SET SCREW 2 703 O RING : 1B G25 2
No. NAME Q’TY 981 NAME PLATE 1 709 O RING : 1B G85 2
04 GEAR PUMP 1 983 RIVET 2 724 O RING : 1B P8 2
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 1-1 Structural exploded view of main pump Τ㧙1㧙1

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DELIVERY PORT PF3/8
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1.1.2 DISASSEMBLY AND ASSEMBLY OF MAIN
PUMP
(1) Tools Table 1-3
The following list shows the tools required for Tool name Dimension
remove and install.
Opposing flats
Allen wrench
6,8,10,14,19mm
(2) Disassembling procedure Eye wrench
1) Selecting a place for disassembly. Socket wrench Opposing flats
Wrench with double 19,24,27,36,46mm
z Choose a clean place. heads (single head)
z Spread rubber sheet or cloth on work Adjust wrench Medium size 1pc.
bench to protect parts from
damaging. Screw driver Flat-bladed screw driver 2pcs.
z Fix the pump by the use of the engine Hammer Plastic hammer 1pc.
mounting holes in front casing (171). For snap ring
On that occasion, use care so as not to Plier
TSR-160, TSR-200, TRR-200
score the surface in contact with the Steel bar for key
engine. Steel bar Approx.108200mm
(0.40˝0.31˝0.79˝ )
One that may be fastened to
2) Cleaning Torque wrench specified torque
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing plug (469 : the surface opposite to
the regulator mounting surface).
z Remove the oil feed port (469: on the
regulator mounting surface side) to
make oil easy to drain.
: 14mm
4) Removing regulator, gear pump and solenoid REGULATOR

proportional valve
Remove the socket bolts (For regulator: 415,
For gear pump: 435, reducing valve mounting
socket bolts) and separate the regulator, the 531(541)
gear pump.
: 6mm, 8mm
z Regarding the disassembly of the

regulator, refer to Regulator ( Τ
-1-18).
z The regulator on the drive side and Fig. 1-3 Removing regulator
the regulator on the driven side are
set at different pressure and flow. It
is recommended to mark them
differently to prevent wrong
assembly.
Τ㧙1㧙4
5) Removing valve cover
Loosen socket bolts (410, 412) that fasten
valve cover (312).
: 14mm
z Do this operation after removing the

regulator, gear pump (04).
6) Disassembling valve cover

Place the pump level and separate valve
cover (312) from pump casing (271).
z Exercise care so valve cover (312) 312

does not fall as it is heavy [approx.
29kg (63 lbs)].
z There are two spring pins (886)
between valve cover (312) and pump
casing (271). 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 spring pins with a
plastic mallet.
z Exercise care so as not to score the
mating surface between valve cover
(312) and pump casing (271). Fig. 1-4 Disassembling valve cover (312)
z When removing valve cover (312), it

comes off with valve plates (313,
314), check valve sub assy (541, 543,
545), O ring (735) and seat packing
(752). However, use care as these
parts are easy to come off.
7) Removing needle bearing

If necessary, separate needle bearing (124)
from valve cover (312).
z Do not draw out needle bearing (124)

except when the service life of it has
run out.
z Do not loosen nut (807) ; a set flow
rate changes.
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(3) Installing procedure
1) Precautions to be exercised in installation 5. O rings and check valves are easy to come off.
Assembly is a reverse order of disassembly, These parts can be set easily in place if they
but notice the following. are coated with grease. Do not coat packings
1. Repair scored parts at disassembly. Get with grease.
replacements ready beforehand.
6. Tighten socket bolts and plugs to specified
2. Entry of foreign matter causes malfunction. torques in this manual, using a torque
Assemble components in a clean place after wrench.
cleaning them in wash oil and blowing them
with jet air. 7. In the case of parallel pumps, the drive pump
turns clockwise and the driven pump turns
3. Do not forget to coat the sliding areas and counterclockwise, as seen from the shaft end.
bearings with clean hydraulic oil. Take care so as not to mix up parts for
different pumps.
4. In principle, replace such sealing parts as
O ring, oil seal, packing and seat packing. 8. The regulator on the drive side and the
regulator on the driven side are set at
different pressure and flow. When
disassembling them, mark them for identity.
2) Installing swash plate support

Mount swash plate support (251) to pump
casing (271) and fix them with socket bolts
(406). 271
: 6mm,
Tightening torque : 3.0kgfym (22
lbfyft)
z There are O rings (724) on the

matching surface in contact with
pump casing (271). Fix it with grease
so it does not come off.
z Positioning pin (888) is placed on the
pump casing (271) side. Adjust it so 251(406)
it enters the groove of swash plate Fig. 1-12 Installing swash plate support (251)
support (251) and fix it.
z Install swash plate support (251) so
it enters straight, while tapping it
lightly.
z Coat socket bolts (406) with adhesive
(Three Bond #1305N).
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z Since spring pin (887) has a tight fit, 271 408
install front casing (171) to drive
shaft (111) upright, while lightly
751 171
tapping front casing (171) with a
plastic mallet. During this
111
installation, use care so as not to
score the moving surface of the oil
seal of drive shaft (111).
z Use care so as not to score the
matching surface between front
casing (171) and pump casing (271).
z Packing (751) is located between Fig. 1-16 Installing front casing (171) [2]
front casing (171) and pump casing
(271). Since the packing (751) is
made of synthetic resin and is easy
to break, be careful to handle it.
Always replace in case it is broken or
scored.
z Packing (751) tends to come off, but
do not coat it with grease.
6) Installing the front cover

Fit front cover (261) to front casing (171) and
fix them with snap ring (827).
z Coat the lip of oil seal (774) in front
cover (261) with a thin film of
grease.
z Take care so as not to score the lip of
261,774,827
oil seal (774) when fitting it.
z When fitting snap ring (827), direct
the sharp edge of snap ring (827) to
the outside.
7) Installing servo piston, tilting pin and servo Fig. 1-17 Installing front cover (261)
cover
Place the pump casing level, attach servo
piston (532), tilting pin (531), stopper (L)
(534) and stopper (S) (535) to the pump
casing, place servo cover (536) to the casing
and fix them with socket bolts (406).
: 6mm,
Tightening torque : 3.0kgfym (22
lbfyft)
z For operation, fix front casing (171),
utilizing the engine mounting holes
in the front casing. Take care so as
not to score the attaching surface in
contact with the engine.
z Tighten servo piston (532) and
tilting pin (531), using a jig so the
head of tilting pin (531) and
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11) Installing check valve sub assy and needle 312 541,543,545
bearing
Insert check valve sub assy (541, 543, 545) and
needle bearing (124) into valve cover (312).
z Place check valve assy (541, 543,

545) into valve cover (312) in correct
order.
z Since check valve sub assy (541, 543,
545) tends to come off, coat the
matching part of valve cover (312)
with grease.
Fig. 1-21 Installing check valve sub assy

12) Fitting O ring and seat packing to the valve
cover : 312(724,726,735)
Fit O rings (724, 726, 735) and seat packing
(752) to the matching surface of pump casing
(271) in contact with valve cover (312).
752
z Since O rings (724, 726, 735) and
seat packing (752) tend to come off,
coat the mounting surface with
grease.
Fig. 1-22 Fitting O ring (724,726,735)

13) Installing valve cover and seat packing (752)
Install valve cover (312) to pump casing (271)
and fasten them together with socket bolts
(410, 412).
: 14mm,
Tightening torque : 24kgfym (170ftylbs)
z Take care so valve cover (312) does

not drop as it is heavy [approx.
29kg(64 lbs)].
z Confirm that swash plate (212) is
not off from swash plate support
(251) and from tilting pin (531), 271
before installation. 410
z Needle bearing (124) is located on 312
the valve cover (312) side ; place the Fig. 1-23 Installing valve cover (312)
valve cover with care.
z When installing valve cover (312),
use care as valve plates (313, 314),
check valve sub assy (541, 543, 545),
O ring (735) and seat packing (752)
may come off in some cases.
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1.1.3 MAINTENANCE STANDARDS
(1) Replacement standards for abrasive parts However, always replace such parts that
Replace or readjust parts that exceed the show excessive damage on appearance.
following standards of wear.
Unit: mm (in)
Standard Recommended
Inspection item value for Remedy
dimension replacement
Clearance between piston and 0.039 0.067
Replace piston or cylinder.
cylinder bore (D㧙d) (0.0015˝ ) (0.0026˝ )
Gap between piston and caulked part 0㨪0.1 0.3

Replace piston shoe assy.
of shoe (Ǭ) (0.004˝ ) (0.012˝ )
4.9 4.7
Thickness of shoe (t) Replace piston shoe assy.
(0.193˝ ) (0.185˝ )
41.1 40.3
Free height of cylinder spring (L) Replace cylinder spring .
(1.62˝ ) (1.59˝ )
Combined height of retainer plate and 12.0 11.0 Replace a set of spherical
spherical bushing (H㧙h) (0.472˝ ) (0.433˝ ) bushing or retainer plate.
d D H
h
Combination of retainer plate and spherical

Clearance between piston and bushing Height=H-h
cylinder bore: D㧙d
Ǭ
t
L
Gap between piston and shoe : Ǭ
Thickness of shoe: t Free height of cylinder spring: L
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section) Surface roughness requiring correction 3㧙Z
Swash plate (shoe plate face)
Cylinder (sliding section) Standard surface roughness
(correction value) Less than 0.4Z (lapping)
Roughness of each surface
Τ㧙1㧙15

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2. CONTROL VALVE
2.1 PREPARATION FOR DISASSEMBLY 2.2 DISASSEMBLY
(1) General precautions The figures in parentheses after part names in
1) As all the hydraulic components are precisely this manual represent those item numbers in the
machined, it is essential to carry out structural drawing under LF24 Component
disassembly and reassembly in an especially System.
clean location.
2) When handling the control valve, take special 1) Place the control valve on a work bench.
care to prevent the entry of foreign matter,
such as dust or sand. Disassemble the valve in a clean
3) Cap each port of the control valve before location, and be careful not to damage
removing the valve from the machine. Before flange surfaces or plate mounting
disassembly, confirm that each cap is in place surfaces.
and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper
or rubber mat over the workbench.
4) When carrying or moving the control valve,
hold the body, and never put pressure on a
lever, an exposed spool, or the end cover.
Handle the valve with care.
5) Tests(for relief characteristics, leaks,
overload valve setting, flow resistance, etc.)
that are desired after disassembly and
reassembly require hydraulic testing
apparatus.
For this reason, do not disassemble hydraulic
units that you are capable of disassembling
but cannot test or adjust.
Prepare beforehand washing fluid, hydraulic Fig. 2-1 Lower side of C/V
oil, grease, etc. .
(2) Tools
Prepare the following tools before disassembling
the control valve.
Table 2-1
No. Tools Q’TY Remarks

a Vise 1
b Box end wrench 1 of each size 24,27mm
c Allen wrench 1 of each size 5,6,10,12mm
d Spaner 1 of each size 22,30,32mm
Fig. 2-2 Upper side of C/V
e Loctite #262 1
f Spatula 1
g Pincers 1
h Adjust wrench 1
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(2) Disassembling arm recirculation spool 273
1) Loosen the socket bolts (273) and remove the
spring cover (204) and the O ring (262) for
arm recirculation.
: 6mm
204
(262)
Fig. 2-5 Removing spring cover (204)

2) Draw out, from casing A (101), the assy of
(325,326,332,334,337)
arm recirculation spool (311), spring seat 101
(332), springs (325), (326), stopper (337) and
bolt (334).
When drawing out the spool assy, use

care so as not to score casing A (101).
Fig. 2-6 Drawing out arm recirculation spool

3) Fix the arm recirculation spool assy with vise assy
via a protective plate (aluminum plate, etc.)
and remove bolt (334). Then separate spring
seat (332), springs (325), (326) and stopper
(337) from arm recirculation spool (311).
: 10mm
337 334
332
326
325
311
Fig. 2-7 Disassembling arm recirculation spool

assy
Τ㧙2㧙3
(3) Disassembling cut spool 204(262) 273
1) Loosen socket bolt (273) and separate spring
cover (204) and O ring (262) from the cut
spool.
: 6mm

2) Draw out the assy of cut spool (309), (310),
spring seat (332), springs (325), (326), stopper 309, (310) (325,326,332,334,337)
(337) and bolt (334) from casing A (101) or 102
casing B (102).
When drawing out the spool assy, take

care so as not to score casing A (101) or
casing B (102).
Fig. 2-9 Drawing out cut spool assy

3) Fix the cut spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (334). Then separate spring seat
(332), springs (325), (326) and stopper (337)
from cut spool (309), (310).
: 10mm 332
334
337
326
325
309, (310)
Fig. 2-10 Disassembling cut spool assy

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(8) Disassembling the swing spool 273 202(261)
swing.
: 6mm

303(321,322,331,333,336)
2) Draw out the assy of swing spool (303), spring 101
seat (331), springs (321), (322), stopper (336)
and bolt (333) from casing A (101).

care so as not to score casing A (101).
Fig. 2-27 Drawing out swing pool assy

3) Fix the swing spool assy with vise via a
333
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat 331
from swing spool (303).
: 10mm
336
322 321
303
Fig. 2-28 Disassemblling swing pool assy
Τ㧙2㧙9
(9) Disassembling the travel spool (left travel
and right travel)
travel. 273
: 6mm
203(262)
2) Draw out the assy of travel spool (306), 306(327,328,332,334,338)
spring seat (332), springs (327), (328), stopper
(338) and bolt (334) from casing A (101) or
casing B (102).

care so as not to score the casing A
(101) or the casing B (102).
102
Fig. 2-28 Drawing out travel spool assy

3) Fix the travel spool assy with vise via a
protective plate (aluminum plate, etc.). 334
Remove bolt (334) and separate spring seat
332
from travel spool (306).
338
: 10mm
327
328 306
Fig. 2-29 Disassembling travel spool assy
Τ㧙2㧙10
(10) Disassembling travel straight spool
travel straight.
: 6mm 273
203(262)

2) Draw out the assy of travel straight spool
(307), spring seat (332), springs (327), (329),
stopper (337) and bolt (334) from casing B
(102).

care so as not to score the casing B
(102). 102
307(327,329,332,334,340)
Fig. 2-31 Drawing out travel straight spool assy
3) Fix the travel straight spool assy with vise
via a protective plate (aluminum plate, etc.). 334
Remove bolt (334) and separate spring seat
(332), springs (327), (329) and stopper (340) 332
from travel straight spool (307).
340
: 10mm
327
307
329
Fig. 2-32 Disassembling travel straight

spool assy
Τ㧙2㧙11
(11) Disassembling the arm conflux spool 204(262) 273
1) Loosen socket bolts (273) and remove spring
cover (204) and O ring (262) for arm conflux.
: 6mm

2) Draw out the assy of arm conflux spool (308),
308(325,326,332,334,337)
spring seat (332), spring (325), (326), stopper
(337) and bolt (334) from casing B (102). 102

care so as not to score casing B (102).
Fig. 2-34 Drawing out arm conflux spool assy

3) Fix the arm conflux spool assy (308) with vise
via a protective plate (aluminum plate, etc.) 334
and remove bolt (334). Then separate spring
seat (332), springs (325), (326) and stopper 332
(337) from arm conflux spool (308).
: 10mm 337
326 308
325
Fig. 2-35 Disassembling arm conflux spool assy
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(14) Remove lock valve selector sub assy
171 211
Loosen socket bolts (171) and remove lock
valve selector (211).
: 5mm
Fig. 2-39 Removing lock valve selector (211)

(15) Removing relief valve
Remove the main relief valve (601) and
overload relief valve (602), (603) and (604)
from the casing.
: 32mm
z Distinguish overload relief valve

601
between (602), (603) and (604) with a
tag to prevent them from being
confused during reassembly, as they
are the same in appearance and
shape but differ in pressure setting. Fig. 2-40 Removing main relief valve (601)
z Regarding the disassembly of the
relief valves themselves, refer to the
disassembly procedure on page 602, 603 or 604
Τ㧙2㧙16.
Fig. 2-41 Removing overload relief valve

(602), (603) and (604)
Τ㧙2㧙14
(16) Remove check valve
1) Conflux check valve (CCb)
Loosen plug (551) and remove poppet (511)
and spring (521).
: 12mm 551
Remove the load check valve the same way. (511,521)
(CP1,LCc,LCb,CCa)
(CP2,LCa,LCs)
Note : LCs is to be equipped with spring (524)

and plug (556).
Fig. 2-42 Removing check valve

2) Lock valve section (Arm ; CRa, Boom ; CRb)
Loosen plug (556) and remove poppet (514)
and spring (524). 556(514,524)
: 12mm
Exercise care so as not to mistake them

as they all differ in kind from 1) above.
Fig. 2-43 Removing poppet in the lock valve

3) Travel straight section (CT1) and (CT2) section
Remove plug (552). Then remove poppet (512)
and spring (522).
: 10mm
4) Main relief valve section (CMR1,CMR2)

552
Remove plug (552) and remove poppet (512) (512,522)
and spring (522).
: 10mm
5) Recirculation check valve (CAr) Fig. 2-44 Removing poppet in the main relief
Remove plug (552) and remove poppet (512) section 552(512,522)
and spring (522).
Remove the load check valve the same way.
: 10mm
Those plugs that are not mentioned in the

foregoing disassembly procedure are blind for
extra holes and cast-on holes; do not remove
them unless necessary.
Τ㧙2㧙15
(17) Disassembling main relief valve
1) Remove plug (103) and seat (541) by pulling
them by hand as C ring (121) is fixed.
2) Draw out spring (521) and plunger (512) from
inside seat (541).
3) Remove locknut (671) and adjust screw (104)
from adjust screw (652) and remove stopper
(613), piston (614), spring (621) and poppet
(611).
: 22mm
4) Loosen lock nut (673) of plug (103) and
remove adjust screw (104).
: 32mm
5) Separate snap ring (121) and spacer (122)
from plug (103).
Filter (125) and filter stopper (124) are

assembled with plug (103) by means of
C ring (123).
Therefore, it can not be disassembled
any further.
541(121) 103
Fig. 2-46 Disassembling main relief valve
(18) Disassembling over load relief valve
1) Loosen plug (102), remove springs (521),
(522) and seat (541) out of body (101) and
draw out piston (301) and plunger (511) out
of seat (541).
: 30mm
2) Separate locknut (671) and adjust screw (651)

from plug (102) and remove spring seat (612),
spring (621) and poppet (611).
: 22mm
102
Filter (125) and filter stopper (124) are

assembled with plug (102) by means of
C ring (123).
Therefore, it can not be disassembled
any further. 101
Fig. 2-47 Disassembling overload relief valve
(19) Disassembling lock valve selector sub assy A, B
Do not disassemble the lock valve

selector.
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3.1 INSTALLATION VIEW
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Apply grease
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top section.

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pressure
adjusting shim Not to be

target value at
PORT 1,3 reused

center

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z When the force of return springs
(221) are low, plug (211) is left in
casing (101) due to sliding resistance
of O ring (214).
211
101
Fig. 3-6 Removing plate (151)

Pull plug (211) out with a driver (㧙).
211
Fig. 3-7 Removing plug (211)
(7) Remove push rod (212), plug (211), pressure
reducing valve assy (spool), return springs 212
(221) from casing (101).
Record combination of port holes on casing 211

and the pulled out parts. The stroke differs
according to direction. 221
101
Fig. 3-8 Removing push rod, plug, pressure

reducing valve and spring
(8) Reverse it to direct port plate (111) upward,
and fix it with vise.
(9) Remove socket bolt (125).

111
: 6mm
125
Fig. 3-9 Removing socket bolt (125)
Τ㧙3㧙4

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(5) Place spring (221) into ports 1,3 of casing
(101), and then install pressure reducing PRESSURE REDUCING
valve assy in it. VALVE ASSY
Place spring (221) into ports 2,4 and install 221
it.
101
Install the removed respective assy into
respective holes.
(6) Fit O ring (214) and seal (213) into plug Fig. 3-17 Installing pressure reducing valve assy
(211). 214 211 213
z Apply hydraulic oil on surface of

push rod.
PLUG (211)
SEAL (213)
O RING (214)
PUSH ROD (212) Apply

hydraulic oil
For the assembling Fig. 3-17 Installing O ring (214) and seal (213)
direction of seal (213).
(7) Insert push rod (212) in plug (211) and
install spring (*246) and spring seat
(*218-1) to push rod (212) on port 1,3 side.
And install spring seat (*218-2) to push
rod on port 2,4 side.
The parts marked * may not be equipped

depending on valve type
212 211 *246 *218㧙1

Fig. 3-19 Assembling push rod, spring (*246)
and seat (*218-1)
(8) Fit plug (211) assy to casing (101).
1) When the force of spring (211) is low, it

stops at the position where it is pushed in
by the sliding resistance of O ring (214).
101 211
Fig. 3-20 Installing plug assy
Τ㧙3㧙7
2) When the force of spring (221) is high, attach
plate (151) and press 4 push rods by hand at
the same time, and tighten joint (301) 301
temporarily.
151
Fig. 3-21 Installing plug assy and plate (151)

(9) Install joint (301) on casing (101) with jig A
securely.
Jig A : Refer to 3.7 JIG on page Τ㧙3㧙10.
Tightening torque : 4.8r0.3kgfym
(35r2.2 lbfyft)
101 JIG A
Fig. 3-22 Installing joint (301)

(10) Install circular plate (302) to joint (301)
Screw it in until it comes in contact

with
4 push rods (212) equally. 312
The exceeding of screw in may cause
malfunction of machine. 302
(11) Screw adjusting nut (312) in until it touches

circular plate (302), and tighten it applying
spanner to stop circular plate returning.
: 32mm
: 22mm Fig. 3-23 Installing circular plate (302)
z Apply Loctite #277 to threads of
joint.
Tightening torque : 7r0.5kgfym GREASE
(51r3.6 lbfyft)
(12) Apply heat-resisting grease to joint (301)

rotating section and the top of push rod (212).
301
(13) Cover it with boots.
(14) Spray rust preventives through each port and
212
attach plug respectively.
Fig. 3-24 Applying grease to joint section and
push rod
Τ㧙3㧙8


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SECTION AA
BUSHING
Material ;
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Installing condition on joint
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Detail of bushing
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4. PILOT VALVE (FOR TRAVEL)
↓Z 33 2 36 33
4.1 CONSTRUCTION 13 12 28
(1) Sectional view 36 14 42
19
37 25
26
1,3 30
20
34 25
22 15
21 42
20
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32 17
33 36 33
44,16 40
6 7 SECTION A-A
18 8
24
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41
27
4 10,11 35
9 31 5 29
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T=Tightening torque : kgfym (ftylbs)

24,41
VIEW Z SECTION B-B
Fig.4-1 Sectional view of pilot valve (for travel)
‫ڏ‬Apply Locktite #262
TIGHTENING TIGHTENING
TORQUE NO. NAME Q’TY TORQUE NO. NAME Q’TY
kgfym (ftylbs) kgfym (ftylbs)
1 ORIFICE (SHIM) 4 22 SPRING 4
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3 ORIFICE (SHIM) 4 2.5 (18) 25 PLUG ; PF1/4 3
4 SPOOL 4 6.0 (43) 26 SOCKET BOLT ; M1060 2
5 BODY 1 0.5 (3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5 (11) 28 SET SCREW ; M8 4
7 SPRING 4 29 WASHER 4
8 SPRING 4 30 WASHER 2
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN ; 5 4
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11 #.1 SUN GEAR 1 27 SPACER 1
12 #.1 PLANETRY PINION 4 31 SET SCREW ; M2030 1
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5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
5.3.1 TOOLS
Code Tool name Remarks
(0.394˝ )
10mm
Material : SS41
65mm
(2.56˝ )
Jig
A
(for press fitting bearing )
∅100r0.5mm
(3.937˝r0.020˝)
∅180r0.5mm
(7.087˝r0.020˝)
B Snap ring plier For shaft
Material : SS41
(0.591˝ )
∅201mm
(7.91˝ )
15mm
C Oil seal fitting jig

∅235- 00.05 mm
0
(9.252˝ - 0.0020˝ )
D Oil seal fitting jig Class 20kgfym (140 lbfyft)

E Plastic hammer (Wooden hammer)
F Press Class 10 ton (22000 lb)
H Flat screwdriver
(0.787˝ )
∅20mm
I Metal bar 3 pcs.

155mm
(6.10˝ )
J General tools Allen key wrench and steel rod

Screw lock compound Three-Bond 1360K
K
Sealing compound Loctite #515
5.3.2 DISASSEMBLY
The numbers in parentheses correspond to
the ones in construction drawings (Fig. 5-2).
(1) Preparation
1) Before disassembly, clean the outside of the 3) Disconnect the drain hose.
reduction unit thoroughly and check for no
damage and scoring. 4) Matching Mark
To facilitate the reassembly of the unit, put
2) Drain gear oil from the reduction unit. matching mark on the joining parts of the
housing before disassembly.
Τ㧙5㧙16
(2) Separating swing motor from reduction unit
SWING MOTOR
1) Preparation for disassembly
Place the reduction unit assy on a stable
work bench as shown in Fig.5-39, remove
plug (35), drain out oil and put a matching 20
mark on the matching surface of the figure on
the right.
H
MATCHING
2) Removing swing motor assy MARK
Loosen all socket bolt (20) (M14). Attach eye
bolts (M121.75) in the lifting bolt holes in
the top surface of the swing motor and lift the
assy by crane. 34
190
If it is hard to remove the swing motor assy (7.48˝)
from the reduction unit, float it by inserting a 35
350
flat-blade screwdriver (H) in the groove of the (13.8˝)
flange. Fig. 5-39 Removing swing motor assy
: 12 mm, 10 11
(3) Disassembling reduction unit

1) Remove #1 sun gear (11).
6
2) Removing #1 spider assy (10). H
The spider assy (10) [consisting of thrust
washer (24), #1 pinion (12), needle bearing
(23) and snap ring (26)] can be removed from
the spline easily if it is lifted up in that 2
condition.
Fig. 5-40 Removing #1 sun gear and #1 spider
assy
3) Removing ring gear (6)
Attach eye bolts (M14) to the top surface of #2 SPIDER ASSY
ring gear (6) and lift the ring gear lightly by a
wire sling.
6
Put a flat-blade screwdriver (H) into the
matching surface of ring gear (6) and housing H
(2) and remove ring gear (6) by lightly
tapping the outer circumference of the ring
gear with a plastic mallet (E). 2
Fig. 5-41 Removing ring gear (6)

#2 SPIDER ASSY
4) Remove #2 sun gear and #2 spider assy. 8
Draw out #2 sun gear (8) and remove the #2
spider assy.
Regarding the disassembly of the #2 assy,
refer to par. (4) which will come up later.
Τ㧙5㧙17

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E235SR
SECTION 34 TRAVEL SYSTEM
TABLE OF CONTENTS
[Part I. Removing and Installing]
1. TRAVEL SYSTEM .................................................................................................... I-1
2. CRAWLER
2.1 Removing crawler .............................................................................................................. I-1
2.2 Installing ............................................................................................................................. I-2
2.3 Construction ....................................................................................................................... I-3
2.4 Maintenance standard ....................................................................................................... I-4
2.5 Tools and jigs...................................................................................................................... I-4
3.UPPER ROLLER
3.1 Upper roller assy ................................................................................................................ I-5
3.2 Removing ........................................................................................................................... I-5
3.3 Installing ............................................................................................................................. I-5
3.4 Construction ....................................................................................................................... I-6
3.5 Disassembly and Assembly ............................................................................................... I-6
3.6 Maintenance standard ....................................................................................................... I-9
3.7 Tools and jigs.................................................................................................................... I-10
4. LOWER ROLLER (TRACK ROLLER)

4.1 Lower roller assy .............................................................................................................. I-11
4.2 Removal ........................................................................................................................... I-11
4.3 Installation ........................................................................................................................ I-11
4.4 Construction ..................................................................................................................... I-12
4.5 Disassembly and Assembly ............................................................................................. I-12
4.6 Maintenance standard ..................................................................................................... I-16
4.7 Tools and jigs.................................................................................................................... I-17
INDEX
5. FRONT IDLER
5.1 Front idler assy ................................................................................................................. I-18
5.2 Removing ......................................................................................................................... I-18
5.3 Idler assy .......................................................................................................................... I-19
5.4 Idler adjuster assy ............................................................................................................ I-23
6. SPROCKET
6.1 Removing ........................................................................................................................ I-27
6.2 Installing .......................................................................................................................... I-27
6.3 Maintenance standard .................................................................................................... I-28
6.4 Sprocket tooth profile gauge ........................................................................................... I-28
7. TRAVEL REDUCTION UNIT

7.1 Travel motor ..................................................................................................................... I-30
7.2 Removing ........................................................................................................................ I-30
7.3 Installing .......................................................................................................................... I-31
8. SWING BEARING
8.1 Swing bearing assy ......................................................................................................... I-32
8.2 Removing ........................................................................................................................ I-32
8.3 Installing .......................................................................................................................... I-33
8.4 Construction .................................................................................................................... I-33
8.5 Disassembly and Assembly ............................................................................................ I-33
8.6 Maintenance Standard .................................................................................................... I-34
[Part II. Disassembling and assembling]
1. TRAVEL MOTOR .................................................................................................... II-1

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1. TRAVEL SYSTEM

8. SWING BEARING

2. CRAWLER
7. TRAVEL MOTOR
6. SPROCKET
5. FRONT IDLER

LOWER FRAME
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3. UPPER ROLLER
GREASE NIPPLE OF THE
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2.4 MAINTENANCE STANDARD
Fig. 2-10
Table 1-1 Unit㧦mm(in)
No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY

A Link pitch 190r0.1 (7.4803r0.0039) 194 (7.64) 198 (7.80) Replace the link
assy if the
B O.D. of bushing ∅58.78r0.05 (2.3142r0.0020) 55 (2.17) 54 (2.13)
service limit is
C Height of link 106r0.3 (4.1732r0.0118) 100 (3.94) 98 (3.86) exceeded
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dimension Tolerance Fit Fit
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and link
(2.3142) Shaft 㧗0.0043 0.05 (0.0020) 0 Replace
㧙0.0020
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pin and link 㧙0.00315
Clearance between 1.5 (0.06) 8 (0.32) 10 (0.39)
G Replace
links (both side) (both side) (both side)
Tightening torque
H 87kgfym (630ftylbs) Reassembly
of shoe bolt
2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig
Unit : mm (in)
NAME OPPOSING FLATS NAME SHAPE

Socket 30
Master pin
fixing jig
for iron
crawler
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4. LOWER ROLLER (TRACK ROLLER)
4.1 LOWER ROLLER ASSY
TRACK ROLLER STD 4 Apply Loctite #262
T=40.5kgfym (290 lbfyft)
ASSY
& LC
LOWER GROUP NLC
ITEM NAME Q̉TY REMARKS
1 LOW ROLLER 16 18
2420P1580D4
2 CAPSCREW 64 72 M1880
2 3
3 TRACK GUIDE 2 ←
Apply Loctite #262
4 CAPSCREW 8 ← M1840 T=40.5kgfym (290 lbfyft) 1
Fig. 4-1 Lower roller assy and track guide
4.2 REMOVAL
(1) Where track guide is removed
1) Preparation for removal
Put safety block (Square timbers) on the front and
rear sides of under section of lower frame, and
stabilize the machine.
2) Removing track guide
Remove capscrews (4) and remove track guide. SAFETY BLOCK
: 27mm (Square timbers)
Weight of track guide : Approx.24kg (52 lb)
Fig. 4-2 Preparation for mounting and
3) Installation dismantling the lower crawler
Coat capscrews (4) with Loctite #262 and fasten in case the track link is equipped
four socket bolts temporarily. Then tighten them to
a specified torque.
: 27mm
Tightening torque : 40.5kgfym(290 lbfyft)
(2) Where crawler is installed.
1) Preparation for removal
Slacken crawler, and stop engine keeping lower
frame lifted up with front attachment.
2) Put safe blocks under the front and rear sides of
lower frame.
3) Remove lower roller
Remove capscrews (2) and remove lower roller (1).
: 27mm Fig. 4-3 Installing lower roller
Weight of lower roller : Approx.35kg (77 lb) (Without track link)
4.3 INSTALLATION GREASE NIPPLE

(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all four capscrews temporarily. Then tighten
them to a specified torque.
: 27mm
Tightening torque : 40.5kgfym(290 lbfyft)
(2) Adjusting tension of crawler.

Tighten grease nipple and fill it with grease.
: 19mm, Fig. 4-4 Adjusting tension of crawler
Tightening torque : 6kgfym(43 lbfyft)
I-11

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5.1 FRONT IDLER ASSY
STD Apply Loctite#262 equivalent

FRONT IDLER T=28.5kgfym (210 lbfyft)
ASSY LC
NLC 1 3 2
No. NAME Q̉TY REMARKS
1 CRAWLER ID. ASSY 2
1-1 IDLER ASSY 1
1-2 IDLER ADJUSTER 1
4
1-3 CAPSCREW 2 M1645
1-4 GREASE NIPPLE 1 2444P803
Fig. 5-1 Front idler assy
5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
BAR
(2) Removing idler assy
Sling idler assy, and push it forward with bar.
Weight of crawler࡮idler assy : 256kg (564 lb)
Keep away from the front side of front

idler.
(3) Installing
Installing is done in the reverse order of
removing.
Fig. 5-2Removing andinstallationthe front idler
(4) Where idling assy (1) has to be separated

1
Loosen capscrew (3), and separate idler assy
(1) from idler adjuster assy (2).
: 24mm
Weight of idler assy : 106kg (234 lb)
Weight of idler adjuster assy : 150kg (331 lb)
2
z The separated idler assy should be
placed on square timbers.
3 4
Fig. 5-3 Separating idler assy (1)

from idler adjuster
Σ㧙18

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7) Installing collar (3)
Fit the half of floating seal (4) on the other
collar (3), press fit it in shaft (6), and drive 8
pin (5) in with hummer. 3
5
8) Filling oil࡮Inspection
Fill in 200cc (12.2cuyin) of engine oil API 1
grade CD #30 through the plug hole of collar
(3), wind seal tape and tighten plug (8).
: 5mm
Fig. 5-12 Installing collar (3) and filling oil
z After installing the idler assy to the
idler adjuster assy, make certain 160 (6.30̢)
that no oil leaks from floating seal C
and plug (8) and that idler (1)
rotates smoothly.

5.3.3 MAINTENANCE STANDARD F
A
B
Fig. 5-13 Front idler

No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
Dia. of idler
A projection ∅535 (21.1) 㧙㧙
B Tread dia. ∅497 (19.6) ∅490 (19.3) ∅487 (19.2) Replace
C Flange width 84r0.5 (3.307r0.020) 78 (3.07) 76 (2.99)

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dimension
Tolerance Fit Fit
Clearance 㧙0.030
D between shaft ∅75
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0
F Oil Engine oil API grade CD#30, 200cc (12.2cuyin) Refill
Idler rotation Rotates smoothly by hand. Reassemble
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7.1 TRAVEL MOTOR Apply Loctite #262
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TY REMARKS
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2 CAPSCREW 52 φ M1860
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1
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Fig. 7-1 Installing travel motor
7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize.
7
(2) Removing cover (1),(2)
Remove sems bolt (7) M12 25 and also 1,2
remove covers (1),(2).
: 19mm Fig. 7-2 Removing and installing cover (1), (2)
(3) Preparation of oil pan
(4) Removing hydraulic pipe

Bleed air in hydraulic oil tank, remove all
pipes connecting to travel motor. Then plug
up all pipes and joint section to protect them
from entry of dust.
: 19mm, 27mm, 32mm, 41mm

Refer to tool 4.plug (1).
Hydraulic pipe plug 4-1
ORS plug 4-1 11 See tools Fig. 7-3 Removing and installing hydraulic pipe
Σ㧙30
(5) Removing sprocket
Removing fifty two (both side) capscrews (2)
M1855.
: 27mm
Fig. 7-4 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3)
Apply match marks on travel motor and Remove pipes.(Disconnect)
crawler frame, and remove fourty (both side)
capscrews (3) M2060.
: 30mm
Fig. 7-5 Removing and installing travel motor

(7) Slinging travel motor assy attaching bolts
Sling travel motor with nylon sling applied on
the side close to sprocket installing section
and remove the motor.
Weight of motor : About. 250kg (551 lb)
7.3 INSTALLING
Installing of the travel motor piping is performed
in the reverse order of removal.
1) Cleaning
Check that contact surface of travel motor and Fig. 7-6 Slinging travel motor
crawler frame is free from burr and stain.
Tightening
Tools RE-MA
NAME SIZE No. Torque
2) Tightening torque
HEX kgfym(ftylbs) RKS
Tighten capscrew and hydraulic pipes to the Sems bolt M12 19 7 8.5 (61) Apply
torque specified in "Tightening Torque". M18 27 2 40.5 (290) loctite
Capscrew #262
3) Fill inside from motor drain port to casing M20 30 3 55 (400)
with hydraulic oil before piping for drain. Flareless 101.5 19 㧙 5 (36)
nut for 182.5 32 㧙 15 (110)
When starting operation, operate motor in low pipes, 28 41 㧙 28 (200)
idling and at low speed for several minutes, sleeve
and check it for possible oil leakage and noise. PF1/4 19 㧙 3.7 (27)
Connector PF1/2 27 㧙 11 (80)
PF1 41 㧙 26 (190)
Σ㧙31
8. SWING BEARING
8.1 SWING BEARING ASSY
SWING BEARING ASSY

No. NAME Q̉TY REMARKS
1 SWING BEARING 1
2 CAPSCREW 36 M20P1.570
FRONT
Inner S zone section of

SECTION A㧙A swing bearing
Fig. 8-1 Swing bearing assy
8.2 REMOVING
(1) Matchmarks Swing bearing
Remove upper structure, apply matchmarks
Outer race
on inner race of swing bearing and lower
frame.
Inner race
(2) Remove thirty six capscrews (2) M2070 for
installation inner race.
Matchmarks
: 30mm
(3) Drawing out grease

Remove grease in grease bath.
(4) Removing swing bearing

Attach eyebolt on swing bearing and sling it. Fig. 8-2 Matchmarks
Swing bearing
Weight of swing bearing : 365kg (805 lb)
Eye bolt
Grease bath
Fig. 8-3 Removing and installing swing
Σ㧙32
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces
of swing bearing and lower frame are free
from dust and stain.
FRONT
(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark
on inner race as shown in the figure.
(3) Temporary fastening of inner race

Coat the threads of the capscrews (2) with Inner S zone section of
Locktite #262 and tighten all the capscrews swing bearing
(2) temporarily. Fig. 8-4 Location of S mark on swing bearing
: 30mm
(4) Regular tightening of inner race

Tighten the capscrews (2) at 180 degrees
intervals alternately to a specified torque.
:30mm, 1
Tightening torque :
2 Loctite #262 or equivalent
to be applied
(5) Filling grease. T=57.5kgfym (420 lbfyft)
Fill grease bath with 15.7kg (34.6 lb) of SECTION A-A
grease NLGI-2 (containing molybdenum Fig. 8-5 Removing and installing capscrew (2)
disulfide) or equivalent.
8.4 CONSTRUCTION
ASSY 6
No. NAME Q̉TY No. NAME Q̉TY 1
1 OUTER RACE 1 6 SEAL 1 9 8
2 INNER RACE 1 7 TAPER PIN 1
3 BALL 92 8 PLUG 1 7
3,4
4 RETAINER 92 9 GREASE NIPPLE 1
5 SEAL 1 (PT1/8) 5
2
8.5 DISASSEMBLY AND ASSEMBLY Fig. 8-6 Cross-sectional view of swing bearing
(1) Disassembly
1) Take out seal (6) fitted in the groove in the EYE BOLT
6 2
outer circumference under inner race (2) and
7
seal (5) fitted in the groove in the inner
circumference on top of outer race (1) and 1
place them level on a square wooden block or Square wooden
something. block
2) Draw out taper pin (7), using a hammer and
an extrusion rod.
8
3) Draw out plug (8), utilizing an pull bolt
inserted in the screwed hole (M10) in the 5
center of the plug and using a puller. Fig. 8-7 Removing swing bearing
Σ㧙33

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1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
1.1 CONSTRUCTION OF TRAVEL MOTOR
1.1.1 CROSS-SECTIONAL VIEW OF TRAVEL 18 18
30 18
MOTOR ASSEMBLY 30
29 29
19 20
$
ඏ 17 69 17
VIEW A SECTION C㧙C SECTION D㧙D
VALVE ASSY
22 23 27 27 21 24 26 23 25 52 17 64 57 58 42 37 38 40 39 48 61 73 72 75 76 74 85 86 87
96
52
17
60
90
51
8
69 91
12
62 92
9
27 88
7
41
10
50 89
11 31
36
6 93
32
16
31 95
13 2
44 83
43
68 94
14
59 97
15
98
56
63
34 5 4 3 67 30 33 35
55 54 1 45 46 70 47 49 53 71 99 77 78 79 80 81 82 84
ඍ
67 68 65 66 67
%
13
15
28
30
18
Fig. 1-1 Cross-sectional view of travel motor unit assembly VIEW B SECTION E㧙E
Τ㧙1
1.1.2 REDUCTION UNIT DRAWING 1.1.3 HYDRAULIC MOTOR DRAWING

17 25 2324 26 21 18 3029 27 69 32 31
83 18 27
84 13
85 93 11 66
12
86 65
16
87
88 14
89 15 10 52 20
9 6 19 23
90 8 7 22
5
91 4
92 30
94 35
34
95 72 33
96 71 59
51 33
73 34
35

2 17
74
60 28
77
30
78 30 3
105 1 4
79 67 18 5
7
98 80 6
97 8
70 68
81 71 9
82 10
12
Base plate assy
11 13
16 14

15

75 48
76 61

50

62

Fig. 1-2 Reduction unit assy

36
41
49
44
53
43
1 42

37
45
40
39

46 38
47
64
63
56
57
58
54
55
54
55
54
Cylinder block assy
Fig. 1-3 Hydraulic motor assy
Τ㧙2
1.2 TOOLS
(1) Standard tools (2) Materials
Tightening Width Tightening Width Application Application
torque across Q̉T
torque across Q̉T Tools name Type࡮size Item (No.) Materials name Description Item (No.)
flats No. NAME flats No. NAME
kgfym(lbfyft) mm Y kgfym(lbfyft) mm Y
Preset torque Nominal 60 16, 28, 29, Sealing tape 18
1 FLANGE 1 51 PIN 1 wrench 30
2 BASE PLATE 1 21 (150) 12 52 SOCKET BOLT ; M1435 10 Adhesive Locktite 76, 82
3 PLANGER ; FOR BRAKE VALVE 1 53 OIL SEAL ; TCN507212 1 Nominal 120 18 Gear oil GL-4#90 equiv. 1, 48, 47,
4 CHECK VALVE 2 54 DISK PLATE 3 Nominal 230 15 Hydraulic oil ISO VG46 equiv. 2, 3, 19,
5 SPRING 2 55 FRICTION PLATE 2 Nominal 450 31 37, 38, 39,
14 (100) 14 6 PLUG ; M24 , P=1.5 2 56 BRAKE PISTON 1 40, 46, 47,
Nominal 900 92, 96
7 O RING 1B P21 2 57 O RING 1 62
8 SPRING SEAT 2 58 O RING 1 Nominal 1800 6, 13, 22,
9 SPRING 2 59 SPRING 8 25, 97 Grease Litium base 7, 12, 14,
10 SPRING SEAT 2 60 KNOCK PIN 4 23, 32, 35,
Nominal 2800 79
11 CAP 2 61 SPRING 2 53, 56, 57,
Nominal 4200 17 58, 62, 64
12 O RING 1B G45 2 62 VALVE PLATE 1
11 (80) 10 13 SOCKET BOLT ; M1240 8 63 O RING 1B P10 4 Nominal 5600 76, 82
Kerosene
14 O RING 1B P8 2 64 O RING 1
Hex bit for socket Opposing flats 2.5 16, 28, 29, Liquid packing Three bond 72, 95
2.1 (15) 14 15 PLUG ; PF1/8 2 65 NAME PLATE 1 wrench 30 For the repair of
0.25 (1.8) 2.5 16 ORIFICE ; M55 2 66 RIVET 2 Lapping plate
moving surface
38 (270) 27 17 RILIEF VALVE ASSY ; PF1-5/16 2 67 PLUG ; PT1 2 Opposing flats 4 18 For the repair of
Lapping medium moving surface
1.0 (7.2) 4 18 PLUG ; NPTF 1/16 4 68 PLUG ; PT1/2 1 Opposing flats 6 31
19 SPOOL A ; 2-SPEED SELECT 1 69 PLUG ; PT1/4 1 Copper plate
Opposing flats 8 96
20 SPOOL C 1 70 FLOATING SEAL 2
Opposing flats 10 13, 22 Tube brush For cleaning 2,37
21 SPRING 1 71 ANGULAR BEARING 2
12 (87) 10 22 PLUG ; PF1/2 1 72 HOUSING (RING GEAR) 1 Opposing flats 12 58, 97 Bamboo brush For cleaning

23 O RING 1B P18 2 73 SHIM (t=0.05, 0.1, 0.3, 0.5, 1.0) 1 Opposing flats 14 6, 15 Oil pan Oil pan

24 SPRING GUIDE 1 74 HOLDER B 1
12 (87) 10 25 PLUG ; PF1/2 1 75 WASHER 8 Torques T type bit Size T50 92 Plastic container Grease container
26 WASHER 1 55 (400)‫ ڏ‬17 76 BOLT ; M2070 8 Size T90 76, 82 Rag

27 PLUG 6 77 THRUST PLATE 4 Socket for socket Opposing flats 10 25 (3) Special tools
0.25 (1.8) 2.5 28 ORIFICE ; M55 1 78 INNER RACE 4 wrench Application
0.25 (1.8) 2.5 29 ORIFICE ; M55 2 79 NEEDLE BEARING 4 Opposing flats 27 17 Special tools name Description Item (No.)

0.25 (1.8) 2.5 30 ORIFICE ; M55 5 80 PLANETARY GEAR B 4 Allen wrench Opposing flats 2.5 16, 28, 29,
3.75 (27) 6 31 PLUG ; PF1/4 4 81 THRUST PLATE 4 30 Pulley puller 49, 50
32 O RING 1B P11 4 55 (400)‫ ڏ‬17 82 BOLT ; M20130 4 Bearing fixing jig 49
Opposing flats 4 18
33 CHECK VALVE 2 83 SUN GEAR B 1 Bearing fixing jig 50
34 SPRING 2 84 SNAP RING 1 Opposing flats 6 31
Floating seal fixing jig 70
35 O RING 1B , P12 2 85 HOLDER A 1 Opposing flats 8 96
Rod 71
36 SHAFT 1 86 THRUST PLATE 3 Opposing flats 10 13, 22
37 CYLINDER BLOCK 1 87 INNER RACE 3 Angular bearing fixing jig 71
38 PISTON ASSY 9 88 NEEDLE BEARING 3 Opposing flats 12 52, 97
Shim thickness adjusting jig 73
39 RETAINER PLATE 1 89 PLANETARY GEAR A 3 Opposing flats 14 6,15
40 RETAINER HOLDER 1 90 THRUST PLATE 3 Rod 3
Spanner Opposing flats 10 25
41 SNAP RING 1 91 THRUST PLATE 1 Thrust plate selecting jig 96
Opposing flats 27 17
42 SPRING SEAT 1 6.0 (43) 8 92 SCREW ; M10 3
43 SPRING 1 93 DRIVE GEAR 1 Radio pench 17 Oil seal fixing jig 53
44 COLLAR 1 94 THRUST PLATE 1 Brake piston positioning jig 56
Snap ring pliers S-2 Type 41
45 PIN 3 95 COVER 1 Snap ring removing/fixing jig 41
46 PLATE (SWASH PLATE) 1 7.48 (54) 8 96 BOLT ; M10 16 Minus driver 6100 70, 68, 2,
62
47 BALL 2 16 (120) 12 97 PLUG ; PF3/4 3
48 PISTON ASSY 2 98 O RING 1B P24 3 (4) Measuring instrument name
Plastic hammer Nominal #3
49 BALL BEARING 1 99 PIN 4 Measuring instrument Application
Eye bolt For M20 name Description Item (No.)
50 BALL BEARING 1
For M12 2 Dial gauge JIS B7503 73,94
‫ڏ‬㧦Apply Loctite
Chain string(wire) Micro meter JIS B7502 73,94
Τ㧙3


1.3.1 DISASSEMBLY PROCEDURE

(1) Removing cap (11) 33,34,35
Fix the motor on a stable work bench, loosen
eight socket bolts (13) and remove cap (11)
with O ring (12).
Next, remove spring seat (10), spring (9) and
spring seat (8).
Then separate O ring (35), spring (34) and 8 17
9
check valve (33).
10
12
: 10mm 11

13
Cap (11) is pressed out by spring(9).
Therefore, do the work, taking care of Fig.1-4 Removing the cap assy
the following.
z Loosen socket bolts (13) evenly all
round.
z Loosen socket bolts (13), holding
down cap (11).

(2) Removing double counterbalance plunger (3)
Push the end of plunger (3) lightly so part of
plunger (3) comes out of base plate (2). Then,
hold the end of plunger (3) by hand and draw
out plunger (3) from base plate (2), while
turning it by hand.

Plunger (3) and base plate (2) have a
very tight fit. Therefore, do the work,
2
paying attention to the following.
z In case plunger (3) gets stuck halfway
and does not come out, do not try to 3
force it out. If it is pulled out by Fig. 1-5 Removing double counterbalance valve
force, the bore surface of base plate spool(3)
(2) and the outer surface of plunger
(3) are scored.
In case the plunger gets stuck
halfway, do as follows:
Put plunger (3) back into base plate
(2) by lightly tapping the end face of
it with a plastic mallet. Then make
sure that the plunger (3) moves
smoothly and draw out the plunger
(3) once again, turning it by hand.
z Do not disassemble plunger (3)
unless it is necessary; the outer
surface of it may be scored at
disassembly.
Τ㧙5
(3) Removing relief valve assy (17)
Loosen plug (17-6) and remove relief valve
assy (17). In that case, poppet seat (17-3) 17́3
remains in base plate (2).

: 27mm

Relief valve assy (17) is set at certain
pressure. The set pressure of it
determines the starting power and the
braking power of the motor. For this
reason, do not do the following. 2
17-6
z Do not loosen nut (17-16) and tamper 17-16
with set screw (17-15). If the set 17-15
screw is turned, the set pressure of
the relief valve changes, making the 17
motor unable to attain required Fig. 1-6 Removing relief valve (17)
performances.
z Do not disassemble the relief valve
assy. Otherwise, the set pressure
changes and the motor is unable to
attain required performances.

(4) Removing poppet seat (17-3)
Separate poppet seat (17-3) from base plate
(2), using the poppet seat removing jig.
z Do not separate it unless it is
necessary for special reason.

(5) Removing auto 2-speed select spool (19) 2
Loosen plugs (22), (25) and take off plugs (22),
(25) and spring (21). Next, push out part of 17-3
spool(19) from base plate (2) by pushing the Fig. 1-7 Removing poppet seat (17-3)
end of spool (19). Then draw spool (19) out of
base plate (2), while holding the end of spool
(19) by hand and turning it.

Spool (19) and base plate (2) are
combined to a very small fit. For this
reason, execute the work, paying 25
attention to the following. 21
z Do not disassemble spool (19) unless
necessary.
z In case the spool gets stuck halfway,
do not force it out. If the spool is 2
forced out, the bore surface of base 19
plate (2) and the outer surface of
spool (19) are scored. 22
If it gets stuck, do as below. Fig.1-8 Removing auto 2-speed select spool (19)
Τ㧙6
Put spool (19) into base plate (2)
once again by lightly tapping the end
face of spool (19) with a plastic
mallet. Then, make certain that
spool (19) moves smoothly and draw
it out, turning spool (19) by hand.
(6) Do not remove orifice plug (18) unless

necessary.
Orifices (28), (29), (30) are caulked so they do
not get loose.
Do not disassemble them. (See Fig.1-1 and 1-3.)
52
(7) Removing base plate (2)
Loosen socket bolts (52) and remove base plate 2
(2). 59
: 12mm
Fig.1-9 Removing base plate (2)ާ1ި
When removing base plate (2), do the
work, taking care of the following.
z Base plate(2) is pushed up by the
action of spring (59). Therefore,
loosen the cap screws evenly all
round.
z A positioning knock pin (60) is
placed between base plate (2) and
the main body. When removing base 2
plate (2), do it upright toward the
motor shaft center so knock pin (60)
is not wrenched. In case it is 60
wrenched, bring knock pin (60) back
in place by lightly tapping base plate Fig.1-10 Removing base plate (2)ާ2ި
(2) with a plastic mallet and remove
the knock pin.
z When removing base plate (2), valve
plate (62) comes with base plate (2).
Since the moving surface of valve
plate (62) tends to be scored, use 62
care so valve plate (62) does not fall.
(8) Removing valve plate (62)

Separate valve plate (62) from base plate (2),
using a flat-blade screwdriver.
When removing valve plate (62), take

care of the following.
z The moving surface of valve plate
(62) tends to be scored. If the surface
is scored, desired performances are Fig.1-11 Removing valve plate (62)
not available; use care so as not to
score it.
Τ㧙7
(9) Removing O rings, knock pin (60) and spring
59
(59).
Take off O rings (63), (64), and knock pin
(60). Then take off spring (59).
(10) Removing brake piston (56) 60

Attach a jet air nozzle to the oil path for the
parking brake of flange (1), make brake 63
piston (56) afloat by blowing jet air into the 64
parking brake cylinder chamber and remove
the brake piston. Fig. 1-12 Taking off O rings (63), (64), knock
After removing brake piston (56), remove pin (60), and spring (59)
disk plate (54) and friction plate (55). Then
separate O rings (57), (58) from brake piston
(56).

When removing brake piston (56), take
care of the following.
z When blowing in jet air from the
parking brake oil path of flange (1),
take measures so jet air does not
leak. 56
z If the jet air pressure is high when
blowing in jet air from the parking
brake oil path of flange (1), you may Fig. 1-13 Removing brake piston (56)
be injured as brake piston (56) pops
out. For this reason, keep the air
pressure less than 3kgf/cm2 (43psi)
and do the work, holding down brake
piston (56) so brake piston (56) does
not jump off.
56

(11) Removing cylinder block (37) 57
58
Take out cylinder block (37) from flange (1). 54
55
54
When drawing out cylinder block (37), 55
54
use care of the following : Fig. 1-14 Removing disk plate (54),
z Hold cylinder block (37) by both friction plate(55), and O rings (57),(58)
hands and take it out slowly, while
turning it both ways lightly.
z Exercise care so as not to score the
moving surface of cylinder block (37)
in contact with valve plate (62). If the
surface is scored, desired
performances will not be attained.
z Exercise care so as not to score the 37
moving surface of the shoe of piston
assy (38). Desired performances will
1
not be attained if the surface is
scored.
Fig. 1-15 Removing cylinder block (37)
Τ㧙8
(12) Disassembling cylinder block (37)
1) Give a matching mark to piston assy (38) and
cylinder block (37) so they can be
reassembled in the same positions. Then
separate piston assy (38) and retainer plate
(39) from cylinder block (37).
37
38
2) Give a matching mark to piston assy (38) and 39
retainer plate (39) so they can be Fig.1-16 Removing piston assy (38)
reassembled in the same position. Then
remove piston assy (38) from retainer plate
(39).
39
38
Fig.1-17 Removing retainer plate (39)
3) Separate retainer holder (40) from cylinder
block (37). Then take off pin (45) from
cylinder block (37).
4) Fix cylinder block (37) on a manual press 45

bench so the moving surface faces upwards.
Take off snap ring (41), push collar (44) with
the jig, bend spring (43) and take off snap
ring (41), using snap ring pliers.
37
When removing snap ring (41), take
care as below, so as not to injure 40
yourself. Fig. 1-18 Removing retainer holder (40) and pin
z If snap ring (41) is tight to remove (45)
with snap ring pliers, you may injure
yourself when the snap ring comes 41
off from the pliers. Always use the
removing jig to remove the snap ring
and make certain that the claw of
JIG
the pliers is set in the hole of the
snap ring.
37
Τ㧙9
5)Separate collar (44), spring (43) and spring 44
seat (42) from cylinder block (37).
43
42
37
(13) Removing swash plate (46) Fig.1-20 Removing collar (44), spring (43)
Separate swash plate (46) from flange(1). and spring seat (42)
Use care of the following when

removing swash plate (46).
z Take care so as not to score the
sliding surface of swash plate (46).
Desired performances will not be 46
attainted if the surface is scored.
z Swash plate (46) comes off with
piston assy (38) and steel ball (47) in 1
some cases. On that occasion, use
care so piston assy (38) and steel
ball(47) do not fall. Fig.1-21 Removing swash plate (46)
(14) Removing travel 2-speed select piston assy

(48) and steel ball (47)
61
Separate piston assy (48) from flange(1).
Then take off spring (61).
Separate steel balls (47) from flange (1).
48
Since steel balls (47) are hard to come 47
off, do it as below :
z Degrease steel balls (47) fixed in 1
flange (1), using kerosene or thinner.
z Separate steel balls (47) from flange
(1), using a magnet.
Fig.1-22 Removing piston assy (48) and steel balls
(15) Removing shaft (36) (47)
Separate shaft (36) and ball bearing (49) from
flange (1).
When removing shaft (36), use care of

the following : 36
zUse care so the spline of shaft () is
49
not damaged.
Exercise care so the sliding part of
oil seal (53) in shaft (36) is not 1
scored. If it is scored, oil leakage
occurs.
Τ㧙10
(16) Draining lube oil from the reduction gear
Next, before disassembling the reduction
unit, put a screw in two tapped holes of 1
flange (1) that are in diagonal positions and
lift the reduction unit by crane. Remove two
plugs (97) and drain lube oil from the
reduction unit.
: 12mm
Prepare an oil container before doing 97 97

the work. Fig.1-24 Draining oil from reduction unit
z Do not lift the reduction unit too
high, but do the work at as low
level as possible.
(height of your knees)
96
(17) Removing cover (95)
Loosen bolts (96) and remove them.
Then remove cover (95).
: 8mm 72
Remove the cover as below 95

z Liquid packing is applied between Fig.1-25 Removing cover (95)
cover (95) and housing (72). For this
reason, the cover is hard to come off.
Loosen bolts (96) and tap the top
and side faces of the removed cover
(95) with a plastic mallet.
z Put a flat-blade screwdriver between
cover (95) and housing (72) and take
off cover (95).
(18) Removing thrust plate (94)

Separate thrust plate (94) from the top face of 91
thrust plate (91)
94
Fig.1-26 Removing thrust plate (94)

(19) Removing drive gear (93)
Remove drive gear (93)
93
Fig.1-27 Removing drive gear (93)
Τ㧙11
(20) Removing the 1st stage holder assy
Remove the 1st stage holder assy that consists
of holder A (85), planetary gear A (89), needle
bearing (88), inner race (87), thrust plate (86),
thrust plate (90), thrust plate (91) and screw
(92).

Use care of the following when
removing the 1st stage holder assy :
z Take care so you do not pinch your
fingers at removing. 1st stage holder assy
(21) Removing the 1st stage holder assy Fig.1-28 Removing the 1st stage holder assy
Fix the 1st stage holder assy in a vise and
heat screw (92) with a hair dryer and loosen
it. Separate screw (92), thrust plate (91),
thrust plate (90), planetary gear A (89), needle
bearing (88), inner race (87) and thrust plate
92
(86), from the holder B, in that order.
85
86
: 8mm 87
88
When loosening screw (92), exercise care of 89
the following : 90
91
Screw (92) is coated with Locktite and Fig.1-29Disassembling the 1st stage holder assy
hard to get slack. If you loosen it by
force, it is scored and can not be reused.
Heat the screw with a hair dryer before
loosening it.
(22) Removing sun gear B (83)

Remove sun gear B (83).
(23) Removing planetary gear B (80)

Fix flange (1), loosen bolt (82) and remove it.
83
Next, separate thrust plate (81), planetary
gear B (80), needle bearing (79), inner race Fig.1-30 Removing sun gear B (83)
(78) and thrust plate (77), in that order.
1
: 17mm
Exercise care of the following when

loosening bolt (82) : 79
z Bolt (82) is coated with adhesive
Locktite to prevent it from loosening.
Fix flange (1) securely for that
reason.
z When loosening bolt (82), use a tool 78
80 77
with a sufficiently long extension 81
such as iron pipe. If you do not use it 82
and try to loosen by force, you may Fig. 1-31 Removing planetary gear B (80)
injure your waist or other parts.
Τ㧙12
(24) Removing holder B (74)
Fix flange (1) and loosen and remove bolt (76).
Holder B (74) is fixed to flange (1) with pin
(99). Attach the removing jig from the motor 74
side and separate holder B (74) by the use of a
press.
: 17mm
76
99
When loosening bolt (76), use care of the
following :
z Coat bolt (76) with screw locking Fig.1-32 Removing holder (74)
agent to prevent it from loosening.
JIG
For that purpose, fix flange (1)
securely. 1
z To loosen bolt (76), use a tool with a
sufficiently long extension such as an
iron pipe. If you loosen it by force, you
may injure your waist or yourself in
99
some cases.
72
(25) Separating flange (1) from housing (72)

Attach a jig to the end face on the outer flange
of housing and separate flange (1) from
housing (72) by pressing flange (1) by press.
72
Fig.1-33 Separating flange (1) from housing (72)
(26) Removing floating seal (70)
Remove floating seal (70) by pushing up the
outer circumference of floating seal (70) with a
flat-blade screwdriver.
(27) Storage of parts

This completes disassembly. Clean the
disassembled parts thoroughly, coat them
with a thick film of rust preventive oil, put
them in plastic bags and store them in a cool,
dark, dry place.
If the parts are stored in a hot humid place,
70
they may be rusted even if rust preventive oil
is applied. Keep the parts so no dust adheres
to them. Fig.1-34 Removing floating seal (70)
Τ㧙13
1.3.2 ASSEMBLING PROCEDURE
<Reduction unit>
(1) Assembling floating seal (70) into flange (1)
Confirm the below items concerning floating
seal (70). Then assemble floating seal (70) to
flange (1), using the floating seal fixing jig. 1
Make certain that there is no dust on 70
the surface of flange (1) in contact with
floating seal (70).
z Thoroughly degrease the surface Floating seal fixing jig
where floating seal (70) of flange (1)
is located. Fig.1-35 Assembling floating seal (70)
z Make sure that no dust is there on
the O ring of floating seal (70).
z Thoroughly degrease the surface of
the O ring in floating seal (70).
(2) Assembling angular bearing (71) to housing
(72)
Press angular bearing (71) into housing (72), 71
using a pressing jig and a press.
(3) Assembling floating seal (70) into housing 72
(72)
71
Make sure of the following as to floating seal
Angular bearing fixing jig
(70). Then assemble floating seal (70) into
housing (72), using the floating seal fixing jig. Fig.1-36 Pressing in angular bearing (71)
Make certain that there is no dust and
foreign matter on the surface on which
floating seal (70) in housing (72) is
located.
z Thoroughly degrease the surface
where floating seal (70) in housing
(72) is located.
z Make sure that there is no dust and Floating seal
foreign matter on the O ring of fixing jig
floating seal (70). 70
z Thoroughly degrease the surface of
the O ring in floating seal (70).
72
(4) Assembling housing (72) into flange (1)
Make sure of the below items and assemble Fig.1-37 Fixing floating seal (70)
housing (72) into flange (1), using a crane, so
floating seal (70) of flange (1) matches
floating seal (70) of housing (72)
Make certain that there is no foreign
matter on the moving surface of the
seal ring located in floating seal (70).
z Apply lubricating oil for the
reduction unit or hydraulic oil to all 1
sliding surface of seal ring located in
floating seal (70).
72
z When assembling housing (72) into
flange (1), make sure that the shaft Fig. 1-38 Assembling housing (72) into flange (1)
centers are aligned with each other.
Τ㧙14
(5) Selecting the thickness of shim (73)
74
Choose the thickness of pre-load adjusting
shims according to the following procedure :
J
1) Press the end face of the inner race of
angular bearing (71) at a load of 3000kgf
(6600 lbf), using the shim thickness adjusting Press load㧦3000kgf (6600 lbf)
jig. Jig
2) In that case, measure the step H between the
end face of the inner race of angular bearing
H
(71) and the end face of flange (1).
3) Measure the step h at holder (74).
71
4) Select and combine the repair kit (t=0.05, 0.1,
0.3, 0.5, 1.0) of shims (73) so as to attain shim
thickness that matches (H-h). 1
Do not reuse shims (73) that were once Fig.1-39 Selecting shim thicknesses (73)
used.
z Do this work without fail. If pre-load
adjustment is not done well, the 74
reduction unit may be broken during
operation. 73
z Clean the measuring surface
thoroughly.
99
(6) Assembling holder B (74)
Fix flange (1) and erect pins (99)ާ four placesި
upright on flange (1). 1
Bring the shims selected under (5) in contact
with holder B (74), using grease, match the
pin holes in holder B (74) to the pins and
press it in by press.
Fit washer (75) to holder B (74), coat bolts
(76) with Locktite and tighten the bolts to a 73
specified torque. 74
: 17mm,
Tightening torque: 55kgfym (400 lbfyft)
Confirm that pins (99) are not inclined.

z Washer (75) is equipped with a spike
to prevent it from getting slack. Fit 99
the spike to the seat of holder B (74).
z Thoroughly clean the threads of bolt 75
(76), degrease it and coat it with 76
75
adhesive Locktite.
z Thoroughly clean and degrease the
inside of the screw threads of flange Beware of the assembling
direction of washer (75).
(1). Look at the direction on the
figure on the right.
Fig.1-40 Installing holder (74)
Τ㧙15
(7) Assembling planetary gear B (80) 72
Assemble thrust plate (77) to planetary gear B 74
(80).
Next, fit needle bearing (79) to planetary gear 77
78
B (80) 80 79
Finally, attach inner race (78). Then install
planetary gear B (80) by engaging the bore
diameter of inner race (78) with trunnions
Place the draft on
(four) of holder B (74). the holder (80)
Assemble thrust plate (77) to planetary

gear B (80) so the draft of the thrust
plate (77) is located on holder B (74) 74
side. Assembling direction of
thrust plate (77)
z When the planetary gears B (80) are
installed finally to the holder B (74), Fig. 1-41 Assembling planetary gear B (80)
mesh the inner gear of housing (72)
with gear of planetary gear B (80).
z Use care of the assembling direction
of planetary gear B (80).
(8) Assembling thrust plate (81)

Install planetary gear B (80) so the chamfer
side in the bolt hole of thrust plate (81) comes
below the neck of bolt (82). 82 81
82
After placing it, coat the screw threads of bolt
(82) with Locktite, attach bolt (82) and tighten
it to a specified torque.
: 8mm, Place so C2 chamfer side

comes on the seat side.
Tightening torque: 55kgfym (400 lbfyft)
Use care of the attaching direction of

thrust plate (81). If the neck of the bolt
is damaged, it breaks down.
z Clean the screw threads of bolt (82)
thoroughly, degrease it and coat it
81
with Locktite.
z Clean the screw threads in the
tapped hole of holder B (74) Fig. 1-42 Assembling thrust plate (81)
thoroughly and degrease it
thoroughly.
80
(9) Assembling sun gear B (83)
Make sure that snap ring (84) is fitted to sun
gear (83). Then attach sun gear B (83) to four
planetary gears B (80).
Engage the teeth of planetary gear B 84 83

(80) with those of sun gear B (83) and
assemble them together. Fig. 1-43 Assembling sun gear B (83)
Τ㧙16
(10) Assembling holder A (85)
Engage the inner gear teeth of holder A (85)
with the teeth of sun gear B (83) and
assemble holder A (85) into sun gear B (83).
83
85
(11) Assembling planetary gear A (89) Fig. 1-44 Attaching holder A (85)
Assemble thrust plate (86) to planetary gear
A (89).
Next, attach needle bearing (88) to planetary
gear A (89).
Finally, attach inner race (87), engage the bore
with the trunnions (3 places) of holder A (85),
86
and assemble planetary gear A (89) into
holder A (85).
89
Attach thrust plate (86) to planetary

gear A (89) so the draft side (by press) 85
of thrust plate (86) is located on the 87
holder A side (85). 88
z Finally, when assembling planetary Place the draft on 89 8688 87
gear A (89) to holder A (85), engage the holder (85) side.
the inner gear teeth of housing (72)
with the teeth of planetary gear A 85
(89)
z Be careful of the assembling Assembling direction of thrust plate (86)
direction of planetary gear A (89). Fig. 1-45 Assembling planetary gear A (89)
(12) Assembling drive gear (93)

Attach thrust plate (90) to planetary gear A
(89) and then attach thrust plate (91). Coat
the threads of screw (92) with Loctite and 89
tighten it to a specified torque. 90
91
: 8mm,
Tightening torque : 6.0kgfym (43 lbfyft) 93
Assemble drive gear (93) to three planetary
gears A (89) by directing the spline of drive
gear (93) toward the motor assembling side. 92 78 79 80 81
Then engage the teeth of planetary gear A
(89) with the teeth of drive gear (93).
Place the draft on the
74 holder (80) side.
Be careful about the assembling
direction of thrust plate (90).
z Thoroughly clean and degrease the
Assembling direction of thrust plate (81)
tapped hole in holder A (85) and the
threads of screw (92). Fig. 1-46 Assembling drive gear (93)
Τ㧙17
(13) Attaching thrust plate (94) 72
Measure the step between the end face of
91
housing (72) and thrust plate (94), using the
thrust plate selecting jig, choose and attach
thrust plate (94) according to the table below : 94
Unit : mm (in)
Shim
Step dimension (T) Thrust plate code thickness (t)
1.20㨪0.67
(0.0472㨪0.0264) 20941㧙62306 2.3
0.66㨪0.04
(0.0260㨪0.0016) 20941㧙62307 2.8
0.03㨪㧙0.16 72
(0.00122㨪㧙0.0063) 20941㧙62308 3.0
㧙0.174㨪㧙0.41 Measure the step T.
(㧙0.00685㨪㧙0.0161) 20941㧙62309 3.2
㧙0.42㨪㧙0.80 91
(㧙0.0165㨪㧙0.0315) B0841㧙23017 3.6
94
Align the hole in the center of thrust
plate (94) with the convex part of drive Fig.1-47 Assembling thrust plate (94)
gear (93) and assemble them together.
(14) Attaching cover (95)

Remove foreign matter completely from the
matching surface between the end face of
72
housing (72) and cover (95).
Next, thoroughly degrease the matching
surface between the end face of housing (72) 95
and cover (95). 96
Further, apply liquid packing to the corner of
the spigot joint on the matching surface side
of housing (72) of cover (95). Match the tapped
holes in housing (72) with the bolt holes in
cover (95) and place cover (95) in housing (72).
Finally, attach bolts (96) and tighten them to
specified torque.
; 8mm,
Tightening torque : 7.48kgfym (54 lbfyft) Fig.1-48 Attaching cover (95)
(15) Fitting plugs (97)

Take off O ring (98) from plug (97), replace it
with a new one and place it in plug (97).
Then, attach plugs (97) to the oil inlet/outlet
and the level ports (3 in all) of cover (95), and 95
tighten them to specified torque.
; 12mm,
Tightening torque :16kgfym (120 lbfyft) 98
97
This completes the assy of the reduction unit.
Next comes the assemble of the motor.
Assemble it, referring to “Assembling the
Motor”.
Fig.1-49 Fixing plugs(97)
Τ㧙18
<Motor>
(1) Fitting oil seal (53)

Make sure that flange (1) is equipped with oil
seal (53). If not, press oil seal (53) into flange
(1), using the oil seal fixing jig.
Oil seal
Before attaching oil seal (53), apply fixing jig
grease to the bore surface of flange (1) 53
(where the oil seal is placed) and outer
diameter surface of oil seal (53).
z Coat the lip of the bore of oil seal 1
(53) with grease and put it in.
z Push the oil seal upright. If it is
tilted, the outer diameter of oil seal Fig.1-50 Fixing oil seal (53)
(53) will be scored.
z Be careful so as not to score the lip of
the bore of oil seal (53) when fixing
it. If the lip is scored, oil leakage
may occur and break the inside of
the reduction gear while the motor is
running.
48
(2) Assembling piston assy (48) 61
Place spring (61) in the hole where piston
assy (48) of flange (1) is located.
Then, mount piston assy (48) to flange (1).
Place spring (61) in the center of the

hole.
z Install piston assy (48) with its
cylindrical part facing downward.
z Before assembling piston assy (48),
apply hydraulic oil to the bore of
flange (1) and the outer surface of 1
the cylindrical part of piston assy
(48).
z After assembling piston assy (48), Fig.1-51 Assembling piston assy (48)
confirm that it moves smoothly.
(3) Fitting steel balls (47)

Fit steel balls (47) in the holes in the
spherical surface of flange (1). 47
Before fixing steel balls (47), apply

hydraulic oil to the bore surface in the
spherical part of flange (1) and steel
balls (47). 1
Fig.1-52 Fixing steel balls (47)
Τ㧙19
(4) Installing shaft (36) 36
Press ball bearing (49) into shaft (36), using
49
the bearing fixing jig. Bearing
Then mount shaft (36) into the center of fixing jig
flange (1).
Assemble ball bearing (49) upright.

z After mounting shaft (36), confirm
that shaft (36) rotates smoothly.
(5) Installing swash plate (46)

Attach flange (1) so the inclined surface of
swash plate (46) faces up.
1
Assemble swash plate (46) by matching
the holes in the rear spherical surface
of the swash plate (46) to steel balls Fig.1-41 Installing shaft (36)
(47).
46
z After coating steel balls (47) with
hydraulic oil and assemble swash
plate (46).
z After assembling swash plate (46),
make sure that the swash plate
moves smoothly.
1
(6) Assembling cylinder block(37)
1) Place cylinder block (37) on a hand press Fig.1-54 Installing swash plate (46)
bench so the sliding surface of valve plate 44
(62) faces up. Assemble cylinder block (37) so
the slope of spring seat (42) faces downward.
Then mount spring (43) and collar (44) on 43
spring seat (42), in that order.
42
41
2) Press in the top face of collar (44), using a jig,
and fix snap ring (41). 37
If snap ring (41) is tight, the snap ring Jig

pliers come off from the snap ring and
you are injured by it, in some cases.
When fixing the snap ring, always use
a jig and make sure that the claw of
the snap ring pliers is engaged in the Fig.1-49 Assembling
hole of the snap ring cylinder block (37)
z If it is difficult to narrow the snap
ring, use snap ring pliers one size Fig.1-56 Fixing snap ring
(41)
larger.
z To press in collar (44), align the
center of the cylinder block with that
of the press.
Τ㧙20
3) Place cylinder block (37) on a work bench so
the sliding surface of cylinder block (37) in 45
contact with valve plate (62) faces downward.
Place three pins (45) into the slanted holes in
cylinder block (37).
37
Before placing cylinder block (37) on a
work bench, make certain that there is
nothing on the work bench.
z Use care so as not to score the
sliding surface of valve plate (62) in
cylinder block (37). If the surface is Fig.1-57 Fixing pins (45)
scored, the motor performances are
deteriorated which leads to a failure
of the motor in an early stage.
z Before fixing pins (45), coat the pin
holes with grease.
4) Install retainer holder (40) to cylinder block

(37).
37
40
Fig.1-58 Attaching retainer holder (40)
5) Attach piston assy (38) ާ 9pcs. ި to retainer
plate (39) so the tapered face of retainer plate
(39) faces downward.
39
38
Fig.1-59 Assembling retainer plate (38)
6) Install piston assy (38) to cylinder block (37).
Coat the piston holes (9 pcs.) in

cylinder block (37) with hydraulic oil,
before installing piston assy (38)
z Coat the spherical surface of retainer
37
holder (40) with hydraulic oil, before
assembling it.
38
Fig.1-60 Assembling piston assy (38)
Τ㧙21
(7) Assembling cylinder block (37)
Engage the inner tooth splines of retainer
holder (40) and cylinder block (37) with the
outer tooth spline of shaft (36) so the sliding
surface of cylinder block (37) in contact with 37
valve plate (62) faces upwards. Then assemble
cylinder block (37) into flange (1).
1
At assy, use care so piston assy (38),
retainer plate (39) and retainer holder (40)
do not come off from cylinder block (37).
z Before assy, coat the surface of swash Fig.1-55 Assembling cylinder block (37)
plate (46) and the sliding surface of
piston assy (38) with hydraulic oil.
(8) Attaching disk plate (54)

Engage the inner teeth of disk plate (54) with
the outer teeth of cylinder block (37) and
mount them to flange (1).
Assemble the convex portion of the outer 54
circumference of friction plate (55) with the 55
54
concavity of flange (1) and install them to flange 55
54
(1). In this way attach disk plate (54) and
friction plate (55) to the flange, in that order.
Disk plate (54) is a wet type disk. Before Fig.1-56 Assembling disk plate (54)
assmbly, immerse the disk plate (54) in
hydraulic oil so disk plate (54) sucks in
sufficient hydraulic oil.
(9) Installing brake piston (56)

Attach O rings (57), (58) to brake piston (56).
Next, mount brake piston (56) to flange (1) so
the larger diameter side of the brake piston
faces upward. 56
Coat O rings (57), (58) with sufficient

57
grease, before fixing them.
z Align the knock pin hole in flange (1) 58
Positioning jig
in contact with base plate (2) with the
knock pin hole in brake piston (56),
using the positioning jig. Then install
brake piston (56).
z Before fitting brake piston (56), coat
the outer surface of the brake piston
and the bore of flange (1) with grease. 56
z Assemble brake piston (56) by pressing
it so it does not tilt. If the brake piston is 1
assembled inclined, it develops trouble
and tears off O rings in some cases.
Fig.1-57 Installing brake piston (56)
Τ㧙22
(10) Fitting springs (59)
Fit springs (59) into eight holes in brake
piston (56).
(11) Attaching valve plate (62)

Place base plate (2) on a work bench and
press bearing (50) in the center of base plate 59
(2), using the bearing fixing jig.
Confirm that knock pin (60) is fixed in base
plate (2) and attach valve plate (62) to base
plate (2).
Place valve plate (62) with the copper Fig.1-64 Fixing spring (59)
alloy side facing upward.
z Coat the matching face between base 62
plate (2) and valve plate (62) with Bearing
grease to prevent the valve plate fixing jig
from falling off.
z Use care so as not to score the copper 50
alloy surface of valve plate (62).
(12) Attaching base plate (2)

Fit O rings (64) and O rings (63)ާ4 placesި to 2
the top face of flange (1).
Fit knock pin (60) to base plate (2). Attach
base plate (2) to flange (1) so the surface of Fig.1-59 Attaching valve plate (62)
valve plate (62) in contact with base plate (2)
faces downward. Then tighten them with 60 2
socket bolts (52).
: 12mm,
52
Coat O ring (64) with grease. 60
z Do not coat O ring (63) with grease.
63
z Fix knock pin (60) with its taper part 64
upward.
z Coat the surface of valve plate (62)
and the cylinder block (37) with
hydraulic oil and install them to Fig.1-66 Attaching base plate (2)
base plate (2).
z Since the surface of the base plate
(2) in contact with base plate (2) z Before assmble, make sure of the
faces downward, take care so the knock pin (60) fixed in base plate (2),
valve plate does not fall. the hole in the base plate (2) into
z When installing base plate (2) to which spring (59) enters, the knock
flange (1), make sure of the location pin hole on the flange side (1), and
of O ring (63) and the location of the the position of spring (59).
oil passage hole in base plate (2). z Tighten socket bolts (52) evenly all
round on the circumference.
Τ㧙23
(13) Assembling travel 2-speed select spool (19)
Attach spring (21) to spool (19). Then attach
them to base plate (2).
After placing spool (19), make certain that O 25
ring (23) is set in plug (22), fit plug (22) to
base plate (2) and tighten it to a specified 21 23
torque. Next, make sure that O ring (23) is
fitted to plug (25), install spring guide (24)
2
and washer (26), place plug (25) to base plate
(2), and tighten it to a specified torque. 19
23
: 10mm, 22
Fig.1-66 Assembling travel 2-speed select spool
Assemble spool A (19) into base plate (19)
(2) so that the pipe port surface of base
plate (2) comes toward yourself and
that the side of spool A (19) on which
spring (21) is placed comes on the
right. If the spool is assembled
inversely, spool change may get out of
order and other trouble may occur in
some cases.
z Coat the outer surface of spool (19)
with hydraulic oil, before assembling it.
z After spool (19) is placed, make
certain that it moves smoothly.
(14) Assembling relief valve (17)

Make sure that poppet seat (17-3) is placed at
the tip of relief valve (17). Then assemble
relief valve (17) to base plate (2) and tighten
them to a specified torque.
: 21mm,
Replace O ring (17-7) with a new one,

before assembly. 17-17,18 2
z Make sure that O ring (17-7) and 17-3
backup ring (17-18) are fitted to
17-7
poppet seat (17-3).
z Coat O ring (17-17) and backup ring
17
(17-18) with grease, before assy.
Fig.1-67 Assembling relief valve (17)
Τ㧙24
(15) Assembling counterbalance valve plunger (3)
Assemble plunger (3) to base plate (2).
Assemble the plunger (3) to the base

plate, while turning the plunger.
z Install plunger (3) straight.
z In case plunger (3) gets stuck, do not
force it in, but tap it lightly with a
plastic mallet. 2
z Coat the outer surface of plunger (3)
3
with hydraulic oil before assmble.
Fig.1-68 Installing spool (3)
(16) Attaching cap (11)
Attach spring seat (8) and spring (9), in that
33
order, to plunger (3). 34
35
Fit check valve (33) and spring (34), in that
order, into the hole beside the hole in base
plate (2) in which cap (11) is placed.
Make sure that O ring (12) is set in cap (11).
Also make sure that O ring (35) is placed in
base plate (2). Fit cap (11) to spring seat (10)
and then place cap (11) to base plate (2). 17
8
Finally, fasten socket bolts (13) to a specified 9
torque. 10
: 10mm,
11,12
13
Coat O ring (12) with grease. Fig.1-69 Fitting cap (11)
z Cap (11) is pushed up by the action of
spring (9). When tightening up socket
bolts (13), hold them down by hand.
z Tighten four socket bolts (13) evenly
all round. If cap (11) is tightened up
tilted, O ring (12) is damaged,
resulting in oil leakage.
This completes assy of the hydraulic motor.
Τ㧙25
(1) Motor parts
Parts Check point Tolerance Remedy

Piston assy (38) 1. Sliding surface of shoe The roughness is 0.8a or Lap the moving surface
the surface is roughened or of shoe (#1000).
the scratch is deeper than If the scratch does not
0.02mm (0.0008in). disappear, replace
cylinder block assy.
2. O.D. of piston The roughness is 1.2a or Replace cylinder block
the surface is roughened or assy.
the scratch is deeper than
0.02mm (0.0008in).
3. O.D. of piston and bore Clearance :
diameter of cylinder 0.060mm (0.00236in)
block
4. Gap on shoe ball Gap 0.4mm (0.016in)
Cylinder block (37) 1. Sliding surface of The roughness is 0.8a or Lap the sliding surface
valve plate the surface is roughened or (#1000).
the scratch is deeper than If the scratch does not
0.02mm (0.0008in). disappear, replace
cylinder block assy.
2. Bore diameter The roughness is 1.6a or Replace cylinder block
the surface is roughened or assy.
the scratch is deeper than
0.02mm (0.0008in).
3. Bore diameter and the Clearance :
O.D. of piston assy 0.060mm (0.00236in)
4. Spline at the joint of The pin that measures Replace cylinder block
shaft (36) the between dia. assy.
38.749mm (1.52732in)
measures 3.333mm
(0.13122in) (V1=2.80) or is
broken.
Valve plate (62) 1. Sliding surface A scratch deeper than Lap the moving surface.
0.02mm (0.0008in) is (#1000) If the scratch
there on the 0.8a does not disappear,
roughness moving surface replace the valve plate.
or a seizure is seen on the
surface. The moving
surface shows abnormal
wear.
Retainer plate (39) 1. Sliding surface The sliding surface of 0.8a Replace retainer plate
Retainer holder (40) roughness shows a and retainer holder.
scratch deeper than
0.02mm (0.0008in) or
shows a seizure.
Swash plate (46) 1. Sliding surface The sliding surface of 0.8a Lap the sliding surface.
roughness shows abnormal (#1000) If the scratch
wear or a scratch deeper does not disappear,
than 0.02mm (0.0008in). replace the valve plate.
2. Spherical hole in The spherical surface of Replace swash plate.
which a steel ball is 1.6a roughness shows a
placed scratch deeper than
0.02mm (0.0008in) or is
roughened.
3. Spherical hole in which Ball depth :
a steel ball is placed 14.5mm (0.571in)
Τ㧙26
Shaft (36) 1. O.D. of oil seal sliding The sliding surface shows a Replace shaft.
surface scratch deeper than
0.02mm (0.0008in) or is
roughened, except the oil
seal lip moving marks on
the 1.6a roughness.
2. Spline at the joint of The pin that measures the
cylinder block (37) over-pin dia. 47.380mm
(1.86535in) measures
3.00mm (0.11811in) or is
broken.
3. Spline at the joint of The pin that measures the
drive gear between dia. 30.498mm
3.33mm (0.13122in) or is
broken.
Brake piston (56) 1. Appearance and Height : Replace brake piston.
dimension 38.2mm (1.504in)
2. Sliding surface Roughness: 2.5a
3. Appearance The surface shows a scratch
deeper than 0.02mm
(0.0008in) or is roughened.
Disk plate (54) 1. Appearance and Thickness : Replace disk plate.
2. Appearance The moving surface has a
deep scratch or the abrasive
material is peeled off.
Ball bearing (49) 1. Rolling surface Flaking or impressed Replace ball bearing.
Ball bearing (50) marks are seen.
2. Function Rotation is abnormal.
(abnormal sound and
uneven rotation)
Piston assy (48) 1. Sliding surface of shoe The roughness is 1.6a or the Lap the sliding surface of
surface is roughened or the shoe. (#1000)
scratch is deeper than In case the scratch does
0.02mm (0.0008in). not disappear, replace the
flange holder kit.
2. O.D. of piston The roughness is 1.2a or the Replace flange holder kit.
surface is roughened or the
scratch is deeper than
0.02mm (0.0008in).
3. O.D. of piston and bore Clearance:
diameter of flange 0.040mm (0.00157in)
holder (1)
4. Gap on shoe ball Gap : 1.0mm (0.039in)
Plunger (3) 1. O.D. of plunger The roughness is 0.8a or the Replace base plate kit.
surface shows a scratch deeper
than 0.02mm (0.0008in) or is
roughened.
2. O.D. and the bore dia. Clearance:
of base plate 0.060mm (0.00236in)
Base plate(2) 1. Hole in which plunger The surface has a roughness Replace base plate kit.
(3) is placed more than 0.8a or shows a
scratch deeper than 0.02mm
2. Bore dia. of base plate Clearance :
and O.D. of plunger 0.060mm (0.00236in)
3. Hole in which spool A The surface has a roughness
(19) is placed more than 0.8a or a scratch
deeper than 0.02mm
4. Bore dia. of base plate Clearance :
and O.D. of spool A (19) 0.060mm (0.00236in)
5. Moving surface and The surface has a scratch
seat of free piston in deeper than 0.02mm
relief valve assy (17) (0.0008in) or is roughened.
Τ㧙27
Spool A (19) 1. O.D. of spool The surface has a Replace base plate kit.
roughness more than 0.8a
or a scratch deeper than
0.02mm (0.0008in) or is
roughened.
2. O.D. of spool and bore Clearance :
dia. of base plate 0.060mm (0.00236in)
Free piston (17-9) 1. Sliding surface and The surface has a scratch Replace relief valve assy.
seat surface of base deeper than 0.02mm
plate (0.0008in) or is
roughened.
Housing (17-1) 1. Moving surface (O.D.) The surface has a scratch
of free piston deeper than 0.02mm
(0.0008in) or is
roughened.
Spring (43) 1. Appearance and Free length :
2. Appearance It is deformed or the coil
surface is damaged.
surface is damaged.
surface is damaged.
surface is damaged.
surface is damaged.
O rings and oil seals At disassy Replace O rings and oil
seals.
Τ㧙28
(2) Reduction unit parts
Planetary gear A (89) Tooth thickness Bridged dimension of 6 teeth : Replace planetary gear.
66.649mm (2.62397in)
Tooth face Pitching or fracture is seen on
10% or more of the tooth face.
Bore diameter Flaking is seen on the bore Replace planetary gear,
surface. needle bearing and inner
Needle bearing (88) Rolling surface of Flaking is seen on the surface. race.
roller
Inner race (87) Outer diameter Flaking is seen on the surface.
surface
Drive gear (93) Tooth thickness Bridged dimension of 3 teeth: Replace drive gear.
29.908mm (1.17748in)
10% or more of the tooth face.
Spline The pin that measures the When drive gear is replaced,
over-pin dia. 38.989mm check shaft at the same time.
(1.53500in) measures ∅3.00mm
(0.11811in) or is broken.
Holder A (85) Tooth thickness The pin that measures the Replace holder.
of inner gear between dia. 66.742mm
(2.62763in) measures ∅7.00mm
(0.27559in) or is broken.
Sun gear B (83) Tooth thickness Bridged dimension of 4 teeth: Replace sun gear B (89)
41.371mm (1.62637in)
more than 10% of the tooth
face.
Planetary gear B (80) Tooth thickness Bridged dimension of 6 teeth: Replace planetary gear.
65.662mm (2.58511in)
more than 10% of the tooth face.
Bore diameter Flaking is seen on the bore Replace planetary gear,
surface. needle bearing and inner
Needle bearing (79) Rolling surface of Flaking is seen on the surface. race.
roller
Inner race (78) Outer diameter Flaking is seen on the surface.
surface
Housing (72) Tooth thickness The pin that measures the Replace housing.
between dia. 330.449mm
∅7.00mm (0.27559in).
more than 10% of the tooth face.
Shim (73) At disassembly Replace shims.
Flange (1) Bore dia. of the Clearance : Replace flange kit.
hole in 2-speed 0.040 mm(0.00157in)
piston and the
O.D. of piston assy
Bore dia. of the The surface has a roughness
hole in 2-speed more than 1.2a or is roughened
piston or has a scratch deeper than
0.02mm (0.0008in).
Thrust plate (94) Thickness The plate thickness is either 3.3, Replace thrust plate.
2.5, 2.9, 2.0 or 2.7 (0.130˝, 0.098˝,
0.114˝, 0.079˝ or 0.106˝ ) or the
moving surface has a deep
scratch.
Τ㧙29
Angular bearing (71) Rolling surface of Flaking is seen. Replace angular bearing
ball
Function Bearing makes an abnormal
sound as it turns. It does not
turn smoothly.
Floating seal (70) Sliding surface A deep scratch that develops Replace floating seal.
oil leaks is on the surface. Do not disassemble any
O ring The surface has developed further as oil leakage may
cracks. occur if the sliding marks on
the seal ring do not match the
surface at disassembly.
O rings At disassembly Replace O rings.
Τ㧙30

1.5 TROUBLE SHOOTING

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E235SR
SECTION 41 TROUBLESHOOTING (MECHATRO CONTROL)
TABLE OF CONTENTS
1. OUTLINE ................................................................................................................... 1
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ................................................. 3
3. TROUBLESHOOTING OUTLINE .............................................................................. 4
4. CHECK POINTS FOR MECHATRO SYSTEM .......................................................... 5

1. OUTLINE

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2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ; MECHATRO CONTROL
Electric
Hydraulic

Arm variable recirculation

Control valve Motor Cylinder Other
Hi pressure sensor (P1)
Hi pressure sensor (P2)
P1 Pump proportional
P2 Pump proportional
Swing parking brake
Low pressure sensor
proportional valve
Proportional valve
proportional valve
proportional valve
Safety lock lever

Actuator
Travel 1-2speed
Travel straight
Arm variable recirculation

Solenoid valve
Solenoid valve
Solenoid valve
P1 bypass cut
P2 bypass cut
Travel straight valve

P2 bypass cut valve
P1 bypass cut valve
Boom conflux valve
Travel right motor

Arm conflux valve
valve
valve
Travel left motor
Boom lock valve
Arm lock valve

Swing motor
Travel right
S S P P P P S S S P P
Travel left
E E S S S S V V V S S
Bucket
֥ ֥ V V V V ֥ ֥ ֥ V V
Bucket
Swing
Boom
Boom
valve
Arm
Operating condition 22 23 ֥ ֥ ֥ ֥ 1 3 4 ֥ ֥
Arm
A B C D 1 2
Boom up slight lever operation ٤ ٤ ٤ ٤ ٤ ٤ ٤

Boom up full lever operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
Boom down operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
Arm out slight lever operation ٤ ٤ ٤ ٤ ٤ ٤ ٤
Independent operation
Arm out full lever operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤

Arm in slight lever operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
Arm in full lever operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤

Heavy duty arm in full lever
operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
Bucket digging ٤ ٤ ٤ ٤ ٤ ٤ ٤
Bucket dump ٤ ٤ ٤ ٤ ٤ ٤ ٤
Swing operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
Travel LH / RH operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
(1st. speed)
Travel LH / RH operation ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
(2nd speed)

3
3. TROUBLESHOOTING OUTLINE ; MECHATRO CONTROL
Location Pilot secondary

pressure Pressure sensor

Pump proportional valve Proportional valve
Arm variable recirculation valve

High pressure Low pressure P2 bypass cut proportional valve
Lever position Att Travel P1 P2
(Pump) (Pilot) Travel straight proportional valve
Operation P1 bypass cut proportional valve
ATT Arm variable recirculation proportional valve
Bucket digging Neutral ; 404mA
Bucket dump More than More than Min ; 706mA
Control lever at More than More than
35kgf/cm2 24kgf/cm2 Max 750 mA Max 750 mA
Boom up full stroke 2.9V 3.7V P2 bypass cut proportional valve
(500psi) (340psi)
Boom down Neutral ; approx 350mA
Swing left Max ; 642mA
Swing right Travel straight proportional valve
Arm in Neutral ; approx 350mA
Arm out Neutral Neutral Max ; 700mA (When releasing pressure)

Less than Less than Less than Less than (Hi idle) (Hi idle) (513mA Except when releasing pressure)
TRAVEL Lever at neutral
6.0kgf/cm2 (85psi) 6.0kgf/cm2 (85psi) 0.5V 0.5V
P1 bypass cut proportional valve
Forward 350mA 350mA
Neutral ; approx 350mA
Reverse
Max ; 642mA
4

4.
CHECK POINTS FOR MECHATRO SYSTEM (FOR TROUBLESHOOTING)

4.1 ATTACHING POSITION OF SENSOR AND ELECTRIC EQUIPMENTS
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SE-9 :
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PRESSURE SENSOR
(TRAVEL LEFT)
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PROPORTIONAL VALVE SENSOR
(P1 PUMP) (P1 PUMP)
SE-23 :
PRESSURE
SENSOR
(P2 PUMP)
PSV-P2 :
PROPORTIONAL VALVE
(P2 PUMP)
HARNESS (UPPER)
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PRESSURE SENSOR
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VIEW II
SE-3 :
PRESSURE SENSOR
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SE-7 :
PRESSURE SENSOR
(ARM IN)
SE-8 :
PRESSURE SENSOR SE-2 :
(ARM OUT) PRESSURE SENSOR
(BUCKET DUMP)
SE-1 :
PRESSURE SENSOR SE-4 :
(BUCKET DIGGING) PRESSURE SENSOR
(BOOM DOWN)
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4.2 EQUIPMENT
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AMP MQS-TYPE 3P (B-TYPE)
CONNECTOR(FEMAIL)
OTHER PARTY
HOUSING 2-967642-1
TERMINAL (GOLD PLATING) 965906-5
CONNECTER TERMINAL
ARRANGEMENT
TERMINAL NO.
1-COMMON
2-OUT PUT(+)
3-POWER SUPPLY(+)
VIEW A
19 21.9 HEX
HEX 22
O RING P11 O RING P14

PF1/4 PF3/8
DETAIL OF SENSOR

E235SR
SECTION 42 TROUBLESHOOTING (HYDRAULIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS ............................................................................................ 1
2. TROUBLESHOOTING .............................................................................................. 3
Engine
Rotation trouble System
Other trouble Drop in output Starting trouble
Group No.
(7)
(6)
(5)
(4)
(2)
start.
Over heat
revolution.
Idling unsmooth
warming-up E/G
(8) Exhaust gas is white
(11) key is turned off.

Trouble
not work properly.

Does not reach max
Component
modes are changed. (Aφ
Exhaust gas is black

(1) Starter does not run.
not disappear after idling.)

(3) High speed unsmooth
Knocking occurs after

Medium speed hunting
(12) OFF but power is not cut off.

When starter key is turned to
E/G deficiency in output
ψM/B)
Accel potentiometer does
Starter runs but does not
(In cold state, white smoke does
(9) Excessive oil consumption.
Engine does not stop when

Max. revolution is too high.
(10) Excessive fuel consumption.

Revolution does not change if work
٤
Fuel not filled up or leaking.
٤
Oil cooler element clogged.
Fuel system trouble(Air or water entered.)
٤
٤
٤
٤
٤
Oil filter clogged.
٤
٤ ٤
٤
Air cleaner clogged.
Filters
Gauze filter clogged.
٤
٤
٤
٤ ٤
٤ ٤ ٤
Fuel filter clogged.
٤
V-belt slips.
Inspection
٤
Breather hose bent.
Cooling water level
٤
٤ ٤
Fuel is of poor quality or leaking.
٤
Specific gravity of battery fluid

Fluid
1. TROUBLE DIAGNOSIS TABLE ; ENGINE
Viscosity of engine oil is not suited, engine oil is
٤
٤
٤
leaking, or the engine oil level not proper.
Poor quality fuel is used or heavy oil is used.

٤
٤
٤ ٤ ٤
٤ ٤
Blowby gas is much.
٤ ٤
٤ ٤
٤ ٤ ٤
٤ ٤ ٤ ٤
Gas leaks from valve and gasket.
٤
٤
Engine oil is too much.
Gas / fluid
Visual check
Battery fluid level

Fuse
٤
Starter key
٤ ٤ ٤ ٤
Battery relay
٤
٤
٤
٤
Mechatoronic controller
Mechatoro “A” adjust.
Shovel side
٤
٤
٤ ٤
٤
٤
Governor motor
Accel potentiometer
٤ ٤ ٤
٤
٤ ٤ ٤ ٤
٤
Connector and electric wiring

٤ ٤
Safety relay
Electrical fittings
Glow relay
٤ ٤
Glow
Starter motor
Engine side
٤ ٤
Starter relay
Alternator
Feed pump function
٤
٤ ٤
Check injection timing

Fuel
٤ ٤
Inspect nozzle.
system
Stop
٤
٤ ٤ ٤
٤ ٤
٤ ٤
Injection pump
position
٤ ٤ ٤ ٤
٤ ٤ ٤ ٤
Valve clearance
٤ ٤ ٤ ٤ ٤ ٤
Valve spring is fatigued.

system
Intake /
exhaust
٤ ٤ ٤ ٤
Air cleaner & muffler

Check if engine oil goes into combustion chamber.
٤
٤
٤
٤
Check relief valve.

Oil strainer clogged.
system
Lubrication
Fuel is mixed.
٤
٤
٤
٤
Check thermostat.
٤ ٤ ٤
Oil cooler element damaged.

Cooling
٤
٤
٤
٤
Compression pressure low.

٤ ٤
Control rack movement unsmooth.

٤ ٤
٤
٤ ٤
٤ ٤ ٤
Governor spring fatigued.

Crank shaft oil seal no good.
Piston liner worn.
٤ ٤ ٤
٤
Piston ring worn.

٤ ٤
٤ ٤ ٤
Valve spring fatigued.

Main structure
٤ ٤ ٤
Internal parts stuck.

Check fuel feed.
٤
٤
٤ ٤
Head gasket faulty.

٤ ٤ ٤
Flywheel gear damaged.

1
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Only arm out operation is slow.
NO
Hyd. oil temperature is 50͠ (122qF) or more. Heat oil and inspect.
YES
(Service diagnosis 28)
Command current for P1 bypass cut NO
proportional valve is approx. 700mA when arm To electrical troubleshooting
out lever is shifted to the full.
YES
Secondary pilot pressure at port Pbc NO NG
Inspect or replace P1 bypass Inspect or replace
(P1 bypass cut valve) is approx. 28kgf/cm2 cut proportional valve. proportional valve block.
(400psi).
YES
Secondary pilot pressure at port PBa (arm out) NO Inspect or replace pilot valve.
is approx. 30kgf/cm2 (430psi) or over.
YES
(Service diagnosis 24,25)
Command current readings for pump
proportional valve lie within standard levels
(below) during the above operation. NO YES
To electricaltroubleshooting
P1 ; approx. 580mA.
P2 ; approx. 580mA.
YES
Relief pressure lies within standard level Inspect or replace overload
NO
(below) when arm out is turned to the full. relief valve at port Ba (arm
350kgf/cm2(4980psi) rod side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken.
assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
Replace arm spool assy.
(Remove pilot cover.) spool is scored.
YES NO NG
Replace control valve.
Return spring of P1 bypass cut valve spool is NO Inspect or replace P1 bypass cut
broken. valve spool assy and pilot cover.
YES
Outer circumference of P1
P1 bypass cut valve spool moves smoothly by NO bypass cut valve spool is
YES Replace P1 bypass cut valve
hand.(Remove pilot cover.) scored. spool assy.
YES NO NG
Inspect or replace arm

NO conflux spool assy and pilot
Arm conflux spool return spring is broken
cover.
YES
Arm conflux spool moves smoothly by hand. NO Outer circumference of arm YES Replace arm conflux spool
(Remove pilot cover.) conflux spool is scored. assy.
YES NO NG
Replace control valve
Replace control valve
9
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Swing power is
Swing speed lies within standerd level NO Refer tǒSwing speed is
; (H-mode HI idle is approx. 13.0rpm or over.) slow.̍.
YES
YES Inspect or replace P2 bypass
Return spring of P2 bypass cut spool is broken. cut spool assy and pilot cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut spool moves smoothly by hand. bypass cut spool is scored. assy.
YES NO NG
Reference Replace control valve.
In case of a machine with a
multi control valve, check if
the condition returns normal
by changing swing lever back
& forth operation.
Secondary pilot pressure for swing motion is NO Dirt or something is stuck in YES
more than 31kgf/cm2 (440psi) when lever is Inspect or replace slow return
the restrictor of slow return
turned to the full in both directions. valve.
valve.
YES NO
Inspect or replace pilot valve .
Swing relief pressure lies within standard level. NO Inspect or replace swing
; 290kgf/cm2 (4140psi). motor relief.
YES NG
Machine drifts largely when swing parking YES Inspect or replace swing
is released (arm in action) on a slope. motor.
NO
The pressure at the P/B (PG) port of swing NO NG

Inspect or replace P2 bypass Inspect or replace
motor is 51kgf/cm2 (730psi) when swing lever is
cut proportional valve. proportional valve block.
turned to the full or during arm in action.
YES
YES Inspect or replace swing spool
Return spring of swing spool is broken.
assy and pilot cover.
NO
Swing spool moves smoothly by hand. NO Outside of swing spool is YES
(Remove pilot cover.) scored. Replace swing spool assy.
YES NO NG
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E235SR
SECTION 43 TROUBLESHOOTING (ELECTRIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................. 1
2. SELF DIAGNOSIS TABLE ......................................................................................... 4
3. SERVICE DIAGNOSIS TABLE ................................................................................... 4
4. TROUBLESHOOTING ............................................................................................... 5
1. TROUBLE DIAGNOSIS TABLE ; ELECTRIC
C1 mechatro controller
Low pressure sensor Power supply & other signal Switch & relay Governor motor & proportional & SOL
Accel motor start point indexing LS
Travel straight proportional valve
Arm variable recirculation proportional valve A

P1 bypass cut proportional valve D
P2 bypass cut proportional valve B
Conflux / single select SW (OPT)
Bucket digging pressure sensor
Boom lowering pressure sensor
Bucket dump pressure sensor

Boom raising pressure sensor
Travel right pressure sensor
P1 pump proportional valve

Engine water temp high LS
Engine oil pressure low LS
Travel left pressure sensor
Component
Front working light relay

P1 pump pressure sensor

Option 2 pressure sensor
Option 1 pressure sensor

Arm out pressure sensor
ATT boost pressure SOL

Governor motor B phase
Power supply grounding

Governor motor A phase
ATT boost pressure SW
Arm in pressure sensor
Swing pressure sensor
Swing P/B release SW
Fuel level thermister

Air filter clogging LS
Travel 1-2speed SOL

Engine speed sensor
Accelerator potentio
Travel 1-2speed SW
Washer motor relay
Swing parking SOL

Power supply +24V
Alternator voltage
Wiper motor relay

KPSS release SW
Shield grounding
Shield grounding
Shield grounding
Travel alarm SW
Key SW GLOW
Battery backup
Gauge cluster
Battery relay
Key SW ON
Group No
System
C
Connector
No. CN-11 CN-12 CN-13 CN-14 CN-15
1 4 7 10 13 16 19 25 28 31 34 1 4 7 13 15 16 17 18 19 20 22 1 1 2 3 4 5 7 8 13 15 16 25 28 1 3 4 6 8 10 12 14 15 17 19 21 22 23 24 25
Trouble ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮
2 5 8 11
Pin No. ࡮ 14 17 20 26 29 32 2 5 8 21 2 26 2 5 7 9 11 13 16 18 20 26
࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮ ࡮
3 6 9 12 15 18 21 27 30 33 3 6 9 3 27
No motions operate. ٤ ٤
(1) Machine moves freely when
lever is at neutral. ٤ ٤ ٤ ٤ ٤ ٤
All operate ٤
Only bucket speed is
٤
Speed is slow
slow.
Only boom raise speed is
slow. ٤ ٤ ٤ ٤ ٤ ٤
Attachment operation
(2) Motions are slow except

boom raise and arm out. ٤ ٤ ٤
Only arm in motion is
slow. ٤ ٤ ٤
Only arm out motion is
slow. ٤ ٤ ٤
All operate
Power is poor
Bucket digging
(3)
Boom raising
Arm in
Bucket digging, dumping ٤ ٤ ٤ ٤ ٤

Fine operation
impossible
٤ ٤ ٤ ٤ ٤
Electric systems
Boom raising, lowering

(4)
Swing ٤
Arm in, out ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
Travel 1-2 speeds can not be
(5) changed ٤ ٤
Travel operation
(6) Travel independent speed is low. ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤

(7) Travel power is poor
operation with
ATT travel combined

(at combined
ATT swing)
and travel straight are

impossible.
(8)
Travel deviates, zigzags. ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
Machine drifts on a downhill
(9) and does not stop still on a slope
(10) Swing motion does not work ٤ ٤ ٤

Swing operation
(11) Swing speed is slow ٤ ٤ ٤

(12) Swing power is poor ٤ ٤
Swing left࡮right ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
(13)
Swing can not be held on a slope ٤ ٤ ٤
(14) Auto idle stop is not actuated
Others
1
Electrical equipments
Proportioal valve Controller Diode Electrical equipments Light Motor Relay
Power window look motor (right, OPT)

Travel straight proportional valve
Arm variable recirculation proportional valve
Power window look motor (left, OPT)

Cab working light relay (OPT)

Power window motor (OPT)
Wiper motor (rise up, OPT)

Boom working light (left)
Power window controller
Air conditioner amplifier
Component
Tuner AM&FM (OPT)
Working light (right)
Washer motor relay
Working light relay

Speaker left (OPT)
Wiper motor relay

Roof wiper motor
Wiper relay assy

Governor motor
Air compressor
Receiver dryer
Washer motor
Gauge cluster
Speaker right
Starter motor
Heater (OPT)
Battery relay
Wiper motor
Safety relay
Hourmeter
Room light
Fuel pump
Horn relay
Glow relay
Alternator
Tuner AM
Fuse box
Resistor
Battery
Group No
Diode
Horn
System
Trouble P P P P P P B C C C D D D D D E E E E E E E E E E E E L L L M M M M M M M M M M R R R R R R R R R
S S S S S S 1 2 4 5 1 2 3 4 5 1 2 3 4 7 7 8 9 10 11 12 14 1 2 3 1 2 3 4 5 6 7 8 9 10 1 3 4 5 6 7 8 9 10
Pin V V V V V V ࡮
No. ֥ ֥ ֥ ֥ ֥ ֥ E
A B C D P P 5
1 2
No motions operate. ٤ ٤
lever is at neutral. ٤ ٤
All operate ٤ ٤ ٤
٤
Speed is slow
slow.
slow. ٤ ٤
(2)
Attachment opration
Motions are slow except

boom raise and arm out. ٤
slow. ٤ ٤
slow. ٤ ٤
All operate ٤ ٤
Power is poor
Bucket digging
(3)
Boom raising
Arm in
Bucket digging, dumping ٤

Fine operation
impossible
Electric systems
Boom raising, lowering ٤

(4)
Swing
Arm in, out ٤ ٤

(5) changed
Travel operation
(6) Travel independent speed is low. ٤

operation with
ATT travel combined

(at combined
ATT swing)

impossible.
(8)
Travel deviates,
zigzags.
٤
(10) Swing motion does not work

Swing operation
(11) Swing speed is slow ٤

(12) Swing power is poor ٤
Swing left࡮right ٤
(13)
Swing can not be held on a slope
(14) Auto idle stopn is not actuated

Others
2
Electrical equipments
Senser Solenooid Switch
Low pressure sensor Pressure
sensor
Engine water temperature sensor
Single/Conflux select SW (OPT)

Engine water temperature, oil pressure,
Auto idle stop select SW


Component
ATT boost pressure SOL
Work light switch (OPT)
ATT boost pressure SW

Wiper inter lock switch
Swing P/B release SW
Safety lock lever SOL
Travel 1-2 speed SOL
Safety lock lever SW

Heater & A/C switch
KPSS release switch
Travel 1-2 speed SW
Engine speed sensor
Swing parking SOL
Horn switch (right)

Horn switch (left)
Bucket digging
Bucket dump
Travel right
Boom lower
Fuel sensor
Accelerator
Boom raise
Key switch
Travel left
filter clogging
Option 1
Option 2
Arm out
Arm in
Swing
Group No
System
S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
Trouble E E E E E E E E E E E E E E E E E V V V V W W W W W W W W W W W W W W
Pin 1 2 3 4 5 7 8 9 10 11 13 14 15 16 20 22 23 1 2 3 4 1 3 4 5 6 10 11 12 20 21 22 23 34 52
No. ࡮ ࡮
7 13
࡮
8
No motions operate. ٤ ٤ ٤ ٤
lever is at neutral. ٤ ٤ ٤ ٤
All operate
٤ ٤ ٤ ٤
Speed is slow
slow.
slow. ٤ ٤
(2)
Attachment opration
Motions are slow except

boom raise and arm out.
slow. ٤
slow. ٤
All operate
Power is poor
Bucket digging
(3)
Boom raising
Arm in
Bucket digging, dumping ٤ ٤

Fine operation
impossible
Electric systems
Boom raising, lowering ٤ ٤

(4)
Swing
Arm in, out ٤ ٤ ٤ ٤

(5) changed ٤ ٤
Travel operation
(6) Travel independent speed is low. ٤ ٤ ٤ ٤ ٤ ٤ ٤

operation with
ATT travel combined

(at combined
ATT swing)

impossible.
(8)
Travel deviates, zigzags. ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤ ٤
(10) Swing motion does not work ٤ ٤ ٤

Swing operation
(11) Swing speed is slow ٤

(12) Swing power is poor ٤
Swing left࡮right ٤ ٤ ٤ ٤ ٤ ٤
(13)
Swing can not be held on a slope ٤ ٤ ٤ ٤
(14) Auto idle stop is not actuated ٤
Others
Regarding the C-1 mechatro controller, refer to two pages back.
3
2. SELF DIAGNOSIS TABLE 3. SERVICE DIAGNOSIS TABLE

The self diagnosis detects errors in the control I/O´s of the pressure sensors and the proportional valves The results of service diagnosis are displayed in up to 23 items according to data from the mechatro
while the machine is in operation and shows them on the multi display of the gauge cluster. controller.
Displaying procedure:
DISPLAY ITEM
1) TurňON̍the starter switch with the buzzer stop switch pressed.
No. Contents Display of monitor No. Contents Display of monitor 2) A mechatro controller parts number and a program version are displayed as the No.1 item.
3) The diagnosis advances like No.2, No.3.... each time the display select switch is pressed.
P1 by-pass cut
1 Mechatro controller fail 16 4) The diagnosis returns like No.40, No.39... each time the buzzer stop switch is pressed.
propo-valve fail
5) The display does not disappear unless the starter switch is turneďOFF̍.
P2 by-pass cut
2 ROM data 17
propo-valve fail
No.1
Travel priority
3 Mechatro set error 18 MAIN CONTROLLER
propo-valve fail
PROGRAM VERSION Display select switch
Arm variable Advances the screen
Boom raising VER 5.30
Buzzer stop switch
4 19 recircula-tion Returns the screen
propo-valve fail
Boom lowering Pump P1 pressure
5 20
pressure sensor fail sensor fail
Arm in pressure Pump P2 pressure SERVICE DIAGNOSIS DISPLAY (Example)

6 21
sensor fail sensor fail
Arm out pressure ATT boost pressure No. DISPLAY No. DISPLAY No. DISPLAY No. DISPLAY
7 22 No.1 No.7 No.13 No.23
sensor fail Solenoid valve fail
MAIN CONT. SOLENOID PRESS. SENSOR PROPO-VALVE
F㧙1 POWER UP B㧙9 TRAVEL (R) D㧙6 A-RECIRCULAT
Bucket digging Travel two-speed 1 PROGRAM VER 7 COMP. OFF 13 3.6V 2.3M 23 COMP. 538mA 1.7M
8 23
pressure sensor fail solenoid valve fail VER 5.30 MEAS. OFF B㧙10 TRAVEL (L) MEAS. 538mA 1.7M
SWITCH OFF 3.6V 2.3M
Bucket dump Swing parking solenoid No.2 No.8 No.14 No.24
9 24
pressure sensor fail valve fail E/G SET 2420 RELAY PRESS. SENSOR PROPO-VALVE
MEAS 2420 I㧙2 BAT. RELAY C㧙1 PUMP P1 E㧙1 P1 PUMP
Swing pressure Governor motor current 2 E/G PRS. LIVE 8 COMP. OFF 14 3.3V 3.5M 24 COMP. 750mA 3.0M
10 25 KPSS SW H MEAS. OFF C㧙2 PUNP P2 MEAS. 750mA 3.0M
sensor fail fail KEY SWITCH OFF 3.3V 3.5M POWER SHIFT 0mA
Travel right pressure Governor motor starting No.3 No.9 No.15 No.25
12 26
sensor fail point indexing fail H㧙1 PRESS. SENSOR PRESS. SENSOR PROPO-VALVE
ACCEL VOLT. 4.2V B㧙1 BOOM RAISE B㧙16 P1 OPT. E㧙2 P2 PUMP
Travel left pressure 3 POS. 100% 9 4.5V 3.0M 15 3.5V 2.3M 25 COMP. 750mA 3.0M
13 27 Accel potentio meter fail MOTOR STEP 256 B㧙2 BOOM LOWER B㧙17 P2 OPT. MEAS. 750mA 3.0M
sensor fail POS. 100% 4.5V 3.0M 3.5V 2.3M POWER SHIFT 0mA
Gauge clusterψ
Pump P1 pressure No.4 No.10 No.20 No.39
14 28 Mechatro controller
sensor fail GOVERNOR MOTOR PRESS. SENSOR PROPO-VALVE MECHATRO ADJT.
communication failure G㧙1 COIL A 0.9A B㧙3 ARM OUT D㧙1 P1 BYPASS CONT. SW TEST
Pump P2 pressure 4 G㧙1 COIL B 1.0A 10 4.5V 3.0M 20 COMP. 706mA 2.8M 39 CONT. VOL 100%
15 29 Battery relay fail G㧙2 LIMIT OFF B㧙4 ARM IN MEAS. 706mA 2.8M PROG. SW OFF
sensor fail 4.5V 3.0M
30 Draining hyd. pressure No.5 No.11 No.21 No.40

SOL.VALVE PRESS. SENSOR PROPO-VALVE RELEASE SW
F㧙2 SWING-BRAKE B㧙5 BUCKET DIG D㧙2 P2 BYPASS KPSS TEST
5 COMP. OFF 11 4.5V 3.0M 21 COMP. 706mA 2.8M 40 SWING BRAKE OFF
31 Fail drain hyd. pressure MEAS. OFF B㧙6 BUCKET DUNP MEAS. 706mA 2.8M
RELEASE SW OFF 4.5V 3.0M
No.6 No.12 No.22

SOL.VALVE PRESS. SENSOR PROPO-VALVE
F㧙3 1/2-TRAVEL B㧙7 SWING (R) D㧙3 S-TRAVEL
6 COMP. OFF 12 4.5V 3.0M 22 COMP. 513mA 1.7M
MEAS. OFF B㧙8 SWING (L) MEAS. 513mA 1.7M
SWITCH OFF 4.5V 3.0M
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(2)-5
Only arm in motion is slow.
(Service diagnosis No.10)

Arm in operation pressure sensor shows YES To hydraulic
4.0V or over when arm in lever is shifted to
troubleshooting
the full.
NO
Trouble disappears if arm in operation YES Arm in operation pressure
pressure sensor (SE-7) is replaced. sensor (SE-7) is faulty.
NO
Faulty symptom changes if the harness for Harness between arm in
YES
the arm in operation pressure sensor is operation pressure sensor
connected with another pressure sensor. and controller is faulty.
NO
Arm in pilot pressure is approx. 35kgf/cm2
(500psi) or over when arm in lever is shifted
YES
Inspect ATT pilot valve.
to the full.
NO To hydraulic
(2)-6 troubleshooting
Only arm out motion is slow.

Arm out operation pressure sensor shows
YES To hydraulic
4.0V or over when arm out lever is shifted to
troubleshooting
the full.
NO Arm out operation
Trouble disappears if arm out operation YES pressure sensor (SE-8) is
pressure sensor (SE-8) is replaced. faulty.
NO
If the harness for the arm out operation Harness between arm out
YES
pressure sensor is connected another operation pressure sensor
pressure sensor, the pressure sensor gets and controller is faulty.
out of order.
NO
Arm out pilot pressure is approx. 35kgf/cm2
(500psi) or over when arm out lever is
YES
shifted to the full.
NO To hydraulic
(4)-1 troubleshooting
Fine operation of bucket digging and dump motions can not be performed.

Bucket digging (dump) Trouble gets normal if
operation pressure NO connector on P1 bypass NO To hydraulic
sensor shows cut proportional valve troubleshooting.
0.7V or over when (PSV-D) is disconnected.
lever is at neutral.
YES (Service diagnosis No.10)
YES Arm in operation pressure Trouble disappears if arm
sensor (SE-7) shows YES in operation pressure YES Arm in operation pressure
approx. 1.3V or over when sensor (SE-7) is faulty.
sensor (SE-7) is replaced.
lever is at neutral.
NO
NO
Arm in pilot pressure is
6kgf/cm2 (85psi) or over YES
when lever is at neutral.
NO Inspect harness between
arm in operation pressure
sensor (SE-7) and C-1
controller.
Continued on the P9. Continued on the P9.
8
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Auto idling stop (AIS) does not function. (E/G does not stop after an
elapse of 60 seconds after the lock lever was moved upward to locked
ii )
In auto warm-up (OPT)
operation, AIS does not
YES work. Switch warm-up SW
Is WARM-UP displayed?
off or check on it after
NO completion of warming up.
When overheating is
YES detected, AIS does not
Is E/G water temperature work to protect E/G.
warning indicated? Check on it in normal
NO operation condition.
When AIS selector SW is

YES off, it does not work.
Is AIS selector SW off? Switch AIS SW on and
check on it.
NO
Are mechatrocontroller NO Check the line between

16-15 pin and grounding grounding - AIS selector
connected? SW - controller.
YES
Is E/G speed indication on

E/G speed display or Check speed sensor gap, or
Service diagnosis display NO check between controller
normal. (About 2220 rpm and speed sensor for
in high idling, about 1000 continuity.
rpm in low idling)?
YES
Is ATT operation possible
even if the lock lever is YES Adjust or replace lock
moved upward to locked lever limit switch.
position ?
NO
Is 24 V loaded on mechatro
YES Check the line between
controller 17-11 when the
lock lever limit switch and
lock lever is moved upward
controller.
to locked position?
NO
YES Replace fuse, or check the

Is fuse No.15 blown? line around the fuse.
NO
* Is set time (60 seconds) YES

until the AIS is tripped Replace controller.
correct?
NO
*Adjust set time.
NOTE :
1. AIS is Auto Idling Stop.
2. For checking and adjusting method of AIS set time shown by mark *,
contact KOBELCO Field Support Group.
19

E235SR
SECTION 44 TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................. 1
2. TROUBLESHOOTING ............................................................................................... 3
1. TROUBLE DIAGNOSIS ; HYDRAULIC SYSTEM
1
1.2 HYDRAULIC PRESSURE MEASUREMENT BY SERVICE DIAGNOSIS
(1) Main circuit pressure (2) Secondary pilot pressure (3) Solenoid primary pressure (4) Solenoid proportional valve secondary
(Att. operation No.Ԙ㨪ԟ Travel operation 1㨪4) pressure

E/G Hi, E/G Hi, E/G Hi, E/G Hi, E/G Hi, E/G Hi,
Operation is not working In operation
Full lever, at relief No load, at neutral Full lever, at relief No load, at neutral Full lever ೈ operation No load, at neutral

No.14 No.9 No.5 No.20
PRESS. SENSOR Main pump P1,P2 PRESS. SENSOR ི ཱི SOL. VALVE Swing P/B PROPO-VALVE P1 bypass cut
C᧩1 PUMP P1 B᧩1 BOOM RAISE F᧩2 SWING-BRAKE Swing & arm digging D᧩1 P1 BYPASS
3.3V 35M 0. 7V 2.0M 4.5V 3.0M 0. 5V 0M COMP. ON OFF indication COMP. 706mA 2.8M 200mA 0M
5.0M
C᧩1 PUMP P2 B᧩2 BOOM LOWER MEAS. ON OFF indication MEAS. 706mA 2.8M 200mA 0M
3.3V 35M 0. 7V 2.0M 4.5V 3.0M 0. 5V 0M RELEASE SW OFF ON/OFF indication

No.21
No.15 No.10 No.6
PROPO-VALVE P2 bypass cut
PRESS. SENSOR OPT PRESS. SENSOR ྲྀ ཷ SOL. VALVE Travel 2-speed select
D᧩2 P2 BYPASS
B᧩16 P1 OPT. B᧩3 ARM OUT F᧩3 1/2-TRAVEL
COMP. 706mA 2.8M 200mA 0M
3.6V 2.3M 0. 5V 0M 4.5V 3.0M 0. 5V 0M COMP. OFF ON indication
5.0M MEAS. 706mA 2.8M 200mA 0M
B᧩17 P2 OPT. B᧩4 ARM IN MEAS. OFF ON indication

3.6V 2.3M 0. 5V 0M 4.5V 3.0M 0. 5V 0M SWITCH OFF ON/OFF indication
No.22
No.11 No.7 PROPO-VALVE Travel straight
PRESS. SENSOR ཰ ཱ SOL. VALVE Boost pressure select D᧩3 TRAVEL STRAIGHT
z Conversion for pressure
B᧩5 BUCKET DIG F᧩1 POWER UP COMP. 513mA 1.7M 350mA 0.7M
1MPa=10.2kgf/cm2=145psi 4.5V 3.0M 0. 5V 0M COMP. OFF ON indication MEAS. 513mA 1.7M 345mA 0.7M
B᧩6 BUCKET DUMP
5.0M
MEAS. OFF ON indication
4.5V 3.0M 0. 5V 0M SWITCH OFF ON/OFF indication No.23
No.12 PROPO-VALVE Arm variable
PRESS. SENSOR ཱུ ུ D᧩6 A-RECIRCULAT recirculation
B᧩7 SWING (R) COMP. 538mA 1.7M 404mA 1.0M
4.5V 3.0M 0. 5V 0M MEAS. 538mA 1.7M 404mA 1.0M
B᧩8 SWING (L)
4.5V 3.0M 0. 5V 0M No.24
PROPO-VALVE P1 pump
No.13 E᧩1 P1 PUMP
PRESS. SENSOR 1,2 3,4 COMP. 750mA 3.0M 350mA 0.7M
B᧩9 TRAVEL (R)
MEAS. 750mA 3.0M 350mA 0.7M
3.6V 2.3M 0. 5V 0M
POWER SHIFT 0mA
B᧩10 TRAVEL (L)
3.6V 2.3M 0. 5V 0M
No.25
PROPO-VALVE P2 pump
E᧩2 P2 PUMP
COMP. 750mA 3.0M 350mA 0.7M
LH. control lever RH. control lever
MEAS. 750mA 3.0M 350mA 0.7M
Ԝ Swing left Ԙ Bucket digging POWER SHIFT 0mA
ԝ Swing right ԙ Bucket dump

Ԟ Arm in Ԛ Boom up
ԟ Arm out ԛ Boom down
NOTE᧷ೈOPERATION
No.20 ARM OUT or ARM IN RELIEF OPERATION
No.21 BOOM UP RELIEF OPERATION
LH. travel lever RH. travel lever No.22 ARM IN RELIEF OPERATION
3 Travel left reverse 1 Travel right reverse No.23 ARM IN OPERATION LEVER TURNED TO FULL
(At 200mA ARM IN RELIEF)
4 Travel left forward 2 Travel right forward
No.24 DURING BUCKET DIGGING OPERATION
No.25 DURING ARM IN OPERATION
2
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(3)
E/G revolution is faulty.
Check high pressure pipe

and injection nozzle. Check
that compression
Idling not smooth.
pressures in cylinder are
even.
Check injection pump and
Idling is faulty.
̪1
Idling revolution is too
high. Adjust mechatrǒA̍.
Medium revolution is Hunting occurs at medium Check control rack.

faulty. revolution. Replace over governor
spring.
Check that air is not mixed YES

in fuel. Bleed air.
OK
Check that air cleaner is
Check air intake system. not clogged.
OK
Check fuel gauge, water
separator and gauze filter.
Check fuel feed system.
Check also that poor
OK quality fuel is not used.
High revolution is faulty.
Check injection nozzle,

injection pump and
injection timing.
E/G does not reach max.

revolution. ̪1
Adjust mechatrǒA̍.
Max revolution is too high.
Checking condition ; E/G water temperature is more than 50r5͠ (122r12q

F).
̪1 ; Refer to Electric Troubleshooting.
5
(6)
E/G output is insufficient.

Check that E/G water OK
temperature lamp is on and Check the contents of
Overheat
that buzzer sounds. work.
NO
Check E/G water
temperature switch, gauge
Inspect electric system.
cluster, electric wiring and
OK connectors.
Check coolant level. Check

that fan belt does not slip.
Check cooling system.
Check thermostat.
OK Also check that radiator.
Oil cooler is not clogged.
Check that poor quality

Check fuel system.
fuel is not used.
OK
Check E/G oil system. Check E/G oil filter.
Check air intake Check that air filter clogged OK Check that air cleaner is
system. display of warning not clogged.
OK
Check fuel feed Check that air is not mixed in
system fuel. Bleed air.
OK OK
Check water separator and Check feed pump
gauze filter. Check also that performance, injection
poor quality fuel is not used. pump, injection nozzle and
injection timing.
Check viscosity of E/G oil if it

Check E/G oil. is suited to ambient Replace engineoil.
temperature.
OK
Check compression
Check that blowby gas is not pressure and valve
much, that gas does not leak clearance. Check that
Check engine
from gasket, and that engine valve spring is not
itself.
oil goes into combustion fatigued. Check that
chamber. control rack moves
smoothly. Check that
Checking condition ; High idling piston ring is not worn.
Check also that head
gasket is not faulty
(7)
Knocking occurs after warming-up E/G.
Check that poor quality fuel is

Check fuelsystem. not used. Replace fuel.
Check that engine oil does not Judge it if oil is there on

Check E/G itself. rise. exhaust port.
OK
Check that blowby gas is not Check compression
much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.
Checking condition ; E/G water temperature is more than 50r5͠(122r12q

F).
6
(8)
Exhaust is abnormal.
Check that air cleaner is not

Exhaust gas is black. clogged. Replace air element.
OK
Check engine oil viscosity.
Check that engine oil is not too
much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is not
fatigued and that piston ring is
not faulty.
Check that water is not mixed

Exhaust gas is white. in fuel. Check water separator.
OK
Check that engine oil goes
into combustion chamber. Check compression pressure
Blowby gas is much. A lot of and injection timing.
gas leaks from gasket.
Checking condition ; Engine water temperature is more than 50r5͠ (122r12q

F).
(9)
Excessive oil consumption.
Check that engine oil is not Check leakage by checking the Retighten.
leaking. ground under E/G or an oil Replace packing and seal.
(Check that engine oil is not OK
filled up too much.) Check that breather hose is not
bent or clogged. Replace breather hose.
OK
Replace fuel.
not used.
OK
Check viscosity of engine oil. Replace engine oil.
OK Check that; CR shaft oil seal is

Check that engine oil goes into not faulty, piston liner is not
Checking condition ; No engine oil leaks. combustion chamber. worn, or piston ring is not
worn.
(10)
Excessive fuel consumption.

Check fuel leakage. not used. Advise to replace fuel.
OK
Blowby gas is much.
Check that gas does not leak Check nozzle function.
from gasket.
OK
Check injection timing.
Check compression pressure.

Checking condition ; Use proper fuel.
7
(11)
E/G does not stop Confirm governor Check if governor Check that governor
motor link
when starter key is lever stop bolt motor is not faulty
connecting bolts are
turned off. position. mechanically.
not loose.
OK Wire No. 60 white /
Check resistance
blue line of
Check that terminal NG between terminals Replace starter key
instrument panel
M of starter key M and B of starter if resistance across
right harness
switch shows 0V. key M and B is 0ǡ.
CN-401F shows 0V.
OK

Check that battery Wire No.700 white
relay terminal B2 /green of upper
Does 72ǡ alive
NG between the terminal
measures 0V four harness battery relay Check C1 controller.
11-1 and 14-22 of C1
seconds after key is connector CN-103F
controller.
turned off. measures 0V.

OK If resistance is 0ǡ,

replace C1 controller.
(12) (See Fig.1.)
When starter key is Does battery YES
turned to OFF, Check that battery Replace battery
power is not cut off. terminals between A
relay operates. relay.
and B measure 0ǡ.

Checking condition ; Starter key is ON.
CN-152F
TERMINAL A1 LOCK
Flowing direction of
main current
TERMINAL A1,A B,B1 TERMINAL

A A TERMINAL B1
FLW FLW
2.0sq 2.0sq TERMINAL A VIEW Σ
FLW2.0sq
TERMINAL B
GW B2 FLW2.0sq
L P COIL
WG
H COIL
BRACKET GROUND
TERMINAL B2
Circuit diagram
L TERMINAL WG
L TERMINAL Σ
AVS1,25L B2 TERMINAL
AVS1,25G
GROUND CABLE
GROUNDING
AVS1,25B
TERMINAL
Fig. 1 Battery relay CN-150M
Fig. 2 Key SW. terminal
8
E235SR
SECTION 51 ENGINE
TABLE OF CONTENTS
0. SUPPLEMENTARY SHOP MANUAL
1. GENERAL ............................................................................................................... 00
2. ENGINE ................................................................................................................... 11
3. LUBRICATION ......................................................................................................... 12
4. FUEL AND ENGINE CONTROL .............................................................................. 13
5. COOLING ................................................................................................................ 14
6. INTAKE AND EXHAUST .......................................................................................... 15
7. ELECTRICAL SYSTEM ........................................................................................... 54

E235SR
SECTION 63 MOUNTING THE BREAKER AND NIBBLER & BREAKER
TABLE OF CONTENTS
1. LIST OF ADDITIONAL PARTS ............................................................................... 1-1
2. SUMMARY
2.1 General Precautions ....................................................................................................................... 2-1
2.2 Basic Method to be Taken when Mounting ...................................................................................... 2-1
2.3 Laying of Piping .............................................................................................................................. 2-2
3. HYDRAULIC CIRCUIT DIAGRAM

3.1 Operation ........................................................................................................................................ 3-1
3.2 Hydraulic Components ................................................................................................................... 3-6
4. ELECTRIC SYSTEM DIAGRAM FOR NIBBLER & BREAKER ............................. 4-1
5. PRECAUTIONS FOR MODIFICATION .................................................................. 5-1
6. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER

6.1 Modification Item ............................................................................................................................. 6-1
6.2 Floor Mat ........................................................................................................................................ 6-1
6.3 Install of the Cab Guard .................................................................................................................. 6-2
6.4 Modification of the Control Valve ..................................................................................................... 6-3
6.5 Replacement of Return Filter of Hydraulic Tank .............................................................................. 6-4
6.6 Control Piping ................................................................................................................................. 6-6
6.7 Upper Hydraulic Piping ................................................................................................................... 6-8
6.8 Install of the Name Plate (N&B) .................................................................................................... 6-11
6.9 Modification of the Instument Panel (Nibbler & Breaker) ............................................................... 6-12
7.MODIFICATION PROCEDUREFOR BREAKER

7.1 Modification Item ............................................................................................................................. 7-1
7.2 Floor Mat ........................................................................................................................................ 7-1
7.3 Control Piping ................................................................................................................................. 7-2
7.4 Upper Hydraulic Piping ................................................................................................................... 7-5
8. MODIFICATION PROCEDURE FOR ATTACHMENT

8.1 Modification Item for Breaker, Nibbler & Breaker Attachment .......................................................... 8-1
8.2 Modification of the 5.65m (18ft-6in) Boom ...................................................................................... 8-2
INDEX
8.3 Hydraulic Piping for 5.65m (18ft-6in) Boom (Breaker, Nibbler & Breaker) ....................................... 8-3
8.4 Modification of the 2.94m (9ft-8in) Arm ........................................................................................... 8-5
8.5 Modification of the 3.33m (10ft-11in) (Long Arm (Breaker) ............................................................. 8-6
8.6 2.94m (9ft-8in) Std Arm Hydraulic Piping (Breaker, Nibbler & Breaker) .......................................... 8-7
8.7.1 Connector Assy (Breaker) ........................................................................................................... 8-9
8.7.2 Connector Assy (Nibbler) ........................................................................................................... 8-10
8.8 Reinforcing the Idler Link (Breaker, Nibbler & Breaker) ................................................................. 8-10
9. REMINDERS ON THE USE OF NIBBLER & BREAKER

9.1 Changing Over the Selector Valve .................................................................................................. 9-1
9.2 Flushing Method ............................................................................................................................. 9-2
9.3 Replacing Hydraulic Oil and Return Filter ....................................................................................... 9-2
9.4 Operating Procedure ...................................................................................................................... 9-2
10. PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT

MANUFACTURERS ............................................................................................ 10-1
11. REFERENCE ..................................................................................................... 11-1

1. LIST OF ADDITIONAL PARTS
How to utilize the list of additional modification parts
This manual describes the parts which are added and canceled on the basis of ̌Parts Manual̍ for
standard machines when the machine is modified into the machines equipped with breaker.
The manual consists roughly of three sections : Oceania, EU and KAI. Each of the section is divided into
five parts, 1. Upper structure, 2. Boom, 3. 2.94m (9̡8̢) arm, and 3.33m (10̡11̢) arm, 4. Connector, 5.
Idler link, each being assigned a kit number. The cab guard should be ordered optionally. In the case of
the arm, select a kit No. suited for the length of arm and attachment (Nibbler, Breaker) for ordering.
1.1 COMPARISON TABLE FOR KIT AND ASSY NO. BY COUNTRY

(1) NIBBLER & BREAKER
Classifi
-cation NAME
Since the cab guard is an option, it is not
assigned a kit No.
Cab
• 1 Guard assy
• 2 Guards assy
Upper structure modification kit No.

• Modification of the control valve
• Modification of the hydraulic tank
(1) Upper
• Remote control piping

• Block control piping
• Upper hydraulic piping
• Modification of the instrument panel
• Install of the name plate
Boom modification kit No.

(2) Boom
• 5.65M (18̡6̢) Boom

• 5.65M (18̡6̢) Boom hydraulic piping
(3㧙1) Arm
2.94M (9̡8̢) STD Arm modification kit No.

(STD)
• 2.94M (9̡8̢) STD Arm N&B

• 2.94M (9̡8̢) STD Arm hydraulic piping
(3㧙2) Arm
3.33M (10̡11̢) Long Arm modification kit No.

(Long)
• 3.33M (10̡11̢) Long Arm B

• 3.33M (10̡11̢) Long Arm hyd. piping. B
Connector
No kit No. is given because it is provided after selection

(4)
• Connector assy (See page 7㧙11)

(5) Idler link
No kit No. is given because only one sort of part is provided

• Idler link (Left)
• Idler link (Right)
1㧙1
(2) BREAKER
Classifi
-cation NAME
Since the cab guard is an option, it is not
assigned a kit No.
Cab
• 1 Guard assy
• 2 Guards assy
Upper structure modification kit No.

• Modification of the control valve
(1) Upper
• Modification of the hydraulic tank

• Remote control piping
• Block control piping
• Upper hydraulic piping
Boom modification kit No.

(2) Boom
• 5.65M (18̡6̢) Boom

• 5.65M (18̡6̢) Boom hydraulic piping
(3㧙1) Arm
2.94M (9̡8̢) STD Arm modification kit No.

(STD)
• 2.94M (9̡8̢) STD Arm N&B

• 2.94M (9̡8̢) STD Arm hydraulic piping
(3㧙2) Arm
3.33M (10̡
11̢
) Long Arm modification kit No.
(Long)
• 3.33M (10̡11̢) Long Arm B

• 3.33M (10̡11̢) Long Arm hyd. piping. B
(5) Idler link (4) Connector
No kit No. is given because it is provided after selection

• Connector assy (See page 7㧙11)
No kit No. is given because only one sort of part is provided

• Idler link (Left)
• Idler link (Right)
1㧙2

CAB GUARD NIBBLER & BREAKER N&B.

Applicable
No. NAME Q’TY REMARK Machines
Since the cab guard is an option,
it is not assigned a kit No.
x 1 GUARD ASSY
135 x x CAB ASSY 1
135-2 x x x PLATE ASSY 2
135-3 x x x PLATE 2
141 x x GUARD 1
181 x x SEMS BOLT 4
x 2 GUARDS ASSY
137 x x CAB ASSY 1
137-3 x x x PLATE 2
141 x x GUARD 1
142 x x GUARD 1
181 x x SEMS BOLT 8
(1) UPPER STRUCTURE NIBBLER & BREAKER N&B.

Applicable
‫ڈ‬,C Upper structure modification kit No. NIBBLER & BREAKER
x MODIFICATION OF THE HYDRAULIC TANK

17-100 x x REPAIR KIT 1
1㧙3
N&B.
Applicable
• REMOTE CONTROL PIPING
1 • • HOSE 1
2 • • HOSE 1
3 • • HOSE 1
4 • • HOSE 1
5 • • PIN 1
6 • • LOCK ASSY 1
7 • • PEDAL 1
8 • • RUBBER 1
9 • • PILOT VALVE 1
10 • • CONNECTOR 2
11 • • PLUG 1
12 • • PRESS SENSOR 1
13 • • ELBOW 3
14 • • ELBOW 1
17 • • CAPSCREW 2
18 • • WASHER 3
19 • • WASHER 4
20 • • NUT 1
21 • • LOCK WASHER 2
32 • • ELBOW 1
37 • • PLATE 1
• BLOCK CONTROL PIPING

4 • • ELBOW 1
11 • • TEE 1
13 • • ELBOW 1
• UPPER HYDRAULIC PIPING

1 • • O RING 2
2 • • WASHER 4
3 • • SUPPORT 1
5 • • WASHER 6
6 • • TUBE 1
7 • • TUBE 1
8 • • TUBE 1
9 • • HOSE 1
10 • • ELBOW 1
11 • • ELBOW 1
12 • • SELECTOR VALVE 1
13 • • CLAMP 2
14 • • HALF CLAMP 4
15 • • O RING 2
20 • • BRACKET 1
1㧙4

N&B.
Applicable
21 • • ELBOW 1
22 • • HOSE 1
24 • • ELBOW 1
26 • • O RING 3
27 • • PLATE 2
• NAME PLATE INSTALL

20 • • LABEL 1
21 • • LABEL 1
22 • • LABEL 1
• MODIFICATION OF THE INSTRUMENT PANEL

39 • • SWITCH (SINGLE/CONFLUX) 1
(2) BOOM BREAKER, NIBBLER & BREAKER B,N&B.

Applicable
ճ Boom modification kit No.
• 5.65M (18´6˝ ) BOOM ASSY

1 • • 5.65M (18´6˝ ) BOOM ASSY (1) With bushing
2 • • TAPPED BLOCK 4
• 5.65M (18´6˝ ) BOOM HYDRAULIC PIPING

1 • • TUBE 1
2 • • TUBE 1
3 • • TUBE 1
4 • • TUBE 1
5 • • PLUG 2
6 • • HOSE 2
7 • • O RING 2
8 • • O RING 2
9 • • O RING 2
10 • • CLAMP 2
11 • • CLAMP 3
12 • • CLAMP 5
13 • • CLAMP 1
24 • • CLIP 1
26 • • ELBOW 2
1㧙5

(3-1) 2.94M (9´8˝ ) STD ARM NIBBLER & BREAKER N&B.

Applicable
ն 2.94M (9´8˝) STD Arm modification kit No.
x 2.94M (9´8˝ ) STD ARM ASSY

1 x x 2.94M (9´8˝ ) STD ARM ASSY (1) With bushing
2 x x TAPPED BLOCK 2
4 x x PLATE 1
5 x x PLATE 1
6 x x PLATE 1
x 2.94M (9´8˝ ) STD ARM HYDRAULIC PIPING

2 x x TUBE 1
3 x x TUBE 1
4 x x HOSE 1
5 x x HOSE 1
6 x x STOP VALVE 2
7 x x CONNECTOR 2
8 x x HALF CLAMP 2
9 x x HALF CLAMP 2
10 x x BRACKET 2
11 x x CLAMP 4
12 x x CLAMP 4
13 x x CAPSCREW 8
14 x x CAPSCREW 8
15 x x CAPSCREW 4
16 x x CAPSCREW 4
17 x x CAPSCREW 4
18 x x WASHER 8
19 x x LOCK WASHER 4
20 x x WASHER 8
21 x x WASHER 4
24 x x BUSHING 2
25 x x BUSHING 2
26 x x O RING 1
27 x x O RING 1
28 x x O RING 2
29 x x WASHER 8
(3-2) 3.33M (10´11˝ ) LONG ARM BREAKER

Applicable
չ 3.33M (10´11˝ ) Long Arm modification kit No.
x 3.33M (10´11˝ ) LONG ARM ASSY

1 x 3.33M (10´11˝ ) LONG ARM ASSY (1) With bushing
2 x x PLATE 1
3 x x PLATE 1
4 x x PLATE 1
1㧙6

No. Applicable
NAME Q’TY REMARK Machines
x 3.33M (10´11˝ ) LONG ARM HYDRAULIC PIPING
1 x x TUBE 1
2 x x TUBE 1
3 x x HOSE 1
4 x x HOSE 1
5 x x STOP VALVE 2
6 x x CONNECTOR 2
7 x x HALF CLAMP 2
8 x x HALF CLAMP 2
9 x x BRACKET 2
10 x x CLAMP 4
11 x x CLAMP 4
12 x x CAPSCREW 8
13 x x CAPSCREW 8
14 x x CAPSCREW 4
15 x x CAPSCREW 4
16 x x CAPSCREW 4
17 x x WASHER 8
19 x x WASHER 8
20 x x WASHER 4
23 x x BUSHING 2
24 x x BUSHING 2
25 x x O RING 1
26 x x O RING 1
27 x x O RING 2
28 x x WASHER 8
4) CONNECTOR ASSY NIBBLER & BREAKER N&B.

Applicable
No kit No. is given because it is provided after selection ̆
x CONNECTOR ASSY 㧙 NPK

x CONNECTOR ASSY 㧙 TOKU࡮KRUPP Select
x CONNECTOR ASSY 㧙 NIBBLER
5) REINFORCING THE IDLER LINK NIBBLER & BREAKER N&B.

Applicable
No kit No. is given because only one sort of part is provided ̆
x IDLER LINK (Right) 1

x IDLER LINK (Left) 1
0 x x IDLER LINK (1) (Right)
0 x x IDLER LINK (1) (Left)
1 x x PLATE 1 (Right)
1 x x PLATE 1 (Left)
1㧙7

1.3 ADDITIONAL PARTS FOR THE MODIFICATION OF THE NIBBLER & BREAKER
CAB GUARD BREAKER BREAKER

Applicable
Since the cab guard is an option,
it is not assigned a kit No.
x 1 GUARD ASSY
135 x x CAB ASSY 1
135-3 x x x PLATE 2
141 x x GUARD 1
181 x x SEMS BOLT 4
x 2 GUARDS ASSY
137 x x CAB ASSY 1
137-3 x x x PLATE 2
141 x x GUARD 1
142 x x GUARD 1
181 x x SEMS BOLT 8
1㧙8

1) UPPER STRUCTURE BREAKER BREAKER

Applicable
Upper structure modification kit No. BREAKER
x MODIFICATION OF THE HYDRAULIC TANK

17-100 x x REPAIR KIT 1
x REMOTE CONTROL PIPING

2 x x HOSE 1
4 x x HOSE 1
5 x x PIN 1
6 x x LOCK ASSY 1
12 x x PRESS SENSOR 1
13 x x ELBOW 1
15 x x CAPSCREW 2
18 x x WASHER 3
20 x x NUT 1
29 x x CONNECTOR 1
32 x x ELBOW 1
45 x x HOSE 1
46 x x HOSE 1
47 x x WASHER 1
48 x x CAPSCREW 2
49 x x WASHER 2
50 x x BRACKET 1
51 x x PIN 1
52 x x PIN 1
53 x x CONNECTOR 1
54 x x TEE 1
55 x x ELBOW 1
56 x x ELBOW 1
57 x x CUSHION RUBBER 1
58 x x PEDAL 1
59 x x COVER 1
60 x x PLATE 2
61 x x PILOT VALVE 1
62 x x CONNECTOR 2
63 x x TEE 1
65 x x TUBE 1
x BLOCK CONTROL PIPING

4 x x ELBOW 1
10 x x CONNECTOR 1
11 x x ELBOW 1
13 x x ELBOW 1
14 x x TEE 1
20 x x ELBOW 1
1㧙9

BREAKER
Applicable
1 • UPPER HYDRAULIC PIPING
2 • • TUBE 1
3 • • TUBE 1
4 • • PLUG 1
5 • • HOSE 1
6 • • ELBOW 1
7 • • CLAMP 2
8 • • CLAMP 2
11 • • O RING 2
12 • • SUPPORT 1
17 • • WASHER 8
21 • • SUPPORT 1
23 • • ELBOW 1
25 • • O RING 2
26 • • PLATE 2
1㧙10
2. SUMMARY
2.1 GENERAL PRECAUTIONS (3) Action of the single / conflux flow spool :
(1) Modifying a Nibbler & Breaker The single/conflux flow select switch is
There are specific procedures to be followed provided on the instrument panel and is
when modifying a nibbler & breaker. connected to the harness to actuate the
Therefore, when they are to be modified at single/conflux flow select spool.
our service shop, contact the nearest breaker
and nibbler manufacturer’s office, and obtain (4) Installing the operation panel :
instructions, so that you install the pipes and A pedal and a pilot valve are mounted to the
handle the machinery correctly. floor plate and a remote control piping is
placed between the option valves and pedal,
(2) Differences between a Nibbler and Breaker in order to operate the breaker or the nibbler.
Piping
(5) Installing the selector valve :
z Nibbler Piping For the machines equipped with nibbler and
The oil flows to the nibbler is conflux breaker, the selector valve which functions to
flow ; the oil flow is changed to the change the oil flow direction according to the
rod and the head of the nibbler use of breaker or nibbler is provided on the
cylinder. main control valve in the inside of guard on
the right side of slewing motor.
2.2 BASIC METHOD TO BE TAKEN WHEN
MOUNTING (6) Reinforcement of the attachment :
When mounting the breaker or nibbler, Reinforcement plates are welded to the
always execute the following seven items : standard arm (civil engineering services : for
general use) and to the idler links of the
(1) Specification prescribed for EU breaker and nibbler & breaker attached
For specifications for nibbler & breaker, machine.
the modification of control valve is not
required. (7) Replace the return filter with new standard
filter.
(2) Functions of the option valve :
The option valve is equipped with spool which
functions to send the pressure oil into nibbler
and breaker, and also to switch the flow
direction to the rod side or head side of the
nibbler cylinder.
2㧙1
2.3 LAYING OF PIPING
(1) Nibbler & Breaker specification
7.1.5 7.1.1
ARM HYDRAULIC BOOM
PIPING
7.1.2
HYDRAULIC PIPING FOR BOOM
6.8
UPPER HYDRAULIC PIPING
7.1.5 RETURN HYDRAULIC PIPING
STOP VALVE
6.3 6.6
CAB GUARD FILTER FOR
BREAKER 6.8
SELECTOR VALVE
7.1.3 or 7.1.4
ARM
6.5
HYDRAULIC 7.1.7 OPTION VALVE
BREAKER ARM TOP (ADD-ON VALVE)
PIPING
Replacing the
6.5
breaker with 6.7.1
the nibbler is MAIN
possible. OPERATING CONTROL
PEDAL
6.10
6.2 FLOOR MAT 6.7
UPPER
REMOTE
HARNESS
6.4 UPPER FRAME CONTROL
PIPING
6.9 SINGLE / CONFLUX FLOW SELECT SWITCH
Fig. 1 Outside view of Nibbler & Breaker-attached machine
2㧙2
3. HYDRAULIC CIRCUIT
DIAGRAM BREAKER SPEC.
No.
NAME

50 P2 OPT. CONTROL VALVE

51 STOP VALVE

52 PILOT VALVE

53 RETURN FILTER

P1 MAIN

CIRCUIT NOTE :
P2 MAIN
CIRCUIT
1 This hydraulic circuit is used by adding to the STD
TRAVEL circuit diagram.
STRAIGHT VALVE
2 Return filter of number 53 shows before modification.
After modification, the filter that is available for
N&B is equipped as standard.
3.1 OPERATION
3.1.1 HYDRAULIC CIRCUIT FOR BREAKER
P2 BYPASS (1) Pilot circuit
CIRCUIT
1) If the breaker pedal is depressed, the
secondary pilot pressure acts upon the PBo2
P2 PARALLEL port of the option valve on the P2 side and
CIRCUIT
changes over the option spool.
2) Concurrently, the voltage output from the
low-pressure sensor (SE-11) is put into the
mechatro controller where pilot signal
processing takes place.
The mechatro controller then puts out
current commands to the P2 bypass cut
proportional valve and the P2 pump
P1 BYPASS CUT P2 BYPASS CUT
proportional valve, according to the value of
the voltage inputs, to switch over the P2
bypass cut spool and change the delivery rate
of the P2 pump.
(2) Main circuit

1) The oil delivered by the P2 pump flows into
the bypass circuit from the main circuit on
the P2 side. However, since it is shut off by
the P2 bypass cut spool that is shiftted, the
oil pushes the load check valve CP2 open and
flows into the parallel circuit on the P2 side.
2) The oil from P2 parallel circuit flows into P2
option valve, and open the load check valve,
but P2 option spool is shifted, so the oil flows
NOTE :
out from Bo2 port and becomes the blowing
1. Adjust the pressure of the port relief valve in the option valve on the P2 side, according to the
power of breaker.
specifications of the breaker to be mounted to the machine.
3) The oil that returns from the breaker returns
directly to the oil tank via the return filter (53).
Fig. 3-1 Hydraulic diagram for Breaker

3㧙1
3.1.2 NIBBLER & BREAKER CIRCUIT
Set the single/conflux flow select switch,
according to the specifications of the nibbler to be
used.
(1) Single flow for nibbler:

1) Pilot circuit z Concurrently, the secondary pilot pressure
z Change the single/conflux flow select switch enters the low-pressure sensor (SE-11) from
to single. the C2 port. The voltage output from the
z Depress the pilot valve (53) for the Nibbler & pressure sensor enters the mechatro
Breaker on your tiptoe. Then the secondary controller where pilot signal processing takes
pilot pressure enters the PAo2 port of the place. The mechatro controller then puts out
control valve from the B port and changes current commands according to the voltage
over the spool of the option valve (50). inputs to the proportional valves for the P1
z Concurrently, the secondary pilot pressure pump, the P2 pump, the P1 bypass cut
enters the low-pressure sensor (SE-11) from proportional valve and the travel straight
the C2 port. The voltage output of the proportional valve.
pressure sensor enters the mechatro z The P1 and P2 pump proportional valves put
controller where pilot signal processing takes out secondary pressure to the pump
place. The mechatro controller then puts out regulators to change delivery rates of the
current commands, according to the voltage pumps.
inputs, to the P2 pump and the P2 bypass cut z The P1 cut proportional valve puts out
proportional valve. secondary pressure to the PCb port of the
control valve and switches the P1 bypass cut
z The P2 pump proportional valve puts out spool.
secondary pressure to the pump regulator to z The P2 cut proportional valve puts out
change the delivery rate of the P2 pump. secondary pressure to the PCa port of the
z The P2 bypass cut proportional valve puts out control valve and switches the P2 bypass cut
secondary pressure to the PCa port of the spool.
control valve and switches the P2 bypass cut z The travel straight proportional valve puts
spool. out secondary pressure to the PTb port of the
control valve and switches the travel straight
2) Main circuit spool.
z The oil delivered by the P2 pump flows into
the bypass circuit on the P2 side from the 2) Main circuit
main circuit on the P2 side. However, since z The oil delivered by the P1 pump enters the
the P2 cut spool has been switched, the oil control valve, but since the travel straight
pushes open the load check valve (CP2) and spool and the P1 bypass cut spool have been
flows into the parallel circuit on the P2 side. switched, the oil pushes the load check valve
z The oil pushes open the load check valve of (CT2) open and flows into the P2 parallel
the option valve (50), passes through the circuit.
spool, is supplied to the head of the nibbler z The oil delivered by the P2 pump enters the
cylinder via the Ao2 port, and causes the control valve, but since the travel straight
nibbler to make closing motions. valve spool, the P1 and P2 bypass cut spools
z The oil that comes back from the nibbler have been switched, the oil pushes the load
cylinder rod returns to the oil tank via the check valve (CP2) open, flows into the P2
Bo2 port of the control valve, the spool and parallel circuit, and combines with the oil
the oil cooler. delivered by the P1 pump.
z The oil pushes open the load check valve in
(2) Conflux circuit for nibbler the option valve (50), is fed to the head of the
1) Pilot circuit nibbler cylinder via the spool and the Ao2
z Change the single/conflux flow select switch port, and causes the nibbler to take close
to conflux. action.
z Depress the pedal of pilot valve (52) for the z The oil that comes back from the rod of the
Nibbler & Breaker on your tiptoe. Then nibbler cylinder returns to the oil tank via
secondary pilot pressure enters the PAo2 port the Bo2 port of the control valve, the spool
of the control valve from the B port and and the oil cooler.
3㧙2
NIBBLER & BREAKER SPEC.

No. NAME

50 P2 OPT. CONTROL VALVE

51 SELECTOR VALVE

52 STOP VALVE
53 PILOT VALVE
54 RETURN FILTER

P2 MAIN
CIRCUIT
TRAVEL
NOTE :
STRAIGHT VALVE 1 This hydraulic circuit is used by adding to the STD
circuit diagram.
2 Return filter of number 54 shows before modification.
After modification, the filter that is available for
N&B is equipped as standard.

P2 BYPASS
P1 BYPASS CIRCUIT
CIRCUIT
P2 PARALLEL
CIRCUIT
P1 PARALLEL
CIRCUIT
z Mark of selector valve (item 51) N : Nibbler, B : Breaker z When using nibbler, according to specification of nibbler installed,
z When using breaker, set B select valve (item 51) to return to hydraulic choose conflux or single flow by conflux flow select switch.
tank directly hydraulic oil from breaker. z Adjust the pressure of the port relief valve in the option valve,
z Selection condition and proportional valve command when any of according to the specifications of the nibbler to be mounted to the
nibbler single & conflux flow or breaker is servise. machine.
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION (W : ‫ޚ‬, W/‫ ޚ‬: ̆)
CONFLUX /SINGLE SELECTOR TRAVEL
VALVE P1 PUMP P2 PUMP STRAIGHT P1 CUT P2 CUT
SELECT SW. (ITEM 51)
NIBBLER CONFLUX CONFLUX ON N ٤ ٤ ٤ ٤ ٤

NIBBLER SINGLE CONFLUX OFF N ̆ ٤ ̆ ̆ ٤
BREAKER CONFLUX OFF B ̆ ٤ ̆ ̆ ٤
Fig. 3-2 Hydraulic diagram for Nibbler & Breaker at nibbler operating
3㧙3
(3) Breaker
z Exchange the return filter in the oil tank
with the filter for the breaker.
z Bring the selector valve (51) to the B position
so as to return the oil from the breaker
directly to the oil tank.
z Adjust the pressure of the port relief valve in
the option valve, according to the
specifications of the breaker to be mounted to
the machine.
1) Pilot circuit
z If the operating pedal (53) for the Nibbler &
Breaker is depressed on your heel, secondary
pilot pressure enters the PBo2 port of the
control valve from the A port and switches
the spool of the option valve.
z Concurrently, the secondary pilot pressure
enters the low-pressure sensor (SE-11) from
the C2 port. The voltage output from the
pressure sensor enters the mechatro
controller where pilot signal processing takes
place. The mechatro controller then puts out
current commands according to the voltage
inputs, to the P2 pump and P2 bypass cut
proportional valves.
z The proportional valve for the P2 pump puts
out secondary pressure to the pump regulator
to change the delivery rate of it.
z The P2 bypass cut proportional valve puts out
secondary pressure to the PCa port of the
control valve and changes over the P2 bypass
cut spool.
2) Main circuit
z The oil delivered by the P2 pump flows into
the main circuit on the P2 side, but since the
P2 bypass cut spool has been switched, the oil
pushes the load check valve (CP2) open and
flows into the parallel circuit on the P2 side.
z The oil pushes open the load check valve in
the option valve (50), is fed to the breaker via
the spool and the Bo2 port, and causes the
breaker to make blow action.
z The oil that comes back from the breaker
returns directly to the oil tank, without
passing through the control valve, because
the selector valve (51) has been switched.
3㧙4
NIBBLER & BREAKER
SPEC.
No. NAME

50 P2 OPT. CONTROL
VALVE
51 SELECTOR VALVE

52 STOP VALVE

53 PILOT VALVE

54 RETURN FILTER
P2 MAIN
CIRCUIT
TRAVEL
STRAIGHT VALVE
P2 BYPASS
CIRCUIT
P2 PARALLEL
CIRCUIT
P2 BYPASS CUT
Fig. 3-3 Hydraulic diagram for Nibbler & Breaker at nibbler operating
3㧙5
3.2 HYDRAULIC COMPONENTS
3.2.1 CONTROL VALVE ASSY

OPTION VALVE

(BREAKER, NIBBLER & BREAKER)
50
4-∅13 drill through
HYDRAULIC CIRCUIT
Fig.3-4 Control valve (Breaker, Nibbler & Breaker)
3㧙6
3.2.3 PILOT VALVE 4. ELECTRIC SYSTEM DIAGRAM FOR NIBBLER & BREAKER
(1) Pilot valve

SECONDARY
PRESSURE OPERATING TORQUE
SECONDARY PRESSURE
OPERATING FORCE
CIRCUIT DIAGRAM STROKE
CONTROL DIAGRAM
Fig. 3-5 Pilot valve (Breaker)
(2) Pilot valve
CIRCUIT DIAGRAM
SECONDARY
PRESSURE OPERATING TORQUE
Fig. 4-1 Single / Conflux flow select switch
SECONDARY PRESSURE
OPERATING FORCE
4-PF1/4 OPERATING ANGLE

JISB2351 O
CONTROL DIAGRAM
2-∅11 THROUGH
Fig. 3-6 Pilot valve (Nibbler & Breaker)
3㧙7 4㧙1
5. PRECAUTIONS FOR MODIFICATION
5.1 GENERAL PRECAUTIONS 5.3 WELDING
1) Before starting the modification work, check 1) Use symbol B welding rods (mild steel 50kg
parts according to the Additional Parts List. grade).
2) When disconnecting and reconnecting pipes, 2) Seal the unwelded areas of the tapped block.
take care, so as not to allow dirt and foreign
matter to enter.
3) At assembly, use care of O rings do not come
off.
4) Apply Locktite #242 to the clamp mounting
bolts.
5.2 TIGHTENING TORQUE

5.2.1 CAPSCREW & SOCKET BOLT
Capscrew (10T)
Thread size Spanner Tightening torque
(mm) kgfym (ftylbs)
M8 13 3.6r0.4 (26r2.9)
M10 17 7.2r0.7 (52r5.1)
M12 19 12.3r1.2 (89r8.7)
M12 10 8.5r0.5 (61r3.6)
(Socket)
M14 22 18.5r2.0 (130r14)
5.2.2 COUPLING & FLARE HOSE

Hydraulic hose
O ring type coupling (30qflare)
Thread size Spanner Tightening torque Tightening torque
(mm) kgfym (ftylbs) kgfym (ftylbs)
1/4 19 3.7r0.2 (27r1.4) 3.0r0.5 (22r3.6)
3/8 22 7.5r0.5 (54r3.6)
3/4 36 16.5r1.5 (120r11)
1 41 26r1.0 (190r7.2) 14r1.5 (100r1.5)
5.2.3 ORS HOSE
Hydraulic hose
(ORS type)
Thread size Spanner Tightening torque
(mm) kgfym (ftylbs)
13/16-12UN 36 18r1.8 (130r13)
17/16-12UN 41 21r2.1 (150r15)
5㧙1
6. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER
6.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a nibbler &
breaker-mounted machine are as follows :
Table 6-1

Main items to be
No. ITEM
added and change

6.2 Modification of the floor mat Floor mat

Install of the 1 Guard Bracket
6.3 cab guard
2 Guards Guard
Option valve
6.4 Modification of the control valve Capscrew
6.5 Modification of the hydraulic tank Replace return filter
Remote
Remote control piping Pilot valve, Pedal
6.6 control and block piping Hose, Elbow
piping
Hose,
6.7 Upper hydraulic piping Selector valve
6.8 Modification of the instrument panel Switch

6.9 Install of the name plate Label

CUT OUT
6.2 FLOOR MAT (NIBBLER & BREAKER)
Make slits to face of the standard floor mat
according to Fig. 1 and cut out the hatching.
Floor mat for nibbler & breaker ;
Fig. 6-1 Modification of floor mat
6㧙1
6.3 INSTALL OF THE CAB GUARD
6.3.1 WITH 1 GUARD, 2 GUARDS
Install the edditional parts listed in table 6-2 to the
cab of the standard machine, as shown Fig. 6-2, 6-3. 137 : Modification of cab with 2 guard
135 : Modification of cab with 1 guard
Table 6-2 181

(F5)
CAB 1 GUARD
ASSY 2 GUARDS
No. NAME Q’TY REMARK
135 CAB ASSY 1 㧙 142

135-2 PLATE ASSY 2 㧙 (F5)
135-3 PLATE 2 㧙
135-4 PLATE ASSY 1 㧙
135-5 PLATE ASSY 1 㧙
137 CAB ASSY 㧙 1
137-2 PLATE ASSY 㧙 3 141
137-3 PLATE 㧙 2
137-4 PLATE ASSY 㧙 1
137-7 PLATE ASSY 㧙 1 181
141 GUARD 1 1
142 GUARD 㧙 1 Fig. 6-2
181 SEMS BOLT 4 8
137-6 137-7
137-2
137-5
135-2
137-2 135-5
137-5
135-2
137-2
135-3
137-3 135-4
135-3 137-4
137-3
CAB ASSY
(MANUAL WINDOW)
(POWER WINDOW)
Fig. 6-3 Mounting procedure of cab guard
6㧙2
6.5 REPLACEMENT OF RETURN FILTER OF
HYDRAULIC TANK
(BREAKER, NIBBLER & BREAKER) VALVE
When the standard machine is modified to nibbler
& Breaker machine, replace the return filter with
new one.
z Be sure to release the internal pressure

remaining in the hydraulic tank and hydraulic
oil circuit before inspection, maintenance and
repair.
Supplementary Explanation : Fig.6-6 Drain pressure for hydraulic tank

The internal pressure in the hydraulic tank can be
released by pushing the valve with the rubber cap
on the upper surface of the tank 5 or 6 times. CAPSCREW
WASHER
6.5.1 REPLACING PROCEDURE
COVER
Remove the capscrew, on the hydraulic tank and
take out the spring, check valve and filter 8
element.
Replace them with return filters shown below SPRING
according to the procedure shown in table 6-5 and
Fig.6-7. Replace it by the reverse procedure of
disassembly. CHECK VALVE
Table 6-5 4
HYDRAULIC TANK ASSY
No. NAME Q’TY REMARK 7

17-100 REPAIR KIT
4 O RING 1
PLATE
5 PACKING 1
5
7 FILTER ELEMENT 2
8 O RING 1
Fig.6-7
6㧙4
This page is left blank for editing convenience.
6㧙5
6.6 CONTROL PIPING (NIBBLER & BREAKER)
6.6.1 REMOTE CONTROL PIPING & BLOCK
CONTROL PIPING
(1) Modification procedure
Assemble the additional parts listed in table
6-6 and 6-7 to the remote control piping of the
standard machine, as shown in Fig. 6-8 and
6-10. On that occasion, some of the existing
parts must be used and some of them become
unnecessary.
REMOTE CONTROL PIPING Table 6-6

REMAR No. NAME Q’TY
K
PF1/4
HOSE L=550 1 PF1/4 ELBOW 1 With filter
2 HOSE L=350 1 PF1/4 17 CAPSCREW 2
3 HOSE L=2700 1 PF1/4 18 WASHER 3
4 HOSE L=4200 1 PF1/4 19 WASHER 4
5 PIN 1 20 NUT 1
6 LOCK ASSY 1 R/H 21 LOCK WASHER 2
7 PEDAL 1 28 CONNECTOR 1 PF3/8
8 RUBBER 1 30 CONNECTOR 1 PF1/4-PF3/8
9 PILOT VALVE 1 32 ELBOW 1 PF1/4-PF3/8
10 CONNECTOR 2 PF1/4 33 CAPSCREW 2 M1030
11 PLUG 1 PF1/4 37 PLATE 1
12 PRESS SENSOR 1 PF1/4 38 CAPSCREW 2 M825
13 ELBOW 3 PF1/4
4
Table 6-7
10
BLOCK CONTROL PIPING
4 ELBOW 1 PF1/4
10 CONNECTOR 1 PF3/8
11 TEE 1 PF3/8
13 ELBOW 1 PF3/8- PF1/4
11
14 CONNECTOR 1 PF3/8 14 13
Fig.6-8 Block control piping (Nibbler & Breaker)

17
(2) Parts to be disused
Concerning the control block piping, the parts
listed in table 6-8 and Fig. 6-9 are disused
from the standard machine.
Table 6-8
5
5 CONNECTOR 1 PF3/8
17 PLUG 1 PF1/4
Fig.6-9 Block control piping (STD)

(Parts to be disused)
6㧙6
CONTROL VALVE
4
4
32
17
21
19 28
8
5
18
20
38 7
18 33 CONTROL VALVE
11
6 19
10
12 9 13
1
37
13
14
10 3 30
2
13
3
4
Fig. 6-10 Remote control piping (Nibbler & Breaker)

8
(2) Parts to be disused 4
Concerning the remote control piping, the
parts listed in table 6-9 and in Fig. 6-11 are 2
disused from the standard machine.
Table 6-9
2 SUPPORT 1
4 COVER 1
8 SEMS BOLT 2
Fig. 6-11 Parts to be disused
6㧙7
6.7 UPPER HYDRAULIC PIPING
(NIBBLER & BREAKER)
Fit the additional parts in table 6-10,
according to Fig. 6-12.
UPPER HYDRAULIC PIPING Table 6-10

No. NAME Q’TY REMARK No. NAME Q’TY REMARK
1 O RING 2 15 O RING 2
2 WASHER 4 16 CAPSCREW 2
3 SUPPORT 1 17 CAPSCREW 4
4 CAPSCREW 4 18 CAPSCREW 8
5 WASHER 6 19 LOCK WASHER 8
6 TUBE 1 20 BRACKET 1
7 TUBE 1 21 ELBOW 1
8 TUBE 1 22 HOSE 1
9 HOSE 1 23 CONNECTOR 1
10 ELBOW 1 24 ELBOW 1
11 ELBOW 1 25 CONNECTOR 1
12 SELECTOR VALVE 1 26 O RING 3
13 CLAMP 2 27 PLATE 2
14 HALF CLAMP 4
CONTROL VALVE
22
Fig. 6-12 (1/2) Upper hydraulic piping (Nibbler & Breaker)
6㧙8
CONTROL VALVE
16
14 26 13
19 5
18
27 5 4 6
16
19 5
1
18 13
7
15
3 8
14 1 22
8 27
11 23 25
26 24
12
2 10 21
6 9
17
15
4
20 HYDRAULIC TANK
5 22
WHEN USING WHEN USING

BREAKER NIBBLER
TO TANK TO TANK
TO
ATTACHMENT
TO
ATTACHMENT

TO CONTROL TO CONTROL
VALVE VALVE

STAMP
CHANGE TRAIN SCHEDULE THE KNACK SELECT
Fig. 6-12 (2/2) Upper hydraulic piping (Nibbler & Breaker)
6㧙9
Concerning the return hydraulic piping, the
parts listed in table 6-11 and Fig. 6-13 is
Table 6-11
RETURN HYDRAULIC PIPING
HYDRAULIC TANK 21
21 PLUG 1
6㧙10
6.8 INSTALL OF THE NAME PLATE
N&B 22
Fit the label shown in table 6-13 to the cab of the
standard machine, according to Fig. 6-15.
Table 6-13
INSTALL OF THE NAME PLATE
20 LABEL 1
21 LABEL 1
22 LABEL 1
20
21
21
20
The cover left & rear side view

of operator seat
22
Attachment operation by foot pedal.

Always check the foot pedal control pattern
before operation.
Always read operators manual before
operating machine.
Fig. 6-15 Name plate install (Nibbler & Breaker)
6㧙11
6.9 MODIFICATION OF THE INSTRUMENT
PANEL (NIBBLER & BREAKER)
Install the additional parts listed in table
6-14 to the instrument panel assy of the
standard machine, as shown in Fig. 6-16. On
that occasion, some parts become
unnecessary.
Table 6-14
39
Fig. 6-16 Modification of instrument panel
For single
39 SWITCH 1 / conflux
switching

When the instrument panel is modificated,
the parts shown in table 6-15 and Fig. 6-17 is
No. PART NAME Q’TY Table 6-15
REMARK
13 CAP 1 13
6㧙12
7. MODIFICATION PROCEDURE FOR BREAKER
7.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a nibbler &
breaker-mounted machine are as follows :
Table 7-1

Main items to be
No. ITEM
added and change

7.2 Modification of the floor mat Floor mat

Refer to Install of the
1 Guard Bracket
6.3 cab guard
Guard
2 Guards

Refer to Option valve,
6.4 Modification of the control valve Capscrew
Refer to
6.5 Modification of the hydraulic tank Replace return filter
Remote
Remote control piping Pilot valve, Pedal
7.3 control and block piping Hose, Elbow
piping
Hose,
7.4 Upper hydraulic piping Selector valve

7.2 FLOOR MAT (BREAKER) CUT OUT
Make slits to face of the standard floor mat
according to Fig. 7-1 and cut out the hatching.
Floor mat for breaker
Fig. 7-1 Modification of floor mat
7㧙1
7.3 CONTROL PIPING (BREAKER)
7.3.1 REMOTE CONTROL PIPING & BLOCK

CONTROL PIPING

Assemble the additional parts listed in table
7-2 and 7-3 to the remote control piping of the
standard machine, as shown in Fig. 7-2 and
7-3. On that occasion, some of the existing
parts must be used and some of them become
unnecessary.
REMOTE CONTROL PIPING Table 7-2

2 HOSE 1 PF1/4 50 BRACKET 1

4 HOSE 1 PF1/4 51 PIN 1
5 PIN 1 52 PIN 1
6 LOCK ASSY 1 R/H 53 CONNECTOR 1 PF1/4
12 PRESS SENSOR 1 PF1/4 54 TEE 1 3-PF3/8
13 ELBOW 1 PF1/4 55 ELBOW 1 PF3/8
15 CAPSCREW 2 56 ELBOW 1 PF1/4
18 WASHER 3 57 CUSHION RUBBER 1
20 NUT 1 58 PEDAL 1
29 CONNECTOR 1 PF1/4 59 COVER 1
32 ELBOW 1 PF1/4-
PF3/8 60 PLATE 2
45 HOSE 1 PF1/4 61 PILOT VALVE 1
46 HOSE 1 PF3/8 62 CONNECTOR 2 PF3/8
47 WASHER 1 63 TEE 1 PF1/4
48 CAPSCREW 2 65 TUBE 1
49 WASHER 2
&21752/9$/9(
Fig. 7-2 (1/2) Remote control piping (Breaker)
7㧙2
&21752/9$/9(
HYDRAULIC TANK ASSY
Fig. 7-2 (2/2) Remote control piping (Breaker)
7㧙3
Table 7-3
BLOCK CONTROL PIPING
4 ELBOW 1 PF1/4
11 TEE 1 PF3/8
PF3/8-P
13 ELBOW 1 F1/4
20 ELBOW 1 PF1/4
Fig. 7-3 Black control piping (Breaker)

Concerning the control block piping, the parts
listed in table 7-4 and Fig. 7-4 are disused
Table 7-4
5 ELBOW 1
9 CONNECTOR 1
17 PLUG 1

Concerning the remote control piping, the
parts listed in table 7-5 and in Fig. 7-5 are
Table 7-5
2 SUPPORT 1
4 COVER 1
8 SEMS BOLT 2
7㧙4
7.4 UPPER HYDRAULIC PIPING (BREAKER)
Fit the additional parts in table 7-6,
according to Fig.7-6.
UPPER HYDRAULIC PIPING Table 7-6
1 TUBE 1 14 CAPSCREW 2
3 PLUG 1 16 CAPSCREW 8
4 HOSE 1 17 WASHER 8
5 ELBOW 1 19 LOCK WASHER 8
7 CLAMP 2 21 SUPPORT 1
8 CLAMP 2 22 CONNECTOR 1 PF1
9 HALF CLAMP 2 23 ELBOW 1 PF1
11 O RING 2 24 CONNECTOR 1 PF1
12 SUPPORT 1 25 O RING 2
13 CAPSCREW 4 26 PLATE 2
CONTROL VALVE
1
2
CONTROL VALVE
14
8
17
9 25
19
16 1
14 26
17
17
11
8
2 13 2
19
16
12
11
26
3
Fig.7-6 (1/2) Upper hydraulic piping (Breaker)

7㧙5
4 22 24
23
15
17 4
7
5
7
1
HYDRAULIC TANK
13
21
17
Fig. 7-6 (2/2) Upper hydraulic piping (Breaker)

Concerning the return hydraulic piping, the
parts listed in table 7-7 and Fig. 7-7 is disused
Table 7-7
RETURN HYDRAULIC PIPING
HYDRAULIC TANK 21
21 PLUG 1
7㧙6
8. MODIFICATION PROCEDURE FOR ATTACHMENT
8.1 MODIFICATION ITEM FOR BREAKER, NIBBLER & BREAKER ATTACHMENT
The main item that are needed to modify the standard boom and standard arm into a breaker and a
nibbler & breaker-mounted machine are as follows:
Table 8-1
Modification
No. Spec. Types of attachment item
8.2 Modification of the 5.65M (18´6˝) boom Tapped block

B, N&B
8.3 5.65M (18´6˝) boom hydraulic piping Tube
8.4 N&B Modification of the 2.94M (9´8˝) STD arm Tapped block Plate
8.5 B Modification of the 3.33M (10´11˝) long arm Tapped block
B, N&B 2.94M (9´8˝ ) STD arm hydraulic piping

8.6 Tube
B 3.33M (10´11˝) long arm hydraulic piping
B NPK, TOKU
8.7 Connector assy Connector
N KRUPP
8.8 B, N&B Reinforcing of the idler link Plate
8㧙1
8.2 MODIFICATION OF THE 5.65M (18ft-6in) BOOM
(1) Modification of the 5.65M (18ft-6in) boom

Breaker, Nibbler & Breaker
3) Weld the additional parts listed in table 8-4

to the boom of the standard specification,
Table 8-4
5.65M (18´6˝ )
BOOM ASSY
1 BOOM ASSY (1) STD
2 TAPPED BLOCK 4
3 TAPPED BLOCK 1
4 TAPPED BLOCK 2
5 TAPPED BLOCK 1
6 TAPPED BLOCK 1
8 TAPPED BLOCK 1
9 TAPPED BLOCK 1
Fig. 8-3 Modification of the 5.65M (18ft-6in) boom (Breaker, Nibbler & Breaker)
8㧙2
8.3 HYDRAULIC PIPING FOR 5.65M (18ft-6in) BOOM

BREAKER, NIBBLER & BREAKER
1) Install the additional parts listed in table 8-6

to the 5.65m (18ft-6in) boom modified under
par. 8.2 as shown in Fig. 8-5.
HYDRAULIC PIPING Table 8-6

FOR 5.65M (18´6˝ )
BOOM
No. NAME Q’TY REMARKS No. NAME Q’TY REMARKS

1 TUBE 1 13 CLAMP 1
5 PLUG 2 18 CAPSCREW 8
6 HOSE 2 19 LOCK WASHER 21
7 O RING 2 20 LOCK WASHER 8
8 O RING 2 21 LOCK WASHER 8
9 O RING 2 22 HALF CLAMP 4
10 CLAMP 2 23 HALF CLAMP 4
11 CLAMP 3 24 CLIP 1
12 CLAMP 5 26 ELBOW 2
Fig. 8-5 Hydraulic piping for 5.65M (18ft-6in) boom (Breaker, Nibbler & Breaker)
8㧙3
8㧙4
8.4 MODIFICATION OF THE 2.94M (9ft-8in) ARM
(1) Modification of the 2.94m (9ft-8in) STD arm
(Nibbler & Breaker)
3) Weld the additional parts listed in table 8-9 to

the arm of the standard specification,
Table 8-9
2.94M (9´8˝ ) ARM ASSY

1 ARM ASSY (1) STD
2 TAPPED BLOCK 2
3 TAPPED BLOCK 4
4 PLATE 1
5 PLATE 1
6 PLATE 1
Finish by
grinder
Fill the bead

throuth smoothly
Fill the bead

throuth smoothly
Finish welding portion by grinder.

Then put plate, heat by burner and weld.
Fig. 8-8 Modification of the 2.94M (9ft-8in) arm (Nibbler & Breaker)
8㧙5
8.5 MODIFICATION OF THE 3.33M (10ft-11in)
LONG ARM (BREAKER)

to the arm of the long specification, acording
to Fig. 8-9.

to the arm of the long specification, acording
to Fig. 8-11.
Table 8-12 Finish by grinder
3.33M (10´11˝ )
ARM ASSY
1 ARM (1)
2 PLATE 1
3 PLATE 1
4 PLATE 1
5 TAPPED BLOCK 2
6 TAPPED BLOCK 4
Fill the bead

throuth smoothly
Fill the bead

throuth smoothly
Finish welding portion by grinder.

Then put plate, heat by burner and weld.
Fig. 8-11 Modification of the 3.33M (10ft-11in) long arm (Breaker)
8㧙6
8.6 2.94M (9ft-8in) STD ARM HYDRAULIC PIPING
3.33M (10ft-11in) LONG ARM HYDRAULIC
PIPING (BREAKER)
1) (STD arm)
This hydraulic piping applies to both the breaker
machine and the nibbler & breaker machine.
Install the additional parts listed in table 8-14 to
the arm body as shown in Fig. 8-13.
2.94M (9´8˝)
ARM HYDRAULIC PIPING Table 8-14
5 HOSE 1 19 LOCK WASHER 4
6 STOP VALVE 2 20 WASHER 8
7 CONNECTOR 2 21 WASHER 4
8 HALF CLAMP 2 22 LOCK WASHER 4
9 HALF CLAMP 2 23 LOCK WASHER 4
10 BRACKET 2 24 BUSHING 2
11 CLAMP 4 25 BUSHING 2
12 CLAMP 4 26 O RING 1
13 CAPSCREW 8 27 O RING 1
15 CAPSCREW 4 29 WASHER 8
Fig.8-13 2.94M (9ft-8in) STD arm hydraulic piping (Breaker, Nibbler & Breaker)
8㧙7
2) (Long arm)
This hydraulic piping applies to the breaker
machine. Install the additional parts listed in
table 8-15 to the arm body as shown in Fig. 8-14.
3.33M (10´11˝)
ARM HYDRAULIC PIPING Table 8-15
4 HOSE 1 18 LOCK 4
WASHER
5 STOP VALVE 2 19 WASHER 8
6 CONNECTOR 2 20 WASHER 4
7 HALF CLAMP 2 21 LOCK 4
WASHER
8 HALF CLAMP 2 22 LOCK 4
WASHER
9 BRACKET 2 23 BUSHING 2
10 CLAMP 4 24 BUSHING 2
11 CLAMP 4 25 O RING 1
14 CAPSCREW 4 28 WASHER 8
Fig.8-14 3.33M (10ft-11in) long arm hydraulic piping (Breaker)
8㧙8
8.7.1 CONNECTOR ASSY (BREAKER) 2 1-5/16-UNF 1 3
When using the machine with a breaker, attach
the below parts to the tip of the stop valve. For
use with NPK, TOKU and KRUPP breakers.
Table 8-16 PF1-1/4

CONNECTOR ASSY
FOR NPK
1 CONNECTOR 1
2 PLUG 1
3 O RING 1 1B P38 Fig. 8-15 Connector assy (NPK)
2 PF1 1 3
Table 8-17 PF1-1/4

CONNECTOR ASSY
FOR TOKU, KRUPP
1 CONNECTOR 1
2 PLUG 1
3 O RING 1 1B P38 Fig. 8-16 Connector assy (TOKU, KRUPP)
8.7.2 CONNECTOR ASSY (NIBBLER)

When using the machine with a nibbler, attach 2 M451.5 1 3
the below parts to the tip of the stop valve.
PF1-1/4
Table 8-18
CONNECTOR
ASSY
1 CONNECTOR 1
2 PLUG 1
1B Fig. 8-17 Connector assy (NIBBLER)
3 O RING 1
P38
8㧙9
8.8 REINFORCING THE IDLER LINK
When using the machine as a breaker, nibbler &
breaker machine, the right and left idler links
need reinforcement. Reinforce them according to
0
table 8-19 and Fig. 8-18.
Table 8-19
IDLER LINK (R.H)
IDLER LINK (L.H) 1
0 IDLER LINK (1) (RH)

0 IDLER LINK (1) (LH)
1 PLATE 1 (RH)
1 PLATE 1 (LH)
IDLER LINK (L.H)
IDLER LINK (R.H)
Fig. 8-18 Reinforcing the idler link
8㧙10
9. REMINDERS ON THE USE OF NIBBLER & BREAKERS
9.1 CHANGING OVER THE SELECTOR VALVE
A nibbler & breaker-attached machine is
equipped with a selector valve in both the
operation circuit and the main circuit. When
running the machine after completion of LOW PRESSUSE
modification, always set the selector valves SIDE (RETURN)
according to a nibbler or a breaker used.

HIGH PRESSUSE
NOTE : Incorrect setting of the selector valves not SIDE
only deteriorates operating efficiency and
decreases speed but also causes failure of
the machine. Therefore, confirm completion
of the modification and give proper advice PLUG
to the user.
BOOM
z Tools used
For main circuit changeover
: 5mm
: 24mm
Changing over procedure of the selector

valve
WHEN USING WHEN USING
1) Remove socket bolt with allen wrench. NIBBLER BREAKER
2) Turn the nibbler or the breaker to its TO TANK TO TANK
operating position, using a spanner.
TO
ATTACHMENT
TO
ATTACHMENT
3) Stop it at a specified position and tighten the

setscrew.
TO CONTROL TO CONTROL
VALVE VALVE
ALLEN WRENCH (HEX 5mm)

STAMP

SPANNER (HEX 24mm) Fig. 9-2 Changing over procedure of
the selector valve

Fig. 9-1 Changing over procedure of
the selector valve
9㧙1
9.2 FLUSHING METHOD
After completion of piping work, connect the high
pressure side and the low pressure side, as shown
in Fig. 9-3, open the stop valves on both sides and (ON) (OFF)
depress the operating pedal to perform flushing.
CONNECTOR(PF3/4)
z Before beginning flushing, run the
engine at low speed, depress the STOP VALVE
HOSE
breaker operating pedal and then
run the engine at high speed.
z Perform flushing operation for at
least 40 minutes, and during the
operation, make sure of no oil
leakage from each of the connections
of the newly attached breaker circuit An example of flushing time (23min.) in a single
and the nibbler & breaker circuits. process

9.3 REPLACING HYDRAULIC OIL AND RETURN
FILTER
Contamination and deterioration of hydraulic oil 5 min 1 min 5 min 1 min
may develop malfunctioning of the control valve, Flushing Stop Flushing Stop
early wear and seizure of the hydraulic pumps
and malfunctioning of the entire hydraulic 5 min 1 min 5 min
circuits : always replace hydraulic oil at regular Flushing Stop Flushing
intervals, based on table 1.
Fig. 9-3 Flushing method
Table 9-1
Inspection / Replacement intervals
Item
maintenance points First replacement 2nd replacement Regular replacement
Hydraulic oil Hydraulic oil tank 㧙㧙 Every 600h
Return filter Hydraulic oil tank 50h 250h Every 250h

9.4 OPERATING PROCEDURE
This machine is provided with breaker single
circuit and nibbler and breaker combined
(conflux) circuit. To use breaker or nibbler, select
circuit appropriate to the specification through
single / conflux select switch on the left rear side
of driver's seat.
9.4.1 SWITCH OPERATING

(NIBBLER & BREAKER SPECIFICATION)
Specification Switch position Circuit
Breaker ( ) OFF Single flow
Nibbler ( ) ON Conflux flow
Never turn switch on (conflux) to operate NIBBLER & BREAKER SPECIFICATION

breaker. It may cause trouble of machine.
9㧙2
9.4.2 THROTTLE POTENTIOMETER
When operating the machine with a hydraulic
breaker, do the following operations :
Use the throttle potentiometer on the high idle
side. (Refer to Fig. 9-4.)
Fig. 9-4 Throttle potentiometer position

9.4.3 CONTROL PEDAL
(1) Hydraulic breaker single circuit
Release pedal lock on the right front side of
driver’s seat to operate pedal.
RELEASE
Precaution for pedal operation LOCK

The operation varies in the specifications, so PUSH LOCK PULL LOCK ROD
before operating, read the Operator Manual ROD FORWARD BACKWARD
carefully. TO RELEASE TO LOCK PEDAL
Foot pedal
depressing section Operating condition.
BREAKER ONLY
Depress toe section Breaker starts operation.
Pedal in neutral position. Breaker stops operating.
(2) Nibbler and breaker combined (conflux)
circuit.
Release pedal lock on the right front side of
driver’s seat to operate pedal.
z Hydraulic breaker
Foot pedal
Pedal in neutral position. Breaker stops operation.
Depress toe section. Breaker starts operating.
z Nibbler
Foot pedal
Depress toe section Nibbler close
Depress heel section Nibbler open N&B PEDAL
9㧙3
9㧙4
10. PRECAUTIONS TO BE EXERCISED ON BREAKERS
OF DIFFERENT MANUFACTURERS
There are some differences between manufac-turers Low pressure : Measure the inlet pressure of the
as to the piping to breakers and the handling of side line filter on the breaker side by
breakers. For this reason, consult with the actuating the breaker at full engine
manufacturer when mounting a breaker in the revolution in the H mode, and in
field. The following is a summary of how breakers case the maximum pressure exceeds
should be handled that is extracted from manu- 55kgf/cm2 (780 psi), install a low
facturers’ catalog use and operation manuals. pressure accumulator.
NOTE : This is a general outline of how breakers Max. < 55kgf/cm2 (780 psi)
should be used and may differ with excavator Regarding the capacity and the
models. Always contact the breaker charge pressure of accumulators,
manufacturer before field mounting. contact the breaker manufacturer
before installation.
(1) Placing high and low pressure accumulators
NPK They must be placed basically (2) Installation of a relief valve
(depending upon models). NPK Installation is not necessary.
(Contact the breaker manufacturer
T O K U Check the oscillation of the as it is necessary depending upon
K R U P P pulsation of the breaker models.)
pressure and if pulsation is
O K A D A large, always install accumu- Installation is necessary.
FURUKAWA lators. A relief valve is specified by each
T O K U
breaker manufacturer. Since the
Standard of judgment on the installation of K R U P P method of pressure setting of the
accumulators relief valve differs with breaker
H pressure : Measure the pulse oscillation by
High O K A D A
manufac-turers, install a relief
side pressure on the high pressure side
T A I S E I valve according to the manufac-
of the breaker at the inspection port
for the pump’s delivery pressure by FURUKAWA turer’s instructions.
actuating the breaker at the full NOTE : Only the B series TOKU machine requires a
revolution of the engine in mode H relief valve to be installed.
and set the maximum pressure
difference to within 20% of the

excavator’s system pressure INSTALLATION OF A RELIEF VALVE
350kgf/cm2 (4980psi).
In case it exceeds 20%, install a
high pressure accumulator.
NOTE : The pulse oscillation is 35020%= LOW PRESSUSE
2
70kgf/cm (1000psi). Therefore, if it is more SIDE (RETURN)
than this level, an accumulator must be
installed.
HIGH PRESSUSE
SIDE
Install accumulator referring to the
result of verification test.

max PLUG

BOOM

min Fig. 10-1 Relief valve mounting
Max. press㧙Min press < system press 20%
10㧙1
6 (4) Changing over the breaker to high and low
4 speeds
N P K
2 These breakers are not so
T O K U
(PF1) 3 constructed as to be switched
TO TANK
T A I S E I over to high and low speed.
FURUKAWA
RETURN SIDE

5 1
KRUPP Breakers on and after MKB1200 are
constructed with a switching function.
It can be operated from inside the cab
by the installation of a solenoid valve.
TO BREAKER OIL SUPPLY SIDE For piping work, consult with the
breaker manufacturer.
1. HIGH PRESSURE HOSE 4. PLUG
2. NIPPLE 5. ELBOW NOTE : Piping work is not required in some cases if
3. ADAPTER 6. RELIEF VALVE a high-low changeover function is not
Fig. 10-2 necessary at user’s request.
On that occasion, it is necessary to fix the
(3) Restriction of engine revolution changeover valve contained in the breaker
NPK Full engine revolution may be used. to the low speed side beforehand. Consult
with the breaker manufacturer in that case.
T O K U There are restriction on the It is prohibited to use the high-low speed
K R U P P engine revolution. Since a changeover valve without laying high-low
specified revolution differs speed piping and without fixing the high-low
O K A D A
with breakers, follow the speed changeover valve.
T A I S E I breaker manufacturer’s
FURUKAWA inst-ructions.
HIGH-LOW SPEED
CHANGEOVER VALVE
NOTE : In the case of a breaker for which the
engine revolution is limited, the breaker
does not increase impact power and cycles
even at full engine revolution.
Since extra hydraulic oil returns to the RELIEF VALVE HYDRAULIC
BREAKER
hydraulic oil via the relief valve, it causes
the hydraulic oil temperature to rise and the TO CONTROL VALVE
fuel consumption to increase. Plaster the
label (furnished by the breaker maker)
indicating the revolution (Check the engine TO TANK
revolution.), to the throttle potentiometer
position. Always observe the indicated
CHECK VALVE
revolution.
Fig. 10-3
10㧙2
11. REFERENCE
Typical combinations are quoted from breaker When fitting a breaker, read through reminders
manufacturer’s catalog use as below, but on the use of breakers and cautions instructed by
concerning applicable breaker models, decide it breaker manufacturers.
after consultation with the breaker manufacturer.
Table 11-1
Working press Oil volume Total weight Total length Bucket
Applicable
Manufacturer kgf/cm2 used /min kg mm capacity m3
breaker
(psi) (gal/min) (lbs) (in) (cuyd)

120㨪140 160㨪200 1,450 2,156
H-10XB
(1,710㨪1,990) (42.2㨪52.8) (3,200) (84.9˝ )
N P K
130㨪150 35㨪60 410 1,644
H-4XE
(1,850㨪2,130) (9.24㨪15.8) (900) (64.7˝ )
100㨪140 110㨪140 1,000 0.55㨪0.70
TNB-10B
(1,420㨪1,990) (29.0㨪37.0) (2,210) (0.72㨪0.92)
120㨪140 140㨪160 1,400 0.70㨪0.90
TNB-14B
(1,710㨪1,990) (37.0㨪42.2) (3,100) (0.92㨪1.18)
100㨪160 45㨪80 391 1,476 0.25㨪0.35
T O K U TNB-6E
(1,420㨪2,280) (11.9㨪21.1) (860) (58.1˝ ) (0.33㨪0.46)
120㨪170 100㨪140 997 1,850 0.55㨪0.70
TNB-10E
(1,710㨪2,420) (26.4㨪37.0) (2,200) (72.8˝ ) (0.72㨪0.92)
130㨪170 130㨪170 1,550 2,190 0.70㨪0.90
TNB-14E
(1,850㨪2,420) (34.3㨪44.9) (3,400) (86.2˝ ) (0.92㨪1.18)
150㨪160 80㨪110 1,100㨪1,250 2,278 0.50㨪0.90
MKB1100
(2,130㨪2,280) (21.1㨪29.0) (2,430㨪2,760) (89.7˝ ) (0.65㨪1.18)
K R U P P
150㨪180 90㨪130 1,120㨪1,200 0.55㨪1.00
MKB1200
(2,130㨪2,560) (23.8㨪34.3) (2,470㨪2,650) (0.72㨪1.31)
150㨪180 110㨪 1,450 2,240 0.70㨪
UB 11
(2,130㨪2,560) (29.0㨪 ) (3,200) (88.2˝) (0.92㨪 )
O K A DA
130㨪160 110㨪155 1,070 2,040 0.55㨪0.70
OUB 310
(1,850㨪2,280) (29.0㨪40.9) (2,360) (80.3˝ ) (0.72㨪0.92)
150㨪170 100㨪120 1,330 ާ1,596ި 0.60㨪0.90
T A I S E I TF-150
(2,130㨪2,420) (26.4㨪31.7) (2,930) (62.8˝ ) (0.78㨪1.18)
160㨪180 125㨪150 1,400 2,119
FURUKAWA HB20G
(2,280㨪2,560) (33.0㨪39.6) (3,100) (83.4˝ )
[ ] Excludes chisels.
General precautions to be exercised on the installation of breakers by different manufacturers
Table 11-2
Installation of Installation of Restriction of
Manufacturer engine High-low speed changeover
accumulators a relief valve revolution
٧ NPK ٤ changeover type not available.
TOKU
٧ ٤ ٤ changeover type not available.
Series B
TOKU
٧ ̪ ٤ changeover type not available.
Series E
changeover type available for large
̆ KRUPP ٌ ٤ ٤
machines.
changeover type available on
̆ OKADA ٌ ٤ ٤
special request.
̆ FURUKAWA ٌ ٤ ٤ changeover type not available.
̆ TAISEI ٌ ٤ ٤ changeover type not available.

٧ Adaptation test completed. ٌ One that must be adjusted at installation.
٤ One that must be installed. ̪ Capacity 1 liter, pressure is 70kgf/cm2 (1,000psi)
One that does not need to be installed.
11㧙1
11㧙2

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E235SR

Workshop Workshop manual

Printed No. 604.13.436

Printed by Studio ti - 20205

ADDITIONAL REFERENCE MANUALS

• In addition to this Workshop Manual, refer also to

- Operation and maintenance instruction

DESCRIPTION OF THE COMPLETE

• The complete Workshop Manual for the excavator

VOLUME MACHINE TYPE PRINT No.

Most accidents, whether they occur in industry, on the farm, at home or on

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION

All rights reserved. Reproduction of text and illustrations in whole or in part, is

Section 21 - Mechatro control system

Section 31 - Disassembling and assembling

Section 41 - Troubleshooting (mechatro control)

Section 63 - Mounting the breaker and nibbler & breaker

SAFETY PRECAUTIONS 5. Do not work on any machine that is supported

The serviceman or mechanic may be unfamiliar with

7. Lower the bucket, dozer, or other attachments to

16. Do not damage wiring during removal operations.

17. Be sure all protective devices including guards

18. The maintenance and repair work while holding

19. Loose or damaged fuel, lubricant and hydraulic

20. Tighten connections to the correct torque. Make

1. GENERAL PRECAUTIONS FOR MAKING REPAIRS ............................................... 1

2. INTERNATIONAL UNIT CONVERSION SYSTEM .................................................... 4

1. GENERAL PRECAUTIONS FOR MAKING REPAIRS

distortion and bend.

2) Flexible hose (F hose)

hose are the same, the parts differ

̪1 Units that are allowed to use

1. NAME OF COMPONENTS ...................................................................................... 1

2. GENERAL DIMENSIONS ......................................................................................... 2

3. WEIGHT OF COMPONENTS ................................................................................... 3

5. SPECIFICATIONS AND PERFORMANCE ............................................................... 6

6. TYPE OF CRAWLER ................................................................................................. 7

7. TYPE OF BUCKET ................................................................................................... 8

8. COMBINATIONS OF ATTACHMENT ........................................................................ 9

9. ENGINE SPECIFICATION ....................................................................................... 10

NOTE : Numerical values marked ೇ indicate the dry weight.

4.2 DIMENSIONS OF ATTACHMENT

Weight kg (lbs) 2,280 (5,030)

(2) ARM AND BUCKET

Weight kg (lbs) 1,690(2,250)

Weight kg (lbs) 1,040 (2,290)

(4) BUCKET (IF EQUIPPED)

Type Hoe bucket

Type Hoe bucket Slope finishing bucket

l Hoe bucket l Slope finishing bucket

Area & Shoe

Gradeability %(degree) 70 (35)

Number of cylinders Bore Stroke 6 104mm 115mm

Rated output / Rotation speed 110kW (150PS) / 2,000rpm

Maximum torque / Rotation speed 59kgf]m (428ft]lbs) / 1,600rpm

Starter 24V / 5.0kW

Alternator 24V / 35A

5.3 HYDRAULIC COMPONENTS

Hydraulic motor (swing) Axial piston motor

Hydraulic motor (travel) 2-speed axial piston motor

Control valve 6-spool control valve

Oil cooler Air-cooled type

5.4 WEIGHT Unit : kg (lbs)